sm-K1010635E (DL400) LowRes

DL400
Shop Manual
K1010635E
Serial Number 5001 and Up
DOOSAN reserves the right to improve our products in a continuing process to provide the best possible
product to the market place. These improvements can be implemented at any time with no obligation to
change materials on previously sold products. It is recommended that consumers periodically contact their
distributors for recent documentation on purchased equipment.
This documentation may include attachments and optional equipment that is not available in your
machine's package. Please call your distributor for additional items that you may require.
Illustrations used throughout this manual are used only as a representation of the actual piece of
equipment, and may vary from the actual item.
K1010635E Shop Manual

Copyright DOOSAN 2006
Pub.No. K1010635E
Serial Number 5001 and Up
DL400
Product Label
Instructions
Trim Out The Label Along

The Lines And Insert Into
Pocket On The Binder Spine
Pub. No. K1010635E

1Table of Contents
Publication Request for Proposed Revision
Safety
Wheel Loader Safety ............................................................................ SP000095
Specifications
Specification for DL400......................................................................... SP000096
General Maintenance
General Maintenance Procedures ........................................................ SP000097
Standard Torques ................................................................................. SP000098
Drive Train
Transmission and Torque Converter (ZF 4WG-260-4)......................... SP000099
Transmission Error Codes (ZF) ............................................................ SP000100
Front Axle (ZF - MT-L 3105) ................................................................. SP000101
Rear Axle (ZF - MT-L 3095).................................................................. SP000107
Drive Shaft ............................................................................................ SP000119
Brake
Service Brake ....................................................................................... SP000120
Brake Supply Valve .............................................................................. SP000121
Parking Brake ....................................................................................... SP000122
Brake Pedal Valve ................................................................................ SP000123
Accumulator.......................................................................................... SP000124
Steering
Steering Unit ......................................................................................... SP000125
Flow Amplifier ....................................................................................... SP000126
Table of Contents
Page I
Cushion Valve....................................................................................... SP000127
Emergency Steering ............................................................................. SP000128
Frame
Articulation Center ................................................................................ SP000129
Counterweight....................................................................................... SP000130
Tank
Oil Tank ................................................................................................ SP000131
Fuel Tank.............................................................................................. SP000132
Hydraulics
Main Control Valve ............................................................................... SP000144
Load Isolation System .......................................................................... SP000149
Cooling System..................................................................................... SP000154
Pilot System.......................................................................................... SP000159
Hydraulic Schematic (DL400) ............................................................... SP000168
Electrical System
Air Conditioner ...................................................................................... SP000172
Electrical System .................................................................................. SP000173
Electrical Schematic (DL400) ............................................................... SP000235
Table of Contents
Page II
1PUBLICATION REQUEST FOR
PROPOSED REVISION
In DOOSAN's continuing effort to provide the best customer satisfaction, we invite you to help us improve
the manuals that you work with on a daily basis. This form is provided to give you a means of feedback to
the publication department.
COMPANY NAME: DATE:

STREET ADDRESS: TELEPHONE:
CITY: FAX:
STATE / PROVINCE:
COUNTRY:
NAME:
MACHINE MODEL:
SERIAL NUMBER:
MANUAL NUMBER:
SHOP MANUAL SECTION NUMBER:
PROPOSED DESCRIPTION OF CORRECTION AND/OR SUGGESTION:
Use additional paper if needed. Please include copy of current manual pages for reference. Attach any photos or
illustrations. If digital photos are available, E-mail them to Bill.Bernhardt@dhiac.com (If possible, use 1024 x 768
resolution.).
HAS THIS BEEN DISCUSSED WITH A DOOSAN SERVICE REPRESENTATIVE: YES NO
IF YES - WHO:
(It is advised to discuss this with a DOOSAN service representative to ensure that the above correction is
appropriate and valid.)
Mail to:
DOOSAN Infracore America Corporation
2905 Shawnee Industrial Way
Suwanee, GA 30024
Attention: Publications
1Safety
SP000095
WHEEL LOADER SAFETYSP000095
Wheel Loader
Safety
Edition 1
Wheel Loader Safety SP000095

Page 1
MEMO
SP000095 Wheel Loader Safety

Page 2
Table of Contents
Wheel Loader Safety

Safety Precautions................................................ 5
Applicable Models................................................. 5
To the Operator of a DOOSAN Wheel Loader...... 6
General Safety Essentials .................................. 10
Location of Safety Labels ................................... 10
Unauthorized Modifications ................................ 10
General Hazard Information ............................... 11
Before Starting Engine ....................................... 20
Machine Operation ............................................. 25
Maintenance ....................................................... 32
Battery ................................................................ 41
Towing................................................................. 43
Shipping and Transportation............................... 44

Page 3
MEMO

Page 4
SAFETY PRECAUTIONS
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
MODEL SERIAL NUMBER RANGE

DL300 5001 and Up
DL400 5001 and Up

Page 5
TO THE OPERATOR OF A
DOOSAN WHEEL LOADER
DANGER!
Unsafe use of the wheel loader could lead to serious injury
or death. Operating procedures, maintenance and
equipment practices or traveling or shipping methods that
do not follow the safety guidelines on the following pages
could cause serious, potentially fatal injuries or extensive
damage to the machine or nearby property.
Please respect the importance of taking responsibility for your

own safety, and that other people who may be affected by your
actions.
Safety information on the following pages is organized into the
following topics.
1. General Safety Essentials on page 1-10.
2. Location of Safety Labels on page 1-10.
3. Unauthorized Modifications on page 1-10.
4. General Hazard Information on page 1-11.
5. Before Starting Engine on page 1-20.
6. Machine Operation on page 1-25.
7. Maintenance on page 1-32.
8. Battery on page 1-41.
9. Towing on page 1-43.
10. Shipping and Transportation on page 1-44.

Page 6
WARNING!
Improper operation and maintenance of this machine can
be hazardous and could result in serious injury or death.
Operator and maintenance personnel should read this
manual thoroughly before beginning operation or
maintenance.
Keep this manual in the storage compartment to the rear of
the operator's seat, and have all personnel involved in
working on the machine periodically read the manual.
Some actions involved in operation and maintenance of the
machine can cause a serious accident, if they are not done
in a manner described in this manual.
The procedures and precautions given in this manual apply
only to intended uses of the machine.
If you use your machine for any unintended uses that are
not specifically prohibited, you must be sure that it is safe
for any others. In no event should you or others engage in
prohibited uses or actions as described in this manual.
DOOSAN delivers machines that comply with all applicable
regulations and standards of the country to which it has
been shipped. If this machine has been purchased in
another country or purchased from someone in another
country, it may lack certain safety devices and
specifications that are necessary for use in your country. If
there is any question about whether your product complies
with the applicable standards and regulations of your
country, consult DOOSAN or your DOOSAN distributor
before operating the machine.

Page 7
SAFETY ALERT SYMBOL
Be Prepared - Get to Know All Operating and Safety
Instructions.
This is the Safety Alert Symbol. Wherever it appears in this
manual or on safety signs on the machine you should be
alert to the potential for personal injury or accidents.
Always observe safety precautions and follow
recommended procedures.
Learn the Signal Words Used with the

Safety Alert Symbol
The words "CAUTION," "WARNING," and "DANGER" used
throughout this manual and on decals on the machine indicate
degree of risk of hazards or unsafe practices. All three degrees
of risk indicate that safety is involved. Observe precautions
indicated whenever you see the Safety Alert "Triangle," no
matter which signal word appears next to the "Exclamation
Point" symbol.
CAUTION!
This word is used on safety messages and safety labels and
indicates potential of a hazardous situation that, if not
avoided, could result in minor or moderate injury. It may
also be used to alert against a generally unsafe practice.
WARNING!
indicates potential of a hazardous situation that, if not
avoided, could result in serious injury or death. It may also
be used to alert against a highly unsafe practice.
DANGER!
indicates an imminent hazard of a situation that, if not
avoided, is very likely to cause death or extremely serious
injury. It may also be used to alert against equipment that
may explode or detonate if handled or treated carelessly.

Page 8
Safety precautions are described in SAFETY from page -10 on.
DOOSAN cannot predict every circumstance that might involve
a potential hazard in operation and maintenance. Therefore the
safety messages in this manual and on the machine may not
include all possible safety precautions. If any procedures or
actions not specifically recommended or allowed in this manual
are used, you must be sure that you and others can do such
procedures and actions safely and without damaging the
machine. If you are unsure about the safety of some procedures,
contact a DOOSAN distributor.

Page 9
GENERAL SAFETY ESSENTIALS
Accessory Applications
This wheel loader has been designed primarily for moving earth
with a bucket. For use as a grapple or for other object handling,
contact DOOSAN. Lifting-work applications are permitted in
approved lift configuration, to rated capacity only, with no side-
loading (unless prohibited by local regulation). Do not use
machine for activities for which it was not intended. Do not use
bucket for lifting work, unless lift slings are used in approved
configuration.
LOCATION OF SAFETY LABELS

Location of safety labels (decals) can vary from unit to unit.
Refer to appropriate Operation and Maintenance Manual, and
Parts Manual for your unit.
There are several specific warning signs on this machine. The
exact location of hazards and the description of the hazards are
reviewed in the appropriate Operation and Maintenance Manual.
Please become familiarized with all warning signs.
Make sure that all of the warning signs are legible. Clean the
warning signs or replace the warning signs if you cannot read
the words. Replace the illustrations if the illustrations are not
visible. When you clean the warning signs, use a cloth, water
and soap. Do not use solvent, gasoline, or other harsh
chemicals to clean the safety signs. Solvents, gasoline, or other
harsh chemicals could loosen the adhesive that secures the
warning sign. Loose adhesive will allow the warning sign to fall
off.
Replace any safety sign that is damaged, or missing. If a safety
sign is attached to a part that is replaced, install a safety sign on
the replacement part.
UNAUTHORIZED
MODIFICATIONS
Any modification made without authorization or written approval
from DOOSAN can create a safety hazard, for which the
machine owner must be held responsible.
For safety's sake, replace all OEM parts with the correct
authorized or genuine DOOSAN part. For example, not taking
the time to replace fasteners, bolts or nuts with the correct
replacement parts could lead to a condition in which the safety
of critical assemblies is dangerously compromised.

Page 10
GENERAL HAZARD
INFORMATION
Safety Rules
Only trained and authorized personnel can operate and maintain
the machine.
Follow all safety rules, precautions and instructions when
operating or performing maintenance on the machine.
Do not operate the machine if you are not feeling well, if you are
taking medication that makes you feel sleepy, if you have been
drinking, or if you are suffering from emotional problems. These
problems will interfere with your sense of judgement in
emergencies and may cause accidents.
When working with another operator or with a person on work
site traffic duty, be sure that all personnel know the nature of the
work and understand all hand signals that are to be used.
Always observe strictly any other rules related to safety.
Safety Features
Be sure that all guards and covers are installed in their proper
position. Have guards and covers repaired immediately if
damaged.
Be sure that you understand the method of use of safety
features such as transmission lever neutral lock and the seat
belt, and use them properly.
Never remove any safety features. Always keep them in good
operating condition.
Failure to use safety features according to the instructions in the
Operation and Maintenance Manual could result in serious
bodily injury.

Page 11
Inside Operator's Compartment
When entering the operator's compartment, always remove all
mud and oil from the soles of your shoes. If you operate the
accelerator and brake pedals with mud or oil stuck to your
shoes, your foot may slip and this may cause a serious accident.
Clean grease and dirt from pedals and controls. This contributes
to safe operation. Cleaning also provides an opportunity to
inspect equipment. Minor damage can be repaired or corrected
before major problems result.
Keep cab floor and consoles free of tools and personal items.
After using the ashtray, make sure that any matches or
cigarettes are properly extinguished, and be sure to close the
ashtray. If the ashtray is left open, there is danger of fire.
Do not stick suction pads to the window glass. Suction pads act
as a lens and may cause fire.
Do not leave lighters laying around the operator's compartment.
If the temperature inside the operator's compartment becomes
high, there is danger that the lighter may explode.
Do not use cellular telephones inside the operator's
compartment when driving or operating the machine. There is
danger that this may lead to an unexpected accident.
Never bring any dangerous objects such as flammable or
explosive items into the operator's cab.
To ensure safety, do not use the radio or music headphones
when operating the machine. There is danger that this may lead
to a serious accident.
When operating the machine, do not put your hands or head out
of the window.
When standing up from the operator's seat, always place
transmission neutral lock lever in the "LOCK" position and set
pilot cutoff switch to "O" (OFF) position. If you accidentally touch
the work equipment levers when they are not locked, the
machine may suddenly move and cause serous injury or
damage.
When leaving the machine, lower the work equipment
completely to the ground, set transmission neutral lock lever in
the "LOCK" position, set pilot cutoff switch to "O" (OFF) position,
"APPLY" parking brake, and shut down engine. Use the key to
lock all the equipment. Always remove the key and take it with
you.

Page 12
Clothing and Personal Protective Items
Contain long hair, and avoid loose clothing and jewelry. They can
catch on controls or in protruding parts and cause serious injury
or death.
Do not wear oily clothes. They are highly flammable.
Full eye protection, a hard hat, safety shoes and gloves may be
required at the work site.
While working on the machine, never use inadequate tools. They
could break or slip, causing injury, or they may not adequately HAOA020L
perform intended functions. Figure 1

Page 13
Breathing Masks, Ear Protection May Be
Required
Do not forget that some risks to your health may not be
immediately apparent. Exhaust gases and noise pollution may
not be visible, but these hazards can cause disabling or
permanent injuries.
NOTE: The equivalent continuous A-weighted sound
pressure level at the workstation for this machine is
given in the operation manual.
Measurement is obtained on a dynamic machine
following the procedures and cab conditions as
described in ISO 6396.
NOTE: The guaranteed sound power level emitted by the
machinery for this machine is given in the operation
manual.
Measurement is obtained on a dynamic machine with
the procedures as described in 2000/14/EC.
Vibration Level Information

Hands/Arms: The weighted root mean square acceleration to
which the hands/arms are subjected, is less than 2.5 m/s2.
Whole body: The weighted root mean square acceleration to
which the whole body is subjected, is less than 0.5 m/s2.
Measurements are obtained on a representative machine, using
measuring procedures as described in the following standard:
ISO 2631/1. ISO 5349, and SAE J1166.
Asbestos Dust Hazard Prevention

Asbestos dust can be HAZARDOUS to your health if it is
inhaled. Materials containing asbestos fiber can be present on
work site. Breathing air that contains asbestos fiber can
ultimately cause serious or fatal lung damage. To prevent lung
damage from asbestos fiber, observe following precautions:
Use a respirator that is approved for use in an
asbestos-laden atmosphere.
Never use compressed air for cleaning. ARO1770L
Use water for cleaning to keep down the dust. Figure 2
Work on the machine or component with the wind at
your back whenever possible.
Always observe any rules and regulations related to
the work site and working environment.

Page 14
Mounting and Dismounting
Before getting on or off the machine, if there is any oil, grease, or
mud on the handrails, steps, or track shoes, wipe it off
immediately. Always keep these parts clean. Repair any damage
and tighten any loose bolts.
Never get on or off a moving machine. In particular, never get on
or off a moving machine. These actions may lead to serious
injury.
When getting on or off the machine, always face the machine, HA3O1003
and maintain a three-point contact (both feet and one hand or
Figure 3
one foot and both hands) with the handholds and steps to
ensure that you support yourself securely.
Never hold any control levers when getting on or off the
machine.
Never get up from operator's seat or leave operator's station and
dismount machine if engine is running.
Fuel, Oil and Hydraulic Fluid Fire Hazards

Fuel, oil and antifreeze will catch fire if it is brought close to a
flame. Fuel is particularly flammable and can be hazardous.
Always strictly observe the following.
Add fuel, oil, antifreeze and hydraulic fluid to the machine only in
a well ventilated area. The machine must be parked with
controls, lights and switches turned "OFF." The engine must be
"OFF" and any flames, glowing embers, auxiliary heating units
or spark causing equipment must be doused, turned "OFF" and/
or kept well clear of the machine.
Static electricity can produce dangerous sparks at the fuel filling
nozzle. In very cold, dry weather or other conditions that could
produce a static discharge, keep the tip of the fuel nozzle in
constant contact with the neck of the fuel filling nozzle, to Figure 4
provide a ground.
Keep fuel and other fluid reservoir caps tight and do not start the
engine until caps have been secured.
Precautions When Handling Fluids at High

Temperature
Immediately after operations are stopped, the coolant, engine
oil, and hydraulic oil are at high temperature and the radiator and
hydraulic tank are still under pressure. Attempting to remove the
cap, drain the oil or coolant, or replace the filters may lead to
serious burns. Always wait for the temperature to go down, and
follow the specified procedures when carrying out these
operations.
HAOA050L
Figure 5

Page 15
To prevent hot coolant from spurting out, shut down engine, wait
for the coolant to cool, then loosen the cap slowly to relieve the
pressure.
To prevent hot oil from spurting out, shut down engine, wait for
the oil to cool, then loosen the cap slowly to relieve the pressure.
HAOA060L
Figure 6
Injury from Work Equipment

Do not enter or put your hand, arm or any other part of your
body between movable parts, such as between the work
equipment and cylinders, or between the machine and work
equipment.
If the control levers are operated, the clearance between the
machine and the work equipment will change and this may lead
to serious damage or personal injury.
If going between movable parts is necessary, always position HDO1010L
and secure the work equipment so that it cannot move.
Figure 7
Fire Extinguisher and First Aid Kit

As a precaution if any injury or fire should occur, always do the
following.
Be sure that fire extinguishers have been provided
and read the labels to ensure that you know now to
use them. It is recommended that an appropriately
sized (2.27 kg [5 lb] or larger) multipurpose "A/B/C"
fire extinguisher be mounted in the cab. Check and
service the fire extinguisher at regular intervals and
make sure that all work site crew members are HDO1009L
adequately trained in its use. Figure 8
Provide a first aid kit in the storage compartment and
keep another at the work site. Check the kit
periodically and make any additions if necessary.
Know what to do in case of injury from fire.
Keep emergency numbers for doctor, ambulance
service, hospital and fire department near your
telephone.
If the machine catches fire, it may lead to serious personal injury
or death. If a fire occurs during operation, escape from the
machine as follows:
Turn the starter switch "OFF" and shut down engine.

Page 16
If there is time, use the fire extinguisher to extinguish
as much of the fire as possible.
Use the handrails and steps to escape from the
machine.
The above is the basic method for escaping from the machine,
but changing the method may be necessary according to the
conditions, so carry out practice drills at the work site.
Protection from Falling or Flying Objects

On work sites where there is danger that falling objects or flying
objects may hit the operator's cab select a guard to match the
operating conditions to protect the operator.
Work in mines, tunnels, deep pits or on loose or wet surfaces
could produce danger of falling rock, roll over or hazardous flying
objects. Additional protection for operator's cab could be
required in form of a FOPS/Falling Object Protective Structure
and/or ROPS/Roll Over Protective Structure reinforcement
system. HAOA110L
Figure 9
Any reinforcement system that is installed on machine must

pass safety and certification standards and carry appropriate
labeling and rating information. For example, most often added
type of reinforcement system, FOPS, must meet or exceed
Society of Automotive Engineers standard SAE J1356,
"Performance Criteria for Falling Object Guards for Wheel
loaders."
Never attempt to alter or modify any type of protective structure
reinforcement system, by drilling holes, welding or remounting or
relocating fasteners. Any serious impact or damage to system
requires a complete integrity reevaluation. Reinstallation, HAOA100L
recertification and/or replacement of system may be necessary. Figure 10
Install Additional Safety Equipment If

Conditions Require
Laminate glass protection for the front, side or rear windows may
also be recommended depending upon particular site
conditions.
Contact your DOOSAN distributor for available safety guards
and/or recommendations if there is any danger of getting hit by
objects that could strike the operator's cab. Make sure that all
other work site crew members are kept well away from wheel
loader and safe from potential hazards.

Page 17
Maintain Standard Safety Equipment in
Good Condition
Machinery guards and body panel covers must be in place at all
times. Keep well clear of rotating parts. Pinch point hazards
such as cooling fan and alternator drive belts could catch hair,
jewelry or oversize or very loose clothing.
Safety labels must be replaced if they are damaged or become
unreadable. Information on labels gives work crew members an
important safety reminder. Part numbers for each decal and
required mounting locations are shown on pages 1-2 through 1-
4 of this section.

Page 18
Attachment Precautions
Options kits are available through your dealer. Contact
DOOSAN for information on available one-way (single-acting)
and two-way (double-acting) piping / valving / auxiliary control
kits. Because DOOSAN cannot anticipate, identify or test all
attachments that owners may wish to install on their machines,
please contact DOOSAN for authorization and approval of
attachments, and their compatibility with options kits.
Accumulator
The pilot control system is equipped with an accumulator. For a
brief period of time after the engine has been shut down, the
accumulator will store a pressure charge that may enable
hydraulic controls to be activated. Activation of any controls may
enable the selected function to operate under force of gravity.
When performing maintenance on the pilot control system, the
hydraulic pressure in the system must be released as describe
in Operation and Maintenance Manual.
The accumulator is charged with high-pressure nitrogen gas, so
it is extremely dangerous if it is handled in the wrong way.
Always observe the following precautions:
Do not drill or make any holes in the accumulator or
expose it any flame, fire or heat source.
Do not weld on the accumulator, or try attaching
anything to it.
When carrying out disassembly or maintenance of
the accumulator, or when disposing of the
accumulator, the charged gas must be properly
released. Contact your DOOSAN distributor.
Wear safety goggles and protective gloves when
working on an accumulator. Hydraulic oil under
pressure can penetrate the skin and cause serious
injuries.
Engine Ventilation
Engine exhaust gases can cause loss of judgment, loss of
alertness, and loss of motor control. These gases can also
cause unconsciousness, serious injury and fatal accidents.
Make sure of adequate ventilation before starting engine in any
enclosed area.
You should also be aware of open windows, doors or ductwork
into which exhaust may be carried, or blown by wind, exposing
others to danger. ARO1770L
Figure 11

Page 19
BEFORE STARTING ENGINE
Work Site Precautions

Before starting operations, thoroughly check the area for any
unusual conditions that could be dangerous.
Check the terrain and condition of the ground at the work site,
and determine the best and safest method of operation.
Make the ground surface as hard and horizontal as possible
before carrying out operations. If there is a lot of dust and sand
on the work site, spray water before starting operations.
If you need to operate on a street, protect pedestrians and cars

by designating a person for work site traffic duty or by erecting
fences and posting "No Entry" signs around the work site.
Erect fences, post "No Entry" signs, and take other steps to
prevent people from coming close to or entering the work site. If
people come close to a moving machine, they may be hit or
caught by the machine, and this may lead to serious personal
injury or death.
Water lines, gas lines, phone lines and high voltage electrical
lines may be buried under the work site. Contact each utility and
identify their locations. Be careful not to damage or cut any of Figure 12
these lines.
NEVER be in water that is in excess of the permissible water
depth. Refer to "Operation Manual."
Any type of object in the vicinity of the boom could represent a
potential hazard, or cause the operator to react suddenly and
cause an accident. Use a spotter or signal person working near
bridges, phone lines, work site scaffolds, or other obstructions.
Minimum levels of insurance coverage, work permits or
certification, physical barriers around the work site or restricted
hours of operation may be mandated by governing authorities.
There may also be regulations, guidelines, standards or
restrictions on equipment that may have to be followed for local
requirements. There may also be regulations related to
performing certain kinds of work. If there is any question about
whether your machine and work site complies with the
applicable standards and regulations contact your local
authorities and agencies.
Avoid entering soft ground. It will be difficult for the machine to
escape.
Avoid operating your machine to close to the edge of cliffs,
overhangs, and deep ditches. The ground may be weak in such
areas. If the ground should collapse, the machine could fall or tip
over and this could result in serious injury or death.
Remember that the soil after heavy rain, blasting or after
earthquakes, is weakened in these areas.

Page 20
Earth laid on the ground and the soil near ditches is loose. It can
collapse under the weight of vibration of your machine and
cause your machine to tip over.
Install the head guard (FOPS) if working in areas where there is
danger of falling rocks.

Page 21
Checks Before Starting Engine
Every day before starting the engine for the first time, carry out
the following checks. If these checks are not carried out properly,
there is danger of serious injury.
Completely remove all wood chips, leaves, grass,
paper and other flammable materials accumulated in
the engine compartment and around the battery.
They could cause a fire. Remove any dirt from the
window glass, mirrors, handrails, and steps.
Do not leave tools or spare parts laying around in the
operator's compartment. The vibration of the machine
when traveling or during operations may cause them
to fall and damage or break the control levers or
switches. They may also get caught in the gap of the
control levers and cause the work equipment to
malfunction or move dangerously. This may lead to
unexpected accidents.
Check the coolant level, fuel level, and hydraulic tank
oil level, and check for clogged air cleaner and
damage to the electrical wiring.
Adjust the operator's seat to a position where it is
easy to operate the machine, and check the seat belt
and mounts for damage and wear.
Check the operation of the gauges and the angle of
the mirrors, and check that the safety lever is in
"LOCKED" position.
If any abnormalities are found in the above checks,
carry out repairs immediately.
Engine Starting
Walk around your machine before getting in
operator's cab. Look for evidence of leaking fluid,
loose fasteners, misaligned assemblies or any other
indications of possible equipment hazard.
All equipment covers and machinery safety guards
must be in place, to protect against injury while
machine is being operated.
Look around work site area for potential hazards, or
people or property that could be at risk while
operation is in progress.
NEVER start engine if there is any indication that
maintenance or service work is in progress, or if a
warning tag is attached to controls in cab.
A machine that has not been used recently, or is
being operated in extremely cold temperatures, could
require a warm-up or maintenance service before
start up.

Page 22
Check gauges and monitor displays for normal
operation before starting engine. Listen for unusual
noises and remain alert for other potentially
hazardous conditions at start of work cycle.
Check tire inflation and check tires for damage or
uneven wear. Perform maintenance before operation.
Do not short circuit the starting motor to start the
engine. This is not only dangerous, but may also
damage the machine.
When starting the engine, sound the horn as an alert.
Start and operate the machine only while seated.

Page 23
Before Operating Machine
If checks are not carried out properly after starting the engine, it
may result in a delay in discovering abnormalities in the
machine, and this may lead to personal injury or damage to the
machine.
Carry out the checks in an open area where there are no
obstructions. Do not let anyone near the machine when carrying
out the checks.
Check the operating condition of the equipment, and
the actuation of the bucket, boom, and travel
systems.
Check the machine for any abnormal noise, vibration,
heat, smell, or abnormality with the gauges. Check
also for leakage of air, oil, and fuel.
If any abnormality is found, repair the problem
immediately. If the machine is used without repairing
the problems, it may lead to unexpected injury or
failure.
Clear all personnel from directly around machine and
from the area.
Clear all obstacles from the machine's path. Beware
of hazards.
Be sure that all windows are clean. Secure the doors
and the windows in the open position or in the shut
position.
Adjust the rear view mirrors for best visibility close to
the machine. Make sure that the horn, the travel
alarm (if equipped), and all other warning devices are
working properly.
Fasten the seat belt securely.
Warm up the engine and hydraulic oil before
operating machine.
Before moving the machine, check the position of
undercarriage. The normal travel position is with idler
wheels to the front under the cab and the drive
sprockets to the rear. When the undercarriage is in
the reversed position, the travel controls must be
operated in opposite directions.

Page 24
MACHINE OPERATION
IMPORTANT
If you need more information or have any questions or
concerns about safe operating procedures or working the
wheel loader correctly in a particular application or in the
specific conditions of your individual operating
environment, please consult your local DOOSAN
representative.
Operate While Seated at Operator's Station

ONLY
Never reach in through a window to work a control. Do not try to
operate wheel loader unless you're in command position -
seated at controls. You should stay alert and focused on your
work at all times. Do not twist out of seat if job activity behind
you (or to the side) requires your attention.
Use a spotter or signal person if you cannot see clearly and
something is happening behind you.
HAOA151L
Replace damaged safety labels and lost or damaged operator's Figure 13
manuals.
Do not let anyone operate machine unless they've been fully and
completely trained, in safety and in operation of the machine.
Seat Belts Should Be Used at All Times

Whenever engine is running, operator should be seated at the
control station with seat belt properly engaged.
Figure 14
Movement Alarms
If wheel loader is equipped with an audible travel movement
alarm, test alarm on a daily basis. Audible alarm should sound
as soon as travel system is engaged.

Page 25
Travel Precautions
When traveling, wheel loader always keeps lights on; make sure
that you are in compliance with all state and local regulations
concerning warning flags and signs.
Never turn the starter switch to the "O" (OFF) position when
traveling. It is dangerous if the engine stops when the machine is
traveling. It will be impossible to operate the steering unless the
unit is equipped with an emergency steering system.
Pilot control valve lever (joystick) should not be operated while
traveling.
Lower work equipment so that it is 400 mm (16 in) above
ground.
Never travel over obstacles or slopes that will cause machine to
tilt severely. Travel around any slope or obstacle that causes 10
tilt, or more.
Do not operate the steering suddenly. The work equipment may
hit the ground and cause the machine to lose its balance, and
this may damage the machine or structures in the area.
When traveling on rough ground, travel at low speed, and avoid
sudden changes in direction.
Always keep to the permissible water depth.
When traveling over bridges or structures on private land, check
first that the bridge or structure can withstand the weight of the
machine. When traveling on public roads, check with the local
authorities and follow their instructions.
Sloping Terrain Requires Caution

Dig evenly around work site whenever possible, trying to TURBO-II
gradually level any existing slope. If it's not possible to level area
)
or avoid working on a slope, reducing size and cycling rate m(16''
400 m
workload is recommended. TURBO-II
On sloping surfaces, use caution when positioning wheel loader

before starting a work cycle. Stay alert for unstable situations to
avoid getting into them. For example, you should always avoid 400 m
working bucket over downhill side of machine when parked m(16
'')
perpendicular to slope. Avoid full extensions of bucket in a AHO0970L
downhill direction. Lifting bucket too high, too close to machine, Figure 15
while wheel loader is turned uphill can also be hazardous.

Page 26
Avoid High Voltage Cables
Serious injury or death can result from contact or proximity to
high voltage electric lines. The bucket does not have to make
physical contact with power lines for current to be transmitted.
Use a spotter and hand signals to stay away from power lines
not clearly visible to operator.
Voltage Minimum Safe Distance

6.6 kV 3 m (9' 10")
33.0 kV 4 m (13' 1")
Figure 16
66.0 kV 5 m (16' 5")
154.0 kV 8 m (26' 3")
275.0 kV 10 m (32' 10")
Use these minimum distances as a guideline only. Depending

upon voltage in line and atmospheric conditions, strong current
shocks can occur with boom or bucket as far away as 4 - 6 m (13
- 20 ft) from power line. Very high voltage and rainy weather
could further decrease that safety margin.
NOTE: Before starting any type of operation near power lines
(either above ground or buried cable type) you should
always contact power utility directly and work out a
safety plan with them.
Before Starting to Dig, Contact Authorities

Below ground hazards also include natural gas lines, water
mains, tunnels and buried foundations. Know what's underneath
work site before starting to dig.
Be Aware of Height Obstacles

Any type of object in vicinity of boom could represent a potential
hazard, or cause operator to react suddenly and cause an
accident. Use a spotter or signal person working near bridges,
phone lines, work site scaffolds, or other obstructions.
Use Care on Loose Support

Working heavy loads over loose, soft ground or uneven, broken
terrain can cause dangerous side load conditions and possible
tipover and injury. Travel without a load or balanced load may
also be hazardous.
If temperatures are changing, be cautious of dark and wet
patches when working or traveling over frozen ground. Stay
away from ditches, overhangs and all other weak support
surfaces. Halt work and install support mats or blocking if work is
required in an area of poor support.

Page 27
Use Solid Support Blocking
Never rely on lift jacks or other inadequate supports when work
is being done. Block wheels fore and aft to prevent any
movement.
Digging Beneath Overhangs

Digging beneath an overhang is dangerous. Overhang could
collapse on top of operator and cause serious injury or death. HDO1042L
Go on to another digging area before steep overhangs are Figure 17
formed. Know height and reach limits of wheel loader and plan
ahead while working. Park wheel loader away from overhangs
before work shut down.
Digging Beneath Wheel Loader

Digging beneath wheel loader is dangerous. Earth beneath
could collapse. This could cause wheel loader to tip, which could
cause serious injury or death to operator. Working around deep
pits, trenching or along high walls may require support blocks,
especially after heavy rainfalls or during spring thaws.
Stay Alert for People Moving Through

Work Area
When loading a truck you should always know where the driver
is.
Avoid loading over the cab of a truck even if the driver is in a safe
spot. Someone else could have gone inside, for any number of
reasons. Avoid working where unseen passersby might be.
Slow down work cycle and use slower travel speeds in
congested or populated areas. Use a commonly understood HAOA171L
signal so that other members of work crew can warn operator to Figure 18
slow or halt work in an impending hazardous situation.
Be Aware of and Conform to Local

Regulations
Minimum levels of insurance coverage, work permits or
certification, physical barriers around work site or restricted
hours of operation may be mandated by governing authorities.
There may also be guidelines, standards or restrictions on
equipment that may be used to perform certain kinds of work.
Check and follow all local requirements, which may also be
related to below ground hazards and power lines.

Page 28
Never Use Ether Starting Aids
An electric grid type manifold heater is used for cold starting.
Glowing heater element can cause ether or other starting fluid to
detonate, causing injury.
Figure 19
Observe General Safety Rules

Only trained and authorized personnel, with a good knowledge
and awareness of safe procedures, may be allowed to operate
or perform maintenance or service on wheel loader.
All personnel at work site should be aware of assigned individual
responsibilities and tasks. Communication and hand signals
used should be understood by everyone.
Terrain and soil conditions at work site, approaching traffic,
weather related hazards and any above or below ground
obstacles or hazards should be observed and monitored by all
work crew members.
Take Time to Provide Good Visibility

Be careful not to go close to the edge of a cliff by mistake.
Use the machine only for its main purpose. Using it for other
purposes will cause failures.
To ensure an ample view, do as follows:
When working in dark areas, attach working lights
and front lights to the machine. If necessary, set up
lighting at the work site.
Stop operations when the visibility is poor, such as in
fog, mist, snow, and rain. Wait for the visibility to
improve to a level which causes no problems for the
operation.
Keep dirt and dust off of windows and off lens
surfaces of work lights. Stop working if lights,
windows or mirrors need cleaning or adjustment.
To avoid hitting the work equipment, always do the following:
When working in tunnels, on bridges, under electric
wires, or when parking the machine or carrying out
other operations in places with limited height, be
extremely careful not to hit the bucket or other parts.
To prevent collisions, operate the machine at a safe
speed when working in confined spaces, indoors, or

Page 29
in crowded areas.
Do not pass the bucket over the heads of workers or
over the operator's compartment of dump truck.
Keep "Pinch Point" Areas Clear - Use

Caution in Reverse
Use a signal person in high traffic areas and whenever
operator's view is not clear, such as when traveling in reverse.
Anyone standing near wheels, or working assemblies of the
attachment, is at risk of being caught between moving parts of
machine.
Never allow anyone to ride on any part of machine or
attachment, including any part of operator's cab. HAOA191L
Figure 20
Operate Carefully on Snow and Ice and in

Very Cold Temperatures
In icy cold weather avoid sudden travel movements and stay
away from even very slight slopes. Machine could skid off to one
side very easily.
Snow accumulation could hide or obscure potential hazards.
Use care while operating or while using machine to clear snow.
Warming up engine for a short period may be necessary, to
avoid operating with sluggish or reduced working capacity.
Jolting shocks and impact loads caused by bumping or
bottoming boom or attachment are more likely to cause severe
stress in very cold temperatures. Reducing work cycle rate and
work load may be necessary.
When the temperature rises, frozen road surfaces become soft,
so the machine travel becomes unstable.
In cold weather, do not touch metal surfaces with your bare
hands. If you touch a metal surface in extremely cold weather,
your skin may freeze to the metal surface.
Parking Machine
Avoid making sudden stops, or parking machine wherever it
happens to be at the end of the work day. Plan ahead so that the
wheel loader will be on firm, level ground away from traffic and
away from high walls, cliff edges and any area of potential water
accumulation or runoff. If parking on inclines is unavoidable,
block wheels to prevent movement. Lower bucket or other
working attachment completely to ground, or to an overnight
support saddle. There should be no possibility of unintended or
accidental movement.
When parking on public roads, provide fences, signs, flags, or
lights, and put up any other necessary signs to ensure that

Page 30
passing traffic can see the machine clearly, and park the
machine so that the machine, flags, and fences do not obstruct
traffic.
Shutdown Control Functions

After bucket has been lowered to overnight storage position,
move all switches and controls to "OFF" position. Pull parking
brake knob to "APPLIED" position. This will apply parking brake.
Move pilot cutoff switch to "LOCK" position. This will disable pilot
control valve lever (joystick). Move key in starter switch to "OFF"
position, and remove key from switch.
Engage all lock-down security equipment that may have been
installed on machine.
IMPORTANT
When hydraulic system maintenance or service work must
be performed, be aware that accumulators in system store
fluid under pressure after system has been shut down. To
release hydraulic pressure in accumulators, operate control
with engine "OFF" until accumulator pressure is completely
dissipated.
Never Let Anyone Ride on Attachment

Never let anyone ride on any work attachment, such as the
bucket, crusher, grapple, or clamshell (grab bucket). There is a
danger of the person falling and suffering serious injury.
HAAD4050
Figure 21

Page 31
MAINTENANCE
Use Warning Tag During Service

Alert others that service or maintenance is being performed and
tag operator's cab controls - and other machine areas if required
- with a warning notice.
Warning tags for controls are available from DOOSAN WARNING
distributors; see Figure 22.
HAOC920L
Figure 22
Clean Before Inspection or Maintenance

Clean the machine before carrying out inspection and
maintenance. This prevents dirt from getting into the machine
and also ensures safety during maintenance.
If inspection and maintenance are carried out when the machine
is dirty, it will become more difficult to locate the problems, and
also there is danger that you may get dirt or mud in your eyes or
that you may slip and injure yourself.
When washing the machine, do the following:
Wear shoes with nonslip soles to prevent yourself
from slipping and falling on wet places.
Wear safety glasses and protective clothing when
washing the machine with high-pressure steam.
Take action to prevent touching high-pressure water
and cutting your skin or having mud fly into your eyes.
ARO1330L
Do not spray water directly on electrical components
Figure 23
(sensors, connector) (1, Figure 23). If water gets into
the electrical system, there is danger that it will cause
defective operation and malfunction.
Pick up any tools or hammers that are laying in the work place,
wipe up any grease or oil or any other slippery substances, and
clean the area to make it possible to carry out the operation in
safety. If the work place is left untidy, you may trip or slip and
suffer injury.

Page 32
Proper Tools
Use only tools suited to the task. Using damaged, low qualify,
faulty, or makeshift tools could cause personal injury. There is
danger that pieces from, chisels with crushed heads, or
hammers, may get into your eyes and cause blindness.
HDO1037L
Figure 24
Use of Lighting
When checking fuel, oil, battery electrolyte, or window washing
fluid, always use lighting with antiexplosion specifications. If
such lighting equipment is not used, there is danger of an
explosion.
If work is carried out in dark places without using lighting, it may
lead to injury, so always use proper lighting.
Even if the place is dark, never use a lighter or flame instead of
lighting. There is danger of fire. There is also danger that the HDO1040L
battery gas may catch fire and cause and explosion.
Figure 25
Fire Prevention and Explosion Prevention

All fuels, most lubricants and some coolant mixtures are
flammable. Leaking fuel or fuel that is spilled onto hot surfaces
or onto electrical components can cause a fire.
Store all fuels and all lubricants in properly marked containers
and away from all unauthorized persons.
Store oily rags and other flammable material in a protective
container.
Do not smoke while you refuel the machine or while you are in a
refueling area.
Do not smoke in battery charging areas or in areas the contain
flammable material.
Clean all electrical connections and tighten all electrical
connections. Check the electrical wires daily for wires that are
loose of frayed. Tighten all lose electrical wires before you
operate the machine. Repair all frayed electrical wires before
you operate the machine.
Remove all flammable materials before they accumulate on the
machine.
Do not weld on pipes or on tubes that contain flammable fluids.
Do not flame cut on pipes or on tubes that contain flammable
fluids. Before you weld on pipes or on tubes or before you flame

Page 33
cut on pipes or on tubes, clean the pipes or tubes thoroughly
with a nonflammable solvent.
Burn Prevention
When checking the radiator coolant level, shut down engine, let
the engine and radiator cool down, then check the coolant
recovery tank. If the coolant level in the coolant recovery tank is
near the upper limit, there is enough coolant in the radiator.
Loosen the radiator cap gradually to release the internal
pressure before removing the radiator cap.
If the coolant level in the coolant recovery tank is below the lower
limit, add coolant.
Cooling system conditioner contains alkali. Alkali can cause
personal injury. Do not allow alkali to contact the skin, the eyes,
or the mouth.
Allow cooling system components to cool before you drain the
cooling system.
Hot oil and hot components can cause personal injury. Do not
allow hot oil or hot components to contact the skin.
Remove the hydraulic tank filter plug only after the engine has
been stopped. Make sure that the hydraulic tank filter plug is
cool before you remove it with your bare hand. Remove the
hydraulic tank filter plug slowly to relieve pressure.
Relieve all pressure in the hydraulic oil system, in the fuel
system, or in the cooling system before you disconnect any
lines, fittings, or related items.
HAAE1980
Batteries give off flammable fumes that can explode.
Figure 26
Do not smoke while you are checking the battery electrolyte
levels.
Electrolyte is an acid. Electrolyte can cause personal injury. Do
not allow electrolyte to contact the skin or the eyes.
Always wear protective glasses when you work on batteries.

Page 34
Welding Repairs
When carrying out welding repairs, carry out the welding in a
properly equipped place. The welding should be performed by a
qualified worker. During welding operations, there is the danger
of, generation of gas, fire, or electric shock, so never let an
unqualified worker do welding.
The qualified welder must do the following:
To prevent explosion of the battery, disconnect the
battery terminals and remove batteries.
To prevent generation of gas, remove the paint from
the location of the weld.
If hydraulic equipment, piping or places close to them
are heated, a flammable gas or mist will be generated
and there is danger of it catching fire. To avoid this,
never subject these places to heat.
Do not weld on pipes or on tubes that contain
flammable fluids. Do not flame cut on pipes or on
tubes that contain flammable fluids. Before you weld
on pipes or on tubes or before you flame cut on pipes
or on tubes, clean the pipes or tubes thoroughly with
a nonflammable solvent.
If heat is applied directly to rubber hoses or piping
under pressure, they may suddenly break so cover
them with a fireproof covering.
Wear protective clothing.
Make sure there is good ventilation.
Remove all flammable objects and provide a fire
extinguisher.
Precautions for Removal, Installation, and

Storage of Attachments
Before starting removal and installation of attachments, decide
the team leader.
Do not allow anyone except the authorized workers close to the
machine or attachment.
Place attachments that have been removed from the machine in
a safe place so that they do not fall. Put up a fence around the
attachments and take other measures to prevent unauthorized HDO1041L
persons from entering. Figure 27

Page 35
Precautions When Working on Machine
When carrying out maintenance operations on the machine,
keep the area around your feet clean and tidy to prevent you
from falling. Always do the following:
Do not spill oil or grease.
Do not leave tools laying about.
Watch your step when walking.
Never jump down from the machine. When getting on or off the ARO1380L
machine, use the steps and handrails, and maintain a three-
Figure 28
point contact (both feet and one hand or both hands and one
foot) to support yourself securely.
If the job requires it, wear protective clothing.
To prevent injury from slipping or falling, when working on the
hood or covers, never use any part except the inspection
passage fitted with nonslip pads.
Lock Inspection Covers

When carrying out maintenance with the inspection cover open,
lock the cover securely in position with the lock bar.
If maintenance work is carried out with the inspection cover
open but not locked, there is danger that it may suddenly close
and cause injury if there is a gust of wind.
Crushing Prevention and Cutting

Prevention
You should always have at least two people working together if
the engine must be run during service. One person needs to
remain in the operator's seat, ready to work the controls or stop
the machine and shut off the engine.
Unless you are instructed otherwise, never attempt adjustments
while the machine is moving or while the engine is running.
Stay clear of all rotating parts and moving parts.
Keep objects away from moving fan blades. The fan blades will
throw objects and the fan blades can cut objects.
Do not use a wire rope cable that is kinked or flayed. Wear
gloves when you handle a wire rope cable.
When you strike a retainer pin, the retainer pin might fly out. The
loose retainer pin can injure personnel. Make sure that the area
is clear of people when you strike a retainer pin. To avoid injury
to your eyes, wear protective glasses when you strike a retainer
pin.

Page 36
Do Not Run Engine If Repairs or Work Are
Being Performed Alone
You should always have at least two people working together if
engine must be run during service. One person needs to remain
in operator's seat, ready to work controls or stop machine and
shut "OFF" engine.
Always Use Adequate Equipment

Supports and Blocking
Do not allow weight or equipment loads to remain suspended.
Lower everything to ground before leaving operator's seat. Do
not use hollow, cracked or unsteady, wobbling weight supports.
Do not work under any equipment supported solely by a lift jack.
Do Not Work on Hot Engines or Hot

Cooling or Hydraulic Systems
Wait for engine to cool off after normal operation. Park wheel
loader on firm, level ground and lower all equipment before
shutting down and switching "OFF" controls. When engine lube
oil, gearbox lubricant or other fluids require change, wait for fluid
temperatures to decrease to a moderate level before removing
drain plugs.
NOTE: Oil will drain more quickly and completely if it is warm.
Do not drain fluids at temperatures exceeding 95C
(203F), however do not allow full cool down.
Hydraulic Cylinder Seals Require Periodic

Replacement
Check cylinder drift rate at regular intervals. Overhaul seal kits
are available through DOOSAN.
High-pressure Hydraulic Lines Can Store a

Great Deal of Energy
Exposed hydraulic hoses on arm or boom could react with
explosive force if struck by a falling rock, overhead obstacle or
other work site hazard. Extra safety guards may be required.
NEVER allow hoses to be hit, bent or interfered with during
operation.

Page 37
Precautions with High-pressure Line,
Tubes and Hoses X
When inspecting or replacing high-pressure piping or hoses,
check that the pressure has been released from the circuit.
Failure to release the pressure may lead to serious injury.
Always do the following:
Wear protective glasses and leather gloves.
Fluid leaks from hydraulic hoses or pressurized
X
components can be difficult to see but pressurized oil
has enough force to pierce the skin and cause
serious injury. Always use a piece of wood or
cardboard to check for suspected hydraulic leaks.
Never use your hands or expose your fingers.
Do not bend high-pressure lines. Do not strike high-
pressure lines. Do not install lines, tubes or hoses
that are bent or damaged.
Make sure that all clamps, guards and heat shields
are installed correctly to prevent vibration, rubbing
against other parts, and excessive heat during
operation.
H D O 10
If any of the following conditions are found, Figure 29
replace the part.
Damage or leakage from hose end.
Wear, damage, cutting of covering, or exposure
of strengthening wire layer.
Cover portion is swollen in places.
There is twisting or crushing at movable parts of
hose.
Foreign material is embedded in the covering.
Hose end is deformed.
NOTE: Refer to "Hose In-service Lifetime Limit
(European Standard ISO 8331 and
EN982 CEN)" in Operation and Maintenance
Manual, for additional European regulations.

Page 38
Obtain Immediate Medical Attention if
Pressurized Oil Pierces Skin.
WARNING!
Failure to obtain prompt medical assistance could result in
gangrene or other serious damage to tissue.
Use Correct Replacement Fasteners

Tightened to Proper Torque
Refer to "General Maintenance" section of Shop Manual for
information on tightening torques and recommended assembly
compounds and always use correct part.
Poor or incorrect fastener connections can dangerously weaken
assemblies.
Safety Critical Parts Must Be Replaced

Periodically
Replace following fire related components as soon as they begin
to show any sign of wear, or at regular periodic intervals,
whether or not deterioration is visible:
Fuel system flexible hoses, the tank overflow drain
hose and the fuel fill cap.
Hydraulic system hoses, especially the pump outlet
lines and front and rear pump branch hoses.
Keep mounting brackets and hose and cable routing
straps tight. Hose routing should have gradual bends.
Dispose of All Petroleum Based Oils and

Fluids Properly X
Physical contact with used motor oil may pose a health risk.
Wipe oil from your hands promptly and wash off any remaining
residue.
Used motor oil is an environmental contaminant and may only
be disposed of at approved collection facilities. To prevent
pollution of the environment, always do the following:
Never dump waste oil in a sewer system, rivers, etc. HAOA470L
Always put oil drained from your machine in Figure 30

containers. Never drain oil directly onto the ground.
Obey appropriate laws and regulations when
disposing of harmful materials such as oil, fuel,
solvent, filters, and batteries.

Page 39
Check Tire Pressure and Condition
Maintain tire pressure but do not overinflate. Inspect tires and
wheels daily. When inflating tires, follow procedures in
Maintenance Section, which include using an extension to allow
you to avoid standing in front of or over a tire. Do not change a
tire unless you have both experience and proper equipment.

Page 40
BATTERY
Battery Hazard Prevention

Battery electrolyte contains diluted sulfuric acid and batteries
generate hydrogen gas. Hydrogen gas is highly explosive, and
mistakes in handling them can cause serious injury or fire. To
prevent problems, always do the following:
Do not smoke or bring any flame near the battery.
When working with batteries, ALWAYS wear safety
glasses and rubber gloves.
If you spill battery electrolyte on yourself or your
clothes, immediately flush the area with water.
If battery electrolyte gets into your eyes, flush them
immediately with large quantities of water and see a
doctor at once.
If you accidentally drink battery electrolyte, drink a
large quantity of water or milk, raw egg or vegetable
oil. Call a doctor or poison prevention center
immediately.
When cleaning the top surface of the battery, wipe it
with a clean, damp cloth. Never use gasoline, thinner,
or any other organic solvent or detergent.
Tighten the battery caps securely.
Explosive battery gas can be set off by sparks from
incidental contact or static discharge. Turn "OFF" all
switches and engine when working on batteries.
Keep battery terminals tight. Contact between a loose
terminal and post can create an explosive spark.
Figure 31
If the battery electrolyte is frozen, do not charge the
battery or start the engine with power from another
source. There is danger that the battery may catch
fire.
When charging the battery or starting with power
from another source, let the battery electrolyte melt
and check that there is no leakage of battery
electrolyte before starting the operation.
Always remove the battery from the machine before
charging.
Disconnect Batteries Before Electrical

Service or Electrical Welding
Remove cable to negative terminal first when disconnecting
cable. Connect positive terminal cables first when installing a
battery.

Page 41
Use Low Heat Portable Lighting
Hot surfaces on trouble lights or portable work lights can set off
fuel or battery explosive gases.
Boost Starting or Charging Engine

Batteries
If any mistake is made in the method of connecting the booster
cables, it may cause an explosion or fire. Always do the
following:
Turn off all electrical equipment before connecting
leads to the battery. This includes electrical switches
on the battery charger or boost starting equipment.
When boost starting from another machine or vehicle HAOA310L
do not allow the two machines to touch. Wear safety Figure 32
glasses or goggles while required battery
connections are made.
24 volt battery units consisting of two series
connected twelve volt batteries have a cable
connecting one positive terminal on one of the 12 volt
batteries to a negative terminal on the other battery.
Booster or charger cable connections must be made
between the nonseries connected positive terminals
and between the negative terminal of the booster
battery and the metal frame of the machine being
boosted or charged. Refer to the procedure and
illustration in Operation and Maintenance Manual.
Connect positive cable first when installing cables
and disconnect the negative cable first when
removing them. The final cable connection, at the
metal frame of the machine being charged or boost
started, should be as far away from the batteries as
possible.

Page 42
TOWING
Precautions When Towing

If any mistake is made in the method of selecting or inspecting
the towing wire or in the method of towing, it may lead to serious
personal injury. Always do the following:
Always use the method of towing given in this
Operation and Maintenance Manual. Do not use any
other method.
Use leather gloves when handling the wire rope.
When carrying out the preparation work for towing
with two or more workers, determine the signals to
use and follow these signals correctly.
If the engine on the problem machine will not start or
there is a failure in the brake system. always contact
your DOOSAN distributor.
Never go between the towing machine and the towed
machine during the towing operation.
It is dangerous to carry out towing on slopes, so
select a place where the slope is gradual. If there is
no place where the slope is gradual, carry out
operations to reduce the angle of the slope before
starting the towing operation.
When towing a problem machine, always use a wire
rope with a sufficient towing capacity.
Do not use a frayed, kinked rope or a rope with any
loss of diameter.

Page 43
SHIPPING AND
TRANSPORTATION
Obey State and Local Over-the-Road

Regulations
Check state and local restrictions regarding weight, width and
length of a load before making any other preparation for
transport.
Hauling vehicle, trailer and load must all be in compliance with
local regulations governing intended shipping route.
Partial disassembly or teardown of wheel loader may be
necessary to meet travel restrictions or particular conditions at
work site.
Refer to the section "Transportation" section of operation
manual.
Summary of Safety Precautions for Lifting
WARNING!
Improper lifting can allow load to shift and cause personal
injury or damage to the machine.
To make safe lifts, the following items must be evaluated by

operator and work site crew.
Condition of ground support. Figure 33
Wheel loader configuration and attachments.

Weight, lifting height and lifting radius.
Safe rigging of load.
Proper handling of suspended load.
Tag lines on opposite sides of load can be very helpful in
keeping a suspended load secure, if they are anchored safely to
control points on ground.

Page 44
1Specifications
SP000096
SPECIFICATION FOR DL400SP000096
Specification
for DL400
Edition 1
Specification for DL400 SP000096

Page 1
MEMO
SP000096 Specification for DL400

Page 2
Table of Contents
Specification for DL400

Component Locations........................................... 6
General Specifications.......................................... 8
Engine Performance Curves............................... 10
Working Range and Dimensions ........................ 12
Working Capacities............................................. 15
Bucket Capacity............................................................. 15
Tipping Load.................................................................. 15
Material Weight................................................... 15
Approximate Weight of Workload Materials .................. 15

Page 3
MEMO

Page 4
SAFETY PRECAUTIONS
CAUTION!
order.
handling load.
responsibility.
APPLICABLE MODELS

DL400 5001 and Up

Page 5
COMPONENT LOCATIONS
48
50 8 49
27
45 30 42 46 29 30 36 32 33 38 34 37 35 28
13 20 39 31 21
24
10
26
13 20 04 31 21
17 18 40
14 15 11 12
03 02
25 08 23
22
19
01
05
06 07
47
44
43
16 34 41 9
FG004702
Figure 1

Page 6
Reference Reference
Description Description
Number Number
1 Counterweight 29 Rear Axle
2 Hood 30 Rear Axle Pivot
3 Muffler 31 Battery Box
4 Hydraulic Oil Tank 32 Transmission
5 Fuel Tank 33 Parking Brake
6 Engine 34 Steering Cylinder
7 Fuel Tank Fill Cap 35 Drive Shaft (Front)
8 Radiator And Oil Cooler 36 Drive Shaft (Rear)
9 T/M Oil Filter Pipe 37 Drive Shaft (Center)
10 Towing Pin 38 T/M Oil Filter
11 Precleaner 39 Return Filter
12 Air Cleaner 40 Rear Work Light
13 Front Fender 41 Articulation Center Pin
14 Bucket Cylinder 42 Engine Oil Filter Pipe
15 Headlight Supporter 43 Engine Oil Level Gauge
16 Boom Cylinder 44 Engine Oil Filter
17 Front Work Light 45 Engine Fuel Prefilter
18 Operator Cab 46 Engine Fuel Filter
19 Boom 47 Engine Coolant Filter
20 Rear Wheel Cover 48 Air-Conditioning Condenser
21 Rear Light 49 CAC Cooler
22 Fan Motor 50 T/M Oil Cooler
23 Cooling Fan
24 Bucket
25 Tilt Lever
26 Tooth Point
27 Radiator Guard Door
28 Front Axle

Page 7
GENERAL SPECIFICATIONS
DL400
Item Specification
Standard Bucket Capacity 3.90 cu. m (5.10 cu. yd.)
Vehicle Weight 22,500 kg (49,603 lb) 22,800 kg (50,264 lb)
Engine
Type QSL9 (TIER-III)
Horsepower (SAE J 1995 Gross) 284 ps @ 2,000 rpm
(209 kw @ 2,000 rpm)
Max. Torque (SAE J 1995 Gross) 148 kgm / 1,400 rpm
(1,071 ft lb @ 1,400 rpm)
Transmission
Full Automatic Power -Shift Full Automatic Power Shift
Speeds 4 Forward, 3 Reverse
Brake Systems
Service Brakes 4 Wheel, Wet Multi Disks, Dual Pedal
Parking Brake Dry Disk on T/M Output Shaft
Performance
Travel Speed (1 / 2 / 3 / 4) 6.5 (4.0) / 12.4 (7.7) / 18.4 (11.4) / 38.0 (22.8) km/h
(MPH)
Steering Angle 40
Min. Tire Turning Radius (Tire Center) 5,959 mm (19' 7")
Max. Tractive Effort 19,500 kg (42,989 lb)
Max. Breakout Force 22,000 kg (48,500 lb)
Bucket Rise Time 5.8 Seconds
Bucket Dump Time 1.4 Seconds
Bucket Descent Time 3.0 Seconds
Maximum Gradeability 58% (30)
Tire Size 26.5-25-20PR(L3) 26.5R25 (R3)
Working Range
Dump Height at 45 (w/o teeth) 3,158 mm (10' 4") 3,153 mm (10' 4")
Dump Reach at 45 (w/o teeth) 1,226 mm (4' 0") 1,216 mm (4' 0")
Max Dump Angle at Fully Raised 46
Max Tilt Angle at Carry 46
Travel Dimension
Overall Length 8,760 mm (28' 9")
Overall Width 3,280 mm (10' 9")
Overall Height 3,522 mm (11' 7") 3,517 mm (11' 6")
Wheel Base 3,500 mm (11' 6")
Tread 2,300 mm (7' 6")
Ground Clearance 510 mm (1' 8") 505 mm (1' 8")

Page 8
Page 9
ENGINE PERFORMANCE
CURVES
150
TORQUE (kg.m)
140
130
120
110
300 100
POWER OUTPUT (ps)
250
FUEL CONSUMPTION (g/ps.h)

200
180
160
150 140
1000 1500 2000
REVOLUTION (rpm)
FG004704
Figure 2

Page 10
Performance standard SAE J 1995 Gross
Horsepower 284 ps @ 2,000 rpm (280 hp @ 2,000 rpm)
Maximum Torque 148 kgm / 1,400 rpm
(1,071 ft lb @ 1,400 rpm)
Fuel Consumption 154-174 g/ps.h
NOTE: Barometric Pressure: 760 mm (30") Mercury

Temperature: 20C (68F)
W/O Cooling Fan: Driven by hydraulic fan motor
Alternator: 24 V, 70 amp
Exhaust System: Complete, attached
Air Cleaner; Installed

Page 11
WORKING RANGE AND
DIMENSIONS
Figure 3, illustrates exterior machine dimensions and working
range of machine when it is equipped with a standard bucket.
K
F
N
J
R=
R=L
R=M
I
I' 890
H'
C
H
820
G
E
D
A
FG004705
Figure 3

Page 12
Category Dimension
Overall Length (A) 8,760 mm (28' 9")
Overall Width, with bucket (B) 3,280 mm (10' 9")
Overall Height (C) 3,522 mm (11' 7")
Digging Depth (D) 130 mm (5")
Wheel Base (E) 3,500 mm (11' 6")

Tread (F) 2,300 mm (7' 7")
Ground Clearance (G) 510 mm (1' 8")
Dump Height at 45 (w/o teeth) (H) 3,158 mm (10' 4")

Dump Height at 45 (w/ teeth) (H') 2,975 mm (9' 9")
Overall Width, without Bucket (K) 2,985 mm (9' 10")
Turning Radius at Tire Center (L) 5,959 mm (19' 6")

Turning Radius at Bucket Edge (M) 6,955 mm (22' 10")
Turning Radius atTire Out (N) 6,350 mm (20' 9")
Dump Reach at 45 (w/o teeth) (I) 1,226 mm (4' 0")
Dump Reach at 45 (w/ teeth) (I') 1,370 mm (4' 5")
Height to Hinge Pin at Fully Raised (J) 4,350 mm (14' 3")
Max. Rollback at Fully Raised () 59
Bucket Dump Angle, Raised () 46
Bucket Tilt Angle, Carry () 46
Tire Size 26.5-25-20 PR(L3)

Page 13
Figure 4 and Figure 5, illustrate working range when machine is
equipped with optional pallet or log fork.
E F
a
F
C
E
B
G
D
FG004710
Figure 4
Reference Reference
Number Number
A 1,663 mm (5' 5") F 2,097 mm (6' 10")
B 2,005 mm (6' 7") G 510 mm (1' 8")
C 4,007 mm (13' 2") a 45
D 9,580 mm (31' 5") b 42
E 2,748 mm (9' 0")
a
b
A
B
FG004714
Figure 5
Reference Reference
Number Number
A 1,655 mm (5' 5") a 45
B 2,840 mm (9' 4") b 43
C 510 mm (1' 8") c 22

Page 14
WORKING CAPACITIES
Bucket Capacity
Standard toothed bucket has a capacity of 3.9 m3 (5.1cu. yd.).
An optional bucket equipped with a cutting edge and no teeth
has a capacity of 3.9 m3 (5.1 cu. yd.).
Tipping Load
Static Tipping Load with bucket in Over Front position is 18,900
kg (41,700 lb). With bucket in Fully Turned position, Static
Tipping Load is 16,500 kg (36,400 lb).
MATERIAL WEIGHT
The data below describes weight of a cubic meter (cubic yard) of
many types of workload materials.
Approximate Weight of Workload Materials
LOW WEIGHT OR MEDIUM WEIGHT OR HIGH WEIGHT OR

DENSITY DENSITY DENSITY
MATERIAL 1,100 KG/M3 1,600 KG/M3 2,000 KG/M3
(1,850 LB/YD3), OR (2,700 LB/YD3), OR (3,370 LB/YD3), OR
LESS LESS LESS
Charcoal 401 kg/m3

--------------------- ---------------------
(695 lb/yd3)
Coke, blast furnace 433 kg/m3

size --------------------- ---------------------
(729 lb/yd3)
Coke, foundry size 449 kg/m3

--------------------- ---------------------
(756 lb/yd3)
Coal, bituminous slack, 801 kg/m3

piled --------------------- ---------------------
(1,350 lb/yd3)
Coal, bituminous r. of 881 kg/m3

m., piled --------------------- ---------------------
(1,485 lb/yd3)
Coal, anthracite 897 kg/m3

--------------------- ---------------------
(1,512 lb/yd3)
Clay, DRY, in broken 1,009 kg/m3

lumps --------------------- ---------------------
(1,701 lb/yd3)

Page 15
LESS LESS LESS
Clay, DAMP, natural 1,746 kg/m3

bed --------------------- ---------------------
(2,943 lb/yd3)
Cement, Portland, DRY 1,506 kg/m3

granular --------------------- ---------------------
(2,583 lb/yd3)
Cement, Portland, DRY 1,362 kg/m3

clinkers --------------------- ---------------------
(2,295 lb/yd3)
Dolomite, crushed 1,522 kg/m3

--------------------- ---------------------
(2,565 lb/yd3)
Earth, loamy, DRY, 1,202 kg/m3
loose --------------------- ---------------------
(2,025 lb/yd3)
Earth, DRY, packed 1,522 kg/m3

--------------------- ---------------------
(2,565 lb/yd3)
Earth, WET, muddy 1,762 kg/m3

--------------------- ---------------------
(2,970 lb/yd3)
Gypsum, calcined, 961 kg/m3

(heated, powder) --------------------- ---------------------
(1,620 lb/yd3)
Gypsum, crushed to 3 1,522 kg/m3

inch size --------------------- ---------------------
(2,565 lb/yd3)
Gravel, DRY, packed 1,810 kg/m3

fragments --------------------- ---------------------
(3,051 lb/yd3)
Gravel, WET, packed 1,922 kg/m3

fragments --------------------- ---------------------
(3,240 lb/yd3)
Limestone, graded 1,282 kg/m3

above 2 --------------------- ---------------------
(2,160 lb/yd3)
Limestone, graded 1-1/ 1,362 kg/m3
2 or 2 --------------------- ---------------------
(2,295 lb/yd3)
Limestone, crushed 1,522 kg/m3
--------------------- ---------------------
(2,565 lb/yd3)
Limestone, fine 1,602 kg/m3

--------------------- ---------------------
(2,705 lb/yd3)
Phosphate, rock 1,282 kg/m3

--------------------- ---------------------
(2,160 lb/yd3)

Page 16
LESS LESS LESS
Salt 929 kg/m3

--------------------- ---------------------
(1,566 lb/yd3)
Snow, light density 529 kg/m3

--------------------- ---------------------
(891 lb/yd3)
Sand, DRY, loose 1,522 kg/m3

--------------------- ---------------------
(2,565 lb/yd3)
Sand, WET, packed 1,922 kg/m3

--------------------- ---------------------
(3,240 lb/yd3)
Shale, broken 1,362 kg/m3
--------------------- ---------------------
(2,295 lb/yd3)
Sulphur, broken 529 kg/m3

--------------------- ---------------------
(1,620 lb/yd3)
IMPORTANT
Weights are approximations of estimated average volume
and mass. Exposure to rain, snow or ground water; settling
or compaction due to overhead weight and chemical or
industrial processing or changes due to thermal or
chemical transformations could all increase value of
weights listed in table.

Page 17
Page 18
1General Maintenance
SP000097
GENERAL MAINTENANCE PROCEDURES
SP000097
General
Maintenance
Procedures
Edition 1
General Maintenance Procedures SP000097

Page 1
MEMO
SP000097 General Maintenance Procedures

Page 2
Table of Contents
General Maintenance Procedures

Welding Precautions and Guidelines.................... 6
Hydraulic System - General Precautions.............. 7
Maintenance Service and Repair Procedure........ 9
General Precautions........................................................ 9
Hydraulic System Cleanliness and Oil Leaks ..... 10
Maintenance Precautions for Hydraulic System Service10
Oil Leakage Precautions ............................................... 11
Cleaning and Inspection ..................................... 12
General Guidelines........................................................ 12
Bearing Inspection......................................................... 13
Normal Bearing ........................................................ 14
Bent Cage ................................................................ 14
Galling ...................................................................... 15
Abrasive Step Wear.................................................. 15
Etching ..................................................................... 16
Misalignment ............................................................ 16
Indentations.............................................................. 16
Fatigue Spalling........................................................ 17
Brinelling .................................................................. 17
Cage Wear ............................................................... 17
Abrasive Roller Wear................................................ 18
Cracked Inner Race.................................................. 18
Smears ..................................................................... 18
Frettage .................................................................... 19
Heat Discoloration .................................................... 19
Stain Discoloration ................................................... 19

Page 3
MEMO

Page 4
SAFETY PRECAUTIONS
CAUTION!
order.
handling load.
responsibility.
APPLICABLE MODELS

ALL MODELS ALL RANGES

Page 5
WELDING PRECAUTIONS AND
GUIDELINES
IMPORTANT
To avoid accidents, personal injury and the possibility of
causing damage to the machine or to components, welding
must only be performed by properly trained and qualified
personnel, who possess the correct certification (when
required) for the specific welding fabrication or specialized
repair being performed.
WARNING!
Structural elements of the machine may be built from a
variety of steels. These could contain unique alloys or may
have been heat treated to obtain particular strength
characteristics. It is extremely important that welding
repairs on these types of steel are performed with the
proper procedures and equipment. If repairs are performed
incorrectly, structural weakening or other damage to the
machine (that is not always readily visible) could be caused.
Always consult DOOSAN After Sales Service before
welding on integral components (loader arm, frames, car
body, track frames, turntable, attachment, etc.) of the
machine. It is possible that some types of structurally
critical repairs may require Magnetic Particle or Liquid
Penetrant testing, to make sure there are no hidden cracks
or damage, before the machine can be returned to service.
CAUTION!
Always perform welding procedures with the proper safety
equipment on hand. Adequate ventilation and a dry work
area are absolutely essential. Keep a fire extinguisher
nearby and always wear protective clothing and the
recommended type of eye protection.

Page 6
CAUTION!
Observe the following safety precautions:
1. Use extra caution and adequate safety shielding when
welding near fuel and oil tanks, batteries, hydraulic
piping lines or other fire hazards.
2. Never weld when the engine is running. Battery cables
must be disconnected before the welding procedure is
started.
3. Never weld on a wet or damp surface. The presence of
moisture causes hydrogen embrittlement and
structural weakening of the weld.
4. If welding procedures are being performed near
cylinder rods, operator's cabin window areas or any
other assemblies that could be damaged by weld
spatters, use adequate shielding protection in front of
the assembly.
5. During equipment setup, always attach ground cables
directly to the area or component being welded to
prevent arcing through bearings, bushings, or
spacers.
6. Always use correct welding rods for the type of weld
being performed and observe recommended
precautions and time constraints. AWS Class E7018
welding rods for low alloy to medium carbon steel
must be used within two hours after removal from a
freshly opened container. Class E11018G welding rods
for T-1 and other higher strength steel must be used
within 1/2 hour.
HYDRAULIC SYSTEM -
GENERAL PRECAUTIONS
Always maintain oil level in the system at recommended levels.
Assemblies that operate under heavy loads, at high speed, with
extremely precise dimensional tolerances between moving parts
- pistons and cylinders, or shoes and swash plates, for example -
can be severely damaged if oil supply runs dry.
Assemblies can be run dry and damaged severely in a very
short time when piping or hoses are disconnected to repair leaks
and/or replace damaged components. Hoses that are
inadvertently switched during disassembly (inlet for outlet and
vice versa), air introduced into the system or assemblies that are
low on oil due to neglect or careless maintenance, could all
produce sufficient fluid loss to cause damage.
When starting the engine (particularly after long layoff or storage
intervals), make sure that all hydraulic controls and operating

Page 7
circuits are in neutral, or "OFF." That will prevent pumps or other
components that may be temporarily oil starved from being run
under a load.
Replacement of any hydraulic system component could require
thorough cleaning, flushing, and some amount of prefilling with
fresh, clean oil if the protective seal on replacement parts has
obviously been broken or if seal integrity may have been
compromised. When protective seals are removed before
installation and reassembly, inspect all replacement parts
carefully, before they are installed. If the replacement part is
bone dry (with no trace of factory prelube) or has been
contaminated by dirt or by questionable oils, flushing and
prefilling with clean hydraulic fluid is recommended.
Vibration, irregular or difficult movement or unusual noise from
any part of the hydraulic system could be an indication of air in
the system (and many other types of problems). As a general
precaution (and to help minimize the risk of potential long-term
damage), allow the engine to run at no-load idle speed
immediately after initial start-up. Hydraulic fluid will circulate,
releasing any air that may have been trapped in the system
before load demands are imposed.
A daily walk-around prestart equipment safety inspection,
including a quick visual scan for any exterior evidence of leaking
hydraulic fluid, can help extend the service life of system
components.
IMPORTANT
Hydraulic system operating conditions (repetitive cycling,
heavy work loads, fluid circulating under high-pressure)
make it extremely critical that dust, grit or any other type of
contamination be kept out of the system. Observe fluid and
filter change maintenance interval recommendations and
always preclean any exterior surface of the system before it
is exposed to air. For example, the reservoir fill cap and
neck area, hoses that have to be disassembled, and the
covers and external surfaces of filter canisters should all be
cleaned before disassembly.

Page 8
MAINTENANCE SERVICE AND
REPAIR PROCEDURE
General Precautions
Fluid level and condition should always be checked whenever
any other type of maintenance service or repair is being
performed.
NOTE: If the unit is being used in an extreme temperature
environment (in subfreezing climates or in high
temperature, high humidity tropical conditions),
frequent purging of moisture condensation from the
hydraulic reservoir drain tap should be a regular and
frequent part of the operating routine. In more
moderate, temperate climates, draining reservoir
sediment and moisture may not be required more
than once or twice every few months.
Inspect drained oil and used filters for signs of abnormal coloring
or visible fluid contamination at every oil change. Abrasive grit or
dust particles will cause discoloration and darkening of the fluid.
Visible accumulations of dirt or grit could be an indication that
filter elements are overloaded (and will require more frequent
replacement) or that disintegrating bearings or other component
failures in the hydraulic circuit may be imminent or have already
occurred. Open the drain plugs on the main pump casings and
check and compare drain oil in the pumps. Look for evidence of
grit or metallic particles.
Vibration or unusual noise during operation could be an
indication of air leaking into the circuit (Refer to the appropriate
Troubleshooting section for component or unit for procedures.),
or it may be evidence of a defective pump. The gear type pilot
pump could be defective, causing low pilot pressure, or a main
pump broken shoe or piston could be responsible.
NOTE: If equipped, indicated operating pressure, as shown
on the multidisplay digital gauge on the Instrument
Panel ("F-Pump" and "R-Pump") will be reduced as a
result of a mechanical problem inside the pump.
However, pressure loss could also be due to
cavitation or air leakage, or other faults in the
hydraulic system.
Check the exterior case drain oil in the main pumps. If no
metallic particles are found, make sure there is no air in the
system. Unbolt and remove the tank return drain line from the
top part of the swing motor, both travel motors and each main
pump. If there is air in any one of the drain lines, carefully prefill
the assembly before bolting together the drain line piping
connections. Run the system at low rpm.

Page 9
HYDRAULIC SYSTEM
CLEANLINESS AND OIL LEAKS
Maintenance Precautions for Hydraulic

System Service
Whenever maintenance, repairs or any other type of
troubleshooting or service is being performed, it's important to
remember that the hydraulic system - including both the interior
and exterior surfaces of assemblies, and every drop of operating
fluid - must be protected from contamination.
Dust and other foreign contaminants are major contributors to
premature wear in hydraulic circuits. The narrow tolerances,
rapidly moving parts and high operating pressures of the system
require that fluid be kept as clean as possible. The performance
and dependability of the machine (and the service lift of
individual components) can be noticeably reduced if proper
precautions are not observed:
Use a safe, noncombustible, evaporative type, low-
residue solvent and thoroughly clean exterior
surfaces of assemblies before any part of the circuit is
opened up or disassembled.
NOTE: It's just as important to clean the cap and
reservoir top before routine fluid changes
or quick checks as it is before major
repairs. (Accumulated dirt attracts
moisture, oil and other fluids - and more
dirt.)
Keep dismantled parts covered during disassembly.
Use clean caps, plugs or tape to protect the
disconnected openings of flanges, manifolds and
piping.
Do not allow cleaning solvents or other fluids to mix
with the oil in the system. Use clean oil to flush any
traces of solvent or other residue before reassembly.
If metal or rubber fragments are found in the system,
flush and replace all fluid in the system and
troubleshoot the circuit to identify the source of
contamination.
IMPORTANT
Make sure that cleaning solvents will be compatible with
rubber materials used in the hydraulic system. Many
petroleum based compounds can cause swelling,
softening, or other deterioration of system sealing
elements, such as O-rings, caps and other seals.

Page 10
Oil Leakage Precautions
Oil that is visibly seeping from joints or seals should always
serve as a "red flag" alarm.
Leaks must alert the machine operator and maintenance crew
that air, water and dirt have an open, free passageway through
which to enter the circuit. Harsh, corrosive salt air, freezing and
thawing condensation cycles and working environments that are
full of fine dust are especially hazardous. Clogging of valve
spools or external piping (especially pilot circuit piping) can
gradually diminish or very suddenly put a complete stop to
normal hydraulic function. You can prevent having to make these
types of repairs by following recommended assembly
procedures:
1. Use new O-rings and oil seals whenever hydraulic
assemblies are rebuilt.
2. Prepare joint surfaces before assembly by checking
alignment and flatness. Clean and repair corrosion or
any other damage.
3. Follow bolt torque recommendations and all other
assembly requirements.
NOTE: Grease lip seals before assembly.
Figure 1

Page 11
CLEANING AND INSPECTION
General Guidelines
All parts must be clean to permit an effective inspection. During
assembly, it is very important that no dirt or foreign material
enters unit being assembled. Even minute particles can cause
malfunction of close fitting parts such as thrust bearing, matched
parts, etc.
WARNING!
Care should be exercised to avoid inhalation of vapors,
exposure to skin and creating fire hazards when using
solvent type cleaners.
1. Clean all metal parts thoroughly using a suitable cleaning

fluid. It is recommended that parts be immersed in
cleaning fluid and moved up and down slowly until all oils,
lubricants, and/or foreign materials are dissolved and parts
are thoroughly clean.
2. For bearings that can be removed, soak them in a suitable
cleaning fluid for a minute or two, then remove bearings
from cleaning fluid and strike flat against a block of wood to
dislodge solidified particles of lubricant. Immerse again in
cleaning fluid to flush out particles. Repeat above
operation until bearings are thoroughly clean. To dry
bearings, use moisture-free compressed air. Be careful to
direct air stream across bearing to avoid spinning bearings
that are not lubricated. DO NOT SPIN BEARINGS WHEN
DRYING; bearings may be rotated slowly by hand to
facilitate drying process.
3. Carefully inspect all bearing rollers, cages and cups for
wear, chipping or nicks to determine condition. Do not
replace a bearing cone or cup individually without
replacing mating cup or cone at the same time. After
inspection, dip bearings in light weight oil and wrap in clean
lintless cloth or paper to protect them until installation.
For those bearings that are to be inspected in place;
inspect bearings for roughness of rotation, scoring, pitting,
cracked or chipped races. If any of these defects are found,
replace bearings. Also, inspect defective bearing housing
and/or shaft for grooved, galled or burred conditions that
indicate bearing has been turning in its housing or on its
shaft.
4. It is more economical to replace oil seals, O-rings, sealing
rings, gaskets and retaining rings when unit is
disassembled than waiting for premature failures; refer to
latest Micro Fiche and/or Parts Book for replacement
items. Be extremely careful when installing sealing
members, to avoid cutting or scratching. Curling under of

Page 12
any seal lip will seriously impair its efficiency. Apply a thin
coat of Loctite #120 to outer diameter, of metal casing, on
oil seals to assure an oil tight fit into retainer. Use extreme
care not to get Loctite on lips of oil seals. If this happens,
that portion of the seal will become brittle and allow
leakage.
When replacing lip type seals, make sure spring loaded
side is towards oil to be sealed.
5. If available, use magna-flux or similar process for checking
for cracks that are not visible to the eye. Examine teeth on
all gears carefully for wear, pitting, chipping, nicks, cracks
or scores. Replace all gears showing cracks or spots
where case hardening has worn through. Small nicks may
be removed with suitable hone. Inspect shafts and quills to
make certain they have not been sprung, bent, or splines
twisted, and that shafts are true.
NOTE: Spline wear is not considered detrimental
except where it affects tightness of splined
parts.
Inspect thrust washers for distortion, scores, burs, and
wear. Replace thrust washer if defective or worn.
6. Inspect bores and bearing surfaces of cast parts and
machined surfaces for scratches, wear, grooves and dirt.
Remove any scratches and burrs with crocus cloth.
Remove foreign material. Replace any parts that are
deeply grooved or scratched which would affect their
operation.
Bearing Inspection
The conditions of the bearing are vital to the smooth and
efficient operation of the machinery. When any component
containing bearings is disassembled, always carefully examine
the condition of the bearings and all of its components for wear
and damage.
Once the bearing is removed, clean all parts thoroughly using a
suitable cleaning solution. If the bearing is excessively dirty soak
the bearing assembly in a light solution and move the bearing
around until all lubricants and or foreign materials are dissolved
and the parts are thoroughly clean.
When drying bearings, moisture free compressed air can be
used. Be careful not to direct the air in a direction which will force
the bearing to dry spin while not being properly lubricated.
After the bearings have been cleaned and dried, carefully
inspect all bearing rollers, cages and cups for wear, chipping or
nicks. If the bearing cannot be removed and is to be inspected in
place, check foe roughness of rotation, scoring, pitting, cracked
or chipped races. If any of these defects are found replace the
whole bearing assembly. NEVER replace the bearing alone
without replacing the mating cup or the cone at the same time.

Page 13
After inspection lightly coat the bearing and related parts with oil
and wrap in a clean lintless cloth or paper and protect them from
moisture and other foreign materials until installation.
It is also important to inspect the bearing housing and/or shaft
for grooved, galled or burred conditions that indicate that the
bearing has been turning in its housing or on its shaft.
If available, use magna-flux or similar process for checking for
cracks that are not visible to the naked eye.
The following illustrations will aid in identifying and diagnosing
some of the bearing related problems.
NOTE: The illustrations will only show tapered roller
bearings, but the principles of identifying, diagnosing
and remedying the defects are common to all styles
and types of bearings.
Normal Bearing
Smooth even surfaces with no discoloration or marks.
Figure 2
Bent Cage
Cage damage due to improper handling or tool usage.
Figure 3

Page 14
Replace bearing.
Figure 4
Galling
Metal smears on roller ends due to overheat, lubricant failure or
overload.
Replace bearing - check seals and check for proper lubrication.
Figure 5
Abrasive Step Wear

Pattern on roller ends caused by fine abrasives.
Clean all parts and housings, check all parts and housings,
check seals and bearings and replace if leaking, rough or noisy.
Figure 6

Page 15
Etching
Bearing surfaces appear gray or grayish black in color with
related etching away of material usually at roller spacing.
Replace bearings - check seals and check for proper lubrication.
Figure 7
Misalignment
Outer race misalignment due to foreign object.
Clean related parts and replace bearing. Make sure races are
properly seated.
Figure 8
Indentations
Surface depressions on race and rollers caused by hard
particles of foreign materials.
Clean all parts and housings, check seals and replace bearings
if rough or noisy.
Figure 9

Page 16
Fatigue Spalling
Flaking of surface metal resulting from fatigue.
Replace bearing - clean all related parts.
Figure 10
Brinelling
Surface indentations in raceway caused by rollers either under
impact loading or vibration while the bearing is not rotating.
Replace bearing if rough or noisy.
Figure 11
Cage Wear
Wear around outside diameter of cage and roller pockets
caused by abrasive material and inefficient lubrication.
Replace bearings - check seals.
Figure 12

Page 17
Abrasive Roller Wear
Pattern on races and rollers caused by fine abrasives.
Clean all parts and housings, check seals and bearings and
replace if leaking, rough or noisy.
Figure 13
Cracked Inner Race

Race cracked due to improper fit, cocking or poor bearing seat.
Replace all parts and housings, check seals and bearings and
replace if leaking.
Figure 14
Smears
Smearing of metal due to slippage caused by poor fitting,
lubrication, overheating, overloads or handling damage.
Replace bearings, clean related parts and check for proper fit
and lubrication.
Replace shaft if damaged.
Figure 15

Page 18
Frettage
Corrosion set up by small relative movement of parts with no
lubrication.
Replace bearing. Clean all related parts. Check seals and check
for proper lubrication.
Figure 16
Heat Discoloration
Heat discoloration can range from faint yellow to dark blue
resulting from overload or incorrect lubrication.
Excessive heat can cause softening of races or rollers.
To check for loss of temper on races or rollers, a simple file test
may be made. A file drawn over a tempered part will grab and
cut metal, whereas a file drawn over a hard part will glide readily
with no metal cutting.
Replace bearing if over heating damage is indicated. Check
seals and other related parts for damage.
Figure 17
Stain Discoloration
Discoloration can range from light brown to black caused by
incorrect lubrication or moisture.
if the stain can be removed by light polishing or if no evidence of
overheating is visible, the bearing can be reused.
Check seals and other related parts for damage.
Figure 18

Page 19
Page 20
SP000098
STANDARD TORQUESSP000098
Standard
Torques
Edition 1
Standard Torques SP000098

Page 1
MEMO
SP000098 Standard Torques

Page 2
Table of Contents
Standard Torques
Torque Values for Standard Metric Fasteners....... 6
Torque Values for Standard U.S. Fasteners.......... 7
Type 8 Phosphate Coated Hardware.................... 9
Torque Values for Hose Clamps ......................... 10
Torque Values for Split Flanges .......................... 11
Torque Wrench Extension Tools ......................... 12
Torque Multiplication...................................................... 12
Other Uses for Torque Wrench Extension Tools............ 13
Tightening Torque Specifications (Metric) ..................... 13
I. "Loctite" Fastener Adhesives................................. 15
II. "Loctite" Pipe Thread Sealant .............................. 15
III. "Loctite" Gasket/flange Sealer............................. 15
IV. "Loctite" Retaining Compounds........................... 16
V. "Loctite" Adhesives............................................... 16

Page 3
MEMO

Page 4
SAFETY PRECAUTIONS
CAUTION!
order.
handling load.
responsibility.
APPLICABLE MODELS

ALL MODELS ALL RANGES

Page 5
TORQUE VALUES FOR
STANDARD METRIC
FASTENERS
NOTE: The units for the torque values are kgm (ft lb).
Grade
Dia. x Pitc
h (mm)
3.6 4.6 4.8 5.6 5.8 6.6 6.8 6.9 8.8 10.9 12.9
(4A) (4D) (4S) (5D) (5S) (6D) (6S) (6G) (8G) (10K) (12K)
0.15 0.16 0.25 0.22 0.31 0.28 0.43 0.48 0.50 0.75 0.90
M5 x Std.
(1.08) (1.15) (1.80) (1.59) (2.24) (2.02) (3.11) (3.47) (3.61) (5.42) (6.50)
0.28 0.30 0.45 0.40 0.55 0.47 0.77 0.85 0.90 1.25 1.50
M6 x Std.
(2.02) (2.16) (3.25) (2.89) (3.97) (3.39) (5.56) (6.14) (6.50) (9.04) (10.84)
0.43 0.46 0.70 0.63 0.83 0.78 1.20 1.30 1.40 1.95 2.35
M7 x Std.
(3.11) (3.32) (5.06) (4.55) (6.00) (5.64) (8.67) (9.40) (10.12) (14.10) (16.99)
0.70 0.75 1.10 1.00 1.40 1.25 1.90 2.10 2.20 3.10 3.80
M8 x Std.
(5.06) (5.42) (7.95) (7.23) (10.12) (9.04) (13.74) (15.18) (15.91) (22.42) (27.48)
0.73 0.80 1.20 1.00 1.50 1.35 2.10 2.30 2.40 3.35 4.10
M8 x 1
(5.28) (5.78) (8.67) (7.23) (10.84) (9.76) (15.18) (16.63) (17.35) (24.23) (29.65)
1.35 1.40 2.20 1.90 2.70 2.35 3.70 4.20 4.40 6.20 7.20
M10 x Std.
(9.76) (10.12) (15.91) (13.74) (19.52) (19.99) (26.76) (30.37) (31.18) (44.84) (52.07)
1.50 1.60 2.50 2.10 3.10 2.80 4.30 4.90 5.00 7.00 8.40
M10 x 1
(10.84) (11.57) (18.08) (15.18) (22.42) (20.25) (31.10) (35.44) (36.16) (50.63) (60.75)
2.40 2.50 3.70 3.30 4.70 4.20 6.30 7.20 7.50 10.50 12.50
M12 x Std.
(17.35) (18.08) (26.76) (23.86) (33.99) (30.37) (45.56) (52.07) (54.24) (75.94) (90.41)
2.55 2.70 4.00 3.50 5.00 4.50 6.80 7.70 8.00 11.20 13.40
M12 x 1.5
(18.44) (19.52) (28.93) (25.31) (36.16) (32.54) (49.18) (55.69) (57.86) (81.00) (96.92)
3.70 3.90 6.00 5.20 7.50 7.00 10.00 11.50 12.00 17.00 20.00
M14 x Std.
(26.76) (28.20) (13.23) (37.61) (54.24) (50.63) (72.33) (83.17) (86.79) (122.96) (144.66)
4.10 4.30 6.60 5.70 8.30 7.50 11.10 12.50 13.00 18.50 22.00
M14 x 1.5
(29.65) (31.10) (47.73) (41.22) (60.03) (54.24) (80.28) (90.41) (94.02) (11.26) (158.12)
5.60 6.00 9.00 8.00 11.50 10.50 15.50 17.90 18.50 26.00 31.00
M16 x Std.
(40.50) (43.39) (65.09) (57.86) (83.17) (75.94) (112.11) (129.47) (133.81) (188.05) (224.22)
6.20 6.50 9.70 8.60 12.50 11.30 17.00 19.50 20.00 28.00 35.50
M16 x 1.5
(44.84) (47.01) (70.16) (62.20) (90.41) (81.73) (122.96) (141.04) (144.66) (202.52) (256.77)
7.80 8.30 12.50 11.00 16.00 14.50 21.00 27.50 28.50 41.00 43.00
M18 x Std.
(56.41) (60.03) (90.41) (79.56) (115.72) (104.87) (151.89) (198.90) (206.14) (296.55) (311.01)
9.10 9.50 14.40 12.50 18.50 16.70 24.50 27.50 28.50 41.00 49.00
M18 x 1.5
(65.82) (68.71) (104.15) (90.41) (133.81) (120.79) (177.20) (198.90) (206.14) (296.55) (354.41)
11.50 12.00 18.00 16.00 22.00 19.00 31.50 35.00 36.00 51.00 60.00
M20 x Std.
(83.17) (86.79) (130.19) (115.72) (159.12) (137.42) (227.83) (253.15) (260.38) (368.88) (433.98)
12.80 13.50 20.50 18.00 25.00 22.50 35.00 39.50 41.00 58.00 68.00
M20 x 1.5
(92.58) (97.64) (148.27) (130.19) (180.82) (162.74) (253.15) (285.70) (296.55) (419.51) (491.84)
15.50 16.00 24.50 21.00 30.00 26.00 42.00 46.00 49.00 67.00 75.00
M22 x Std.
(112.11) (115.72) (177.20) (151.89) (216.99) (188.05) (303.78) (332.71) (354.41) (484.61) (542.47)
17.00 18.50 28.00 24.00 34.00 29.00 47.00 52.00 56.00 75.00 85.00
M22 x 1.5
(122.96) (133.81) (202.52) (173.59) (245.92) (209.75) (339.95) (44.76) (405.04) (542.47) (614.80)
20.50 21.50 33.00 27.00 40.00 34.00 55.00 58.00 63.00 82.00 92.00
M24 x Std.
(148.27) (155.50) (238.68) (195.29) (289.32) (245.92) (397.81) (419.51) (455.67) (593.10) (655.43)
23.00 35.00 37.00 31.00 45.00 38.00 61.00 67.00 74.00 93.00 103.00
M24 x 1.5
(166.35) (253.15) (267.62) (224.22) (325.48) (202.52) (441.21) (484.61) (535.24) (672.66) (744.99)

Page 6
TORQUE VALUES FOR
STANDARD U.S. FASTENERS
S.A.E. Bolt Head
Type Description
Grade Marking
WILL HAVE NO MARKINGS IN THE CENTER OF THE

HEAD.
1 1 OR 2
Low or Medium Carbon Steel Not Heat Treated.
WILL HAVE THREE RADIAL LINES.

5 5
Quenched and Tempered Medium Carbon Steel.
WILL HAVE 6 RADIAL LINES.

8 8
Quenched and Tempered Special Carbon or Alloy Steel.
Recommended torque, in foot pounds, for all Standard

Application Nuts and Bolts, provided:
1. All thread surfaces are clean and lubricated with SAE-30
engine oil. (See Note.)
2. Joints are rigid, that is, no gaskets or compressible
materials are used.
3. When reusing nuts or bolts, use minimum torque values.
NOTE: Multiply the standard torque by:
0.65 When finished jam nuts are used.
0.70 When Molykote, white lead or similar
mixtures are used as lubricants.
0.75 When Parkerized bolts or nuts are used.
0.85 When cadmium plated bolts or nuts and
zinc bolts w/waxed zinc nuts are used.
0.90 When hardened surfaces are used under
the nut or bolt head.
NOTE: When reusing bolts and nuts in service, use
minimum torque values.

Page 7
The following General Torque Values must be used in all cases
where SPECIAL TORQUE VALUES are not given.
NOTE: Torque values listed throughout this manual are lubricated (wet) threads; values should be
increased 1/3 for nonlubricated (dry) threads.
Heat Treated Material Grade 5 and Grade 8
Grade 5 Grade 8
Thread Size (3 Radial Dashes On Head) (6 Radial Dashes On Head)
Foot Pounds Newton Meter Foot Pounds Newton Meter
(ft lb) (Nm) (ft lb) (Nm)
1/4" - 20 6 8 9 12
1/4" - 28 7 9 11 15
5/16" - 18 13 18 18 24
5/16" - 24 15 20 21 28
3/8" - 16 24 33 34 46
3/8" - 24 27 37 38 52
7/16" - 14 38 52 54 73
7/16" - 20 42 57 60 81
1/2" - 13 58 79 82 111
1/2" - 20 65 88 90 122
9/16" - 12 84 114 120 163
9/16" - 18 93 126 132 179
5/8" - 11 115 156 165 224
5/8" - 18 130 176 185 251
3/4" - 10 205 278 290 393
3/4" - 16 240 312 320 434
7/8" - 9 305 414 455 617
7/8" - 14 334 454 515 698
1" - 8 455 617 695 942
1" - 14 510 691 785 1064
1 1/8" - 7 610 827 990 1342
1 1/8" - 12 685 929 1110 1505
1 1/4" - 7 860 1166 1400 1898
1 1/4" - 12 955 1295 1550 2102
1 3/8" - 6 1130 1532 1830 2481
1 3/8" - 12 1290 1749 2085 2827
1 1/2" - 6 1400 2034 2430 3295
1 1/2" - 12 1690 2291 2730 3701
1 3/4" - 5 2370 3213 3810 5166
2" - 4 1/2 3550 4813 5760 7810
NOTE: If any bolts and nuts are found loose or at
values less than what the chart states, it is
recommended that the loose bolt and/or nut be
replaced with a new one.

Page 8
TYPE 8 PHOSPHATE COATED
HARDWARE
This chart provides tightening torque for general purpose
applications using original equipment standard hardware as
listed in the Parts Manual for the machine involved. DO NOT
SUBSTITUTE. In most cases, original equipment standard
hardware is defined as Type 8, coarse thread bolts and nuts and
thru hardened flat washers (Rockwell "C" 38 - 45), all phosphate
coated and assembled without supplemental lubrication (as
received) condition.
The torques shown below also apply to the following:
1. Phosphate coated bolts used in tapped holes in steel or
gray iron.
2. Phosphate coated bolts used with phosphate coated
prevailing torque nuts (nuts with distorted threads or plastic
inserts).
3. Phosphate coated bolts used with copper plated weld nuts.
Markings on bolt heads or nuts indicate material grade ONLY
and are NOT to be used to determine required torque.
Standard Torque 10%

Nominal Thread Diameter Kilogram Meter Foot Pounds
(kgm) (ft lb)
1/4" 1.1 8
5/16" 2.2 16
3/8" 3.9 28
7/16" 6.2 45
1/2" 9.7 70
9/16" 13.8 100
5/8" 19.4 140
3/4" 33.2 240
7/8" 53.9 390
1" 80.2 580
1 - 1/8" 113.4 820
1 - 1/4" 160.4 1160
1 - 3/8" 210.2 1520
1 - 1/2" 279.4 2020
1 - 3/4" 347.1 2510
2 522.8 3780

Page 9
TORQUE VALUES FOR HOSE
CLAMPS
The following chart provides the tightening torques for hose
clamps used in all rubber applications (radiator, air cleaner,
operating lever boots, hydraulic system, etc.).
Torque
Radiator, Air Cleaner, Boots, Etc. Hydraulic System
Clamp Type And Size
Kilogram Meter Inch Pounds Kilogram Meter Inch Pounds
(kgm) (in lb) (kgm) (in lb)
"T" Bolt (Any Diameter) 0.68 - 0.72 59 - 63 ------- ------
Worm Drive - Under
44 mm (1-3/4 in) Open 0.2 - 0.3 20 - 30 0.5 - 0.6 40 - 50
Diameter
Worm Drive - Over 44 mm
0.5 - 0.6 40 - 50 ------- ------
(1-3/4 in) Open Diameter
Worm Drive - All "Ultra-
0.6 - 0.7 50 - 60 0.5 - 0.6 40 - 50
Tite"

Page 10
TORQUE VALUES FOR SPLIT
FLANGES
The following chart provides the tightening torques for split
flange connections used in hydraulic systems. Split flanges and
fitting shoulders should fit squarely. Install all bolts, finger tight
and then torque evenly.
NOTE: Over torquing bolts will damage the flanges and/or
bolts, which may cause leakage.
Bolt Torque
Flange Bolt
Kilogram Meter Foot Pounds
Size (*) Size
(kgm) (ft lb)
1/2" 5/16" 2.1 - 2.5 15 - 18
3/4" 3/8" 3.0 - 3.7 22 - 27
1" 3/8" 3.7 - 4.8 27 - 35
1 - 1/4" 7/16" 4.8 - 6.2 35 - 45
1 - 1/2" 1/2" 6.4 - 8.0 46 - 58
2" 1/2" 7.6 - 9.0 55 - 65
2 - 1/2" 1/2" 10.9 - 12.6 79 - 91
3" 5/8" 19.1 - 20.7 138 - 150
3 - 1/2" 5/8" 16.2 - 18.4 117 - 133
(*) - Inside diameter of flange on end of hydraulic tube or hose

fitting.
NOTE: Values stated in chart are for Standard Pressure
Series (Code 61) Split Flanges.

Page 11
TORQUE WRENCH EXTENSION
TOOLS
Very large diameter, high grade fasteners (nuts, bolts, cap
screws, etc.) require a great deal of turning force to achieve
recommended tightening torque values.
Common problems that could occur as a result are:
Recommended torque exceeds the measuring
capacity of the torque wrench.
Specialized sockets do not fit the adapter on the front
end (nose) of the torque wrench.
Generating adequate force on the back end (handle)
of the wrench is difficult or impossible.
Restricted access or an obstruction may make use of
the torque wrench impossible.
A unique application requires fabrication of an
adapter or other special extension.
Most standard torque wrenches can be adapted to suit any one
of the proceeding needs or situations, if the right extension tool
is used or fabricated.
Torque Multiplication
A wrench extension tool can be used to increase the tightening
force on a high capacity nut or bolt.
For example, doubling the distance between the bolt and the
back (handle) end of the torque wrench doubles the tightening
force on the bolt. It also halves the indicated reading on the
scale or dial of the torque wrench. To accurately adjust or
convert indicated scale or dial readings, use the following
formula:
I = A x T / A + B where:
I = Indicated force shown on the torque wrench scale or dial.
T = Tightening force applied to the nut or bolt (actual Torque). Figure 1
A = Length of the torque wrench (between the center of the nut

or bolt and the center of the handle).
B = Length of the extension.
As an example, if a 12" extension is added to a 12" torque
wrench, and the indicated torque on the dial reads "150 ft lb," the
real force applied to the bolt is 300 ft lb:
AxT 12 x 300 3600

I= = = = 150
A+B 12 + 12 24
NOTE: The formula assumes that there is no added

deflection or "give" in the joint between the

Page 12
extension and torque wrench. Readings may
also be inaccurate:
If the extension itself absorbs some of the tightening
force and starts to bend or bow out.
If an extension has to be fabricated that is not
perfectly straight (for example, an extension made to
go around an obstruction, to allow access to a difficult
to tighten fastener), the materials and methods used
must be solid enough to transmit full tightening
torque.
Other Uses for Torque Wrench Extension

Tools
Torque wrench extensions are sometimes made up for reasons
other than increasing leverage on a fastener.
For example, a torque wrench and extension can be used to
measure adjustment "tightness" of a linkage or assembly.
Specially fabricated extensions can be used to make very
precise checks of the force required to engage or disengage a
clutch mechanism, release a spring-applied brake assembly, or
"take up" free play in most any movable linkage.
Once the value of the adjustment force is established, repeated
checks at regular intervals can help to monitor and maintain
peak operating efficiency. These types of adjustment checks are
especially useful if physical measurements of linkage travel are
difficult to make or will not provide the needed degree of
precision and accuracy.
To allow the assembly or mechanism to accept a torque wrench,
welding a nut or other adapter on the end of a linkage shaft or
other leverage point will allow turning the shaft or assembly
manually.
Tightening Torque Specifications (Metric)

(For coated threads, prelubricated assemblies.)

Page 13
CAUTION!
Disassembly, overhaul and replacement of components on
the machine, installation of new or replacement parts and/
or other service related maintenance may require the use of
thread or flange sealing assembly compound.
Use the information on this page as a general guide in
selecting specific formulas that will meet the particular
requirements of individual assembly installations. DOOSAN
does not specifically endorse a specific manufacturer or
brand name but the following table of "Loctite" applications
is included for which cross-references to other makers'
products should also be widely available.
IMPORTANT
Use primer "T" or "N" for all cold weather assembly of
fastener adhesives, with Thread locker sealers 222, 242/243,
262, 271, 272, or 277.

Page 14
I. "Loctite" Fastener Adhesives
Breakaway Cure
Product Application Color Removal Strength (in lb) of
Sealer Alone
Low strength for 6 mm (1/4") or
222 Purple Hand tools 45
smaller fasteners.
Medium strength for 6 mm (1/4") and
242 or 243 Blue Hand tools 80
larger fasteners.
Heat/260C (500F)
High strength for high grade fasteners Remove HOT
262 Red 160
subject to shock, stress and vibration.
(NO solvent)
Extra high strength for fine thread Heat/260C (500F)
271 Red 160
fasteners up to 25 mm (1") diameter. Remove HOT
High temperature/high strength for
Heat/316C (600F)
272 hostile environments to 232C Red 180
Remove HOT
(450F).
Extra high strength for coarse thread
Heat/260C (500F)
277 fasteners 25 mm (1") diameter and Red 210
Remove HOT
larger.
II. "Loctite" Pipe Thread Sealant
Product Application Color Removal Required Setup

"No-filler/nonclog" formula for high-
4 Hours (or 1/2
pressure hydraulic systems. Over
545 Purple Hand tools hour with Locquic
application will not restrict or foul
"T" Primer)
system components.
4 Hours (or 1/2
Solvent resistant, higher viscosity
656 White Hand tools hour with Locquic
tapered thread sealer.
"T" Primer)
III. "Loctite" Gasket/flange Sealer
Product Application Color Notes

Gasket eliminator specifically made
for aluminum flanges/surfaces. For Use Locquic "N" primer for fast (1/2 - 4
518 Red
hydraulic systems to 34,475 kPa hours) setup. Unprimed setup 4 - 24 hours.
(5,000 psi).
Low-pressure/wide-gap gasket
eliminator compound. Fills gaps to Use Locquic "N" primer for faster (1/2 - 4
504 Orange
0.0012 mm (0.030"), cures to rigid hours) setup. Unprimed setup 4 - 24 hours.
seal.
General purpose, fast setup, flexible-
cure gasket eliminator. For nonrigid Use Locquic "N" primer for faster (1/4 - 2
515 Purple
assemblies subject to shock, vibration hours) setup. Unprimed setup 1 - 12 hours.
or deflection.

Page 15
IV. "Loctite" Retaining Compounds

For bushings, sleeves, press fit
Use Locquic "N" primer for increased bond
bearings, splines and collars. For gaps
609 Green strength and all cold temperature
to 0.0002 mm (0.005"), temperatures
applications.
to 121C (250F).
For high temperatures to 232C
620 Green Same as 609, above.
(450F).
For high strength bonds and tight
680 clearance gaps, to 0.00008 mm Green Same as 609, above.
(0.002").
V. "Loctite" Adhesives

Black Max instant adhesive for shock May take 120 hours to reach full cure
380 Black
and vibration-resistant bonds. strength.
454 Adhesive for porous surfaces. Clear Full strength in 24 hours.
Increased strength (+50%), shock and
480 Black Full strength in 24 hours.
vibration-resistant.

Page 16
1Drive Train
SP000099
TRANSMISSION AND TORQUE CONVERTER
(ZF 4WG-260-4) SP000099
Transmission
and Torque
Converter
(ZF 4WG-260-4)
Edition 1
Transmission and Torque Converter (ZF 4WG- SP000099

260-4) Page 1
MEMO
SP000099 Transmission and Torque Converter (ZF 4WG-

Page 2 260-4)
Table of Contents
Transmission and Torque Converter

(ZF 4WG-260-4)
General ................................................................. 8
Transmission and Torque Converter ................... 10
Powershift Transmission ................................................ 11
Transmission Control ..................................................... 11
Schedule of Measuring Points and Connection 4 WG-260-
4 .................................................................................... 13
Oil Circuit Diagram 4WG - 260-4 Forward 1st Speed ... 15
Transmission Electric Components..................... 18
TCU (Transmission Control Unit)................................... 20
Transmission Control Valve ........................................... 20
Transmission Oil Temperature Sensor........................... 20
Engine Pickup Sensor ................................................... 21
Central Gear Pickup Sensor.......................................... 21
Turbine Pickup Sensor................................................... 21
Output Speed Sensor.................................................... 22
Shift Lever Switch (DW-3).............................................. 22
Forward, Reverse Switch Lever (Optional) .................... 23
Fingertip Work Lever ..................................................... 24
2-Lever (Optional)..................................................... 24
3-Lever (Optional)..................................................... 24
Switch Circuit............................................................ 25
Auto Selector Switch ..................................................... 25
Display........................................................................... 26
Transmission Faults Codes................................. 27
Fault Display .................................................................. 27
CAN - Message ............................................................. 27
Description of Fault Codes ............................................ 27
Abbreviations................................................................. 28
Definition of Operation Modes ....................................... 28

260-4) Page 3
Normal...................................................................... 28
Substitute Clutch Control.......................................... 28
Limp-home ............................................................... 28
Transmission Shut Down .......................................... 29
TCU Shut Down ....................................................... 29
Table of Fault Codes...................................................... 29
Measurement of Resistance at Actuator/sensors and
Cable ............................................................................. 29
Actuator .................................................................... 29
Cable ........................................................................ 29
Transmission Electrical Circuits .......................... 30
T/M Controller Circuit .................................................... 30
Traveling Circuits ........................................................... 31
Neutral...................................................................... 32
Forward First Gear ................................................... 33
Forward Second Gear .............................................. 34
Forward Third Gear .................................................. 35
Forward Fourth Gear ................................................ 36
Reverse First Gear ................................................... 37
Reverse Second Gear .............................................. 38
Reverse Third Gear .................................................. 39
Downshift....................................................................... 40
Overview .................................................................. 40
Kick-down: Forward Second Gear to Forward First
Gear
(Auto Selector Switch "OFF"- Manual Mode) ........... 41
Downshift (Auto Selector Switch "Step 2" - Auto Mode)
42
44
Transmission Cutoff ....................................................... 45
LIS (Load Isolation System) - Option ............................ 46
AEB Starter......................................................... 48
Introduction.................................................................... 48
AEB Check Connector .................................................. 48
Procedure to Start AEB ................................................. 49

Page 4 260-4)
Display During AEB-mode............................................. 49
Installation View.................................................. 52
Inner Section ................................................................. 52
Front View ..................................................................... 54
Side View ...................................................................... 55
Rear View ...................................................................... 56
Hydraulic Control Unit (HSG-94) ........................ 57
Disassembly .................................................................. 58
Reassembly................................................................... 61
Transmission Disassembly ................................. 67
Converter Input.............................................................. 67
Drive Shaft Pump Power Take-off.................................. 70
Transmission Pump ....................................................... 72
Output - Layshaft Assembly .......................................... 72
Disassemble Clutches and Layshaft Gear .................... 77
Disassemble Power Take-off II ...................................... 78
Disassemble Clutches ................................................... 79
Clutch - K3/K4 .......................................................... 79
Clutch - KR/K2.......................................................... 82
Clutch - KV/K1.......................................................... 85
Transmission Reassembly .................................. 88
Power Take-off II............................................................ 88
Clutch K3/K4 ................................................................. 90
Clutch K3.................................................................. 90
General Instructions for Plate Installation................. 92
Clutch - K4................................................................ 96
Clutch KR/K2............................................................... 100
Clutch - KV/K1............................................................. 108
Install Multidisk Clutches, Layshaft Gear and Output Gear
116
Install Filter .................................................................. 130
Hydraulic Pump ........................................................... 130
Drive Shaft (Power Take-off Pump) ............................. 132
Input - Converter ......................................................... 136

260-4) Page 5
Converter..................................................................... 140
Mount Hydraulic Control Unit (HSG-94) ...................... 142
Inductive Transmitter and Speed Sensor..................... 144
Setting Inductive Transmitter ....................................... 146
Speed Sensor (Hall Sensor) N Output and Speedometer.
147

Page 6 260-4)
SAFETY PRECAUTIONS
CAUTION!
order.
handling load.
responsibility.
APPLICABLE MODELS

DL400 5001 and Up

260-4)
Page 7
GENERAL
Figure 1, shows layout of drive train assemblies. The engine (1,
Figure 1) drives a torque converter (2), which drives a power
shift transmission (3). Two output shafts extend out of the
transmission. Each output shaft has a drive shaft attached to it.
Front drive shaft (4) drives a final drive shaft (6) that drives the
front differential (7).
A parking brake (8, Figure 1) is mounted on the front differential
input or transmission output shaft. The front differential is
enclosed in the front axle housing (9). Each end of the front axle
housing contains reduction gearing (10). Each end of the front
axle housing also contains a service brake (11). Rear drive shaft
(5) drives the rear differential (12). The rear differential is
enclosed in the rear axle housing (13). Each end of the rear axle
housing contains reduction gearing (10). Each end of the rear
axle housing also contains a service brake (11).
2 1
3
8 12
4
10
11
5
13
7 6
11
10
FG004082
Figure 1

260-4)
Page 8
Reference Reference
Number Number
1 Engine 8 Parking Brake
2 Torque Converter 9 Front Axle Housing
3 Transmission 10 Reduction Gearing
4 Center Drive Shaft 11 Service Brake
5 Rear Drive Shaft 12 Rear Differential
6 Front Drive Shaft 13 Rear Axle Housing
7 Front Differential

260-4)
Page 9
TRANSMISSION AND TORQUE
CONVERTER
The machine contains a powershift transmission that has four
forward speeds and three speeds in reverse. Gear changes are
made by an electrohydraulic control valve that is mounted on
transmission. Moving gear select lever in cab, generates an
electrical signal that is transmitted to the control valve. The
control valve contains proportional valves that direct pressurized
fluid to various clutches that control the forward and reverse
gears.
Item DL400
Model 4WG 260-4 (Full Auto)
Type Free Wheel Stator
Oil Cooler Water-cooled (multiplate) and Air-cooled
135 l/min at 2,000 rpm
Charging Pump
(36 U.S. gpm at 2,000 rpm)
Torque Converter
Hydraulic Pump PTO 1:1
T/C Size 370.0 mm (14.57 in)
Stall Ratio 2,104
11 Bar
Safety Relief
(160 psi)
Type Full Power Shift, Counter shaft
Speeds 4 Forward / 3 Reverse
F: 4.187 / 2.207 / 1.421 / 0.625
Ratio
Transmission R: 4.187 / 2.207 / 0.969
16 - 18 bar
Power Shift Control Pressure
(232 - 261 psi)
Shift Control Electric Shift with Proportional Valve
54 liters
Oil Capacity
(14 U.S. gal)
810 kg
Dry Weight
(1,785 lb)
Front 8.5 C Mechanics
Output Flange
Rear 7 C Mechanics
496 kgm at a slope of 50%
Static
(avail 559 kgm)
Torque
148 kgm at an emergency stop
Parking Brake Dynamic
(avail 453 kgm)
88.69 - 120 Bar
Release Press.
(1,286 - 1,740 psi)
Drive Flange 8.5 C

260-4)
Page 10
Powershift Transmission
The multispeed reversing transmission in countershaft design is
power shiftable by hydraulically actuated multidisk clutches.
All gears are constantly meshing and carried on antifriction
bearings.
The gear wheels, bearings and clutches are cooled and
lubricated with oil.
The 4-speed reversing transmission is equipped with 6 multidisk
clutches.
At the shifting, the actual plate pack is compressed by a piston,
movable in axial direction, which is pressurized by pressure oil.
A compression spring takes over the pushing back of the piston,
thus the release of the plate pack. As to the layout of the
transmission and the specifications of the closed clutches in the
single speeds, See Schedule of Measuring Points and
Connection 4 WG-260-4 on page -13. and Oil Circuit Diagram
4WG - 260-4 Forward 1st Speed on page 1-15.
Transmission Control
Transmission control, See Schedule of Measuring Points and
Connection 4 WG-260-4 on page -13., Electrohydraulic unit on
page -14 and Oil Circuit Diagram 4WG - 260-4 Forward 1st
Speed on page 1-15.
The transmission pump, necessary for the oil supply of the
converter, and for the transmission control, is sitting in the
transmission on the engine dependent input shaft.
The feed rate of the pump is Q = 115 l/min at nEngine = 2000 min-1
(Q = 30 U.S. gpm at nEngine = 2000 min-1).
This pump is sucking the oil via the coarse filter out of the oil
sump and delivers it via the ZF-Fine filter - the filters is fitted
externally from the transmission - to the main pressure valve.
ZF-Fine filter
Filtration ratio according to ISO 4572: 30 75 15 = 25 10 = 5.0
Filter surface at least: 2 x 6,700 cm2 = 13,400 cm2
Dust capacity according to ISO 4572 at least: 17 g
The six clutches of the transmission are selected via the 6
proportional valves P1 to P6.
The proportional valve (pressure regulator unit) is composed of
pressure regulator (e.g. Y6). follow-on slide and vibration
damper.
The control pressure of 9 bar (130 psi) for the actuation of the
follow-on slides is created by the pressure reducing valve. The
pressure oil (16 - 18 bar (230 - 260 psi)) is directed via the
follow-on slide to the respective clutch.

260-4)
Page 11
Due to the direct proportional selection with separated pressure
modulation for each clutch, the pressure to the clutches, which
are engaged in the gear change, will be controlled. In this way, a
hydraulic intersection of the clutches to be engaged and
disengaged becomes possible. This is creating spontaneous
shiftings without traction force interruption.
At the shifting, the following criteria will be considered:
- Speed of engine, turbine, central gear train and output.
- Transmission temperature.
- Shifting mode (up-, down-, reverse shifting and speed
engagement out of Neutral).
- Load condition (full and part load, traction, overrun
inclusive consideration of load cycles during the shifting).
The main pressure valve is limiting the max. control pressure to
16 - 18 bar (230 - 260 psi) and releases the main stream to the
converter and lubricating circuit.
In the inlet to the converter, a converter safety valve is installed
which protects the converter from high internal pressure
(opening pressure 11 bar (160 psi)).
Within the converter, the oil serves to transmit the power
according to the well-known hydrodynamic principle.
To avoid cavitation, the converter must be always completely
filled with oil.
This is achieved by a converter pressure backup valve, rear
mounted to the converter, with an opening pressure of at least 5
bar (73 psi).
The oil, escaping out of the converter, is directed to a heat
exchanger.
From the heat exchanger, the oil is directed to the transmission
and there to the lubricating oil circuit, so that all lubricating points
are supplied with cooled oil.
The allocation of the pressure regulators to the single speeds
can be seen on the Schedule of Measuring Points and
Connection 4 WG-260-4 on page 1-13 and Oil Circuit Diagram
4WG - 260-4 Forward 1st Speed on page 1-15.

260-4)
Page 12
Schedule of Measuring Points and
Connection 4 WG-260-4
The marked positions (e.g. 53) correspond with the positions on
the Oil Circuit Diagram 4WG - 260-4 Forward 1st Speed on
page 1-15.
The measurements have to be carried out at hot transmission
(about 80 - 90C).
Marking on the
No. Denomination of the Position Connection
Valve Block
Measuring Points for Pressure Oil and Temperature
51 In front of the converter - Opening pressure 11 bar (160 M10 x 1 H
psi)
52 Behind the converter - Opening pressure 5 bar (73 psi) M14 x 1.5
53 Clutch Forward 16 - 18 bar (230 - 260 psi) KV M10 x 1 B
55 Clutch Reverse 16 - 18 bar (230 - 260 psi) KR M10 x 1 E
56 Clutch Reverse 16 - 18 bar (230 - 260 psi) K1 M10 x 1 D
57 Clutch Reverse 16 - 18 bar (230 - 260 psi) K2 M10 x 1 A
58 Clutch Reverse 16 - 18 bar (230 - 260 psi) K3 M10 x 1 C
60 Clutch Reverse 16 - 18 bar (230 - 260 psi) K4 M10 x 1 F
63 Behind the Converter
M14 x 1.5
Temperature 100C, Short-time 120C
65 System Pressure 16 - 18 bar (230 - 260 psi) K4 M10 x 1 K
10 Breather M10 x 1
15 Connection to the Heat Exchanger -------
16 Connection from the Heat Exchanger -------
28 To the Filter M42 x 2
29 From the Filter M42 x 2
30 From the Filter Bypass M42 x 2
36 Oil Filter Plug M42 x 2
49 Plug Connection on the Electrohydraulic Control Unit
68 System Pressure (Option) M16 x 1.5 G
69 Control System (Option) M16 x 1.5 J
Inductive Transmitters and Speed Sensor
5 Inductive Transmitter n Turbine M18 x 1.5
9 Inductive Transmitter n Central Gear Train M18 x 1.5
13 Speed Sensor n Output and Speedometer -------
14 Inductive Transmitter n Engine M18 x 1.5

260-4)
Page 13
Figure 2

260-4)
Page 14
Oil Circuit Diagram 4WG - 260-4 Forward
1st Speed
The marked positions (e.g. 53) correspond with the positions on
Schedule of Measuring Points and Connection 4 WG-260-4 on
page 1-13
Reference
Positions
Number
WT Heat Changer
WGV Converter Back Pressure Valve 5 bar (73 psi)
WSV Converter Safety Valve 11 bar (160 psi)
HDV Main Pressure Valve 16 - 18 bar (230 - 260 psi)
RV-9 Pressure Reducing Valve 9 bar (130 psi)
NFS Follow-on Slide
D Vibration Damper
B Orifice
P1 Proportional Valve - Clutch KR
P2 Proportional Valve - Clutch K4
P5 Proportional Valve - Clutch KV
Y1 -Y6 Pressure Regulator
TEMP Temperature Sensor
Figure 3

260-4)
Page 15
P1 P2 P3 P4 P5 P6
WT
(SCOPE OF SUPPLY
CUSTOMER)
LEGEND:
= MAIN PRESSURE
= REGULATED MAIN PRESSURE
= PILOT PRESSURE
= CONVERTER INPUT PRESSURE
= CONVERTER OUTPUT PRESSURE
= LUBRICATION
= RETURN INTO THE SUMP
AJS0870L
Figure 4

260-4)
Page 16
260-4)
Page 17
TRANSMISSION ELECTRIC
COMPONENTS
20
30
13
21 10
40
50
0 km/h
10 18
19
14 17
20
15
3 2 1
1
16
1-4 A
MAN
3
9
2
11
12 4
6 7
FG004369
Figure 5

260-4)
Page 18
Reference Reference
Number Number
1 T/M Controller 12 T/M Cutoff Pressure Switch
2 T/M Control Valve 13 Downshift Switch
3 T/M Oil Temperature Sensor 14 Safety Starter Switch
4 Engine Pickup Sensor 15 Fuse Box
5 Central Gear Pickup Sensor 16 Parking Brake Switch
6 Turbine Pickup Sensor 17 Control Unit
7 Output Speed Sensor 18 Starter Controller
8 Shift Lever Switch 19 LIS (Load Isolation System)
9 Auto Selector Switch Switch (Option)
10 Display 20 LIS Solenoid Valve
11 T/M Cutoff Switch 21 Speedometer

260-4)
Page 19
TCU (Transmission Control Unit)
1. Sending a control signal transmitted from the shift lever to
the control valve, generates a speed.
2. At the auto mode, transmits the appreciate signals to the
control valves according to the load and engine rpm.
3. Detecting a fault, controls various clutches.
AJS0200L
Figure 6
Transmission Control Valve

+ VPS1
1. The transmission control valve contains a temperature
Y2
sensor and proportional solenoid valves (Y1 - Y6) that Y1
direct pressurized fluid to various clutches that generates a Y3
speed with control the shift gears. Y4

Y5
2. Specification of the proportional solenoid valve. Y6
TEMP
Resistance: 19 1.9 ohm at 20C. TEMP
Pressure: 0.80 kg/cm (11.4 psi) 8.30 kg/cm (118

psi) FG005184
Figure 7
3. The contained temperature sensor detects the temperature
of the control valve and transmits the electrical signal to the
TCU, and serves TCU determines gears to change.
Neutral: At temperature less than -30C
1st or 2nd gear: At temperature less than -10C
Normal Operation: At temperature greater than -10C
Transmission Oil Temperature Sensor

1. Detecting a oil temperature of transmission and send a
control signal to transmission oil temperature gauge.
2. Specification
Resistance
216 30 Ohm (at 60C)
81.2 10 Ohm (at 90C)
36.5 3.5 Ohm (at 120C) AJS0220L
Figure 8
18.7 2.1 Ohm (at 150C)

260-4)
Page 20
Engine Pickup Sensor
1. Detect a revolution of gear array in engine side.
2. Specification
Resistance: 1050 10% (at 20C)
Fasten torque: 30 Nm
Gap: 0.5 - 0.8 mm (0.0197 - 0.0315 in)
Operation temperature: -40C - +150C
AJS0230L
Output: 60 Pulse/Rev.
Figure 9
Central Gear Pickup Sensor

1. Detect a revolution of central gear array
2. Specification
Gap: 0.3 - 0.4 mm (0.0118 - 0.0157 in)
AJS0240L
Figure 10
Turbine Pickup Sensor

1. Detect a revolution of gear array in turbine side.
2. Specification
Gap: 0.5 - 0.8 mm (0.0197 - 0.0315 in)
AJS0250L
Figure 11

260-4)
Page 21
Output Speed Sensor 3(+)
1. Detect a revolution of gear array in transmission output 2(SIG)
side. 1(-)
2. Specification.
Voltage Supply: 20 V - 32 V
Operation Frequency: 2 Hz - 5 KHz
Fasten torque (M8): 23 Nm 1.5 40
Gap: 1.0 - 1.5 mm (0.0394 - 0.0591 in) AJS0260L
Figure 12
Shift Lever Switch (DW-3)

1. Forward, Reverse and Shift
F: Forward F
N: Neutral
R: Reverse N KD
1, 2, 3, 4: Shift Step
SHIFT SWITCH
* Forward shift range: 1 - 4
LEVER LOCK KEY
* Reverse shift range: 1 - 3 R (N/D)
2. Kick-down (Down Shift) Switch AJS0270L
Figure 13
KD: Kick-down Switch
3. Lever Lock Key
N: Neutral (The lever is not moved.)
D: Driving (The lever is released.)
4. Switch Circuit
B A AD3 (B3)
1 2 G B AD2 (B2)
1 2 L X1
C AD1 (B1)
1 2 V
D AD7 (KD)
R A ED1 (+/VP)
2 Gr
1 D AD6 (N)
3 2
1
3 Y B AD4 (F) X2
1 2
3 P C AD5 (R)
AJS0280L
Figure 14

260-4)
Page 22
5. Terminal position and color
TERMINAL COLOR
(AD6) GREY
D C B A
(AD5) PINK
X2
(AD4) YELLOW
(VP) RED
(AD7) VIOLET
D C B A
(AD1) BLUE
X1
(AD2) GREEN
(AD3) BLACK
AJS0290L
Figure 15
6. Switch Connection
GEAR FORWARD REVERSE NEUTRAL KICK

TERMINAL 1 2 3 4 1 2 3 4 1 2 3 4 DOWN
ED1 VP
AD1 B1
AD2 B2
AD3 B3
AD4 V
AD5 R
AD6 AS
AD7 KD
AJS0300L
Figure 16
Forward, Reverse Switch Lever (Optional) F R

N
1. Forward, Reverse Switch H
KD
F: Forward
N: Neutral
R: Reverse
2. Horn Switch
H: Horn Switch
FG004370
3. Kick-down (Down Shift) Switch
Figure 17

260-4)
Page 23
Fingertip Work Lever
2-Lever (Optional) BUCKET BOOM

1. Horn Switch
H KD
H: Horn Switch
12 11 10 9 8 7
DEUTSCH
1 2 3 4 5 6
FG004371
Figure 18
3-Lever (Optional)
AUX. BUCKET BOOM
1. Horn Switch
H KD
H: Horn Switch
12 11 10 9 8 7
DEUTSCH
1 2 3 4 5 6
FG004372
Figure 19

260-4)
Page 24
Switch Circuit
1
12 1
RETURN TO DIG
12 MAGNET
2
11 2
FLOAT
11 MAGNET
3
10 3
RAISE
10 MAGNET
4
HORN
9
5
DOWN SHIFT
8
FG004373
Figure 20
7 6
8 5
DEUTSCH
9 4
10 3
11 2
12 1
FG004374
Figure 21
Auto Selector Switch

1. This is an auto/manual selector switch.
2. When the switch is in the "I" - (Auto) position, the gear 1-4 A
shifting will take place automatically to be selected by the
operator, according to the load and to the vehicle speed. MAN 2-4
3. Automatic shifting takes place between gears.
1st ('MAN'): Manual
2nd ('1 - 4'): Auto (Forward): 1st - 2nd - 3rd - 4th
3rd ('2 - 4'): Auto (Forward): 2nd - 3rd - 4th
FG004375
(Reverse): 2nd - 3rd
Figure 22
4. When the switch is in the "O" - (Manual) position, the
shifting is returned to the manual mode and the control
signal shifts the transmission to gear selected by the
operator.

260-4)
Page 25
Display
NOTE: See "Transmission Error Codes (ZF)" shop manual
section.

260-4)
Page 26
TRANSMISSION FAULTS CODES
The transmission has a monitoring system that indicates when a
malfunction is occurring.
Fault Display h
left
character
right
character g
If a fault is detected, the display shows a spanner symbol (g) for

a fault. The display shows the fault code, if the gear selector is in
neutral.
If more than one fault is detected, each fault code is shown for
about 1 second.
BAR
CAN - Message FG004442
The TCU sends the fault code of a detected fault in the specified Figure 23
CAN - message, while the fault is active.
If more than one fault is detected, the fault code scrolls.
Description of Fault Codes

First Number Meaning of Number
1 Hex Digital Input Signal
2 Hex Analog Input Signal
3 Hex Speed Signal
4 Hex Can Signal Error
7 Hex Analog Current Output Signal
9 Hex Digital Output Signal
A Hex Digital Output Signal
B Hex Transmission Fault, Clutch Error
C Hex Logical Fault
D Hex Power Supply
E Hex High Speed Signal
F Hex General Fault

260-4)
Page 27
Abbreviations
Throughout this section the following abbreviations are used to
indicate various conditions.
Abbreviations
O.C. Open Circuit
S.C. Short Circuit
Op-Mode OPeration Mode
TCU Transmission Control Unit
ABS Anti Blocking System
ASR Anti Slipping Regulation
EEC Electronic Engine Controller
PTO Power Take Off
CCO Clutch Cutoff
Definition of Operation Modes
Normal
There is no failure detected in transmission system or 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 cannot change gears or direction under control of normal
clutch modulation. TCU uses 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.

260-4)
Page 28
Transmission Shut Down
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 ADM 1 to ADM 8.
The operator has to slow down the vehicle. The transmission will
stay in neutral.
TCU Shut Down

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 all functions are disabled which use ADM 1 to ADM
8. The transmission will stay in neutral.
Table of Fault Codes

Fault codes are given in a separate section "Transmission Error
Codes (ZF)."
Measurement of Resistance at Actuator/

sensors and Cable
Actuator
open circuit:R12 R1G R2G 1
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) R
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). 2
G
HBOE640I
Figure 24
Cable
UBat
open circuit:
R12 R1P R1C R2P R2C P (power supply)
TCU
short cut to ground: Actuator /
1 2
Sensor
R12 0;R1C R2C 0,R1P R2P
C (chassis)
short cut to battery:
R12 0,R1C R2C ,R1P R2P 0 Gnd
HBOE650I
Figure 25

260-4)
Page 29
TRANSMISSION ELECTRICAL
CIRCUITS
T/M Controller Circuit
19
6 4WG-260 MISSION CONNECTION
SOLENOID FORWARD REVERSE
13 CLUTCH
VALVE 1 2 3 4 1 2 3
0
KV Y5
14 5 I
3
1 II KR Y1
9 14 BATT
10 K1 Y3
K2 Y6
17
(8)
10 20 K3 Y4
(N) 87a 87a K4 Y2
18 87
30 30
87 +
85 86 86 85 - 21
11
1-4 2-4 1
23 5
22 68 14 2-1 2-3
87a
30 52
87 30
86 8 16
85 8 36 (CN1-4) SIG. 15
53 21 2 4
57
3
12 62 2
VPS1 7 13 11
+
Y1 1 10
4 1 9
Y2 2 56
Y3 3 32
Y4 4 55 15 2 1
3 Y5 5 9 18 4 26 3
KICK 1 2 3 4
Y6 6 51 DOWN STEP STEP STEP STEP F N R
TEMP 8 39 45 X2-A VP
TEMP 9 46 67 X2-D AD6
X1-A AD3
23 49
22 X1-D AD7 2
63 X1-C AD1
17
24 65 X1-B AD2
43 X2-B AD4
64 X2-C AD5
A 25
26 CC-TV
B 120 OHM
C
27 59
4P CONN(4) 29
28
12 19 44 F 7 0
27 (ENGINE) 35 N 5 I
3
41 31 R II
(TURBINE) 10 9
42
(CENTRAL
3 30
GEAR CHAIN)
EST-37
3
1
28
AUTO(1-4) 29
AUTO(2-4) 20 2 F 2-LEVER (OPT)
5
TML 1 2 3 1 4 N
PST
MANUAL 2 7
AUTO(1-4) R
AUTO(2-4)
MONO-LEVER (OPT)
25 66 1
F/R SELECT 7 5
L11 7
ELEC. STEERING
L14
7 10 9
1 6
7 0
NC 3
1
31 NO
C 3 5 I
1 II
2 9
32 19
10
3
87a 28
30
3 87 87a 87a
2 30 30
85 86 87 87
1
85 86 86 85
PVED
7
35 34
4
5 8 33
6
36 ELECTRIC STEERING (OPT) 9
FG004376
Figure 26
The transmission proportioning solenoid valves are shown here

as (Y1 thru Y6, Figure 26).

260-4)
Page 30
Reference Reference
Number Number
1 T/M Controller 19 Fuse Box 2
2 Shift Lever Switch 20 Reverse Relay
3 T/M Control Valve 21 Reverse Warning Buzzer
4 Fuse Box 1 22 LIS Relay
5 Auto Selector Switch 23 T/M Oil Pressure Sensor
6 T/M Cutoff Selector Switch 24 Bypass Filter Switch
7 T/M Cutoff Pressure Switch 25 Gauge Panel
8 Display 26 AEB Check Connector
9 Downshift Switch 27 Diagnostic Connector
10 Safety Starter Switch 28 FNR Switch
11 Output Speed Sensor 29 FNR Selector Switch
12 Speed Pickup 3 30 Mono Lever Switch
13 LIS (Load Isolation System) 31 Armrest Switch
Switch 32 Electric Steering Relay 1
14 LIS Solenoid Valve 33 Electric Steering Relay 2
15 Speedometer 34 FNR Selector Relay
16 Parking Brake Switch 35 Electric Steering Switch
17 Control Unit 36 Electric Steering Equipment
18 Starter Relay
Traveling Circuits
Shift Lever Position TCU Input TCU Output T/M Control Valve
Neutral 45, 67, 20 (12, 13) -
1st Gear 45, 20, 43, 63 (12, 13) - 32, 9 Y3, Y5
2nd Gear 45, 20, 43 (12, 13) - 9, 51 Y5, Y6
Forward
3rd Gear 45, 20, 43, 65 (12, 13) - 55, 9 Y4, Y5
4th Gear 45, 20, 43, 63, 65 (12, 13) - 56, 55 Y2, Y4
1st Gear 45, 20, 64, 63 (12, 13) - 10, 32 Y1, Y3
Reverse 2nd Gear 45, 20, 64 (12, 13) - 10, 51 Y1, Y6
3rd Gear 45, 20, 64, 65 (12, 13) - 32, 9 Y1, Y4

260-4)
Page 31
Neutral
(8)
17 10 4
(N) 87a
18 87
30 11
85 86 1 8
1-4 2-4 1
52 14 2-1 2-3
19
BATT 14 23
36 (CN1-4) 16
68 SIG. 15
21 2
12
VPS1 7 13 3
+
62 2
Y1 1 10 11
Y2 2 56
4 1 9
Y3 3 32
Y4 4 55
3 Y5 5 9 EST-37
KICK 1 2 3 4
TEMP 9 46 67 X2-D AD6
49 X1-A AD3
23 22 X1-D
17 63 X1-C
AD7 2
24 65 X1-B
AD1
AD2
19 43 X2-B AD4
(ENGINE) 64 X2-C AD5
41
12 (TURBINE)
42
(CENTRAL
3
GEAR CHAIN)
7 6
AUTO(1-4) 29 66 1
5
AUTO(2-4) 20 7
10 9
PST TML 1 2 3 1
MANUAL 2
5 AUTO(1-4)
AUTO(2-4)
FG004377
Figure 27
When all transmission solenoid valves are de-energized (OFF)

the transmission is in "NEUTRAL."

260-4)
Page 32
Forward First Gear
(8)
17 10 4
(N) 87a
18 87
30 11
85 86 1 8
1-4 2-4 1
52 14 2-1 2-3
19
BATT 14 23
36 (CN1-4) 16
68 SIG. 15
21 2
12
VPS1 7 13 3
+
62 2
Y1 1 10 11
Y2 2 56
4 1 9
Y3 3 32
Y4 4 55
3 Y5 5 9 EST-37
KICK 1 2 3 4
TEMP 9 46 67 X2-D AD6
49 X1-A AD3
23 22 X1-D
17 63 X1-C
AD7 2
24 65 X1-B
AD1
AD2
19 43 X2-B AD4
41
12 (TURBINE)
42
(CENTRAL
3
GEAR CHAIN)
7 6
AUTO(1-4) 29 66 1
5
AUTO(2-4) 20 7
10 9
PST TML 1 2 3 1
MANUAL 2
5 AUTO(1-4)
AUTO(2-4)
FG004378
Figure 28
Transmission solenoid valves (Y3 and Y5, Figure 28) are

energized when in forward first gear.

260-4)
Page 33
Forward Second Gear
17 10 4
(N) 87a
18 87
30 11
85 86 1 8
1-4 2-4 1
52 14 2-1 2-3
19
BATT 14 23
36 (CN1-4) 16
68 SIG. 15
21 2
12
VPS1 7 13 3
+
62 2
Y1 1 10 11
Y2 2 56
4 1 9
Y3 3 32
Y4 4 55
3 Y5 5 9 EST-37
KICK 1 2 3 4
TEMP 9 46 67 X2-D AD6
49 X1-A AD3
23 22 X1-D
17 63 X1-C
AD7 2
24 65 X1-B
AD1
AD2
19 43 X2-B AD4
41
12 (TURBINE)
42
(CENTRAL
3
GEAR CHAIN)
7 6
AUTO(1-4) 29 66 1
5
AUTO(2-4) 20 7
10 9
PST TML 1 2 3 1
MANUAL 2
5 AUTO(1-4)
AUTO(2-4)
FG004379
Figure 29

energized when in forward second gear.

260-4)
Page 34
Forward Third Gear
(8)
17 10 4
(N) 87a
18 87
30 11
85 86 1 8
1-4 2-4 1
52 14 2-1 2-3
19
BATT 14 23
36 (CN1-4) 16
68 SIG. 15
21 2
12
VPS1 7 13 3
+
62 2
Y1 1 10 11
Y2 2 56
4 1 9
Y3 3 32
Y4 4 55
3 Y5 5 9 EST-37
KICK 1 2 3 4
TEMP 9 46 67 X2-D AD6
49 X1-A AD3
23 22 X1-D
17 63 X1-C
AD7 2
24 65 X1-B
AD1
AD2
19 43 X2-B AD4
41
12 (TURBINE)
42
(CENTRAL
3
GEAR CHAIN)
7 6
AUTO(1-4) 29 66 1
5
AUTO(2-4) 20 7
10 9
PST TML 1 2 3 1
MANUAL 2
5 AUTO(1-4)
AUTO(2-4)
FG004380
Figure 30

energized when in forward third gear.

260-4)
Page 35
Forward Fourth Gear
17 10 4
(N) 87a
18 87
30 11
85 86 1 8
1-4 2-4 1
52 14 2-1 2-3
19
BATT 14 23
36 (CN1-4) 16
68 SIG. 15
21 2
12
VPS1 7 13 3
+
62 2
Y1 1 10 11
Y2 2 56
4 1 9
Y3 3 32
Y4 4 55
3 Y5 5 9 EST-37
KICK 1 2 3 4
TEMP 9 46 67 X2-D AD6
49 X1-A AD3
23 22 X1-D
17 63 X1-C
AD7 2
24 65 X1-B
AD1
AD2
19 43 X2-B AD4
41
12 (TURBINE)
42
(CENTRAL
3
GEAR CHAIN)
7 6
AUTO(1-4) 29 66 1
5
AUTO(2-4) 20 7
10 9
PST TML 1 2 3 1
MANUAL 2
5 AUTO(1-4)
AUTO(2-4)
FG004381
Figure 31

energized when in forward fourth gear.

260-4)
Page 36
Reverse First Gear
(8)
17 10 4
(N) 87a
18 87
30 11
85 86 1 8
1-4 2-4 1
52 14 2-1 2-3
19
BATT 14 23
36 (CN1-4) 16
68 SIG. 15
21 2
12
VPS1 7 13 3
+
62 2
Y1 1 10 11
Y2 2 56
4 1 9
Y3 3 32
Y4 4 55
3 Y5 5 9 EST-37
KICK 1 2 3 4
TEMP 9 46 67 X2-D AD6
49 X1-A AD3
23 22 X1-D
17 63 X1-C
AD7 2
24 65 X1-B
AD1
AD2
19 43 X2-B AD4
41
12 (TURBINE)
42
(CENTRAL
3
GEAR CHAIN)
7 6
AUTO(1-4) 29 66 1
5
AUTO(2-4) 20 7
10 9
PST TML 1 2 3 1
MANUAL 2
5 AUTO(1-4)
AUTO(2-4)
FG004382
Figure 32

energized when in reverse first gear.

260-4)
Page 37
Reverse Second Gear
17 10 4
(N) 87a
18 87
30 11
85 86 1 8
1-4 2-4 1
52 14 2-1 2-3
19
BATT 14 23
36 (CN1-4) 16
68 SIG. 15
21 2
12
VPS1 7 13 3
+
62 2
Y1 1 10 11
Y2 2 56
4 1 9
Y3 3 32
Y4 4 55
3 Y5 5 9 EST-37
KICK 1 2 3 4
TEMP 9 46 67 X2-D AD6
49 X1-A AD3
23 22 X1-D
17 63 X1-C
AD7 2
24 65 X1-B
AD1
AD2
19 43 X2-B AD4
41
12 (TURBINE)
42
(CENTRAL
3
GEAR CHAIN)
7 6
AUTO(1-4) 29 66 1
5
AUTO(2-4) 20 7
10 9
PST TML 1 2 3 1
MANUAL 2
5 AUTO(1-4)
AUTO(2-4)
FG004383
Figure 33

energized when in reverse second gear.

260-4)
Page 38
Reverse Third Gear
(8)
17 10 4
(N) 87a
18 87
30 11
85 86 1 8
1-4 2-4 1
52 14 2-1 2-3
19
BATT 14 23
36 (CN1-4) 16
68 SIG. 15
21 2
12
VPS1 7 13 3
+
62 2
Y1 1 10 11
Y2 2 56
4 1 9
Y3 3 32
Y4 4 55
3 Y5 5 9 EST-37
KICK 1 2 3 4
TEMP 9 46 67 X2-D AD6
49 X1-A AD3
23 22 X1-D
17 63 X1-C
AD7 2
24 65 X1-B
AD1
AD2
19 43 X2-B AD4
41
12 (TURBINE)
42
(CENTRAL
3
GEAR CHAIN)
7 6
AUTO(1-4) 29 66 1
5
AUTO(2-4) 20 7
10 9
PST TML 1 2 3 1
MANUAL 2
5 AUTO(1-4)
AUTO(2-4)
FG004384
Figure 34

energized when in reverse third gear.

260-4)
Page 39
Downshift
Overview
1. There are two downshift switches down Figure 35, and it is
possible for operators to select one of them according to
the condition.
2. If the downshift switch is depressed during the machine
moving, downshifting takes place automatically. As a
result, fast digging and moving is possible. But at the
manual mode the kick-down can only be activated.
3. If a change or traveling direction takes place or the
downshift switch is depressed a second time, downshifting FG004391
is released automatically. Figure 35

260-4)
Page 40
Kick-down: Forward Second Gear to Forward First Gear
(Auto Selector Switch "OFF"- Manual Mode)
11
1 8
1-4 2-4 1
52 14 2-1 2-3
19
BATT 14 23
36 (CN1-4) 16
68 SIG. 15
21 2
12
VPS1 7 13 3
+
62 2 4
Y1 1 10 11
Y2 2 56
4 1 9
Y3 3 32
Y4 4 55
3 Y5 5 9 EST-37
KICK 1 2 3 4
TEMP 9 46 67 X2-D AD6
49 X1-A AD3
23 22 X1-D
17 63 X1-C
AD7 2
24 65 X1-B
AD1
AD2
19 43 X2-B AD4
41
12 (TURBINE)
42
(CENTRAL
3
GEAR CHAIN)
7 6
AUTO(1-4) 29 66 1
5
AUTO(2-4) 20 7
10 9
PST TML 1 2 3 1
MANUAL 2
5 AUTO(1-4)
AUTO(2-4)
FG004385
Figure 36
With the auto selector switch (Figure 37) is in the "MANUAL" and
the forward second gear is selected, if either downshift switch
(Figure 35) is activated, a pulse is sent to the "22" transmission 1-4
controller. This signal energizes solenoid valves, (Y3 and Y5),
which shifts the transmission to the forward first gear. When MAN 2-4
either switch (Figure 35) is selected a second time, the
transmission pulse signal of the "22" terminal is interrupted and
solenoid valve, Y5 and Y6, are energized and the transmission
returns to the forward second gear.
FG004927
Figure 37

260-4)
Page 41
11
1 8
1-4 2-4 1
52 14 2-1 2-3
19
BATT 14 23
36 (CN1-4) 16
68 SIG. 15
21 2
12
VPS1 7 13 3
+
62 2 4
Y1 1 10 11
Y2 2 56
4 1 9
Y3 3 32
Y4 4 55
3 Y5 5 9 EST-37
KICK 1 2 3 4
TEMP 9 46 67 X2-D AD6
49 X1-A AD3
23 22 X1-D
17 63 X1-C
AD7 2
24 65 X1-B
AD1
AD2
19 43 X2-B AD4
41
12 (TURBINE)
42
(CENTRAL
3
GEAR CHAIN)
7 6
AUTO(1-4) 29 66 1
5
AUTO(2-4) 20 7
10 9
PST TML 1 2 3 1
MANUAL 2
5 AUTO(1-4)
AUTO(2-4)
FG004386
Figure 38
When the auto selector switch (Figure 38) is in the "Auto (1-4)"
position, the "29" terminal of transmission controller is
energized. This allows the transmission to automatically upshift
and downshift gears depending on the load and on the engine
speed.
If either downshift switch (Figure 35) is activated, a pulse signal
is sent to the "22" terminal of transmission controller. This signal
shifts the transmission to the next lowest gear.
Automatic
Downshift Switch "Activated"
Gear Selection
Fourth Gear Downshift to Third Gear
Third Gear Downshift to Second Gear
Second Gear Downshift to First Gear
First Gear Remains in First Gear

260-4)
Page 42
When either downshift (Figure 35) is depressed a second time,
the transmission pulse signal of the "22" is interrupted and the
transmission returns to normal operation.
NOTE: The fourth to the third gear changes without any rpm
change when the downshift switch is pressed.
NOTE: The third to the second gear, and the third to the first
gear, changes occur when the rpm is reduced 200 -
300 rpm from current setting.

260-4)
Page 43
11
1 8
1-4 2-4 1
52 14 2-1 2-3
19
BATT 14 23
36 (CN1-4) 16
68 SIG. 15
21 2
12
VPS1 7 13 3
+
62 2 4
Y1 1 10 11
Y2 2 56
4 1 9
Y3 3 32
Y4 4 55
3 Y5 5 9 EST-37
KICK 1 2 3 4
TEMP 9 46 67 X2-D AD6
49 X1-A AD3
23 22 X1-D
17 63 X1-C
AD7 2
24 65 X1-B
AD1
AD2
19 43 X2-B AD4
41
12 (TURBINE)
42
(CENTRAL
3
GEAR CHAIN)
7 6
AUTO(1-4) 29 66 1
5
AUTO(2-4) 20 7
10 9
PST TML 1 2 3 1
MANUAL 2
5 AUTO(1-4)
AUTO(2-4)
FG004387
Figure 39
When the auto selector switch (Figure 38) is in the "Auto (2-4)"
position, the "20" terminal of transmission controller is
energized. This allows the transmission to automatically upshift
and downshift gears depending on the load and on the engine
speed.
If either downshift switch (Figure 35) is activated, a pulse signal
is sent to the "22" terminal of transmission controller. This signal
shifts the transmission to the next lowest gear.
Automatic
Downshift Switch "Activated"
Gear Selection
Fourth Gear Downshift to Third Gear
Third Gear Downshift to Second Gear
Second Gear Downshift to First Gear
First Gear Remains in First Gear

260-4)
Page 44
When either downshift (Figure 35) is depressed a second time,
the transmission pulse signal of the "22" is interrupted and the
transmission returns to normal operation.
NOTE: The fourth to the third gear changes without any rpm
change when the downshift switch is pressed.
NOTE: The third to the second gear, and the third to the first
gear, changes occur when the rpm is reduced 200 -
300 rpm from current setting.
Transmission Cutoff
When the brake pedal is depressed while transmission cutoff
switch (Figure 40) is in the "I" position, the transmission cutoff
pressure switch turns "ON" and current is supplied to the "66"
terminal of the transmission controller.
All current being supplied to the transmission solenoid valves O
(Y1 thru Y6) is cut off and the transmission is in "NEUTRAL."
NOTE: To protect transmission, transmission cutoff switch I
does not function in third and fourth gears.
HA3O2018
CAUTION! Figure 40
When the machine is traveling or working in the place of

inclination, the transmission cutoff switch (Figure 40) must
be placed in position 'O' for the purse of using engine
braking and the normal braking function at the same time.

260-4)
Page 45
17 10 4
(N) 87a
18 87
30 11
85 86 1 8
1-4 2-4 1
52 14 2-1 2-3
19
BATT 14 23
36 (CN1-4) 16
68 SIG. 15
21 2
12
VPS1 7 13 3
+
62 2
Y1 1 10
4 1
11
Y2 2 56 9
Y3 3 32
Y4 4 55
3 Y5 5 9 EST-37
KICK 1 2 3 4
TEMP 9 46 67 X2-D AD6
49 X1-A AD3
23 22 X1-D AD7
17 63 X1-C
24 65 X1-B
AD1
AD2
19 43 X2-B AD4
41
12 (TURBINE)
42
(CENTRAL
3
GEAR CHAIN)
7 6
AUTO(1-4) 29 66 1
5
AUTO(2-4) 20 7
10 9
PST TML 1 2 3 1
MANUAL 2
5 AUTO(1-4)
AUTO(2-4)
FG004388
Figure 41
LIS (Load Isolation System) - Option

Excessive bucket pitching is drastically reduced and good
flotation is maintained for minimum operator fatigue and
maximum productivity.
LIS is useful for sites where frequent cycles of loading and carry
are needed or rough terrain. O
1. When the LIS switch is "I," it is for manual operating I
position and LIS device which has no relation with traveling II
speed always operates.
2. When the LIS switch is "ll," it is for automatic operating
position and LIS device operates when the forward FG004389
traveling speed is above 6km/h and LIS device stops the Figure 42
operation when the forward traveling speed is below 4km/
h.
3. LIS device operates when the reverse traveling speed is
above 4km/h and LIS device stops the operation when the
reverse traveling speed is below 2km/h.

260-4)
Page 46
19
6
13
0
3
14 5 I
1 II
9 14 BATT
10
11
1-4 2-4 1
23 5
22 68 14 2-1 2-3
87a
30 52
87 30
85 86 8 36 (CN1-4)
8 16
SIG. 15
53 21 2 4
57
3
62 2
11
4 1 9
KICK 1 2 3 4
DOWN STEP STEP STEP STEP F N R
45 X2-A VP
67 X2-D AD6
X1-A AD3
22 X1-D
63 X1-C
AD7 2
AD1
65 X1-B AD2
19 43 X2-B AD4
41
12 (TURBINE)
42
(CENTRAL
GEAR CHAIN) 3
AUTO(1-4) 29
AUTO(2-4) 20
PST TML 1 2 3 1
MANUAL 2
5 AUTO(1-4)
AUTO(2-4)
FG004390
Figure 43

260-4)
Page 47
AEB STARTER
Introduction
1. The AEB starter is for a device which achieves the AEB
(Automatic Filling Parameter Adjustment) of transmission
at easy.
2. The message for the present condition of AEB is indicated AEB Starter
through a display and AEB starter itself cannot know the Start
present progress condition.
3. The following case, AEB starter should be operated surely
for the best equipment efficiency.
Change of the transmission controller
BOS0360L
Reinstallation of the transmission after perfect
Figure 44
disassembling and reassembling
Change of the transmission
4. "F6" is indicated on the display when controller do not
achieve AEB.
AEB Check Connector

The AEB check connector is the connecting components to
connect the AEB starter. It is fastened to the harness on the left
side wall of the electric box.
Figure 45

260-4)
Page 48
Procedure to Start AEB
Step to do Display message Remarks
1 Warm up transmission Normal operating messages
2 Turn off starter switch Nothing
3 Plug in AEB-starter
4 Bring shift lever to "N" position.
Engage park brake.
5 Start engine "PL" TCU must recognize PL for at
least 2s before you can press
the button
6 Put engine speed to 800 rpm "PL" if start conditions are
ok
7 Press button of the AEB-Starter "ST" if start conditions are The button must not be
ok released before TCU has
started the AEB or quit whit an
error code
8 Hold button until AEB has "K1" (Information about TCU has started the AEB, and
started the AEB state) goes on adjusting K1, K2, ,
KR. (Button may be released)
9 Wait until AEB has finished "OK" (AEB has been
successful)
10 Turn off starter switch and Nothing
unplug AEB-Starter
Display During AEB-mode

Symbol Meaning Remarks
AEB - Starter is plugged at the
PL
diagnostic plug
ST AEB Starter button is pressed
K1 KV, KR Calibrating clutch K1 K4, KV, KR
Wait for start, initialization of clutch Kx,
+ Kx x: 1, 2, 3, 4, V, R
Fast fill time determination of clutch Kx
+ Kx
Compensating pressure determination

+ Kx of clutch Kx
Calibration for all clutches finished Transmissions stays in neutral, you have
OK to restart the TCU (starter switch off/on)
after removing AEB-Starter
AEB canceled (activation stopped) Transmissions stays in neutral, you have
STOP
to restart the TCU (starter switch off/on)
AEB stopped, clutch Kx cannot be Transmissions stays in neutral, you have
STOP + Kx
calibrated to restart the TCU (starter switch off/on)
Kx couldn't be calibrated, AEB finished Transmissions stays in neutral, you have
+ Kx to restart the TCU (starter switch off/on)

260-4)
Page 49
Engine speed too low, raise engine
+E speed
Engine speed too high lower engine
+E speed
Transmission oil temperature too low
+T heat up transmission
Transmission oil temperature too high
+T cool down transmission
Transmission temperature not in Transmissions stays in neutral, you have
FT
defined range during calibration to restart the TCU (starter switch off/on)
Operating mode not NORMAL or Transmissions stays in neutral, you have
transmission temperature sensor to restart the TCU (starter switch off/on)
FB
defective or storing of calibrated
values to EEPROM has failed.
Output speed not zero Transmissions stays in neutral, you have
FO
Shift lever not in Neutral position Transmissions stays in neutral, you have
FN
Parking brake not applied Transmissions stays in neutral, you have
FP
AEB - Starter was used incorrect or is Transmissions stays in neutral, you have
STOP
defective to restart the TCU (starter switch off/on)
NOTE: To prevent the transmission oil temperature

from falling down while AEB operating, keep the
transmission oil temperature about 80C before
starting AEB. (Temperature Range: 60C -
90C)

260-4)
Page 50
260-4)
Page 51
INSTALLATION VIEW
Inner Section
Figure 46

260-4)
Page 52
Reference Reference
Number Number
1 Engine Connection - Direct 8 Clutch K1
Mounting 9 Clutch K2
2 Converter 10 Clutch K3
3 Breather 11 Output - Front Axle
4 Drive 12 Output - Rear Axle
5 Electrohydraulic Shift Control 13 Layshaft
6 1st Power Take Off 14 Clutch K4
7 Converter Charge and Control 15 Clutch Kr
Pressure Pump
16 Clutch Kv

260-4)
Page 53
Front View
Figure 47
Reference Reference
Number Number
1 Lifting Lugs 7 Coarse Filter
2 Breather 8 Oil Drain Plug
3 Electrohydraulic Shift Control 9 Attachment Possibility for Oil
4 Diaphragms - Direct Mounting Filter Tube with Oil Dipstick
(Converter Side)
5 Converter
10 Oil Fill Tube with Oil Dipstick
6 Output Flange (Converter Side)
(Rear Side)

260-4)
Page 54
Side View
Figure 48
Reference Reference
Number Number
1 Diaphragms for Direct Mounting 8 Oil Fill Tube with Oil Dipstick
2 Converter (Rear Side)
3 Converter Bell 9 Cover
4 Lifting Lug 10 Gearbox Housing
5 Breather 11 Output Flange (Converter Side)
6 Electrohydraulic Shift Control 12 Transmission Suspension M20
7 Output Flange (Rear -side)

260-4)
Page 55
Rear View
Figure 49
Reference Reference
Number Number
1 1st Power Take-off 9 Attachment Possibility for
2 Pressure Line Clutch KV Emergency Steering Pump
3 2nd Power Take-off 10 Oil Filter Tube With Oil Dipstick
4 Lifting Lug 11 Model Identification Plate
5 Pressure Oil Line Clutch K1 12 Output Flange (Rear Side)
6 Pressure Oil Line Clutch K4 13 Lubricating Oil Line "S2" Clutch
K4 / K3
7 Pressure Oil Line Clutch K3
14 Pressure Oil Line Clutch KR
8 Lubricating Oil Line "S1" Clutch
KR / K2 15 Pressure Oil Line Clutch K2

260-4)
Page 56
HYDRAULIC CONTROL UNIT
(HSG-94)
The following illustration shows a sectional view of the HSG-94.
IMPORTANT
Different versions in relation to the position of the cable
harness are possible.
In this connection, pay attention to the Specifications of the
Vehicle Manufacturer.
Figure 50

260-4)
Page 57
Section A - A
Figure 51
Disassembly
1. Illustration on right shows complete Control unit.
Figure 52

260-4)
Page 58
2. Mark installation position of different covers, housing and
cable harness with valve housing.
Figure 53
3. Loosen socket head screws.

4. Separate duct plate, 1st gasket, intermediate plate and 2nd
gasket from valve housing.
Figure 54
5. Remove retaining clip.
Figure 55
6. Loosen socket head screws.

7. Separate cover from housing and cable harness.
Figure 56

260-4)
Page 59
8. Disassemble opposite cover.
9. Disconnect pressure regulator and remove cable harness.
Figure 57
10. Loosen socket head screws, remove fixing plate and

pressure regulators (3x).
Figure 58
11. Loosen two socket head screws and locate housing

provisionally, using adjusting screws. (Housing is under
spring preload). Now, loosen remaining socket and screws.
Figure 59
12. Separate housing from valve housing by loosening

adjusting screws uniformly.
Figure 60

260-4)
Page 60
13. Remove components (Figure 61).
14. Remove opposite pressure regulators, housing and
components accordingly (Figure 62).
Figure 61
Figure 62
Reassembly
NOTE: Check all components for damage and replace if
necessary. Before installation, check free travel of all
moving parts in housing. Spools can be exchanged
individually. Oil components before reassembly
according to ZF-List of lubricants TE-ML 03.
Insert diaphragms with concave side showing upward
until seated.
NOTE: Installation position, see arrows.
Figure 63
1. Illustration on left shows the following components:
Reference
Description
Number
1 Vibration Damper (3x
Spool and
Compression Spring)
2 Follow-on Site (3x
Spool and
Compression Spring)
3 Pressure Reducing
Valve (1x Spool and Figure 64
Compression Spring)

260-4)
Page 61
2. Install components according to Figure 64.
NOTE: Preload compression spring of the follow-on
sitie slides and locate spool provisionally using
cylindrical pins 5.0 mm (0.1969 in) (assembly
aid), See Figure 65.
Figure 65
3. Install two adjusting screws.

4. Assemble gasket (1, Figure 66) and housing cover (Figure
66). Now, position housing cover uniformly, using adjusting
screws, until seated and remove cylindrical pins (assembly
aid) again (Figure 66).
NOTE: Pay attention to different housing covers.
5. Install recess 15.0 mm (0.5906 in) (2, Figure 66), facing
spring of pressure reducing valve.
Figure 66
Figure 67
6. Fasten housing cover using socket head screws.

NOTE: Torque limit 0.56 kgm (4 ft lb).
Figure 68

260-4)
Page 62
7. Install pressure regulators and attach using fixing plates
and socket head screws.
NOTE: Install fixing plate, with claw showing downward.
Pay attention to radial installation position of
pressure regulators, see Figure 69.
Figure 69
8. Preassemble opposite side.

A. Illustration on left side shows the following
components:
Reference
Description
Number
1 Main Pressure Valve
(1x Spool and
Compression Spring.)
2 Follow-on Slide (3x
Spool and
Compression Spring) Figure 70
3 Vibration Damper (3x
Spool and
Compression Spring)
B. Install components according to Figure 70.

C. Preload compression springs of the follow-on slides
and locate spool provisionally using cylindrical pins
5.0 mm (0.1969 in) (assembly aid). See arrows.
D. Install two adjusting screws.
E. Assemble gasket (1, Figure 71) and housing cover,
and position them uniformly against shoulder, using
adjusting screws.
NOTE: Pay attention to different housing covers,
install the recess 19.0 mm (0.7480 in)
(2, Figure 71), facing the main pressure
valve.
F. Down, fasten housing cover using socket head
screws.
Figure 71
G. Remove cylindrical pins (assembly aid) again.

260-4)
Page 63
H. Install pressure regulators and attach using fixing
plates and socket head screws.
NOTE: Install fixing plates, with claw showing
downward.
I. Pay attention to radial installation position of pressure
regulators, see Figure 72.
NOTE: Torque limit 5.5 N.
Figure 72
J. Install cable harness and connect pressure

regulators (6x).
NOTE: Pay attention to installation position of
cable harness, see markings (Figure 53).
Figure 73
K. Install female connector against shoulder, with groove

facing guide nose of cover.
L. Install gaskets (Figure 74) and fasten cover using
socket head screws.
Figure 74
M. Install female connector using retaining clamp, see

Figure 75.
N. Install opposite cover.
Figure 75

260-4)
Page 64
O. Install two adjusting screws and mount gasket I.
NOTE: Pay attention to different gaskets, see
Figure 76 and Figure 79.
Figure 76
9. Intermediate plate version with screens:

A. Insert screens (6x) flash -mounted into bore of
intermediate plate, see Figure 77.
NOTE: Pay attention to installation position-
screens are showing upward (facing duct
plate).
Figure 77
B. Mount intermediate plate, with screens with screens

showing upward.
Figure 78
C. Mount gasket II.
Figure 79

260-4)
Page 65
D. Mount duct plate and fasten it uniformly using socket
head screws.
Figure 80
E. Equip screw plugs (8x) with new O-rings and install

them.
NOTE: The installation of hydraulic control unit is
described in following section, Mount
Hydraulic Control Unit (HSG-94) on
page 1-142.
Figure 81

260-4)
Page 66
TRANSMISSION DISASSEMBLY
1. Fasten transmission on an appropriate support stand.
Figure 82
2. Disassemble complete shift control, remove pressure lines

and duct plate.
Figure 83
Converter Input
1. Separate torque converter from transmission, using lifting
device.
Figure 84

260-4)
Page 67
2. Loosen screw connection.
3. Separate bearing cover from converter bell, using three
jacking screws.
Figure 85
4. Pull oil feed flange out of converter bell, using special

device (S).
Figure 86
5. Remove converter safety valve (composed of ball, spring

and disk.).
Figure 87
6. Separate converter bell from gearbox housing, using lifting

device and pry bar.
Figure 88

260-4)
Page 68
7. Remove shim.
Figure 89
8. Remove rectangular ring (Figure 90).
Figure 90
9. Press drive shaft out of spur gear bearing. Remove

released inner bearing race and spur gear.
10. If necessary, drive outer bearing race out of housing bores.
Figure 91
11. Press inner bearing race from drive shaft.
Figure 92

260-4)
Page 69
12. Remove converter pressure valve.
Figure 93
Drive Shaft Pump Power Take-off

1. Pull complete drive shaft out of gearbox housing (pump).
Figure 94
2. Remove rectangular ring (Figure 95).
Figure 95
3. Separate spur gear from shaft and remove retaining ring

(Figure 96).
Figure 96

260-4)
Page 70
4. Pull inner bearing race from spur gear.
Figure 97
5. Loosen socket head screw and remove it along with

clamping plate.
Figure 98
6. Pull inner bearing race and drive from shaft.

NOTE: Support puller on end face/drive shaft. Pay
attention to released shims.
Figure 99
7. Separate inner bearing race from driver.

NOTE: Pay attention to released shim.
8. Remove retaining rings (3x).
Figure 100

260-4)
Page 71
Transmission Pump
1. Tilt gearbox housing 180.
2. Loosen hex. head screws and remove both pump flanges.
Figure 101
3. Loosen socket head screws (M8) and position Puller

device (s).
4. Pull transmission pump out of housing bore.
NOTE: Tapping housing face is a help during extraction
operation.
Figure 102
Output - Layshaft Assembly n

o
1. Loosen screw connection and remove brake caliper. t
e
1
Figure 103
2. Unlock and loosen hex. head screws, tap brake disk loose
and separate it from output shaft.
Figure 104

260-4)
Page 72
3. Pry shaft seal out of housing bore.
Figure 105
4. Tilt gearbox housing.

5. Remove sealing covers (Figure 106).
Figure 106
6. Loosen hex. head screws.
Figure 107
7. Pull idler shaft using puller out of housing bore.
Figure 108

260-4)
Page 73
9. Loosen hex. head screws and pull bearing cover -K1/KV
out of housing bore.
Figure 109
10. Loosen hex. head screws and remove bearing cover KR/
K2 and K3/K4.
Figure 110
11. Remove rectangular rings (3 pieces/axle), see Figure 111.
Figure 111
12. Remove retaining ring and remove released washers.
Figure 112

260-4)
Page 74
13. Support output flange against gearbox housing, see Figure
113.
Figure 113
14. Loosen hex. head screws and separate housing cover from
gearbox housing, using forcing screws and lifting device.
Figure 114
15. Unlock and loosen hex. head screws.

16. Remove output flange and pry shaft seal out of housing.
Figure 115
17. Loosen hex. head screws and remove oil baffle.
Figure 116

260-4)
Page 75
18. Remove output gear along with shaft.
Figure 117
19. Separate output shaft from spur gear.
Figure 118
20. Pull inner bearing race from output gear.
Figure 119
21. Remove plate.
Figure 120

260-4)
Page 76
22. Drive roller bearing out of housing bore and remove it.
Figure 121
Disassemble Clutches and Layshaft Gear

1. Remove clutches - K3/K4, KR/K2 and KV/K1- using lifting
device.
NOTE: At the removal of the clutch - K3/K4, displace
clutch - KR/K2 in direction of arrow (Figure
122).
Figure 122
2. Illustration on right shows clutches in removed condition.
Figure 123
3. Remove layshaft gear.
Figure 124

260-4)
Page 77
Disassemble Power Take-off II
1. Remove retaining ring and remove shim(s).
Figure 125
2. Pull PTO shaft using internal puller out of housing bore

until outer bearing race is released.
Figure 126
3. Take shaft out of housing.
Figure 127
4. Pull inner bearing race from shaft (Figure 128).

5. Press opposite inner bearing race from shaft.
NOTE: Separation of shaft and gear is not possible.
Figure 128

260-4)
Page 78
Disassemble Clutches
Clutch - K3/K4
1. Remove three rectangular rings (Figure 129).
Figure 129
2. Loosen slotted nut.

NOTE: Slotted nut is secured with Loctite.
To prevent damage of thread, heat slotted nut
before loosen it (about 120C (248F)).
Figure 130
3. Remove taped roller bearing.
Figure 131
4. Removed flanged disk.
Figure 132

260-4)
Page 79
5. Remove upper roller bearing.
Figure 133
6. Remove angle ring, retaining ring, and thrust ring.
Figure 134
7. Press spur gear K3 from plate carrier and remove released

roller bearing.
Figure 135
8. Remove split ring.
Figure 136

260-4)
Page 80
9. Remove retaining ring and remove complete plate pack
K3.
Figure 137
10. Tilt clutch 180.

NOTE: Slotted nut is secured with Loctite. To prevent
damage of thread, heat slotted nut before
loosen it (about 120C (248F)).
Figure 138
12. Remove tapered roller bearing.
Figure 139
13. Pull spur gear from plate carrier.
Figure 140

260-4)
Page 81
14. Remove oil feed ring and pull ball bearing from plate
carrier.
Figure 141
15. Remove retaining ring and remove complete plate pack -

K4.
Figure 142
16. Preload compression spring using special device (S).

Remove retaining ring (Figure 143) and released
components.
17. Now, separate piston from plate carrier, using compressed
air.
18. Disassemble opposite piston accordingly.
Figure 143
Clutch - KR/K2
1. Locate clutch using Special device (s) and loosen slotted
nut.
2. Loosen opposite slotted nut (Figure 144) accordingly.
NOTE: The slotted nuts are secured with Loctite heat
before loosen them.
Figure 144

260-4)
Page 82
Figure 145
4. Press spur gear K-2 from shaft.

5. Remove released shim and bush.
Figure 146
Figure 147
7. On opposite side, pull off tapered roller bearing.
Figure 148

260-4)
Page 83
8. Pull spur gear KR from shaft.
9. Remove released inner bearing race, disassemble both
outer bearing races and retaining ring.
Figure 149
10. Remove adjusting ring.
Figure 150
11. Remove tapered bearing (spur gear bearing).
Figure 151
12. Disassemble plate packs KR and K2 and compression

springs and piston (accordingly as at clutch K3/K4.
Figure 152

260-4)
Page 84
Clutch - KV/K1
2. Loosen opposite slotted nut (Figure 153) accordingly.
NOTE: The slotted nuts are secured with Loctite and
require heating before loosen them.
Figure 153
Figure 154
4. Remove shim.
Figure 155
5. Using a suitable puller remove spur gear K1.

6. Now, remove retaining ring and drive ball bearing from spur
gear bore.
Figure 156

260-4)
Page 85
7. Remove both rings.
Figure 157
8. Using a suitable puller second ball bearing (spur gear

bearing).
Figure 158
9. On opposite side, pull off tapered roller bearing.
Figure 159
10. Pull spur gear KV from shaft.

11. Remove released inner bearing race, disassemble both
outer bearing race and retaining ring.
Figure 160

260-4)
Page 86
12. Remove adjusting ring.
Figure 161
13. Remove tapered roller bearing (spur gear bearing).

14. Now, remove plate pack KV and K1 and compression
springs and piston (accordingly as at clutch K3/K4.
Figure 162

260-4)
Page 87
TRANSMISSION REASSEMBLY
Power Take-off II
1. Cool shaft down (about 80C (176F)) and heat gear
(about 120C (248F)) and assemble, resp. press it against
shoulder.
Figure 163
2. Press inner bearing race against shoulder. Press opposite

inner bearing race against shoulder until contract is
obtained.
Figure 164
3. Insert outer bearing race (Figure 165) into housing bore

until seated.
Figure 165

260-4)
Page 88
4. Position preassembled PTO shaft in housing.
Figure 166
5. Insert outer bearing race. Bearing must have free play.
Figure 167
6. Adjust PTO bearing free play, using disk (s) and retaining
ring.
Figure 168

8. Insert sealing disk (Figure 169) into housing bore until
seated.
NOTE: Cover contact surfaces with Loctite #262).
IMPORTANT
Do not damage centric orifice hole 0.80 mm (0.0315 in)
during installation of sealing disk.
Figure 169

260-4)
Page 89
Clutch K3/K4
1. Install plate carrier using clamping ring (s).
2. Close both bores (Figure 170) using set screws.
NOTE: Insert set screws with Loctite #262.
Figure 170
Clutch K3
1. Insert purge valve (Figure 171) until seated.
Figure 171
2. Insert both O-rings into ring grooves of piston, see Figure

172.
Figure 172
3. Oil O-rings and piston race, and insert piston until seated.
NOTE: Pay attention to installation position of piston,
see Figure 173.
Figure 173

260-4)
Page 90
4. Install disk (Figure 174) and compression spring.
5. Lay guide ring upon compression spring and assemble
retaining ring (Figure 174).
NOTE: Pay attention to installation position of guide
ring install chamber (Figure 174) showing
upward.
Figure 174
6. Now, preload compression spring and install it by engaging

retaining ring (Figure 176).
Figure 175
Figure 176

260-4)
Page 91
General Instructions for Plate Installation
In principle, stacking of outer and inner plates has to be carried
out 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 on the end
shim side. The uncoated side must be always installed facing the
piston, resp. the end shim. At plates with different thickness
(inner plates), the thinner plates must be installed on the end
shim side.
Number and installation position of the plates, see also the
corresponding Spare Parts List. The respective clutch side can
be identified on the length of the plate carrier, see Draft
Dimension X.
Install Plate pack - K3, see Draft and Figure 178, EXAMPLE A:
Plate arrangement - K3 (long plate carrier side):
Active number of the friction surfaces = 14.
1 outer plate (one sided coated)
7 outer platess = 2.50 mm (0.0984 in)
3 inner platess = 3.50 mm (0.1378 in)
3 inner platess = 3.00 mm (0.1181 in)
1 inner plate (optional)s = 2.00 - 4.00 mm (0.0787 - 0.1575 in)
Draft:
K4 K3
X
HLA2130L
Figure 177

260-4)
Page 92
1. Install plate pack, mount end shim and attach it using
retaining ring.
Figure 178
2. Check plate clearance - K3 = 2.20 - 2.40 mm (0.0866 -

0.0945 in) (Figure 179, EXAMPLE A).
A. Determined Dimension I from end face of plate
carrier to end shim.
NOTE: Dimension I, e.g. 2.40 mm (0.0945 in).
Figure 179
B. Position end shim against retaining ring (toward

upward) until seated and determine Dimension II.
NOTE: Dimension II, e.g. 0.20 mm (0.0079 in).
EXAMPLE A:
Dimension I 2.40 mm (0.0945 in) Figure 180

Dimension II - 0.20 mm (0.0079 in)
Difference = Plate = 2.20 mm (0.0866 in)
clearance
IMPORTANT
In case of a deviation from the required plate
clearance, correction can be carried out with
corresponding inner plates. (optional s = 2.00 -
4.00 mm (0.0787 - 0.1575 in)) or with different retaining
rings (Figure 178).

260-4)
Page 93
3. Tilt clutch into horizontal position and install spur gear K3
until all inner plates are accommodated.
NOTE: This step will facilitate later spur gear
installation. Now, tilt clutch again into vertical
position and pull spur gear carefully out of plate
pack.
Figure 181
4. Insert split ring (Figure 182) with grease into recess.

NOTE: Pay attention to exact contact of split ring in
bottom of recess.
NOTE: Carry out following steps of Figure 183 and
Figure 184 immediately in chronological order
to prevent a cooling down of heated
components.
5. Heat bearing bore of spur gear (Figure 183) and inner
bearing race of roller bearing (Figure 184) to about 120C
(248F).
Figure 182
6. Install heated spur gear until all inner plates are

accommodated.
Figure 183
7. Insert heated inner bearing race until seated.
Figure 184

260-4)
Page 94
8. Install disk, lift spur gear slightly and install retaining ring
into annular groove of spur gear.
Figure 185
9. Install angle ring, with stepped face facing retaining ring.
Figure 186
10. Install inner bearing race and mount flanged disk.

NOTE: Install flanged disk, with chamfer on inner
diameter showing upward.
Figure 187
11. Heat inner bearing race and place it against shoulder.
Figure 188

260-4)
Page 95
Clutch - K4
Install purge valve, piston and compression spring accordingly
as at clutch K3 (Figure 177).
Install plate pack K4 and check plate clearance.
Plate arrangement K4 (short plate carrier side):
Active number of the friction surfaces = 12
1 inner plates = 3.00 mm (0.1181 in)
i1 inner plate (optional)s = 2.00 - 4.00 mm (0.0787- 0.1575 in)
IMPORTANT
Pay attention to the General Instructions for the Plate
Installation (See page -92)
Check plate clearance - K4 = 2.20 - 2.40 mm (0.0866 -

0.0945 in) accordingly as at clutch K3 (See page -90).
1. Tilt clutch into horizontal position and install spur gear K4
until all inner plates are accommodated.
NOTE: This step will facilitate the later reassembly of
spur gear.
2. Now, tilt clutch again into vertical position and pull spur
gear carefully out of plate pack.
Figure 189
3. Spur gear K4
IMPORTANT
The following steps (Figure 190 thru Figure 193) are
describing reassembly of spur gear bearing-K4.
Version with ball bearing.
At the version with the tapered roller bearing, the
reassembly has to be carried out accordingly as at
spur gear KR. In this connection pay attention to steps
Figure 190
of Figure 201 thru Figure 211.

260-4)
Page 96
4. Heat ball bearing and assemble it until seated. See Figure
190.
NOTE: Before install the spur gear (Figure 191), cool
ball bearing.
5. Mount Oil feed ring (Figure 191).
Figure 191
IMPORTANT
Carry out steps of Figure 192 and Figure 193 in
immediate sequence, to prevent a cooling down of the
components. Heat bearing bore of the spur gear
(Figure 192) and ball bearing (Figure 193) to about
120C.
6. Install heated spur until all inner plates are accommodated.

Figure 192
7. Insert heated ball bearing until seated.
Figure 193

260-4)
Page 97
8. Heat tapered roller bearing and assemble it until seated.
Figure 194
9. Preload complete clutch pack through both inner bearing

races (Figure 195) with 100 000 N (10 ton). In this way, the
exact contact of the components, resp. the settling of the
complete bearing is ensure.
Figure 195
10. Mount disk. Wet thread of slotted nut with Loctite #262 and
install slotted nut with chamfer showing downward (Figure
196).
Figure 196
11. Tighten slotted nut.

NOTE: Torque limit 56 kgm (405 ft lb).
Figure 197

260-4)
Page 98
12. Tilt clutch 180 (K3-side).
13. Wet thread of slotted nut with Loctite #262 and install
slotted nut with chamfer showing downward.
Figure 198
14. Check function of clutch using compressed air:

A. For this purpose, install rectangular rings, engage
them and assemble bearing cover.
NOTE: At correctly installed components, the
closing resp. opening of the clutches is
clearly audible.
B. Now, remove bearing cover again.
Figure 199

260-4)
Page 99
Clutch KR/K2
Install purge valves, piston and compression spring (each clutch
side 1 set of the components) accordingly as at multidisk clutch
K3 (Figure 171 thru Figure 176).
Install plate pack KR and K2 and check plate clearance, see
also following Draft.
Draft:
KR K2
Figure 200
Plate arrangement - KR (long plate carrier side):

Active number of the friction surfaces = 24.
2 outer plates (one sided coated)
11 outer plates (s) = 2.50 mm (0.0984 in)
11 inner plates (s) = 2.50 mm (0.0984 in)
1 inner plate (optional) (s) = 2.00 mm (0.0787 in)
IMPORTANT
Installation (See page -92).
Check Plate clearance - K2 = 2.80 - 3.00 mm (0.1102 -

0.1181 in) accordingly as at clutch K-3 (See page -90).
Plate arrangement - K2 (short plate carrier side):
Active number of friction surfaces = 16.

260-4)
Page 100
1 inner plate (optional) (s) = 2.00 - 4.00 mm (0.0787 - 0.1575 in)
IMPORTANT
Check Plate clearance- K2 = 2.20 mm (0.0866 in) accordingly as

at clutch K3 (See page -90).
Spur gear KR
Components:
Reference
Description
Number
1 Inner Bearing Race
2 Outer Bearing Race
3 Spur Gear
4 Retaining Ring
5 Adjusting Ring (Optional)
Figure 201
1. Determines axial play of the spur gear bearing 0.03 -

0.08 mm (0.0012 - 0.0031 in) (Figure 202).
EXAMPLE B:
A. Install retaining ring (4) and outer bearing race (2)
against shoulder.
Figure 202
B. Place spur gear upon inner bearing race.

NOTE: Support inner bearing race.
Figure 203

260-4)
Page 101
C. Measure Dimension I from end face to inner bearing
race.
Figure 204
D. Determine Dimension II from end face to retaining

ring.
Figure 205
E. Determine differential dimension from outer bearing

race to inner bearing race on upper tapered roller
bearing.
NOTE: Figure 206, shows two tapered roller
bearings with different measuring results.
NOTE: Dimension III (Differential dimension) in
the actual case, e.g. 0.15 mm (0.0059 in).
HLA2159L
Figure 206
Figure 207
EXAMPLE B:

260-4)
Page 102
Dimension I 24.95 mm (0.9823 in)
Intermediate result 4.10 mm (0.1614 in)
Dimension III + 1.15 mm (0.0453 in)
Result = Differential = 4.25 mm (0.1673 in)
dimension - zero
Required Axial Play (0.03 + 0.05 mm (0.0020 in)
- 0.08 mm (0.0012 -
0.0031 in)) e.g
Result = Adjusting Ring = 4.30 mm (0.1693 in)
F. Select adjusting ring with corresponding thickness.

2. Check axial play (Figure 208).
A. Install upper outer bearing race. Insert adjusting ring,
e.g. s = 4.30 mm (0.1693 in) and inner bearing race.
Preload spur gear bearing with about 50 000 N (5 to).
Determine axial play.
NOTE: At deviations from the required axial play
0.03 - 0.08 mm (0.0012 - 0.0031 in)
correct with corresponding adjusting ring.
Figure 208
3. Heat lower tapered roller bearing and assemble it until

seated.
Figure 209
4. Install spur gear KR into preassembled plate carrier until all

inner plates are accommodated.
Figure 210

260-4)
Page 103
5. Assemble adjusting ring, e.g. s = 4.30 mm (0.1693 in) (See
EXAMPLE B).
NOTE: Pay attention to installation position of oil feed
grooves. They should be showing upward.
6. Now, heat upper inner bearing race (spur gear bearing)
and assemble it until seated.
Figure 211
7. Heat inner bearing race (clutch bearing) and assemble it

until seated.
Figure 212
Spur gear K2
Reference
Description
Number
1 Tapered Roller Bearing
2 Bushing
3 Shim
4 Spur Gear
Figure 213
8. Adjust axial play of spur gear bearing 0.05 - 0.15 mm

(0.0020 - 0.0059 in) (Figure 214 thru Figure 217):
A. Place spur gear upon inner bearing race.
NOTE: Support inner bearing race.
Figure 214

260-4)
Page 104
B. Install bushing and shim (s = 3.80 mm (0.1496 in) /
empirical value) and align it centrically.
Figure 215
C. Install upper tapered roller bearing.
Figure 216
D. Preload spur gear bearing with about 50,000 N (5

ton) and determined axial play.
NOTE: At a deviation from required axial play 0.05
- 0.15 mm (0.0020 - 0.0059 in), correct
with corresponding shim (Figure 213).
Figure 217
9. Heat inner bearing race and assemble it until seated.
Figure 218

260-4)
Page 105
10. Install spur gear K2 until all inner plates are
accommodated.
Figure 219
11. Install bushing and corresponding shim.
Figure 220
12. Heat second tapered roller bearing of spur gear bearing

Figure 221
13. Heat inner bearing race (clutch bearing) and place it

against shoulder.
Figure 222

260-4)
Page 106
races (Figure 223) with 100,000 N (10 ton) In this way, an
exact contact of components, resp. the setting of the
Figure 223
15. Install and tighten both slotted nuts.

NOTE: Pay attention to installation position of slotted
nuts chamfer is always facing inner bearing
race. Secure slotted nuts with Loctite #262.
Figure 224

260-4)
Page 107
Clutch - KV/K1
Install purge valves, piston and compression spring (each clutch
side 1 set of the components) accordingly as at clutch (Figure
171 thru Figure 176).
Install plate pack - KV and K1 and check plate clearance, see
also Draft.
Draft.
KV K1
HLA2178L
Figure 225
Plate arrangement - KV (long plate carrier side):

Active number of friction surfaces = 24.
2 outer plates (one sided coated)
1 inner plate (optional) (s) = 2.50 - 4.00 mm (0.0984 - 0.1575 in)
IMPORTANT

260-4)
Page 108
1. Check plate clearance- K1 = 2.20 - 2.40 mm (0.0866 -
0.0945 in) accordingly as at clutch - K3 (See page -90).
2. Close both bores (Figure 226) using set screws.
NOTE: Insert set screws with Loctite #262).
Figure 226
Spur gear - KV
Reference
Description
Number
1 Bearings Inner Race
2 outer bearing Race
3 Spur Gear
4 Retaining Ring
5 Ring (Optional)
Figure 227
3. Determine axial play of spur gear bearing 0.03 - 0.08 mm

(0.0012 - 0.0031 in) (Figure 228, EXAMPLE C).
A. Install retaining ring (4) in position and install outer
bearing race (2) against shoulder.
Figure 228
B. Place spur gear upon inner bearing race.

NOTE: Support inner bearing races.
Figure 229

260-4)
Page 109
C. Measure Dimension I from end face to inner bearing
race.
Figure 230
D. Determine Dimension II from end face to retaining

ring.
Figure 231
E. Determine Differential dimension from outer bearing

race to inner bearing race on upper tapered roller
bearing.
NOTE: The illustration on right shows two tapered
roller bearings with different measuring
results.
NOTE: Dimension III (Differential dimension) in
actual case, e.g. 0.15 mm (0.0059 in).
HLA2159L
Figure 232
Figure 233
EXAMPLE C

260-4)
Page 110
Result A 4.10 mm (0.1614 in)
Dimension - Zero
Required Axial Play (0.03 + 0.05 mm (0.0020 in)
- 0.08 mm (0.0012 -
0.0031 in)) e.g
Result = Adjusting Ring = 4.30 mm (0.1693 in)
NOTE: Select adjusting ring with corresponding

thickness.
4. Check axial play (Figure 234):
A. Install upper outer bearing race.
B. Insert adjusting ring, e.g. s = 4.30 mm and inner
bearing race. Preload spur gear bearing with about
50,000 N (5 ton) Determine axial play.
NOTE: At deviations from the required axial play
0.03 - 0.08 mm (0.0012 - 0.0031 in)
correct with corresponding adjusting ring.
Figure 234
5. Heat lower inner bearing race and assemble it until seated.
Figure 235
6. Install spur gear KR into preassembled plate carrier until all

inner plates are accommodated.
Figure 236

260-4)
Page 111
7. Assemble adjusting ring, e.g. s = 4.30 mm (See EXAMPLE
C).
NOTE: Pay attention to installation position - oil feed
grooves are showing upward.
8. Now, heat upper inner bearing race (spur gear bearing)
Figure 237
9. Heat inner bearing race (clutch bearing) and assemble it

until seated.
Figure 238
Spur Gear - K1
Reference
Description
Number
1 Ball Bearing
2 Ring (Optional)
3 Splash Ring
4 Retaining Ring
5 Spur Gear
6 Ball Bearing
Figure 239
10. Adjust axial play of spur gear bearing = 0.01 - 0.04 mm

(0.0004 - 0.0016 in) (Figure 240 and Figure 241):
A. Determine thickness of splash ring (3), e.g. s =
17.15 mm (0.6752 in).
Figure 240

260-4)
Page 112
NOTE: Total dimension of retaining ring 4 and ring
2 (optional) must be selected 0.01 -
0.04 mm (0.0004 - 0.0016 in) thinner.
NOTE: Total dimension of retaining ring and ring
therefore 17.14 - 17.11 mm (0.6736 -
0.6748 in).
Figure 241
11. Heat ball bearing and assemble it until seated. Now, cool
ball bearing down to room temperature, to allow later
installation of spur gear (Figure 245).
Figure 242
12. Assemble ring (optional) and splash ring.
Figure 243
13. Install retaining ring into annular groove of spur gear.
Figure 244

260-4)
Page 113
IMPORTANT
Carry out steps of Figure 245 and Figure 246, in
immediate sequence to prevent cooling down of
components.
14. Heat bearing bores of spur gear (Figure 245) and ball
bearing (Figure 246). Install spur gear until all inner plates
are accommodated.
Figure 245
15. Install heated ball bearing until seated.
Figure 246
16. Assemble spacer (s = 1.50 mm (0.0591 in)). Heat tapered

roller bearing and place it against shoulder.
Figure 247

races (Figure 248) with 100 000 N (10 to). In this way, an
exact contact of components, resp. the setting of the
Figure 248

260-4)
Page 114
18. Secure clutch pack using disks (Figure 249) and slotted
nuts.
NOTE: Pay attention to installation position of slotted
nuts, chamfer is always facing inner bearing
race. Wet thread of slotted nuts with Loctite
#262.
Figure 249
19. Tighten both slotted nuts.

Figure 250
20. Install and engage rectangular rings (3x, see Figure 251).
Figure 251
21. Assemble bearing cover and check function of clutches

using compressed air.
NOTE: At correctly installed components, the closing
resp. opening of the clutches is clearly audible.
Now, remove bearing cover gain.
Figure 252

260-4)
Page 115
Install Multidisk Clutches, Layshaft Gear
and Output Gear
1. Install retaining rings in position, see Figure 253.
Figure 253
2. Install spacer ring.
Figure 254
3. Insert outer bearing race until seated.

NOTE: Install spacer rings, resp. outer bearing races of
clutch KR.K2 and KV/K1 accordingly, see
Figure 255.
Figure 255
4. Install roll pin.
Figure 256

260-4)
Page 116
5. Adjust axial play of layshaft gear bearing = 0.00 - 0.05 mm
(0.0000 - 0.0020 in).
6. (EXAMPLE D):
A. Determine Dimension I, see Figure 257.
Figure 257
B. Install both inner bearing races and determine

Dimension I: (total height of layshaft bearing).
Figure 258
C. Determine Dimension III from contact face of inner

bearing race to contact face of axle.
NOTE: Dimension III, e.g. 0.60 mm (0.0236 in).
EXAMPLE D: Figure 259
Dimension II. 53.95 mm (2.1240 in)

Intermediate Result A = 54.55 mm (2.1476 in)

Intermediate Result A - 54.55 mm (2.1476 in)
Dimension - Zero
NOTE: At a required axial play of 0.0 - 0.05 mm (0.0000

- 0.0020 in), the shim has therefore to be
selected thinner for max. 0.05 mm (0.0020 in).
D. Shim thickness therefore 2.50 - 2.55 mm (0.0984 -
0.1004 in).

260-4)
Page 117
7. Position shim and layshaft gear.
NOTE: The installation of layshaft gear can be carried
out only after installation of clutch.
Figure 260
8. Position clutch KV/K1 using lifting device.
Figure 261
9. Install clutch KR/K2.
Figure 262
10. Displace clutch KR/K2 in direction of arrow (Figure 263)

and position clutch K3/K4.
Figure 263

260-4)
Page 118
11. Cool down outer bearing race and insert into housing bore
until seated.
Figure 264
Figure 265
13. Position oil baffle.
Figure 266
14. Install output gear.
Figure 267

260-4)
Page 119
15. Insert second oil baffle and fasten both plates using hex.
head screws (mount plain washer).
NOTE: Torque limit (M8/8.8) 2.35 kgm (17 ft lb).
NOTE: Secure hex. head screws with Loctite #262.
Figure 268
16. Cool down output shaft and install it until seated.

NOTE: Pay attention to installation position, see Figure
269.
Figure 269
17. Wet mounting face with sealing compound (Loctite #574).

18. Install two adjusting screws and position housing cover
using lifting device on gearbox housing until seated.
Figure 270
19. Install both cylindrical pins (1 and 2, Figure 271) and roll
pin (3).
Figure 271

260-4)
Page 120
20. Fasten housing cover using socket head screws (2 pieces)
and hex. head screws.
NOTE: Pay attention to position of two socket head
screws, see Figure 272.
Figure 272
21. Adjust axial play of outer bearing = 0.03 - 0.05 mm (0.0012

- 0.0020 in (Figure 273 thru Figure 275):
A. Determine Dimension I from plane face/housing to
end face/output shaft.
NOTE: Dimension I e.g 53.20 mm (2.0945 in).
Figure 273
B. Measure Dimension II from plane face/housing to

contact face of ball bearing.
EXAMPLE E: Figure 274

Dimension Ii - 50.40 mm (1.9843 in)
Difference = 2.80 mm (0.1102 in)
Required Axial Play (0.03 - - 0.40 mm (0.0157 in)
0.05 mm (0.0012 -
0.0020 in)), e.g.
Gives Shim S = 2.40 mm (0.0945 in)

260-4)
Page 121
22. Assemble shim (e.g s = 2.40 mm (0.0945 in)).
Figure 275
23. Insert bearing until seated.
Figure 276
24. Secure ball bearing using disk (s = 4.00 mm (0.1575 in))

shim (optional) and retaining ring free play.
Figure 277
25. Install shaft seal with sealing lip showing downward.

NOTE: At the use of the prescribed driver, the exact
installation depth is obtained. Cover outer
diameter with sealing compound Loctite #547.
Grease sealing lip.
Figure 278

260-4)
Page 122
26. Assemble output flange.
Figure 279
27. Wet contact face of disk with sealing compound. Mount

disk and fasten output flange using hex. head screws.
Figure 280
28. Secure hex. head screws using lock plate.
Figure 281
29. If necessary, install studs, insert O-ring into annular groove

(Figure 282) and fasten cover using hex. nuts.
NOTE: Insert studs with Loctite #262.
Figure 282

260-4)
Page 123
30. Install screw plug (1, Figure 283). Mount gasket and fasten
cover (2) using hex. head screws.
Figure 283
31. Fasten brake assemble (according to version) on housing,

using hex. head screws.
NOTE: Torque limit (M14/10.9) 19 kgm (136 ft lb).
IMPORTANT
At works on the brake assembly, the Specifications of
the Brake Manufacturer, resp. Vehicle Manufacturer are
binding.
Figure 284
32. Cool down outer bearing races (clutches K3/K4 and KR/
K2) and insert them into housing bores until seated.
Figure 285
33. Adjust bearing preload - clutch K3/K4 = 0.15 - 0.20 mm

(0.0059 - 0.0079 in) (Figure 286 thru Figure 289):
A. Align clutches centrically by rotating output flange
and place outer bearing race carefully against
shoulder.
IMPORTANT
Bearing must not be preload - Bearing cage, resp.
bearing rollers are stilled easy to be moved.
Figure 286

260-4)
Page 124
B. Determine Dimension I from outer bearing race to
mounting face.
NOTE: Apply several measuring points and
determine average.
Figure 287
C. Measure Dimension I from mounting face/cover to

contact face/outer bearing race.
EXAMPLE F: Figure 288
Dimension II 7.13 mm (0.2807 in)

Dimension I - 5.70 mm (0.2244 in)
Difference required 1.43 mm (0.0563 in)
bearing preload
(0.15 - 0.20 mm (0.0059 + 0.17 mm (0.0067 in)
- 0.0079 in))
Result = shim, e.g. = 1.60 mm (0.0630 in)
34. Insert shim (e.g. s = 1.60 mm (0.0630 in)) with grease into
bearing cover. Insert O-ring into annular groove (Figure
289) and grease it.
Figure 289

260-4)
Page 125
35. Install rectangular rings (3 pieces, see Figure 290) and
engage them. Now, grease rectangular rings and align
them centrically.
Figure 290
36. Pull cover using hex. head screws uniformly against

shoulder.
37. Mount bearing cover KR/K2 accordingly.
NOTE: Bearing preload KR/K2 = 0.02 - 0.25 mm
(0.0008 - 0.0098 in).
Figure 291
38. Close both bores of bearing cover KV/K1 using slotted

plug.
NOTE: Insert slotted plug with Loctite #262.
Figure 292
39. Adjust bearing preload clutch KV/K1 = 0.15 - 0.20 mm

(0.0059 - 0.0079 in) (Figure 293, EXAMPLE G).
A. Install outer bearing race.
Figure 293

260-4)
Page 126
B. Press outer bearing race uniformly on and determine
Dimension I from mounting face to outer bearing
race.
NOTE: Apply several measuring points ad
determine average.
Figure 294
C. Measure Dimension II from mounting face of cover

(Figure 295) to contact face/outer bearing race.
EXAMPLE G: Figure 295

Difference 1.05 mm (0.0413 in)
Required Bearing Preload + 0.15 mm (0.0059 in)
(0.15 - 0.20 mm (0.0059 -
0.0079 in)), e.g.
Result = Shim S = 1.20 mm (0.0472 in)
40. Install shim (e.g s= 1.20 mm (0.0472 in)) cool down outer
bearing race and insert it until seated. Insert O-ring into
annular groove (Figure 296) and grease it.
Figure 296

260-4)
Page 127
41. Install rectangular rings (3 pieces) into annular grooves of
clutch shaft (Figure 297) and engage them. Now, grease
rectangular rings and align them centrically.
Figure 297
42. Install two adjusting screws, install bearing cover and pull it
uniformly against shoulder, using hex. head screws.
Figure 298
43. Tilt housing 180. Align layshaft gear and shim centrically,
cool down preassembled bolt and insert it until seated.
NOTE: Pay attention to overlapping of roll pin with bore
in housing.
Figure 299
44. Install bolt axially using hex. head screw.

Figure 300

260-4)
Page 128
NOTE: Wet thread of hex. head screw Drive in sealing
covers (1 thru 4, Figure 301) flush mounted,
with end face showing downward. Install sealing
cover (5) with recess showing upward.
NOTE: Wet thread surfaces with Loctite #262.
Figure 301
45. Install shaft seal (Figure 302) with sealing lip showing
downward.
NOTE: At the use of the prescribed driver (S), the exact
installation position is obtained. Cover outer
diameter with sealing compound Loctite #534).
Grease sealing lip.
Figure 302
46. Assemble output flange. Wet contact face of disk with

sealing compound Loctite #574 and secure output flange
using hex. head screws.
Figure 303
47. Secure hex. head screws using lock plate.
Figure 304

260-4)
Page 129
Install Filter
1. Mount filter (complete).
NOTE: Grease sealing ring (Figure 305).
Figure 305
2. Fasten cover using hex. head screws (mount plain

washers).
NOTE: Install new O-rings (Figure 306).
Figure 306
3. Equip screw plug (1, Figure 307) with new O-ring and instal
it. Mount gasket and fasten cover plate using hex. head
screws (2).
Figure 307
Hydraulic Pump
1. Press needle sleeve in, with reinforced shell facing press in
tool until seated.
Figure 308

260-4)
Page 130
2. Insert outer bearing race until seated.
Figure 309
3. Cool pump to about 80C (176F). Clean area of suction

and pressure port (1, Figure 310) again and wet it with
Loctite #262. Assemble and oil O-ring (2).
Figure 310
4. Install two adjusting screws and install pump.

NOTE: Pay attention to radial installation position.
Figure 311
5. Install O-ring (Figure 312) and fasten pump flange, resp.

pump using hex. head screws.
Figure 312

260-4)
Page 131
6. Insert O-ring (Figure 313) into annular groove of pump
flange (power take off) and oil it. Mount two adjusting
screws and fasten flange using hex. head screws.
Figure 313
Drive Shaft (Power Take-off Pump)

1. Install V-rings (3x) into recess of driver (internal gearing).
Mount fitting key (Figure 314).
Figure 314
2. Adjust gap = 0.50 mm (0.0197 in) (driver drive shaft)

Figure 315 thru Figure 319.
Figure 315
3. Assemble disk s = 1.90 mm (0.0748 in) and place inner

bearing race against shoulder.
Figure 316

260-4)
Page 132
A. Determine Dimension I from inner bearing race to
end face/driver.
Figure 317
B. Determine Dimension II (A - B).

Figure 318
EXAMPLE H:

Dimension I - 9.60 mm (0.3780 in)
Required Gap + 0.50 mm (0.0197 in)
Gives Shim (S) = 1.50 mm (0.0591 in)
4. Assemble shim e.g s = 1.50 mm (0.0591 in) and position

driver, resp. inner bearing race against shoulder.
Figure 319

260-4)
Page 133
5. Attach driver using clamping disk and socket head screw.
NOTE: Insert socket head screw with Loctite #242.
NOTE: Torque limit (M10/8.8 DIN 6912) 3.26 kgm
(24 ft lb).
Figure 320
6. Press inner bearing race upon collar of drive gear power

take off.
Figure 321
7. Install retaining ring (Figure 322) and assemble drive gear.
Figure 322
8. Install and engage rectangular ring (Figure 323).
Figure 323

260-4)
Page 134
9. Install preassembled drive shaft.
NOTE: Pay attention to overlapping of fitting key/fitting
key groove.
Figure 324
10. Adjust axial play of drive shaft bearing = 0.0 - 0.05 mm

(0.0000 - 0.0020 in) Figure 325 thru Figure 327).
11. Mount gasket. Mount outer bearing race, press it uniformly
on and determine Dimension I from mounting face (gasket)
to outer bearing race.
NOTE: Apply several measuring points and determine
average.
Figure 325
12. Measure Dimension II from mounting face/converter bell to

contact face/outer bearing race.
Figure 326
NOTE: Shims are available in 0.05 mm (0.0020 in)

graduation.
13. Insert shim, e.g. s = 2.10 mm (0.0827 in) and position
outer bearing race against shoulder.
Figure 327

260-4)
Page 135
Input - Converter
1. Insert outer bearing race into housing bore until seated
and install bearing race, see Figure 328.
Figure 328
2. Install spur gear (Figure 329) starting from side, with long
collar showing, and position it.
Figure 329
3. Insert both roll pins ( 2.50 mm (0.0984 in) and

1.50 mm (0.0591 in)) flush mounted into bore (Figure 330)
of drive shaft.
Figure 330
4. Cool down drive shaft and install it until seated.
Figure 331

260-4)
Page 136
Figure 332
6. Place outer bearing race against shoulder.

NOTE: Spur gear bearing must have free play.
Figure 333
7. Adjust bearing preload of drive gear bearing 0.00 -

0.07 mm (0.0000 - 0.0028 in).
8. (Figure 334, EXAMPLE K:
A. Measure Dimension I from mounting face to outer
bearing race.
Figure 334
B. Mount gasket (Figure 335) and determine Dimension

II from mounting face to contact face of outer bearing
race.
Figure 335

260-4)
Page 137
EXAMPLE K:

Difference = 1.25 mm (0.0492 in)
Bearing Preload (0.07 - + 0.05 mm (0.0020 in)
0.90 mm (0.0028 -
0.0354 in)) e.g
Gives Shim = 1.30 mm (0.0512 in)
NOTE: Reassemble of shim, see Figure 339.

9. Insert needle bearing until seated Insert shaft seal flush
mounted, with sealing lip showing downward.
NOTE: Wet outer diameter of shaft seal with sealing
compound Loctite #574. Grease sealing lip.
Figure 336
10. Install two adjusting screws and mount gasket. Install

converter safety valve, composed of disk, compression
spring and ball (1, Figure 337).
11. Install rectangular ring into annular groove of drive shaft
and engage it (2, Figure 337). Now, grease rectangular
ring and align it centrically.
Figure 337
IMPORTANT
Carry out following steps (Figure 338 thru Figure 341)
immediately within short chronological order.
12. Cool down oil feed flange about - 80C (176F) Clean area
of suction and pressure port (Figure 338) again and wet it
with Loctite #241.
Figure 338

260-4)
Page 138
13. Make shim, e.g. s = 1.30 mm (0.0512 in) (See EXAMPLE
K.). adhere with grease in bearing bore.
Figure 339
14. Install oil feed flange.

Figure 340
15. Mount gasket (Figure 341) and install bearing cover.

Figure 341
16. Insert roll pin.
Figure 342

260-4)
Page 139
17. Install converter pressure valve. Install temperature sensor
(1, Figure 343) and screw plug (2).
NOTE: Install new O-ring each time.
Figure 343
18. Heat housing bore (about 120C (248F)).
Figure 344
19. Install two adjusting screws and mount gasket (1, Figure
345) Install converter bell using lifting device until seated
and fasten it using hex. head screws.
Slight rotary motions of drive shaft will facilitate
insertion.
Figure 345
Converter
1. Fasten diaphragms (3x) on converter, using hex. head
screws (mount plain washer).
NOTE: Insert hex. head screws with Loctite #243.
Figure 346

260-4)
Page 140
2. Install and engage rectangular ring (Figure 347). Now,
grease rectangular and align it centrically.
Figure 347
3. Install converter using lifting drive.
Figure 348
4. Tilt transmission 90. Install breather (Figure 349) Insert

pot flush mounted to housing surface.
NOTE: Wet sealing surface with Loctite #262.
Figure 349
5. Equip screw plug (1 and 2, Figure 350) with new O-rings

and install them. Install both fixing plates (3).
NOTE: Torque limit (screw plug M42x2) 16 kgm
(107 ft lb).
Figure 350

260-4)
Page 141
Mount Hydraulic Control Unit (HSG-94)
1. Preassemble and mount plate (Figure 351 thru Figure
355).
2. Equip fittings (1 thru 6, Figure 351) with new O-rings and
install them. Install screw plug (7 and 8).
NOTE: Install new O-rings each time.
Figure 351
3. Install two adjusting screws (M6) and mount housing

gasket.
NOTE: At the following steps (Figure 352 thru Figure
356) pay attention to installation position of
different gaskets.
Figure 352
4. Mount intermediate plate.
Figure 353
5. Mount 2nd gasket.
Figure 354

260-4)
Page 142
6. Mount plate and fasten it uniformly using socket head
screws.
Figure 355
7. Mount gasket.
Figure 356
8. Assemble complete control unit and fasten it uniformly

using socket head screws (2x M6 x 105 and
21 x M6 x 80 mm).
NOTE: Pay attention to position of two socket head
screws M6 x 105, see Figure 357.
Figure 357

260-4)
Page 143
9. Install pressure lines according to following draft.
IMPORTANT
The arrangement of lines is different according to the
Version. In this connection, pay attention to the
Perspective Illustration in the corresponding Spare
Parts List.
Reference
Description
Number
KV Hydraulic Line Clutch
KV
KR Hydraulic Line Clutch
KR
K1 Hydraulic Line Clutch
K1
K2
K3
K4 Hydraulic Line Clutch Figure 358
K4
S1 Lubricating Oil Line
Clutch KR/K2
S2 Lubricating Oil Line
Clutch K4/K3
Inductive Transmitter and Speed Sensor

1. The following illustrations show installation position of
single inductive transmitters and speed sensor.
Reference
Description
Number
5 Inductive
Transmission N-
central Gear Train
9 Inductive
Transmission N-
engine
14 Inductive
Transmission N-
turbine
13 Speed Sensor N-
output and
Speedometer
Figure 359

260-4)
Page 144
Figure 360

260-4)
Page 145
Setting Inductive Transmitter
1. The following illustrations describe the reassembly, resp.
the setting of the Inductive transmitter N engine (9, Figure
359). The reassembly of the Inductive transmitter N turbine
(14) and N central gear train (5) has to be carried out
accordingly.
IMPORTANT
Pay attention to different setting dimensions. Setting
dimension corresponds to distance between contact
face inductive transmitter and tooth tip, see Figure
361.
2. Setting dimensions - Inductive transmitter N engine (9,

Figure 359) and n turbine (14, Figure 359) = 0.03 -
0.08 mm (0.0012 - 0.0031 in).
3. Setting dimension - Inductive transmitter N central gear
train (5, Figure 359) = 0.03 - 0.04 mm (0.0012 - 0.0016 in).
Figure 361
4. Turn counting disk radially until one tooth tip is situated

centrally to inductive transmitter hole.
5. Insert measuring pin (S) until end face has got contact on
tooth tip, resp. the retaining ring on screw - in face of
housing.
Figure 362
6. Remove measuring pin and measure Dimension I from end

face/measuring pin to retaining ring.
7. Measure Dimension II from contact face- inductive
transmitter to contact face.
Figure 363

260-4)
Page 146
EXAMPLE L:

Required Gap (0.03 - - 0.60 mm (0.0236 in)
0.08 mm (0.0012 -
0.0031 in)) e.g
Gives Installation Dimension = 29.50 mm (1.1614 in)
EXAMPLE L:

Installation Dimension - 29.50 mm (1.1614 in)
Difference = Shim = 0.50 mm (0.0197 in)
8. Assemble corresponding shim and wet thread (Figure 364)

with Loctite #574.
Figure 364
9. Install inductive transmitter N engine (9, Figure 365), N

turbine (14) and N central gear train (5).
10. Now, install screw plugs (Figure 365).
NOTE: Equip screw plugs with new O-ring.
NOTE: Torque limit (M26x1.5) 8.16 kgm (59 ft lb).
NOTE: Torque limit (M18 x 1.5) 5.10 kgm (37 ft lb).
Figure 365
Speed Sensor (Hall Sensor) N Output and

Speedometer
1. Illustration on right shows speed sensor 13.
Reference
Description
Number
1 Speed Sensor
2 Plate
3 O-ring
Figure 366

260-4)
Page 147
2. Grease O-ring and fasten speed sensor (Figure 367) using
socket head screw.
IMPORTANT
Before putting transmission into service, carry out oil
filling according to Operation and Maintenance
Manual.
Figure 367
3. Setting dimension - speed sensor = 1.0 - 1.5 mm (0.0394 -

0.0591 in).
Figure 368

260-4)
Page 148
SP000100
TRANSMISSION ERROR CODES (ZF)SP000100
Transmission
Error Codes (ZF)
Edition 1
Transmission Error Codes (ZF) SP000100

Page 1
MEMO
SP000100 Transmission Error Codes (ZF)

Page 2
Table of Contents
Transmission Error Codes (ZF)

Introduction........................................................... 6
Abbreviations ........................................................ 6
Display .................................................................. 7
Description of Fault Codes .............................................. 7
Display During Operation...................................... 8
Display During AEB-Mode .................................. 10
Definition of Operating Modes ............................ 12
Normal........................................................................... 12
Substitute Clutch Control............................................... 12
Limp-home .................................................................... 12
Transmission shut Down................................................ 12
TCU Shut Down ............................................................ 13
Table of Fault Codes ........................................... 14
Table of Fault Codes - ERGO-Control ................ 50
Measurement of Resistance at Actuator/sensors
and Cable ........................................................... 53
Actuator ......................................................................... 53
Cable ............................................................................. 53

Page 3
MEMO

Page 4
SAFETY PRECAUTIONS
CAUTION!
order.
handling load.
responsibility.
APPLICABLE MODELS

DL400 5001 and Up

Page 5
INTRODUCTION
The "WG" series of ZF Transmissions use an electronic control
system called "ZF-ERGO power."
The Ergo System (for short) allows the transmission to function
either in a manual powershift mode, or in a fully automatic mode.
An LCD display (Figure 1) is in the cab. This display gives the
machine operator a continuos status of the operating condition
of the system. It displays normal operational codes, and fault
codes.
ABBREVIATIONS
Throughout this section the following abbreviations are used to
indicate various conditions.
Abbreviations
O.C. Open Circuit
S.C. Short Circuit
Op-Mode OPeration Mode
TCU Transmission Control Unit
EEC Electronic Engine Controller
PTO Power Take-off

Page 6
DISPLAY h
left
character
right
character g
If a fault is detected, the display shows a spanner symbol (g) for

a fault. The display shows the fault code, if the gear selector is in
neutral position.
If more than one fault is detected, each fault code is shown for
about 1 second.
Reference Description
BAR
Letter
FG004442
a, f Automatic Range (Upshifting
and Downshifting) Figure 1
b, c, d, e Preselected Gear
g EST-37 has detected an
error and is flashing.
h This character will not be
used at the EST-37.
Description of Fault Codes

The first number of the error code is the category that it is
grouped into. They are as follows for the first number.
First Number Meaning of Number

1 Hex Digital Input Signal
2 Hex Analog Input Signal
3 Hex Speed Signal
4 Hex CAN Signal Error
9 Hex Digital Output Signal
A Hex Digital Output Signal
B Hex Transmission Fault, Clutch Error
C Hex Logical Fault
D Hex Power Supply
E Hex High Speed Signal
F Hex General Fault

Page 7
DISPLAY DURING OPERATION

1F, 1R Actual gear and direction. ---------------
2F, 2R Left digit shows actual gear.
3F, 3R Right digit shows actual direction.
4F
5F
6F
LF, LR Limp home gear.
F or R, no gear Clutch Cut Off. ---------------
F or R flashing Direction F or R selected while ---------------
turbine speed is too high.
CAUTION: Gear will engage if
turbine speed drops.
NN Not neutral, waiting for neutral after Go engage a gear, first move shift selector to
power up or a severe fault. neutral position and again to F or R position.
** Oil temperature too low, no gear Warm up engine / transmission.
available.
*N Oil temperature low, only one gear Warm up engine / transmission.
available.
1 bar (special Manual mode 1. gear. ---------------
symbol)
2 bars Manual mode 2. gear. ---------------
4 bars and 2 Automatic mode. ---------------
arrows
Bars flashing 6 WG: converter lockup clutch Difference of engine and turbine speed above
open. a certain limit and lockup clutch not activated.
4 WG: Downshift mode active.
Spanner At least one fault active. Select neutral to get fault code displayed.
Fault code See fault code list (See page -14). ---------------
WS Warning sump temperature. Changes between actual gear/direction while
driving, in neutral only displayed if no fault is
detected (spanner).
WR Warning retarder temperature. Changes between actual gear/direction while
detected (spanner).
WT Warning torque converter temperature. Changes between actual gear/direction while
detected (spanner)
WE Warning high engine speed. Changes between actual gear/direction while
detected (spanner).

Page 8
PN Direction F or R selected while Transmission in neutral until parking brake is
parking brake engaged. released.
CAUTION: Vehicle starts to move after
release of parking brake.
EE flashing No communication with display. Checked wiring from TCU to display.

Page 9
DISPLAY DURING AEB-MODE

PL AEB - Starter is plugged at the ---------------
diagnostic plug.
ST AEB - Starter button is pressed. ---------------
K1... K4, KV, KR Calibrating clutch K1... K4, KV or ---------------
KR resp.
Wait for start, initialization of clutch ---------------
+ Kx Kx.
x: 1, 2, 3, 4, V, R
Fast fill time determination of clutch ---------------
+ Kx
Kx.
Compensating pressure ---------------
+ Kx determination of clutch Kx.
OK Calibration for all clutches finished Transmissions stays in neutral, you have to
restart the TCU (ignition off/on) after
removing AEB-starter
STOP AEB canceled (activation stopped) Transmissions stays in neutral, you have to
restart the TCU (ignition off/on)
STOP and Kx AEB stopped, clutch Kx cannot be Transmissions stays in neutral, you have to
calibrated. restart the TCU (ignition off/on)
Kx couldn't be calibrated, AEB ---------------
+ Kx finished
Engine speed too low. ---------------

+E
raise engine
Engine speed too high. ---------------
+E
lower engine speed.
Transmission oil temperature too ---------------
+T low.
Heat up transmission
Transmission oil temperature too ---------------
+T high.
Cool down transmission
FT Transmission temperature not in Transmissions stays in neutral, you have to
defined range during calibration restart the TCU (ignition off/on)
FB Operating mode not NORMAL or Transmissions stays in neutral, you have to
transmission temperature sensor restart the TCU (ignition off/on)
defective or storing of Calibrated
values to EEPROM has failed.
FO Output speed not zero Transmissions stays in neutral, you have to
FN Shift lever not in Neutral position Transmissions stays in neutral, you have to
FP Park brake not applied Transmissions stays in neutral, you have to

Page 10
STOP AEB - Starter was used incorrect or Transmissions stays in neutral, you have to
is defective. Wrong device or wrong restart the TCU (ignition off/on)
cable used.

Page 11
DEFINITION OF OPERATING
MODES
Normal
There is no failure detected in transmission system or failure has
no or slight effects on transmission control. TCU will work
without or in special cases with little limitations. (See Table of
Fault Codes on page -14.)
Substitute Clutch Control

TCU cannot change gears or direction under control of normal
clutch modulation. TCU uses 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 shut Down

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 ADM 1 to ADM 8.
The operator has to slow down the vehicle. The transmission will
stay in neutral.

Page 12
TCU Shut Down
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
all functions are disabled which use ADM 1 to ADM 8.
The transmission will stay in neutral.
NOTE: VPS2: is the LIS (option power supply).

Page 13
TABLE OF FAULT CODES
The fault codes shown in this table are a complete list of codes
that are common to more than one version of the transmission.
Some of the versions are 4WG (four speed) and 6WG (six
speed).
NOTE: This fault code list is valid for the ZF Software
Versions V 53.x to V58.0
Fault Meaning of the Fault Code Reaction of the TCU Possible Steps to Remarks
Code (Possible reason for fault Repair
(hex) detection.)
11 Logical error at gear range signal. TCU shifts Check cables from Failure cannot be
transmission to neutral. TCU to shift lever. detected in systems
TCU detected a wrong signal
with DW2/DW3 shift
combination for gear range. Op-Mode: transmission Check signal
lever.
shut down. combinations of shift
Cable from shift lever to TCU is
lever positions for gear Fault is taken back if
broken.
range. TCU detects a valid
Cable is defective and is signal for position.
contacted to battery voltage or
vehicle ground.
Shift lever is defective.
12 Logical error at direction select TCU shifts Check cables from Fault is taken back if
signal. transmission to neutral. TCU to shift lever. TCU detects a valid
signal for direction at
TCU detected a wrong signal Op-Mode: transmission Check signal
shift lever.
combination for direction. shut down. combinations of shift
lever positions F-N-R.
Cable from shift lever to TCU is
broken.
Cable is defective and is
vehicle ground.
13 Logical error at engine derating After selecting neutral, Check engine derating This fault is reset after
device. TCU changes to OP- device. power up of TCU.
Mode limp home.
TCU detected no reaction of
engine while derating device
active.
14 Logical error at park brake status TCU shifts Check the cables from ---------------
park brake status signal measured transmission to DCO- electronic boxes to
by TCU and park brake status State. status switches.
signal send by CAN don't fit.
OP-Mode: normal Check signals of the
One of the cables from status status switches.
switch to electronic box is broken.
One of the status switches is
defective.

Page 14
(hex) detection.)
15 Logical error at direction select TCU shifts Check the cables from Fault is taken if TCU
signal 2. shift lever. transmission to neutral TCU to shift lever2. detects a valid neutral
if selector active signal for the direction
TCU detected a wrong signal Check signal
at the shift lever.
combination for the direction. OP-Mode: transmission combinations of shift
shutdown if selector lever positions F-N-R
Cable from shift lever 2 to TCU is
active.
broken.
vehicle ground.
16 Logical error at axle connection OP-Mode: normal Check the cables from ---------------
feedback axle connection TCU to feedback axle
measured by TCU and output connection switch.
signal axle connection don't fit.
Check signals of the
Axle can't be connected or feedback axle
disconnected due to mechanical connection switch.
problem.
One of the cables from feedback
axle connection switch to TCU is
broken.
17 S.C. to ground at customer specific Customer specific. Check cable from TCU 1)
See Measurement
(Function No. 1) to customer specific of Resistance at
(Function No. 1) Actuator/sensors and
TCU detected a wrong voltage at
device. Cable on page 1-53.
output pin, that looks like a S.C. to
vehicle ground. Check connectors
from customer specific
(Function No. 1) to
contacted to vehicle ground.
TCU.
Customer specific (Function No.
Check resistance of
1) device has an internal defect.
customer specific
Connector pin is contacted to (Function No. 1)
vehicle ground. device.
18 S.C. to battery voltage at customer Customer specific. Check cable from TCU 1) See Measurement
specific (Function No. 1). to customer specific of Resistance at
battery voltage. Check connectors
(Function No. 1) to
contacted to battery voltage.
TCU.
Check resistance of
customer specific
battery voltage. device.

Page 15
(hex) detection.)
19 O.C. at customer specific (Function Customer specific. Check cable from TCU 1)
See Measurement
No. 1). to customer specific of Resistance at
output pin, that looks like a O.C. for
this output pin. Check connectors
Cable is defective and has no
(Function No. 1)
connection to TCU.
device to TCU.
Check resistance of
customer specific
Connector has no connection to (Function No. 1)
TCU. device.
1A S.C. to ground at customer specific Customer specific. Check cable from TCU 1)
See Measurement
(Function No. 2). to customer specific of Resistance at
(Function No. 2)
device to TCU.
Check resistance of
customer specific
1B S.C. to battery voltage at customer Customer specific. Check cable from TCU 1)
See Measurement
(Function No. 2)
device to TCU.
Check resistance of
customer specific
1C O.C. at customer specific (Function Customer specific. Check cable from TCU 1) See Measurement
(Function No. 2)
connection to TCU.
device to TCU.
Check resistance of
customer specific
TCU. device.

Page 16
(hex) detection.)
1D S.C. to ground at customer specific Customer specific. Check cable from TCU 1)
See Measurement
(Function No. 3). to customer specific of Resistance at
(Function No. 3)
device to TCU.
Check resistance of
customer specific
1E S.C. to battery voltage at customer Customer specific. Check cable from TCU 1)
See Measurement
(Function No. 3)
device to TCU.
Check resistance of
customer specific
1F O.C. at customer specific (Function Customer specific. Check cable from TCU 1)
See Measurement
(Function No. 3)
connection to TCU.
device to TCU.
Check resistance of
customer specific
TCU. device.
21 S.C to battery voltage at clutch Clutch cutoff function is Check the cable from ---------------
cutoff input. disabled TCU to the sensor.
The measured voltage is too high. OP-Mode: normal Check the connectors.
Cable is defective and is Check the clutch cutoff
contacted to battery voltage. sensor.
Clutch cut off sensor has an
internal defect.
Connector pin is contacted to
battery voltage.

Page 17
(hex) detection.)
22 S.C. to ground or O.C. at clutch Clutch cutoff function is Check the cable from ---------------
cutoff input. disabled TCU to the sensor.
The measured voltage is too low: OP-Mode: normal Check the connectors.
Cable is defective and is Check the clutch cutoff
contacted to vehicle ground. sensor.
Clutch cutoff sensor has an
internal defect.
vehicle ground or is broken.
23 S.C. to battery voltage at load Retarder function is Check the cable from Availability of retarder
sensor input. affected TCU uses TCU to the sensor. depends on default
default load load.
The measured voltage is too high Check the connectors.
OP-Mode: normal
Cable is defective and is Check the load sensor
Check the assembly
Load sensor has an internal tolerances of load
defect. sensor.
battery voltage.
24 S.C. to ground or O.C. at load Retarder function is Check the cable from Availability of retarder
sensor input. affected TCU uses TCU to the sensor. depends on default
default load. load.
The measured voltage is too low: Check the connectors.
OP-Mode: normal
Cable is defective and is contacted Check the load
to vehicle ground. sensor.
Cable has no connection to TCU. Check the assembly
tolerances of load
Load sensor has an internal defect.
sensor.
vehicle ground or is broken.
25 S.C. to battery voltage or O.C. at No reaction. Check cable from TCU ---------------
transmission sump temperature to sensor.
TCU uses default
sensor input.
temperature. Check connectors.
The measured voltage is too high:
Op-Mode: normal. Check temperature
Cable is defective and is sensor.
Cable has no connection to TCU.
Temperature sensor has an
internal defect.
battery voltage or is broken.
26 S.C. to ground at transmission No reaction. Check cable from TCU ---------------
sump temperature sensor input. to sensor.
TCU uses default
The measured voltage is too low: temperature. Check connectors.
Cable is defective and is Op-Mode: normal. Check temperature
internal defect.
vehicle ground.

Page 18
(hex) detection.)
27 S.C. to battery voltage or O.C. at No reaction. Check cable from TCU ---------------
retarder temperature sensor input. to sensor.
TCU uses default
The measured voltage is too high: temperature. Check connectors.
internal defect.
28 S.C. to ground at retarder No reaction. Check cable from TCU ---------------
temperature sensor input. to sensor.
TCU uses default
The measured voltage is too low: temperature. Check connectors.
internal defect.
vehicle ground.
29 S.C. to battery voltage or O.C. at TCU uses default Check cable from TCU ---------------
parking brake sensor input. value. to sensor.
The measured voltage is too high: Op-Mode: normal. Check connectors.
Cable is defective and is Check parking brake
Sensor has an internal defect.
2A S.C. to ground parking brake TCU uses default Check cable from TCU ---------------
sensor input. value. to sensor.
The measured voltage is too low: Op-Mode: normal. Check connectors.
Cable is defective and is Check parking brake
Sensor has an internal defect.
vehicle ground.
2B Inch sensor signal mismatch During inching mode: Check cable from TCU ---------------
TCU shifts to neutral. to sensor.
The measured voltage from CCO
and CCO2 signal don't match: While not inching: no Check connectors.
Cable is defective. change Check sensor.
Sensor has an internal defect OP-Mode: normal

Page 19
(hex) detection.)
31 S.C. to battery voltage or O.C. at Op-Mode: substitute Check cable from TCU ---------------
engine speed input. clutch control. to sensor.
TCU measures a voltage higher Check connectors.
than 7.00 V at speed input pin.
Check speed sensor.
Speed sensor has an internal
defect.
battery voltage or has no contact.
32 S.C. to ground at engine speed Op-Mode: substitute Check cable from TCU ---------------
input. clutch control. to sensor.
TCU measures a voltage less than Check connectors.
0.45V at speed input pin.
Check speed sensor.
Cable / connector is defective and
is contacted to vehicle ground.
defect.
33 Logical error at engine speed Op-Mode: substitute Check cable from TCU This fault is reset after
input. clutch control. to sensor. power up of TCU.
TCU measures a engine speed Check connectors.
over a threshold and the next
Check speed sensor.
moment the measured speed is
zero. Check sensor gap.
has bad contact.
defect.
Sensor gap is incorrect.
turbine speed input. clutch control. to sensor.
TCU measures a voltage higher If a failure is existing at Check connectors.
than 7.00 V at speed input pin. output speed.
Check speed sensor.
Cable is defective and is TCU shifts to neutral.
Op-Mode: limp home.
defect.

Page 20
(hex) detection.)
35 S.C. to ground at turbine speed Op-Mode: substitute Check cable from TCU ---------------
TCU measures a voltage less than If a failure is existing at Check connectors.
0.45V at speed input pin. output speed.
Check speed sensor.
Cable / connector is defective and TCU shifts to neutral.
Op-Mode: limp home.
defect.
36 Logical error at turbine speed Op-Mode: substitute Check cable from TCU This fault is reset after
TCU measures a turbine speed If a failure is existing at Check connectors.
over a threshold and at the next output speed.
Check speed sensor.
TCU shifts to neutral.
Op-Mode: limp home.
has bad contact.
defect.
internal speed input. clutch control. to sensor.
TCU measures a voltage higher Check connectors.
than 7.00 V at speed input pin.
Check speed sensor.
defect.
38 S.C. to ground at internal speed Op-Mode: substitute Check cable from TCU ---------------
TCU measures a voltage less than Check connectors.
0.45V at speed input pin.
Check speed sensor.
defect.

Page 21
(hex) detection.)
39 Logical error at internal speed Op-Mode: substitute Check cable from TCU This fault is reset after
TCU measures a internal speed Check connectors.
over a threshold and at the next
Check speed sensor.
has bad contact.
defect.
3A S.C. to battery voltage or O.C. at Special mode for gear Check cable from TCU ---------------
output speed input. selection; to sensor.
TCU measures a voltage higher Op-Mode: substitute Check connectors.
than 12.5 V at speed input pin. clutch control.
Check speed sensor.
Cable is defective and is If a failure is existing at
contacted to battery voltage. turbine speed.
Cable has no connection to TCU. TCU shifts to neutral.
Speed sensor has an internal Op-Mode: limp home.
defect.
3B S.C. to ground at output speed Special mode for gear Check cable from TCU ---------------
input. selection. to sensor.
TCU measures a voltage less than Op-Mode: substitute Check connectors.
1.00V at speed input pin. clutch control.
Check speed sensor.
Cable / connector is defective and If a failure is existing at
is contacted to vehicle ground. turbine speed.
Speed sensor has an internal TCU shifts to neutral.
defect.
Op-Mode: limp home.
3C Logical error at output speed input. Special mode for gear Check cable from TCU This fault is reset after
selection. to sensor. power up of TCU.
TCU measures a output speed
over a threshold and at the next Op-Mode: substitute Check connectors.
moment the measured speed is clutch control.
Check speed sensor.
zero.
If a failure is existing at
Check sensor gap.
Cable / connector is defective and turbine speed.
has bad contact.
Op-Mode: limp home.
defect.
3D Turbine speed zero doesn't fit to --------------- --------------- Not used.
other speed signals

Page 22
(hex) detection.)
3E Output speed zero doesn't fit to Special mode for gear Check sensor signal of This fault is reset after
other speed signals. selection. output speed sensor. power up of TCU.
If transmission is not neutral and Op-Mode: substitute Check sensor gap of
the shifting has finished. clutch control. output speed sensor.
TCU measures output speed zero If a failure is existing at Check cable from TCU
and turbine speed or internal turbine speed. to sensor.
speed not equal to zero.
Op-Mode: limp home.
defect.
40 Gear range restriction signal No gear range Check cluster ---------------
restriction controller
CAN signal for gear range
restriction is defective. Check wire of CAN-
Bus
Cluster controller is defective.
Check cable to cluster
Interference on CAN-Bus
controller
40 FCAN MESSAGE 'Gear range gear range set from 1st Check FWD controller ---------------
select (ZF 3 IDENT)' contains to 5th
Check wire of CAN-
invalid data
Bus
41 Declutch modulation selection --------------- --------------- ---------------
signal
41 TCU receives messages 'Gear ignore FWD Reconfigure with TCU ---------------
range select (ZF 3 IDENT)' and commands Configuration
'Front wheel drive status' (V IDENT Command (ID PC)
FWD)
Although configuration states that
FWD controller is not installed.
50 FMR1 time out TCU operates like jake Check engine ---------------
brake is off and controller.
Time out of CAN-message FMR1
exhaust brake is off.
from engine controller. Check wire of CAN-
OP-Mode: normal Bus.
Check cable to engine
CAN wire/ connector is broken
controller.
CAN wire/ connector is defective
and has contact to vehicle ground
or battery voltage.
Engine controller is defective.
51 FMR2 time out OP-Mode: substitute Check engine ---------------
clutch control controller.
Time out of CAN-message FMR2
from engine controller. Check wire of CAN-
Bus.
controller.
or battery voltage.

Page 23
(hex) detection.)
52 EAMODUL1 time out TCU shifts to neutral Check I/O controller. ---------------
and uses substitute
Time out of CAN-message EAM1 Check wire of CAN-
gear selector.
from I/O controller. Bus.
OP-Mode: normal
Interference on CAN-Bus Check cable to I/O
controller.
or battery voltage.
53 ABS time out No reaction. Check ABS controller. ---------------
Time out of CAN-message ABS Check wire of CAN-
from ABS controller. Bus.
Interference on CAN-Bus Check cable to ABS
controller.
or battery voltage.
54 MDU1 time out TCU keeps old auto Check cluster ---------------
downshift information controller.
Time out of CAN-message MDU1
and old manual
from cluster controller. Check wire of CAN-
downshift information.
Bus.
OP-Mode: normal
controller.
or battery voltage.
54 DCT1 time out TCU keeps old auto Check cluster ---------------
downshift information controller.
Time out of CAN-message DCT1
and old manual
from cluster controller. Check wire of CAN-
downshift information.
Bus.
OP-Mode: normal
controller.
or battery voltage.
54 Gear range select time out. Gear range set from 1st Check wire of CAN- ---------------
Bus.
Time out of CAN-message 'Gear to 5th.
range select (ZF 3 IDENT)' Check FWD controller.
or battery voltage.
FWD controller is defective.

Page 24
(hex) detection.)
55 DNS1 time out TCU shifts to neutral. Check OMRON- ---------------
OP-Mode: normal master.
Time out of CAN-message DNS1
from OMRON-master. Check wire of CAN-
Bus.
Check cable to
OMRON-master.
or battery voltage.
55 SCT1 time out. OP-Mode: normal Check steering ---------------
computer.
Time out of CAN-message SCT1
from steering computer. Check wire of CAN-
Bus.
Interference on CAN-Bus.
Check cable to
steering computer.
or battery voltage.
55 Front wheel drive status time out. TCU shifts to neutral. Check wire of CAN- ---------------
Bus.
Time out of CAN-message
Check FWD controller.
'Front wheel drive status (V IDENT
FWD)'
or battery voltage.
FWD controller is defective.
56 Engine configuration time out. Op-Mode: substitute Check engine ---------------
clutch control controller.
Time out of CAN-message Engine
configuration from engine Check wire of CAN-
controller. Bus.
Interference on CAN-Bus. Check cable to engine
controller.
or battery voltage.
57 EEC1 time out. Op-Mode: substitute Check EEC controller. ---------------
clutch control
Time out of CAN-message EEC1 Check wire of CAN-
from EEC controller. Bus.
Interference on CAN-Bus. Check cable to EEC
controller.
or battery voltage.

Page 25
(hex) detection.)
58 EEC3 time out. Op-Mode: substitute Check EEC controller. ---------------
clutch control
Time out of CAN-message EEC3 Check wire of CAN-
controller.
or battery voltage.
59 Test mode signal Test mode is aborted, if Check cluster ---------------
active. controller.
CAN signal for test mode status is
defective. Check wire of CAN-
Bus.
controller.
5A Park brake status signal No reaction. Check cluster ---------------
controller.
CAN signal for park brake status is
Bus.
controller.
5B Shift quality selector signal Last selection is kept. Check cluster ---------------
controller.
CAN signal for shift quality
selection is defective. Check wire of CAN-
Bus.
controller.
5C Auto downshift signal Last selection is kept. Check cluster ---------------
controller.
CAN signal for automatic downshift
is defective. Check wire of CAN-
Bus.
controller.
5D Manual downshift signal Last selection is kept. Check cluster ---------------
controller.
CAN signal for automatic downshift
is defective. Check wire of CAN-
Bus.
Check cable to????
controller
5E CCO request signal Last selection is kept. Check cluster ---------------
controller.
CAN signal for CCO request is
Bus.
Check cable to????
controller

Page 26
(hex) detection.)
5F Shift lever signal TCU shifts to neutral Check I/O controller. ---------------
and uses informations
CAN signal for shift lever is Check wire of CAN-
from substitute shift
defective. Bus.
lever.
I/O controller is defective. Check cable to I/O
OP-Mode: normal
controller
5F Transmission neutral request OP-Mode: normal Check steering ---------------
signal computer.
CAN signal for transmission Check wire of CAN-
neutral request is defective. Bus.
Steering computer is defective. Check cable to
steering computer.
5F CAN message 'Front wheel drive TCU shifts to neutral Check FWD controller. ---------------
status (V IDENT FWD)' contains
invalid data.
60 Additional brake status signal No reaction. Check I/O controller. ---------------
CAN signal for additional park OP-Mode: normal Check wire of CAN-
brake status is defective. Bus.
controller
61 AEB request signal No reaction. Check I/O controller. ---------------
CAN signal for AEB request is OP-Mode: normal Check wire of CAN-
defective Bus.
Last selection is kept
controller
62 PTO torque signal No reaction. Check I/O controller. ---------------
CAN signal for PTO torque is TCU uses default PTO Check wire of CAN-
defective torque signal Bus.
I/O controller is defective. OP-Mode: normal Check cable to I/O
controller
63 Driving mode signal No reaction. Check I/O controller. ---------------
CAN signal for driving mode is TCU uses default Check wire of CAN-
defective. driving mode signal Bus.
controller
64 Starting gear signal No reaction. Check I/O controller. ---------------
CAN signal for starting gear is TCU uses default Check wire of CAN-
defective. starting gear Bus.
controller
65 Engine torque signal OP-Mode: substitute Check engine ---------------
clutch control controller
CAN signal for engine torque is
defective Check wire of CAN-
Bus.
controller

Page 27
(hex) detection.)
69 Reference engine torque signal OP-Mode: substitute Check engine ---------------
CAN signal for reference of engine
torque id defective Check wire of CAN-
Bus.
controller
6A Actual engine torque signal OP-Mode: substitute Check engine ---------------
CAN signal for actual engine
torque is defective Check wire of CAN-
Bus.
controller
6B NOM friction torque signal OP-Mode: substitute Check engine ---------------
CAN signal for nominal friction
torque is defective Check wire of CAN-
Bus.
controller
6E EEC2 time out No reaction. Check EEC controller ---------------
Time out of CAN-message EEC2 TCU uses default Check wire of CAN-
from EEC controller signal accelerator Bus.
pedal in idle position
OP-Mode: normal controller
or battery voltage.
71 S.C. to battery voltage at clutch K1. TCU shifts to neutral. Check cable from TCU 1)
See Measurement
to gearbox. of Resistance at
The measured resistance value of Op-Mode: limp home.
valve is out of limit, voltage at K1 Check connectors Actuator/sensors and
If failure at another Cable on page 1-53.
valve is too high. from TCU to gearbox.
clutch is pending.
Cable / connector is defective and Check regulator
has contact to battery voltage. resistance. 1)
Op-Mode: TCU shut
Cable / connector is defective and Check internal wire
down.
has contact to another regulator harness of gearbox.
output of TCU.
Regulator has an internal defect.
72 S.C. to ground at clutch K1. TCU shifts to neutral. Check cable from TCU 1) See Measurement
valve is too low. from gearbox to TCU.
clutch is pending.
has contact to vehicle ground. resistance. 1)
Op-Mode: TCU shut
Regulator has an internal defect. Check internal wire
down.
harness of gearbox.

Page 28
(hex) detection.)
73 O.C. at clutch K1. TCU shifts to neutral. Check cable from TCU 1)
See Measurement
valve is out of limit. Check connectors Actuator/sensors and
from gearbox to TCU.
Cable / connector is defective and clutch is pending.
has no contact to TCU. Check regulator
Regulator has an internal defect. resistance. 1)
Op-Mode: TCU shut
down. Check internal wire
harness of gearbox.
See Measurement
valve is too high. from gearbox to TCU.
clutch is pending.
Op-Mode: TCU shut
down.
output of TCU.
75 S.C. to ground at clutch K2. TCU shifts to neutral. Check cable from TCU 1) See Measurement
clutch is pending.
Op-Mode: TCU shut
down.
harness of gearbox.
76 O.C. at clutch K2. TCU shifts to neutral. Check cable from TCU 1) See Measurement
Op-Mode: TCU shut
harness of gearbox.
See Measurement
clutch is pending.
Op-Mode: TCU shut
down.
output of TCU.

Page 29
(hex) detection.)
78 S.C. to ground at clutch K3. TCU shifts to neutral. Check cable from TCU 1)
See Measurement
clutch is pending.
Op-Mode: TCU shut
down.
harness of gearbox.
79 O.C. at clutch K3. TCU shifts to neutral. Check cable from TCU 1)
See Measurement
Op-Mode: TCU shut
harness of gearbox.
7A S.C. to battery voltage at converter --------------- --------------- ---------------
clutch
7B S.C. to ground at converter clutch --------------- --------------- ---------------
7C O.C. at converter clutch --------------- --------------- ---------------
7D S.C. to ground at engine derating Engine derating will be Check cable from TCU 1) See Measurement
device. on until TCU power to engine derating of Resistance at
down even if fault device. Actuator/sensors and
vanishes (loose Cable on page 1-53.
contacted to vehicle ground. Check connectors
connection). (Only Mega 500-V)
from engine derating
Engine derating device has an
Op-Mode: normal. device to TCU.
internal defect.
Connector pin is contacted to Check resistance 1) of
vehicle ground. engine derating
device.
7E S.C. to battery voltage at engine No reaction. Check cable from TCU Only Mega 500-V
derating device. to engine derating
Op-Mode: normal.
device.
is contacted to battery voltage. Check connectors
from backup alarm
Engine derating device has an
device to TCU.
internal defect.
Check resistance 1) of
backup alarm device.
7F O.C. at engine derating device. No reaction. Check cable from TCU 1) See Measurement
to engine derating of Resistance at
TCU detected a wrong voltage at Op-Mode: normal.
device. Actuator/sensors and
this output pin. Check connectors Cable on page 1-53.
from engine derating (Only Mega 500-V)
device to TCU.
connection to TCU.
Engine derating device has an Check resistance 1) of
internal defect. engine derating
device.
Connector has no connection to
TCU.

Page 30
(hex) detection.)
See Measurement
clutch is pending.
Op-Mode: TCU shut
down.
output of TCU.
82 S.C. to ground at clutch K4. TCU shifts to neutral. Check cable from TCU 1)
See Measurement
clutch is pending.
Op-Mode: TCU shut
down.
harness of gearbox.
83 O.C. at clutch K4. TCU shifts to neutral. Check cable from TCU 1) See Measurement
Op-Mode: TCU shut
harness of gearbox.
84 S.C. to battery voltage at clutch KV. TCU shifts to neutral. Check cable from TCU 1) See Measurement
valve is out of limit, voltage at KV Check connectors Actuator/sensors and
clutch is pending.
Op-Mode: TCU shut
down.
output of TCU.
85 S.C. to ground at clutch KV. TCU shifts to neutral. Check cable from TCU 1) See Measurement
valve is out of limit, voltage at KV Check connectors Actuator/sensors and
clutch is pending.
Op-Mode: TCU shut
down.
harness of gearbox.

Page 31
(hex) detection.)
86 O.C. at clutch KV. TCU shifts to neutral. Check cable from TCU 1)
See Measurement
Op-Mode: TCU shut
harness of gearbox.
87 S.C. to battery voltage at clutch TCU shifts to neutral. Check cable from TCU 1)
See Measurement
KR. to gearbox. of Resistance at
Op-Mode: limp home.
The measured resistance value of Check connectors Actuator/sensors and
valve is out of limit, voltage at KR from gearbox to TCU.
clutch is pending.
valve is too high.
Check regulator
Cable / connector is defective and resistance. 1)
has contact to battery voltage. Op-Mode: TCU shut
Cable / connector is defective and harness of gearbox.
has contact to another regulator
output of TCU.
88 S.C. to ground at clutch KR. TCU shifts to neutral. Check cable from TCU 1)
See Measurement
valve is out of limit, voltage at KR Check connectors Actuator/sensors and
clutch is pending.
Op-Mode: TCU shut
down.
harness of gearbox.
89 O.C. at clutch KR. TCU shifts to neutral. Check cable from TCU 1) See Measurement
Op-Mode: TCU shut
harness of gearbox.
91 S.C. to ground at relay reverse Backup alarm will be Check cable from TCU 1) See Measurement
warning alarm. on until TCU power to backup alarm of Resistance at
down even if fault device. Actuator/sensors and
vanishes (loose Cable on page 1-53.
output pin, that looks like a S.C. to Check connectors
connection).
vehicle ground. from backup alarm
Op-Mode: normal. device to TCU.
contacted to vehicle ground. Check resistance 1) of
Backup alarm device has an backup alarm device.
internal defect.
vehicle ground.

Page 32
(hex) detection.)
92 S.C. to battery voltage at relay No reaction. Check cable from TCU 1)
See Measurement
reverse warning alarm. to backup alarm of Resistance at
Op-Mode: normal.
output pin, that looks like a S.C. to Check connectors Cable on page 1-53.
battery voltage. from backup alarm
device to TCU.
contacted to battery voltage. Check resistance 1) of
internal defect.
battery voltage.
93 O.C. at relay reverse warning No reaction. Check cable from TCU 1)
See Measurement
alarm. to backup alarm of Resistance at
Op-Mode: normal.
output pin, that looks like a O.C. for Check connectors Cable on page 1-53.
this output pin. from backup alarm
device to TCU.
connection to TCU. Check resistance 1) of
internal defect.
TCU.
94 S.C. to ground at relay starter No reaction. Check cable from TCU 1)
See Measurement
interlock. to starter interlock of Resistance at
Op-Mode: normal.
relay. Actuator/sensors and
vehicle ground. from starter interlock
relay to TCU.
Starter interlock relay has an starter interlock relay.
internal defect.
vehicle ground.
95 S.C. to battery voltage at relay No reaction. Check cable from TCU 1) See Measurement
starter interlock. to starter interlock of Resistance at
Op-Mode: normal.
battery voltage. from starter interlock
relay to TCU.
Starter interlock relay has an starter interlock relay.
internal defect.
battery voltage.

Page 33
(hex) detection.)
96 O.C. at relay starter interlock. No reaction. Check cable from TCU 1)
See Measurement
to starter interlock of Resistance at
this output pin. Check connectors Cable on page 1-53.
from starter interlock
relay to TCU.
connection to TCU.
Starter interlock relay has an Check resistance 1) of
internal defect. starter interlock relay.

TCU.
97 S.C. to ground at park brake No reaction. Check cable from TCU 1)
See Measurement
solenoid. to the park brake of Resistance at
Op-Mode: normal.
solenoid. Actuator/sensors and
vehicle ground. from park brake
solenoid to TCU.
contacted to vehicle ground Check resistance 1) of
Park brake solenoid has an park brake solenoid.
internal defect.
vehicle ground.
98 S.C. to battery voltage at park No reaction. Check cable from TCU 1) See Measurement
brake solenoid to the park brake of Resistance at
Optional: (some
TCU detected a wrong voltage at customers)
the output pin, that looks like a S.C. Check connectors Cable on page 1-53.
TCU shifts to neutral
to battery voltage. from park brake
caused by park brake
solenoid to TCU.
Cable is defective and is feed back.
Op-Mode: normal.
Park brake solenoid has an park brake solenoid.
internal defect.
vehicle ground
99 O.C. at park brake solenoid TCU No reaction. Check cable from TCU ---------------
detected a wrong voltage at the to the park brake
Optional: (some
output pin, that looks like a O.C. for solenoid.
customers)
this output pin.
Check connectors
TCU shifts to neutral
Cable is defective and has no from park brake
caused by park brake
connection to TCU. solenoid to TCU.
feed back.
Park brake solenoid has an Check resistance 1) of
Op-Mode: normal.
internal defect. park brake solenoid.
TCU.

Page 34
(hex) detection.)
9A S.C. to ground at converter lock up No reaction. Check cable from TCU ---------------
clutch solenoid. to the converter clutch
Op-Mode: normal.
solenoid.
the output pin, that looks like a S.C. Check connectors
to vehicle ground. from converter clutch
solenoid to TCU.
Converter clutch solenoid has an converter clutch
internal defect. solenoid.

vehicle ground.
9B O.C. at converter lock up clutch Converter clutch Check cable from TCU 1)
See Measurement
solenoid. always open, retarder to the converter clutch of Resistance at
not available. solenoid. Actuator/sensors and
the output pin, that looks like a Op-Mode: normal. Check connectors Cable on page 1-53.
O.C. for this output pin. from converter clutch
solenoid to TCU.

TCU.
9C S.C. to battery voltage at converter No reaction. Check cable from TCU 1)
See Measurement
lock up clutch solenoid. to the converter clutch of Resistance at
Op-Mode: normal.
to battery voltage. from converter clutch
solenoid to TCU.
contacted to battery voltage Check resistance 1) of

battery voltage
9D S.C. to ground at retarder solenoid. No reaction. Check cable from TCU 1) See Measurement
to the retarder of Resistance at
the output pin, that looks like a S.C.
to vehicle ground. Check connectors Cable on page 1-53.
from retarder solenoid
to TCU.
Retarder solenoid has an internal Check resistance 1) of
defect. retarder solenoid.

vehicle ground.

Page 35
(hex) detection.)
9E O.C. at retarder solenoid. No reaction. Check cable from TCU 1)
See Measurement
to the retarder of Resistance at
the output pin, that looks like a
O.C. for this output pin. Check connectors Cable on page 1-53.
from retarder solenoid
to TCU.
connection to TCU.
Retarder solenoid has an internal Check resistance 1) of
defect. retarder solenoid.

TCU.
9F S.C. to battery voltage at retarder No reaction. Check cable from TCU 1)
See Measurement
solenoid. to the retarder of Resistance at
Op-Mode: normal.
to battery voltage. from retarder solenoid
to TCU.
Retarder solenoid has an internal retarder solenoid.
defect.
battery voltage
A1 S.C. to ground at difflock or axle No reaction. Check cable from TCU 1) See Measurement
connection solenoid. to the difflock of Resistance at
Op-Mode: normal.
to vehicle ground. from difflock solenoid
to TCU.
Difflock solenoid has an internal difflock solenoid.
defect.
vehicle ground
A2 S.C. to battery voltage at difflock or No reaction. Check cable from TCU 1)
See Measurement
axle connection solenoid. to the difflock of Resistance at
Op-Mode: normal.
to battery voltage. from difflock solenoid
to TCU.
defect.
battery voltage

Page 36
(hex) detection.)
A3 O.C. at difflock or axle connection No reaction. Check cable from TCU 1)
See Measurement
solenoid. to the difflock of Resistance at
Op-Mode: normal.
the output pin, that looks like a Check connectors Cable on page 1-53.
O.C. for this output pin. from difflock solenoid
to TCU.
defect.
TCU.
A4 S.C. to ground at warning signal No reaction. Check cable from TCU 1)
See Measurement
output. to the warning device. of Resistance at
Op-Mode: normal.
TCU detected a wrong voltage at Check connectors Actuator/sensors and
the output pin, that looks like a S.C. from warning device to Cable on page 1-53.
to vehicle ground. TCU.
Cable is defective and is Check resistance 1) of
contacted to vehicle ground warning device.
Warning device has an internal
defect.
vehicle ground
A5 O.C. at warning signal output No reaction. Check cable from TCU 1)
See Measurement
to the warning device. of Resistance at
the output pin, that looks like a Check connectors Actuator/sensors and
O.C. for this output pin. from warning device to Cable on page 1-53.
TCU.
Warning device has an internal warning device.
defect.
TCU.
A6 S.C. to battery voltage at warning No reaction. Check cable from TCU 1)
See Measurement
signal output. to the warning device. of Resistance at
Op-Mode: normal.
TCU detected a wrong voltage at Check connectors Actuator/sensors and
the output pin, that looks like a S.C. from warning device to Cable on page 1-53.
to battery voltage. TCU.
Cable is defective and is Check resistance 1) of
contacted to battery voltage warning device.
Warning device has an internal
defect.
battery voltage

Page 37
(hex) detection.)
A7 S.C. to ground at customer specific Customer specific. Check cable from TCU 1)
See Measurement
function No. 4 to customer specific of Resistance at
function No. 4 device. Actuator/sensors and
to vehicle ground. from customer specific
function No. 4 device
to TCU.
Customer specific function No. 4 Check resistance 1) of
device has an internal defect. customer specific
function No. 4 device.
vehicle ground
A8 S.C. to battery voltage at customer Customer specific. Check cable from TCU 1)
See Measurement
specific function No. 4 to customer specific of Resistance at
to battery voltage. from customer specific
to TCU.
battery voltage
A9 O.C. at customer specific function Customer specific. Check cable from TCU 1)
See Measurement
No. 4. to customer specific of Resistance at
O.C. for this output pin. from customer specific
to TCU.
connection to TCU.
TCU.
AA S.C. to ground at customer specific Customer specific. Check cable from TCU 1) See Measurement
to TCU.
vehicle ground

Page 38
(hex) detection.)
AB S.C. to battery voltage at customer Customer specific. Check cable from TCU 1)
See Measurement
to TCU.
battery voltage
AC O.C. at customer specific function Customer specific. Check cable from TCU 1)
See Measurement
to TCU.
connection to TCU.
TCU.
AD S.C. to ground at customer specific Customer specific. Check cable from TCU 1)
See Measurement
to TCU.
vehicle ground
AE S.C. to battery voltage at customer Customer specific. Check cable from TCU 1) See Measurement
to TCU.
battery voltage

Page 39
(hex) detection.)
AF O.C. at customer specific function Customer specific. Check cable from TCU 1)
See Measurement
to TCU.
connection to TCU.
TCU.
B1 Slippage at clutch K1. TCU shifts to neutral. Check pressure at ---------------
clutch K1.
TCU calculates a differential speed Op-Mode: limp home.
at closed clutch K1. If this Check main pressure
If failure at another
calculated value is out of range, in system.
clutch is pending.
TCU interprets this as slipping
Check sensor gap at
clutch. TCU shifts to neutral.
internal speed sensor.
Low-pressure at clutch K1. Op-Mode: TCU shut
Check sensor gap at
down.
Low main pressure. output speed sensor.
Wrong signal at internal speed Check signal at
sensor. internal speed sensor.
Wrong signal at output speed Check signal at output
sensor. speed sensor.
Sensor gap is incorrect. Replace clutch.
Clutch is defective.
clutch K2.
clutch is pending.
Check sensor gap at
Check sensor gap at
down.

Page 40
(hex) detection.)
clutch K3.
clutch is pending.
Check sensor gap at
Check sensor gap at
down.
clutch K4.
clutch is pending.
Check sensor gap at
Check sensor gap at
down.
Low main pressure. turbine speed sensor.
Wrong signal at turbine speed Check signal at
sensor. turbine speed sensor.
B5 Slippage at clutch KV. TCU shifts to neutral. Check pressure at ---------------
clutch KV.
at closed clutch KV. If this Check main pressure
clutch is pending.
Check sensor gap at
Low-pressure at clutch KV. Op-Mode: TCU shut
Check sensor gap at
down.

Page 41
(hex) detection.)
B6 Slippage at clutch KR. TCU shifts to neutral. Check pressure at ---------------
clutch KR.
at closed clutch KR. If this Check main pressure
clutch is pending.
Check sensor gap at
Low-pressure at clutch KR. Op-Mode: TCU shut
Check sensor gap at
down.
B7 Over temperature sump. No reaction. Cool down machine. ---------------
TCU measured a temperature in oil Op-Mode: normal. Check oil level.
sump that is over allowed
Check temperature
threshold.
sensor.
B8 Over temperature retarder. TCU disables retarder. Cool down machine. ---------------
TCU measured a temperature in Op-Mode: normal. Check oil level.
retarder oil that is over allowed
Check temperature
threshold.
sensor.
B9 Over speed engine. Retarder applies if --------------- ---------------
configured
Op-Mode: normal.
BA Differential pressure oil filter No reaction. Check oil filter. ---------------
TCU measured a voltage at Op-Mode: normal. Check the cable from
differential pressure switch out of TCU to the differential
the allowable range. pressure switch.
Oil filter is dirty. Check differential
pressure switch.
Cable or connectors are defect
and are contacted to battery
voltage.
and are contacted to vehicle
ground.
Differential pressure switch is
defective.

Page 42
(hex) detection.)
BB Slippage at converter lockup --------------- Check pressure at ---------------
clutch. converter lockup
clutch.
TCU calculates a differential speed
at closed converter lockup clutch. If Check main pressure
this calculated value is out of in system.
range, TCU interprets this as
Check sensor gap at
slipping clutch.
engine speed sensor.
Low-pressure at converter lockup
Check sensor gap at
clutch.
turbine speed sensor.
Low main pressure.
Check signal at engine
Wrong signal at engine speed speed sensor.
sensor.
Check signal at
Wrong signal at turbine speed turbine speed sensor.
sensor.
Replace clutch.
BD S.C. to ground at engine brake No reaction. Check cable from TCU 1) See Measurement
solenoid. to the engine brake of Resistance at
Op-Mode: normal.
to vehicle ground. from engine brake
solenoid to TCU.
Engine brake solenoid has an engine brake solenoid.
internal defect.
vehicle ground
BE S.C. to battery voltage at engine No reaction. Check cable from TCU 1)
See Measurement
brake. to engine brake of Resistance at
Op-Mode: normal.
to battery voltage. from customer engine
brake solenoid to
TCU.
Engine brake solenoid has an Check resistance 1) of
internal defect. engine brake solenoid.

battery voltage
BF O.C. at engine brake No reaction. Check cable from TCU 1)
See Measurement
to the engine brake of Resistance at
O.C. for this output pin. Check connectors Cable on page 1-53.
from engine brake
solenoid to TCU.
connection to TCU.
Engine brake solenoid has an Check resistance 1) of
internal defect. engine brake solenoid.

TCU.

Page 43
(hex) detection.)
C3 Over temperature converter No reaction. Cool down machine. ---------------
output.
Op-Mode: normal. Check oil level.
TCU measured a oil temperature
Check temperature
at the converter output that is over
sensor.
allowed threshold.
C4 S.C. to ground joystick status No reaction. Check cable from TCU 1)
See Measurement
indicator. to joystick status of Resistance at
Op-Mode: normal.
indicator. Actuator/sensors and
to vehicle ground. from joystick status
indicator to TCU.
Joystick status indicator has an joystick status
internal defect. indicator.

vehicle ground
C5 S.C. to battery voltage at joystick No reaction. Check cable from TCU 1)
See Measurement
status indicator. to joystick status of Resistance at
Op-Mode: normal.
indicator. Actuator/sensors and
to vehicle ground. from joystick status
indicator to TCU.

vehicle ground.
C5 S.C. to battery voltage at joystick No reaction. Check cable from TCU ---------------
status indicator. to joystick status
Op-Mode: normal.
indicator.
the output pin, that looks like a S.C. Check connectors
to battery voltage. from joystick status
indicator to TCU.

battery voltage.
C6 O.C. at joystick status indicator No reaction. Check cable from TCU ---------------
to the joystick status
indicator.
O.C. for this output pin. Check connectors
from joystick status
indicator to TCU.
connection to TCU.
Joystick status indicator has an Check resistance 1) of
internal defect. joystick status
indicator.
TCU.

Page 44
(hex) detection.)
C7 S.C. to ground at over temperature No reaction. Check cable from TCU 1)
See Measurement
neutral indicator. to over temperature of Resistance at
Op-Mode: normal.
neutral indicator. Actuator/sensors and
to vehicle ground. from over temperature
neutral indicator to
TCU.
contacted to vehicle ground
Over temperature status indicator Check resistance 1) of
has an internal defect. over temperature
neutral indicator.
vehicle ground
C8 S.C. to battery voltage at over No reaction. Check cable from TCU 1)
See Measurement
temperature neutral indicator. to over temperature of Resistance at
Op-Mode: normal.
neutral indicator. Actuator/sensors and
to battery voltage. from over temperature
TCU.
Over temperature status indicator Check resistance 1) of
has an internal defect. over temperature
neutral indicator.
battery voltage.
C9 O.C. at over temperature neutral No reaction. Check cable from TCU ---------------
indicator to the over
Op-Mode: normal.
temperature neutral
indicator.
O.C. for this output pin. Check connectors
from over temperature
connection to TCU.
TCU.
Over temperature status indicator
has an internal defect. Check resistance 1) of
over temperature
Connector has no connection to neutral indicator.
TCU.
CA Engine retarder configuration time Op-Mode: substitute Check EEC controller. ---------------
out clutch control.
Check wire of CAN-
Time out of CAN-message Bus.
Engine retarder configuration from Check cable to EEC
EEC controller. controller.
CAN wire/ connector is broken.
an has contact to vehicle ground or
battery voltage.

Page 45
(hex) detection.)
CB ERC1 time out. Op-Mode: substitute Check EEC controller. ---------------
clutch control.
Time out of CAN-message ERC1 Check wire of CAN-
Interference on CAN-Bus Check cable to EEC
controller.
battery voltage.
D1 S.C. to battery voltage at power See fault codes No. 21 Check cables and Fault codes No. 21 to
supply for sensors. - 2C. connectors to sensors, No. 2C may be a
which are supplied reaction of this fault.
TCU measures more than 6V at
from AU1.
the pin AU1 (5V sensor supply).
Check the power
supply at the pin AU1
(should be
approximately 5V).
D2 S.C. to ground at power supply for See fault codes No. 21 Check cables and Fault codes No. 21 to
sensors. - 2C. connectors to sensors, No. 2C may be a
which are supplied reaction of this fault.
TCU measures less than 4V at the
from AU1.
pin AU1 (5V sensor supply).
Check the power
supply at the pin AU1
(should be
approximately 5V).
D3 Low power at battery. Shift to neutral. Check power supply ---------------
battery.
Measured voltage at power supply Op-Mode: TCU shut
is lower than 18 V. down. Check cables from
batteries to TCU.
Check connectors
from batteries to TCU.
D4 High power at battery. Shift to neutral. Check power supply ---------------
battery.
Measured voltage at power supply Op-Mode: TCU shut
is higher than 32 V. down. Check cables from
batteries to TCU.
Check connectors
from batteries to TCU.

Page 46
(hex) detection.)
D5 Error at switch 1 for valve power Shift to neutral. Check fuse. ---------------
supply VPS1.
Op-Mode: TCU shut Check cables from
TCU switched on VPS1 and down. gearbox to TCU.
measured VPS1 is off or TCU
Check connectors
switched off VPS1 and measured
VPS1 is still on.
Replace TCU.
voltage.
ground.
Permanent power supply KL30
missing.
TCU has an internal defect.
D6 Error at switch 2 for valve power Shift to neutral. Check fuse. ---------------
supply VPS2.
Op-Mode: TCU shut Check cables from
TCU switched on VPS2 and down. gearbox to TCU.
measured VPS2 is off or TCU
Check connectors
switched off VPS2 and measured
VPS2 is still on.
Replace TCU.
voltage.
ground.
Permanent power supply KL30
missing.
TCU has an internal defect.
E3 S.C. to battery voltage at display No reaction. Check the cable from ---------------
output. TCU to the display.
Op-Mode: normal.
TCU sends data to the display and Check the connectors
measures always a high voltage at the display.
level on the connector.
Change display.
Cable or connectors are defective
voltage.
Display has an internal defect.
E4 S.C. to ground at display output. No reaction. Check the cable from ---------------
TCU to the display.
TCU sends data to the display and Op-Mode: normal.
measures always a high voltage Check the connectors
level on the connector. at the display.
Cable or connectors are defective Change display.
ground.
Display has an internal defect.

Page 47
(hex) detection.)
E5 DISPID1 time out TCU select parameter Check display ---------------
set with ID0. controller.
Time out of CAN-message
DISPID1 from display controller. Op-Mode: Limp Home Check wire of CAN-
Bus.
Check cable to display
controller.
battery voltage.
E5 CL1 time out TCU keeps old Check cluster ---------------
information for: controller.
Time out of CAN-message CL1
from cluster controller. Status test mode Check wire of CAN-
Bus.
Interference on CAN-Bus Status block
CAN wire/ connector is broken. Shift quality selection
controller.
CAN wire/ connector is defective Gear range restriction
Op-Mode: normal
battery voltage.
E6 Illegal ID request via CAN Transmission stay --------------- ---------------
neutral
Op-Mode: normal
F1 General EEPROM fault. Transmission stay Replace TCU. Often shown together
neutral. with fault code F2.
TCU cannot read nonvolatile
memory. Op-Mode: TCU shut
down.
TCU is defective.
F2 Configuration lost. Transmission stay Reprogram the correct ---------------
neutral. configuration for the
TCU has lost the correct
vehicle (e.g. with
configuration and can't control the Op-Mode: TCU shut
cluster controller,...).
transmission. down.
Interference during saving data
on nonvolatile memory.
TCU is brand new or from
another vehicle.
F2 FWD configuration lost Gear range set from Reconfigure with TCU ---------------
1st to 4th. configuration
TCU has lost the FWD
command (ID PC).
configuration.
Interference during saving data on
non volatile memory.
TCU is brand new or from another
vehicle.
F3 Application error. Transmission stay Replace TCU! This fault occurs only if
neutral. an test engineer did
Something of this application is
something wrong in
wrong. Op-Mode: TCU shut
the application of the
down.
vehicle.
F4 Limp home request. Shift to neutral. The external controller ---------------
has to cancel the
No fault! Indicates that another Op-Mode: limp home.
request.
computer requested limp home via
CAN.

Page 48
(hex) detection.)
F5 Clutch failure. Transmission stay Check clutch. TCU shows also the
neutral. affected clutch on the
AEB was not able to adjust clutch
Display.
filling parameters. Op-Mode: TCU shut
down.
One of the AEB-Values is out of
limit.
F6 Clutch adjustment data lost or inch Default values = 0 for Execute AEB. ---------------
pedal calibration data lost. AEB offsets used.
TCU was not able to read correct Op-Mode: normal.
clutch adjustment parameters.
No Inch mode
Interference during saving data available.
on nonvolatile memory.
TCU is brand new.

Page 49
TABLE OF FAULT CODES -
ERGO-CONTROL
Error Code
Meaning of Error Code Remarks
Number
11 Logical error at gear range signal.

12 Logical error at direction select signal.
21 Short circuit to battery voltage at clutch cutoff input.
22 Short circuit to ground or open circuit at clutch cutoff input.
23 Short circuit to battery voltage at load sensor input. Not used.
24 Short circuit to ground or open circuit at load sensor input. Not used.
25 Short circuit to battery voltage or open circuit at temperature sensor

input.
26 Short circuit to ground at temperature sensor input.
31 Short circuit to battery voltage at engine speed input.
32 Short circuit to ground or open circuit at engine speed input.
33 Logical error at engine speed input.
34 Short circuit to battery voltage at turbine speed input.
35 Short circuit to ground or open circuit at turbine speed input.
36 Logical error at turbine speed input.
37 Short circuit to battery voltage at internal speed input.
38 Short circuit to ground or open circuit at internal speed input.
39 Logical error at internal speed input.
3A Short circuit to battery voltage at output speed input.
3B Short circuit to ground or open circuit at output speed input.
3C Logical error at output speed input.
71 Short circuit to battery voltage at clutch K1.
72 Short circuit to ground at clutch K1.

73 Open circuit at clutch K1.

Page 50
Error Code
Number
7A Short circuit to battery voltage at converter clutch. Not used.
7B Short circuit to ground at converter clutch. Not used.
7C Open circuit at converter clutch. Not used
81 Short circuit battery voltage at clutch K4.

84 Short circuit to battery voltage at clutch KV.
85 Short circuit to ground at clutch KV.

86 Open circuit at clutch KV.
87 Short circuit to battery voltage at clutch KR.
88 Short circuit to ground at clutch KR.
89 Open circuit at clutch KR.
91 Short circuit battery voltage at relay reverse warning alarm.
92 Short circuit to ground at relay reverse warning alarm.
93 Open circuit at relay reverse warning alarm.
94 Short circuit to battery voltage at relay starter interlock.
95 Short circuit to ground at relay starter interlock.
96 Open circuit at relay starter interlock.
97 Short circuit to battery voltage at park brake solenoid.

98 Short circuit ground at park brake solenoid.
99 Open circuit at park brake solenoid.
B1 Slippage at clutch K1.
B5 Slippage at clutch KV.

Page 51
Error Code
Number
B6 Slippage at clutch KR.
BA Differential pressure oil filter.
D1 Short circuit to battery voltage at power supply for sensors.
D2 Short circuit to ground at power supply for sensors.
D3 Low power at battery.

D4 High power at battery.
D5 Error at switch 1 for valve power supply.
D6 Error at switch 2 for valve power supply.
E1 Short circuit to battery at speedometer output. Not used.
E2 Short circuit to ground or open circuit at speedometer output. Not used.

E3 Short circuit to battery voltage at display output. Not used.
E4 Short circuit to ground or open circuit at display output. Not used.
E5 Error at communication on CAN.
F1 General EEPROM fault.
F2 Configuration lost.
F3 Application error.

Page 52
MEASUREMENT OF
RESISTANCE AT ACTUATOR/
SENSORS AND CABLE
Actuator
Open circuit:R12 R1G R2G 1
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) R
Short cut to battery:R12 R;R1G 0, R2G R or R1G R, R2G

2
0 (for S.C. to battery, G is connected to battery voltage. G
HBOE640I
Figure 2
Cable
UBat
open circuit:
R12 R1P R1C R2P R2C
P (power supply)
TCU
Actuator /
short cut to ground: 1 2
Sensor
R12 0;R1C R2C 0,R1P R2P

C (chassis)
short cut to battery:

Gnd
R12 0,R1C R2C ,R1P R2P 0
HBOE650I
Figure 3

Page 53
Page 54
SP000101
FRONT AXLE (ZF - MT-L 3105)SP000101
FRONT AXLE
(ZF - MT-L 3105)
Edition 1
Front Axle (ZF - MT-L 3105) SP000101

Page 1
MEMO
SP000101 Front Axle (ZF - MT-L 3105)

Page 2
Table of Contents
Front Axle
(ZF - MT-L 3105)
General Description.............................................. 7
Outline ............................................................................. 7
Drive Axle ........................................................................ 7
Axle Mount ................................................................. 7
Differential ..................................................................... 10
Differential Operation ............................................... 10
Limited Slip Differential Cross Section ..................... 11
Axle Hub Section........................................................... 12
Axle Differential Section ................................................ 13
Lubrication Instructions ................................................. 14
Oil Drain ................................................................... 15
Oil Filling................................................................... 15
Check ....................................................................... 15
Oil Change Intervals................................................. 15
Oil Level Check ........................................................ 15
Bleeders ................................................................... 15
Brake ........................................................................ 15
Brake Bleeding at the Vehicle................................... 15
Axle Oils for DL400, DL300, DL250 .............................. 17
Lubricant Class 05E ................................................. 17
Lubricant Class 05F ................................................. 17
Lubricant Class 05G................................................. 18
Make Wear Measurement on Multidisk Brake ............... 19
Wear Measurement of Multidisk Brake..................... 19
Inscriptions on Model Identification Plate ...................... 20
Torque Limits for Screws ............................................... 21
Torque Limits for Screws (In Nm) According
to ZF-Standards 148 ................................................ 21
Examples of Gear Tooth Contact Patterns
for the Gleason Gear-tooth System............................... 22

Page 3
Special Tool ........................................................ 25
List of Special Tools for Disassembly and Reassembly. 25
ZF - Multitrac Rigid Axle MT-L 3095 ................... 35
Disassembly of Output and Brake ................................. 35
Reassembly of Output and Brake.................................. 44
Disassembly of Differential Carrier and Brake Tubes .... 57
Disassembly of Differential Carrier ........................... 57
Disassembly of Limited Slip Differential ................... 60
Disassembly of Drive Pinion..................................... 62
Disassembly of Oil Pipes.......................................... 64
Reassembly of Oil Pipes and Differential Carrier .......... 66
Reassembly of Oil Pipes .......................................... 66
Reassembly of Differential Carrier ........................... 71
Determine Shim Thickness for Tooth Contact Pattern..
71
Install Drive Pinion.................................................... 72
Reassemble of Limited Slip Differential.................... 76
Determine Disk Clearance 0.2 - 0.8 mm .................. 78
Adjustment of Backlash and Bearing Preload .......... 81
Parking Brake ..................................................... 84
Functional Characteristics and Maintenance Instructions
for Spring Loaded Sliding Caliper Brakes...................... 84
1. Functional Characteristics of Spring Loaded Sliding
Caliper Brakes.......................................................... 84
2. Mounting and Basic Setting Regulations.............. 85
3. Adjusting Regulations........................................... 86
4. Emergency Release of Parking Brake.................. 86
5. Maintenance and Repair Work............................. 87
Maintenance and Exchange of Brake Pads ............. 87
Changing the Seal.................................................... 88
6. General................................................................. 89

Page 4
SAFETY PRECAUTIONS
CAUTION!
order.
handling load.
responsibility.
APPLICABLE MODELS

DL400 5001 and Up

Page 5
Page 6
GENERAL DESCRIPTION
Outline
Front Axle
Frame-Fixed,
Type
Semifloating
Overall Reduction Ratio 23.334
Differential type STD. Limited Slip Differential (Locking Ratio: 30%)
46,900 kg
Max Static Load
(103,400 lb)
17,500 kgm
Max Output Torque
(126,580 ft lb)
Type Multi Wet Disk
Brake 3,998 kgm at 80 Bar
Torque
(28,914 ft lb at 1,160 psi)
Drive Axle
The drive axle consists of differential, final reduction gear
assembly, wet type hydraulic disk brake unit, and axle shafts to
which wheels are attached.
The power from drive unit is transmitted through the drive shafts
to the front and rear drive axles. The power is then transmitted to
the differential where it is divided into right and left axle shafts to
the final reduction gear assembly on each shaft end, thus driving
the wheels.
The wet type hydraulic disk brake unit is installed in front of final
reduction gear assembly and serves as a service brake.
Axle Mount
The front axle is bolted directly to the front frame.
The rear axle is supported by the trunnion method in which axle
supports are installed across the rear axle and bolted to the rear
frame. Consequently, the rear axle is cradled up and down
around the center line of differential according to the ground
condition the loader travels. The trunnion mounted drive axle
helps improve operator comfort because loaders with a trunnion
mounted drive axle jolt less than those with the conventional
cradle supported drive axle, when they travel on bad ground
conditions.

Page 7
3
4
A A
NOTE
3
B B
2
NOTE
9
NOTE
8
REAR AXLE FRONT AXLE

6
NOTE
4
1
NOTE NOTE NOTE NOTE NOTE
6 4 5 5 5 5 5 5 2
`C'
NOTE
1
`E' `G'
NOTE
7
7
NOTE
5 9
SECTION A-A
(Rear Axle) SECTION B-B
(Front Axle)
DETAIL C DETAIL E,G

S=1/1 S=1/1
FG005329
Figure 1 DRIVE AXLE ASSEMBLY

Page 8
Reference Reference
Number Number
1 Front Axle 6 Bushing
2 Rear Axle 7 Thrust Plate
3 Axle Support (Front) 8 Thrust Cap
4 Axle Support (Rear) 9 Thrust Washer
5 Packing
NOTE: 1) 28 kgm (203 ft lb) Threaded area: Loctite

#262
2) 170 kgm (1230 ft lb)
3) 170 kgm (1230 ft lb)
4) Inner surface: Grease (Assemble with
chamfered surface toward axle.)
5) Assemble with lip pointing outward.
6) Assemble with groove pointing toward plate
(7).
7) Apply grease and assemble.
8) Tightening Torque: 85 3 kgm
(614 22 ft lb) (Nut: 20 - M22x1.5)
9) Tightening Torque: 85 3 kgm
(614 22 ft lb) (Nut: 20 - M22x1.5)

Page 9
Differential
The differential is integral with the reduction gear.
The power from drive shafts is transmitted through the drive
pinion and the ring gear to the differential gear case. It is then
sent through the right and left side gears to the final reduction
gear assembly. The speed reduction of power is accomplished
by the drive pinion and the ring gear.
Differential Operation
While the loader travels straight, the ring gear, differential gear
case, and side gears rotate together, with the pinion gears inside
the differential gear case not rotating. The power of same speed
is thus transmitted from right and left side gears through the axle
shafts to the wheels. When the loader makes a turn, the right
and left wheels rotate at different speeds; the pinion gears in the
differential gear case rotate around their own axes according to
the difference in speed between the right and left side gears.
Figure 2 DIFFERENTIAL GEAR OPERATION
Reference Reference
Number Number
1 Pinion Gear 5 Spider
2 Side Gear 6 Drive Pinion
3 Axle Shaft 7 Ring Gear
4 Differential Gear Case

Page 10
Limited Slip Differential Cross Section
Figure 3, shows a cross-sectional view of parts contained in the
limited slip differential.
Reference
Description
Number
1 Ring Gear
2 Bevel Pinion
3 Cross
4 Upper Thrust Ring
5 Outer Disk
6 Inner Disk
7 Cover
8 Clutch Disk
9 Side Gear
10 Lower Thrust Ring
Figure 3

Page 11
Axle Hub Section
Figure 4

Page 12
Axle Differential Section
Figure 5

Page 13
Lubrication Instructions
Oils according to ZF List of lubricants TE-ML 05 that are
allowed to be used for ZF-Axles MT-L 3105.
The basic condition for a correct oil change of axle is the
horizontal plane of installation in every direction.
Place vehicle in a horizontal position.
All drain, filter and level plugs must be cleaned carefully
before opening.
Only drain oil immediately after a longer running time.
Reference
Description
Number
1 Oil drain hole M24x1.5
Axle casing
Outputs
3 Oil filler hole M36x1.5
4 Brake bleeder
5 Bleeder
Figure 6
Figure 7

Page 14
Oil Drain
Remove drain plugs 1 and 2 and drain oil.
Oil Filling
Provide drain plugs (M24x1.5) with new O-ring and install
them.
Tightening torque MA= 7.14 kgm (52 ft lb).
Fill oil to the overflow on filler/level plug 3.
Filling quantity approx. 30 liters (8 U.S. gal.).
Check
Check oil level after a few minutes and fill up to the
specified level, until level remains constant.
Provide filler/level plug (M36x1.5) with new O-ring and
install it.
Tightening torque MA= 13.26 kgm (96 ft lb).
Oil Change Intervals

1st oil change after 500 operating hours, further oil
changes every 1500 operating hours, however, at least
once a year.
Oil Level Check

Oil level check once a month, but especially before starting
a vehicle with new or repaired axles and axle components
respectively.
Bleeders
At initial operation and during the oil change intervals,
clean Bleeder 3 and 5 and make a functional check.
Brake
For the pneumatic-hydraulic or via an accumulator system
operated brake actuation the following oils are permissible:
1.Motor oils SAE 10W according to specification MIL-L
2104 C, MIL-L 46152, API-CC, CD, SC, SD, SE
2.ATF-Oils Type A, Suffix A, Dexron of II D
Brake Bleeding at the Vehicle

1. Open the bleeder (4).
2. Slowly depress the brake pedal until oil flows from bleeder.
3. Close the bleeder again.
4. Slowly pressurize the brake and hold the pressure for
some seconds.

Page 15
NOTE: The brake piston extends and the cylinder
chamber fills p with oil. The air accumulates in
the upper section of cylinder chamber.
5. Release the brake pedal and loosen the brake.
NOTE: The reversing piston presses the air from upper
section of cylinder into brake line.
6. Open the bleeder (4) again.
NOTE: Repeat procedure - Item 3 - 7 - until - at Item 7 -
from beginning of actuation no more air exits
from bleeder.

Page 16
Axle Oils for DL400, DL300, DL250
Examples of oils which meet the requirements according to the
table on the previous page.
Lubricant Class 05E

Viscosity grades: SAE 20W-40 / 80W-140
Oil Company Trade Name
CASTROL INTERNATIONAL, PANGBOURNE READING/GB KOMATSU WBL 20W40
CNH, BURR RIDGE/USA CASE TRANSAXLE FLUID, SAE 80W-140
EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA MOBILFLUID 2040
FUCHS PETROLUB AG, MANNHEIM/D TITAN HYDRA ZF 20W-40
MAZIVA ZAGREB D.O.O. ZAGREB/HR INA TRASHIDROL ZF 20W-40

OMV AG, SCHWECHAT/A MOV AUSTROMATIC ZF SAE 20W-40
PAKELO MOTOR OIL S.R.L., SAN BONIFACIO (VR)/I PAKELO UTTO FLUID 4D SAE 20W-40
STRUB + CO AG, REIDEN/CH VULCOTRAC UTTO SAE 20W-40
Lubricant Class 05F
76 LUBRICANTS COMPANY, COSTA MESA/USA 76 HYDRAULIC/TRACTOR FLUID

ARAL AG, BOCHUM/D ARAL FLUID HGS SAE 80W
AVIA MINERALOL-AG, MUNCHEN/D AVIA HYDROFLUID DLZ
BP INTERNATIONAL, PANGBOURNE, READING/GB BP OLEX GO 4926

BP INTERNATIONAL, PANGBOURNE, READING/GB BP TERRAC SUPER TRANSMISSION
BP INTERNATIONAL, PANGBOURNE, READING/GB BP TRACTRAN TF 10
BUCHER AG LANGENTHAL, LANGENTHAL/CH MOTOREX POLYFARM 304

CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL AGRI POWERTRANS 10W-30
CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL AGRI TRANS PLUS 10W-30
CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL KOMATSU UTTO 10W-30
CATERPILLAR MULTIPURPOSE
CATERPILLAR INC., PEORIA/USA
TRACTOR OIL (MTO) 10W-30
ENGEN PETROLEUM LTD., CAPE TOWN/ZA ENGEN AGRIFLUID
ENI S.P.A. REFINING and MARKETING DIVISION, ROME/I ROTRA JD/F

EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA ESSO TORQUE FUID 56
EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA MOBIL AGRIFLUID 424
EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA MOBIL FLUID 424

Page 17
FLITALIA S.P.A., VILLASTELLONE/I AMBRA MULTI G
FUCHS PETROLUB AG, MANNHEIM/D TITAN HYDRA J20C

GINOUVES GEORGES SA, LA FARLEDE/F YORK 676 SAE 10W30
IGOL FRANCE SA, AMIENS/F TICMA FLUID MU SAE 80W
JOHN DEERE, MANNHEIM/D JOHN DEERE HY-GARD

KENDALL MOTOR OIL, COSTA MESA/USA KENDALL HYKEN 052
KUWAIT PETROLEUM RandT B.V., EUROPOORT RT/NL Q8 T 2000

OEL-BRACK AG, HUNZENSCHWIL/CH MIDLAND TOU
OMV AG, SCHWECHAT/A OMV AUSTROMATIC IGB SAE 10W-30
PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO UTTO FLUID 4D SAE 10W/30
PANOLIN AG, MADETSWIL/CH PANOLIN JD 303
PETROGAL S.A., LISBOA/P GALP TRALUB 807S
REPSOL LUBRICANTES, MADRID/E AGRO ORION SAE 10W30
SHELL ASEOL AG, BERN 5/CH ASEOL MULTITRAC 85W
SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D WINTERSHALL HYDROFLUID N
Lubricant Class 05G
CATERPILLAR INC., PEORIA/USA CATERPILLAR MULTIPURPOSE TRACTOR OIL(MTO)

ZF FRIEDRICHSHAFEN AG, FRIEDRICHSHAFEN/D ZF-POWERFLUID

Page 18
Make Wear Measurement on Multidisk
Brake
NOTE: A wear measurement on multidisk brake has to be
made at least once a year, especially in case of a
changed braking behavior like, e.g.
Braking noise
Braking power reduced
Deceleration changed
Brake fluid level changed
Braking pressure changed
Wear Measurement of Multidisk Brake

A wear measurement has to be made on both output sides.
Remove plug, actuate brake and determine
Dimension X according to Figure 8 using a feeler gauge.
Dimension X corresponds with thickness of inner clutch disk on
piston side.
NOTE: If Dim. X <= 3.4 mm (0.13 in), the lined disks on both
output sides have to be replaced!
Figure 8
Following to this provide level plug with a new O-ring and install
it!
Tightening torque MA = 7.14 kgm (52 ft lb)
Figure 9

Page 19
Inscriptions on Model Identification Plate
Figure 10
Reference
Description
Number
1 Axle Type
2 Axle Serial No.
3 ZF - Parts - List No.
4 Total-Ratio of Axle / Version with or without
ZF-multidisk self-locking differential
5 Type of lubricant
6 Lubricant specifications
NOTE: ZF - List of lubricants for ZF - Axles TE-ML 05

Page 20
Torque Limits for Screws

to ZF-Standards 148
Coefficient of friction: m total 0.12 for screws and nuts
without after treatment and for phosphate nuts.
NOTE: Tighten by hand.
Torque limits, if not specifically shown, can be taken from
following list:
Metric ISO-Standard Thread DIN 13 Metric ISO-Fine Thread DIN 13

Size 8.8 10.9 12.9 Size 8.8 10.9 12.9
M4 2.8 4.1 4.8 M8x1 24 36 43
M5 5.5 8.1 9.5 M9x1 36 53 62
M6 9.5 14.0 16.5 M 10 x 1 52 76 89
M7 15 23.0 28.0 M 10 x 1, 25 49 72 84
M8 23 34 40 M 12 x 1, 25 87 125 150
M 10 46 68 79 M 12 x 1, 5 83 120 145
M 12 79 115 135 M 14 x 1, 5 135 200 235
M 14 125 185 215 M 16 x 1, 5 205 300 360
M 16 195 280 330 M 18 x 1, 5 310 440 520
M 18 280 390 460 M 18 x 2 290 420 490
M 20 390 560 650 M 20 x 1, 5 430 620 720
M 22 530 750 880 M 22 x 1, 5 580 820 960
M 24 670 960 1,100 M 24 x 1, 5 760 1,100 1,250
M 27 1,000 1,400 1,650 M 24 x 2 730 1,050 1,200
M 30 1,350 1,900 2,250 M 27 x 1, 5 1,100 1,600 1,850
M 33 1,850 2,600 3,000 M 27 x 2 1,050 1,500 1,800
M 36 2,350 3,300 3,900 M 30 x1, 5 1,550 2,200 2,550
M 39 3,000 4,300 5,100 M 30 x 2 1,500 2,100 2,500
M 33 x 1, 5 2,050 2,900 3,400
M 33 x 2 2,000 2,800 3,300
M 36 x 1, 5 2,700 3,800 4,450
M 36 x 3 2,500 3,500 4,100
M 39 x 1, 5 3,450 4,900 5,700
M 39 x 3 3,200 4,600 5,300

Page 21
for the Gleason Gear-tooth System
Ideal tooth contact pattern; i.e. pinion distance is correct
Coast side (concave)
Figure 11
Drive side (convex)
Figure 12
Pinion distance must be increased
Figure 13

Page 22
Figure 14
Figure 15
Pinion distance must be decreased
Figure 16
Figure 17

Page 23
Figure 18

Page 24
SPECIAL TOOL
List of Special Tools for Disassembly and

Reassembly
ZF - Multitrac MT - L 3105 / Output and Brake
4474 054 011
Disassembly Reassembly Subject-No. Designation / Application Special Tools (S)

Figure 26 5870 350 000 Assembly truck assembly with tilting device
5870 350 077 Holding fixture (set of 2)
5870 350 075 Clamps
Figure 29 5870 345 065 Pry bar (set of 2)
Figure 59
Figure 61
Figure 30 5870 650 001 Striker
Figure 31 Figure 102 5870 656 078 Socket Spanner #
5870 912 028 Centering bracket #
Figure 32 Figure 100 5870 281 043 Lifting bracket
Figure 37 5870 300 019 Extractor
Figure 38 Figure 93 5870 900 015 Set of external pliers A1-A2-A3-A4
Figure 39 5870 971 002 Three-armed puller
Figure 40 5873 001 058 Gripping insert
5873 001 000 Basic device
Figure 41 5870 970 007 Two-armed puller
Figure 56
5870 654 034 Clamping bracket (set of 2)
5870 506 140 Press bush
Figure 46 5870 900 016 Set of external pliers A11-A21-A31-A41
Figure 50 Figure 79 5870 900 051 Assembly pliers #
Figure 53 5870 400 001 Adjusting device
Figure 57 Figure 69 5870 281 047 Lifting chain
5870 204 071 Eyebolts (set of 2)
Figure 60 5873 014 011 Rapid grip #
5873 004 001 Basic device #
Figure 62 5870 610 010 Wheel bolt puller - Basic set
5870 610 011 Insert 7/8" - 14UNF
Figure 64 5870 506 141 Pressure ring # EBM = 16.8 - 0.2 mm
Figure 66 5870 051 052 Driver # EBM = 6 + 0.2 mm
Figure 75 5870 345 096 Assembly fixture #
Figure 76
Figure 82 5870 705 011 Drive mandrel EBM = 4 mm
Figure 89 5870 204 029 Adjusting screws (set of 2)
Figure 94 5870 200 072 Digital Depth gauge # 200 mm
Figure 97 5870 200 022 Straightedge # 580 mm

Page 25
5870 200 066 Gauge blocks # 60 mm
Figure 106 5870 287 007 HD-Pump #
5870 950 115 Measuring hub # 9/16" - 18UNF
5870 350 075 Clamps
Figure 111
Figure 114 Figure 202 5870 281 044 Lifting tackle
Figure 117 Figure 198 5870 656 079 Socket spanner
Figure 118 5870 221 500 Hot air blower # 230 V
Figure 122 5873 002 027 Gripping insert #
5873 002 001 Basic set (size 2)
5873 002 001 Basic set (size 2)
Figure 129 Figure 173 5870 401 139 Slotted nut wrench #
Figure 176
5870 240 002 Fixture #
Figure 132 5870 970 007 Two-armed puller #
5873 002 001 Basic set (size 2)
5870 500 046 Adapter pieces #
Figure 160 5870 500 030 Adapter pieces #
Figure 161 5870 500 001 Measuring shaft #
5870 351 016 Measuring pin #
5870 351 019 Stop washer
Figure 185 5870 200 066 Gauge blocks # 60 mm
Figure 186
Figure 165 5870 050 009 Driver
5870 260 004 Handle
5870 260 002 Handle
5870 260 002 Handle
Figure 175 5870 048 233 Driver EBM = 15.2 mm
Figure 198 5870 200 055 Magnetic stand #
5870 200 057 Dial indicator #
Figure 199 5870 200 058 Caliper gauge 0 - 500 mm

Page 26
# Particularly important special tools for partial
repair (wear part repair).

Page 27
Figure 19

Page 28
Figure 20

Page 29
Figure 21

Page 30
Figure 22

Page 31
Figure 23

Page 32
Figure 24

Page 33
Figure 25

Page 34
ZF - MULTITRAC RIGID AXLE MT-
L 3095
Disassembly of Output and Brake

1. Fasten axle on assembly truck.
(S) Assembly truck 5870 350 000
(S) Holding fixtures 5870 350 077
(S) Clamps 5870 350 075
Figure 26
2. Remove drain plugs (3x, Figure 27 and Figure 28) and

drain oil from axle casing.
Figure 27
Figure 28

Page 35
3. Remove cover from output shaft.
(S) Pry bar set 5870 345 065
Figure 29
4. Remove slotted pin using striker (S) from bore in slotted

nut.
(S) Striker 5870 650 001
Figure 30
5. Remove slotted nut.

(S) Socket spanner
(S) Centering bracket
Figure 31
6. Secure output using lifting tackle (S) and remove hex

screws.
(S) Lifting bracket 5870 281 043
Figure 32

Page 36
7. Separate complete output from axle casing.
NOTE: Pay attention to released O-ring (see arrow).
Figure 33
8. Remove stub shaft from sun gear shaft.

NOTE: Pay attention too possibly released shim(s).
Figure 34
9. Remove shim(s) from sun gear shaft.
Figure 35
10. Remove sun gear shaft from planet gears.
Figure 36

Page 37
11. Lift planet carrier from brake housing.
(S) Internal extractor 5870 300 019
Figure 37
12. Remove retaining ring.

(S) Set of external pliers 5870 900 015
Figure 38
13. Remove planet gear and remove released inner bearing

race.
(S) Three-armed puller 5873 971 002
Figure 39
14. Remove inner bearing race.

(S) Gripping insert 5873 001 020
(S) Basic set 5873 001 000
Figure 40

Page 38
15. Separate ring gear from brake housing using two-armed
puller (S).
(S) Two-armed puller 5870 970 007
Figure 41
16. Remove O-rings (see arrows) from annular grooves of ring

gear.
Figure 42
17. Remove O-ring (see arrow) from recess of brake housing.
Figure 43
18. Remove disk pack from brake housing.
Figure 44

Page 39
19. Install slotted pins (6x) in support shim until they are flush
mounted.
Figure 45

Figure 46
21. Remove piston from brake housing using compressed air.
Figure 47
22. Remove support shim from piston using automatic piston

adjusting.
Figure 48

Page 40
23. Remove slotted pins (6x) from support shim.
Figure 49
24. Preload cup springs using a press and remove retaining

ring.
(S) Assembly pliers 5870 900 051
(S) Assembly fixture 5870 345 096
Figure 50
25. Remove pin from support shim and remove released cup
springs.
Figure 51
26. Press gripping rings from pin.
Figure 52

Page 41
27. Lift piston from brake housing.
(S) Adjusting device 5870 400 001
Figure 53
28. Remove guide ring, support rings and U-rings from annular
grooves of brake housing.
NOTE: See Figure 55, for installation position of single
parts.
Figure 54
Reference
Description
Number
1 Brake housing
2 Guide ring
3 Support ring
4 U-ring
5 U-ring
6 Support ring
7 Output shaft
Figure 55

Page 42
29. Remove brake housing using two-armed puller (S) from
output shaft and remove released inner bearing race.
(S) Clamping bracket 5870 654 034
(S) Press bush 5870 506 140
Figure 56
30. Lift brake housing with lifting tackle (S) from output shaft.
(S) Lifting chain 5870 281 047
(S) Eyebolts 5870 204 071
Figure 57
31. If necessary drive both outer bearing races from bearing

bores in brake housing.
Figure 58
32. Press shaft seal out of brake housing.

(S) Pry bar set 5870 345 065
Figure 59

Page 43
33. Remove inner bearing race from output shaft.
(S) Rapid grip 5873 014 011
(S) Basic set 5873 004 001
Figure 60
34. Remove bearing sheet from output shaft.

(S) Pry bar set 5870 345 065
Figure 61
Reassembly of Output and Brake

1. Insert wheel bolt into output shaft until seated.
(S) Wheel bolt puller - basic set 5870 610 010
(S) Insert (7/8" - 14 UNF) 5870 610 011
Figure 62
2. Assemble bearing sheet (shaft seal / Part 2).
Figure 63

Page 44
3. Press bearing sheet over collar of output shaft.
(S) Pressure ring 5870 506 141
NOTE: The exact installation position of bearing sheet
will be obtained by using specified pressure
ring.
Figure 64
4. Heat roller bearing and install it until seated.

NOTE: After cooling down bearing. it has to be installed
subsequently.
Figure 65
5. Press both outer bearing races into brake housing until

seated.
Figure 66
6. Install shaft seal with sealing lip showing to oil chamber,

see Figure 68.
(S) Driver 5870 051 052
NOTE: The exact installation position of shaft seal will
be obtained by using specified driver (S).
NOTE: Just before installation, wet outer diameter of
shaft seal with mineral spirits.
Figure 67

Page 45
Reference
Description
Number
1 Shaft seal
2 Brake housing
* Grease filling
NOTE: Fill space between sealing and dust lips with

grease.
Figure 68
7. Install preassembled brake housing using lifting tackle (S)

over output shaft until seated.
(S) Eyebolts 5870 204 071
Figure 69
Figure 70
9. Insert support and U-rings into annular grooves of brake

housing.
72.
Figure 71

Page 46
Reference
Description
Number
1 Brake housing
2 Guide ring
3 Support ring
4 U-ring
5 U-ring
6 Support ring
7 Output shaft
Figure 72
10. Clean annular groove of brake housing with mineral spirits.

Then insert guide ring into annular groove (also see Figure
72) and secure with Loctite #415 at its extremities.
NOTE: Guide ring must have contact on whole
circumference.
NOTE: Upon installation orifice of guide ring must show
upwards (12 o'clock).
Figure 73
11. Insert piston into brake housing and install it cautiously

until seated.
NOTE: Apply sufficiently oil on sliding surface of piston
or support rings, U-rings and guide ring (use W-
10 oils).
Figure 74
12. Insert pins into assembly fixture (S) until seated.

Figure 75

Page 47
13. Press gripping rings (4x, see arrows) onto pins until seated
on assembly fixture (S).
NOTE: The exact installation dimension (see Figure 78)
of gripping rings is obtained when using
specified assembly fixture.
NOTE: Observe installation position, install gripping
rings with orifices offset by 180 to each other.
Figure 76
14. Install cup springs (7 pieces each / pin).

NOTE: Pay attention to installation position of cup
springs, see Figure 78.
Figure 77
Reference
Description
Number
1 Pin
2 Gripping rings
3 Cup springs
4 Support shim
5 Retaining Ring
X Installation dimension
Gripping rings 10.5
+0.3 mm
Figure 78
15. Insert preassembled pins into support shim and secure

using retaining ring.4
NOTE: Pay attention to clearance of cup springs.
Figure 79

Page 48
16. Insert preassembled support shim into piston.
Figure 80
17. Install support shim using retaining ring.
Figure 81
18. Drive slotted pins (6x) into bores of support shim to lock
retaining ring.
(S) Drive mandrel 5870 705 011
83.
Figure 82
Reference
Description
Number
1 Brake housing
2 Retaining Ring
3 Slotted pin
4 Support shim
5 Piston
X Installation dimension 4 -
0.5 mm
Figure 83

Page 49
19. Drive stop bolt into planet carrier until seated.
Then wet spline with anticorrosive Weicon Anti Size (ZF
Part Number: 0671 196 001) (see arrow).
Figure 84
20. Insert planet carrier into spline of output shaft until seated.
Figure 85
21. Install outer and inner clutch disks alternately starting with
an outer clutch disk.
NOTE: Oil clutch disks according to ZF List of
Lubricants TE-ML 05.
Figure 86
22. Insert O-ring (see arrow) into recess of brake housing.
Figure 87

Page 50
23. Grease both O-rings (see arrows) and insert them into
annular grooves of ring gear.
Figure 88
24. Install two adjusting screws (S) and insert ring gear into
brake housing until seated.
(S) Adjusting screws 5870 204 029
NOTE: Pay attention to radial location.
Figure 89
25. Heat inner bearing races and install them until seated with
big radius showing to planet carrier (downwards).
NOTE: Subsequently install inner bearing races after
cooling down.
Figure 90
26. Put planet gears onto inner bearing races.
Figure 91

Page 51
27. Heat inner bearing races and install them on planet gears
until seated.
cooling down.
Figure 92
28. Fasten planet gears using retaining rings.

Figure 93
29. Adjust end play of sun gear shaft 0.5 - 2.0 mm (0.0197 -
0.0787 in)
30.
Fasten ring gear using cap screws until seated.
Then determine Dimension I, from mounting face of ring
gear up to face of stop bolt.
Dimension I, e.g. 67.90 mm (2.6732 in)
(S) Digital depth gauge 5870 200 072
(S) Gauge blocks 5870 200 066
Figure 94
(S) Straightedge 5870 200 022
31. Insert stub shaft into spline of axle bevel gear until seated.
Figure 95

Page 52
32. Assemble sun gear shaft until seated.
Figure 96
33. Determine Dimension II from face of sun gear shaft up to

mounting face of axle casing.
Dimension II, e.g. 63.0 mm (2.4803 in)
Figure 97
EXAMPLE

required end play, e.g. - 1.10 mm (0.0433 in)
Difference = shim, e.g. = 3.80 mm (0.1496 in)
34. Insert sun gear shaft into planet carrier.
Figure 98

Page 53
35. Install determined shim(s), e.g. s = 3.80 mm (0.1496 in),
into sun gear shaft using grease.
Figure 99
36. Install O-ring (see arrow) into recess of axle casing using
grease and install preassembled output to axle casing until
seated using lifting tackle (S).
Figure 100
37. Fasten output using hex screws and washers.

NOTE: Tightening torque (M18 / 10.9) MA = 39.77 kgm
(288 ft lb)
Figure 101
38. Unscrew slotted nut by hand and then fasten it.

NOTE: Tightening torque MA = 153 - 173 kgm (1,106 -
1254 ft lb)
(S) Socket spanner 5870 656 078
(S) Centering bracket 5870 912 028
Figure 102

Page 54
39. Secure slotted nut using slotted pin.
Figure 103
40. Assemble O-ring (see arrow) to cover.
Figure 104
41. Insert cover into output shaft until seated.

(S) Hammer (Plastic 60) 5870 280 004
Figure 105
42. Leakage test of brake hydraulics

NOTE: Before starting test, bleed brake hydraulics
completely.
1. Open bleeder.
2. Slowly actuate HP-pump until oil flows from bleeder.
3. Close bleeder again.
4. Slowly pressurize HP-pump with p > 10 bar (145 psi)
and hold pressure for some seconds.
NOTE: The brake piston extends and cylinder
Figure 106
chamber fills up with oil. The air
accumulates in upper section of cylinder
chamber.

Page 55
5. Remove shutoff valve on HP-pump.
NOTE: The reversing piston presses air from
upper section of cylinder into brake line.
6. Open bleeder again.
NOTE: Repeat procedure - Item 3-7 - until - at
Item 7 - from beginning of actuation no
more air exits from bleeder.
NOTE: Then pressurize brake temporarily (5x)
with p = 100 bar max.
High-pressure test
Increase test pressure up to p = 100 -10 bar and close
connection to HD-pump using shutoff valve. During a 5
min. testing time, a pressure drop of max. 2% (2 bar) is
allowed.
NOTE: If maximum pressure of 100 bar is exceeded,
there will be an excessive piston adjustment
and a repeated disassembly of brake or
adjusting is required to reset gripping rings to
adjusting dimension.
Low-pressure test
Reduce test pressure to p = 5 bar and close shutoff valve
again. During a 5 min. testing time, a pressure drop is not
allowed.
Test media
Motor oils SAE 10-W corresponding with,
MIL-L 2104 C, MIL-L 46152,
API-CC, CD, SC, SD, SE,
ATF-Oils Type A, Suffix A Dexron of II D.
(S) HD-Pump 5870 287 007
(S) Mini-measuring hub (9 / 16" - 18UNF) 5870 950 115
NOTE: Before putting axle into operation, fill it with oil
according to Lubrication Instructions on
page 1-14.

Page 56
Disassembly of Differential Carrier and
Brake Tubes
Disassembly of Differential Carrier

(S) Clamps 5870 350 075
Figure 107
2. Remove plugs (3x, Figure 108, Figure 109) and drain oil
from axle casing.
Figure 108
Figure 109

screws.
NOTE: Repeat steps (Figure 110 thru Figure 112) on
both output sides.
Figure 110

Page 57
Figure 111

NOTE: Pay attention to released shim(s).
Figure 112
6. Remove hex screws.

NOTE: Mark location of differential carrier to axle
casing (see arrows).
Figure 113
7. Lift differential carrier using lifting tackle (S) from axle

casing.
(S) Lifting tackle 5870 281 044
Figure 114

Page 58
8. Fasten differential carrier to assembly truck.
(S) Holding fixture 5870 350 034
Figure 115
9. Drive out slotted pins.
Figure 116
10. Remove both adjusting nuts.

Figure 117
11. Heat axle drive housing using hot air blower (S).
(S) Hot air blower 230 V 58770 221 500
(S) Hot air blower 115 V 5870 221 501
NOTE: Hex screws are installed with Loctite #262.
Figure 118

Page 59
12. Remove hex screws bearing bracket.
NOTE: Remove hex screws by hand only.
Figure 119
13. Remove both outer bearing races.
Figure 120
14. Lift differential from housing using lifting tackle (S).

Figure 121
Disassembly of Limited Slip Differential

1. Remove inner bearing race form differential housing.
(S) Basic set 5873 002 001
Figure 122

Page 60
2. Remove inner bearing race from housing cover.
(S) Rapid grip 5873 012 017
(S) Basic set 5873 002 001
Figure 123
3. Fasten differential using press and remove locking screws.
Figure 124
4. Remove cap screws and housing cover.
Figure 125
5. Remove all single parts from differential housing.
Figure 126

Page 61
6. Press off crown wheel from differential housing.
Figure 127
Disassembly of Drive Pinion

1. Heat slotted nut using hot air blower (S).
(S) Hot air blower 230 V 5870 221 500
(S) Hot air blower 115 V 5870 221 501
NOTE: Slotted nut is locked with Loctite #262.
Figure 128
2. Remove slotted nut and washer.

(S) Slotted nut wrench 5870 401 139
(S) Fixture 5870 240 002
Figure 129
3. Remove input flange from drive pinion.
Figure 130

Page 62
4. Remove shaft seal from axle drive housing.
Figure 131
5. Remove drive pinion from axle drive housing using two-

armed puller (S) and remove released inner bearing race.
Figure 132
6. Remove spacer ring and pull inner bearing race from drive
pinion.
(S) Basic set 5873 002 001
Figure 133
7. If necessary, remove both outer bearing races from axle

drive housing.
Figure 134

Page 63
Disassembly of Oil Pipes
1. Remove both pipe unions (also see arrow).
Figure 135
2. Remove hex screw.
Figure 136
3. Remove pipe union.

both sides.
Figure 137
4. Remove hex screw and cooling pipe from axle casing.
Figure 138

Page 64
5. Remove connection part from axle casing.
Figure 139
6. Remove hex nut.
Figure 140
7. Remove union screw.
Figure 141
8. Remove pipe union and brake tube from axle casing.
Figure 142

Page 65
9. Remove vent valve from connection part.
Figure 143
10. Remove connection part and from axle casing.
Figure 144
Reassembly of Oil Pipes and Differential

Carrier
Reassembly of Oil Pipes

1. Preassemble connection part as shown in (Figure 145).
Reference
Description
Number
1 Vent valve
2 Connection part Figure 145
3 O-ring
4 Rectangular ring

both output sides.

Page 66
2. Install connection part.
NOTE: Tightening torque MA = 13.26 kgm (96 ft lb)
Figure 146
3. Provide union screw with new O-ring and install it.

Figure 147
4. Insert O-ring (see arrow) into annular groove of brake tube.
Figure 148
5. Insert brake tube into axle casing, assembling connection

part (see arrow 1) through union screw (see arrow 2).
Figure 149

Page 67
6. Fasten brake tube using hex nut and union nut (Figure
150).
Figure 150
Figure 151
7. Provide connection part with new O-ring and install it.

Figure 152
8. Install connection socket.

Figure 153

Page 68
9. lace cooling pipe into axle casing and preliminarily fasten P
union or union nut by hand.
Figure 154
10. lace connection tube into axle casing and preliminarily P

fasten it by hand.
Figure 155
11. Fasten connection tube using hex screw and washer.

NOTE: Tightening torque (M8/8.8) MA = 2.35 kgm
(17 ft lb)
Figure 156
12. Fasten cooling pipes using hex screws and washers.

(17 ft lb)
Figure 157

Page 69
13. Finally fasten all unions of cooling pipes.
Figure 158
14. Install vent valve.
Figure 159

Page 70
Reassembly of Differential Carrier
NOTE: If crown wheel or drive pinion are damaged, both
parts have to be replaced together. For new
installation of a complete bevel gear set, pay attention
to same pair number of drive pinion and crown wheel.
Determine Shim Thickness for Tooth Contact Pattern

NOTE: Make following measurements with accuracy. Inexact
measurements result in a faulty tooth contact pattern
and require a repeated disassembly and reassembly
of drive pinion and of differential.
15. Install adapter pieces (1) and preliminarily fasten bearing
bracket using hex screws.
Then install stop washer (4) and measuring pin (3) and
assemble measuring shaft (2), see Figure 160.
(S) Adapter piece 5870 500 046
(S) Measuring shaft 5870 500 001
(S) Measuring pin 5870 351 016
(S) Stop washer 5870 351 019
Figure 160
16. Determine gap (Dimension b) between measuring shaft

and measuring pin using a feeler gauge.
Dimension b, e.g. 5.60 mm (0.2205 in)
Figure 161
EXAMPLE "A"
Dimension a (= Measuring 225.00 mm (8.8583 in)

pin + stop washer)
Dimension b + 5.60 mm (0.2205 in)
Dimension c + 15.00 mm (0.5906 in)
Dimension X = 245.60 mm (9.6693 in)

Page 71
17. Determine Dimension I (bearing width).
Figure 162
18. Read Dimension II (dimension for pinion).

Figure 163
EXAMPLE "B"

Dimension II + 181.05 mm (7.1280 in)
Dimension Y = 220.10 mm (8.6654 in)
EXAMPLE "C"
Dimension X 221.20 mm (8.7087 in)

Dimension Y - 220.10 mm (8.6654 in)
Difference = Shim, e.g. = 1.10 mm (0.0433 in)
Install Drive Pinion

1. Place determined shim, e.g. s = 1.10 mm (0.0433 in) into
bearing bore.
Figure 164

Page 72
2. Cool outer bearing race and insert it into bearing bore until
seated.
(S) Driver 5870 058 060
(S) Handle 5870 260 002
Figure 165
3. Cool outer bearing race on input flange side and inset it

until seated.
(S) Driver 5870 058 079
(S) Handle 5870 260 002
Figure 166
4. Press inner bearing race on drive pinion until seated.
Figure 167
5. Adjust rolling moment of drive pinion bearing 1.5 - 3.0 Nm

(Figure 168 thru Figure 176).
Assemble spacer ring (e.g. s = 8.10 mm (0.3189 in)).
NOTE: As per experience, required rolling moment is
obtained by use of spacer ring (e.g. s =
8.10 mm (0.3189 in)) available at disassembly.
However, a later checking of rolling moment is
imperative.
Figure 168

Page 73
6. Insert preassembled drive pinion into axle drive housing
and assemble heated inner bearing race until seated.
Figure 169
7. Press dust protection on input flange until seated.

(S) Driver 5870 056 003
Figure 170
8. Assemble input flange.
Figure 171
9. Assemble washer.
Figure 172

Page 74
10. Unscrew slotted nut by hand and tighten it.
(S) Fixture 5870 240 002
NOTE: When tightening rotate drive pinion in both
directions several times.
Figure 173
11. Check rolling moment (1.5 - 3.0 Nm).

NOTE: For new bearings, it should be tried to achieve
maximum value of rolling moment.
NOTE: If required rolling moment is not obtained,
correct it with an adequate spacer ring (Figure
168), according to following indications:
Rolling moment too low - install a thinner spacer
ring.
Rolling moment too high - install a thicker
spacer ring.
Figure 174
Then loosen slotted nut again and pull input flange from
drive pinion.
12. Install shaft seal with sealing lip showing to oil chamber
(downwards).
(S) Driver 5870 048 233
be obtained by using exact driver (S).
shaft seal with mineral spirits. and fill space
between sealing and dust lip with grease.
Figure 175
13. Assemble input flange and finally fasten in using washer

and slotted nut.
NOTE: Apply Loctite #262 onto thread of slotted nut.
Figure 176

Page 75
Reassemble of Limited Slip Differential
1. Place both thrust washers into differential housing.
NOTE: Before installation, all single parts of differential
must be oiled according to ZF List of lubricants
TE-ML 05.
Figure 177
2. Starting with an outer clutch disk, install alternately outer

and inner clutch disks.
NOTE: Thickness of disk pack must be identical on
both sides.
Figure 178
3. Install pressure ring.
Figure 179
4. Insert axle bevel gear until seated and at same time

assemble all inner clutch disks with splines.
Figure 180

Page 76
5. Preassemble differential spider and insert it into differential
housing.
Figure 181
6. Install second axle bevel gear.
Figure 182
7. Insert second pressure ring into differential housing.
Figure 183
8. Starting with an inner clutch disk, install alternately inner

and outer clutch disks.
NOTE: Thickness of clutch disk pack must be identical
on both sides.
Figure 184

Page 77
Determine Disk Clearance 0.2 - 0.8 mm
1. Determine Dimension I, from mounting face of differential
housing to plane face of outer clutch disk.
Figure 185
2. Determine Dimension II, from contact surface of outer

clutch disk to mounting face of housing cover.
Figure 186
EXAMPLE "D"

Difference = Disk clearance = 0.35 mm (0.0138 in)
NOTE: If required disk clearance is not obtained,

correct it with adequate outer clutch disks (s =
2.7, s = 2.9, s = 3.0, s = 3.1 or s = 3.3 mm),
taking care that difference in thickness between
left and right disk pack must only be 0.01 at a
maximum.
3. Install both thrust washers with grease into recess of
housing cover.
Figure 187

Page 78
4. Install housing cover and fasten it using cap screws (2x).
(34 ft lb)
Figure 188
5. Heat crown wheel and install it until seated.

Figure 189
6. Install differential using press and fasten crown wheel

using new locking screws.
NOTE: Only use of new locking screws is permissible.
Figure 190
7. Press on both outer bearing races until seated.
Figure 191

Page 79
8. Insert differential into axle drive housing using lifting tackle
(S).
Figure 192
9. Place outer bearing race into axle drive housing.
Figure 193
10. Preliminarily install outer bearing race using adjusting nut.
Figure 194
11. Install crown wheel side outer bearing race.
Figure 195

Page 80
12. Preliminarily install crown wheel side outer bearing race
using second adjusting nut.
Figure 196
13. Install bearing bracket and fasten it using hex screws and
washers.
(207 ft lb)
NOTE: Pay attention to clearance of adjusting nut.
NOTE: Apply Loctite #262 onto threads of hex screws.
Figure 197
Adjustment of Backlash and Bearing Preload

1. Place dial indicator at a right angle to outer diameter of
tooth flank (crown wheel). Then install both adjusting nuts
only to such an extent that required backlash is obtained.
See that value etched on outer diameter of crown wheel is
reached.
(S) Magnetic stand 5870 200 055
(S) Dial indicator 5870 200 057
NOTE: During this step, rotate differential several times. Figure 198
2. Determine bracket width and correct it on both adjusting

nuts, if required.
Bracket width 418 -0.05 mm

(S) Caliper gauge 5870 200 058
Then check backlash again.
NOTE: Adjusting of bracket width results in required
bearing preload.
Figure 199

Page 81
3. Cover some tooth flanks of crown wheel with marking ink
and roll crown wheel in both directions over drive pinion.
Compare obtained tooth contact pattern with examples on
(See page -22)
NOTE: If tooth contact pattern differs, there has been a
measuring error at determination of shim
(Figure 164), what is imperative to be corrected.
Figure 200
4. Secure both adjusting nuts using slotted pins.
Figure 201
5. Install two adjusting screws (S) and insert differential

carrier into axle casing until seated using lifting tackle (S).
NOTE: Observe radial location (see marking Figure
113).
NOTE: Apply sealing compound (Three Bond Type
1215, ZF Part Number 0666 791 002) on
mounting face.
Figure 202
6. Fasten differential carrier using new locking screws.

Figure 203

Page 82
Then install O-ring (see arrow) using grease into recess of
axle casing.
both output sides.
Figure 204
8. Thrust washer(s) removed at disassembly have to be held

in sun gear shaft using grease.
Figure 205
9. Place complete output using lifting tackle (S) to axle casing

until seated.
Figure 206

(288 ft lb)
NOTE: Before putting into operation of axle, fill oil in
accordance with Lubrication Instructions on
page 1-14.
Figure 207

Page 83
PARKING BRAKE
Functional Characteristics and

Maintenance Instructions for Spring
Loaded Sliding Caliper Brakes

Caliper Brakes
The two identical brake pads (3) and (4) slide freely on guide
bolt (2), which is fastened in housing (1). The guide bolts (2) are
guided in an additional brake anchor plate which in turn is
screwed onto vehicle; i.e. its axle.
On actuation, the brake generates a clamping force at the brake
lining plates (3) and (4), which causes a tangential force/braking
moment to be generated at the brake disk, the extent of which
depends on coefficients of friction generated by the linings.
The clamping force is generated by the bank of cup springs (5),
during which the piston (6) is moved together with the adjusting
screw (7), the thrust bolt (8) and the brake pad (3) towards the
brake disk.
When the brake pad (3) comes into contact with the brake disk,
the reaction force shifts the housing (1) onto guide bolts (2) until
the brake pad (4) is also pressed against the brake disk.
The brake is released by complete pretensioning of bank of cup
springs (5). During this process, through application of
necessary release pressure after overcoming the cup spring
force, the piston (6) must move back until it comes to rest
against the pressure ring (9).
The clamping force diminishes with wear of brake lining and
brake disk. The brake must be adjusted at the latest at the times
indicated by the adjusting specification below (point 3).

Page 84
Figure 208
2. Mounting and Basic Setting Regulations

Basic brake setting is required after mounting new brake lining
plates or brake disks, and during all repair stages and in case of
insufficient braking performance.
All mounting and basic setting work must be carried out on brake
when cold. Proceed as follows:
1. Release the screw cap (12).
2. Release the lock nut (11) (size 24 or 30) and turn the
adjusting screw (7) counterclockwise using a size 8 or 10
socket wrench until the pressure bolt (8) comes to rest
against the face surface of piston (6).
3. In this status, the brake can be mounted onto brake disk
and fastened.
4. Mount the pressure connection and apply necessary
release pressure to the brake until the bank of cup springs
(5) is completely pretensioned.
5. Turn the adjusting screw (7) manually clockwise until both
brake pads (3) and (4) make contact with the brake disk (it
is then no longer possible to turn the adjusting screw (7)
without exerting a major amount of force).
6. Turn the adjusting screw (7) counterclockwise in order to
set the following rated clearances:

Page 85
Type Adjusting screw Clearance (mm) Revolutions
min. 0.5 1/4
Small M16 (size 8) Rated clearance 1.0 12
max. 1.5 3/4
min. 1.0 2/5
Large M20 (size 10) Rated clearance 2.0 4/5
max. 3.0 1 1/5
7. Hold the adjusting screw in position (7) with a hex socket

wrench and lock with lock nut (11).
8. Mount the screw cap (12) and tighten as far as possible
manually.
9. Mount the pressure connection in accordance with the
instructions of axle/gear manufacturer and bleed the piston
chamber using bleeding valve (19).
3. Adjusting Regulations
During this adjusting process, the parking brake must be
released; i.e. the bank of cup springs (5) must be completely
pretensioned.
1. Park the vehicle on an even surface and secure against
rolling away. Only then, release the parking brake.
2. Release the screw cap (12) and unscrew.
adjusting screw (7) with socket wrench size 8 or 10
manually clockwise until the two brake pads (3) and (4)
make contact with the brake disk.
4. Turn the adjusting screw (7) counterclockwise and set the
clearance specified in the above table.
5. Hold the adjusting screw (7) in position with the hex socket
wrench and lock with the lock nut (11).
manually.
7. Actuate the brake valve several times and check the
braking efficiency of parking brake on a slope.
4. Emergency Release of Parking Brake

After the failure of pressure, release the parking brake by using
following manual procedure.
1. The vehicle has to be against moving away.
manually counterclockwise until the brake disk is free.
NOTE: You need for the emergency release an
actuation torque of 4.08 kgm (30 ft lb)

Page 86
respectively 7.14 kgm (52 ft lb).
4. Mount the lock nut (11) and the screw cap (12) and tighten
both as far as possible manually. (Protection against dirt)
NOTE: Now, the vehicle do not have any brake
function. The vehicle must be secured against
moving away with proper means. Before putting
the vehicle into operation again, the brake has
to be adjusted according to point 2. respectively
point 3.
5. Maintenance and Repair Work
Maintenance and Exchange of Brake Pads

The brake pads themselves are maintenance free. All that is
required here is a check for damaged parts, and inspection to
ensure that the brake disk remains easy running.
The thickness of brake lining must be subjected to a visual
inspection at regular intervals, which depend on vehicle usage,
but every six months at the latest. In case of a minimal residual
lining thickness, these intervals must be reduced accordingly in
order to avoid major damage to the brake or disk.
Small brake: min. residual thickness 1.0 mm (0.0394 in) per
brake lining plate (6 mm carrier plate thickness)
Large brake: min. residual thickness 2.0 mm (0.0787 in) per
brake lining plate (8.0 mm (0.3150 in) carrier plate thickness)
Once these thickness are reached, the brake lining must be
replaced in accordance with the following regulation:
rolling away. Only then, release the parking brake by
applying the necessary release pressure.
manually clockwise until it lies flush with the inside of
piston (6).
4. Press back the pressure bolt (8) using a suitable
screwdriver until it comes to rest against the piston (6) (i.e.
by levering).
5. Depending on free space available, release one of two
guide bolts (2), removing the safety splint (21), unscrewing
the castellated nut (22) and pulling the guide bolt (2) from
brake anchor plate (1). The brake lining plates (3) and (4)
can now be removed tangentially to the brake disk.
NOTE: In case of minimal clearance; i.e. it is not
possible for space reasons to exchange the
brake lining plate in accordance with these
instructions, the brake must be moved
completely. To do this, pull the two guide bolts
from brake anchor plate.

Page 87
NOTE: Check the pressure hose. If the pressure hose
is too short, it must be unscrewed in order to
allow the brake to be removed.
Carrier on page 1-66, must always have been
performed beforehand, than release pressure
by actuating the hand brake valve!
6. Exchange the brake pads (3) and (4) and insert the guide
bolts (2) into brake anchor plate (1), checking whether the
permanent magnets (20) still have sufficient magnetic force
to hold the brake lining plates (3) and (4).
NOTE: Should this not be the case, the permanent
magnets (20) must also be changed ("lever out"
using a suitable screwdriver).
NOTE: When the brake has been completely removed,
the pressure hose must be screwed back on
and the brake bled.
7. Secure the guide bolts (2) with castellated nut (22) and
locking splint (21).
NOTE: Only Knott original spare lining plates may be
used. If any other spare parts are used, no
warranty claims will be accepted for either the
brakes or their functional characteristics.
After mounting new brake lining plates or their repair, the
brake must be correctly set in accordance with the
instructions under point 3.
Changing the Seal

Faulty seals must be exchanged in accordance with the
instructions below:
manually counterclockwise until the adjuster screw (7)
measured 27 mm - 30 mm outside of piston (6).
4. Release pressure by actuating the hand brake valve, than
unscrew the pressure hose and completely remove brake.
The bank of cup springs (5) is now completely
depressurized.
5. Remove retaining ring (18) and remove pressure ring (9)
from housing (1).
6. Remove bank of cup springs (5) and piston (6).
7. Exchange the seals (14) (15) and (17) and replace the
individual parts in reverse sequence.

Page 88
NOTE: Pay attention to the mounting direction of seal
rings (14) and (15), otherwise leaks can occur.
NOTE: When mounting the new seal rings, pay
attention not to damage the sealing lip by using
a suitable mounting needle with rounded edges.
When mounting the piston, the sliding and sealing surfaces
must be greased lightly using lubricating grease to DIN
51825.
The dust protection cap (13) is fitted with a vulcanized steel
ring that is used to press it through the locating hole. For
exchanging, "lever out" the ring using a suitable tool. The
new dust protection cap must be pressed in with the aid of
a suitable mounting ring and screw clamps or a lever
press.
8. Mount the brake in accordance with the above procedure
into vehicle / at the axle.
NOTE: For exchange purpose, only use Knott original
spare and spare parts sets. These must be
ordered through the vehicle manufacturer.
6. General
Any discovered defects or damage to parts not listed here must
naturally be repaired or replaced using original parts.
For any other information not contained in these instructions or
for more detailed instructions, please contact the vehicle or
brake manufacturer.

Page 89
Page 90
SP000107
REAR AXLE (ZF - MT-L 3095)SP000107
REAR AXLE
(ZF - MT-L 3095)
Edition 1
Rear Axle (ZF - MT-L 3095) SP000107

Page 1
MEMO
SP000107 Rear Axle (ZF - MT-L 3095)

Page 2
Table of Contents
Rear Axle
(ZF - MT-L 3095)
Outline ............................................................................. 7
Drive Axle ........................................................................ 7
Axle Mount ................................................................. 7
Differential (Standard) ................................................... 10
Differential Operation ............................................... 10
Limited Slip Differential Cross Section ..................... 11
Lubrication Instructions ................................................. 11
Oil Drain ................................................................... 12
Oil Filling................................................................... 12
Check ....................................................................... 12
Oil Change Intervals................................................. 12
Oil Level Check ........................................................ 12
Bleeders ................................................................... 12
Brake ........................................................................ 13
Brake Bleeding at the Vehicle................................... 13
Axle Oils for DL400, DL300, DL250 .............................. 14
Lubricant Class 05E ................................................. 14
Lubricant Class 05F ................................................. 14
Lubricant Class 05G................................................. 15
Make Wear Measurement on Multidisk Brake ............... 16
Wear Measurement of Multidisk Brake..................... 16
Inscriptions on Model Identification Plate ...................... 17
Torque Limits for Screws ............................................... 18
to ZF-Standards 148 ................................................ 18
for the Gleason Gear-tooth System............................... 19
Special Tool ........................................................ 22
List of Special Tools for Disassembly and Reassembly. 22

Page 3
ZF - Multitrac Rigid Axle MT-L 3095 ................... 32
Disassembly of Output and Brake ................................. 32
Reassembly of Output and Brake.................................. 41
Disassembly of Differential Carrier and Brake Tubes .... 54
Disassembly of Differential Carrier ........................... 54
Disassembly of Limited Slip Differential ................... 58
Disassembly of Drive Pinion..................................... 59
Disassembly of Brake Tubes .................................... 61
Reassembly of Brake Tubes and Differential Carrier..... 62
Reassembly of Brake Tubes..................................... 62
Reassembly of Differential Carrier ........................... 65
Determine Shim Thickness for Tooth Contact Pattern..
65
Install Drive Pinion.................................................... 67
Reassemble of Limited Slip Differential.................... 70
Determine Disk Clearance 0.2 - 0.8 mm .................. 72
Adjustment of Backlash and Bearing Preload .......... 75

Page 4
SAFETY PRECAUTIONS
CAUTION!
order.
handling load.
responsibility.
APPLICABLE MODELS

DL400 5001 and Up

Page 5
Page 6
GENERAL DESCRIPTION
Outline
Rear Axle
Trunnion Mounting,
Type
Semifloating
Overall Reduction Ratio 23.334
Differential type STD. Limited Slip Differential (Limited Slip: 45%)
Max Static Load 46,900 kg
(103,400 lb)
Max Output Torque 11,800 kgm
(85,350 ft lb)
Type Multi Wet Disk
Brake Torque 3,300 kgm at 80 bar
(23,865 ft lb at 1,160 psi)
Drive Flange 7C
Drive Axle
The drive axle consists of differential, final reduction gear
assembly, wet type hydraulic disk brake unit, and axle shafts to
which wheels are attached.
The power from drive unit is transmitted through the drive shafts
to the front and rear drive axles. The power is then transmitted to
the differential where it is divided into right and left axle shafts to
the final reduction gear assembly on each shaft end, thus driving
the wheels.
The wet type hydraulic disk brake unit is installed in front of final
reduction gear assembly and serves as a service brake.
Axle Mount
The front axle is bolted directly to the front frame.
The rear axle is supported by the trunnion method in which axle
supports are installed across the rear axle and bolted to the rear
frame. Consequently, the rear axle is cradled up and down
around the center line of differential according to the ground
condition the loader travels. The trunnion mounted drive axle
helps improve operator comfort because loaders with a trunnion
mounted drive axle jolt less than those with the conventional
cradle supported drive axle, when they travel on bad ground
conditions.

Page 7
3
4
A A
NOTE
3
B B
NOTE
9
NOTE
8
REAR AXLE FRONT AXLE

6
NOTE
4
1
NOTE NOTE NOTE NOTE NOTE
6 4 5 5 5 5 5 5 2
`C'
NOTE
1
`E' `G'
NOTE
7
7
NOTE
5 9
SECTION A-A
(Rear Axle) SECTION B-B
(Front Axle)
DETAIL C DETAIL E,G

S=1/1 S=1/1
FG005330
Figure 1 DRIVE AXLE ASSEMBLY

Page 8
Reference Reference
Number Number
1 Front Axle 6 Bushing
2 Rear Axle 7 Thrust Plate
3 Axle Support (Front) 8 Thrust Cap
4 Axle Support (Rear) 9 Thrust Washer
5 Packing
NOTE: 1) 28 kgm (203 ft lb) Threaded area: Loctite

#262
NOTE: 2) 170 kgm (1230 ft lb)
NOTE: 3) 170 kgm (1230 ft lb)
NOTE: 4) Inner surface: Grease (Assemble with
chamfered surface toward axle.)
NOTE: 5) Assemble with lip pointing outward.
NOTE: 6) Assemble with groove pointing toward plate
(7).
NOTE: 7) Apply grease and assemble.
NOTE: 8) Tightening Torque: 85 3 kgm
(614 22 ft lb) (Nut: 20 - M22x1.5)
NOTE: 9) Tightening Torque: 85 3 kgm (614 22 ft lb)
(Nut: 20 - M22x1.5)

Page 9
Differential (Standard)
The differential is integral with the reduction gear.
The power from drive shafts is transmitted through the drive
pinion and the ring gear to the differential gear case. It is then
sent through the right and left side gears to the final reduction
gear assembly. The speed reduction of power is accomplished
by the drive pinion and the ring gear.
Differential Operation
While the loader travels straight, the ring gear, differential gear
case, and side gears rotate together, with the pinion gears inside
the differential gear case not rotating. The power of same speed
is thus transmitted from right and left side gears through the axle
shafts to the wheels. When the loader makes a turn, the right
and left wheels rotate at different speeds; the pinion gears in the
differential gear case rotate around their own axes according to
the difference in speed between the right and left side gears.
Figure 2 DIFFERENTIAL GEAR OPERATION
Reference Reference
Number Number
1 Pinion Gear 5 Spider
2 Side Gear 6 Drive Pinion
3 Axle Shaft 7 Ring Gear
4 Differential Gear Case

Page 10
Limited Slip Differential Cross Section
Figure 3, shows a cross-sectional view of parts contained in the
limited slip differential.
Reference
Description
Number
1 Ring Gear
2 Bevel Pinion
3 Cross
4 Upper Thrust Ring
5 Outer Disk
6 Inner Disk
7 Cover
8 Clutch Disk
9 Side Gear
10 Lower Thrust Ring
Figure 3
Lubrication Instructions
Oils according to ZF List of lubricants TE-ML 05 that are
allowed to be used for ZF-Axles MT-L 3095.
The basic condition for a correct oil change of axle is the
horizontal plane of installation in every direction.
Place vehicle in a horizontal position.
All drain, filter and level plugs must be cleaned carefully
before opening.
Only drain oil immediately after a longer running time.
Reference
Description
Number
Axle casing
Outputs
3 Oil filler hole M36x1.5
4 Brake bleeder
5 Bleeder
Figure 4

Page 11
Figure 5
Oil Drain
Remove drain plugs 1 and 2 and drain oil.
Oil Filling
Provide drain plugs (M24x1.5) with new O-ring and install
them.
Tightening torque MA = 7.14 kgm (52 ft lb).
Fill oil to the overflow on filler/level plug 3.
Filling quantity approx. 30 liters (8 U.S. gal.).
Check
Check oil level after a few minutes and fill up to the
specified level, until level remains constant.
Provide filler/level plug (M36x1.5) with new O-ring and
install it.
Tightening torque MA = 13.26 kgm (96 ft lb).
Oil Change Intervals

1st oil change after 500 operating hours, further oil
changes every 1500 operating hours, however, at least
once a year.
Oil Level Check

Oil level check once a month, but especially before starting
a vehicle with new or repaired axles and axle components
respectively.
Bleeders
At initial operation and during the oil change intervals,
clean Bleeder 3 and 5 and make a functional check.

Page 12
Brake
For the pneumatic-hydraulic or via an accumulator system
operated brake actuation the following oils are permissible:
1.Motor oils SAE 10W according to specification MIL-L
2104 C, MIL-L 46152, API-CC, CD, SC, SD, SE
2.ATF-Oils Type A, Suffix A, Dexron of II D
Brake Bleeding at the Vehicle

1. Open the bleeder (4).
3. Close the bleeder again.
4. Slowly pressurize the brake and hold the pressure for
some seconds.
NOTE: The brake piston extends and the cylinder
chamber fills p with oil. The air accumulates in
the upper section of cylinder chamber.
5. Release the brake pedal and loosen the brake.
NOTE: The reversing piston presses the air from upper
section of cylinder into brake line.
6. Open the bleeder (4) again.
NOTE: Repeat procedure - Item 3 - 7 - until - at Item 7 -
from beginning of actuation no more air exits
from bleeder.

Page 13
Axle Oils for DL400, DL300, DL250
Examples of oils which meet the requirements according to the
table on the previous page.
Lubricant Class 05E

Viscosity grades: SAE 20W-40 / 80W-140
CASTROL INTERNATIONAL, PANGBOURNE READING/GB KOMATSU WBL 20W40
CNH, BURR RIDGE/USA CASE TRANSAXLE FLUID, SAE 80W-140
EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA MOBILFLUID 2040
FUCHS PETROLUB AG, MANNHEIM/D TITAN HYDRA ZF 20W-40
MAZIVA ZAGREB D.O.O. ZAGREB/HR INA TRASHIDROL ZF 20W-40

OMV AG, SCHWECHAT/A MOV AUSTROMATIC ZF SAE 20W-40
PAKELO MOTOR OIL S.R.L., SAN BONIFACIO (VR)/I PAKELO UTTO FLUID 4D SAE 20W-40
STRUB + CO AG, REIDEN/CH VULCOTRAC UTTO SAE 20W-40
Lubricant Class 05F
76 LUBRICANTS COMPANY, COSTA MESA/USA 76 HYDRAULIC/TRACTOR FLUID

ARAL AG, BOCHUM/D ARAL FLUID HGS SAE 80W
AVIA MINERALOL-AG, MUNCHEN/D AVIA HYDROFLUID DLZ
BP INTERNATIONAL, PANGBOURNE, READING/GB BP OLEX GO 4926

BP INTERNATIONAL, PANGBOURNE, READING/GB BP TERRAC SUPER TRANSMISSION
BP INTERNATIONAL, PANGBOURNE, READING/GB BP TRACTRAN TF 10
BUCHER AG LANGENTHAL, LANGENTHAL/CH MOTOREX POLYFARM 304

CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL AGRI POWERTRANS 10W-30
CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL AGRI TRANS PLUS 10W-30
CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL KOMATSU UTTO 10W-30
CATERPILLAR MULTIPURPOSE
CATERPILLAR INC., PEORIA/USA
TRACTOR OIL (MTO) 10W-30
ENGEN PETROLEUM LTD., CAPE TOWN/ZA ENGEN AGRIFLUID
ENI S.P.A. REFINING and MARKETING DIVISION, ROME/I ROTRA JD/F

EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA ESSO TORQUE FUID 56
EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA MOBIL AGRIFLUID 424

Page 14
FLITALIA S.P.A., VILLASTELLONE/I AMBRA MULTI G
FUCHS PETROLUB AG, MANNHEIM/D TITAN HYDRA J20C

GINOUVES GEORGES SA, LA FARLEDE/F YORK 676 SAE 10W30
IGOL FRANCE SA, AMIENS/F TICMA FLUID MU SAE 80W

KENDALL MOTOR OIL, COSTA MESA/USA KENDALL HYKEN 052

OEL-BRACK AG, HUNZENSCHWIL/CH MIDLAND TOU
OMV AG, SCHWECHAT/A OMV AUSTROMATIC IGB SAE 10W-30
PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO UTTO FLUID 4D SAE 10W/30
PANOLIN AG, MADETSWIL/CH PANOLIN JD 303
PETROGAL S.A., LISBOA/P GALP TRALUB 807S
REPSOL LUBRICANTES, MADRID/E AGRO ORION SAE 10W30
SHELL ASEOL AG, BERN 5/CH ASEOL MULTITRAC 85W
SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D WINTERSHALL HYDROFLUID N
Lubricant Class 05G
CATERPILLAR INC., PEORIA/USA CATERPILLAR MULTIPURPOSE TRACTOR OIL(MTO)

ZF FRIEDRICHSHAFEN AG, FRIEDRICHSHAFEN/D ZF-POWERFLUID

Page 15
Make Wear Measurement on Multidisk
Brake
NOTE: A wear measurement on multidisk brake has to be
made at least once a year, especially in case of a
changed braking behavior like, e.g.
Braking noise
Braking power reduced
Deceleration changed
Brake fluid level changed
Braking pressure changed
Wear Measurement of Multidisk Brake

A wear measurement has to be made on both output sides.
Remove plug, actuate brake and determine
Dimension X according to Figure 6 and Figure 7 using a feeler
gauge. Dimension X corresponds with thickness of inner clutch
disk on piston side.
NOTE: If Dim. X <= 3.4 mm (0.13 in), the lined disks on both
output sides have to be replaced.
Figure 6
Following to this provide level plug with a new O-ring and install
it.
NOTE: Tightening torque MA =7.14 kgm (52 ft lb)
Figure 7

Page 16
Inscriptions on Model Identification Plate
Figure 8
Reference
Description
Number
1 Axle Type
2 Axle Serial No.
3 ZF - Parts - List No.
4 Total-Ratio of Axle / Version with or without
ZF-multidisk self-locking differential
5 Type of lubricant
6 Lubricant specifications
NOTE: ZF - List of lubricants for ZF from Axles TE-ML

05

Page 17
Torque Limits for Screws

to ZF-Standards 148
Coefficient of friction: m total 0.12 for screws and nuts
without after treatment and for phosphate nuts.
NOTE: Tighten by hand.
Torque limits, if not specifically shown, can be taken from
following list:
Metric ISO-Standard Thread DIN 13 Metric ISO-Fine Thread DIN 13

Size 8.8 10.9 12.9 Size 8.8 10.9 12.9
M4 2.8 4.1 4.8 M8x1 24 36 43
M5 5.5 8.1 9.5 M9x1 36 53 62
M6 9.5 14.0 16.5 M 10 x 1 52 76 89
M7 15 23.0 28.0 M 10 x 1, 25 49 72 84
M8 23 34 40 M 12 x 1, 25 87 125 150
M 10 46 68 79 M 12 x 1, 5 83 120 145
M 12 79 115 135 M 14 x 1, 5 135 200 235
M 14 125 185 215 M 16 x 1, 5 205 300 360
M 16 195 280 330 M 18 x 1, 5 310 440 520
M 18 280 390 460 M 18 x 2 290 420 490
M 20 390 560 650 M 20 x 1, 5 430 620 720
M 22 530 750 880 M 22 x 1, 5 580 820 960
M 24 670 960 1,100 M 24 x 1, 5 760 1,100 1,250
M 27 1,000 1,400 1,650 M 24 x 2 730 1,050 1,200
M 30 1,350 1,900 2,250 M 27 x 1, 5 1,100 1,600 1,850
M 33 1,850 2,600 3,000 M 27 x 2 1,050 1,500 1,800
M 36 2,350 3,300 3,900 M 30 x1, 5 1,550 2,200 2,550
M 39 3,000 4,300 5,100 M 30 x 2 1,500 2,100 2,500
M 33 x 1, 5 2,050 2,900 3,400
M 33 x 2 2,000 2,800 3,300
M 36 x 1, 5 2,700 3,800 4,450
M 36 x 3 2,500 3,500 4,100
M 39 x 1, 5 3,450 4,900 5,700
M 39 x 3 3,200 4,600 5,300

Page 18
for the Gleason Gear-tooth System
Ideal Tooth-contact Pattern I. E. Pinion Distance Is Correct
Coast side (concave).
Figure 9
Drive side (convex).
Figure 10
Pinion distance must be increased.
Figure 11

Page 19
Figure 12
Figure 13
Pinion distance must be decreased.
Figure 14
Figure 15

Page 20
Figure 16

Page 21
SPECIAL TOOL
List of Special Tools for Disassembly and

Reassembly
ZF - Multitrac MT - L 3095 / Output and Brake
4474 053 007

5870 350 075 Clamps
Figure 27 5870 345 065 Pry bar (set of 2)
Figure 57
Figure 59
Figure 28 5870 650 001 Striker
Figure 29 Figure 100 5870 656 078 Socket Spanner #
5870 912 028 Centering bracket #
Figure 35 5870 300 019 Extractor
Figure 36 Figure 91 5870 900 015 Set of external pliers A1-A2-A3-A4
Figure 37 5870 971 002 Three-armed puller
Figure 38 5873 001 020 Gripping insert
5873 001 000 Basic device
Figure 39 5870 970 007 Two-armed puller
Figure 54
5870 654 034 Clamping bracket (set of 2)
5870 506 140 Press bush
Figure 44 5870 900 016 Set of external pliers A11-A21-A31-A41
Figure 48 Figure 77 5870 900 051 Assembly pliers #
Figure 51 5870 400 001 Adjusting device
Figure 55 Figure 67 5870 281 047 Lifting chain
5870 204 071 Eyebolts (set of 2)
5873 004 001 Basic device #
Figure 60 5870 610 010 Wheel bolt puller - Basic set
5870 610 011 Insert 7/8" - 14UNF
Figure 62 5870 506 141 Pressure ring # EBM = 16.8 - 0.2 mm
Figure 64 5870 051 052 Driver # EBM = 6 + 0.2 mm
Figure 73 5870 345 096 Assembly fixture #
Figure 74
Figure 80 5870 705 011 Drive mandrel EBM = 4 mm
Figure 95 5870 200 022 Straightedge # 580 mm

Page 22
5870 200 066 Gauge blocks # 60 mm
Figure 104 5870 287 007 HD-Pump #
5870 950 115 Measuring hub # 9/16" - 18UNF
5870 350 075 Clamps
Figure 109 Figure 195
Figure 115 Figure 186 5870 656 079 Socket spanner
5873 002 001 Basic set (size 2)
5873 002 001 Basic set (size 2)
Figure 127 Figure 161 5870 401 139 Slotted nut wrench #
Figure 164
5870 240 002 Fixture #
Figure 130 5870 970 007 Two-armed puller #
5873 002 001 Basic set (size 2)
Figure 148 5870 500 007 Adapter pieces #
Figure 149 5870 500 001 Measuring shaft #
5870 351 016 Measuring pin #
5870 351 029 Stop washer
Figure 173 5870 200 066 Gauge blocks # 60 mm
Figure 174
5870 260 002 Handle
5870 260 002 Handle
5870 260 002 Handle
Figure 163 5870 048 233 Driver EBM = 15.2 mm
Figure 186 5870 200 055 Magnetic stand #
5870 200 057 Dial indicator #
Figure 187 5870 200 058 Caliper gauge 0 - 500 mm

Page 23
# Particularly important special tools for partial
repair (wear part repair).

Page 24
Figure 17

Page 25
Figure 18

Page 26
Figure 19

Page 27
Figure 20

Page 28
Figure 21

Page 29
Figure 22

Page 30
Figure 23

Page 31
ZF - MULTITRAC RIGID AXLE MT-
L 3095
Disassembly of Output and Brake

(S) Clamps 5870 350 075
Figure 24
2. Remove plugs (3x, Figure 25 and Figure 26) and drain oil
from axle casing.
Figure 25
Figure 26

Page 32
3. Press off cover from output shaft.
(S) Pry bar set 5870 345 065
Figure 27
4. Remove slotted pin using striker (S) from bore in slotted

nut.
(S) Striker 5870 650 001
Figure 28
5. Remove slotted nut.

(S) Socket spanner
(S) Centering bracket
Figure 29

screws.
Figure 30

Page 33
Figure 31

NOTE: Pay attention too possibly released shim(s).
Figure 32
9. Remove shim(s) from sun gear shaft.
Figure 33
10. Remove sun gear shaft from planet gears.
Figure 34

Page 34
11. Remove planet carrier from brake housing.
(S) Internal extractor 5870 300 019
Figure 35

Figure 36
13. Remove planet gear and inner bearing race.

(S) Three-armed puller 5873 971 002
Figure 37
14. Remove inner bearing race.

(S) Basic set 5873 001 000
Figure 38

Page 35
15. Separate ring gear from brake housing using two-armed
puller (S).
Figure 39
16. Remove O-rings (see arrows) from annular grooves of ring

gear.
Figure 40
17. Remove O-ring (see arrow) from recess of brake housing.
Figure 41
18. Remove disk pack from brake housing.
Figure 42

Page 36
19. Install slotted pins (6x) in support shim until they are flush
mounted.
Figure 43

Figure 44
21. Remove piston from brake housing using compressed air.
Figure 45
22. Remove support shim from piston using automatic piston

adjusting.
Figure 46

Page 37
23. Remove slotted pins (6x) from support shim.
Figure 47
24. Preload cup springs using a press and remove retaining

ring.
Figure 48
25. Remove pin from support shim and remove released cup
springs.
Figure 49
26. Press gripping rings from pin.
Figure 50

Page 38
27. Remove piston from brake housing.
(S) Adjusting device 5870 400 001
Figure 51
28. Remove guide ring, support rings and U-rings from annular
grooves of brake housing.
NOTE: See Figure 53, for installation position of single
parts.
Figure 52
Reference
Description
Number
1 Brake housing
2 Guide ring
3 Support ring
4 U-ring
5 U-ring
6 Support ring
7 Output shaft
Figure 53

Page 39
29. Remove brake housing using two-armed puller (S) from
output shaft and remove released inner bearing race.
(S) Clamping bracket 5870 654 034
(S) Press bush 5870 506 140
Figure 54
30. Lift brake housing with lifting tackle (S) from output shaft.
(S) Eyebolts 5870 204 071
Figure 55
31. If necessary drive both outer bearing races from bearing

bores in brake housing.
Figure 56
32. Remove shaft seal from brake housing.

(S) Pry bar set 5870 345 065
Figure 57

Page 40
33. Remove inner bearing race from output shaft.
(S) Rapid grip 5873 014 013
(S) Basic set 5873 004 001
Figure 58
34. Press off bearing sheet from output shaft.

(S) Pry bar set 5870 345 065
Figure 59
Reassembly of Output and Brake

1. Insert wheel bolt into output shaft until seated.
(S) Wheel bolt puller - basic set 5870 610 010
(S) Insert (7/8" - 14 UNF) 5870 610 011
Figure 60
2. Assemble bearing sheet (shaft seal / Part 2).
Figure 61

Page 41
3. Press bearing sheet over collar of output shaft.
(S) Pressure ring 5870 506 141
NOTE: The exact installation position of bearing sheet
will be obtained by using specified pressure
ring.
Figure 62

NOTE: After cooling down bearing, it has to be installed
subsequently.
Figure 63
5. Press both outer bearing races into brake housing until

seated.
Figure 64
6. Install shaft seal with sealing lip visible to oil chamber, see
Figure 66.
(S) Driver 5870 051 052
be obtained by using specified driver (S).
shaft seal with mineral spirits.
Figure 65

Page 42
Reference
Description
Number
1 Shaft seal
2 Brake housing
* Grease filling
NOTE: Fill space between sealing and dust lips with

grease.
Figure 66
7. Install preassembled brake housing using lifting tackle (S)

over output shaft until seated.
(S) Eyebolts 5870 204 071
Figure 67
Figure 68
9. Insert support and U-rings into annular grooves of brake

housing.
70.
Figure 69

Page 43
Reference
Description
Number
1 Brake housing
2 Guide ring
3 Support ring
4 U-ring
5 U-ring
6 Support ring
7 Output shaft
Figure 70
10. Clean annular groove of brake housing with mineral spirits.

Then insert guide ring into annular groove (also see Figure
70) and secure with Loctite #415 at its extremities.
NOTE: Guide ring must have contact on whole
circumference.
NOTE: Upon installation the orifice of guide ring must
show upwards (12 o'clock).
Figure 71
11. Insert piston into brake housing and install it cautiously

until seated.
NOTE: Apply sufficiently oil on sliding surface of piston
or support rings, U-rings and guide ring (use W-
10 oils).
Figure 72

Page 44
12. Insert pins into assembly fixture (S) until seated.
Figure 73
13. Press gripping rings (4x, see arrows) onto pins until seated
on assembly fixture (S).
NOTE: The exact installation dimension (see Figure 76)
of gripping rings is obtained when using
specified assembly fixture.
NOTE: Observe installation position, install gripping
rings with orifices offset by 180 to each other.
Figure 74
14. Install cup springs (7 pieces each / pin).

NOTE: Pay attention to installation position of cup
springs, see Figure 76.
Figure 75
Reference
Description
Number
1 Pin
2 Gripping rings
3 Cup springs
4 Support shim
5 Retaining Ring
X Installation dimension
Gripping rings 10.5
+0.3 mm
Figure 76

Page 45
15. Insert preassembled pins into support shim and secure
using retaining ring.4
NOTE: Pay attention to clearance of cup springs.
Figure 77
16. Insert preassembled support shim into piston.
Figure 78
17. Install support shim using retaining ring.
Figure 79
18. Drive slotted pins (6x) into bores of support shim to lock
retaining ring.
(S) Drive mandrel 5870 705 011
81.
Figure 80

Page 46
Reference
Description
Number
1 Brake housing
2 Retaining Ring
3 Slotted pin
4 Support shim
5 Piston
X Installation dimension 4 -
0.5 mm
Figure 81
19. Drive stop bolt into planet carrier until seated.

Then wet spline with anticorrosive Weicon Anti Size (ZF
Part Number: 0671 196 001) (see arrow).
Figure 82
20. Insert planet carrier into spline of output shaft until seated.
Figure 83
21. Install outer and inner clutch disks alternately starting with
an outer clutch disk.
NOTE: Oil clutch disks according to ZF List of
Lubricants TE-ML 05.
Figure 84

Page 47
22. Insert O-ring (see arrow) into recess of brake housing.
Figure 85
23. Grease both O-rings (see arrows) and insert them into
annular grooves of ring gear.
Figure 86
24. Install two adjusting screws (S) and insert ring gear into
brake housing until seated.
NOTE: Pay attention to radial location.
Figure 87
25. Heat inner bearing races and install them until seated with
big radius showing to planet carrier (downwards).
cooling down.
Figure 88

Page 48
26. Put planet gears onto inner bearing races.
Figure 89
27. Heat inner bearing races and install them on planet gears
until seated.
cooling down.
Figure 90
28. Fasten planet gears using retaining rings.

Figure 91
29. Adjust end play of sun gear shaft 0.5 - 2.0 mm (0.0197 -
0.0787 in)
Fasten ring gear using cap screws until seated.
Then determine Dimension I, from mounting face of ring
gear up to face of stop bolt.
Figure 92

Page 49
Figure 93
31. Assemble sun gear shaft until seated.
Figure 94
32. Determine Dimension II from face of sun gear shaft up to

mounting face of axle casing.
Figure 95
EXAMPLE

required end play, e.g. - 1.00 mm (0.0394 in)
Difference = shim, e.g. = 2.20 mm (0.0866 in)

Page 50
33. Insert sun gear shaft into planet carrier.
Figure 96
34. Install determined shim(s), e.g. s = 2.20 mm (0.0866 in),

into sun gear shaft using grease.
Figure 97
35. Install O-ring (see arrow) into recess of axle casing using
grease and install preassembled output to axle casing until
seated using lifting tackle (S).
Figure 98

NOTE: Tightening torque (M18 / 10.9) MA = 39.77 kgm
(288 ft lb)
Figure 99

Page 51
37. Unscrew slotted nut by hand and then fasten it.
NOTE: Tightening torque MA = 152.96 - 173.35 kgm
(1,106 - 1,254 ft lb)

(S) Centering bracket 5870 912 028
Figure 100
38. Secure slotted nut using slotted pin.
Figure 101
39. Assemble O-ring (see arrow) to cover.
Figure 102
40. Insert cover into output shaft until seated.

(S) Hammer (Plastic 60) 5870 280 004
Figure 103

Page 52
41. Leakage test of brake hydraulics
NOTE: Before starting test, bleed brake hydraulics
completely.
1. Open bleeder.
3. Close bleeder again.
4. Slowly pressurize HP-pump with p > 10 bar and hold
pressure for some seconds.
NOTE: The brake piston extends and cylinder
Figure 104
chamber fills up with oil. The air
accumulates in upper section of cylinder
chamber.
5. Remove shutoff valve on HP-pump.
NOTE: The reversing piston presses air from
upper section of cylinder into brake line.
6. Open bleeder again.
NOTE: Repeat procedure - Item 3-7 - until - at
Item 7 - from beginning of actuation no
more air exits from bleeder.
NOTE: Then pressurize brake temporarily (5x)
with p = 100 bar max.
High-pressure test
Increase test pressure up to p = 100 -10 bar and close
connection to HD-pump using shutoff valve. During a 5
min. testing time, a pressure drop of max. 2% (2 bar) is
allowed.
NOTE: If maximum pressure of 100 bar is exceeded,
there will be an excessive piston adjustment
and a repeated disassembly of brake or
adjusting is required to reset gripping rings to
adjusting dimension.
Low-pressure test
Reduce test pressure to p = 5 bar and close shutoff valve
again. During a 5 min. testing time, a pressure drop is not
allowed.
Test media
Motor oils SAE 10-W corresponding with,
MIL-L 2104 C, MIL-L 46152,
API-CC, CD, SC, SD, SE,
ATF-Oils Type A, Suffix A Dexron of II D.
(S) HD-Pump 5870 287 007
(S) Mini-measuring hub (9 / 16" - 18UNF) 5870 950 115

Page 53
NOTE: Before putting axle into operation, fill it with oil
according to Lubrication Instructions on
page 1-11.
Disassembly of Differential Carrier and

Brake Tubes
Disassembly of Differential Carrier

(S) Clamps 5870 350 075
Figure 105
2. Remove plugs (3x, Figure 106, Figure 107) and drain oil
from axle casing.
Figure 106
Figure 107

Page 54
screws.
both output sides.
Figure 108

Figure 109

NOTE: Pay attention to released shim(s).
Figure 110
6. Remove hex screws.

NOTE: Mark location of differential carrier to axle
casing (see arrows).
Figure 111

Page 55
7. Remove differential carrier using lifting tackle (S) from axle
casing.
Figure 112
8. Fasten differential carrier to assembly truck.

(S) Holding fixture 5870 350 034
Figure 113
9. Drive out slotted pins.
Figure 114
10. Remove both adjusting nuts.

Figure 115

Page 56
11. Heat axle drive housing using hot air blower (S).
(S) Hot air blower 230 V 58770 221 500
(S) Hot air blower 115 V 5870 221 501
NOTE: Hex screws are installed with Loctite #262.
Figure 116
12. Remove hex screws and bearing bracket.

NOTE: Remove hex screws by hand only.
Figure 117
13. Remove both outer bearing races.
Figure 118
14. Remove differential from housing using lifting tackle (S).

Figure 119

Page 57
Disassembly of Limited Slip Differential
1. Remove inner bearing race from differential housing.
(S) Basic set 5873 002 001
Figure 120
2. Remove inner bearing race from housing cover.

(S) Rapid grip 5873 012 018
(S) Basic set 5873 002 001
Figure 121
3. Fasten differential using press and remove locking screws.
Figure 122
4. Remove cap screws and housing cover.
Figure 123

Page 58
5. Remove all single parts from differential housing.
Figure 124
6. Press off crown wheel from differential housing.
Figure 125
Disassembly of Drive Pinion

1. Heat slotted nut using hot air blower (S).
(S) Hot air blower 230 V 5870 221 500
(S) Hot air blower 115 V 5870 221 501
NOTE: Slotted nut is locked with Loctite #262.
Figure 126
2. Remove slotted nut and washer.

(S) Fixture 5870 240 002
Figure 127

Page 59
3. Remove input flange from drive pinion.
Figure 128
4. Remove shaft seal from axle drive housing.
Figure 129
5. Press drive pinion from axle drive housing using two-

armed puller (S) and remove released inner bearing race.
Figure 130
6. Remove spacer ring and pull inner bearing race from drive
pinion.
(S) Basic set 5873 002 001
Figure 131

Page 60
7. If necessary, remove both outer bearing races from axle
drive housing.
Figure 132
Disassembly of Brake Tubes

1. Remove plug with vent valve from axle casing.
Figure 133
2. Remove hex nut.

both sides.
Figure 134
3. Remove union screw.
Figure 135

Page 61
4. Remove pipe union and brake tube from axle casing.
Figure 136
5. Remove vent valve from connection part.
Figure 137
6. Remove connection part from axle casing.
Figure 138
Reassembly of Brake Tubes and

Differential Carrier
Reassembly of Brake Tubes

1. Preassemble connection part as shown in Figure 139.
Reference
Description
Number
1 Vent valve
2 Connection part Figure 139
3 O-ring

Page 62
Reference
Description
Number
4 Rectangular ring

both output sides.
2. Install connection part.
Figure 140
3. Provide union screw with new O-ring and install it.

Figure 141
4. Insert O-ring (see arrow) into annular groove of brake tube.
Figure 142

Page 63
5. Insert brake tube into axle casing, assembling connection
part (see arrow 1) through union screw (see arrow 2).
Figure 143
6. Fasten brake tube using hex nut and union nut (Figure
144).
Figure 144
Figure 145
7. Preassemble screw plug as shown in Figure 146.
Reference
Description
Number
1 O-ring
2 Screw Plug
3 Vent valve
Figure 146

Page 64
8. Install screw plug.
Figure 147
Reassembly of Differential Carrier

NOTE: If crown wheel or drive pinion are damaged, both
parts have to be replaced together. For new
installation of a complete bevel gear set, pay attention
to same pair number of drive pinion and crown wheel.
Determine Shim Thickness for Tooth Contact Pattern

NOTE: Make following measurements with accuracy. Inexact
measurements result in a faulty tooth contact pattern
and require a repeated disassembly and reassembly
of drive pinion and of differential.
9. Install adapter pieces (1) and preliminarily fasten bearing
bracket using hex screws.
Then install stop washer (4) and measuring pin (3) and
assemble measuring shaft (2), see Figure 148.
(S) Measuring shaft 5870 500 001
(S) Measuring pin 5870 351 016
(S) Stop washer 5870 351 029
Figure 148
10. Determine gap (Dimension b) between measuring shaft

and measuring pin using a feeler gauge.
Dimension b, e.g. 0.20 mm (0.0079 in)
Figure 149

Page 65
EXAMPLE "A"
Dimension a (= Measuring 206.00 mm (8.1102 in)

pin + stop washer)
Dimension b + 0.20 mm (0.0078 in)
Dimension c + 15.00 mm (0.5906 in)
Dimension X = 221.20 mm (8.7087 in)
11. Determine Dimension I (bearing width).

Figure 150
12. Read Dimension II (dimension for pinion).

Figure 151
EXAMPLE "B"

Dimension II + 181.05 mm (7.1280 in)
Dimension Y = 220.10 mm (8.6654 in)
EXAMPLE "C"
Dimension X 221.20 mm (8.7087 in)

Dimension Y - 220.10 mm (8.6654 in)
Difference = Shim, e.g. = 1.10 mm (0.0433 in)

Page 66
Install Drive Pinion
1. Place determined shim, e.g. s = 1.10 mm (0.0433 in) into
bearing bore.
Figure 152
2. Cool outer bearing race and insert it into bearing bore until
seated.
(S) Driver 5870 058 060
(S) Handle 5870 260 002
Figure 153
3. Cool outer bearing race on input flange side and inset it

until seated.
(S) Driver 5870 058 079
(S) Handle 5870 260 002
Figure 154
4. Press inner bearing race on drive pinion until seated.
Figure 155

Page 67
5. Adjust rolling moment of drive pinion bearing 1.5 - 3.0 Nm
(Figure 156 thru Figure 164).
Assemble spacer ring (e.g. s = 8.10 mm (0.3189 in)).
NOTE: As per experience, required rolling moment is
obtained by use of spacer ring (e.g. s =
8.10 mm (0.3189 in)) available at disassembly.
However, a later checking of rolling moment is
imperative.
Figure 156
6. Insert preassembled drive pinion into axle drive housing

and assemble heated inner bearing race until seated.
Figure 157
7. Press dust protection on input flange until seated.

(S) Driver 5870 056 003
Figure 158
8. Assemble input flange.
Figure 159

Page 68
9. Assemble washer.
Figure 160
10. Unscrew slotted nut by hand and tighten it.

(S) Fixture 5870 240 002
NOTE: When tightening rotate drive pinion in both
directions several times.
Figure 161
11. Check rolling moment (1.5 - 3.0 Nm).

NOTE: For new bearings, it should be tried to achieve
maximum value of rolling moment.
NOTE: If required rolling moment is not obtained,
correct it with an adequate spacer ring (Figure
156), according to following indications:
Rolling moment too low - install a thinner spacer
ring
Rolling moment too high - install a thicker
spacer ring.
Figure 162
Then loosen slotted nut again and pull input flange from
drive pinion.
12. Install shaft seal with sealing lip showing to oil chamber
(downwards).
(S) Driver 5870 048 233
be obtained by using exact driver (S).
shaft seal with mineral spirits. and fill space
between sealing and dust lip with grease.
Figure 163

Page 69
13. Assemble input flange and finally fasten in using washer
and slotted nut.
NOTE: Apply Loctite #262 onto thread of slotted nut.
Figure 164
Reassemble of Limited Slip Differential

1. Place both thrust washers into differential housing.
NOTE: Before installation, all single parts of differential
must be oiled according to ZF List of lubricants
TE-ML 05.
Figure 165
2. Starting with an outer clutch disk, install alternately outer

and inner clutch disks.
NOTE: Thickness of disk pack must be identical on
both sides.
Figure 166
3. Install pressure ring.
Figure 167

Page 70
4. Insert axle bevel gear until seated and at same time
assemble all inner clutch disks with splines.
Figure 168
5. Preassemble differential spider and insert it into differential

housing.
Figure 169
6. Install second axle bevel gear.
Figure 170
7. Insert second pressure ring into differential housing.
Figure 171

Page 71
8. Starting with an inner clutch disk, install alternately inner
and outer clutch disks.
NOTE: Thickness of clutch disk pack must be identical
on both sides.
Figure 172
Determine Disk Clearance 0.2 - 0.8 mm

1. Determine Dimension I, from mounting face of differential
housing to plane face of outer clutch disk.
Figure 173
2. Determine Dimension II, from contact surface of outer

clutch disk to mounting face of housing cover.
Figure 174
EXAMPLE "D"

Difference = Disk clearance = 0.35 mm (0.0138 in)
NOTE: If required disk clearance is not obtained,

correct it with adequate outer clutch disks (s =
2.7, s = 2.9, s = 3.0, s = 3.1 or s = 3.3 mm),
taking care that difference in thickness between
left and right disk pack must only be 0.01 at a
maximum.

Page 72
3. Install both thrust washers with grease into recess of
housing cover.
Figure 175
4. Install housing cover and fasten it using cap screws (2x).

(34 ft lb)
Figure 176
5. Heat crown wheel and install it until seated.

Figure 177
6. Install differential using press and fasten crown wheel

using new locking screws.
Figure 178

Page 73
7. Press on both outer bearing races until seated.
Figure 179
8. Insert differential into axle drive housing using lifting tackle

(S).
Figure 180
9. Place outer bearing race into axle drive housing.
Figure 181
10. Preliminarily install outer bearing race using adjusting nut.
Figure 182

Page 74
11. Install crown wheel side outer bearing race.
Figure 183
12. Preliminarily install crown wheel side outer bearing race

using second adjusting nut.
Figure 184
13. Install bearing bracket and fasten it using hex screws and
washers.
(207 ft lb)
NOTE: Pay attention to clearance of adjusting nut.
NOTE: Apply Loctite #262 onto threads of hex screws.
Figure 185
Adjustment of Backlash and Bearing Preload

1. Place dial indicator at a right angle of outer diameter of
tooth flank (crown wheel). Then install both adjusting nuts
only to such an extent that required backlash is obtained.
See that value etched on outer diameter of crown wheel is
reached.
(S) Magnetic stand 5870 200 055
(S) Dial indicator 5870 200 057
NOTE: During this step, rotate differential several times. Figure 186

Page 75
2. Determine bracket width and correct it on both adjusting
nuts, if required.
Bracket width 418 -0.05 mm

(S) Caliper gauge 5870 200 058
Then check backlash again.
NOTE: Adjusting of bracket width results in required
bearing preload.
Figure 187
3. Cover some tooth flanks of crown wheel with marking ink

and roll crown wheel in both directions over drive pinion.
Compare obtained tooth contact pattern with examples on
(See page -19)
NOTE: If tooth contact pattern differs, there has been a
measuring error at determination of shim
(Figure 152), what is imperative to be corrected.
Figure 188
4. Secure both adjusting nuts using slotted pins.
Figure 189
5. Install two adjusting screws (S) and insert differential

carrier into axle casing until seated using lifting tackle (S).
NOTE: Observe radial location (see marking Figure
111).
NOTE: Apply sealing compound (Three Bond Type
1215, ZF Part Number 0666 791 002) on
mounting face.
Figure 190

Page 76
6. Fasten differential carrier using new locking screws.
Figure 191
Then install O-ring (see arrow) using grease into recess of
axle casing.
both output sides.
Figure 192
8. Thrust washer(s) removed at disassembly have to be held

in sun gear shaft using grease.
Figure 193
9. Place complete output using lifting tackle (S) to axle casing

until seated.
Figure 194

Page 77
(288 ft lb)
NOTE: Before putting into operation of axle, fill oil in
accordance with Lubrication Instructions on
page 1-11.
Figure 195

Page 78
SP000119
DRIVE SHAFT SP000119
Drive Shaft
Edition 1
Drive Shaft SP000119

Page 1
MEMO
SP000119 Drive Shaft

Page 2
Table of Contents
Drive Shaft
Drive Shaft Weight........................................................... 6
Drive Shaft Coupling Dimension ..................................... 6
Drive Shaft, Tightening Torque ........................................ 6

Page 3
MEMO

Page 4
SAFETY PRECAUTIONS
CAUTION!
order.
handling load.
responsibility.
APPLICABLE MODELS

DL400 5001 and Up

Page 5
Drive Shaft Weight
Front drive shaft (1): approx. 34 kg (75 lb).
Center drive shaft (2): approx. 34.4 kg (75 lb).
Rear drive shaft (3): approx. 15.1 kg (33 lb).
Drive Shaft Coupling Dimension

Front/ Center drive shaft: 8.5C
Rear drive shaft: 7C
Drive Shaft, Tightening Torque

Front/ Center/ Rear drive shaft: 15kgm (109 lb ft)
Threaded area: Loctite #262
FRONT AXLE 1 2
3
REAR AXLE
FG004080
Figure 1

Page 6
1Brake
SP000120
SERVICE BRAKE SP000120
Service Brake
Edition 1
Service Brake SP000120

Page 1
MEMO
SP000120 Service Brake

Page 2
Table of Contents
Service Brake
Service Brake System .......................................... 8

Page 3
MEMO

Page 4
SAFETY PRECAUTIONS
CAUTION!
order.
handling load.
responsibility.
APPLICABLE MODELS

DL400 5001 and Up

Page 5
GENERAL DESCRIPTION
This machine is equipped with a fully hydraulic operated brake
system and have independent circuit for the front axle and rear
axle.
The brake system is composed of brake pedal valve, brake
supply valve and accumulators and provided with oil through
brake supply valve from pump.
A system pressure drop below 65 bar (943 psi) will be indicated
on the display panel in the cab, warning light will flash and also
alarm will sound.
1 2
3 4 8
9
FG004089
Figure 1

Page 6
Reference Reference
Number Number
1 Brake Pedal Valve 5 Brake Pump
2 Brake, Pilot and Fan Motor 6 Brake Filter
Supply Valve 7 Parking Brake
3 Brake Accumulator 8 Rear Axle
4 Pilot Accumulator 9 Front Axle

Page 7
SERVICE BRAKE SYSTEM
A brake pump (10, Figure 2) supplies pressurized fluid to the
brake hydraulic system. Force on the brake pedal (5) moves two
spools in the brake valve (9). The spools are proportional. The
farther the brake pedal is pushed, the greater the amount of fluid
that passes through each spool. One spool ports fluid to brake
pistons in the front axle (3). The other spool ports fluid to brake
pistons in the rear axle (1). Pressure on the brake pistons
applies pressure to the brake disks, and this stops axle shaft and
wheel rotation. The brake hydraulic system also contains three
accumulators (8). The accumulators hold a volume of
pressurized fluid large enough to allow the brakes to be applied
nine times with full pressure, after the engine has been turned
off. The brake hydraulic system includes a pressure operated
transmission cutoff switch (2, Figure 2). Pressing the brake
pedal (5) will open cutoff switch (2). When the transmission
cutoff switch in the operator's cab is selected, this will cut off
current to a solenoid operated hydraulic valve in the
transmission. This prevents operation of the forward clutch in the
transmission. This prevents the transmission from driving the
wheels forward when the brake pedal is pressed.

Page 8
0.5 BAR
(3) (4) (1)
(6)
3/8"
(9)
CLOSES 3B
3/8"
STOP (2)
L.H Brake valve BR1 BR2
FRONT AXLE OPENS 25B REAR AXLE

T/M DISCONNECT
(5) T/M
P1 T1 P2 T2
(7)
E/G
R.H Brake pedal (8)
(12)
LPWS
30B 65bar 30B 30B 30B 15B
parking brake
100ccr 0.75L 0.75L 0.75L 0.75L 0.32L
100 l/min * TUV only Lpws A1 A1 P1 P2 A2 A2 A3 TP1

1/4" 3/8" 3/8" 3/8" 3/8" 3/8" 3/8" 3/8" 1/4"
(10) 1" 3/4" (15)

A4 C3 C3 (11)
3/8" C4
53.2 l/min at 6.9B at 1,900 rpm TP2 C2 C3
28ccr Pilot Pilot 20 l/min
X 1/4" at 30bar
3/8"
3" 1/2" Fo 27B

(13)
1/2"
1/2"
C1 C3
L 100ccr 20 abs safety
Fan motor Park

Fi
3/8"
1/2" (14)
120bar
1/4"
C6
C5
Pkws
T 190bar
3/4" M
1/2"
27ccr
T1 3/8" T2 1/4"
P BRAKE, PILOT & FAN MOTOR

1/2" SUPPLY VALVE
L 7/16"
FG004512
Figure 2
Reference Reference
Number Number
1 Rear Axle 9 Brake Valve
2 Transmission Cutoff Switch 10 Brake Pump
3 Front Axle 11 Pilot Supply Line
4 Brake 12 Low-pressure Warning Switch
5 Brake Pedal 13 Parking Brake Valve
6 Stop Light Switch 14 Low-pressure Warning Switch
7 Parking Brake 15 Brake and Pilot Filter
8 Accumulators: Brake

Page 9
Page 10
SP000121
BRAKE SUPPLY VALVESP000121
Brake Supply
Valve
Edition 1
Brake Supply Valve SP000121

Page 1
MEMO
SP000121 Brake Supply Valve

Page 2
Table of Contents
Brake Supply Valve

Brake, Pilot and Fan Motor Supply Valve.............. 6
Specifications .................................................................. 8

Page 3
MEMO

Page 4
SAFETY PRECAUTIONS
CAUTION!
order.
handling load.
responsibility.
APPLICABLE MODELS

DL400 5001 and Up

Page 5
BRAKE, PILOT AND FAN MOTOR
SUPPLY VALVE
This valve controls oil flow to the brake pedal valve for braking,
to the pilot controller for operation of bucket and boom, and to
the fan motor.
Figure 1

Page 6
Reference Reference
Number Number
1 Body (200*120*79) 5 Solenoid (C4 and C5)
2 Sequence (C1) 6 Coil (C4 and C5)
3 Reducing (C2) 7 Relief Valve (C6)
4 Check (C3)

Page 7
A1-1 A1 LP P1 P2 A2 A2-2 A3 TP1
C3-1 C3-2
A4 C2 C3-3
TP2 PL
C4
SAFETY
FO
C1 C3-4
PA
FI
C5 PK
C6
M
T1 T2
FG004516
Figure 2 Hydraulic Circuit
Specifications
Item Specifications
Max. Operating Pressure 210 kg/cm2
(3,000 psi)
Max. Flow 57 l/min
(15 U.S. gpm)
System Pressure 120 kg/cm2
(1,710 psi)
Setting Pressure C1 120 2 kg/cm2 at 53 l/min
(1710 28 psi at 14 U.S. gpm)
C2 30 kg/cm2 at 20 l/min
(427 psi at 5.3 U.S. gpm)
C3 Cracking Pressure 2.40 kg/cm2
(34.1 psi)
C6 190 kg/cm2
(2,700 psi)
Port Size FO, F1, M PF 1/2 O-ring
TP1, TP2, T2 PF 1/4 O-ring
LP, PK 30 PF 1/4 BSP
All other ports PF 3/8 O-ring

Page 8
SP000122
PARKING BRAKE SP000122
Parking Brake
Edition 1
Parking Brake SP000122

Page 1
MEMO
SP000122 Parking Brake

Page 2
Table of Contents
Parking Brake
Functional Characteristics and Maintenance Instructions
for Spring Loaded Sliding Caliper Brakes........................ 8
Caliper Brakes ................................................................. 8
2. Mounting and Basic Setting Regulations................... 10
3. Adjusting Regulations................................................ 11
4. Emergency Release of Parking Brake....................... 11
5. Maintenance and Repair Work .................................. 12
Maintenance and Exchange of Brake Pads ............. 12
Changing the Seal.................................................... 13
6. General...................................................................... 14

Page 3
MEMO

Page 4
SAFETY PRECAUTIONS
CAUTION!
order.
handling load.
responsibility.
APPLICABLE MODELS

DL400 5001 and Up

Page 5
GENERAL DESCRIPTION
Type Electrically controlled hydraulic caliper brake

Control Pressure 120 kg/cm2 (1,740 psi)
3 2 1
FG004088
Figure 1
Reference Reference
Number Number
1 Transmission 3 Parking Brake
2 Parking Brake Disk

Page 6
Page 7
Functional Characteristics and
Maintenance Instructions for Spring
1. Functional Characteristics of Spring

The two identical brake pads (3) and (4) slide freely on guide bolt
(2), which is fastened in housing (1). The guide bolts (2) are
guided in an additional brake anchor plate which in turn is
screwed onto vehicle; i.e. its transmission.
On actuation, the brake generates a clamping force at the brake
lining plates (3) and (4), which causes a tangential force/braking
moment to be generated at the brake disk, the extent of which
depends on coefficients of friction generated by the linings.
The clamping force is generated by the bank of cup springs (5),
during which the piston (6) is moved together with the adjusting
screw (7), the thrust bolt (8) and the brake pad (3) towards the
brake disk.
When the brake pad (3) comes into contact with the brake disk,
the reaction force shifts the housing (1) onto guide bolts (2) until
the brake pad (4) is also pressed against the brake disk.
The brake is released by complete pretensioning of bank of cup
springs (5). During this process, through application of
necessary release pressure after overcoming the cup spring
force, the piston (6) must move back until it comes to rest
against the pressure ring (9).
The clamping force diminishes with wear of brake lining and
brake disk. The brake must be adjusted at the latest at the times
indicated by the adjusting specification below (point 3).

Page 8
Figure 2
Figure 3

Page 9
2. Mounting and Basic Setting Regulations
Basic brake setting is required after mounting new brake lining
plates or brake disks, and during all repair stages and in case of
insufficient braking performance.
All mounting and basic setting work must be carried out on brake
when cold. Proceed as follows:
1. Release the screw cap (12).
adjusting screw (7) counterclockwise using a size 8 or 10
socket wrench until the pressure bolt (8) comes to rest
against the face surface of piston (6).
3. In this status, the brake can be mounted onto brake disk
and fastened.
4. Mount the pressure connection and apply necessary
release pressure to the brake until the bank of cup springs
(5) is completely pretensioned.
5. Turn the adjusting screw (7) manually clockwise until both
brake pads (3) and (4) make contact with the brake disk (it
is then no longer possible to turn the adjusting screw (7)
without exerting a major amount of force).
6. Turn the adjusting screw (7) counterclockwise in order to
set the following rated clearances:
Type Adjusting screw Clearance (mm) Revolutions

min. 0.5 1/4
Small M16 (size 8) Rated clearance 1.0 12
max. 1.5 3/4
min. 1.0 2/5
Large M20 (size 10) Rated clearance 2.0 4/5
max. 3.0 1 1/5
7. Hold the adjusting screw in position (7) with a hex socket

wrench and lock with lock nut (11).
manually.
9. Mount the pressure connection in accordance with the
instructions of axle/gear manufacturer and bleed the piston
chamber using bleeding valve (19).

Page 10
3. Adjusting Regulations
During this adjusting process, the parking brake must be
released; i.e. the bank of cup springs (5) must be completely
pretensioned.
rolling away. Only then, release the parking brake.
manually clockwise until the two brake pads (3) and (4)
make contact with the brake disk.
4. Turn the adjusting screw (7) counterclockwise and set the
clearance specified in the above table.
5. Hold the adjusting screw (7) in position with the hex socket
wrench and lock with the lock nut (11).
manually.
7. Actuate the brake valve several times and check the
braking efficiency of parking brake on a slope.
4. Emergency Release of Parking Brake

After the failure of pressure, release the parking brake by using
following manual procedure.
1. The vehicle has to be secured against rolling away.
manually counterclockwise until the brake disk is free.
NOTE: You need for the emergency release an
actuation torque of 4.08 kgm (30 ft lb)
respectively 7.14 kgm (52 ft lb).
4. Mount the lock nut (11) and the screw cap (12) and tighten
both as far as possible manually. (Protection against dirt)
NOTE: Now, the vehicle do not have any brake function.
The vehicle must be secured against moving
away with proper means. Before putting the
vehicle into operation again, the brake has to be
adjusted according to point 2. respectively point
3.

Page 11
5. Maintenance and Repair Work
Maintenance and Exchange of Brake Pads

The brake pads themselves are maintenance free. All that is
required here is a check for damaged parts, and inspection to
ensure that the brake disk remains easy running.
The thickness of brake lining must be subjected to a visual
inspection at regular intervals, which depend on vehicle usage,
but every six months at the latest. In case of a minimal residual
lining thickness, these intervals must be reduced accordingly in
order to avoid major damage to the brake or disk.
Small brake: min. residual thickness 1.0 mm (0.0394 in) per
Large brake: min. residual thickness 2.0 mm (0.0787 in) per
Once these thickness are reached, the brake lining must be
replaced in accordance with the following regulation:
manually clockwise until it lies flush with the inside of
piston (6).
4. Press back the pressure bolt (8) using a suitable
screwdriver until it comes to rest against the piston (6) (i.e.
by levering).
5. Depending on free space available, release one of two
guide bolts (2), removing the safety splint (21), unscrewing
the castellated nut (22) and pulling the guide bolt (2) from
brake anchor plate (1). The brake lining plates (3) and (4)
can now be removed tangentially to the brake disk.
NOTE: In case of minimal clearance; i.e. it is not
possible for space reasons to exchange the
brake lining plate in accordance with these
instructions, the brake must be moved
completely. To do this, pull the two guide bolts
from brake anchor plate.
NOTE: Check the pressure hose. If the pressure hose
is too short, it must be unscrewed in order to
allow the brake to be removed.
Carrier, must always have been performed
beforehand, than release pressure by actuating
the hand brake valve!
6. Exchange the brake pads (3) and (4) and insert the guide
bolts (2) into brake anchor plate (1), checking whether the

Page 12
permanent magnets (20) still have sufficient magnetic force
to hold the brake lining plates (3) and (4).
NOTE: Should this not be the case, the permanent
magnets (20) must also be changed ("lever out"
using a suitable screwdriver).
NOTE: When the brake has been completely removed,
the pressure hose must be screwed back on
and the brake bled.
7. Secure the guide bolts (2) with castellated nut (22) and
locking splint (21).
NOTE: Only Knott original spare lining plates may be
used. If any other spare parts are used, no
warranty claims will be accepted for either the
brakes or their functional characteristics.
After mounting new brake lining plates or their repair, the
brake must be correctly set in accordance with the
instructions under point 3.
Changing the Seal

Faulty seals must be exchanged in accordance with the
instructions below:
manually counterclockwise until the adjuster screw (7)
measured 27 mm - 30 mm outside of piston (6).
4. Release pressure by actuating the hand brake valve, than
unscrew the pressure hose and completely remove brake.
The bank of cup springs (5) is now completely
depressurized.
5. Remove retaining ring (18) and remove pressure ring (9)
from housing (1).
6. Remove bank of cup springs (5) and piston (6).
7. Exchange the seals (14) (15) and (17) and replace the
individual parts in reverse sequence.
NOTE: Pay attention to the mounting direction of seal
rings (14) and (15), otherwise leaks can occur.
NOTE: When mounting the new seal rings, pay
attention not to damage the sealing lip by using
a suitable mounting needle with rounded edges.
When mounting the piston, the sliding and sealing surfaces
must be greased lightly using lubricating grease to DIN
51825.

Page 13
The dust protection cap (13) is fitted with a vulcanized steel
ring that is used to press it through the locating hole. For
exchanging, "lever out" the ring using a suitable tool. The
new dust protection cap must be pressed in with the aid of
a suitable mounting ring and screw clamps or a lever
press.
8. Mount the brake in accordance with the above procedure
into vehicle / at the axle.
NOTE: For exchange purpose, only use Knott original
spare and spare parts sets. These must be
ordered through the vehicle manufacturer.
6. General
Any discovered defects or damage to parts not listed here must
naturally be repaired or replaced using original parts.
For any other information not contained in these instructions or
for more detailed instructions, please contact the vehicle or
brake manufacturer.

Page 14
SP000123
BRAKE PEDAL VALVESP000123
Brake Pedal
Valve
Edition 1
Brake Pedal Valve SP000123

Page 1
MEMO
SP000123 Brake Pedal Valve

Page 2
Table of Contents
Brake Pedal Valve

Theory of Operation ........................................................ 6
Specification .................................................................... 8

Page 3
MEMO

Page 4
SAFETY PRECAUTIONS
CAUTION!
order.
handling load.
responsibility.
APPLICABLE MODELS

DL400 5001 and Up

Page 5
GENERAL DESCRIPTION
Theory of Operation
The brake pedal valve is attached to, and operated by, the brake
pedal. See Figure 1. The valve contains two spools. See Figure
2. One spool ports fluid to the brake pistons in the front axle, and
the other spool ports fluid to the brake pistons in the rear axle.
Maximum system operating pressure is 80 3 bars (1,160 44
psi). If something in one of the circuits should fail, the other
circuit will continue to operate.
AJS0720L
Figure 1

Page 6
When the brake pedal is depressed, force is applied to the
working element (6, Figure 2). This force is transferred to the
primary control spool (1) and the secondary control spool (2) by
the main control spring (5). This causes the control spool lands
to close the path from the supply ports (P1 and P2) to the tank
ports (T1 and T2). Simultaneously, the spool then open a path
from the brake circuit ports (Br1 and Br2) to the supply ports (P1
and P2). Drilled passages in the control spools (1 and 2) allow
fluid pressure in the ports P1 and P2 to act against the main
control spring (5). This allows the brake pressure in both circuits
to rise proportionally to the force applied to the brake pedal.
As the force applied to the brake pedal becomes constant, the
control spools (1 and 2) move into a balanced position and hold
the braking pressure constant.
When force is removed from the brake pedal, this removes force
from the control spring. The return springs (3 and 4) now move
the control spools (1 and 2) to the upward. The spools open a
path from the brake circuit ports (Br1 and Br2) to the tank ports
(T1 and T2) and this releases the pressure from the brake
circuits.
4
1 5
P2 T2 P1 T1
3
6
BR BR BL
BL
2 BR2 BR1
P2 T2 P1 T1
AJS0740L
Figure 2
Reference Reference
Number Number
1 Primary Control Spool 4 Upper Spring
2 Secondary Control Spool 5 Main Control Spring
3 Lower Spring 6 Working Element

Page 7
Specification
Item Specification
Braking Pressure 80 3 kg/cm2
Pedal Force 21 2 kg
Operating Angle 18 2

Page 8
SP000124
ACCUMULATOR SP000124
Accumulator
Edition 1
Accumulator SP000124
Page 1
MEMO
SP000124 Accumulator
Page 2
Table of Contents
Accumulator
Specifications .................................................................. 8
Page 3
MEMO
Page 4
SAFETY PRECAUTIONS
CAUTION!
order.
handling load.
responsibility.
APPLICABLE MODELS

DL400 5001 and Up
Page 5
GENERAL DESCRIPTION
FG004518
Figure 1
Reference Reference
Number Number
1 Brake Accumulator - 3ea 2 Pilot Accumulator
Page 6
The accumulator is a gas charged storage device designed to
hold a reserve quantity of hydraulic fluid under pressure.
Accumulators are used in hydraulic circuits in much the same
way that condensers (or capacitors) are used to collect, store
and maintain electrical charge in a circuit.
In a hydraulic circuit, minor variations or lags in pump output that
might otherwise cause unsteady or irregular operation are made
up from the supply of pressurized oil in the accumulator.
Reference
Description
Number
1 Shell
2 Diaphragm
3 Poppet
4 Fluid Port
Figure 2
Accumulators are solidly constructed to resist the high operating
pressures of the fluids they contain. There are only three main
moving parts: a valve assembly at the top allows adding or
expelling gas from the compressible, precharged upper
chamber; a valve assembly at the bottom of the accumulator for
passing hydraulic fluid in and out, and an elastic diaphragm to
separate the two chambers. The flexible diaphragm changes
shape to conform to the changing pressures and volumes of the
two fluids in the upper and lower chambers.
There are six possible positions the diaphragm can be in and
they are as follows: Pressure Fluid Nitrogen
1. With no gas charge in the upper chamber 0 bar (0 psi,

empty) and no oil in the bottom 0 bar (0 psi, dry) the elastic
diaphragm hangs loosely.
2. When the prepressure charge of gas (usually nitrogen) is
introduced through the valve at the top of the accumulator,
the diaphragm expands to maximum size. The valve button 1 2 3
in the center of the diaphragm pushes into the fluid
opening in the bottom chamber, sealing off the lower valve.
If the pressure of the gas charge exceeds system oil
pressure, no fluid enters the accumulator. The button also
keeps the diaphragm from protruding into the lower valve
opening.
NOTE: Precharge pressure is referred to as the "P1"
pressure. The accumulator manufacturer's "P1" 4 5 6
ARS1800L
rated pressure should be stamped or marked on
the accumulator's rating plate. Annual checks of Figure 3
actual precharge pressure should be made by
tapping a hydraulic pressure gauge (and 3-way
adapter coupling) into the valve on the bottom of
the accumulator. When hydraulic fluid is pushed
out the lower valve opening by the pressure of
the gas charge on the other side of the
diaphragm - and there is no counter pressure
from system oil - the valve button on the bottom
of the diaphragm eventually seals off the lower
oil passage. Just after the needle on the gauge
Page 7
reaches its highest point (when there is 0 bar (0
psi) resistance from hydraulic system pressure)
pressure on the gauge will drop sharply to zero,
as the accumulator is completely emptied of oil
and the diaphragm button closes.
Record the highest gauge reading and compare to the "P1"
rated precharge pressure on the accumulator
manufacturer's data label. Repeat this test at least once a
year to verify proper functioning of the accumulator.
3. As hydraulic system pressure overcomes accumulator
precharge pressure, the flexible diaphragm begins to
retract upward.
4. When system oil is at highest working pressure and the
accumulator fills to maximum reserve capacity, the flexible
diaphragm is pushed up into the top of the upper chamber.
The highest working pressure is sometimes referred to as
the "P3" pressure and can also be referenced on the
manufacturer's data label on the exterior of the
accumulator.
5. If system oil pressure begins to fall off or is momentarily
checked or interrupted, the energy stored on the other side
of the diaphragm, in the form of compressed gas, pushes
oil back out of the lower chamber, maintaining oil pressure
of the circuit.
6. With minimal system pressure, an equilibrium point may be
reached in which accumulator precharge pressure and
hydraulic system oil pressure achieve a rough balance. In
this condition a minimal amount of oil is stored in the
accumulator.
Specifications
System Charge Pressure Volume
30 kg/cm2 750 cc
Brake
(430 psi) (45.77 in3)
15 kg/cm2 320 cc
Pilot
(210 psi) (19.53 in3)
Page 8
1Steering
SP000125
STEERING UNIT SP000125
Steering Unit
Edition 1
Steering Unit SP000125

Page 1
MEMO
SP000125 Steering Unit

Page 2
Table of Contents
Steering Unit
Power Steering System ................................................... 6
Power Steering Unit.................................................... 8
Specifications .................................................................. 8
Parts List ......................................................................... 9
Function......................................................................... 10
Neutral Operation ..................................................... 10
Right Turn ................................................................. 10
Left Turn ................................................................... 10
Gerotor Operation ......................................................... 11

Page 3
MEMO

Page 4
SAFETY PRECAUTIONS
CAUTION!
order.
handling load.
responsibility.
APPLICABLE MODELS

DL400 5001 and Up

Page 5
GENERAL DESCRIPTION
Power Steering System
9 8 7
FG004090
Figure 1
Reference Reference
Number Number
1 Supply Line to Control Valve 6 Cushion Valve
2 Steering Pump 7 Jerk Softener
3 Flow Amplifier 8 Main LS Block
4 Steering Unit 9 Transmission
5 Steering Cylinder

Page 6
1
EF 3 T
P 7
14
L
HT
R
20 20 4
R
P
CR
240
14
240
T
CL L
LS
LS
185
STEER CYL.
5
15B 15B
6
< <
CUSHION VALVE
FG004091
Figure 2 HYDRAULIC CIRCUIT
Reference Reference
Number Number
1 Supply Line to Control Valve 5 Steering Cylinder
2 Steering Pump 6 Cushion Valve
3 Flow Amplifier 7 Jerk Softener
4 Steering Unit

Page 7
Power Steering Unit.
The machine contains a fully hydraulic steering unit. Rotating the
steering wheel controls hydraulic flow through the steering valve.
The steering valve meters the volume of pump flow that is
supplied to the steering cylinders
The steering unit contains a gerotor. This allows the operator to
steer the machine when the engine is not running or when the
steering pump has failed. The gerotor functions as a manual
hydraulic pump that is powered by the rotation of the steering
wheel. Rotating the steering wheel will cause the gerotor to draw
oil from the hydraulic tank and send this oil to the steering
cylinders.
The shaft that is rotated by the steering wheel is attached to the
spool (2, Figure 3) by the engagement of a spline. The spool is
surrounded by a sleeve (2). The spool and sleeve are connected
by the centering spring (12). At the steering wheel neutral
position, the center pin does not contact the spool. A drive shaft
(11) extends through the spool. The upper end of the drive shaft
engages the center pin (9). The lower end of the drive shaft
engages the spline in the gerotor (5).
Specifications
General
Type Open Load Sensing Non Reaction
Rated Displacement 200 cc/rev
(12.2 in3/rev)
Max. Pressure ON P - Port 185 bar (2,683 psi)
Max. Pressure ON T - Port 15 bar (218 psi)
Max. Pressure ON L, R - Port 240 bar (3,481 psi)
Rated Oil Flow 20 l/min (5.3 U.S. gpm)
(@steering speed 100 rev/min)
Operating Condition
Max. Pump Discharge Flow 220 l/min (58 U.S. gpm)
Max. Pump Pressure 185 bar (2,683 psi)
Hydraulic Oil ISO VG 46 WR or SIMILAR
Hydraulic Oil Temperature -20 - +90 C
Atmospheric Temperature -30 - +45 C

Page 8
Parts List
Figure 3
Reference Reference
Number Number
1 Dust Seal Ring 13 O-ring
2 Housing Spool and Sleeve not 14 Distributor Plate
Sold Separately 15 Gearwheel Set
3 Ball 8.5 mm 17 End Cover
4 Thread Bushing 18 Washer
5 O-ring / Roto Clyd 20 Screw with Pin
7 Bearing Assembly 21 Screw
8 Ring 22 Name Plate
9 Cross Pin 32 Check Valve
11 Cardan Shaft 33 Screw
12 Set of Springs 34 Ball 3.0 mm

Page 9
Function
Neutral Operation
With the steering wheel in the neutral position (wheels turned
neither right nor left), the spool (2, Figure 4) and sleeve (1) are
stationary at the position where the center pin (6) becomes
centered in the spool space by the centering springs (3). Oil flow
through the load sensing line (LS), port L, port R, and port T are
bypassed to the tank line and the oil supply (P) is blocked by the
directional spool in the steering unit (1, Figure 1). Even if an
external force is applied to the steering cylinder, the steering unit
is protected because the oil path is blocked by the directional
spool.
Reference
Description
Number
1 Sleeve
2 Spool
3 Centering Spring
4 Spool
5 Sleeve
6 Center Pin
7 Drive shaft
Figure 4
Right Turn
The spool (2, Figure 4) is engaged with the spline of the steering
shaft. When the steering wheel is turned to the right, the spool
turns. The sleeve (1) is connected to the spool (2) by centering
springs (3). When spool turns, the sleeve turns. The sleeve
turning angle is about 10 less than the spool turning angle. This
allows the longitudinal slots in the spool to align with the ports in
the sleeve. Oil from port P on the steering unit (1, Figure 1)
travels through the control spool and is directed to port R which
directs the oil to the steering cylinders (3, Figure 1). The amount
of flow metered to port R is controlled by the amount of steering
wheel rotation. Excess oil flow through port P that is not metered
to port R, is directed by the spool to port T and is then directed
through the il cooler and into the tank.
Left Turn
The spool (2, Figure 4) is engaged with the spline of the steering
shaft. When the steering wheel is connected to the spool (2) by
centering springs (3). When the spool turns, the sleeve turns.
The sleeve turning angle is about 10 less than the spool turning
angle. This allows the longitudinal slots in the spool to align with
the ports in the sleeve. When the steering wheel is turned to the
left, oil from port P on the steering unit (1, Figure 1) is directed
through the control spool in the steering unit, out port L and into
the steering cylinders (3, Figure 1). The amount of oil flow

Page 10
metered to port L is controlled by the amount of steering wheel
rotation. Excess oil flow through port P that is not metered to
port L, is directed by the spool to port T and is then directed
through the oil cooler and into the tank.
Gerotor Operation
If the engine or pump is not operating, the steering unit (1,
Figure 1) works as a manual pump when the steering wheel is
turned. The gerotor will work when the input torque to the
steering wheel is less than 12 kgm (87 ft lb). If the necessary
input torque is greater than this, the gerotor will not function.
When the steering wheel is turned, the gerotor creates a
vacuum that draws oil from port T. See Figure 1. The gerotor
pumps this oil through the control spool and into the steering
cylinders. Return oil flows back to the spool and is used to
lubricate the steering unit (1, Figure 1). The return oil then flows
back into the tank line and is recirculated back to the gerotor and
the steering cylinders.

Page 11
Page 12
SP000126
FLOW AMPLIFIER SP000126
Flow Amplifier
Edition 1
Flow Amplifier SP000126

Page 1
MEMO
SP000126 Flow Amplifier

Page 2
Table of Contents
Flow Amplifier
Parts List ......................................................................... 6
Specifications .................................................................. 7
Special Tools and Materials.................................. 8
Special tools .................................................................... 8
Troubleshooting, Testing and Adjustment ............. 9
Steering System with OSQA/B and OSPBX-LS.............. 9
Disassembly ....................................................... 11
Cleaning and Inspection (Wear Limits and
Tolerances) ......................................................... 31
Cleaning ........................................................................ 31
Inspection and Replacement......................................... 31
Lubrication..................................................................... 31
Reassembly ........................................................ 31

Page 3
MEMO

Page 4
SAFETY PRECAUTIONS
CAUTION!
order.
handling load.
responsibility.
APPLICABLE MODELS

DL400 5001 and Up

Page 5
GENERAL DESCRIPTION
Flow amplifier contains a directional valve, an amplification
stage, a priority valve, a pilot pressure relief valve and shock and
suction valve.
Parts List
Figure 1

Page 6
Reference Reference
Number Number
1 O-ring 21 Shock and Suction Valve
2 O-ring 22 Stopper
3 O-ring 23 Stopper
4 O-ring 24 Spring Guide
5 Washer 25 Drive Screw
6 Washer 26 Name Plate
7 O-ring 27 Orifice
8 O-ring 28 Spring
9 Housing, Amplifier Spool, Priority 29 Spring
Valve Spool and Directional 30 Spring
Valve Spool not Sold Separately.
31 Throttle Check Valve
10 Check Valve
32 Orifice
11 Screw
34 Orifice
12 Spring Washer
35 Orifice
13 Screw
36 Orifice
14 Spring Washer
37 Orifice
15 End Cover
38 Plug
16 End Cover
39 Count. Pres. Valve
17 Relief Valve
40 Spring
20 Plug
41 Spring
Specifications
General
Amplification Factor 8
Rated Oil Flow 240 l/min
Max. Pressure in Steering Circuit (CF, LS) 210 bar (3,046 psi)
Max. Pressure in Working Circuit (HP, EF, 280 bar (4,061 psi)
CL, CR)
Max. Pressure in Tank Circuit (HT, T) 15 bar (218 psi)
Priority Valve Control Spring Pressure 10.5 bar (152 psi)
LS Relief Valve Setting 185 5 bar (2,683 72 psi
Shock Valves Setting 240 10 bar (3,480 145 psi
Operating Condition
Max. Pump Discharge Flow 220 l/min
Max. Pump Pressure 195 bar (2,828 psi)
Vibration 3 - 5 G/ 30 Hz
Shock 10 G

Page 7
SPECIAL TOOLS AND
MATERIALS
Special tools
Guide screws Material: M8 x 1
Hook Material: Wire
Figure 2

Page 8
TROUBLESHOOTING, TESTING
AND ADJUSTMENT
Figure 3 Flow Amplifier Circuit
Steering System with OSQA/B and

OSPBX-LS
Problem Possible Causes Remedies
Amplification too large Dirty, leaky or missing check valve (1). Clean or replace check valve.
Piston (2) sticks in the open position. Clean and check that the piston
moves easily.
Amplification too small Piston (2) sticks in the closed position. Clean and check that the piston
moves easily.
Piston (2) incorrectly installed (only Rotate the piston 180 on its
OSQA/B-5). axle.
Heavy turning of Dirty orifices (3) in directional valve. Clean or replace orifice.
steering wheel and Dirty orifices (4) in the combination valve Clean or replace orifice.
slow increase of spool.
amplification
Dirty orifices (5) in housing. Clean or replace orifice.
Dirty orifices (6) in LS-port. Clean or replace orifice.
Dirty orifices in throttle/check valve (7) in Clean or replace throttle/check
PP-port. valve.

Page 9
Problem Possible Causes Remedies
No end stop in one or One or both shock valves (8) set too low. Setting takes a long time without
both directions. special equipment. Contact the
nearest service shop.
One or both anticavitation valves (9) Clean or replace completely
leaky, or sticks. shock/anticavitation valve(s).
Missing end stop plate(s) pos. 10 for Fit end stop plates.
directional valve.
"Hard" point when Air in LS and/or PP pipes. Bleed pipes.
starting to turn the Spring force in the built in priority valve Replace spring with one which is
steering wheel too weak (11). more powerful. (There are three
sizes: 4, 7 and 10 bar).
Orifices in respectively LS-(6) or PP-(7) Take out and clean orifices.
ports blocked.
No pressure buildup LS-pressure limitation valve (12) Remove plug and set to specified
adjusted too low. pressure.
Spool and sleeve in OSPBX steering Take out spool set and turn the
unit put together incorrectly. inner spool 180 in the outer
sleeve. (See service manual)
Emergency control ball in steering unit Install new ball.
missing.
Pump does not run or is defective. Repair or replace pump.

Page 10
DISASSEMBLY
1. Dismantling counter pressure valve.
A. Unscrew plug with O-ring. (Hex socket for 8 mm
socket head bolt.)
Figure 4
B. Remove small spring (hook).
Figure 5
C. Remove ball (magnetic rod).
Figure 6

Page 11
D. Remove piston.
Figure 7
E. Remove spring.
Figure 8
F. Counter pressure valve shown dismantled.
Figure 9

Page 12
G. Counter pressure valve with orifice shown
dismantled.
Figure 10
2. Removing pressure relief valve.

A. Unscrew plug with washer (hex socket for 8 mm
socket head bolt).
Figure 11
B. Screw pressure relief valve out (10 mm L-wrench).
Figure 12
C. Remove washer (magnetic rod).
Figure 13

Page 13
3. Dismantling pressure relief valve.
A. Hold cartridge and screw adjustment screw out
(5 mm L-wrench).
Figure 14
B. Pressure relief valve shown dismantled.
Figure 15
4. Removing end cover at PP-connection.

A. Unscrew screws with spring washer hex socket for
13 mm socket and 10 mm socket head bolt.
Figure 16

Page 14
B. Remove end cover.
Figure 17
C. Remove stop and 2 springs.
Figure 18
D. Remove spring.
Figure 19

Page 15
E. Remove plate and six O-rings.
Figure 20
F. Remove spring guide.
Figure 21
5. Removing end cover at LS-connection.

A. Unscrew screws with spring washer using hex socket
for 13 mm socket and 10 mm socket head bolt.
Figure 22

Page 16
B. Remove end cover.
Figure 23
C. Remove stop and two springs.
Figure 24
D. Remove stop and spring.
Figure 25

Page 17
E. Remove plate and four O-ring.
Figure 26
F. Remove spring guide.
Figure 27
6. Removing spools.
A. Remove directional spool.
Figure 28

Page 18
B. Remove amplifier spool.
Figure 29
C. Remove priority valve spool.
Figure 30
7. Removing orifice and throttle check valve.

A. Unscrew orifice in LS-connection with 6 mm L-
wrench.
Figure 31

Page 19
B. Unscrew throttle check valve in PP-connection with
6 mm L-wrench.
Figure 32
C. Unscrew orifice in housing with 4 mm L-wrench.
Figure 33
8. Removing shock valves.

A. Remove shock valve with screwdriver and L-wrench.
Figure 34

Page 20
9. Overview of dismantled parts.
A. Housing and end cover with accessories.
Figure 35
B. Spool with accessories.
Figure 36
10. Dismantling of directional spool.

A. Unscrew orifice with 4 mm L-wrench. Use a mandrel.
Figure 37

Page 21
B. Directional spool shown dismantled.
Figure 38
11. Dismantling of priority valve spool.

A. Unscrew plug or throttle check valve with 8 mm L-
wrench.
Figure 39
B. Priority valve spool with plug for external PP shown

dismantled.
Figure 40

Page 22
C. Priority valve spool with throttle check valve for
internal PP shown dismantled.
Figure 41
12. Dismantling of amplifier spool.

A. Carefully remove spring from recess with 3 mm
screwdriver.
NOTE: Avoid damage to spring ring.
Figure 42
B. Carefully guide spring ring back.
Figure 43

Page 23
C. Carefully take spring ring from recess and guide it
back with 3 mm screwdriver.
NOTE: Avoid damage to spring ring.
Figure 44
D. Press pin out gently with finger.
Figure 45
E. Remove plug.
Figure 46

Page 24
F. Remove spring.
Figure 47
G. Remove pin with 3 mm screwdriver.
Figure 48
H. Remove inner spool.
Figure 49

Page 25
I. Unscrew check valve with hex socket for 17 mm
socket and mandrel in pin hole.
Figure 50
J. Unscrew orifice out of plug with 4 mm L-wrench. Use

a mandrel.
Figure 51
K. Amplifier spool shown dismantled.
Figure 52

Page 26
13. Dismantling of check valve.
A. Unscrew plug with 4 mm L-wrench and hex socket for
17 mm socket.
Figure 53
B. Check valve shown dismantled.
Figure 54
14. Dismantling of shock valve / suction valve.

A. Unscrew lock nut with hex socket for 13 mm socket.
Use a mandrel.
NOTE: When readjusting shock valve hold lock
nut with 13 mm ring spanner.
Figure 55

Page 27
B. Remove disk and spring.
Figure 56
C. Remove housing.
Figure 57
D. Unscrew pilot valve with hex socket for 19 mm socket.

Use a mandrel.
Figure 58

Page 28
E. Remove pilot valve and spring.
Figure 59
F. Remove spool.
Figure 60
G. Unscrew adjustment screw and remove spring and

ball.
Figure 61

Page 29
H. Shock valve/suction valve shown dismantled.
Figure 62

Page 30
CLEANING AND INSPECTION
(WEAR LIMITS AND
TOLERANCES)
For general cleaning and inspection procedures, refer to
"General Maintenance Procedures" section.
Cleaning
Clean all parts carefully with low aromatic kerosine.
Inspection and Replacement

Replace all gaskets and sealing washers. Check al other parts
carefully and replace if necessary.
Lubrication
Before assembly, lubricate all parts with hydraulic oil.
REASSEMBLY
1. Assemble shock valve/suction valve.
A. Guide spring with cone into housing.
Figure 63

Page 31
B. Install adjustment screw.
Figure 64
C. Install spool.
Figure 65
D. Install spring.
Figure 66

Page 32
E. Install pilot valve. Remember O-ring.
Figure 67
F. Tighten with torque wrench for 19 mm socket. Use a

mandrel.
NOTE: Tightening torque: 2 0.5 daNm.
(175 45 in lb).
Figure 68
G. Install housing.
Figure 69

Page 33
H. Install spring.
Figure 70
I. Fir disk.
Figure 71
J. Install lock nut. Tighten torque 1.5 0.2 daNm.

(135 20 in lb).
Figure 72

Page 34
2. Assemble check valve.
A. Install ball, spring and plug.
NOTE: Tightening torque: 0.5 1 daNm.
(45 90 in lb).
Figure 73
3. Assembly of amplifier spool.

A. Install orifice in plug.
NOTE: Tightening torque: 0.5 1 daNm.
(45 90 in lb).
Figure 74
B. Install check valve.

(175 25 in lb).
NOTE: Avoid damaging spool surface. Remember
O-ring.
Figure 75

Page 35
C. Place inner spool in correct position.
NOTE: When assembling OSQA 5 and OSQB 5
there are two ways of installing inner
spool. Only one is correct. The pilot
channel which is faced upwards must be
lined up with one of five amplification holes
in the outer spool.
Figure 76
D. Guide inner spool in.
Figure 77
E. Install pin.
Figure 78

Page 36
F. Push spring ring into position. Place spring ring into
recess with ends facing away from pin plate.
Figure 79
G. Install spring.
Figure 80
H. Install plug.
Figure 81

Page 37
I. Install pin.
Figure 82
J. Push spring ring into position. pLace spring ring into

recess with ends facing away from pin holes.
Figure 83
4. Assembly of priority valve spool.

A. Install plug or throttle check valve.
B. External pp: plug.
C. External pp: throttle check valve.
(90 25 in lb).
Figure 84

Page 38
5. Assembly of directional spool.
A. Screw in orifice.
NOTE: Tightening torque: 0.5 0.1 daNm.
(45 10 in lb).
Figure 85
6. Installation of orifice and throttle check valve.

A. Install orifice in housing.
NOTE: Tightening torque: 0.5 0.1 daNm
(45 10 in lb).
Figure 86
B. Install orifice in LS-connection.

C. Tighten torque: 1 0.3 daNm. (90 25 in lb).
Figure 87

Page 39
D. Install throttle check valve in PP-connection.
E. Tighten torque: 1 0.3 daNm. (90 25 in lb).
7. Comments on flow amplifiers with internal PP:
A. 1/4 BSP.F in PP-connection: Install washer and plug.
NOTE: Tightening torque 4 0.3 daNm
(355 25 in lb).
B. 7/116 - 20 UNF in PP-connection: Install O-ring and
plug.
NOTE: Tightening torque: 1.5 0.5 daNm
(135 45 in lb).
Figure 88
8. Installation of shock valves.

A. Guide shock valve in and secure it by hand.
Remember O-ring.
Figure 89
9. Assembly of pressure relief valve.

A. Guide adjustment screw, spring and cone up into
cartridge.
Figure 90

Page 40
B. Screw adjustment screw so far in that 10 mm L-
wrench fully engages.
Figure 91
10. Installation of pressure relief valve.

A. Let washer drop into hole.
Figure 92
B. Install pressure relief valve. Tighten torque: 3 0.3

daNm. (265 25 in lb).
Figure 93

Page 41
C. Install plug with washer. Tighten torque: 6 0.5
daNm. (530 45 in lb).
Figure 94
11. Installation of back pressure valve.

A. First Install spring in piston with Vaseline. Install
assembled piston and spring.
Figure 95
B. Let ball drop down.
Figure 96

Page 42
C. Install spring in plug with Vaseline. Install assembled
plug and spring. Remember O-ring.
NOTE: Tightening torque 2.5 0.03 daNm
(220 25 in lb).
Figure 97
12. Installation of spools.

A. Install directional spool. Install priority valve spool.
NOTE: Spring control must be placed in correct
position against LS-connection.
Figure 98
B. Install spring.
NOTE: Spring must be by LS-connection.
Figure 99

Page 43
C. Install amplifier spool.
NOTE: The orifice must be placed in correct
position against LS-connection.
Figure 100
13. Installation of end cover at PP-connection.

A. Install spring with Vaseline on amplifier spool.
NOTE: The spring must be installed at PP-
connection.
Figure 101
B. Install spring guide with Vaseline.
Figure 102

Page 44
C. Install large and small springs with Vaseline.
Figure 103
D. Install guide screws.
Figure 104
E. Install four large and two small O-rings.
Figure 105

Page 45
F. Guide plate in.
Figure 106
G. Install stop (thickness: 5 mm) in end cover with

Vaseline.
Figure 107
H. Guide end cover in.
Figure 108

Page 46
I. Install screw with spring washer.
Figure 109
J. Install screw with spring washer.

NOTE: Tightening torque: 2.5 0.5
daNm.(220 45 in lb).
Figure 110
14. Installation of end cover at LS-connection.

A. Install guide screws.
B. Install remote control valve with Vaseline.
Figure 111

Page 47
C. Install large and small springs with Vaseline.
Figure 112
D. Guide in plate with four O-rings.
Figure 113
E. Install stop priority valve spool.

F. (thickness: 8 mm) with Vaseline.
Figure 114

Page 48
G. Install stop for directional spool (thickness: 5 mm)
with Vaseline.
Figure 115
H. Guide in end cover.
Figure 116
I. Install large screw with spring washer.
Figure 117

Page 49
J. Install screws with spring washers.
NOTE: Tightening torque: 2.5 0.5 daNm.
(220 45 in lb).
NOTE: Tightening torque for large screw: 8 1
daNm (710 90 in lb).
Figure 118
K. Install plastic plugs.
Figure 119

Page 50
SP000127
CUSHION VALVE SP000127
Cushion Valve
Edition 1
Cushion Valve SP000127

Page 1
MEMO
SP000127 Cushion Valve

Page 2
Table of Contents
Cushion Valve
Cushion Valve....................................................... 6
Cushion Valve Operation................................................. 6
Function...................................................................... 6
Working Principle ....................................................... 6
Specifications .................................................................. 6
Parts List ......................................................................... 7
Jerk Softener (Dual Cross Relief Valve) ............... 8
Specifications .................................................................. 8
Parts List ......................................................................... 8

Page 3
MEMO

Page 4
SAFETY PRECAUTIONS
CAUTION!
order.
handling load.
responsibility.
APPLICABLE MODELS

DL400 5001 and Up

Page 5
CUSHION VALVE
Cushion Valve Operation
Function
The cushion valve absorbs any excessive peak pressure that
maybe generated during initial movement of the steering wheel
or during a change in steering direction. The cushion valve also
prevents excessive high-pressure and shock that can result from
steering load inertia.
Working Principle
If a high-pressure oil is fed back to port R, it pushes spring (3)
and opens poppet (2). This operation directs the high-pressure
oil to port L through the center hole in spool (12) and the check
valve poppet in port L part. At the same time, oil reaches the
pressure room of the plug through orifice (8). This operation
closes the passage from port R to port L. This releases the
pressure and prevents machine shock by intercepting oil. If a
low-pressure oil flows, the cushion operation is not necessary. It
is due to the speed of closing spool (12) is faster than the speed
of opening poppet (2), therefore, the cushion valve does not
work.
Specifications
General
Max. Pressure 210 bar (3,046 psi)
Main Relief Pressure 15 bar (218 psi)
Environments
Vibration 3 - 5G/ 30 Hz
Shock 10G

Page 6
Parts List
Figure 1
Reference Reference
Number Number
1 Body 10 Spring
2 Seat Valve 11 Back up Ring
3 Poppet 12 O-ring
4 Spring 13 O-ring
5 Plug 14 O-ring
6 Spring 15 Plug
7 Spool 16 Plug
8 Plug 17 Orifice
9 Poppet

Page 7
JERK SOFTENER (DUAL CROSS
RELIEF VALVE)
Specifications
Rated Flow 30 lpm
Setting Pressure 20 bar (290 psi)
Parts List
Reference
Description
Number
1 Relief Cartridge
2 Valve Body
2 FG004094
Figure 2

Page 8
SP000128
EMERGENCY STEERINGSP000128
Emergency
Steering
Edition 1
Emergency Steering SP000128

Page 1
MEMO
SP000128 Emergency Steering

Page 2
Table of Contents
Emergency Steering
Emergency Steering Function Test ................................. 8
Emergency Steering Automatic Test ............................... 8
Pump and DC Motor........................................... 10

Page 3
MEMO

Page 4
SAFETY PRECAUTIONS
CAUTION!
order.
handling load.
responsibility.
APPLICABLE MODELS

DL400 5001 and Up

Page 5
GENERAL DESCRIPTION
This system is designed for applications requiring a secondary
steering when the primary source becomes nonfunctional and
includes electrically driven hydraulic pump controlled by the
emergency steering relay.
From Oil Tank
3
4
2
FG004095
Figure 1
Reference Reference
Number Number
1 Pump and DC Motor 3 Flow Amplifier
2 Steering Pump 4 Check Valve
If travel speed exceeds 5 km/h and the pressure at the check

valve (4) is under 3 bar (44 psi), emergency steering starts. This
is run for 60 seconds by the timer.

Page 6
X
100ccr
L
to STEER CYL.
28ccr
X
Travel speed > 5KPH L 100ccr

P=2.0B
EST-37A EMERG.STEER
EMERG.STEER 0.5" K
CHECK V/V
EMERG.STEER TEST PRESS. S/W
PRESS. S/W <3Bar
CHECK V/V
EMG.
STEERING
BATTERY 10Bar
TIMER
62 Bar
EMG STEERING RELAY
M 16ccr
24v DC MOTOR PUMP

for EMERG. STEER
FG004096
Figure 2 ELECTRIC CIRCUIT

Page 7
Emergency Steering Function Test
Emergency steering system function test is performed on a
stationary machine with engine off. The starter switch must be in
position I (ON). When test switch in the cabin is pressed, turn
steering wheel at the same time. If system is functioning
properly the machine should steer.
O
AJO0011L
Figure 3 TEST SWITCH
The secondary steering indicator light should turn "ON."

Emergency steering indicator light (option) indicates that
emergency steering pump starts (1).
30 15
20 20
10
40
10 25
5
50 30
0 0
km/h x100r/min
CHECK
STOP
F/R
1
FG004535
Figure 4
Emergency Steering Automatic Test

This is a system that check a pressure on the emergency
steering line. It starter switch turn to I (ON) position, a
emergency light on the front gauge panel light up about 3
seconds.

Page 8
Do not press test switch continuously. Continuously pressing
switch will cause heavy battery discharge. The emergency
steering DC-motor uses high consumption of power as Figure 5.
< Performance of Pump and Motor >

28.00 800
700
24.00
600
20.00
500
16.00
AMPS
GPM
400
12.00
300
8.00
200
4.00 100
0.00 0
0 500 1000 1500 2000 2500 3000 3500
PSI
Flow, 16 cc Amps, 16 cc
FG004097
Figure 5

Page 9
PUMP AND DC MOTOR
Figure 6
Reference Reference
Number Number
1 Retaining Ring 7 DC Motor
2 Shaft Seal 8 Start Sw Kit
3 Backup Ring 9 Gasket
4 Seal 10 Lock Washer
5 O-ring 11 Mounting Screw
6 Valve Assembly 12 Pump Assembly

Page 10
1Frame
SP000129
ARTICULATION CENTERSP000129
Articulation
Center
Edition 1
Articulation Center SP000129

Page 1
MEMO
SP000129 Articulation Center

Page 2
Table of Contents
Articulation Center
Maintenance Standard .................................................... 7

Page 3
MEMO

Page 4
SAFETY PRECAUTIONS
CAUTION!
order.
handling load.
responsibility.
APPLICABLE MODELS

DL400 5001 and Up

Page 5
GENERAL DESCRIPTION
The loader frame is an articulated type: the front frame is joined
to the rear frame with two hinge pins around which the loader
pivots for steering.
CAUTION!
When the loader is steered, the area near the center hinge
pins becomes so narrow that you might get caught between
the front and rear frames. Before trying to service the
loader, make sure to set the frame lock plate.
Before moving (traveling) the loader, make sure the frame
lock plate is set to the original position.
Figure 1

Page 6
Maintenance Standard
AJS0710L
Figure 2

Page 7
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between upper size clearance limit
1
hinge pin and rear frame -0.030 +0.071 0.066 -
80 -
-0.076 +0.036 0.147
Clearance between upper
-0.030 +0.060 0.060 -
2 hinge pin and spacer 80 -
-0.076 +0.030 0.136
(small)
Clearance between upper -0.030 0 0.015 -
3 80 -
hinge pin and bearing -0.076 -0.015 0.076
Clearance between upper
-0.030 +0.060 0.060 -
4 hinge pin and spacer 80 -
-0.076 +0.030 0.136
(large)
Clearance between rear -0.036 +0.071 0.072 -
5 95 -
frame and spacer (large) -0.090 +0.036 0.161
Replace
Clearance between front
0 -0.048 -0.023 -
6 frame and upper hinge 130 -
-0.025 -0.088 -0.088
bearing
Clearance between lower -0.030 +0.054 0.030 -
7 80 -
hinge pin and rear frame -0.076 0 0.130
Clearance between lower -0.030 0 0.015 -
8 80 -
hinge pin and bearing -0.076 -0.015 0.076
Clearance between front
0 -0.048 -0.023 -
9 frame and lower hinge 130 -
-0.025 -0.088 -0.088
bearing
Height of upper hinge
11 33.5 0.1 - - 0 0
spacer (small)
Height of upper hinge
12 730.1 - - 0 0
spacer (large)
Shim thickness for upper
13 hinge and retainer 0.5 - 1.04 - - - -
(front frame)
Shim thickness for upper
2.24 -
14 hinge and retainer - - - -
3.55
(rear frame)
Tightening torque of upper When adjusting with shim: 80.2 kgm
15 hinge retainer mounting
bolt Final value: 13 1.0 kgm
Tightening torque of upper When adjusting with shim: 80.2 kgm
16 hinge retainer mounting
bolt Final value: 30 1.0 kgm Retighten
Tightening torque of upper
17 13 1.0 kgm
hinge pin mounting bolt
Tightening torque of lower
18 13 1.0 kgm
hinge pin mounting bolt

Page 8
Page 9
Page 10
SP000130
COUNTERWEIGHT SP000130
Counterweight
Edition 1
Counterweight SP000130
Page 1
MEMO
SP000130 Counterweight
Page 2
Table of Contents
Counterweight
Specifications ....................................................... 6
Counterweight....................................................... 6
Page 3
MEMO
Page 4
SAFETY PRECAUTIONS
CAUTION!
order.
handling load.
responsibility.
APPLICABLE MODELS

DL400 5001 and Up
Page 5
SPECIFICATIONS
NOTE: Weight.
Model Weight Serial Number Range

DL400 1,450 kg (3,417 lb) S/N 5001 and Up
COUNTERWEIGHT
AJS0620L
Figure 1
NOTE: 1) Tighten bolts to the torque value list in the
following table.
DL400 250 kgm (1,800 ft lb)
Page 6
1Tank
SP000131
OIL TANK SP000131
Oil Tank
Edition 1
Oil Tank SP000131

Page 1
MEMO
SP000131 Oil Tank

Page 2
Table of Contents
Oil Tank
Parts List ......................................................................... 6
Specifications .................................................................. 7
Oil Tank SP000131

Page 3
MEMO
SP000131 Oil Tank

Page 4
SAFETY PRECAUTIONS
CAUTION!
order.
handling load.
responsibility.
APPLICABLE MODELS

DL400 5001 and Up
SP000131 Oil Tank

Page 5
GENERAL DESCRIPTION
Parts List
1
6
2
7
8
3
9
4
10
11
5
12
13
14
16
15
FG004100
Figure 1
Oil Tank SP000131

Page 6
Reference Reference
Number Number
1 Cover 9 Spring
2 Spring 10 Rod
3 Bypass Valve 11 Suction Filter
4 Bypass Strainer 12 Level Gauge
5 Return Filter 13 Oil Tank
6 Air Breather 14 Drain Valve
7 Cover 15 Main Suction Pipe
8 Cover 16 Steer Suction Pipe
Specifications
Oil Tank
Type Pressurized Sealing
Capacity (System) 220 liters (58 U.S. gal.)
Air Breather
Open Pressure 0.40 kg/cm2 (5.7 psi)
Vacuum pressure 0.035 kg/cm2 (0.5 psi) at 900 liters/min. (238 U.S. gal./min.)
Return Filter
Filtration Rating 10
Pressure Drop 0.25 kg/cm2 (3 psi) at 680 liters (159 U.S. gal.), 20 cSt
Filtration Efficiency Over 99.5%
Suction Filter
Bypass Valve
Cracking Pressure 1.5 kg/cm2 (21 psi) at 40 liters (10.5 U.S. gal.), 20 cSt
Pressure Drop 2.0 kg/cm2 (28 psi) at 40 liters (10.5 U.S. gal.), 20 cSt
SP000131 Oil Tank

Page 7
Oil Tank SP000131
Page 8
SP000132
FUEL TANK SP000132
Fuel Tank
Edition 1
Fuel Tank SP000132

Page 1
MEMO
SP000132 Fuel Tank

Page 2
Table of Contents
Fuel Tank
Parts List ......................................................................... 6
Specifications .................................................................. 7
Fuel Sender Setting.................................................... 7
Fuel Tank SP000132

Page 3
MEMO
SP000132 Fuel Tank

Page 4
SAFETY PRECAUTIONS
CAUTION!
order.
handling load.
responsibility.
APPLICABLE MODELS

DL400 5001 and Up
SP000132 Fuel Tank

Page 5
GENERAL DESCRIPTION
Parts List
2
5
3
6
4
1
10
13 12 11
FG004101
Figure 1
Reference Reference
Number Number
1 Fuel Tank 8 Hose; Engine Oil Drain
2 Fuel Pipe 9 O-ring
3 Packing 10 Cover
4 Suction Filter 11 Sender Cover
5 Fuel Cap 12 Fuel Sender
6 Fuel Strainer 13 Step
7 Drain Valve
Fuel Tank SP000132

Page 6
Specifications
Fuel Tank
Capacity (System) 374 liters (98.8 U.S. gal.)
Suction Filter
Ambient Temperature Range -40 - +80C
Fuel Strainer
Ambient Temperature Range -40 - +80C
Fuel Sender Setting
POINTER Position Unit E 1/4 H 3/4 F

Float Height mm 97 180 246 332 371
Available Fuel Volume liter 23.5 69.5 141 208.5 357
Ratio (/Total Volume) % 6.5 19.5 39.5 58.5 100
Figure 2
SP000132 Fuel Tank

Page 7
Fuel Tank SP000132
Page 8
1Hydraulics
SP000144
MAIN CONTROL VALVESP000144
Main Control
Valve
Edition 1
Main Control Valve SP000144

Page 1
MEMO
SP000144 Main Control Valve

Page 2
Table of Contents
Main Control Valve

Parts List............................................................... 6
Specifications ..................................................... 11
Hydraulic Circuit Diagram Detailing Basic Function
13
Spool Function.................................................... 14
Neutral Position (Held Cylinder) .................................... 14
Bucket Dump ................................................................. 16
Bucket Crowd ................................................................ 17
Boom Up ....................................................................... 18
Boom Up (I) ................................................................... 19
Boom Up (II) .................................................................. 20
Boom Up (III) ................................................................. 21
Boom Down (Low Pilot Pressure - Below 18 bar) ......... 22
Boom Down I (Low Pilot Pressure - Below 18 bar) ....... 23
Boom Down II (Low Pilot Pressure - Below 18 bar) ...... 24
Boom Down III (Low Pilot Pressure - Below 18 bar) ..... 25
Boom Down IV (Low Pilot Pressure - Below 18 bar) ..... 26
Boom Down (High Pilot Pressure - Above 25 bar) ........ 27
Boom Down I (High Pilot Pressure - Above 25 bar) ...... 28
Boom Down II (High Pilot Pressure - Above 25 bar) ..... 29
Boom Down III (High Pilot Pressure - Above 25 bar) .... 30
Bucket Crowd and Boom Down..................................... 31
Priority Function ............................................................ 32
Load Sensing Line (LD Line) ......................................... 33
Load Signal Drain Valve (LD Valve)............................... 34
Load Sensing Line (LS Line) ......................................... 34
Make Up and Relief Valve ............................................. 35
Counter Pressure Valve................................................. 36

Page 3
MEMO

Page 4
SAFETY PRECAUTIONS
CAUTION!
order.
handling load.
responsibility.
APPLICABLE MODELS

DL400 5001 and Up

Page 5
GENERAL DESCRIPTION
The main control valve controls the operation of the bucket,
boom, and option cylinders. The control valve is a closed center
side valve equipped with pilot controlled load holding valve.
The valve is made-up of a section with built-in lifting/lowering
and tilt function spools.
The load holding valve pilot spools for each function are located
in the control valve end plates.
The lifting/lowering function and the tilt function are coupled
serially, which implies that these functions can be operated
simultaneously.
PARTS LIST
Figure 1

Page 6
Reference Reference
Number Number
1, 2 Plug 22 Plug
3 Distance Ring 23, 24 Supply Check Valve
(2, 4, 7, 1) Shock Valve 25, 26 Plug
9, 10 Check Valve 27, 28 Counter Pressure Valve
13 - 17 LS Check Valve 29, 30, 31 Cover
19 Sealing Ring 32, 33, 34 Cover
20 Plug 35 Lifting Eye
21 Sealing Ring

Page 7
Figure 2
Reference Reference
Number Number
4, 5, 6, 7 Servo Spool, Supply Check 8 Screw
2, 11 Seal Kit, Intersection 9 Sealing Ring
6, 9 Seal Kit, Block A 10 Plug

Page 8
Figure 3
Reference Reference
Number Number
1 Screw 7 Plug
2, 3, 4, 5 Load Signal Drainage Valve 8 Sealing Ring
6, 9 Seal Kit Intersection 10, 11 Supply Check Valve

Page 9
Figure 4
Reference Reference
Number Number
1 Orifice 0.6 (Brown) 6, 10, 15, 24 Seal Kit
3, 24, 32 Seal Kit Intersection 22, 23, 24 Cover
Servo Spool, Supply Check 3, 24, 32 Seal Kit Intersection
4, 5, 6, 7
Valve 28 Screw
8, 9, 10, 11, 33, 34, 35,
LS Check Valve Spring Package
12, 13 36, 37

Page 10
SPECIFICATIONS
Figure 5
Reference Reference
Number Number
1 Lifting Eye 9 Service Port A (Section 2)
2 Service Port A (Section 1) Load Holding poppet,
10
Pressure Relief Valve in service Service Port B (Section 2)
3
port A (Section 1) 11 Service Port B (Section 2)
4 Pilot Spool Gauge Port,
12
5 Spool Section 1 Service Port B (Section 2)
6 Pilot Pressure Connections 13 Tank Connection
7 Pump Connection 14 Counterpressure Valve
8 Spool Section 2

Page 11
Pressure
Pump Connection Max. working Pressure 275 bar (3,989 psi)
Pump Connection Max. Peak Pressure 300 bar (4,351 psi)
Service Port Max. 400 bar (5,802 psi)
Tank Connection, Static Max. 50 bar (725 psi)
Flow Rate
Pump Connection 900 l/min (238 U.S gpm)
Return from Service Port 1,000 l/min (264 U.S gpm)
Max. Flow Rate to Service Port 450 l/min (120 U.S gpm) *
Leakage from Service Port to Tank
From A or B port: Max. 20 cm3/min at 100 bar (1,450 psi),
Oil Temperature 50 C (122 F) and viscosity 30 mm2/s (cSt).
Oil Temperature -20 - +90 C (-4 - +194 F)

Page 12
HYDRAULIC CIRCUIT DIAGRAM
DETAILING BASIC FUNCTION
Figure 6
Reference Reference
Number Number
1 Counterpressure Valve Service ports in section 1
2 Spool in Section 1 is of type D. protected against overload and
9 Cavitation by combined port
3 Spool in Section 2 is of type F.
relief and anticavitation valve
Spool in Section 1 controlled by type PA.
4
spool actuator type PC.
Service port B in section 2
6 Prioritizing Function 10 protected against cavitation by
All service ports equipped with anticavitation valve type N.
7
load holding poppet. Service port A in section 2
Pilot spool for control of load 11 protected against overload by
8
holding poppet. port relief valve type PAY.
Load signal system drained via
12 load signal drainage poppet type
LD.

Page 13
SPOOL FUNCTION
Neutral Position (Held Cylinder)
Figure 7

Page 14
Figure 8

Page 15
Bucket Dump
Figure 9

Page 16
Bucket Crowd
Figure 10

Page 17
Boom Up
Figure 11

Page 18
Boom Up (I)
Figure 12

Page 19
Boom Up (II)
Figure 13

Page 20
Boom Up (III)
Figure 14

Page 21
Boom Down (Low Pilot Pressure - Below
18 bar)
Figure 15

Page 22
Boom Down I (Low Pilot Pressure - Below
18 bar)
Figure 16

Page 23
Boom Down II (Low Pilot Pressure - Below
18 bar)
Figure 17

Page 24
Boom Down III (Low Pilot Pressure - Below
18 bar)
Figure 18

Page 25
Boom Down IV (Low Pilot Pressure -
Below 18 bar)
Figure 19

Page 26
Boom Down (High Pilot Pressure - Above
25 bar)
Figure 20

Page 27
Boom Down I (High Pilot Pressure - Above
25 bar)
Figure 21

Page 28
Boom Down II (High Pilot Pressure - Above
25 bar)
Figure 22

Page 29
Boom Down III (High Pilot Pressure -
Above 25 bar)
Figure 23

Page 30
Bucket Crowd and Boom Down
Figure 24

Page 31
Priority Function
Figure 25

Page 32
Load Sensing Line (LD Line)
Figure 26

Page 33
Load Signal Drain Valve (LD Valve)
Figure 27
This valve makes oil flow in LS line maintain and drain LS line oil
to tank when machine goes to neutral condition.
Load Sensing Line (LS Line)
Figure 28

Page 34
Make Up and Relief Valve
Figure 29

Page 35
Counter Pressure Valve
Figure 30

Page 36
SP000149
LOAD ISOLATION SYSTEMSP000149
Load Isolation
System
Edition 1
Load Isolation System SP000149

Page 1
MEMO
SP000149 Load Isolation System

Page 2
Table of Contents
Load Isolation System

Over View ........................................................................ 7
Hydraulic Circuit .............................................................. 8
Function........................................................................... 9
Accumulator Charging Method ........................................ 9
LIS Valve-RSM2 ............................................................ 11
Specification ............................................................. 11
Characteristic Curve...................................................... 11
Parts List ....................................................................... 12
Accumulator .................................................................. 13
Specification ............................................................. 13
Parts List .................................................................. 13

Page 3
MEMO

Page 4
SAFETY PRECAUTIONS
CAUTION!
order.
handling load.
responsibility.
APPLICABLE MODELS

DL400 5001 and Up

Page 5
GENERAL DESCRIPTION
Load Isolation System (LIS) reduces pitching movements that
effect the vehicle and driver.
For this the lifting line is connected to the hydraulic accumulator
via a switching valve that absorbs the loads caused by the
pitching movement.
The following advantages apply when Load Isolation System is
fitted:
Higher transport speeds
Higher handling rates
Stable steering characteristics
Shorter braking distances
Higher comfort for the driver
Lower mechanical loading of the entire machine
Fewer repairs or down times with identical handling
rates

Page 6
Over View
1
7
FG004175
Figure 1

Page 7
Hydraulic Circuit
Figure 2
Reference Reference
Number Number
1 LIS Valve (RSM2) 5 Emergency Drain Screw
2 Valve spool 6 Accumulator
3 3/2-way Directional Valve, 7 Lift Cylinder
Solenoid Operated 8 Control Valve
4 Pressure Relief Valve (EC
Design Tested)

Page 8
Function
If the hydraulic cylinder (7) has pressure applied to the piston
side, then the pressure is also applied to the check valve in the
valve spool (2) and the accumulator (6).
Dependent on B120 > from 120 bar (1,740 psi) the connection
from the lifting cylinder (7) to the accumulator (6) via the valve
spool (2) is interrupted (switched position 2).
A pressure reducing function for the accumulator (6) is
integrated in switched position 3 of the valve spool (2).
The pressure reducing function lies approx. 30 bar (435 psi) over
the pressure relief valve.
The damping valve can be automatically activated via the travel
speed.
The 3/2-way directional valve (3) is switched into switched
position 2.
The valve spool (2) moves into the 4th switched position and
opens the connection from the piston side of the hydraulic
cylinder (7) to the accumulator (6) and the rod side of the
hydraulic cylinder (7) to tank.
The pressure relief valve (4) prevents the pressure from
impermissibly exceeding the pressure in the accumulator.
(setting < permissible accumulator pressure).
Accumulator Charging Method

Before charging accumulator, bucket has to be on the ground.
Rotate screw (5) of LIS valve (1) 3.5 turn in counterclockwise
direction and accumulator will be unloaded Via the emergency
drain screw (5) (shown in the circuit as a mechanically operated
2/2-way directional valve).
After residual pressure is removed, tighten drain screw again.
Remove gas valve guard and gas valve cap of accumulator.
Back gas chuck "T" handle of charging kit all the way out
(counterclockwise) before attaching charging assembly to
accumulator gas valve.
Close bleed valve.
Attach swivel nut to gas valve and tighten (10-15 in lb) (11.5-17
cm kg).
Crack open nitrogen bottle valve and slowly fill accumulator.
Shut off when gauge indicates desired precharge 20 bar (290
psi).
Let the precharge set for 10 to 15 minutes. This will allow the gas
temperature to stabilize. If the desired precharge 20 bar (290
psi) is exceeded, close nitrogen bottle valve, then slowly open
bleed valve. Do not reduce precharge by depressing valve core
with a foreign object. High-pressure may rupture rubber valve
seat.

Page 9
When finished precharging accumulator, turn "T" handle all the
way out on gas chuck, then open bleed valve.
Hold gas valve to keep from turning, loosen swivel nut, remove
assembly. Check for precharge leak using a common leak
reactant.
Replace gas valve cap (10-15 in lb) (11.5-17 cm kg) and valve
guard.
Figure 3
CAUTION!
The safety technical requirements of the vehicle have to be
taken into account!
Before carrying out any maintenance work the
accumulators must be unloaded. (zero pressure).

Page 10
LIS Valve-RSM2
Specification
General
Installation Optional
Ambient Temperature Range - 20 - + 80 C
15 kg
Weight
(33 lb)
Hydraulic
Ports A, B 420 bar (6,092 psi)
Max. Operating Pressure Port X2 350 bar (5,076 psi)
Port T 30 bar (435 psi)
Max. Nominal Flow Ports A, X2 150 l/min
Pressure Fluid Mineral Oil (HL, HLP) to DIN 51 524
Viscosity range 10 - 380 mm2/s
Degree of Contamination
ISO 4406 (C) class 20/18/15
(Max. Permissible)
Electrical
Control Voltage 12, 24 V
Power Consumption (Solenoid) 14.4 W
Characteristic Curve
(measured with HLP 68, Oil = 40 5C)
Figure 4

Page 11
Parts List
Figure 5
Reference Reference
Number Number
10 Housing 140 Compression Spring
20 Piston 160 Plug
40 Socket 170 Plug
70 Spring Disk 190 Plug
80 Valve Seat 230 Cheese Head Screw
90 Valve Seat 260 FTWE
100 Throttle Pin 270 DBDS
110 Grub Screw 330 Plug
130 Compression Spring

Page 12
Accumulator
Specification
General
Ambient Temperature
- 53 - + 204 C
Range
28.70 kg
Weight
(63 lb)
Hydraulic
Operating Pressure 275 bar (3,989 psi)
Max. Nominal Flow 380 l/min
Capacity (Oil) 3.79 liters
Parts List
Figure 6
Reference Reference
Number Number
01 Accumulator Body 08 Gas Valve Body
02 Hydraulic Cap 8A Gas Valve O-ring
03 Gas Cap 09 Protective Strap
04 Piston 9A Protective Screw
05 V O-ring 10 Name Plate
5A Backup Washer 13 Port Protector
07 End Seal O-ring 15 Mounting Bracket Assembly
7A Backup Washer

Page 13
Page 14
SP000154
COOLING SYSTEM SP000154
Cooling
System
Edition 1
Cooling System SP000154

Page 1
MEMO
SP000154 Cooling System

Page 2
Table of Contents
Cooling System
General ................................................................. 7
Cooling System .................................................... 8
Circuit .............................................................................. 9
Specifications ................................................................ 10
Cooling Fan / Brake Pump ....................................... 11
Checking Hydraulic Function......................................... 12
Maximum Fan Speed, Checking .............................. 12
Fan Motor ........................................................... 13
Cooling Fan: Bidirectional motor with speed control ..... 14
Cooling Fan Maximum Speed ....................................... 14
Proportional Pressure Relief Cartridge ......................... 15
Function.................................................................... 15
Proportional Inverse Pressure Relief Valve ................... 15
Screw In Cartridge ................................................... 15
Efficiency .................................................................. 16
Parts List ....................................................................... 17
Solenoid Operated Spool Valve..................................... 18
Check Valve................................................................... 18
Cooling Fan: Bidirectional Motor ................................... 18

Page 3
MEMO

Page 4
SAFETY PRECAUTIONS
CAUTION!
order.
handling load.
responsibility.
APPLICABLE MODELS

DL400 5001 and Up

Page 5
Page 6
GENERAL
The cooling system is to minimize energy consumption and
noise by speed control of fan motor. The cooling is accomplished
by continuously monitoring the temperature of the cooling water
of engine and oil of the transmission and fitting the required fan
speed.
1 2 11
3, 4
10
5
7 6
9
8
FG004196
Figure 1
Reference Reference
Number Number
1 Radiator Assembly 7 Bypass Valve
2 Fan Guard 8 Block Valve
3 Fan Motor (Rear Side) 9 Transmission Oil Filter
4 Cooling Fan (Rear Side) 10 Oil Tank
5 Engine 11 Radiator Cap
6 Transmission

Page 7
COOLING SYSTEM
By the motor integrated proportional pressure relief valve, the
fan speed (and therewith the cooling performance) can be
infinitely controlled in dependence on two different
simultaneously input signals from temperature sensors.
The electronic control unit ECU processes the input signals and
controls the valve coil current. The proportional relief valve has a
fail safe characteristic, this means, max. relief valve setting is
adjusted automatically at interrupted voltage supply (e.g. broken
wire). This results in a max. fan speed and therefore in a max.
cooling performance.
Figure 2
Reference Reference
Number Number
1 Engine 6 Cooling Fan
2 Brake and Pilot Pump 7 Temperature Sensor
3 Cooler 8 Temperature Sensor
4 Electronic Unit (ECU) 9 Transmission
5 Fan Motor

Page 8
Circuit
Figure 3
This system have advantages as following:

1. lower fuel consumption
2. lower sound level
3. Faster warming of the transmission
4. Faster warming of the oil in the hydraulic oil tank

Page 9
Specifications
Cooling Fan Pump / Brake Pump
Type Gear Pump
Displacement 28 cc/rev
(1.71 in3/rev)
Flow 56 l/min
(15 U.S. gpm)
Thermostat
No. 1 ea.
Begins Temperature to Open 82 C
Fully Opened Temperature 92 C
Cooling Fan
Size 36"
No. Of Blade 8 ea.
Bypass valve
Rated Flow 105 l/min
(28 U.S. gpm)
Cracking Pressure 3 0.6 kg/cm2
(42.7 8.5 psi)
Pressure Difference 3 kg/cm2 at 1 l/min
(42.7 psi at 0.26 U.S. gpm.)
4.5 kg/cm2 at 105 l/min
(64 psi at 28 U.S. gal.)

Page 10
Cooling Fan / Brake Pump
Figure 4
Reference Reference
Number Number
1 Gear 5 Shaft Seal
2 Bearing 6 Plain Bearing
3 Extruded Aluminium Body 7 Thrust Pressure Seal
4 Cover 8 Gear Pairs

Page 11
Checking Hydraulic Function
4
2
5
1
FG004236
Figure 5
Reference Reference
Number Number
1 Fan Motor 4 Drain Line
2 Fan Guard 5 Outlet Line
3 Inlet Line
Maximum Fan Speed, Checking

1. Open the radiator grille in order to connect the pressure
gauge
2. Connect the pressure gauge to the pressure port (6) on the
inlet hose (3)
Check the maximum pressure by pressing in towards the
end position of accelerator pedal and reading the pressure
in the gauge.
Maximum fan motor pressure: 140 2 kg/cm2 (1,990 28.4

psi) (The fan speed is approximately 1200 rpm at this time)
3. If fan speed requires adjusting, shut down engine and
adjust a proportional relief valve of the fan motor or the
program of control unit.
WARNING
A modifying program of the control unit is permitted by an
authorized person.

Page 12
FAN MOTOR
The cooling fan is driven by a proportional and bidirectional fan
motor.
3 2 1
T
3/4"
27ccr
4
P
1/2"
L
7/16" FG004241
Figure 6
Reference Reference
Number Number
1 Motor 3 Prop. Pressure Relief Cartridge
2 Solenoid Operated Spool Valve 4 Check Valve

Page 13
Cooling Fan: Bidirectional motor with
speed control
Figure 7
Reference Reference
Description Qty. Description Qty.
Number Number
1 Front Bearing 1 9 Idler Gear 1
2 Seal 2 10 Valve Cover 1
3 Bearing Block 2 11 Bolt 4
4 O-ring 2 12 Prop. Relief Valve 1
5 Dowel Pin 4 Cartridge
6 Gear Housing 1 13 Solenoid Operated 1
Spool Valve
7 Coupling 1
14 Check Valve Cartridge 1
8 Drive Gear 1
Cooling Fan Maximum Speed

Max. speed 1200 rpm
Noise reduction kit 840 rpm
Max. speed when faulty signals 1200 rpm or above
Max. reverse speed 1200 rpm or above

Page 14
Proportional Pressure Relief Cartridge
Function
The principal function of the pilot operated PRV is controls the
motor speed from idle to max. speed by infinitely adjusting the
applied solenoid current. Further, the PRV protects the motor
from over pressurization. Due to the fail safe function, maximum
PRV pressure is automatically set when solenoid de-energized
(motor runs at max. speed = max. cooling power). Increasing
solenoid current results in decreasing induced spring force,
thereby reducing valve opening pressure (motor speed
decreases). The nominal pressure is factory set, not adjustable.
Because of the pilot operation, the minimal adjustable pressure
drop across the valve is slightly higher than for direct operated
RV at the same flow.
NOTE: In the case of bidirectional motor with pressurized
outlet port, the back pressure is added to the nominal
PRV setting (due to the internal PRV drain).
Proportional Inverse Pressure Relief Valve
Screw In Cartridge
Pilot operated
Nominal pressure adjustable + 20% / - 30%
Qmax = 100 l/min
Pmax = 400 bar (5,802 psi)
PN max = 200 bar (2,901 psi)
General Specifications
Description Pilot operated proportional inverse pressure relief valve

Construction Screw in cartridge, cavity to ISO 7789
Operation Proportional solenoid with slip-on coil
Mounting Screw in thread M22x1.5
Ambient temperature -30 - +90C
Fastening torque MD = 40 Nm for screw in cartridge
MD max = 5 Nm for coil retaining nut
Weight m = 0.45 kg (0.99 lb)

Page 15
Hydraulic Specifications
Fluid Mineral oil, Other fluid on request

Contamination ISO 4406: 1999, class 18/16/13
Viscosity range 10 mm2/s - 320 mm2/s
Fluid temperature -25 - +90C
Peak pressure Pmax = 400 bar (5,802 psi)
Tank pressure in port T Pmax = 50 bar (725 psi)
Nominal pressure ranges PN = 160 bar (2,321 psi)
Recommended volume flow Q = 5 -100 l/min with PN = 100 / 160 bar (1,450 / 2,321 psi)
Q =10 -100 l/min with PN = 200 bar (2,901 psi)
Electrical Control
Construction Solenoid, Wet pin, Push type, Pressure tight with

exchangeable slip-on coil
Standard nominal voltage U = 24 VDC
Limiting current IG = 680 mA
Protection class IP 65 to EN 60 529
(only with tested connector)
Efficiency
Figure 8

Page 16
Parts List
Figure 9
Reference Reference
Number Number
10 Coil KJ35/16 - G24 40 O-ring Viton ID 18.77x1.78
20 Retaining Nut M16x1x9.2 50 O-ring Viton ID 15.60x1.78
25 Hex Nut M8x1 60 Backup Ring RD 14.6x17.5x1.4
30 O-ring Viton ID 14.00x1.78

Page 17
Solenoid Operated Spool Valve
This can be used for cleaning the guard grille at the fan inlet
side. The 2-way SV controls the direction of the flow through the
motor and thereby the motor rotation. The maximum motor
speed and protection against over pressurization in both
directions is provided by a double acting RV. The AC check valve
prevents cavitation and erosion during motor speed deceleration
and spin down.
Check Valve
The AC check valve prevents cavitation and erosion during
motor speed deceleration and spin down.
Cooling Fan: Bidirectional Motor

In case of this fan, the cooling system have only a bidirectional
rotation without a speed control. The pump of pilot and fan motor
provides the required oil flow for the hydrostatic fan drive system
as shown on the following schematic. The oil flow drives the
hydraulic motor and the fan impeller mounted on the motor shaft.
Figure 10

Page 18
3 2 1
T
3/4"
4
27ccr
5
28ccr
P
X 1/2"
L 100 ccr L
7/16"
FG004252
Figure 11
Reference Reference
Number Number
1 Motor 4 Check Valve
2 Solenoid Operated Spool Valve 5 Pilot and Brake Pump
3 Pressure Relief Cartridge

Page 19
Figure 12
Reference Reference
Description Qty. Description Qty.
Number Number
1 Front Bearing 1 9 Idler Gear 1
2 Seal 2 10 Valve Cover 1
3 Bearing Block 2 11 Bolt 4
4 O-ring 2 12 Relief Valve Cartridge 1
5 Dowel Pin 4 13 Solenoid Operated 1
6 Gear Housing 1 Spool Valve
7 Coupling 1 14 Check Valve Cartridge 1
8 Drive Gear 1

Page 20
SP000159
PILOT SYSTEM SP000159
Pilot System
Edition 1
Pilot System SP000159

Page 1
MEMO
SP000159 Pilot System

Page 2
Table of Contents
Pilot System
Overview............................................................... 6
Function................................................................ 7
Block Diagram ...................................................... 8
Fingertip 3 Lever + 3 Spool Control Valve ....................... 8
Fingertip 2 Lever + 2 Spool Control Valve ....................... 8
FNR Lever + 3 Spool Control Valve................................. 9
FNR Lever + 2 Spool Control Valve................................. 9
Fingertip Joystick................................................ 10
Specification .................................................................. 10
Parts List ....................................................................... 11
Walvoil FNR Joystick .......................................... 12
Specification .................................................................. 12
Parts List ....................................................................... 13

Page 3
MEMO

Page 4
SAFETY PRECAUTIONS
CAUTION!
order.
handling load.
responsibility.
APPLICABLE MODELS

DL400 5001 and Up

Page 5
OVERVIEW
FG004255
Figure 1
Reference Reference
Number Number
1 Oil Tank 5 Main Control Valve
2 Pilot Control Valve 6 Aux. Control Valve
3 Brake and Pilot Supply Valve 7 Pilot Accumulator
4 Pilot Plate 8 Brake and Pilot Filter

Page 6
FUNCTION
The pilot system uses low-pressure oil to operate the main
control valves. The main components of the pilot system are
pump, pressure reducing valve, accumulator, pilot cutoff valve
and pilot valves.
With the engine running, oil flows from hydraulic tank to pilot
pump. The oil flows from the pump through pressure reducing
valve to pilot cutoff valve. The pressure reducing valve maintains
pilot system pressure at 30 kg/cm2 (435 psi).
From the pilot cutoff valve the oil flows into the pilot control
valves. Pilot valve is a closed center valve.
The oil cannot flow through the valve when it is in the HOLD
position because it is a closed center valve.
When the control lever is moved to the DUMP position, oil flows
through oil lines to the ends of the bucket spool of main control
valve. This causes the main control valve spool to move.
Movement of the spool opens passages for attachment pressure
oil to flow to the rod end of the bucket cylinder.
Spool movement also opens a passage for return oil from the
head end of the bucket cylinder to flow back to hydraulic tank.
Attachment pressure oil acts on the rod end of the bucket
cylinder and, because the head end of the cylinder is now
vented to tank, the bucket will dump.
When the control lever is moved to the CROWD position, oil
flows through oil lines to the ends of the bucket spool of main
control valve. This causes the main control valve spool to move
in the opposite direction.
Movement of the spool in this direction opens passages for
pressure oil to flow to the head end of the tilt cylinder. Spool
movement also opens a passage for return oil from the rod end
of the tilt cylinder to flow back to the hydraulic tank. Attachment
pressure oil acts on head end of the tilt cylinder and because the
rod end of the cylinder is now vented to tank, the bucket will
crowd.

Page 7
BLOCK DIAGRAM
Fingertip 3 Lever + 3 Spool Control Valve
Figure 2
Fingertip 2 Lever + 2 Spool Control Valve
Figure 3

Page 8
FNR Lever + 3 Spool Control Valve
Figure 4
FNR Lever + 2 Spool Control Valve
Figure 5

Page 9
FINGERTIP JOYSTICK
Specification
Supply Pressure Max. 100 bar (1,450 psi)
Control Pressure Max. 75 bar (1,090 psi)
Breakaway Pressure 1 bar - 16 bar (14.5 - 232 psi)
Return Line Pressure Max. 3 bar (44 psi)
Control Flow Max. 15 l/min (4 U.S. gpm)
Hysteresis Max. 0.5 bar (7.3 psi)
Ambient Temperature -40 - +60 C
Leakage Max. 20 cm3/min
(From pump connection to tank with the spool in neutral position and a supply pressure of 40 bar
(580 psi))
System Voltage 24V
Reference
Description
Number
P Brake and Pilot Supply
Valve ('PL' port)
T Tank Return
A1 Bucket Dump
A2 Boom Down
A3 Aux. (A port)
B1 Bucket Crowd
B2 Boom Up
B3 Aux. (B port)
Figure 6

Page 10
Parts List
Figure 7

Page 11
WALVOIL FNR JOYSTICK
Specification
Hydraulic Fluid ISO VG #46 or SIMILAR
Ambient Temperature -29 - +93 C
Vibration 3 -5G/ 30Hz
Shock 10G
Supply Pressure 28 bar (1,450 psi)
Supply Flow 42 lpm
Contamination NAS 9 Grade after Flushing
Reference
Description
Number
P Brake and Pilot Supply
Valve (PL port)
T Tank Return
1 Boom Up
2 Bucket Crowd
3 Boom Down
4 Bucket Dump
5 Option
6 Option
Figure 8

Page 12
Parts List
Figure 9

Page 13
Page 14
SP000168
HYDRAULIC SCHEMATIC (DL400)SP000168
1Hydraulic
Schematic
(DL400)
Edition 1
Hydraulic Schematic (DL400) SP000168

Page 1
MEMO
SP000168 Hydraulic Schematic (DL400)

Page 2
Table of Contents
Hydraulic Schematic
(DL400)
DL400 ................................................................... 8

Page 3
MEMO

Page 4
SAFETY PRECAUTIONS
CAUTION!
order.
handling load.
responsibility.
APPLICABLE MODELS

DL400 5001 and Up

Page 5
Page 6
GENERAL DESCRIPTION
Schematic(s) presented in this section are laid out on facing
pages.
An overlapping edge has been taken into consideration so that a
photocopy can be made and pasted together to make a
complete schematic.
1. PUMP
2. PILOT FILTER
C/V PA 3. SOLENOID VALVE (CUT OFF)
4. ACCUMULATOR
SH
Dr Pi Pi N Am Am N Pi Pi Dr OPTION APPLIED PART 5. SOLENOID VALVE (PACKAGE)
6. JOYSTICK VALVE(L)
ONE-WAY ; JOYSTICK BOTTON 24 25 26 7. JOYSTICK VALVE(R)
B FORWARD
A FORWARD
Au
Dr
PG 8. PEDAL VALVE
ONE-WAY ; JOYSTICK BOTTON or PEDAL 24 25 29 30 26 9. SHUTTLE VALVE
S 10. CONTROL VALVE
q2 min.
q2 min.
ONE/TWO-WAY 24 25 26 27 28 29 30 26
T 11. BOOM CYLINDER
BACKWARD B
BACKWARD A
q1
q1
max.
max.
ROTATING ; JOYSTICK SWITCH 31 32 33 34 D 12. ARM CYLINDER
GB GA 13. BUCKET CYLINDER
1 2 Pi Dr 4 3
14 ROTATING ; PEDAL 31 32 34 35 14. SWING DEVICE
Dr Bm Bm Dr 15. TRAVEL DEVICE
B RIGHT Mu LEFT A
15 TRAVEL MOTOR (L) 16 TRAVEL MOTOR (R) 15 QUICK COUPLER 36 16. CENTER JOINT
17. RESTRICTION VALVE
19. OIL COOLER
20. FULL FLOW FILTER
21. AIR BREATHER
22. HYDRAULIC TANK
a A B
DR2 DR3 DR4 Valve;control
23. LOCK VALVE
V2 T E 24. PROPORTIONAL VALVE
34
DR1
23
25. HIGH PRESS. RETURN FILTER
11 11 10 12
Pi1 of Pump C2 P 26. ONE/TWO-WAY SELECT V/V 1
Pi2 of Pump from #32
ps2
T2 T1 T3
ps1 27. ONE/TWO-WAY SELECT V/V 2
O 28. STOP VALVE
Pi1 E
P 29. OPT. PEDAL VALVE 1
T 30. SHUTTLE VALVE for OPT.
C2 C2 pc1 T 31. PTO
E E 36
32. ADDITIONAL GEAR PUMP
A5 b
33. SOL. V/V for ROTATING
34. ROTATING VALVE
Pi1 Pi1 pb9 ARM2 ARM1 B5
2 2 4 2
35. OPT. PEDAL VALVE 2
T T P 36. QUICK CLAMP VALVE
V2 V2 pb5
pa9 39. SOL. VLAVE E3C
1 1 3 1
23 23
pc2
pa5
A8 T
pc3
8
B8
B4 T P
35 T P T P
29
13 pb8 BOOM1 BOOM2 pb4
pa4 L.H
pa8 B3
B7
A3
A7
BKT SWING OPT. PEDAL 1
L.TRAVEL R.TRAVEL
OPT. PEDAL 1
pb3
27 2 1 2 1 4 3 2 1
pb7 CW CCW FORWARD FORWARD
pa7
pa3 28 BACKWARD BACKWARD
pi4 A pb6 pa6 pb1 pa1

Pi B2 B
B6 A2 T
OPT R.H
A6 pb2
TR(L) 26
P4
pb6 33
pa2
B1
pa6 P1
A1
TR(R) from JOYSTICK(L) SWITCH
pb1
25
pa1
VALVE(LEFT) VALVE(RIGHT) 6 7
pr PA PT T P T P
P2 P3 PH PP P1
PH of Sol. v/v 2 2
19k
SWING MOTOR SH 19k 1 3 1 3
4 4
SWING ARM BOOM BUCKET
1 3 2 4 2 4 1 3
19 LEFT DUMP DOWN CROWD
17 UP DUMP
RIGHT CROWD
24
A1 A2 A3 A4 A5 A6 A7 A8 30
18 9
A9 A10
ps1
B1 S1 B2 B3 B5 B6 B7 B8 B9 S2 B10
Pi1 Hammer Operating
B4
21 A1 A2 PH pc3 pa3 pb3 pb5 pb8 pa7 pa8 pb7 pb2
Psv a4
Safety Cut-off
Swing Priority
pa2
Pressure up
from PRESS. SWITCH ON #30
high speed
4 SOL. V/V P3 pa5
500k
a2 500k Travel 5
a1
20 (FRONT) SENSOR SENSOR (REAR) pc1 pc2 Pi
P2 HO TR2 PH SP
1
10u T
P1 ACC
22 G1 Opt. Pedal
P Hammer Select
177u Operating A B
Pi1 Pi2
ps1 ps2 A
T T
2 P1
P4 P5 P3
40k 3
ENGINE SHUTTLE VALVE S1
B1
a3
A3 from JOYSTICK(R) BOTTON

Dr1 B3 Dr3 P1 P1
Hammer Select
31
from JOYSTICK(R) SWITCH
32 to #34 P from SELECT SWITCH
Hammer Select Shear Select
Shear Select
1. PUMP
2. PILOT FILTER
4. ACCUMULATOR
SH
B FORWARD
A FORWARD
Au
Dr
PG 8. PEDAL VALVE
S 10. CONTROL VALVE
q2 min.
q2 min.
ONE/TWO-WAY 24 25 26 27 28 29 30 26
T 11. BOOM CYLINDER
BACKWARD B
BACKWARD A
q1
q1
max.
max.

1 2 Pi Dr 4 3
B RIGHT Mu LEFT A
19. OIL COOLER
21. AIR BREATHER
22. HYDRAULIC TANK
a A B
23. LOCK VALVE
34
DR1
23
11 11 10 12
ps2
T2 T1 T3
O 28. STOP VALVE
Pi1 E
C2 C2 pc1 T 31. PTO
E E 36
A5 b
34. ROTATING VALVE
2 2 4 2
V2 V2 pb5
1 1 3 1
23 23
pc2
pa5
A8 T
pc3
8
B8
B4 T P
35 T P T P
29
pa4 L.H
pa8 B3
B7
A3
A7
L.TRAVEL R.TRAVEL
OPT. PEDAL 1
pb3 27 2 1 2 1 4 3 2 1
pa7

Pi B2 B
B6 A2 T
OPT R.H
A6 pb2
TR(L) 26
P4
pb6 33
pa2
B1
pa6 P1
A1
pb1
25
pa1
pr PA PT T P T P
P2 P3 PH PP P1
PH of Sol. v/v 2 2
19k
4 4
1 3 2 4 2 4 1 3
17 UP DUMP
RIGHT CROWD
24
A1 A2 A3 A4 A5 A6 A7 A8 30
18 9
A9 A10
ps1
B1 S1 B2 B3 B5 B6 B7 B8 B9 S2 B10
Pi1
Hammer Operating
B4
Psv a4
Safety Cut-off
Swing Priority
pa2
Pressure up

high speed
4 SOL. V/V P3 pa5

500k 500k 5
Travel
a1 a2
P2 HO TR2 PH SP
1
10u T
P1 ACC
22 G1 Opt. Pedal
P Hammer Select
177u Operating A B
Pi1 Pi2
ps1 ps2 A
T T
2 P1
P4 P5 P3
40k 3
B1
a3

Dr1 B3 Dr3 P1 P1
Hammer Select
31
Shear Select
FG001424
Figure 1

Page 7
DL400
CLOSES 3B
STOP
3/8"
0.5 BAR L.H Brake valve BR1 BR2
OPENS 25B
FRONT AXLE T/M DISCONNECT
REAR AXLE
P1 T1 P2 T2
Cracking T/M
1.5 BAR R.H Brake pedal
LPWS E/G
30B 65bar 30B 30B 30B 15B
0.75L 0.75L 0.75L 0.75L 0.32L
* TUV only A1-1 Lpws A1 P1 P2 A2 A2 A3 TP1

3/8" 1/4" 3/8" 3/8" 3/8" 3/8" 3/8" 3/8" 1/4"
A4 C3 C3 pa
3/8" C4
C2 C3
TP2
Pilot Pilot 20 l/min
1/4" 3/8" at 30bar
1/2" 1/2" Fo 30B
1/2"
C1 C3
20 abs safety
Park
Fi
3/8"
1/2"
120bar
C6 1/4"
C5
T M 190bar Pkws
3/4" 1/2"
100LM
T1 3/8" T2 1/4"
27ccr
3/4" P
1/2"
BRAKE, PILOT & FAN MOTOR
1" SUPPLY VALVE
L
7/16"
3/4"
Relief pressure max at pump(1) 250 bar, Flow 190 l/min @ 1900 rpm
C1
280
C3
S P P1 P3
100cc < 1.1/4" 1.1/4"
T
Pressure cut-off : 250 bar 1/4"
EF EF T 1/2"
1/4"
X BLOCK VALVE 1.1/4" 1.1/4"
L P 1/2"
14
R2 2" R1 L 1/2"
2"
28cc C 1" HT
(Fan & Brake & pilot supply) R 1/2"
HT 1"
< < 1"

26 26 LX
S P MLSO
100cc
3/4"
1/4"
P
1/4" MLSI SLSO SLSI CL 1"
240
14
Pressure cut-off : 250 bar 240
PVFC T
CR 1" 3/4"
X LS
L JERK
SOFTENER
LS 1/4"
EST-37A
<10Bar
185
EMERG.STEER TEST
PRESS/ S/W
EMG.
GAUGE
PANEL STEERING
BATTERY
TIMER P=2.4B FLOW AMPLIFIER
EMG STEERING RELAY
STARTER <3Bar
ACC
SWITCH
C
62 Bar STEER CYL.
* EMERG.STEER
B
BR
M 16ccr * EMERG. STEER HP 1.1/4" PRESS/ S/W
R2
6B CHECK VALVE ( lock to lock )
Relief pressure max at pump(2) 250 bar @ Front relief, Flow 190 l/min @ 1900 rpm
Relief pressure max at pump(2) 210 bar @ Steering only relief
* ELECTRIC EMERGENCY STEERING (OPT.)
15B 15B
< <
CUSHION VALVE
Figure 2

Page 8
P
T
LS
* JOYSTICK VALVE
(3-SP. OPT.) PILOT
Kick-down Horn
BLCOK
CLOSE OPEN
DUMP CROWD AUTO RETURN RAISE LOWER
CLOSES 3B
STOP
3/8" TO DIG
R2 D.C D.R D.F
OPENS 25B
T/M DISCONNECT
REAR AXLE
P2 T2
T
T/M
P
4 3 2 1 6 5
E/G
30B 30B 15B
0.75L 0.75L 0.32L
2 A2 A2 A3 TP1
" 3/8" 3/8" 3/8" 1/4"
parking brake
C4
C3
Pilot Pilot 20 l/min
3/8" at 30bar
30B
safety
Park
3/8"
1/4"
C5
Pkws
/8" T2 1/4"
JOYSTICK VALVE Horn Kick-down
(2-SP. STD.)
BRAKE, PILOT & FAN MOTOR
SUPPLY VALVE
DUMP CROWD AUTO RETURN RAISE LOWER
TO DIG
D.C D.R D.F

ELEC.STEER VALVE (OPT.)
1900 rpm
T
P 2 4 3 1
A PSS (Bucket dump) PS (Boom down) ps
B P
P
T 5 bar
26 LX 280 bar 280 bar
B1 A1
A2
280 bar
R B2
3/4"
P
P A1
T
B1
T
P A2
A1 T
B2
T A2
PVFC T
3/4"
L B2
B1
LS
K LS
ENER
STEER VALVE (STD.) LS
A1 ps A2
PSL (Bucket crowd) B1 PL (Boom up) B2
6 liter
pre charge : 20 bar
X2 T
LSP 260B
T1
STEER CYL.
CONTROL V/V (2-SP, STD.) PL BUCKET CYL.
( lock to lock )
A B
* LIS (OPT.) BOOM CYL.
P1
15B
280 bar 280 bar
* 3rd SPOOL (OPT.)
< < A3 B3
CUSHION VALVE
DL400
FG004254

Page 9
Page 10
1Electrical System
SP000172
AIR CONDITIONER SP000172
Air Conditioner
Edition 1
Air Conditioner SP000172

Page 1
MEMO
SP000172 Air Conditioner

Page 2
Table of Contents
Air Conditioner
Refrigerant Circulation........................................ 10
Control Panel ...................................................... 12
Control Specifications......................................... 13
Temperature Level Control and Display.............. 14
Air Discharge According to Path Selection ......... 15
Air-conditioning System Circuit Diagram ............ 18
Troubleshooting .................................................. 20
Weight of R134a Gas Used In Machines............ 23
Refrigerant System Repairs ............................... 24
Refrigerant Safe Handling Procedures.......................... 24
Repair and Replacement Procedure ............................. 25
Refrigerant Recovery .................................................... 27
Vacuuming Refrigerant System ..................................... 27
Leakage Check ............................................................. 28
Refrigerant Charging ..................................................... 29
Inspecting System for Leakage ..................................... 31

Page 3
MEMO

Page 4
SAFETY PRECAUTIONS
CAUTION!
order.
handling load.
responsibility.
APPLICABLE MODELS

DL400 5001 and Up
DL300 5001 and Up

Page 5
Page 6
GENERAL DESCRIPTION
FG004488
Figure 1
The heater and air conditioner are combined into one blower unit
in the right control stand of operator's seat. If necessary, the
operator can control inner temperature using the operation panel
installed in the top of the right side door.

Page 7
The unit is equipped with an air filtration system which filters out
dirt and dust particles from air being circulated into the
operator's cab. This filter (1, Figure 2) should be cleaned out at
1
approximately every 500 hours and replaced with a new one
every 1,000 hours.
NOTE: In the event that the unit is being operated in a dusty
environment, cleaning and replacement should be
performed more frequently.
WARNING!
All service and inspection of the air-conditioning system
should be performed with the starter switch in the "O" AJS0530L
(OFF) position. Figure 2
NOTE: Refer to appropriate operation and maintenance

manual for latest service intervals.

Page 8
Page 9
REFRIGERANT CIRCULATION
4
7
3
HBOI020L
Figure 3
Reference Reference
Number Number
1 Evaporator 5 Compressor
2 Expansion Valve 6 Blower Fan
3 Condenser 7 Receiver Dryer
4 Condenser Fan

Page 10
Shading Temperature Refrigerant State
High High-pressure Gas
High High-pressure Liquid
Low Low-pressure Liquid
High High-pressure Gas/Liquid
Low Low-pressure Gas
Refrigerant (R134a) is compressed to approximately

15 kg/cm2 (213 psi) within the compressor.
The compressed refrigerant flows into the condenser
at high temperature (approximately 80C (176F)).
The refrigerant in the condenser is cooled to
approximately 60 by the condenser fan. At this time
the refrigerant changes from the gas to the liquid
state, even though the temperature has only been
reduced 20C (68F). (From 80 - 60C (176 -
140F)).
The refrigerant in its liquid form is injected into the
evaporator through the expansion valve. At this time
the pressure is reduced by approximately 2 kg/cm2
(28 psi) and the temperature is also reduced. As a
result, the refrigerant absorbs the heat from the air
surrounding the evaporator creating a cooling effect
and changes from the gas to the liquid state.
The refrigerant again flows into the compressor in the
gaseous state and the process is repeated.
WARNING!
Refrigerant gas is pressurized and sealed in the air-
conditioning system. Special precautions are required for
the proper recharging or release of refrigerant. Release of
refrigerant into the atmosphere is strictly regulated by law.
Make sure that you are in compliance with all mandated
federal, state and municipality requirements, before starting
any service or repair of the air conditioner. Refrigerant gas
used in the system must meet or exceed specifications for
R134a refrigerant, or any subsequently issued
environmentally mandated standard.

Page 11
CONTROL PANEL
FG004455
Figure 4
INPUT CONTROL OUTPUT

PANEL
DISPLAY
TEMPERATURE
SENSOR
LOW SPEED RELAY
OFF SW MID SPEED RELAY BLOWER

MOTOR
A / C SW
VENT SW HIGH SPEED RELAY
DEF. SW
HEAT SW A/C TEMP. CONTROL MIX DOOR
ACTUATOR
FRE SW CONTROL
REC SW PANEL VENT ACTUATOR VENT CONTROL
LOW SW
MID SW DEF. ACTUATOR FOOT / DEF.
HI SW
COOL SW INTAKE RECYCLE/FRESH
ACTUATOR AIR CONTROL
WARM SW
TEMPERATURE COMP. RELAY COMPRESSOR
CONTROL ACTUATOR
CONDENSER CONDENSER
FAN RELAY FAN
HDA6048L
Figure 5

Page 12
CONTROL SPECIFICATIONS
Control Item Control Switch Control Specifications

Temperature "COOL" Switch
MAX COOL
Control
"WARM" Switch 100%
50%
MAX HOT
0%
HDA6049L
Figure 6
Temperature control switch consists of a 24 step

variable selector. The display uses 7, Green / Red two
color LED's to display the selected temperature.
Blower Fan "OFF" Switch
Speed Control
"LOW" Switch
"MID" Switch HI RELAY
"HI" Switch MID RELAY
LOW RELAY
OFF LOW MID HI
HDA6050L
Figure 7
Compressor Temperature Sensor

Control
COMP ON
COMP OFF
1.5 C 4.0 C
HDA6051L
Figure 8

Page 13
TEMPERATURE LEVEL
CONTROL AND DISPLAY
Position
Step LED 1 LED 2 LED 3 LED 4 LED 5 LED 6 LED 7 Sensor Remark
Voltage
0 Green Green Green Green Green Green Green 4.50 V 0.2 MAX. COOL
1 Green Green Green Green Green Green Green 4.33 V 0.2
2 Green Green Green Green Green Green Green 4.15 V 0.2
3 Red Green Green Green Green Green Green 3.98 V 0.2
6 Red Red Green Green Green Green Green 3.46 V 0.2
9 Red Red Red Green Green Green Green 2.93 V 0.2
12 Red Red Red Red Green Green Green 2.41 V 0.2
15 Red Red Red Red Red Green Green 1.89 V 0.2
18 Red Red Red Red Red Red Green 1.37 V 0.2
21 Red Red Red Red Red Red Red 0.85 V 0.2
22 Red Red Red Red Red Red Red 0.67 V 0.2
23 Red Red Red Red Red Red Red 0.50 V 0.2 MAX. HOT

Page 14
AIR DISCHARGE ACCORDING
TO PATH SELECTION
Face + Rear
FG004481
Figure 9
Foot + Rear
FG004482
Figure 10

Page 15
Defroster + Rear
FG004483
Figure 11

Page 16
Page 17
AIR-CONDITIONING SYSTEM
CIRCUIT DIAGRAM
3
5 2
B A
15A 15A 10A 30A

BR
4
E
1
6
0
6 I 2
3 II
10 9
15-1 15-2
15 + -
M
14
15-3 15-4 15-5

22
11 13
LED 1~12
7
8 87a
30
3 11 HIGH
5 12 MID
- + 87
M 8 13 LOW
85 86 18 9 REC
19 10 FRE
10 M
15-6
MODE SELECT
23 7 VENT
AIR MODE
9 21 17 DEF
87a
RECIRCLE/FRESH 20 8 FOOT 15-7
30 BLOWER SPEED
M
87 TEMP. CONTROL
85 86 14 3 (WARM)
15 2 (COOL) M
2 4
9 16 5
15-8
4 1
DEF 2 7 1 6
10 M FOOT
3 6
15-9
26 16
CN7 HRS 26P
CN1 AMP MIC 13P + 250 4P
14
11 15
HRS NO.GT7A-26PD-DS 26P AMP MIC 13P
6 5 4 3 2 1
13 13 12 11 10 9 8 7 6 5 4 3 2 1
12 26 25 24 23 22 21 20 19 18 17 16 15 14
13 12 11 10 9 8 7
(CN7) (CN1)
FG004394
Figure 12

Page 18
Reference Reference
Number Number
1 Battery 14 A/C Control Panel
2 Battery Relay 15 A/C Unit
3 Fusible Link 15-1 Blower Motor
4 Circuit Breaker 15-2 Resister
5 Fuse Box 15-3 High Speed Relay
6 Headlight Switch 15-4 Mid Speed Relay
7 Condenser Fan Relay 15-5 Low Speed Relay
8 Condenser Fan Motor 15-6 Recirculate / Fresh Air Control
9 Compressor Relay Actuator
10 Foot / Defrost Control Actuator 15-7 Vent Actuator
11 Receiver Drier 15-8 Temperature Control Actuator
12 Diode 15-9 Temperature Sensor
(Evaporator)
13 Compressor

Page 19
TROUBLESHOOTING
Refrigerant Pressure Check
Figure 13
1. Open all doors and windows.

2. Install manifold gauge set.
3. Start engine and maintain engine speed at 1,800 - 2,000
rpm.
4. Check high / low-pressure of refrigerant.
High-pressure: 8 - 10 kg/cm2 (114 - 142 psi)

1
Low-pressure: Approximately 1 kg/cm2 (14 psi)
Possible Cause: Low Refrigerant Level
Step Inspection Item Remedy
Reassemble using correct
Yes
1 Check for traces of refrigerant oil. tightening torque.
No Go to next step.
Using a leak detection device or soapy water Yes Repair leaking component.
2 check for refrigerant leakage at all major No Recharge system to correct
components and joints. pressure.
High-pressure: Over 23 kg/cm2 (327 psi)

2
Low-pressure: Approximately 2.5 - 3 kg/cm2 (36 - 43 psi)
Possible Cause: Overcharge, Frost on condenser
Check for condenser pin damage or Yes Clean, repair or replace condenser.
1
contamination. No Refrigerant overcharge.

Page 20
High-pressure: Approximately 20 - 25 kg/cm2 (284 - 356 psi)
3
Low-pressure: Approximately 2.5 - 3.5 kg/cm2 (36 - 50 psi)
Possible Cause: Air in system.
1. Recover any remaining refrigerant.
2. Vacuum out system.
3. Recharge system.
NOTE: If the system has been exposed to the air for a long period of time, replace the receiver
dryer.
4 High-pressure: Over 6 kg/cm2 (85 psi)

Low-pressure: Approximately 760 mmHg (Negative Pressure)
Possible Cause: Refrigerant does not circulate
1. Connect manifold gauge and start engine.
2. Turn on air conditioner. Moisture in system, replace
Yes
receiver dryer.
3. Set blower switch to HIGH position.
4. Turn air conditioner OFF and wait 10
1 minutes.
Contaminated system, replace
5. Recheck high / low-pressure readings. expansion valve.
No
High-pressure: 13 - 19 kg/cm2 (185 - 270 psi) (Replace evaporator core
assembly.)
Low-pressure: 1.5 - 3.3 kg/cm2 (21 - 47 psi)
5 High-pressure: Over 6 - 18 kg/cm2 (85 - 256 psi)

Low-pressure: 500 mmHg (Negative Pressure) - Dial indicator needle unstable.
Possible Cause: Moisture in system has iced up the expansion valve.
NOTE: When the absorbed moisture freezes the pressure readings may look normal. Careful
readings should be made to determine whether pressure is in normal range.
1. Recover any remaining refrigerant.
2. Vacuum out system.
3. Recharge system.
NOTE: If the system has been exposed to the air for a long period of time, replace the receiver
dryer.

Page 21
High-pressure: Over 22 - 23 kg/cm2 (313 - 327 psi)
6
Low-pressure: 2.5 kg/cm2 (36 psi)
Possible Cause: Refrigerant pressure problem due to defective expansion valve or temperature sensor.
Inspect whether the temperature sensor is Yes Replace expansion valve.
1
installed properly. No Exchange duct sensor.
High-pressure: Over 7 - 11 kg/cm2 (100 - 156 psi)

7
Low-pressure: 4 - 6 kg/cm2 (57 - 85 psi)
Possible Cause: Low refrigerant pressure due to poor compressor compression
Inspect and replace compressor if necessary.

Page 22
WEIGHT OF R134a GAS USED IN
MACHINES
Model Weight of Gas

DX300LC 800 20 grams (28 0.7 oz)
DX340LC 800 20 grams (28 0.7 oz)
DX420LC 800 20 grams (28 0.7 oz)
DX480LC 800 20 grams (28 0.7 oz)
DX520LC 800 20 grams (28 0.7 oz)
DX140W 800 20 grams (28 0.7 oz)
DL300 850 20 grams (30 0.7 oz)
DL400 850 20 grams (30 0.7 oz)

Page 23
REFRIGERANT SYSTEM
REPAIRS
WARNING!
Always wear protective glasses and gloves when handling
refrigerant. If refrigerant comes in contact with the skin or
eyes, immediately flush with clean, running water and
consult a physician.
Select a clean and well ventilated area to work.
The refrigerant container is under high-pressure and
should be stored below 40C (104F). Be careful not to drop
the container from a high location
The contents are under high-pressure and should not be
used with compressed air or near an open flame.
Refrigerant Safe Handling Procedures
UNION NUT
TORQUE WRENCH
CORRECT WRONG
WRONG
WRONG
CORRECT
O - RING POSITION
CAP & PLUG CORRECT WRONG WRONG
HDA6066L
Figure 14
The following procedures should be observed for safe handling

of refrigerant during vacuum and charging process.
1. Use an approved recovery / charging device which can
safely perform vacuum and charge work simultaneously.
2. The new refrigerant has improved cooling characteristics
than the old type and care should be used not to
overcharge the system.

Page 24
3. Do not over tighten connections when working on
refrigerant system.
4. The new refrigerant system standards require new tools,
equipment and parts. Do not attempt to use equipment use
in servicing the old refrigerant system.
5. The new refrigerant oil (PAG type) has a high moisture
absorption characteristic. When the refrigerant system
vacuum seal has been broken, immediately plug up all
openings to prevent moisture from entering into the
system.
6. When joining unions which use O-ring seals, lightly coat O-
rings with refrigerant oil. Be careful not to drip oil on the
threads of the nut.
7. Be certain the O-rings are seated properly on the
refrigerant line lip. Always use new O-rings when
reassembling parts. Do not reuse old O-rings.
8. Use a vacuum pump to evacuate refrigerant system of air.
9. When charging the refrigerant system with the engine
running, do not open the high-pressure valve on the
manifold gauge as the reverse flow of high-pressure
refrigerant will rupture the hose.
10. When releasing the high-pressure hose after completing
the charging process, quickly disconnect the hose to
minimize refrigerant released to the air.
Repair and Replacement Procedure

1. Work Procedure.
A. Before repairing or replacing any refrigerant
components first, return all refrigerant oil to the
compressor and perform recovery procedures.
2. Operating Condition.
A. Run engine at maximum engine speed.
B. Select "HI" blower fan speed and select A/C switch to
"ON."
C. Set the temperature control switch for maximum
cooling and leave running for approximately 20
minutes.
NOTE: The manifold gauge dial pointer can vary
depending on the outdoor temperatures.

Page 25
INSTALL REPAIR TOOL
RECOVER REFRIGERANT
REPAIR / REPLACE DEFECTIVE PARTS
VACUUM SYSTEM (OVER 5 MINUTES)
CHECK SYSTEM FOR AIR LEAKAGE REPAIR
VACUUM SYSTEM (OVER 20 MINUTES)
CHARGE SYSTEM (APPROXIMATELY 100 g)
CHECK SYSTEM FOR REFRIGERANT LEAKAGE
CHARGE SYSTEM TO PROPER LEVEL

(Standard Capacity less Initial Charge)
CHECK SYSTEM FOR REFRIGERANT LEAKAGE
CHECK FOR PROPER REFRIGERANT LEVEL
RUN SYSTEM
RECOVER REFRIGERANT IN CHARGING HOSE
REMOVE REPAIR TOOLS

HDA6067L
Figure 15

Page 26
Refrigerant Recovery
Reference 2 3
Description
Number
1 4
1 To Compressor
2 Low-pressure Side
3 High-pressure Side
4 From Receiver
5 Refrigerant Recovery Tank
1. Attach the manifold gauges and the refrigerant recovery 5

unit to the refrigerant lines as shown. HDA6067L
Figure 16
NOTE: Be careful not to switch the connections for the
low and high-pressure valves.
2. Open the high-pressure valve slowly to release the
refrigerant to the recovery unit.
NOTE: Open the valve slowly, while checking to see
that refrigerant is not leaking out.
3. When the manifold gauge dial falls below 3.5 kg/cm2 (50
psi), slowly open the low-pressure valve.
4. Open both the high and low-pressure valves slowly until
the manifold gauge dials indicates 0 kg/cm2 (0 psi).
Vacuuming Refrigerant System

2 3
Reference 1 4
Description
Number
1 To Compressor
2 Low-pressure Side
4 From Receiver
5 Vacuum Pump 5
HDA6068L
1. Vacuuming Procedure. Figure 17
NOTE: When the A/C system has been exposed to the
air, it must be vacuumed out. Perform vacuum
process for 30 minutes for complete moisture
and air evacuation.
A. Attach the manifold gauges and vacuum pump to the
refrigerant system as shown.
B. Turn on the vacuum pump and open both valves.
C. When the low-pressure gauge shows approximately
710 mmHg, close both valves and turn off vacuum
pump.

Page 27
2. Check system for vacuum leak.
Allow system to sit for 10 minutes and check whether the
system is holding the pressure. If the pressure has
dropped, it must be repaired before proceeding to the next
step.
3. Vacuuming Procedure.
If the system is holding the pressure and it has not
changed for 10 minutes, vacuum out the system for an
additional 20 minutes.
A. Turn on the vacuum pump and slowly open both
Figure 18
valves.
B. Allow vacuum pump to run for additional 20 minutes
until the low-pressure gauge dial reads approximately
750 mmHg.
C. Close both valves and stop the vacuum pump.
4. Installation of Refrigerant Container.
Reference
Description
Number
1 Handle
2 Hose Connection
3 Mounting Disk
A. Before mounting valve on the container, make sure

the handle is in the counterclockwise most position,
with the puncture pin retracted and the mounting disk
is in the raised position. Figure 19
B. Attach the manifold gauge center hose to the valve
assembly.
C. Turn the disk in the clockwise direction and securely
mount valve onto refrigerant container.
D. Turn the valve handle in the clockwise direction and
puncture the container seal with the pin.
E. Once the can has been punctured, turn the handle in
the counterclockwise direction so the refrigerant can
flow into the manifold gauge center hose. At this time,
do not open the low and high-pressure valves of the
manifold gauge.
F. Press the manifold gauge low side valve to eliminate
the trapped air in the hose.
Leakage Check
NOTE: Perform the leakage check after completing
vacuuming process.
1. After attaching the manifold gauge, open the high side
valve.

Page 28
2. Charge system until the low side gauge dial indicates a
pressure of 1 kg/cm2 (14 psi) and close the high side valve.
3. Using a refrigerant leak detector or soapy water check
each joint for leakage.
Reference
Description
Number
Refrigerant Leak
1
Detection Device
4. If a leak is detected, check for O-ring damage or correct

tightening torque and replace or repair as necessary.
5. If no leaks are detected, proceed with the charging
process. Figure 20
WARNING!
For accurate refrigerant leak detection, perform leak
detection procedure in a well ventilated area.
Refrigerant Charging
1. Perform the vacuuming procedure, vacuum holding and
leaking tests as described in the proceeding headings.
NOTE: First charge the refrigerant system with 100 g
(3.5 ounces) of refrigerant with the engine off.
Then using the manifold gauges as a guide fully
charge the system with the engine running.
When exchanging refrigerant containers, press
the manifold gauge low side valve to eliminate
air from the charging hose.
Reference
Description 2 3
Number
1 4
1 To Compressor
2 Low-pressure Side
4 From Receiver
5 Refrigerant Supply
Container
5
2. Charge the system by opening the manifold gauge low side HDA6072L
valve. Figure 21
Initial charge amount: 100 g (3.5 ounces).

Page 29
3. If refrigerant does not flow freely into system, try starting
engine first before operating air conditioner.
Temperature control switch setting: Maximum Cooling
Blower Speed Setting: Hi (3 step)
Engine Speed: 1,300 - 1,500 rpm
WARNING!
When charging refrigerant system with the engine running;
Always keep refrigerant supply container in the
upright position.
Never open the high side pressure valve.
4. Open the manifold gauge low side valve and charge

system to standard capacity.
Gauge Dial Standard Reading
High Side Gauge 13 - 20 kg/cm2

(185 - 285 psi)
Low Side Gauge 1.5 - 3.5 kg/cm2

(21 - 50 psi)
NOTE: These standards are for outside temperatures

between 30 - 35C (86 - 95F). The gauge
readings may vary for extreme temperature
conditions.
WARNING!
When outside temperature is low, warm the
refrigerant supply container with warm water not
exceeding 40C (104F). Do not allow water to
come in contact with the charging adapter valve
handle.
When outside temperature is high, cool off
refrigerant supply container and condenser to aid
the refrigerant charging process.
5. Close low-pressure side valve.

6. Shut off engine and close refrigerant supply container
adapter valve. Disconnect manifold gauge hoses from
vehicle.

Page 30
Inspecting System for Leakage
After completing charging procedures, clean all joints and
connections with a clean dry cloth. Using a refrigerant leak
detecting device or soapy water, inspect system for leaks
starting from the high-pressure side.
NOTE: When the refrigerant circulation has been stopped
the high-pressure will start to decrease and the low-
pressure will start to increase until they are
equalized. Starting the inspection from the high side
will result in a accurate test.
Reference
Description
Number Figure 22
1 Pressure
2 High-pressure
3 Low-pressure
4 Compressor Stop
Inspection Procedure
1. High-pressure side.
Compressor outlet condenser inlet receiver dryer
inlet air conditioner unit inlet
2. Low-pressure side.
Compressor inlet air conditioner unit outlet
3. Compressor.
Compressor shaft area, bolt hole area and magnetic clutch
area.
4. Receiver dryer.
Pressure switch and plug area.
5. Connection valve area.
Inspect all valve areas.
Verify all valves are capped to prevent leaking.
Check for foreign material inside of valve cap.
6. Interior of air conditioner unit.
After stopping engine, insert detector probe into drain
hose. (Leave inserted for 10 seconds minimum.)
NOTE: When inspecting leakage from the air
conditioner unit, perform the inspection in a well
ventilated area.

Page 31
Page 32
SP000173
ELECTRICAL SYSTEMSP000173
Electrical
System
Edition 1
Electrical System SP000173

Page 1
MEMO
SP000173 Electrical System

Page 2
Table of Contents
Electrical System
Overview............................................................... 6
Electric Supply System......................................... 7
Engine Starting Circuit.......................................... 9
Operation During Start Process ...................................... 9
Operation After Start Process ....................................... 12
Engine Preheating System ................................. 15
Engine Stop System ........................................... 18
Charging System ................................................ 20
Monitoring System.............................................. 21
Instrument Panel ........................................................... 22
Function Check ............................................................. 23
Monitoring System Schematic....................................... 24
Operation....................................................................... 26
Windshield Wiper................................................ 34
Front windshield wiper................................................... 34
Rear Windshield wiper .................................................. 36
Lighting System .................................................. 38
Light Circuit ................................................................... 38
ECU System ....................................................... 42
ECU Electric Circuit....................................................... 43
ECU System Component .............................................. 44
Engine Fault Code .............................................. 48
Cooling Fan Control System............................... 61
Outline ........................................................................... 61
Diagram ......................................................................... 62
Electrical Diagram ......................................................... 63
Parts of Cooling Fan Control System ............................ 64
Operation of Cooling Fan Control System ..................... 66

Page 3
MEMO
Self Diagnosis and Display of Cooling Fan.................... 68

Failure Indications and Actions...................................... 69
Emergency Steering System (Option) ................ 70
Block Diagram ............................................................... 70
Emergency Steering System Components ................... 71
Emergency Steering System Electric Circuit................. 74
Electric Detent System ....................................... 75
Electric Circuit ............................................................... 75
Boom Kick-out ............................................................... 76
Return To Dig ................................................................ 76

Page 4
SAFETY PRECAUTIONS
CAUTION!
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
order.
handling load.
responsibility.
APPLICABLE MODELS

DL400 5001 and Up

Page 5
OVERVIEW
The electrical system for this equipment is DC 24 volts. The
rated voltage for all electric components is 24 volts with the
exception of the stereo and the air-conditioning control actuator.
The system contains two 12 volt batteries connected in series
and a three phase AC generator with a rectifier. The electric
wiring used in the system is easily identifiable by the insulator
color. The color symbols used in the electrical system are listed
in the following chart.
Electric Wire Color
Symbol Color
W White
G Green
Or Orange
B Black
L Blue
Lg Light green
R Red
Gr Gray
P Pink
Y Yellow
Br Brown
V Violet
NOTE: RW: Red wire with White stripe

R - Base Color, W - Stripe Color
NOTE: 0.85G: Nominal sectional area of wire core less
insulator = 0.85 mm2 (0.03 in2).

Page 6
ELECTRIC SUPPLY SYSTEM
The electric power circuit supplies electric current to each
electric component. It consists of a battery, battery relay, starter
switch, circuit breaker, fusible link and fuse box.
The negative terminal of the battery is grounded to the vehicle
body.
Even when the starter switch is in the "OFF" position, electric
current is supplied to the following components through battery,
to the fusible link, and then to the fuse box.
1. Cabin light, No. 1 terminal of DC-DC converter (back up for
stereo memory).
2. "B" terminal of starter switch and No. 22 terminal of air
conditioner control panel (back up)
3. No. 23 and No. 68 terminals of transmission controller
(back up for memory)
4. "B" terminal of blinker unit (for hazard warning light)
5. The source terminal of electric power of engine control unit
(ECU).
When the starter switch is in the "PREHEAT, ON and START"
positions, the current flows from the battery, to the fusible link, to
the fuse box, to the starter switch "B" terminal/starter switch
"BR" terminal, to the diode, and then to the battery relay "BR"
terminal. which activates the coil of the battery relay and the
electric supply system is energized.
When the battery relay's contacts are connected, all electric
devices can be operated.
While the engine is not running, the electric power for all electric
devices are supplied by the battery. Once the engine is started
the power is supplied from the alternator.

Page 7
STARTER SWITCH CONNECTION
TML ACC C
PST B BR R1 R2 C ACC
OFF
B 5
R2
PREHEAT BR
0.5G
R1
ON
START
6 3
8
9 4 2
CN1-1 B A
CHANGE CN2-5 BR
L5
E
L P B
REGULATOR
7 - + - +
F+
F-
1
FG004395
Figure 1 ELECTRICAL POWER CIRCUIT DIAGRAM
Reference Reference
Number Number
1 Battery 6 Fuse Box
2 Battery Relay 7 Alternator
3 Fusible Link 8 Diode
4 Circuit Breaker 9 Gauge Panel
5 Starter Switch

Page 8
ENGINE STARTING CIRCUIT
Operation During Start Process

When the starter switch is turned to the start position, then the
"S" and "E" terminal of the starter controller (7) are connected.
At this time the contacts in the starter relay (8) are closed by the
current flow from the battery (1), to the fusible link (3), to the "B"
terminal of the starter switch (5), to the "C" terminal of the starter
switch (5), to the "C" terminal of the starter relay (8), to the "D"
terminal of starter relay (8), to the "S" terminal of starter
controller (7), to the "E" terminal of the starter controller, and
then to the ground.
The contact point "B" and "PP" of starter relay (8) are connected,
the pinion gear of the starter (9) is pushed forward and makes
contact with the ring gear of the flywheel and the internal
contacts of the starter are connected.
The current flows from the battery (1), to the "A" terminal of the
battery relay (2), to the "B" terminal of the battery relay (2), and
then to the "B" terminal of the starter (9). The starter motor is
rotated and the engine is started.
While, signals from sensors installed in engine are carried to
engine control unit (ECU) (15), then ECU (15) flows current to
injector solenoid (16) to supply fuel for starting the engine.
The engine can be cranked only when the transmission selector
switch (11) is the neutral position. If the transmission selector
switch (11) is in the forward or reverse, the current that flows the
switch (11) to the starter controller (7) opens the path to ground
for the starter relay (8). This prevents the start relay (8) from
closing.

Page 9
14 7 8
87a N S D PP C
30
87 B C B B
86 85 12 9
P E
A
13
52
67
11
F ACC
N C
R B
R2
BR
5 R1
3
6
4 2
B A
BR
E
L B
12
P
REGULATOR - + - +
10
F+
1
F-
E
15
PST TML B BR R1 R2 C ACC
CN9-39 OFF
H
#1 PREHEAT
J2
D ON
(50-PIN) #2
START
CN10-3 G
#3
CN10-4 C
16
CN10-1 A
#4
CN10-2
B
#5
J3
(4-PIN) E
17 #6
F
J1
FG005229
Figure 2 STARTER CIRCUIT (1) - WHILE STARTING

Page 10
Reference Reference
Number Number
1 Battery 10 Alternator
2 Battery Relay 11 Transmission Selector Switch
4 Circuit Breaker 13 Transmission Controller
5 Starter Switch 14 Safety Starter Relay
6 Fuse Box 15 Engine Control Unit (ECU)
7 Starter Controller 16 Injector Solenoid
8 Starter Relay 17 Engine Sensor
9 Starter

Page 11
Operation After Start Process
Once the engine has been started, the belt driven alternator (10)
generates a current. The output generated by the alternator is a
square wave pulse voltage through the "P" terminal and the
frequency of the pulse voltage is proportional to the rotation of
the alternator. The starter controller (7) monitors the frequency
of the output current. Once the frequency equivalent to 500 rpm
is sensed the connection between "S" and "E" terminals and the
connection between "B" and "PP" terminals are opened. As a
result the rotation of the starter (9) is stopped. Once the engine
is running, the starter (9) will not operate even if the starter
switch (5) is moved to the start position, preventing possible
damage to the starter (9).

Page 12
14 7 8
87a N S D PP C
30
87 B C B B
86 85 12
P E
9
A
13
52
67
11
F ACC
N C
R B
R2
BR
5 R1
3
6
2
4
B A
BR
E
L B
12
P
REGULATOR - + - +
10
F+
1
F-
E
15
CN9-39 OFF
H
#1 PREHEAT
J2
D ON
(50-PIN) #2
START
CN10-3 G
#3
CN10-4 C
16
CN10-1 A
#4
CN10-2
B
#5
J3
17 (4-PIN) E
#6
F
J1
FG005230
Figure 3

Page 13
Reference Reference
Number Number
1 Battery 10 Alternator
2 Battery Relay 11 Transmission Selector Switch
4 Circuit Breaker 13 Transmission Controller
5 Starter Switch 14 Safety Starter Relay
6 Fuse Box 15 Engine Control Unit (ECU)
7 Starter Controller 16 Injector Solenoid
8 Starter Relay 17 Engine Sensor
9 Starter

Page 14
ENGINE PREHEATING SYSTEM
Intake air heaters are installed at two places. When the starter
switch (5) is turned to the "ON" position, resistance equivalent to
engine temperature sensor (11) is sent to engine control unit (8).
The engine control unit (8) read the temperature according to
the checked resistance. When the temperature is below
specified coolant temperature the engine control unit (8) flows
current from CN9-40, 42 terminals to heater relay (7).
The current from air heater relay (7) through "C" an "D" terminals
activate the coil, then current flow sequentially from battery (1),
to battery relay (2), to "B" and "H" terminal of air heater relay (7),
to air heater (10) to finally preheat the engine.
While the preheating lamp lights on the gauge panel. Preheating
time can be different each time according to the engine
temperature.

Page 15
3
9 4
CN2-1 2
ACC C B A
PREHEAT CN1-5
L1 B 5
R2 BR
R1 BR E
12
CN9-50
11 CN9-40
B A
8
CN9-42 C B
- + - +
200A
CN10-1,2
7 1
- +
STARTER SWITCH CONNECTION D H

OFF 10
PREHEAT (1) (2)
ON + -
START
FG004402
Figure 4 ENGINE PREHEAT CIRCUIT
Reference Reference
Number Number
1 Battery 7 Air Heater Relay
2 Battery Relay 8 Engine Control Unit (ECU)
3 Fusible Link 9 Preheat Indicator Light
4 Circuit Breaker 10 Air Heater
5 Starter Switch 11 Engine Thermo Sensor
6 Fuse Box 12 Diode

Page 16
Page 17
ENGINE STOP SYSTEM
This system has no engine stop system for special use like an
engine stop motor or a fuel shutoff valve and so stops the engine
by shutting off fuel when the fuel injector solenoid (9) controlling
engine output acts opening and shutting movement according to
the position of the starter switch (5).
When the starter switch (5) is in off position, CN9-39 terminal
voltage of engine control unit (8) is shut off, the source of electric
power of injector solenoid (9) is shut off, and fuel supplying to
engine cylinder is shut off and so the engine is stopped.
ACC C
B 5 4 2
R2 B A
BR
R1 7
BR
E
CN9-39
CN10-3,4
- + - +
8
STARTER SWITCH CONNECTION CN10-1,2
TML
1
PST B BR R1 R2 C ACC
OFF #1~#6
PREHEAT
ON
9
START
FG004403
Figure 5 ENGINE STOP CIRCUIT - STOP MODE

Page 18
Reference Reference
Number Number
2 Battery Relay 5 Diode
3 Fusible Link 8 Engine Control Unit (ECU)
4 Circuit Breaker 9 Injector Solenoid
5 Starter Switch

Page 19
CHARGING SYSTEM
When the starter switch (5) is turned to the "ON" position, an
initial excited current flows to the battery relay (2), to the circuit
breaker (4), to the fuse (6), to the charge light of instrument
panel (9), and resistor (10), then to the "L" terminal of alternator
(7), and to the field coil. When the engine is started from this
condition the alternator (7) starts charging. The current flows
from the "B" terminal of alternator (7), to the circuit breaker (4),
to the battery relay (2), and to the battery (1).
The alternator also supplies electric current to other electrical
components.

OFF
PREHEAT
ACC C
ON
START
B 5
R2
BR
0.5G
R1
6
3
9 8
CN1-1
4 2
B A
10 BR
CHARGE CN2-5 E
L5
L P B
REGULATOR - + - +
7
F+
1
F-
FG005231
Figure 6 CHARGING CIRCUIT
Reference Reference
Number Number
2 Battery Relay 7 Alternator
4 Circuit Breaker 9 Gauge Panel
5 Starter Switch 10 Resistor

Page 20
MONITORING SYSTEM
17 2
+
3
-
B+
16 W
D+C
15 5
20
30 15
20
6
10
40
10 25
5
50 30
0 0
km/h x100r/min
CHECK
STOP
F/R
7
J O
I II
12 10 11 9 8
FG004407
Figure 7
Reference Reference
Number Number
1 Instrument Panel 10 Turn Signal Light Switch
2 Battery 11 High Beam Switch
3 Alternator 12 Working Light Switch
4 Speed Sensor 13 Brake Oil Pressure Switch
5 Coolant Temperature Sensor 14 Parking Brake Pressure Switch
6 Fuel Sensor 15 Transmission Cutoff Switch
7 Transmission Oil Temperature 16 Control unit
Sensor 17 Engine Control Unit (ECU)
8 Air Cleaner Indicator
9 Hazard Warning Light Switch
The monitoring system displays the various data and warning

signals onto the instrument panel by processing the information
gathered from the various sensors throughout the equipment.

Page 21
Instrument Panel
9 8 1 7 2 17 18
30 15
20 20
10 10 19
40
10 25
5
11 20
50 30
0 0
km/h x100r/min
12 21
CHECK
STOP
F/R
13 22
14 15 16 4 5 6 24 23
HOURS
1
10 3
< CONNECTOR AND TERMINAL NO.>
AMP MIC 13P AMP MIC 17P

6 5 4 3 2 1 8 7 6 5 4 3 2 1
4 3 2 1 8 7 6 5
13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9
(CN1) (CN2) (CN3) FG004408
Figure 8

Page 22
Gauges Warning Lights
1. Speed Meter 8. Turn and Hazard Warning 17. Turn and Hazard Warning
Light Light
2. Tachometer
9. High Beam Indicator 18. Charging Warning Light
3. Hour Meter
10. Working Light Indicator 19. Parking Brake Indicator Light
4. Fuel Gauge
11. Preheat Completion Indicator 20. Brake Oil Pressure Warning
5. Engine Coolant Temperature
Light
Gauge 12. Mirror Heater Indicator
21. Air Cleaner Clogged Warning
6. Transmission Oil 13. Cooling Fan Reverse
Light
Temperature Gauge Indicator
22. Engine Check Warning Light
7. Display 14. Maintenance Indicator
23. Engine Stop Warning Light
15. Forward / Reverse Indicator
Light 24. Emergency Steering
Indicator Light
16. Electric Steering Indicator
Light
Function Check
When the starter switch is turned to the "ON" position, all
displays, switch lights and warning lights except turn and hazard
warning light, high beam indicator, working light indicator and
emergency steering indicator will be turned "ON" for two
seconds and the warning buzzer will sound. Any lights which do
not light up during the function check should be replaced.

Page 23
Monitoring System Schematic
1 25 24
CN1 AMP MIC 13P L P B
9 B A
+ SIG CN1-4
SPEED BR
- E
E
+ S CN1-3
TACHO - REGULATOR
+ S CN1-6
WATER - 11 F+
TEMP
F-
+ S CN1-7 - + - +
FUEL - 12 12V 150AH 23 12V 150AH
E
+ S CN1-8
T/M OIL
TEMP
- CN1-13 13
10 27
2-3 1-4 CN3-8
3
2 HOUR 1
26
2-4 2-1 CN3-1
CN3-4
CN3-3
2 21
ILLUMINATION
CN1-9
CN1-1
20
CN1 AMP MIC 13P
CHARGE CN2-5 1
L5
ENGINE STOP CN2-4 4 2
L4
MIRROR HEATING CN2-12
L12 BUZZER CIRCUIT
BRAKE OIL PRESS
L10
CN2-10 6
8
3
PARK BRAKE
L16
CN2-16 7 22
AIR CLEANER 87a
CN2-2
L2
10 9
4 87
30
SPARE CN2-3
L3
F/R SELECT CN2-11 13 85 86
L11
REVERSE FAN CN2-13
L13
CN1-10
WORKING
L9
CN2-9 8
TURN SIGNAL (R)
L8
CN2-8 7
TURN SIGNAL (L)
L6
CN2-6 6
HI BEAM
L7
CN2-7 5
ELEC. STEERING CN2-14
L14 36
EMG STEERING CN2-15 14
L15
CN1-2 7
PREHEAT CN2-1
19
L1
CN1-5
E/G DIAGNOSTIC CN2-17
L17
CN1-11
CN2 AMP MIC 17P

CN9-50
15
14 CN9-41
CN9-44
18 CN9-43
17
FG004410
Figure 9

Page 24
Reference Reference
Number Number
1 Instrument Panel 14 Air Cleaner Indicator
2 Headlight Switch 15 Engine Control Unit (ECU)
3 Forward Lever Switch 17 Brake Oil Pressure Switch
4 Reverse Lever Switch 18 Parking Brake Pressure Switch
5 High Beam Switch 19 Transmission Controller
6 Left Turn Signal Switch 20 Control Unit
7 Right Turn Signal Switch 21 Pilot Buzzer
8 Work Light Switch 22 Alarm Relay 2
9 Alternator 23 Battery
10 Hour Meter 24 Battery Relay
11 Coolant Temperature Sensor 25 Circuit Breaker
12 Fuel Sensor 26 Fuse Box 2
Transmission Oil Temperature 27 Fusible Link
13
Sensor

Page 25
Operation
Instruments
Sensor Specification
Function Display Input
Input Specification
Terminal
10 km/h- 852 Hz
20 km/h- 1704 Hz
30 30 km/h- 2556 Hz
20
40 CN1-4 40 km/h- 3408 Hz
Speedometer 10
CN1-5 * = 85.2 V [Hz]
50
0 km/h : Frequency of T/M
Controller
v : Speed [km/h]
500 rpm - 100 Hz
1000 rpm - 200 Hz
15
20 1500 rpm - 300 Hz
10
2000 rpm - 400 Hz
25
Tachometer 5 CN1-3 2500 rpm - 500 Hz
30
0 * = 0.2 N [Hz]
x100r/min
: Frequency of alternator "P"
terminal
N : Engine rpm
ALTERNATOR "L"
Hour Meter
Terminal voltage (24V)
HAOA601L
(1/2)
EMPTY FULL
EMPTY - Above 90 Ohm
Fuel Level
CN1-7 1/2 - 38 Ohm
Gauge
FULL - Below 10 Ohm

Page 26
Sensor Specification
Function Display Input
Input Specification
Terminal
50C - Above 188.2 Ohm

67 C 105 C
50 C 125 C 67C - 102 Ohm
Engine Coolant 105C - 32 Ohm

CN1-6
Temperature Gauge 125C - Below 19.8 Ohm
120 C
50 C 150 C
50C - Above 188 Ohm
Transmission Oil
Temperature CN1-8 120C - 21 Ohm
Gauge
150C - Below 0.7 Ohm

Page 27
Indicator Lights
Input
Description Symbol Operation Remarks
Terminal
Lights up while the
air heater is heated.
CN2 - 1 (Terminal input is to

Preheating 24V.)
CN1 - 5
Lights up when air

cleaner is clogged.
(When the terminal
Air Cleaner CN2 - 2 input is grounded.)
Lights up when the

nonfatal system error In the diagnostic
occurred at the mode, will flash after
Engine CN2 - 17
engine itself or the engine stop light
Check CN1 - 11 peripherals. completes the three-
(Terminal input is to digit fault code.
24V.)
Lights up when the

fatal system error
happened to the Also used to flash out
engine itself or the fault code number
Engine Stop STOP CN2 - 4
peripherals. in the diagnostic
mode.
(When the terminal
input is grounded.)
Lights up when not Under normal
charging. conditions, will turn
"ON" before engine
(and "R" terminal
start-up and shut off
Charge CN2 - 5 output drops below
once engine is
24V)
running.
HAOA610L
Lights up when left

turn signal or hazard
light is operated.
Left Turn and (Terminal input is to
CN2 - 6
Hazard Light 24V)

Page 28
Input
Terminal
Lights up when right
turn signal or hazard
light is operated.
Right Turn
and Hazard CN2 - 8 (Terminal input is to
Light 24V)
Lights up when high

beam is operated.
(Terminal input is to
High Beam CN2 - 7 24V)
Lights up when work Light off when the

light is operated. engine is started.
(Terminal input is to
Work Light CN2 - 9 24 V)
Lights off when brake Under normal

oil pressure conditions, will turn
increases over 65 kg/ "ON" before engine
cm2, and light turns start-up and shut off
Brake Oil "ON" when brake oil once engine is
CN2 - 10
Pressure pressure drops below running.
60 kg/cm2.
(When terminal input
is connected)
Lights up when the Under any conditions,
parking brake switch will be light turns "ON"
is applied and before engine start-
Parking
Brake P CN2 - 16
parking brake
pressure is above 65
kg/cm2.
up.
Lights up when mirror

heater is operated.
(When the terminal
Mirror Heater CN2 - 12 input is grounded.)

Page 29
Input
Terminal
Lights up when the
cooling fan turns to
reverse.
Cooling Fan (When the terminal
CN2 - 13
Reverse input is grounded.)
Lights up when the F/ Blank out when initial

R switch is "ON" starting.
Forward /
Reverse F/R CN2 - 11
Lights up when the Blank out when initial

emergency steering starting.
pump is activated.
Emergency
CN3 - 15
Steering
Initial Operation
Input
Item Output (Operation and initial setting mode)
(Terminal)
Initial Operation CN 1-1 All warning lights are turned "ON" and turned "OFF" after 2
seconds.
(Except for turn signal indicator, high beam indicator, working
light indicator and transmission cutoff indicator and
emergency steering indicator.
Warning buzzer is activated and turned "OFF" after 2
seconds.
Monitoring system displays present condition.

Page 30
Control Unit Operation
5
1
2
MIRROR HEATING
L12 6
AIR CLEANER
L2 7 8
F/R SELECT 1
L11
REVERSE FAN 4 2 I
L13
ENGINE STOP
CHARGE
L4
6
BUZZER CIRCUIT 3
L5
7 8
BRAKE OIL PRESS 87a
L10 30 4
PARK BRAKE 10 9 87
L16
13 85 86
CN1 AMP MIC 13P
11 < CONNECTOR AND TERMINAL NO.>

9
AMP MIC 13P
10 6 5 4 3 2 1
13 12 11 10 9 8 7
FG004460
Figure 10
Reference Reference
Number Number
1 Instrument Panel 7 Pilot Buzzer
2 Starter Switch 8 Alternator
3 Forward Lever Switch 9 Brake Oil Pressure Switch
4 Reverse Lever Switch 10 Parking Brake Pressure Switch
5 Fuse Box 11 Alarm Relay 2
6 Control Unit

Page 31
Characteristic of Operation
Input Output
All warning lights are
1 When the starter switch is "ON." turned "ON" and turned
"OFF" after 2 - 2.5 seconds.
Warning buzzer sounds
Brake oil pressure switch is "ON."
When "P" terminal voltage of immediately
2
alternator is above 12 1 V Forward or Reverse lever switch is "ON" Warning buzzer sounds
and Parking brake pressure switch is "ON." immediately

Page 32
Page 33
WINDSHIELD WIPER
Front windshield wiper

You can control windshield wiper by operating wiper washer
switch (2).
1. Low speed wiper action (1st).
Wiper acts in low speed through fuse box (1) to the 15,53
terminal of wiper switch (2) to the L,E terminal of wiper
motor (5).
2. High speed wiper action (2nd).
Wiper acts in high speed through fuse box (1) to the 15,53b
terminal of wiper switch (2) to the H,E terminal of wiper
motor (5).
3. When you turn off switch during Low speed wiper action
(1st) or high speed wiper action (2nd), electric currents
flow through Fuse box (1) to the B,S terminal of wiper
motor (5) to the 87a,30 terminal of wiper relay (3) to the
31b,53 terminal of wiper switch (2) - L,E terminal of wiper
motor (5). Wiper acts until wiper rotates to the stop
position, than the wiper stops.
4. Intermittent wiper action.
Fuse box (1) to the 15,J terminal of wiper switch (2) to the
1,4 terminal of wiper timer (4) are connected intermittently,
and electric current flow into 86,85 terminal of wiper relay
(3) than 87 terminal and 30 terminal are connected.
Therefore, electric current flow through fuse box (1) to the
87,30 terminal of wiper relay (3) to the 31b,53 terminal of
wiper switch (2) to the L,E terminal of wiper motor (5), and
wiper operates intermittently in low speed.

Page 34
Front Windshield Wiper Circuit
6
+ (R) -
P
+ (F) -
P
1
7
2
CN5-6 15(53a)
CN5-8 53c
CN4-2 H
CN5-7 J
H CN5-3 53b
L CN5-1 53
87a CN5-4 31b
S
5 LO 30
HI 87 TML J 0 I II OFF ON OFF ON
M SW WIPER WASHER HORN
STOP B 86 85
- RUN
E
3
4 1
2
5 4 3
FG004463
Figure 11
Reference Reference
Number Number
1 Fuse Box 2 5 Wiper Motor
2 Wiper Washer Switch 6 Washer Tank
3 Wiper Relay 7 Diode
4 Wiper Timer

Page 35
Rear Windshield wiper
You can control rear windshield wiper by pressing wiper washer
switch (2) in the switch panel.
1. 1st wiper action (Wiper and washer activate the same time,
automatic return).
Fuse box (1), to the washer tank (4), to the 5,7 terminal of
switch (20) are connected, then activates windshield
washers. Also fuse box (1), to the B,L terminal of wiper
motor (3), to the diode (5), to the 5,7 terminal of switch (2)
are connected, then activates wiper.
3
B
+
STOP RUN E
2
M L 2
4 II
-
S 6 0
5 I 7
10 9
5 5
5
+ (R) -
P
+ (F) - 4
P
FG004464
Figure 12 REAR WINDSHIELD WIPER 1ST ACTION CIRCUIT
Reference Reference
Number Number
1 Fuse Box 1 4 Washer Tank
2 Wiper/washer Switch 5 Diode
3 Wiper Motor
2. 2nd wiper action (Only wiper action).

Fuse box (1), to the B,L terminal of wiper motor (3), to the
4,2 terminal of switch (2) are connected, then activates
wiper.
3. When you turn off windshield wiper switch in 1st or 2nd
position, electric current flows fuse box (1), to the B,L
terminal of wiper motor (3), to the 4,6 terminal of wiper
switch (2), to the diode (6), to the S,E terminal of wiper
motor (3).

Page 36
1
3
B
+
STOP RUN E 2
M L 2
4 II
-
S 6 0
5 I 7
10 9
5 5
5
+ (R) -
P
+ (F) - 4
P
FG004465
Figure 13 REAR WINDSHIELD WIPER STOP CIRCUIT
Reference Reference
Number Number
1 Fuse Box 1 4 Washer Tank
2 Wiper/washer Switch 5 Diode
3 Wiper Motor

Page 37
LIGHTING SYSTEM
Light Circuit
22
87a
30 28
87 87a 29
30 87a
(RR) 85 86 87 30
87
(FR) 23 85 86
85 86
19 (RL) 21
20 1
5 0
(FL) 7 6 I 2
(CR)
10 9 3 II
24 9 10 27 -
18 (CL)
18 +
17
1
CN2-9 L9 WORKING
CN2-7 HI BEAM
L7
CN2-6 TURN SIGNAL (L)
L6
CN2-8 TURN SIGNAL (R)
L8 B 26
CN1-2
2 E B ACC
7
L
1 8 3
10 11 5 87a
30
7 87 0
6 I 2
2 85 86
6 3 II
1 5 4 6 3 2 2 3 6 4 5 1 8 9 10
10 9
6 SW TURN SIGNAL HEAD LAMP

(clearanc)
(clearanc)
(turn sig)
(turn sig)
18 TML N
(high)
(high)
(low)
(low)
CN4-8
49a
CN4-4 R
CN4-1 L
CN4-5
56
4
CN4-6
56b
CN4-7
56a
CN4-9
15/1
25
(clearanc)
(clearanc)
(back up)
(back up)
(turn sig)
(turn sig)
(stop)
(stop)
9
C A B E F D D F E B A C 87a
30
87
F
85 86
14 16 15 R
5
FG005232
Figure 14 LIGHT CIRCUIT

Page 38
Reference Reference
Number Number
1 Fuse Box 1 17 Instrument Panel
2 Blinker Unit 18 Diode
3 Headlight Switch 19 Front Working Light Switch
4 Combination Switch 20 Front Working Light
5 Shift Lever Switch 21 Rear Working Light Switch
6 Hazard Switch 22 Working Light Relay
7 Stop Light Switch 23 Rear Working Light 1
8 Headlight Relay 24 Rear Working Light 2
9 Reverse Relay 25 Fuse Box 2
10 Headlight (L) 26 Starter Switch
11 Headlight (R) 27 Pilot Buzzer
14 Rear Combination Light (L) 28 Alarm Relay 1
15 Rear Combination Light (R) 29 Alarm Relay 2
The lighting system consists of the headlight, the position light,

the turn signal light, the hazard light, the stop light, the license
plate light, the working light, the rotating beacon light (option)
and the switches, which are used to turn "ON" the lights.
1. When the headlight switch (3) is in the first step, through
the fuse box 1 (1) to the "2," "6" terminal of headlight switch
(3), the following lights will be turned "ON."
A. The headlight (L) (10) and rear combination light (L)
through the fuse box 2 (25).
B. The headlight (R) (11) and rear combination light (R)
through the fuse box 2 (25).
C. The illumination lights through the "9" terminal of all
kind of rocker switches include the headlight switch
(3), the front working light switch (19), the rear
working light (21) and the hazard switch (6).
D. The license plate light (16).
2. When the headlight switch (3) is in the second step, the
current flows through the fuse box 1 (1), to the "2," "3"
terminal of headlight switch (3) and to the "86," "85"
terminal of headlight relay (8), and the "30," "87" terminal
of headlight relay (8) is connected. As a result, through the
fuse box 1 (1) to the "30," "87" terminal of headlight relay
(8), the voltage is applied to the "56" terminal of
combination switch (R) (4).
A. At this time if the combination switch (4) is in the "0"
position, the current flows to the "56b" terminal and it
allow the low light, which is in the headlight (L) (10)
and the headlight (R) (11), to be light turns "ON."
B. Also if the combination switch (4) is in the "t " position,
the current flows to the "56a" terminal and it allow the
high light, which is in the headlight (L) (10) and the

Page 39
headlight (R) (11), to be light turns "ON." At the same
time the current flows to the "CN2-7" terminal of
instrument panel (17) and the headlight indicator L7
will be turned "ON."
C. And if the combination switch (4) is in the "s " position,
the current flows to the "56b" terminal and it allows
the low light, which is in the headlight (L) (10) and the
headlight (R) (11), to be light turns "ON."
At the same time another current flows from the fuse
box 1 (1) to the "15/1," "56b" terminal of combination
switch (4) and the highlight, which is in the headlight
(L) (10) and the headlight (R) (11) will be turned
"ON," and the other current flows to the "CN2-7"
terminal of instrument panel (17) and the headlight
indicator will be turned "ON." The combination switch
(4) is returned automatically.
3. When the combination switch (4) is in the "" (or
"")position, the current flows from the fuse box 1 (1), to
the blinker unit (2), to the "L" (or "R") terminal through
"49a" terminal of combination switch (4), to the "C" terminal
of front combination light (L) (12) and the rear combination
light (L) (14) (or to the front combination light (R) (13) and
the rear combination light (R) (15)). This current makes the
turn signal light turn "ON." At the same time the current
flows to the "CN2-6" terminal (or to the CN2-8 terminal) of
instrument panel and the turn signal light indicator L6 (or
L8) will be turned "ON."
4. If you operates the hazard light switch (6), the current flows
from to the fuse box 1 (1), to the blinker unit (2), to the "5,"
"1" terminal of hazard switch (6), to the diode (18), to the
front combination light (L) (12) and the front combination
light (R) (13), to the "C" terminal of rear combination light
(L) (14) and rear combination light (R) (15). This current
makes the turn signal light turn "ON." At the same time
through the "2," "6" terminal of hazard switch (6), the
voltage is applied to the "9" terminal and the indicator light
used to light the symbol will be turned "ON." Also the
current flows to the "CN2-6," "CN2-8" terminal of
instrument panel (17) and the turn signal light indicator "L,"
"L8" will be turned "ON."
5. When the shift lever switch (5) is in the "R" position, the
contact points "30" and "87" of the reverse relay (9) are
closed due to current flowing from the fuse box 2 (23), to
the shift lever switch (5), to the "86" terminal of reverse
relay (9) and to the ground. Thus the current flows from
fuse box 2 (23), to the reverse relay (9) and to the "D"
terminal of rear combination light (L) (14) and rear
combination light (R) (15), and the reverse light will be
turned "ON."
6. When the brake pedal is depressed and at the same time
the stop light switch (7) is turned "ON," the current flows
the from fuse box 1 (1), to the stop light switch (7) and to
the "F" terminal of rear combination light (L) (14) and rear

Page 40
combination light (R) (15), and the stop light will be turned
"ON."
7. When the front working light switch (19) is in the "ON"
position, the current flows from the fuse box 1 (1), to the
"5," "1" terminal of front working light switch (19) and to the
front working light (20).
This current makes the front working lights turn "ON." At
the same time the working light indicator, L9," is turned
"ON" due to the current flowing from the diode (8) to the
"CN2-9" terminal of instrument panel (17).
8. When the rear working light switch (21) is in the second
step, the contact points "30" and "87" of the working light
relay (22) is closed due to the flowing current from the fuse
box 1 (1), to the "2" and "6" terminal of the working light
switch (21), to the "86" terminal of the working light relay
(22) and to the ground. Thus the current flows from the
fuse box 1 (1), to the working light relay (22) and to the rear
working light 1 (23) mounted on right/left rear fender. As a
result the rear working light (23) light turns "ON." At the
same time the working light indicator "L9" light turns "ON"
due to the current flowing from the diode (18) to the "CN2-
9" terminal of the instrument panel.
9. When the rear working light switch (21) is in the second
step, the contact points "30" and "87" of the working light
relay (22) is closed due to the flowing current from the fuse
box 1 (1), to the "2" and "6" and "3" terminal of the working
light switch (21), the rear working (23) is operated like
being described above clause "8" and the rear working
light (24) mounted on the cabin light turns "ON" at the
same time.
10. When the headlight switch (3) is in the first step or in the
second step while the starter switch (26) is in the "OFF"
position, the contact point "30," "87" of alarm relay 1 (28) is
closed due to the excited current, which flows to the coil of
alarm relay 1 (28) and the pilot buzzer (27) will sound.
But when the headlight switch (3) is in the first step or in
the second step while the starter switch (26) is in the "ON"
position, the contact point "3," "87" of alarm relay 2 (29) is
closed due to the excited current, which flows to the coil of
alarm relay 2 (29). At the same time the current is not
supplied to the "30" terminal of alarm relay 1 (28) and the
pilot buzzer will not sound any more.

Page 41
ECU SYSTEM
5 6
STOP
30
20
40
7 10
0 50
Km/h
Insite
ECU
1
3P
10 A
B
FG004434
Figure 15
Reference Reference
Number Number
1 ECU (Engine Control Unit) 6 Engine Stop Warning Light
3 Electronic Accelerator Pedal 7 Tachometer
4 Engine Diagnostic Connector 8 Transmission Controller
5 Engine Check Warning Light 10 Fuse Box

Page 42
ECU Electric Circuit
DRC 26-50S-04 DTP 06-4S
10 9 8 7 6 5 4 3 2 1
B 20 19 18 17 16 15 14 13 12 11 1 4
A 30 29 28 27 26 25 24 23 22 21
C 40 39 38 37 36 35 34 33 32 31 2 3
50 49 48 47 46 04 45 44 43 42 41
(CN10)
(CN8) (CN9)
ECU
ENGINE OEM
CONN CONN
GAUGE PANEL
44 0.85BW DIAGNOSTIC LAMP (-)
50 0.85LB PREHEAT LAMP
43 0.85YB ENG STOP LAMP
CIRCUIT BREAKER
TACHO S + FUSE 2 (1)
41 0.85WG
- TACHO
10A
ACCELERATOR PEDAL
22 0.85R A
09 0.85G B PT POSITION
SENSOR
23 0.85B C
01 0.85Or E IDLE
VALIDATION
11 0.85V F
0.85BL D
34 0.85BL
INCREMENT/DECREMENT SW
24 0.85Lg 1 I
3 0.85BL
0
25 0.85LgW 7 II
0.5B 10 9
DIAGNOSTIC SW
1
02 0.85BW 5
7
0.5B 10 9
DIAGNOSTIC
CONN
46 J1939 (+) 0.5Y 0.5Y
A
47 J1939 (-) 0.5YB 0.5YB
B
37 J1939 DATALINK SHIELD SHIELD
C
CAN RESISTOR 3 PIN DATA LINK

A B C CN8
CONNECTOR
120 OHM AIR HEATER RELAY
H 200A B
40 0.85W AIR HEATER RELAY (+) C D

42 0.85BG AIR HEATER RELAY (-)
FUSIBLE LINK 1
STARTER SWITCH
FUSE 1 (8)
39 0.5Br KEY SW
10A
FUSIBLE LINK 2
CN9
BATTERY RELAY
OEM-J2
B A
CN10 BR E
DTP 06-4S FUSE 1 (13)
3 3RW B(+) 15A +
4 FUSE 1 (14)
3RW B(+)
15A
1 3B B(-) -
BATTERY +
2 3B B(-)
J1 OEM-J3
2B
GROUND TO FRAME
FG004435
Figure 16

Page 43
ECU System Component
Engine Control Unit (ECU)

1. Engine is automatic controlled through all sorts of control
devices after receiving all sorts of sensor input signals from
engine.
2. ECU is attached to engine and operates sensitively to ECU
circumferential temperature.
3. ECU detects the abnormal conditions of engine system
and give trouble position by self diagnostic code through a
diagnostic light or an exclusive use diagnostic device.
FG004436
Figure 17
Engine Diagnostic Connector

1. Information stored in ECU can be known through a monitor
after connecting ECU and an inside TM which is a service
Insite TM
tool.
ECU
3P
B
A
C
FG004437
Figure 18
2. The engine diagnostic connector is positioned at the lower

part of the left wall side of the electric components box.
Figure 19

Page 44
Economic Mode Switch
This economic mode switch allows the operator to switch
between 100% throttle torque and droop curve and about
an 80% derated torque curve and droop. In the economy
mode, fuel consumption is clearly reduced by utilizing a O
reduced-power characteristic map for the engine. This is of
benefit with all general loading work.
I
O. In this position torque switch is set to the "off"
position, and 100% torque is permitted for hard
digging or driving up sleep inclines. FG004998
I. In this position torque switch is turn "ON", which limits Figure 20

engine torque to 80% of maximum.
Alternative Idle Switch

The alternate low idle switch allows operator to select an
alternate idle speed. This feature is activated whenever the
normally open alternate low idle switch is closed and 0
volts are detected by the ECM on the alternate low idle O
signal line. This is convenient to use when operator wants
to decrease warm-up time in the winter and improve
machine acceleration.
I
O. "OFF" position.
I. "ON" position. AQO0100L
Figure 21
Idle Speed Control Switch

The idle speed control switch allows the idle speed to be
adjusted in 25-rpm increments by pressing the rocker switch.
The switch will only work from 700 to 1200 rpm.
Pressing the "I" position of the switch will increase (+) engine O O
rpm.
Pressing the "II" position of the switch will decrease (-) engine I II
rpm.
This switch is also used to view the next or previous fault code in AQO0110L
the diagnostic mode.
Figure 22

Page 45
Engine Diagnostic Switch
If the engine check light (Yellow) or the engine stop light (Red) or
the engine maintenance light (Blue) comes on when the engine
is running, it means a fault code has been recorded.
O
During this time, the engine diagnostic switch allows the
operator to view the fault codes.
The severity of the fault will determine the light that will come
I
"ON" and the active fault codes can be viewed using the engine
stop light as described below.
AQO0120L
To view the fault codes:
Figure 23
1. Engine must be shut off (not running)
2. Starter switch must be in the "ON" position.
3. Engine diagnostic switch must be in the "I" position.
The engine stop and check lights flash if there are any fault
codes to display. If there are no fault codes to display, the engine
stop and check lights will remain lit.
Engine Fault Codes

If there are fault codes to be displayed, the engine check light 1 2
will flash momentarily. Then the engine stop light will flash the
first, second and third digits of the fault code.
1. Engine Check Light (Yellow)
2. Engine Stop Light (Red) STOP
FG004439
Figure 24
Example:
NOTE: The engine check light will flash between each
fault code. Fault Code 423 (example)
This pattern repeats itself until the fault is cleared or the
diagnostic switch is turned "OFF."
To view the next or previous fault code, press the idle speed
control switch (Figure 22) in the "I" position or "II" position.
: Flash : Pause
AQO0010L
Figure 25

Page 46
Electronic Accelerator
ACCELERATOR ASS'Y
A 0.5R
POSITION PT B 0.5B
SENSOR
C 0.5W
IDLE E 0.5G
VALIDATION
F 0.5L
STROKE 17 D 0.85Or
FOOT PEDAL
DETAIL "A"
D A
E B
"A"
F C
PEDAL SENSOR IDLE VALIDATION SW. Switch Closed

Switch Open
WHITE BLACK RED BLUE ORANGE GREEN 100%
OV C B A +VE F D E
C.W. C.W.
IDLE ON
V span
IDLE OFF
64 % Output
Voltage
(% Vref)
PIN
LOCATION DESCRIPTION COLOR
B
C A THROTTLE POSITION + V SUPPLY RED
A
B THROTTLE POSITION SIGNAL BLACK
E
C THROTTLE POSITION RETURN WHITE 0%
F
58.3%
48.3% W.O.T
-5.2 C.T
0 Datum
45.8%
D D COMMON ORANGE
-15.2
-11.0
Degrees Travel
-2.7
E OFF IDLE POSITION (NO) GREEN

PEDAL SENSOR Driver Travel
F ON IDLE POSITION (NC) BLUE Sensor Rotation
FG004438
Figure 26

Page 47
ENGINE FAULT CODE
Fault J1939 J1939

Light Fault Description (Reason) Fault Effect
Code SPN FMI
Engine Control Module Critical Internal
Possible no noticeable
Failure - Bad Intelligent Device or
performance effects,
111 Red 629 12 Component. Error internal to the ECM
engine dying, or hard
related to memory hardware failures or
starting.
internal ECM voltage supply circuits.
Engine Magnetic Crankshaft Speed/
Position lost both of two signals - Data
Erratic, Intermittent, or Incorrect. The Fueling to injectors is
115 Red 612 2 ECM has detected that the primary disabled and the engine
engine speed sensor and the backup cannot be started.
engine speed sensor signals are
reversed.
Intake Manifold 1 Pressure Sensor
Circuit - Voltage Above Normal, or
122 Yellow 102 3 Shorted to High Source. High signal Engine power derated.
voltage detected at the intake manifold
pressure circuit.
Intake Manifold 1 Pressure Sensor
Circuit - Voltage Below Normal, or
123 Yellow 102 4 Shorted to Low Source. Low signal Engine power derated.
voltage or open circuit detected at the
intake manifold pressure circuit.
Intake Manifold 1 Pressure - Data Valid
but Above Normal Operational Range -
Moderately Severe Level. Intake
124 Yellow 102 16 Engine power derated.
manifold pressure has exceeded the
maximum limit for the given engine
rating.
Accelerator Pedal or Lever Position
Severe decrease in
Sensor 1 Circuit - Voltage Above
power output of the
131 Red 91 3 Normal, or Shorted to High Source.
engine. Limp home
High voltage detected at accelerator
power only.
pedal position circuit.
Severe decrease in
Sensor 1 Circuit - Voltage Below
power output of the
132 Red 91 4 Normal, or Shorted to Low Source. Low
engine. Limp home
voltage detected at accelerator pedal
power only.
position signal circuit.
Remote Accelerator Pedal or Lever
Position Sensor 1 Circuit - Voltage Remote accelerator will
Above Normal, or Shorted to High not operate. Remote
133 Red 974 3
Source. High voltage detected at accelerator position will
remote accelerator pedal position be set to zero percent.
circuit.

Page 48
Fault J1939 J1939
Code SPN FMI
Remote Accelerator Pedal or Lever
Position Sensor 1 Circuit - Voltage Remote accelerator will
Below Normal, or Shorted to Low not operate. Remote
134 Red 974 4
Source. Low voltage detected at accelerator position will
remote accelerator pedal position be set to zero percent.
signal circuit.
Engine Oil Rifle Pressure 1 Sensor
Circuit - Voltage Above Normal, or None on performance.
135 Yellow 100 3 Shorted to High Source. High signal No engine protection for
voltage detected at the engine oil oil pressure.
pressure circuit.
Engine Oil Rifle Pressure 1 Sensor
Circuit - Voltage Below Normal, or None on performance.
141 Yellow 100 4 Shorted to Low Source. Low signal No engine protection for
voltage detected at engine oil pressure oil pressure.
circuit.
Engine Oil Rifle Pressure - Data Valid
143 Yellow 100 18 but Below Normal Operational Range - None on performance.
Moderately Severe Level.
Possible white smoke.
Engine Coolant Temperature 1 Sensor
Fan will stay ON if
controlled by ECM. No
144 Yellow 110 3 Shorted to High Source. High signal
engine protection for
voltage or open circuit detected at
engine coolant
engine coolant temperature circuit.
temperature.
Engine Coolant Temperature 1 Sensor
Fan will stay ON if
145 Yellow 110 4 Shorted to Low Source. Low signal
voltage detected at engine coolant
engine coolant
temperature circuit.
temperature.
Engine Coolant Temperature - Data
Valid but Above Normal Operational Progressive power
Range - Moderately Severe Level. derated increasing in
146 Yellow 110 16
Engine coolant temperature signal severity from time of
indicates engine coolant temperature is alert.
above engine protection warning limit.
Accelerator Pedal or Lever Position 1
Sensor Circuit Frequency - Data Valid
Severe derated in power
but Below Normal Operational Range -
147 Red 91 1 output of the engine.
Most Severe Level. A frequency of less
Limp home power only.
than 100 Hz has been detected at the
frequency throttle input to the ECM.
Sensor 1 - Data Valid but Above
Severe derated in power
Normal Operational Range - Most
148 Red 91 0 output of the engine.
Severe Level. A frequency of more than
Limp home power only.
1500 Hz has been detected at the
frequency throttle input to the ECM.

Page 49
Fault J1939 J1939
Code SPN FMI
Progressive power
derated increasing in
severity from time of
Valid but Above Normal Operational
alert. If Engine
Range - Most Severe Level. Engine
151 Red 110 0 Protection Shutdown
coolant temperature signal indicates
feature is enabled,
engine coolant temperature above
engine will shut down 30
engine protection critical limit.
seconds after Red Stop
Light starts flashing.
Intake Manifold 1 Temperature Sensor
Fan will stay ON if
voltage detected at intake manifold air
intake manifold air
temperature.
Intake Manifold 1 Temperature Sensor
Fan will stay ON if
154 Yellow 105 4 Shorted to Low Source. Low signal
voltage detected at intake manifold air
intake manifold air
temperature.
Progressive power
Intake Manifold 1 Temperature - Data derated increasing in
Valid but Above Normal Operational severity from time of
Range - Most Severe Level. Intake alert. If Engine
155 Red 105 0 manifold air temperature signal Protection Shutdown
indicates intake manifold air feature is enabled,
temperature above engine protection engine will shut down 30
critical limit. seconds after Red Stop
Sensor Supply 2 Circuit - Voltage
Below Normal, or Shorted to Low
Source. Low voltage detected at the
sensor supply number 2 circuit.
Coolant Level Sensor 1 Circuit -
Voltage Above Normal, or Shorted to
195 Yellow 111 3 None on performance.
High Source. High signal voltage
detected at engine coolant level circuit.
Coolant Level Sensor 1 Circuit -
Voltage Below Normal, or Shorted to
Low Source. Low signal voltage
detected at engine coolant level circuit.
Coolant Level - Data Valid but Below
Normal Operational Range -
Moderately Severe Level. Low coolant
level has been detected.
Barometric Pressure Sensor Circuit -
detected at barometric pressure circuit.

Page 50
Fault J1939 J1939
Code SPN FMI
Barometric Pressure Sensor Circuit -
Low Source. Low signal voltage
detected at barometric pressure circuit.
Above Normal, or Shorted to High
Source. High voltage detected at
Engine Crankshaft Speed/Position -
Data Valid but Above Normal Fuel injection disabled
Operational Range - Most Severe until engine speed falls
234 Red 190 0
Level. Engine speed signal indicates below the overspeed
engine speed above engine protection limit.
limit.
Progressive power
Coolant Level - Data Valid but Below
alert. If Engine
Normal Operational Range - Most
235 Red 111 1 Protection Shutdown
Severe Level. Low engine coolant level
feature is enabled,
detected.
engine will shut down 30
seconds after Red Stop
External Speed Command Input
(Multiple Unit Synchronization) - Data
237 Yellow 644 2 Erratic, Intermittent, or Incorrect.
Communication between multiple
engines may be intermittent.
Possible hard starting
238 Yellow 520196 4 Source. Low voltage detected on the
and rough running.
+5 volt sensor supply circuit to the
engine speed sensor.
Engine speed limited to
Maximum Engine Speed
Wheel Based Vehicle Speed - Data without VSS parameter
241 Yellow 84 2 Erratic, Intermittent, or Incorrect. The value. Cruise control,
ECM lost the vehicle speed signal. gear-down protection,
and road speed
governor will not work.
Engine speed limited to
Maximum Engine Speed
Wheel Based Vehicle Speed Sensor
without VSS parameter
Circuit tampering has been detected -
value. Cruise control,
242 Yellow 84 10 Abnormal Rate of Change. Signal
gear-down protection,
indicates an intermittent connection or
and road speed
VSS tampering.
g+H53overnor will not
work.
Fan Control Circuit - Voltage Below
The fan may stay on
Normal, or Shorted to Low Source. Low
245 Yellow 647 4 continuously or not run
signal voltage detected at the fan
at all.
control circuit when commanded on.

Page 51
Fault J1939 J1939
Code SPN FMI
Fuel Pump Pressurizing Assembly 1 Engine will run poorly at
Circuit - Voltage Below Normal, or idle. Engine will have
271 Yellow 1347 4 Shorted to Low Source. Low signal low power. Fuel
voltage detected at the fuel pump pressure will be higher
actuator circuit. than commanded.
Fuel Pump Pressurizing Assembly 1
Engine will not run or
engine will run poorly.
fuel pump actuator circuit.
Fuel Pump Pressurizing Assembly 1 -
Engine will not run or
281 Yellow 1347 7 Mechanical System Not Responding
possible low power.
Properly or Out of Adjustment.
SAE J1939 Multiplexing PGN Time-out
Error - Abnormal Update Rate. The At least one multiplexed
285 Yellow 639 9 ECM expected information from a device will not operate
multiplexed device but did not receive it properly.
soon enough or did not receive it at all.
SAE J1939 Multiplexing Configuration
Error - Out of Calibration. The ECM At least one multiplexed
286 Yellow 639 13 expected information from a device will not operate
multiplexed device but only received a properly.
portion of the necessary information.
SAE J1939 Multiplexed Accelerator
Pedal or Lever Sensor System -
Engine may only idle or
Received Network Data In Error. The
287 Yellow 91 19 engine will not
OEM vehicle electronic control unit
accelerate to full speed.
(VECU) detected a fault with its
accelerator pedal.
SAE J1939 Multiplexing Remote The engine will not
Accelerator Pedal or Lever Position respond to the remote
Sensor Circuit - Received Network throttle. Engine may only
288 Red 974 19
Data In Error. The OEM vehicle idle. The primary or cab
electronic control unit (VECU) detected accelerator may be able
a fault with the remote accelerator. to be used.
Auxiliary Temperature Sensor Input 1 - Possible engine power
292 Red 441 14
Special Instructions. derated.
Auxiliary Temperature Sensor Input 1
293 Yellow 441 3 Shorted to High Source. High signal None on performance.
OEM auxiliary temperature circuit.
Auxiliary Temperature Sensor Input 1
294 Yellow 441 4 Shorted to Low Source. Low signal None on performance.
voltage detected at the OEM auxiliary
Auxiliary Pressure Sensor Input 1 - Possible engine power
296 Red 1388 14
Special Instructions. derated.

Page 52
Fault J1939 J1939
Code SPN FMI
Auxiliary Pressure Sensor Input 1
297 Yellow 1388 3 Shorted to High Source. High signal None on performance.
voltage detected at the OEM pressure
circuit.
Auxiliary Pressure Sensor Input 1
298 Yellow 1388 4 Shorted to Low Source. Low signal None on performance.
OEM pressure circuit.
None on performance.
Real Time Clock Power Interrupt - Data
Yellow Data in the ECM will not
319 251 2 Erratic, Intermittent, or Incorrect. Real
(Blinking) have accurate time and
Time Clock lost power.
date information.
Injector Solenoid Driver Cylinder 1
Circuit - Current Below Normal, or
Open Circuit. High resistance detected
Engine can possibly
322 Yellow 651 5 on injector Number 1 circuit or no
misfire or run rough.
current detected at Number 1 Injector
driver or return pin when the voltage
supply at the harness is on.
Engine can possibly
current detected at Number 5 injector
Engine can possibly
Engine can possibly
Engine can possibly

Page 53
Fault J1939 J1939
Code SPN FMI
Engine can possibly
Erratic, Intermittent, or Incorrect. The The ECM will estimate
334 Yellow 110 2 engine coolant temperature reading is engine coolant
not changing with engine operating temperature.
conditions.
Electronic Calibration Code Possible no noticeable
Incompatibility - Out of Calibration. An performance effects,
342 Red 630 13
incompatible calibration has been engine dying, or hard
detected in the ECM. starting.
Engine Control Module Warning
No performance effects
internal hardware failure - Bad
343 Yellow 629 12 or possible severe
Intelligent Device or Component.
power derated.
Internal ECM failure.
Possible smoke, low
Injector Power Supply - Bad Intelligent
power, engine misfire,
351 Yellow 627 12 Device or Component. The ECM
and/or engine will not
measured injector boost voltage is low.
start.
Source. Low voltage detected at sensor
supply number 1 circuit.
Above Normal, or Shorted to High
Source. High voltage detected at
Progressive power
Engine Oil Rifle Pressure - Data Valid severity from time of
but Below Normal Operational Range - alert. If Engine
415 Red 100 1 Most Severe Level. Oil pressure signal Protection Shutdown
indicates oil pressure below the engine feature is enabled,
protection critical limit. engine will shut down 30
seconds after red stop
light starts flashing.
Water in Fuel Indicator - Data Valid but
Possible white smoke,
Yellow Above Normal Operational Range -
418 97 15 loss of power, or hard
(Blinking) Least Severe Level. Water has been
starting.
detected in the fuel filter.
Water in Fuel Indicator Sensor Circuit -
428 Yellow 97 3 No water in fuel warning
High Source. High voltage detected at
available.
the water in fuel circuit.

Page 54
Fault J1939 J1939
Code SPN FMI
Water in Fuel Indicator Sensor Circuit -
429 Yellow 97 4 No water in fuel warning
Low Source. Low voltage detected at
available.
the water in fuel circuit.
Accelerator Pedal or Lever Idle
Validation Switch - Data Erratic,
Intermittent, or Incorrect. Voltage
431 Yellow 558 2 Engine will only idle.
detected simultaneously on both idle
validation and off-idle validation
switches.
Accelerator Pedal or Lever Idle
Validation Circuit - Out of Calibration.
432 Red 558 13 Voltage at idle validation on-idle and Engine will only idle.
off-idle circuit does not match
accelerator pedal position.
Engine Oil Rifle Pressure - Data
Erratic, Intermittent, or Incorrect. An
435 Yellow 100 2 No engine protection for
error in the engine oil pressure switch
oil pressure.
signal was detected by the ECM.
Battery 1 Voltage - Data Valid but
Below Normal Operational Range - Engine may stop
441 Yellow 168 18 Moderately Severe Level. ECM supply running or be difficult to
voltage is below the minimum system start.
voltage level.
Battery 1 Voltage - Data Valid but
Above Normal Operational Range - Possible electrical
442 Yellow 168 16 Moderately Severe Level. ECM supply damage to all electrical
voltage is above the maximum system components.
voltage level.
None or possible engine
noise associated with
Injector Metering Rail 1 Pressure -
higher injection
Data Valid but Above Normal
449 Red 157 0 pressures (especially at
Operational Range - Most Severe
idle or light load).
Level.
Engine power is
reduced.
Injector Metering Rail 1 Pressure
Sensor Circuit - Voltage Above Normal,
Power and or speed
451 Yellow 157 3 or Shorted to High Source. High signal
derated.
voltage detected at the rail fuel
pressure sensor circuit.
Injector Metering Rail 1 Pressure
Sensor Circuit - Voltage Below Normal,
Power and or speed
452 Yellow 157 4 or Shorted to Low Source. Low signal
derated.
voltage detected at the rail fuel
pressure sensor circuit.

Page 55
Fault J1939 J1939
Code SPN FMI
Intake Manifold 1 Temperature - Data
Valid but Above Normal Operational
Progressive power
Range - Moderately Severe Level.
decrease, increasing in
488 Yellow 105 16 Intake manifold air temperature signal
indicates intake manifold air
alert.
temperature is above the engine
protection warning limit.
Multiple Unit Synchronization Switch -
Data Erratic, Intermittent, or Incorrect.
Auxiliary Intermediate (PTO) Speed
523 Yellow 611 2 Switch Validation - Data Erratic, None on performance.
Intermittent, or Incorrect.
Auxiliary Input/Output 2 Circuit -
527 Yellow 702 3 High Source. High signal voltage or None on performance.
open circuit has been detected at the
auxiliary input/output 2 circuit.
Auxiliary Alternate Torque Validation
528 Yellow 93 2 Switch - Data Erratic, Intermittent, or
Incorrect.
Auxiliary Input/Output 3 Circuit -
529 Yellow 703 3 High Source. Low signal voltage has Engine will only idle.
been detected at the auxiliary input/
output 2 circuit.
Data Valid but Above Normal
Possibly hard to start,
Operational Range - Moderately
553 Yellow 157 16 low power, or engine
Severe Level. The ECM has detected
smoke.
that fuel pressure is higher than
commanded pressure.
Injector Metering Rail 1 Pressure - Either the engine will not
Data Erratic, Intermittent, or Incorrect. start or the engine will
554 Yellow 157 2
The ECM has detected that the fuel not have starter lockout
pressure signal is not changing. protection.
Data Valid but Below Normal
The engine will not have
Operational Range - Moderately
559 Yellow 157 18 starter lockout
Severe Level. The ECM has detected
protection.
that fuel pressure is lower than
commanded pressure.
Starter Relay Driver Circuit - Voltage Engine power derated.
Above Normal, or Shorted to High The ECM uses an
584 Yellow 677 3
Source. Open circuit or high voltage estimated turbocharger
detected at starter lockout circuit. speed.
Starter Relay Driver Circuit - Voltage
Amber light will light until
585 Yellow 677 4 high battery voltage
Source. Low voltage detected at starter
condition is corrected.
lockout circuit.

Page 56
Fault J1939 J1939
Code SPN FMI
Turbocharger 1 Speed - Data Valid but
Amber light will light until
Above Normal Operational Range -
595 Yellow 103 16 low battery voltage
Moderately Severe Level. High
condition is corrected.
turbocharger speed has been detected.
None or possible engine
noise associated with
higher injection
Auxiliary Commanded Dual Output
599 Red 640 14 pressures (especially at
Shutdown - Special Instructions.
idle or light load).
Engine power is
reduced.
Turbocharger 1 Speed - Data Valid but
Below Normal Operational Range -
687 Yellow 103 18 Moderately Severe Level. Low Engine power derated.
turbocharger speed detected by the
ECM.
689 Yellow 190 2 Data Erratic, Intermittent, or Incorrect. Engine power derated.
Loss of signal from crankshaft sensor.
Turbocharger 1 Compressor Inlet
Temperature Circuit - Voltage Above Engine will run derated.
Normal, or Shorted to High Source. Excessive black smoke,
691 Yellow 1172 3
High signal voltage detected at hard start, and rough
turbocharger compressor inlet air idle possible.
Turbocharger 1 Compressor Inlet
Temperature Circuit - Voltage Below
performance effects,
692 Yellow 1172 4 Normal, or Shorted to Low Source. Low
engine dying, or hard
signal voltage detected at turbocharger
starting.
compressor inlet air tempera
Engine Speed / Position Camshaft and
Crankshaft Misalignment - Mechanical
System Not Responding Properly or Possible poor starting.
731 Yellow 723 7
Out of Adjustment. Mechanical Engine power derated.
misalignment between the crankshaft
and camshaft engine speed sensors.
Electronic Control Module data lost -
Possible engine power
757 Yellow 611 31 Condition Exists. Severe loss of data
derated.
from the ECM.
performance effects or
Engine Camshaft Speed / Position
engine dying or hard
Sensor - Data Erratic, Intermittent, or
starting. Fault
778 Yellow 723 2 Incorrect. The ECM has detected an
information, trip
error in the camshaft position sensor
information, and
signal.
maintenance monitor
data may be inaccurate.
Auxiliary Equipment Sensor Input 3 -
779 Yellow 703 11 Engine will shut down.
Root Cause Not Known.

Page 57
Fault J1939 J1939
Code SPN FMI
Power Supply Lost With Ignition On -
Supply voltage to the ECM fell below
1117 None 627 2 6.2 volts momentarily, or the ECM was Engine will shut down.
not allowed to power down correctly
(retain battery voltage for 30 seconds
after key OFF).
Engine will only idle.
OEM Data Link Cannot Transmit - Data FC 1633 is a general
Erratic, Intermittent, or Incorrect. OEM data link FC and
1633 Yellow 625 2
Communications within the OEM data will point service to the
link network is intermittent. appropriate OEM guide
lines
Above Normal, or Shorted to High Possibly hard to start,
2185 Yellow 520197 3 Source. High voltage detected at +5 low power, or engine
volt sensor supply circuit to the smoke.
accelerator pedal position sensor.
Sensor Supply 4 Circuit - Voltage None or possible engine
Below Normal, or Shorted to Low noise associated with
2186 Yellow 520197 4 Source. Low voltage detected at +5 volt higher injection
sensor supply circuit to the accelerator pressures (especially at
pedal position sensor. idle or light load).
Data Valid but Below Normal
Operational Range - Most Severe Engine may be difficult
2249 Yellow 157 1
Level. The ECM has detected that fuel to start.
pressure is lower than commanded
pressure.
Electric Lift Pump for Engine Fuel
Supply Circuit - Voltage Above Normal,
2265 Yellow 1075 3 or Shorted to High Source. High Possible low power.
voltage or open detected at the fuel lift
pump signal circuit.
Engine may exhibit
misfire as control
Electric Lift Pump for Engine Fuel switches from the
Supply Circuit - Voltage Below Normal, primary to the backup
2266 Yellow 1075 4 or Shorted to Low Source. Low signal speed sensor. Engine
voltage detected at the fuel lift pump power is reduced while
circuit. the engine operates on
the backup speed
sensor.
Electronic Fuel Injection Control Valve
Circuit - Condition Exists. Fuel pump
2311 Yellow 633 31 Possible low power.
actuator circuit resistance too high or
too low.
2321 None 190 2 Engine power derated.
Crankshaft engine speed sensor
intermittent synchronization.

Page 58
Fault J1939 J1939
Code SPN FMI
Engine Camshaft Speed / Position
Sensor - Data Erratic, Intermittent, or
2322 None 723 2 Engine power derated.
Incorrect. Camshaft engine speed
sensor intermittent synchronization.
Turbocharger 1 Speed - Abnormal Rate
of Change. The turbocharger speed
sensor has detected an erroneous
speed value.
Turbocharger Turbine Inlet Temperature
Engine brake on
(Calculated) - Data Valid but Above
cylinders 1, 2, and 3
Normal Operational Range - Least
2346 None 2789 15 cannot be activated or
Severe Level. Turbocharger turbine
exhaust brake will not
inlet temperature has exceeded the
operate.
engine protection limit.
Turbocharger Compressor Outlet
Engine brake on
Temperature (Calculated) - Data Valid
2347 None 2790 15 cylinders 4, 5, and 6
but Above Normal Operational Range -
cannot be activated.
Least Severe Level.
Fan Control Circuit - Voltage Above Variable geometry
Normal, or Shorted to High Source. turbocharger may be in
2377 Yellow 647 3
Open circuit or high voltage detected at either the open or
the fan control circuit. closed position.
VGT Actuator Driver Circuit - Voltage
The intake air heaters
2384 Yellow 641 4 may be ON or OFF all
Source. Low voltage detected at
the time.
turbocharger control valve circuit.
VGT Actuator Driver Circuit - Voltage
Above Normal, or Shorted to High The intake air heaters
2385 Yellow 641 3 Source. Open circuit or high voltage may be ON or OFF all
detected at turbocharger control valve the time.
circuit.
Intake Air Heater 1 Circuit - Voltage
Above Normal, or Shorted to High Cannot control
2555 Yellow 729 3
Source. High voltage detected at the transmission.
intake air heater signal circuit.
Intake Air Heater 1 Circuit - Voltage
Below Normal, or Shorted to Low Cannot control
2556 Yellow 729 4
Source. Low voltage detected at the transmission.
intake air heater signal circuit.
Power derated and
Auxiliary PWM Driver 1 Circuit -
possible engine
2557 Yellow 697 3 shutdown if engine
protection shutdown
detected at the analog torque circuit.
feature is enabled.
Auxiliary PWM Driver 1 Circuit - Progressive power
Voltage Below Normal, or Shorted to derated increasing in
2558 Yellow 697 4
Low Source. Low signal voltage severity from time of
detected at the analog torque circuit. alert.

Page 59
Fault J1939 J1939
Code SPN FMI
Intake Manifold 1 Pressure - Data
Erratic, Intermittent, or Incorrect. The
2973 Yellow 102 2 ECM has detected an intake manifold
pressure signal that is too high or low
for current engine operating conditions.

Page 60
COOLING FAN CONTROL
SYSTEM
Outline
It controls the speed of cooling fan according to temperature of
coolant or transmission oil.
Its reverse rotation function can be used for cleaning.
Information on temperature of coolant and transmission oil are
sent to the cooling fan controller via communication line (CAN).

Page 61
Diagram
9 10
3
1
4
ECU
5
6 3 1
4 2
7
11
FG005241
Figure 27
Reference Reference
Number Number
1 Cooling Fan Controller 7 Fan Check Connector
2 Reverse Rotation Light 8 ECU
3 Cooling Fan Reverse Switch 9 Transmission Controller (TCU)
4 Cooling Fan Proportional Valve 10 Transmission Oil Temperature
5 Reverse Rotation Solenoid Sensor
6 Fuse Box 11 Coolant Temperature Sensor

Page 62
Electrical Diagram
14
6
15 13
ACC C B A
B
AMP 040 36P R2 BR
R1 BR E
10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11 16 15 14 13 12 11 10 9 16 17
(CN12) (CN11)
- + - +
2 12
CN1-1
CN2-13
L13
9
10
8
46 J1939 (+) 25
47 J1939 (-) 26 120 OHM
37 27
A B C 28
120 OHM
11
1
CN11
CN12-1
CN12-4
CN11-1 CN12-2
A
CN11-2
B
7 C
CN11-3 CN12-11
CN12-12
CN12-13
4 3
CN12-14 1
CN11-13
5
7
5 CN12-19 10 9
CN12
FG004490
Figure 28
Reference Reference
Number Number
1 Cooling Fan Controller 10 Transmission Oil Temperature
2 Reverse Rotation Light Sensor
3 Cooling Fan Reverse Rotation 11 Coolant Temperature Sensor
Switch 12 Battery
4 Cooling Fan Proportional Valve 13 Battery Relay
5 Reverse Rotation Solenoid 14 Fuse Light Link
6 Fuse Box 15 Circuit Breaker
7 Engine Diagnostic Connector 16 Starter Switch
8 ECU 17 Diode
9 Transmission Controller (TCU) 18 Fan Check Connector

Page 63
Parts of Cooling Fan Control System
Cooling Fan Controller

1. It controls the speed of the cooling fan according to
temperature of coolant or transmission oil, reversing the
rotation of the cooling fan.
2. It is located in the electric box and has a self diagnosis
function to check if it operates properly or fails.
3. Refer to Operation of Cooling Fan Control System on
page 1-66
4. Refer to Self Diagnosis and Display of Cooling Fan on
FG004491
page 1-68
Figure 29
Cooling Fan Proportional Valve

1. Nominal current: 680 mA
2. Resistance: 25 Ohm (20C)
Figure 30
Reverse Rotation Solenoid

1. Minimum operation voltage: 20 V
2. Resistance: 25 Ohm (20C)
FG004939
Figure 31

Page 64
Cooling Fan Reverse Rotation Switch
1. It is used to reverse the radiator cooling fan.
2. Pressing the switch reverses the radiator cooling fan, which
helps clean the radiator. O
3. To do so, put the Start switch OFF ON and put this
switch OFF (0) ON (1) before starting the engine.
I
4. To forward rotation, put off the engine, put the cooling fan
reverse rotation switch OFF (0), and start the engine.
FG004493
Figure 32
Reverse Rotation Light

1. It light turns "ON" when the cooling fan rotates reversely.
FG004492
Figure 33

Page 65
Operation of Cooling Fan Control System
Communication Monitoring
1. Communication port
A. SAE J1939 data link
B. CAN H, CAN L, SHIELD
2. Communication failure
A. E0, E1, or E2 is shown on the controller display.
B. If there shows no error message, it means normal
operation.
Control of Cooling Fan

1. The cooling fan controller controls the speed of the cooling
fan according to temperature of transmission oil and
coolant. It adjusts current of the proportional valve of
hydraulic motor, changing the pressure of the motor to
control the speed of fan connected to the hydraulic motor.
So, it is more efficient in fuel save and noise reduction
comparing to fan operation at a stead speed.
2. Limits of sensor temperature
A. Transmission oil: Upper and lower limits are 90C
(T1H) and 80C (T1L), respectively.
B. Coolant: Upper and lower limits are 93C (T2H) and
83C (T2L), respectively.
3. Cooling fan proportional valve outputs
A. Its control features are shown in the figures below,
and it outputs lower current (higher fan rotation)
between both curves.
Current Current
530mA 50mA 530mA 50mA

(Cooling Fan Rotation (Cooling Fan Rotation
Low Speed) Low Speed)
50mA 10mA 50mA 10mA

(Cooling Fan Rotation (Cooling Fan Rotation
High Speed) High Speed)
T1L T1H Temperature T2L T2H Temperature
< Transmission Oil Temperature vs. current > < Coolant Temperature vs. current >
FG005288
Figure 34
B. When the temperature sensor is opened: Minimum

current is 50mA 10mA

Page 66
C. Fail safe function: When communication fails or
temperature pressure is abnormal, minimum current
is output (while the cooling fan operates at maximum
speed).
4. Fan reverse rotation control
Fan Reverse Fan Reverse Cooling Fan

Order of Input Rotation Rotation Warning Proportional Remarks
Solenoid Light Valve Current
Start switch ON ON ON Minimum current Max. operation
Reverse Switch OFF (Max. fan speed) time: 5 min.
ON Start Engine
Other Conditions OFF OFF Normal control
NOTE: When coolant or transmission temperature is

overheated reverse rotation is not operated,
when overheat occurs during operating reverse
rotation it is changed to regular rotation
automatically. And then when reverse rotation
operating hour passes 5 minutes it is changed
to regular rotation automatically.

Page 67
Self Diagnosis and Display of Cooling Fan
Normal Operation Display

1. Operation mode display
Categories LED Display System Status

LOW L Minimum current (cooling fan at high speed)
2 20 - 24% output of duty
Forward 5 45 - 54% output of duty
Prop. Control
Rotation 6 55 - 64% output of duty
High H Maximum current (cooling fan at low speed)
Reverse
ON Normal Reverse Operation
L
Rotation
Monitoring of Voltage to Controller
Input LED Display

Decimal point light
18.51</= Vin </= 32.51V
Voltage of controller turns "ON."
input terminal = Vin Vin < 18.51V or
Decimal point is out.
Vin > 32.51V
LED
All the segments light up for one second when power is first
supplied to the controller.

Page 68
Failure Indications and Actions
Inputs Outputs
No. Detection Criteria
Fault Location Fault Status Displays Actions
1 Communication ECU / TCU E 0 Min. output of
error J1939 communication fault proportional valve -
current
2 Communication TCU E 1 Min. output of
error TCU communication fault proportional valve -
current
3 Communication ECU E 2 Min. output of
error ECU communication fault proportional valve -
current
4 Cooling fan Circuit Short E 3 Cutoff of Resistance of
proportional valve proportional valve proportional valve
current (0 mA) below 7 [Ohm]
5 Reverse rotation Circuit Short E 5 Cutoff of solenoid Detected current
solenoid current (0 mA) 1.65 0.2A
6 Reverse rotation Circuit Open E 6 Detected current
-
solenoid 0.26 0.1A

Page 69
EMERGENCY STEERING
SYSTEM (OPTION)
Block Diagram
3
5
6
8
4
FG004925
Figure 35 EMERGENCY STEERING SYSTEM BLOCK DIAGRAM
Reference Reference
Number Number
1 Fuse Box 5 Emergency Steering Pump
2 Emergency Steering Switch 6 Emergency Steering Indicator
3 Emergency Steering Timer 7 Transmission Controller
4 Emergency Steering Pressure 8 Battery
Switch 9 Main Steering Pressure Switch
When the speed of the vehicle exceeds 5 km/h and the main
steering pressure is less than 3 kg/cm2, an electrically powered
hydraulic pump will be operated for a time limited 60 seconds
and thus the emergency steering is possible.
This system includes the electrically powered hydraulic pump,
which is controlled by the emergency steering timer (3). The
emergency steering timer (3) obtains signals from the main
steering pressure switch (9) and the transmission controller (7).
When the emergency steering is activated, the emergency
steering indicator (6) light turns "ON."

Page 70
Emergency Steering System Components
Emergency Steering Timer

1. Obtains signals from the main pressure switch (9) and the
transmission controller (7), and play a role in operating the EMG STEERING TIMER
emergency steering pump (5). PART NO.

VOLT
LOT NO.
537-00039B
24V
2. As the frequency signal of the transmission controller is

differ from each machine, the reference frequency is 405
Hz which come under about 5 km/h. 12 8 4
11 7 3
10 6 2
3. When the starter switch is "ON," the characteristic of 9 5 1
operation is following.
FG004921
Figure 36
Emergency Steering Timer Connector
No. Wire size and Color

1 0.85 LR
12 8 4
2 0.5 G
11 7 3
3 0.5 WB 10 6 2
4 0.85 W 9 5 1
5 0.85 B
6 0.5 WG
7 0.5 RW FG004922
8 0.5 BY Figure 37
9 0.5 BL

Page 71
Emergency Steering Timer Circuit
4
A B
5 C
1 4 D
S0
6 S3
8
7 S1 3
2
7
1
8 S2 6
E1 (28V) 9 S4 9 5
SPEED
3
FG004923
Figure 38
Reference Reference
Number Number
1 Emergency Steering Timer 6 Starter Switch "START"
2 Emergency Steering Indicator 7 Main Steering Pressure Switch
3 Transmission Controller (TCU) 8 Emergency Steering Pressure
4 Emergency Steering Pump Switch
5 Starter Switch "ON" 9 Emergency Steering Switch
Test Mode before Emergency Steering Start
Input Condition Output

Emergency Steering
S0 S3 S4 Light
Pump
will be turned "ON" only
one time for 3 seconds.
will be operated only one
- will be put out when S2 is
OFF ON OFF OFF time for 3 seconds and
"ON."
stop.
- will be blinked continually
when S2 is "OFF"
OFF ON ON OFF OFF putting out light
Pump will be operated Light will be turned "ON"
OFF ON - ON
equally with S4 "ON" time. equally with S4 "ON" time.

Page 72
Operating Character when Emergency Steering Normal
Mode
Input Condition Output

Standard input Remark
S1 Emergency Steering Pump Light
Frequency
ON - OFF putting out light Vp=205V
will be turned "ON" only Duty Cycle 50%
When above will be operated only one time
one time for 6010
40530 Hz for 6010 seconds and stop.
seconds and put out. Vp
OFF
When below
OFF putting out light
40530 Hz
0
t
Emergency Steering Pump

This is an electrically powered hydraulic pump and includes an
emergency steering relay (1, Figure 39), which is excited by the 1
signal of the emergency steering timer.
AJS0480L
Figure 39 EMERGENCY STEERING PUMP
Emergency Steering Switch

1. When the switch is in the "I" position, the emergency
steering pump and the emergency steering indicator of the
instrument panel are activated simultaneously.
2. The basic usage of this switch is testing function whether O
the emergency steering system is all right or not.
I
WARNING
AJO0011L
Make sure that no persons are near the machine when Figure 40 EMERGENCY STEERING
testing the function of the emergency steering system, SWITCH
there is a risk that someone may be crushed between the
front and the rear frame.
3. This returns automatically when not pressed down.

NOTE: Because the emergency steering pump
consumes high current, it's forbidden to use
continuously to avoid discharging of battery and
a risk of overheating.

Page 73
Emergency Steering System Electric
Circuit
When the control signal, which is transmitted from the "36"
terminal of the transmission controller, is inputted to the "2"
terminal of the emergency steering timer (3) and the emergency
steering pressure switch (4) is "OFF," the contact points "A" and
"B" of the emergency steering pump (5) is closed due to the
current flowing from the fuse box (1), to the "C" and "D" coil of
the emergency steering pump (5), and to the "4" and "5" terminal
of the emergency steering timer (3).
Thus the high current flows from the battery (11) to the "A" and
"B" terminal of the emergency steering pump (5), which is
operated. At the same time the emergency steering indicator
light turns "ON" due to the current flowing from the "B" terminal
of the steering pump (5), to the fusible link (7) and to the
emergency steering indicator.
A
11
C
5
- + D P
8
E
2
1 10 5 1
0
2 I 6 9 10
II 3
10 9
4
9 3
4 3bar
1 7
6
8
10bar
3
C 7
ACC 36 2
B 9 5 6
12
FG004924
Figure 41 EMERGENCY STEERING SYSTEM CIRCUIT
Reference Reference
Number Number
1 Fuse Box 8 Diode
2 Emergency Steering Switch 9 Transmission Controller
3 Emergency Steering Timer 10 Headlight Switch
4 Main Steering Pressure Switch 11 Battery
5 Emergency Steering Pump 12 Starter Switch
6 Emergency Steering Indicator 13 Emergency Steering Pressure
7 Emergency Steering Pressure Switch
Switch

Page 74
ELECTRIC DETENT SYSTEM
The electric detent system separated into boom kick-out and
return to dig.
An each part consists of magnetic locking lever and proximity
switch detecting the position of bucket or boom.
Electric Circuit
7 2 87a
7 30
87
10
+ 2 85 86
O 1
-
5 12
7
10 9 4
8
3 6
6
87a 1 87a
30 8 30
87 87
11
+ 85 86 86
O
12 85 6
- 12
1
9 5 3
+
O
-
FG004461
Figure 42 ELECTRIC DETENT CIRCUIT
Reference Reference
Number Number
1 Fuse Box 2 7 Float Magnetic
2 Float Kick-out Switch 8 Return to Dig Magnetic
3 Raise Relay 9 Raise Proximity Switch
4 Float Relay 10 Float Proximity Switch
5 Return to Dig Relay 11 Return to Dig Proximity Switch
6 Raise Magnetic 12 Diode 3ea

Page 75
Boom Kick-out
When the work lever (joystick) is in the "FLOAT" (or "RAISE")
position, lever is locked and boom is lowered (or lifted). When
the boom is matched to setting position, lever locking is released
and lever is returned to "NEUTRAL" position automatically and
boom lowering (or lifting) is stopped.
1. Boom Raise Kick-out
With the raise magnetic (5) is energized and the work lever
(joystick) is held in "RAISE," then boom is approaching to
the raise proximity switch (8). When the raise proximity
switch (8) and the boom are matched, the contact points
"30" and "87a" of the raise/float relay (3) is opened due to
the current flowing from the fuse box (1), to the coil of the
raise relay (3) and to the "0" and "-" terminal of the raise
proximity switch (8).
As a result the magnetic (5) is de-energized and the locked
lever is returned to "NEUTRAL" position, boom lifting is
stopped.
2. Boom Float Kick-out (Option)
With the float kick-out switch shown in Figure 43, is in the
"I" position and the float magnetic (6) is energized and the
work lever (joystick) is held in "FLOAT," then boom is
approaching to the float proximity switch (9).
When the float proximity switch (9) and the boom are
matched, the contact points "30" and "87a" of the raise/
float relay (3) is opened due to the current flowing from the
fuse box (1), to the coil of the raise/float relay (3), to the
terminal "5" and "1" of the float kick-out switch (2) and to
the "0" and "-" terminal of the raise proximity switch (9). As
O
a result the magnetic (6) is de-energized and the locked
lever is returned to "NEUTRAL" position, and boom I
lowering is stopped.
HA0O2027
Return To Dig Figure 43
After dumping, if the work lever (joystick) is in the "CROWD"
position, the work lever (joystick) will be locked and the bucket
will be crowded. When the bucket is matched to setting position,
the lever is returned to the "NEUTRAL" position and bucket
crowding will be stopped. After this operation, if the boom is
lowered the bucket is in parallel with ground.
With the return to dig proximity switch (10) and the bucket
positioned are matched, the contact points "30" and "87" of the
return to dig relay (4) is closed due to the current flowing from
fuse box (1), to the coil of the return to dig relay (4) and to the "0"
and "-" terminal of the return to dig proximity switch (10).
In this states, if the work lever (joystick) is in the "CROWD"

position, the lever is locked and the bucket positioner is
approaching out of the return to dig proximity switch (10). That

Page 76
is, bucket is crowded. If the bucket positioner is out of the return
to dig proximity switch (10), the float magnetic (9) is de-
energized.
As a result the lever is returned to "NEUTRAL" position and
bucket is set to the selected digging angle.
Proximity Switch OPERATION INDICATOR
Operating Distance: 10 1 mm POSITIONER
Operation Indicator Light: Lights up when the object

is detected. (OPERATING DISTANCE)
MAIN POWER
CIRCUIT
AJS0510L
Figure 44

Page 77
Page 78
9 SP000235
9 ELECTRICAL SCHEMATIC (DL400)SP000235
1Electrical
Schematic
(DL400)
Edition 1
Electrical Schematic (DL400) SP000235

Page 1
MEMO
SP000235 Electrical Schematic (DL400)

Page 2
Table of Contents
Electrical Schematic
(DL400)
DL400 ................................................................... 8

Page 3
MEMO

Page 4
SAFETY PRECAUTIONS
CAUTION!
order.
handling load.
responsibility.
APPLICABLE MODELS

DL400 5001 and Up

Page 5
Page 6
GENERAL DESCRIPTION
Schematic(s) presented in this section are laid out on facing
pages.
An overlapping edge has been taken into consideration so that a
photocopy can be made and pasted together to make a
complete schematic.
1. PUMP
2. PILOT FILTER
4. ACCUMULATOR
SH
B FORWARD
A FORWARD
Au
Dr
PG 8. PEDAL VALVE
S 10. CONTROL VALVE
q2 min.
q2 min.
ONE/TWO-WAY 24 25 26 27 28 29 30 26
T 11. BOOM CYLINDER
BACKWARD B
BACKWARD A
q1
q1
max.
max.
1 2 Pi Dr 4 3
B RIGHT Mu LEFT A
19. OIL COOLER
21. AIR BREATHER
22. HYDRAULIC TANK
a A B
23. LOCK VALVE
34
DR1
23
11 11 10 12
ps2
T2 T1 T3
O 28. STOP VALVE
Pi1 E
C2 C2 pc1 T 31. PTO
E E 36
A5 b
34. ROTATING VALVE
2 2 4 2
V2 V2 pb5
1 1 3 1
23 23
pc2
pa5
A8 T
pc3
8
B8
B4 T P
35 T P T P
29
pa4 L.H
pa8 B3
B7
A3
A7
L.TRAVEL R.TRAVEL
OPT. PEDAL 1
pb3
27 2 1 2 1 4 3 2 1
pa7

Pi B2 B
B6 A2 T
OPT R.H
A6 pb2
TR(L) 26
P4
pb6 33
pa2
B1
pa6 P1
A1
pb1
25
pa1
pr PA PT T P T P
P2 P3 PH PP P1
PH of Sol. v/v 2 2
19k
4 4
1 3 2 4 2 4 1 3
17 UP DUMP
RIGHT CROWD
24
A1 A2 A3 A4 A5 A6 A7 A8 30
18 9
A9 A10
ps1
B1 S1 B2 B3 B5 B6 B7 B8 B9 S2 B10
Pi1 Hammer Operating
B4
Psv a4
Safety Cut-off
Swing Priority
pa2
Pressure up
high speed
4 SOL. V/V P3 pa5
500k
a2 500k Travel 5
a1
P2 HO TR2 PH SP
1
10u T
P1 ACC
22 G1 Opt. Pedal
P Hammer Select
177u Operating A B
Pi1 Pi2
ps1 ps2 A
T T
2 P1
P4 P5 P3
40k 3
B1
a3

Dr1 B3 Dr3 P1 P1
Hammer Select
31
Shear Select
1. PUMP
2. PILOT FILTER
4. ACCUMULATOR
SH
B FORWARD
A FORWARD
Au
Dr
PG 8. PEDAL VALVE
S 10. CONTROL VALVE
q2 min.
q2 min.
ONE/TWO-WAY 24 25 26 27 28 29 30 26
T 11. BOOM CYLINDER
BACKWARD B
BACKWARD A
q1
q1
max.
max.

1 2 Pi Dr 4 3
B RIGHT Mu LEFT A
19. OIL COOLER
21. AIR BREATHER
22. HYDRAULIC TANK
a A B
23. LOCK VALVE
34
DR1
23
11 11 10 12
ps2
T2 T1 T3
O 28. STOP VALVE
Pi1 E
C2 C2 pc1 T 31. PTO
E E 36
A5 b
34. ROTATING VALVE
2 2 4 2
V2 V2 pb5
1 1 3 1
23 23
pc2
pa5
A8 T
pc3
8
B8
B4 T P
35 T P T P
29
pa4 L.H
pa8 B3
B7
A3
A7
L.TRAVEL R.TRAVEL
OPT. PEDAL 1
pb3 27 2 1 2 1 4 3 2 1
pa7

Pi B2 B
B6 A2 T
OPT R.H
A6 pb2
TR(L) 26
P4
pb6 33
pa2
B1
pa6 P1
A1
pb1
25
pa1
pr PA PT T P T P
P2 P3 PH PP P1
PH of Sol. v/v 2 2
19k
4 4
1 3 2 4 2 4 1 3
17 UP DUMP
RIGHT CROWD
24
A1 A2 A3 A4 A5 A6 A7 A8 30
18 9
A9 A10
ps1
B1 S1 B2 B3 B5 B6 B7 B8 B9 S2 B10
Pi1
Hammer Operating
B4
Psv a4
Safety Cut-off
Swing Priority
pa2
Pressure up

high speed
4 SOL. V/V P3 pa5

500k 500k 5
Travel
a1 a2
P2 HO TR2 PH SP
1
10u T
P1 ACC
22 G1 Opt. Pedal
P Hammer Select
177u Operating A B
Pi1 Pi2
ps1 ps2 A
T T
2 P1
P4 P5 P3
40k 3
B1
a3

Dr1 B3 Dr3 P1 P1
Hammer Select
31
Shear Select
FG001424
Figure 1

Page 7
DL400
STARTER SWITCH CONNECTION 4WG-260 TRANSMISSION CONNECTION MIRROR

PST TML B BR R1 R2 C ACC FORWARD REVERSE SEAT HEATER (OPT) SEAT AIR SUSPENSION (OPT) 87a
(545-0
CLUTCH SOLENOID GAUGE PANEL ASS'Y 30 201D
OFF 1 2 3 4 1 2 3 SEAT HEATER SW AIR SUSPENSION 1.25BL 201A
(K1006353 ) 1.25B 87
(2549-9098 ) (401-00 )
PREHEAT KV Y5
CN1 AMP MIC 13P +(2190-2036D31) 1.25B B A 152D 1.25RB 0.5B 85 86 200B
ON KR Y1 1.25B 202B 1.25R 202A 1 P
+ SIG 27A 0.85G 1.25BL 201B
CN1-4 -> TCU 5 152C 1.25RB
START K1 Y3
SPEED - 7
K2 Y6 SEAT HEATER MIRROR HEATER RELAY 0.5RG
K3 Y4 + S -> ECU (545-000 ) 10 9 60Q (2544-9033 )
CN1-3 28A 0.85WG 0.5B
K4 Y2 TACHO - 0.5WR
TERMINAL NO 22C 0.85RG REAR WORKING LAMP

+ S CN1-6 29A 0.85L 29B
0.85L (534-00085 )x4 87a
W/TEMP SENSOR (FR)
WATER
TEMP - (2547-6028 ) ROTATING BEACON FRONT 0.85B
24V 70W
87
WORKING LAMP 144C 0.85RW 1.25RW
AMP 9PT 1-480673 AMP 9PR 1-480672-0
(OPTION) (534-00064 )x2 144A 85
+ S 30A 0.85YR 30B 0.85B (RR)
AMP MIC 13P AMP MIC 17P CN1-7 0.85YR FUEL SENSOR 22D 0.85RG 0.85B
24V 70W 0.5B
FUEL - (547-00019A) ROTATING BEACON
6 5 4 3 2 1 8 7 6 5 4 3 2 1 4 3 2 1 8 7 6 5 (FL)
3 2 1 1 2 3 (534-00062 ) 0.85B (RADIATOR)
+ S TRANSMISSION OIL HELLA 0.85RW
13 12 11 10 9 8 7 17 16 15 14 13 12 11 10 9 6 5 4 4 5 6 CN1-8 31A 0.85GR 0.85GR 31B 0.85R 104B 1.25RG REAR LAMP
T/M OIL TEMP SENSOR (RL) (2544-9033
(CN3) 9 8 7 7 8 9 - CN1-13 0.85B 0.85B
(CN1) (CN2) TEMP (2547-6028 ) 0.85B 1 0.5RW
1.25RG
(CN4) (CN5) DISPLAY 87a 5 20B 1.25RY 40B 0.85RW
T/M CONTROLLER (ZF 68P) 0.85R 22A
2-3 1-4 CN3-8 39A 0.5BY 0.5BY 39B 30 22B 7
T/M SELECTOR SWITCH (PACKARD) 87 1 (CR)
0.5B 1 0.85B 1.25B
5 114A 1.2
22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 2-4 2-1 CN3-1 56B 0.5WG -> TCU 104A 0.85RY DA4-1 10 9 0.5WR
23 1 0.5WR 60AB 86 85 0.5B 7 3
45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 0.5B 60C (CABIN)
CN3-4 26F 0.85R 149A 40C 0.85RW
68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46
10 9 60N FRONT LAMP SW
0.5B 0.5WR
A B C D D C B A CN3-3 0.85B (2549-9098 ) (CL) 0.85B
DISPLAY ILL RELAY +(2190-2036D5)
(CN6) X1 X2 (2544-9033 ) 0.85G BEACON SW
CN1-9 60V 0.85WR 0.85WR (2549-9098 ) 0.85RY
HRS NO.GT7A-26PD-DS 26P DRC 26-50S-04 +(2190-2036D10) 1.25RY
DTP 06-4S ILLUMINATION CN1-1 26C 1.25R 1.25R DA4-2
0.5RL 149B 4 2 144B 0.5RW 0.5RW
B 10 9 8 7 6 5 4 3 2 1 0.5WG
13 12 11 2 1 0.5RW 0.5RW
10 9 8 7 6 5 4 3 201C
A
C
20 19 18 17 16 15 14 13 12 11 1 4 MIRROR HEATING CN2-12 0.85BL
26 25 24 23 22 21 20 19 18 17 16 15 14 L12
30 29 28 27 26 25 24 23 22 21 0.85WR 0.85WR
40 39 38 37 36 35 34 33 32 31 2 3 AIR CLEANER CN2-2 112A 0.85BW 112B 0.85B
(CN7) L2 0.85G 0.85LB
(CN8) 50 49 48 47 46 04 45 44 43 42 41
(CN10) F/R SELECT CN2-11 203A 0.85LG 1.25R 0.5WG

L11 INDICATOR
(CN9) (2170-9005 ) 0.5WG 0.5BrW
REVERSE FAN CN2-13 180A 0.5GB
DIODE ARRAY L13 0.85L
CONTROL UNIT
AMP 040 36P ENG STOP CN2-4 108A 0.5YB
L4 (543-00001) B 23D 0.85L
5 6 7 8 3 4 +
CHARGE CN2-5 9C 0.5RW 0.5RW CN1 AMP MIC 13P 1 26B 0.85R STOP RUN E 0.85B
10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 L5
20 19 18 17 16 15 14 13 12 11 16 15 14 13 12 11 10 9 RESISTOR M
(ENG MAINTENANCE) CN2-3 4 2 18C 0.5WG L 24A 0.85LW 0.85LW
1 2 3 4 1 2 L3 (K1015621) TIME DELAY
(CN12) (CN11)
- DA2-1
BRAKE OIL PRESS CN2-10 110A 0.5YL 0.5YL 110B 6 S 181B 0.85Y 0.85YB
5 1
L10 BUZZER CIRCUIT
DA1 DA2 ~ DA7 181A 25B
PARK BRAKE CN2-16 111A 0.5Lg 0.5Lg 111B 7
L16 24B
REAR WIPER MOTOR
CN1-10 115A 0.85LR 8 57B 0.5BrW (2538-9005 ) 2
EMG STEERING (OPTION) ELEC. STEERING CN2-14 187F 0.5LY 0.85B 13

DA2-2
6
L14 DA2-3
B 0.85L 23C 7 3 32B 0.85BR 32C 0.85BR
EMG STEERING CN2-15 205B 0.5RW 0.85LR 115B 10 9 183B 0.85LB
L15
A 60R B
STARTER 149C 0.5RL WINDOW WASHER
WORKING CN2-9 0.5RL 0.5RL
C 13G 0.85LR L9 (4916-9006 )
EMG STEERING PUMP 0.5GR 0.5GR HO
P 13H TURN SIGNAL (R) CN2-8 84C 0.5GR + (R) - 32A 0.85BR
(401-00127A) D 207A 0.85W L8 0.85L 23B (516
0.5GL 0.5GL P
DIODE 5 TURN SIGNAL (L) CN2-6 85C 0.5GL 0.5R 0.5R
EMG STEERING SW L6
60B E 0.85BR 96B + (F) - 0.85B
(2549-9110 ) 207B HI BEAM CN2-7 87B 0.5R 110C P HO
+(2190-2036D21) L7 0.85YL 0.85B BRAKE OIL PRESS SW (516
CN1-2 0.85B 65bar (2549-9093 )
0.85B 1 5 206B 0.85BR 111C 0.85BR 96C 8 4 0.85B
0.85Lg 0.85B PARK BRAKE PRESS SW
PREHEAT CN2-1 26D 65bar
10 9 60M 0.5WR L1 (2549-9093 ) DA2-4
0.85BR
0.5B CN1-5 113A 0.5LB
0.5G 1.25R
0.85BR
E/G DIAGNOSTIC CN2-17 26E 1.25RB
9 206A L17
MAIN STEERING 0.85YB 0.85YB
PRESS SW 208B 0.85WB 208A 3 4 207C 0.85W CN1-11 156A
0.85B 0.85LR 0.85LR
(2549-1135D11) EMG STEERING 0.5BW
3bar 1 13F 0.85LR CN2 AMP MIC 17P
TIMER FLOAT RELAY
EMG STEERING 0.85B 204B 0.85WG 204A 6 8 11D 0.85BY C
(537-00039B) STARTER SW (2544-9033 )
PRESS SW 10bar 7 205A 0.5RW 0.5RW
0.85B 5 34C 87a 0.85RW
0.85RY 0.85RY 30 33B 0.85RB
2 27C 0.5G 0.5G 34A
7
87 2RL
ELECTRIC STEERING 0.5LY DA1-3 2
3
11 0.85RY 85 86 33C 0.85RB STOP LAMP SW (L)
EMG STEERING 0.85LR 34B 0.85GW 88A 89B 0.85GY
174A
DIAGNOSTIC (-) 0.5BW 34B' 5bar
FLOAT
ELECTRIC STEERING (OPTION) 1/2 PREHEAT 0.5LB
MAGNET
(549-00010)
HEAD LAMP(L) HEAD LAMP(R)
0.5LY 0.5LY (K1005906 ) (K1005907 )
ENG STOP 0.5YB
21W 3W 70W 70W 70W 70W 3W
SAUER-DANFOSS SUPPLY PART
ELEC. STEERING RELAY 1
NC
C ELECTRIC STEERING 0.85YB
FLOAT KICK-OUT ASS'Y (OPTION)
JOY-STICK (2544-9033 ) 0.85YL NO 184B TACHO 0.5WG FLOAT KICK-OUT SW
(JS-120) 87a 185C 185A (FLOAT KICK-OUT) (2549-9098 )
188A 1 30 ELEC. STEERING RELAY 2 ARM REST REVERSE FAN 0.5GB
0.85LY 87 87a CUT-OFF SWITCH + 33M 0.85RB +(2190-2036D22) 1 5 4 6 3 2 2 3 6 4
189A 2 F/R SELECT 0.5LG 85B 16C 16D 87C 86B 86C 87D 17D 17C 8
30 0.85YL O 173B 0.85W 173A 1
0.85B
187C 86 187A 87 5 174B 0.85RY
190A 3 85
0.85WR
0.85RW
0.85RW
0.85WR
185D
0.85WL
0.85WL
0.85GL
- 0.85B
0.85R
0.85R
7
187B 85 86 0.85LgB 185B
0.85RW
0.5BrW
0.5GR
0.85G
0.5GL
0.5GL
0.5B 186E 186B
0.5R
7 PROXIMITY SW 10 9 60
2RL
0.5B 0.5WR
(clearanc)
(clearanc)
0.85Lg 3 190B (4549-1148 )
(turn sig)
187G 0.5B ELEC. STEERING SW
(high)
(high)
(low)
(low)
0.85LgR 2 189B 8 0.85LY (RAISE)
0.85B 0.85LgB
0.85LgW 1 188B + 33K 0.85RB 0.85RB
0.85LY 0.85LY 0.85RY
PVED O 38B 0.85RY
0.5GR
4 163B J1939 (+) 0.5Y - 0.85B
RETURN TO DIG RAISE 0.85GL
5 164B J1939 (-) 0.5YB RETURN TO DIG RELAY
MAGNET RAISE RELAY MAGNET
6 165B J1939 DATALINK SHIELD (2544-9033 ) (2544-9033 ) 37A 0.85RW
(RETURN TO DIG) 1 0.85G 87a 33F 33D 87a 0.85R 3 0.85R
+ 33L 0.85RB 0.85B 12 30 0.85RB 0.85RB 30 10
35B 37B 0.85WR
35A 87 87
ECU O 36B 0.85WG 35B' 37B' 0.85GW
(539-000 ) 85 86 0.85RB 0.85RB 86 85
- 0.85B 2 6 0.85RY
5 1
36A 33G 33E 38A
ENGINE OEM 35C 37C
(stop)
0.85WL (clearanc)
CONN CONN DA1-2
0.85GL (turn sig)

DA1-1
0.85RY (back up)
0.85RY (back up)

PROXIMITY SW
DIAGNOSTIC (-) 0.85WG 0.85B
156B 44 0.85BW 0.85BW (4549-1148 )x2 0.85RB 0.85B 0.85B
0.85WR
PREHEAT
0.85GW
113B 50 0.85LB 0.85LB 0.5WR 0.5WR 0.5WR
0.5BrW 0.5BrW 0.85B
108B 43 0.85YB ENG STOP LIS ASS'Y (OPTION) SAFETY START RELAY
85E 88B 16B 58C 60X 58D
BACK UP RELAY
LIS SOL-VALVE LIS SELECT SW (2544-9033 ) C A B E F D D F E
28B 41 0.85WG TACHO (2544-9033 )
(K ) 0.85LY (549-00083 ) 0.5BrW 57A 87a 87a
+(2190-2036D3) 30 45B 0.5RL 45D 30
ACCELERATOR PEDAL 127C 87 87 58A 0.85RY
0 21W 21W 5W 21W
3 33J 85 86 45C 0.5RL
160A 22 0.85R 160B A 127B 5 I 0.85RB 0.5Gr 145A 0.5P 85 86 45E 0.5RL REAR COMBI LAMP LICENCE LAMP REA
146A (K1003561 ) (K1005717 )
161B 09 0.85G 161A B PT POSITION 0.85LY 124A 1 II
2RL
SENSOR 0.5B 10 9 60 0.5WR
162B 23 0.85B 162A C 0.85RL 0.85RY 58B +
LIS RELAY PILOT CU
0.5P
158A 01 0.85Or 158B E IDLE (2544-9033 ) 0.85B - (2549-9
VALIDATION 146B 5 0.85WG
87a 0.85RY +(2190-2036
159A 11 0.85V 159B F PILOT CUT OFF
30 33H 0.85RB 0.5Gr 145B 52 14 56A BACK BUZZER 44B 44A 1
0.85RB SOL-VALVE 0.85BW
0.85BL 169A D 127A 87 0.85RY 124B 30 23 14C 0.85RW (2516-1124 )
86 125B 0.85LR DA5-1 7
126A 85 0.85LR 0.85LR 125A 8 68 14D 0.85RW
169D 34 1 3 44C
0.85BL
0.85LR 125C 53 36 27B 0.85G 0.85B 10
INCREMENT/DECREMENT SW 0.85BL 0.85BL 0.85BL 126B 57 45P 0.5B
0.85RL 3
(549-00069)
TRANSMISSION 62 141A 0.85YR 0.85YR 141B 2 SPEED SENSOR
+(2190-2584D10) (ZF 0501 209 560)
0.85R 128A 12 CONTROLLER
24 4 142A 0.85RB 0.85RB 142B 1
166A 0.85Lg 166B 1 I 0.5LG EST-37A
3 169B + VPS1 7 128C 0.85R 0.85R 128B 13 0.85V
0.85BL 0.5GB 4WG-260
0
T/MISSION Y1 1 129A 0.85YG 0.85YG 129B 10 (K1006351 ) 21 42D 0.85Or 0.85Or
167A 25 0.85LgW 167B 7 II
VALVE ASS'Y Y2 2 130A 130B 56 (STD + WALVOIL) 29 150B AUTO(1-4)
10 9 60L 0.85LW 0.85LW 0.85W
0.5B 0.5WR HSG-94
Y3 3 131A 0.85GL 0.85GL 131B 32 20 55B 0.85WL AUTO(2-4)
(K1006352 )
Y4 4 132A 0.85WB 0.85WB 132B 55 66 48B 0.85RY
(TWO LEVER)
DIAGNOSTIC SW
Y5 5 133A 0.85GR 0.85GR 133B 9 15 147B 0.85GW 147A 2 1 45G 0.85RL
(2549-9098)
+(2190-2584D9) Y6 6 134A 0.85WL 0.85WL 134B 51 18 148B 0.85BrL 148A 4 3 0.85B
KIC
1 169C TEMP 8 135B 0.85LB 0.85LB 135A 39
168B 02 5 AEB CHECK CONN DOW
0.85BW 168A 0.5Y TEMP 9 136B 136A 46 45 45F 45K
7 0.85Br 0.85Br 0.85RL 0.85RL X2-A VP
0.5YB 67 49B 0.85Gr 0.85Gr 49A X2-D
0.85Br 136C 176B 0.85GL 176A 49 AD6
0.5B 10 9 60K 0.5WR X1-A AD3
0.5LG F/R SELECT T/M OIL TEMP SENSOR (2)
22 46D 0.85V 0.85V 46B X1-D AD7
DIAGNOSTIC 0.5Y
0.85Br 136D 109B 0.85L 109A 17 63 51A 0.85L 0.85L 51B X1-C
CONN AD1
0.5YB 5.7bar
46 J1939 (+) 0.5Y 0.5Y 163E 65 52A 0.85G 0.85G 52B X1-B
163A A AD2
BY-PASS FILTER SW 203B 7
47 J1939 (-) 0.5YB 0.5YB 164E FAN CONTROLLER 43 53A 0.85Y 0.85Y 53B X2-B
164A B AD4
(K1006348 ) 0.5Y 163D 25 64 54A 0.85P 0.85P 54B X2-C
165A 37 J1939 DATALINK SHIELD SHIELD 165E (REVERSE FAN) AD5
C 0.5YB 164D 26
CN11 040 16P 120 OHM 0.85P 54C CC-TV
SHIELD 164G 27 4P CONN(4)
3 PIN DATA LINK CN8 0.5GB CN12-4 180B 186D 59 0.85LgB 0.85LgB 186A
CONNECTOR 0.5Y CN11-1 163C 165D 28 0.85RL
163F 164F SPEED
CAN RESISTOR 0.5YB CN11-2 164C PICK-UP 137B 0.85LgR 137A 19 193D 44 0.85Lg F 0.85Lg 193A 7
A B C (ZF 0501
DT04-3P-P006 SHIELD CN11-3 165C (ENGINE) 140A 0.85Lg 194D 35 0.85LgW N 0.85LgW 194A 5
(DEUTSCH) FAN CHECK CONN 209 688)x3
138B 0.85LgW 138A 41 195D 31 0.85LgR R 0.85LgR 195A 1
120 OHM 212B 0.5Y CN11-4 212A
1 (TURBINE) 140B
213B 0.5YB CN11-5 213A CN12-11 0.85B 0.85Lg 0.85V 0.5B 10
2
214B CN11-6 139B 0.85LgB 139A 42
0.5B 214A CN12-12 0.85B (CENTRAL 0.85Lg
3 FNR SWITCH 45N
215B GEAR CHAIN) 140C 0.85Lg 140D 3
4
SHIELD CN11-7 215A 193C 3 2
1
7C 39 0.5Br KEY SW 1 +(2
177B CN11-13 0.85BrL 177A
178B 1.25GrL CN12-13 178A F
153A 40 0.85W AIR HEATER RELAY (+) 5 105F 0.85LR 0.85B 1 194C 2 HORN 0.85Lg 193B 7
COOLING FAN SPEED 7 6 95A'
154B 42 0.85BG AIR HEATER RELAY (-) 0.85B 2 0.85LgW 0.85LgW 194B 5
PROPORTIONAL V/V 179A 1.25GrR CN12-14 179B
105D CN12-1 0.85LR CN6 AMP 68P N
CN9 0.5B 10 9 60J 0.5WR 0.85LgR 195C 4 0.85LgR 195B 1
0.85LR 5 46A'
175A 0.85BL CN12-19 175B 105E CN12-2 10
0.85LgB 186C 7 0.5B
OEM-J2 REVERSE FAN SW R KD
REVERSE FAN CN12 040 20P
(2549-9098)+(2190-2584D20)
MONO-LEVER TYPE (OPT)
SOLENOID 105G 0.85LR 0.85LR 0.85LR
CN10
DTP 06-4S 0.5WR 0.5WR 0.5WR
19C 3 3RW B(+) 1.25RW 1.25RW 1.25RW
19D 4 3RW B(+) 1.25RW 1.25RW 1.25RW
0.85Br 0.85Br 0.85Br
1 3B B(-) 0.85W 0.85W 0.85W
2 3B B(-) 0.85BG 0.85BG 0.85BG
0.85LgB 0.85LgB 0.85V
J1 OEM-J3
2B 0.85LY 0.85LY 0.85LY
Figure 2

Page 8
MIRROR HEATER MIRROR HEATER SW
(2549-9098 )
PENSION (OPT) 87a
(545-000 )
+(2190-2036D29)
30 201D 1.25BL 201A 1.25RB CLOCK
R SUSPENSION
(401-00 ) 1.25B 87 200A 1 FUEL HEATER (OPT) (528-00039)
152E 5 152B 0.5RB
A 152D 1.25RB 0.5B 85 86 200B (R) 7 CLOCK RELAY
P FUEL HEATER RELAY
1.25BL 201B 1.25RB (2544-9033 ) (2544-9033 )
60I 9 10 0.5B
152F 87a 87a 3 2 4 1
30 197B 2.5RG 0.5R 122B 30 0.5B
MIRROR HEATER RELAY 0.5RG (L) 87 155A 155B 122D
(2544-9033 )
2.5R 199A 87 0.5WG
1.25RB 0.5RG
199B
0.5B 85 86 0.5RY 198A 1 0.5LR 13E 86 85 0.5B 0.5R
0.5WR 5
198B
22C 0.85RG REAR WORKING LAMP 7
197C
(FR) (534-00085 )x4 87a
0.85B 30 143B 1.25RY 0.5B 10 8
24V 70W
MP 144C 0.85RW 1.25RW 87 FUEL HEATER
0.85WR 106C 1 2 122A 0.85R
60R DC/DC
(RR) 144A 85 86
22D 0.85RG 0.85B 0.5RG FUEL HEATER SW CONVERTER 2 0.85R
0.5B 2.5B 0.85B 3 122C CAR STEREO SPEAKER
21B (2549-9098 ) (2531-1003 ) + 12V POWER
(FL) 0.85B (RADIATOR) (541-00010 ) (2541-9020 )x2
+(2190-2036D30) SOCKET
0.85RW REAR LAMP SW - (527-00006) ANTENNA (LH) (RH)
RG REAR LAMP RELAY
(2549-9109 ) 0.85B 16
(RL) 0.85B (2544-9033 ) HOUR METER
+(2190-2036D20) ALARM RELAY 1 MICOM
1 0.5RW (2544-9033 ) ALARM RELAY 2 (2528-9043 )
RG 143C 9D 3 MODULE + - + -
5 20B 0 (2544-9033 ) PILOT BUZZER 0.5RW
22A 1.25RY 40B 0.85RW 87a 2 0.5B (K1006364 )
21A 6 2 1.25RY 30 182B 0.85WL 182A 87a (2516-1102A) 6C 117B 118B 119B 120B
7 I 0.5WR 1 HOUR
(CR) 0.85B 1.25B 87 30 116B 0.85WB 116A - Vcc(+5V) 117A 7 0.85GrR
1.25RW 40A 3 II 87
4-1 10 9 0.85LB
0.5WR 85 86 0.5WR 0.85RW 14B + 118A 17 0.85BY
(CABIN) 0.5B 10 9 0.5WR 183A 85 86 0.5LR 0.85BR 121B 14
0.5B 60C
40C 0.85RW 60D 60 119A 2 0.85GrL
FRONT LAMP SW 13C 0.85L 90C 5
(2549-9098 ) (CL) 0.85WR DC/DC 3 121A 0.85BR 120A 10 0.85BW
0.85B 0.85B 1 87a 3 91C
+(2190-2036D5) 0.5B CONVERTER 1 0.5LW 11 0.5B
106B (2531-1003 )
2 90A 0.85L 0.85L 90B 30
87 91A 0.85LW 4 91B
0.85RY 0.85RY 99
1.25RY 0.5LR 0.5LR 13D 86 85 0.5B 15 0.85B
DA4-2 Vcc(+5V)
149B 4 2 144B 0.5RW 0.5RW 1.25WR OFF
10W
0.5RW 0.5RW 0.5WR 6D B+ DR E 0.5B
STEREO RELAY
0.85WR 0.85WR ON (2544-9033 )
0.85LB 0.85LB STARTER CONTROLLER STARTER RELAY
ROOM LAMP (534-00079 )
0.5WG 0.5WG 0.5WG (2543-9015 ) (2544-1022)
0.5BrW 0.5BrW 0.5BrW 0.5BrW 57C N 12C S 0.85BW D PP 3Y
0.85L 0.85LR 0.85LR 0.85LR 13B B 12B 12A 5A

C B 3W
DIODE 3
0.85L 0.5RW 0.85BY
B 23D 18B
0.85L CIGAR LIGHTER 11C 4C
+ REAR WIPER SW 2.5RG
E (545-00001) P E
STOP RUN 0.85B (2549-9129 ) 1.25WG 0.85BY
+(2190-2036D18) 2RW 0.5WG 11B
M L 24A 0.85LW 24C 4 2 0.85B - 1.25B 0.85B
0.85LW II 0.85WL 209B CC-TV 0.85BY
- DA2-1 4P CONN(1)
S 181B 0.85Y 1.25W 1.25W + 3W
5 1 0.85YB 25A 6 0
1.25WR
0.85WL
1.25RB
1.25RY
0.85RY
1.25W
181A 25B 7
0.85L
32D 5 0.85B 151B
2RW
2RG
2RY
0.85RG
24B 10 9 1.25WR 1.25WR
REAR WIPER MOTOR 3Y S
60E 0.5WR 5B
(2538-9005 ) 2
DA2-2 197A 143A 152A 20A 106A 14A 23A 41A 114A 209A 151A 81A 6A 11D
6 0.5B EMG STEERING
DA2-3 9 10 11 12 13 14 1 2 3 4 5 6 7 8 8
0.85L 23C 32B 0.85BR 32C 0.85BR TIMER
7 3
30A 20A 15A 15A 15A 15A 10A 10A 10A 10A 10A 10A 10A 10A
2WR 2WR 2WR
WINDOW WASHER 17 18 2C 15 16
123B 0.85RY 4G 5W 5W 4D 2B 15R 157A B
(4916-9006 )
HORN (H) H.F 0.85B 0.85RG
0.85L 23B + (R) - 32A 0.85BR (516-00014 ) FUSE BOX 2 FUSE BOX 1
P 5W 5W BLINKER 60R
1.25WR
(K1006678 ) (K1006678 )
0.85LR
0.85BY
UNIT
81B
4F 60BC 4E B (2525-1011 )
0.85BR 96B + (F) - 0.85B 123C 0.85RY 11A
P HORN (L) 15 16 0.85WR 17 18 15B 3WR
ACC
L.F 0.85B E 0.85B C A
(516-00015 ) 10A 10A 10A 10A 10A 10A 10A 10A 30A 20A 15A 15A 15A 15A 13A
0.85BR 96C 8 4 0.85B B
1 2 3 4 5 6 7 8 9 10 11 12 13 14
L 10A 6B BR 0.85Br
82A E STARTER (CUMMINS )
DA2-4 26A 89A 33A 184A 92A 16A 17A 63A 59A 45A 105A 19B 19A R2 85B
0.85BR 0.85BR 0.85GY 7A ST 2001 24V 25KW
0.85WR
0.85WL
0.85LB
1.25R 1.25R R1 FUSIBLE LINK 2

1.25RW
1.25RW
0.85RW
0.85LR
1.25LR
1.25RB 1.25RB 1.25RW STARTER SWITCH (2527-1023A)

2RG
2RL
2RL
0.85YB 0.85YB 1.25RW (K1001654A) 3WR 3R

0.85LR 0.85LR 5W 5W 5W 15A 1C
0.5G
2WR 1.25RW 0.85Br
FUSIBLE LINK 1
2LR 2LR (2527-1023A)
0.85RW 0.85RW 0.5RW 0.85Br 2WR 2R
2RL 2RL 2RL 1.25LR 7B 60R 2A 1B
0.5G
STOP LAMP SW (L) 0.85WL 0.85WL
3W
0.85GW 88A 89B 0.85GY 1.25RG DIODE 2 CIRCUIT BREAKER BATTERY RELAY
5bar (2544-9024 ) 2R 3R
0.85WR 0.85WR 0.85WR (2527-9004 )
(549-00010) 8A B
0.85GY A
HEAD LAMP(L) 5W 8W 8W
HEAD LAMP(R)
1.25RW
1.25RW
1.25RW
HORN RELAY
0.85RG
1
1.25LR
0.5RW
0.85LY 83A HEAD LAMP RELAY LAMP SWITCH

(K1005906 ) (K1005907 ) (2544-9033 ) 5 82B
2LR 4B 3B 3A
0.85GY (2544-9033 ) (2549-9109 ) 1A
21W 3W 70W 70W 70W 70W 3W 21W 0.85RY 0.85LB 7 1.25BrW BR
87a 1.25RG +(2190-2036D4) 1.25BrW 8C
30 92B 87a
123A 87 30 59B 0
0.5LY 83B 2 E
1.25WY 62A 87 60A 6 I 2
85 86 0.5BrY 6 196A 1.25B
1 5 4 6 3 2 2 3 6 4 5 1 8 0.5B 85 86 61B 0.5WY 61A 3 81C
0.5B 0.5WR 60T II
85B 16C 16D 87C 86B 86C 87D 17D 17C 84D 95C 60R
0.5WL
0.85LY
60B 9 10
0.85B
0.85B
60B 60R
0.5B 10 9
0.85WR
0.85RW
0.85RW
0.85WR
0.85WL
0.85WL
0.85GR
0.85GL
0.5WR
0.85R
0.85R
0.85LB 196B
0.85WR
0.85WR
0.85WL
0.85WL
CC-TV
0.85BR
60U
0.5BrW
0.5B
0.5GR
0.85G
0.5GL
0.5GL
0.5BrY HAZARD SWITCH 4P CONN(2)

2RL
(clearanc)
(clearanc)
(2549-9138 )
(turn sig)
(turn sig)
83C 83D - + - +
SW TURN SIGNAL
(high)
(high)
HEAD LAMP
(low)
+(2190-2036D2)
(low)
1 2 12V 150AH 12V 150AH

DA3-1 DA3-2 TML N
3 4
0.85GY 82C CN4-8
49a BATTERY
0.5GR 0.85GR 85B 84B 0.85GR 84A CN4-4 R (2506-6008 )x2
0.85GL 0.85GL 0.85GL 85A CN4-1 AVX 8W
L COMBINATION
0.85RW 0.85RW 1.25WY 62B CN4-5 SWITCH (R) AVX 1.25WG
56
0.85R 0.85R 0.85RW 86A CN4-6 (4549-9418) 1.25RW AVX 2RW
56b
0.85WR 0.85R 87A CN4-7
56a 9A 18A 4A
0.85GW 0.85RG 59C CN4-9 0.85W L B
15/1 P
1.25RW
1.25RW
92F CN5-6
1.25LR
0.5LB 0.85LB
0.5RW
0.85RY 15(53a) AIR HEATER

0.5Br
2LR
(clearanc)
153B 157B
(turn sig)
0.85BR 0.85BR 96A CN5-8

(stop)
53c E
0.85WL (clearanc)
0.85GL (turn sig)
0.85RY (back up)
0.85RY (back up)
C B
(stop)
0.5BrY 0.85BrY 95B CN4-2 - +

0.85B H
0.85B 0.85WR 94A CN5-7
HORN SWITCH 2 0.5BL
200A
J
0.85GW
0.85GR
0.85WR
0.85GW
92D 95A 0.85BrY H 97B 0.85RY 97A CN5-3 REGULATOR

53b
0.85B 4 9 L 98B 98A CN5-1
0.85LB 0.85YB
85E 88B 16B 58C 60X 58D 17B 88C 84E 43A 53
C A B E F D D F E B A C 0.85W 0.85BrL 100B CN5-4 (1) (2) F+
(ON JOYSTICK)-L S 101A 0.85Y 31b
LO + -
TML J 0 I II OFF ON OFF ON 154A D
HI H
DOWN SHIFT SW 15L F-
M STOP SW WIPER WASHER HORN 0.85BG
21W 21W 5W 21W 21W 92E
0.85WL 41B 46A 0.85V - B 0.85L 172A 172B
REAR COMBI LAMP LICENCE LAMP REAR COMBI LAMP RUN
5 8 0.5BL 94B 1 PREHEAT RELAY
(K1003561 ) (K1005717 ) (K1003561 ) E 0.85B ALTERNATOR E
(544-00007 ) 99
(ON JOYSTICK)-R (CUMMINS) 3972735
2RL
0.5BL 94C 2 8B
0.85RY 58B 101B 87a WIPER TIMER 24SI 24V 70A
+ PILOT CUT OFF SW WIPER MOTOR 30 100A 0.85BrL 94D
0.85B - (2549-9098 ) 0.5BL 3 (2537-9002 )
(4538-9017 ) 0.85LB 92C 87
+(2190-2036D17)
PILOT CUT OFF 0.85W AIRCON UNIT
BACK BUZZER 44B 0.85BW 44A 1 1 85 86 93B 93A (4920-9050A)
SOL-VALVE 0.5B 0.5L 4
85RW (2516-1124 ) 5 41C 0.85WL 0.85WL 41D 5
DA5-1 7 7 42A 0.85Or 0.85Or PARKING BRAKE 0.5B 5 BLOWER
85RW 44C RELEASE SOL-VALVE WIPER RELAY 15
1 3
42B 2LR 63D + -
(2544-9033 ) M
0.85G 0.85B 10 9 60F 0.5WR 0.5WR 60G 9 10 0.5B
14
1.25RW 0.85LR 63E
45P 0.5B DA5-2
0.85RL 3
42C 4 2
1.25RW
0.85YR 0.85YR 141B 2 SPEED SENSOR PARKING BRAKE SW
(ZF 0501 209 560) 0.85B 0.85Br
(2549-9098 )
0.85RB 0.85RB 142B 1
+(2190-2036D16) 0.85W
0.85V
0.85BG
0.85Or 0.85Or 0.85Or
AUTO(1-4) 0.85W
LOG FORK (OPT) 0.85LR
69B 3 69A 11
0.85W 0.5LB HIGH
AUTO(2-4)
0.85W
0.85WL 0.85WL 70B 5 0.5LY 70A 12 MID
(1) 43B 43C
0.85RY 0.85RY 71B 8 0.5LW 71A 13 LOW
3
0.85GW 147A 2 1 45G 0.85RL 0.85RL 1
DA6-1
72B 18 0.5GrG 72A 9 REC
148A 4 3 0.85B CONDENSER FAN RELAY 1.25LR
0.85BrL 0.85B 13 63F 73B 19 73A 10
KICK 1 CONDENSER ASS'Y (2544-9033 ) 0.5GrY FRE
2 3 4 INTAKE
F N R (520-00001 ) 87a 0.5RW 22 14E
AEB CHECK CONN DOWN STEP STEP STEP STEP ACTUATOR
0.85W 30 105B 0.85LR M
0.85RL 0.85RL 45K X2-A + 68B
VP (2) 0.85B - 68A 87
0.85Gr 0.85Gr 49A X2-D M
AD6 4 0.85L 85 86 105C 74B 23 0.5OrR 74A 7 OPEN
DW-3 DA6-2 0.5LR
X1-A AD3 2 75B 20 0.5OrW 75A 8 CLOSE
T/M SELECTOR SW 67A VENT
0.85V 0.85V 46B X1-D 0.85B
AD7 (4549-6072 ) ACTUATOR
10 67B M
0.85L 0.85L 51B X1-C (ZF 0501 210 702) 0.5YB 0.5YB
AD1
0.85G 0.85G 52B X1-B AD2 76A 14 0.5LgW 76B 3 (WARM)
COMPRESSOR RELAY
0.85Y 0.85Y 53B X2-B 0.85W 0.85RL
AD4 (2544-9033 ) 77A 15 0.5LgB 77B 2 (COOL)
M
0.85P 0.85P 54B X2-C 0.85WL 87a
AD5 150A 45J 30 63B 0.85LR 78A 2 0.5YR 78B 4 MIX
0.85P 54C CC-TV 55A
0.85BW 65A 87 79A 16 0.5YW 79B 5 ACTUATOR
4P CONN(4)
0.85LgB 186A 45M 0.85RL PST TML 3 2 1
0.5RB 64A 85 86 63C 0.5LR 80A 4 0.5YG 80B 1
0.85RL FNR SELECT SW
(K1006360 ) 2-LEVER (OPT) MANUAL
1 0.5B 0.85B 6
F 0.85Lg 193A 7 0 AUTO(1-4) THERMISTOR
3 0.85RL 9
N 0.85LgW 194A 5 I 191B 0.85Br 191A 87a AUTO(2-4) 0.5RB 64B
30 26 1.25B 2B 16
R 0.85LgR 195A 1 II AUTO SHIFT MODE SW
0.85BrL 192A 87 45H
0.85V 0.5B 10 9 60S (K1006355 ) RECEIVER DRIER COMPRESSOR
0.85RY 0.85RL (4208-6018 ) CN1 AMP MIC 13P + 250 4P
0.5WR 85 86 (2204-6039A)
0.85Lg FNR SWITCH 48A 0.85L 47A 1 66B
45N FNR SWITCH MAGNET
0.85LY 5 45L A/C CONTROL
193C 3 2x(549-00083 ) 25bar 47B 66A 0.85LW CLUTCH
1 0.5B 187D 7 PANEL 1. DIODE PART NO.
+(2190-2584D23) T/M CUT OFF SW 1 NOTE.
65B (K1010519 )
F (4549-9080 )
194C 2 HORN FNR SELECT RELAY 10 9 LOW PRESS HIGH PRESS DIODE 2 ~ 5 : 2548-1027
0.85Lg 193B 7 0 0.5WR
6 95A' 3 (2544-9033 ) 0.5B CUT OFF SW CUT OFF SW 66C DA1 ~ DA2 : K1000815
0.85LgW 0.85LgW 194B 5 I 192B 60H
N DIODE 4 DA3 ~ DA6 : K1000814
0.85LgR 195C 4 0.85LgR 195B 1 II DOWN SHIFT SW T/M CUT OFF SW 2 0.85B
5 46A'
0.85LgB 186C 7 0.5B 10 9 60Z 0.5WR 0.85V 0.85LY
ELECTRIC STEERING (2549-9098 )
R KD +(2190-2036D15) 0.85B
46C 187E (OPTION) 2/2
0.85LR 0.85LR LED 1~12
0.5WR 0.5WR 0.5WR 60W 11
1.25RW 1.25RW
1.25RW 1.25RW
DUCT/DEF DEF 2 102B 0.5G 102A 7
0.85Br 0.85Br ACTUATOR
DUCT 3 103B 0.5GW 103A 6
0.85W 0.85W (2213-9002 ) M
CN7 HRS 26P
0.85BG 0.85BG
0.85V
DL400
0.85LY
FG004940

Page 9
Page 10

sm-K1010635E (DL400) LowRes

Hochgeladen von

Dokumentinformationen

Originaltitel

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

sm-K1010635E (DL400) LowRes

Hochgeladen von

Copyright:

Verfügbare Formate

DL400

K1010635E Shop Manual

Trim Out The Label Along

Pub. No. K1010635E

COMPANY NAME: DATE:

Wheel Loader Safety SP000095

SP000095 Wheel Loader Safety

Wheel Loader Safety

Wheel Loader Safety SP000095

SP000095 Wheel Loader Safety

MODEL SERIAL NUMBER RANGE

SP000095 Wheel Loader Safety

Please respect the importance of taking responsibility for your

Wheel Loader Safety SP000095

SP000095 Wheel Loader Safety

Learn the Signal Words Used with the

Wheel Loader Safety SP000095

SP000095 Wheel Loader Safety

LOCATION OF SAFETY LABELS

Wheel Loader Safety SP000095

SP000095 Wheel Loader Safety

Wheel Loader Safety SP000095

SP000095 Wheel Loader Safety

Vibration Level Information

Asbestos Dust Hazard Prevention

Wheel Loader Safety SP000095

Fuel, Oil and Hydraulic Fluid Fire Hazards

Precautions When Handling Fluids at High

SP000095 Wheel Loader Safety

Injury from Work Equipment

Fire Extinguisher and First Aid Kit

Wheel Loader Safety SP000095

Protection from Falling or Flying Objects

Any reinforcement system that is installed on machine must

recertification and/or replacement of system may be necessary. Figure 10

Install Additional Safety Equipment If

SP000095 Wheel Loader Safety

Wheel Loader Safety SP000095

SP000095 Wheel Loader Safety

Work Site Precautions

If you need to operate on a street, protect pedestrians and cars

Wheel Loader Safety SP000095

SP000095 Wheel Loader Safety

Wheel Loader Safety SP000095

SP000095 Wheel Loader Safety

Wheel Loader Safety SP000095

Operate While Seated at Operator's Station

Seat Belts Should Be Used at All Times

SP000095 Wheel Loader Safety

Sloping Terrain Requires Caution

On sloping surfaces, use caution when positioning wheel loader

Wheel Loader Safety SP000095

Voltage Minimum Safe Distance

Use these minimum distances as a guideline only. Depending

Before Starting to Dig, Contact Authorities

Be Aware of Height Obstacles

Use Care on Loose Support

SP000095 Wheel Loader Safety

Digging Beneath Overhangs

Digging Beneath Wheel Loader

Stay Alert for People Moving Through

Be Aware of and Conform to Local

Wheel Loader Safety SP000095