HL740 9S

CONTENTS
FOREWORD -------------------------------------------------------------------------------------------------------------------------- 0-1
SECTION 1 GENERAL
Group 1 Safety Hints -------------------------------------------------------------------------------------------------------- 1-1

Group 2 Specifications ----------------------------------------------------------------------------------------------------- 1-10
Group 3 Operational Checkout Record Sheet --------------------------------------------------------------- 1-23
SECTION 2 ENGINE
Group 1 Structure and Function -------------------------------------------------------------------------------------- 2-1

Group 2 Fuel warmer system ----------------------------------------------------------------------------------------- 2-7
Group 3 Engine speed and Stall rpm ----------------------------------------------------------------------------- 2-8
SECTION 3 POWER TRAIN SYSTEM

Group 2 Operational Checks and Troubleshooting ------------------------------------------------------- 3-53
Group 3 Test and Adjustments ---------------------------------------------------------------------------------------- 3-64
Group 4 Disassembly and Assembly ----------------------------------------------------------------------------- 3-66
SECTION 4 BRAKE SYSTEM

Group 3 Tests and Adjustments -------------------------------------------------------------------------------------- 4-38
Group 4 Disassembly and assembly ------------------------------------------------------------------------------ 4-40
SECTION 5 STEERING SYSTEM

SECTION 6 WORK EQUIPMENT

SECTION 7 ELECTRICAL SYSTEM
Group 1 Component Location --------------------------------------------------------------------------------------- 7-1

Group 2 Electrical Circuit ----------------------------------------------------------------------------------------------- 7-3
Group 3 Monitoring System ------------------------------------------------------------------------------------------ 7-21
Group 4 Electrical Component Specification --------------------------------------------------------------- 7-48
Group 5 Connectors ------------------------------------------------------------------------------------------------------- 7-55
Group 6 Troubleshooting ------------------------------------------------------------------------------------------------ 7-75
FOREWORD
1. STRUCTURE
This service manual has been prepared as an aid to improve the quality of repairs by giving the
serviceman an accurate understanding of the product and by showing him the correct way to
perform repairs and make judgements. Make sure you understand the contents of this manual and
use it to full effect at every opportunity.
This service manual mainly contains the necessary technical information for operations performed in
a service workshop.
For ease of understanding, the manual is divided into the following sections.
Structure and function

This group explains the structure and function of each component. It serves not only to give an
understanding of the structure, but also serves as reference material for troubleshooting.
Operational checks and troubleshooting
This group explains the system operational checks and troubleshooting charts correlating problem to
remedy.
Tests and adjustments
This group explains checks to be amide before and after performing repairs, as well as adjustments
to be made at completion of the checks and repairs.
Disassembly and assembly
This section explains the order to be followed when removing, installing, disassembling or
assembling each component, as well as precautions to be taken for these operations.
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Contact your Hyundai distributor for the latest information.
0-1
2. HOW TO READ THE SERVICE MANUAL
Distribution and updating Revised edition mark (①②③…)
Any additions, amendments or other changes When a manual is revised, an edition mark is
will be sent to HYUNDAI distributors. recorded on the bottom outside corner of the
Get the most up-to-date information before you pages.
start any work.
Revisions
Filing method Revised pages are shown at the list of revised
1. See the page number on the bottom of the pages on the between the contents page and
page. section 1 page.
File the pages in correct order.
2. Following examples shows how to read the Symbols
page number. So that the shop manual can be of ample
Example 1 practical use, important places for safety and
3-3 quality are marked with the following symbols.
Section number (3. Power train
system)
Consecutive page number for Symbol Item Remarks
each section.
Special safety precautions are
3. Additional pages : Additional pages are necessary when performing the
indicated by a hyphen(-) and number after the work.
Safety
page number. File as in the example. Extra special safety precautions
10 - 4 are necessary when performing
10 - 4 - 1 the work because it is under
Added pages internal pressure.
10 - 4 - 2
10 - 5 Special technical precautions or
※ Caution
other precautions for preserving
standards are necessary when
performing the work.
0-2
3. CONVERSION TABLE
Method of using the Conversion Table
The Conversion Table in this section is provided to enable simple conversion of figures. For details of
the method of using the Conversion Table, see the example given below.
Example
1. Method of using the Conversion Table to convert from millimeters to inches
Convert 55 mm into inches.
(1) Locate the number 50 in the vertical column at the left side, take this as ⓐ, then draw a horizontal
line from ⓐ.
(2) Locate the number 5in the row across the top, take this as ⓑ, then draw a perpendicular line
down from ⓑ.
(3) Take the point where the two lines cross as ⓒ. This point ⓒ gives the value when converting
from millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.

(1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place
to the left) to convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal
point one place to the right) to return to the original value.
This gives 550 mm = 21.65 inches.
Millimeters to inches ⓑ
1mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
ⓒ
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
ⓐ
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
0-3
Millimeters to inches 1mm = 0.03937in
0 1 2 3 4 5 6 7 8 9
0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to Pound 1kg = 2.2046lb
0 1 2 3 4 5 6 7 8 9
0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84

10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.5. 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
0-4
Liter to U.S. Gallon 1ℓ = 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378

10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.6076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.631 25.625 25.889 26.153
Liter to U.K. Gallon 1ℓ = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980

10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
0-5
kgf·m to lbf
kgf lbf·ftft 1kgf·m = 7.233lbf·ft
0 1 2 3 4 5 6 7 8 9
7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1

10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 396.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 10005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
0-6
kgf/cm2 to lbf/in2 1kgf / cm2 = 14.2233lbf / in2
0 1 2 3 4 5 6 7 8 9
14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0

10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 2863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 5603 2617 2631 2646 2660 2674 2688
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
0-7
TEMPERATURE
Fahrenheit-Centigrade Conversion.
A simple way to convert a fahrenheit temperature reading into a centigrade temperature reading or vice verse
is to enter the accompanying table in the center or boldface column of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
˚C ˚F ˚C ˚F ˚C ˚F ˚C ˚F
-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 117.8
-37.2 -35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
-26.7 -16 3.2 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
-26.1 -15 5.0 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

-25.0 -13 8.6 -5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
-24.4 -12 10.4 -5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
-23.9 -11 12.2 -4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

-22.2 -8 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
-20.6 -5 23.0 -1.1 35 95.0 21.1 70 158.0 51.7 125 257.0
-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

-19.4 -3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
-18.9 -2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 172 347.0
0-8
SECTION 1 GENERAL
Group 1 Safety Hints --------------------------------------------------------------------------------------------------------1-1

Group 2 Specifications -----------------------------------------------------------------------------------------------------1-10
Group 3 Operational Checkout Record Sheet ---------------------------------------------------------------1-23
SECTION 1 GENERAL
GROUP 1 SAFETY HINTS
FOLLOW SAFE PROCEDURE

Unsafe wor k practices are dangerous.
Understand service procedure before doing
work; Do not attempt shortcuts.
WEAR PROTECTIVE CLOTHING

Wear close fitting clothing and safety equipment
appropriate to the job.
73031GE01
WARN OTHERS OF SERVICE WORK

Unexpected machine movement can cause
serious injury.
Before performing any work on the wheel load-
WARN
er, attach a「DoDo Not Operate
Operate」tag on the right
DO
side controller lever.
NOT
OPERATE
7579S1GE01
USE HANDHOLDS AND STEPS

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

steps, and handrails when leaving the machine.
1-1
PREPARE FOR EMERGENCIES
Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors,
ambulance ser vice, hospital, and fire
department near your telephone.
73031GE03
WORK IN CLEAN AREA

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

Guard against injury from flying pieces of metal
or debris; Wear goggles or safety glasses.
73031GE04
PROTECT AGAINST NOISE

Prolonged exposure to loud noise can cause
impairment or loss of hearing.
Wear a suitable hearing protective device such
as earmuffs or earplugs to protect against
objectionable or uncomfortable loud noises.
73031GE05
1-2
PARK MACHINE SAFELY
Before working on the machine:
· Park machine on a level surface.
· Lower bucket to the ground.
· Turn key switch to OFF to stop engine.
Remove key from switch.
· Move pilot control shutoff lever to locked
position.
· Allow engine to cool. 73031GE23
SUPPORT MACHINE PROPERLY

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

Explosive release of fluids from pressurized
cooling system can cause serious burns.
Shut off engine. Only remove filler cap when
cool enough to touch with bare hands.
73031GE07
HANDLE FLUIDS SAFELY-AVOID FIRES

Handle fuel with care; It is highly flammable.
Do not refuel the machine while smoking or
when near open flame or sparks. Always stop
engine before refueling machine.
Fill fuel tank outdoors.
73031GE08
1-3
Store flammable fluids away from fire hazards.
Do not incinerate or puncture pressurized
containers.
Make sure machine is clean of trash,
grease, and debris.
Do not store oily rags ; They can ignite and
burn spontaneously.
73031GE09
BEWARE OF EXHAUST FUMES

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

HEATING
Avoid potentially toxic fumes and dust.
Hazardous fumes can be generated when paint
is heated by welding, soldering, or using a torch.
Do all work outside or in a well ventilated area.
Dispose of paint and solvent properly.
Remove paint before welding or heating:
· If you sand or grind paint, avoid breathing the
dust. Wear an approved respirator.
· If you use solvent or paint stripper, remove
stripper with soap and water before welding.
Remove solvent or paint stripper containers
and other flammable material from area.
Allow fumes to disperse at least 15 minutes
before welding or heating. 73031GE10
1-4
ILLUMINATE WORK AREA SAFELY
Illuminate your work area adequately but safely.
Use a portable safety light for working inside or
under the machine. Make sure the bulb is
enclosed by a wire cage. The hot filament of an
accidentally broken bulb can ignite spilled fuel
or oil.
73031GE11
SERVICE MACHINE SAFELY

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

Entanglements in moving parts can cause
serious injury.
To prevent accidents, use care when working
around rotating parts.
73031GE13
1-5
AVOID HIGH PRESSURE FLUIDS
Escaping fluid under pressure can penetrate the
skin causing serious injury.
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten
all connections before applying pressure.
Search for leaks with a piece of cardboard.
Protect hands and body from high pressure
73031GE14
fluids.
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be
surgically removed within a few hours or
gangrene may result.
73031GE15
AVOID HEATING NEAR PRESSURIZED

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

Keep sparks, lighted matches, and flame away
from the top of battery. Battery gas can
explode.
Never check battery charge by placing a metal
object across the posts. Use a volt-meter or
hydrometer.
Do not charge a frozen battery; It may explode.
73031GE17
Warm battery to 16˚C (60˚F).
1-6
PREVENT ACID BURNS
Sulfuric acid in battery electrolyte is poisonous. It
is strong enough to burn skin, eat holes in
clothing, and cause blindness if splashed into
eyes.
1. Avoid the hazard by:
2. Filling batteries in a well-ventilated area.
3. Wearing eye protection and rubber gloves.
Avoiding breathing fumes when electrolyte
is added.
4. Avoiding spilling of dripping electrolyte.
5. Use proper jump start procedure.
1. If you spill acid on yourself:
2. Flush your skin with water.
Apply baking soda or lime to help neutralize
the acid.
3. Flush your eyes with water for 10-15 minutes.
Get medical attention immediately.
1. If acid is swallowed:
2. Drink large amounts of water or milk.
Then drink milk of magnesia, beaten eggs,
or vegetable oil.
73031GE18
3. Get medical attention immediately.
USE TOOLS PROPERLY

Use tools appropriate to the work. Makeshift
tools, parts, and procedures can create safety
hazards.
Use power tools only to loosen threaded tools
and fasteners.
For loosening and tightening hardware, use the
correct size tools. Avoid bodily injury caused by
73031GE19
slipping wrenches.
Use only recommended replacement parts.
(See Parts catalogue.)
1-7
SERVICE TIRES SAFELY
Explosive separation of a tire and rim parts can
cause serious injury or death.
Do not attempt to mount a tire unless you have the
proper equipment and experience to perform the job.
Always maintain the correct tire pressure. Do not
inflate the tires above the recommended pressure.
Never weld or heat a wheel and tire assembly.
The heat can cause an increase in air pressure
resulting in a tire explosion.
Welding can structurally weaken or deform the
wheel.
When inflating tires, use a clip-on chuck and
extension hose long enough to allow you to stand
to one side and not in front of or over the tire
assembly. Use a safety cage if available.
Check wheels for low pressure, cuts, bubbles, 73031GE24
damaged rims or missing lug bolts and nuts.
USE PROPER LIFTING EQUIPMENT

Lifting heavy components incorrectly can cause
severe injury or machine damage.
Follow recommended procedure for removal and
installation of components in the manual.
73031GE25
DISPOSE OF FLUIDS PROPERLY

Improperly disposing of fluids can harm the
environment and ecology. Before draining any
fluids, find out the proper way to dispose of waste
from your local environmental agency.
Use proper containers when draining fluids. Do
not use food or beverage containers that may
mislead someone into drinking from them.
73031GE20
DO NOT pour oil into the ground, down a drain, or
into a stream, pond, or lake. Observe relevant
environmental protection regulations when
disposing of oil, fuel, coolant, brake fluid, filters,
batteries, and other harmful waste.
1-8
REPLACE SAFETY SIGNS
Replace missing or damaged safety signs.
See the machine operator's manual for correct
safety sign placement.
73031GE21
LIVE WITH SAFETY

Before returning machine to customer, make
sure machine is functioning properly, especially
the safety systems. Install all guards and
shields.
K E E P RO P S I N S TA L L E D P RO P E R LY
(option)
Make certain all parts are reinstalled correctly if
the roll-over protective structure (ROPS) is
loosened or removed for any reason. Tighten
mounting bolts to proper torque.
The protection offered by ROPS will be
impaired if ROPS is subjected to structural
damage, is involved in an overturn incident, or is
in any way altered by welding, bending, drilling, 73031GE22
or cutting. A damaged ROPS should be
replaced, not reused.
1-9
GROUP 2 SPECIFICATION
1. MAJOR COMPONENT
Bucket Tire Head light Hydraulic tank Air cleaner Radiator
Boom Boom cylinder Main control valve Battery Counterweight
Precleaner(option)
Bell crank Bucket cylinder Cab Main pump Rain cap(std) Muffler Engine
Bucket link Front axle Steering cylinder Transmission Rear axle Fuel tank
7609S2SE01
1-10
2. SPECIFICATIONS
1) WITH BOLT-ON CUTTING EDGE TYPE BUCKET (HL757-9S)
5250
B
F
I
H
3910
C
K
G
40
52
D
0
617 0
5
E
A
7579S2SE03
Description Unit Specification

Operating weight kg (lb) 14000 (30860)
Struck 2.3 (3.0)
Bucket capacity m3 (yd3)
Heaped 2.7 (3.5)
Overall length A 7540 (24' 9")
Overall width B 2740 ( 9' 0")
Overall height C 3400 (11' 2")
Ground clearance D 410 ( 1' 4")
Wheelbase E mm (ft-in) 3050 ( 10' 0")
Tread F 2050( 6' 9")
Dump clearance at 45˚ G 2860 ( 9' 5")
Dump reach (full lift) H 1040 ( 3' 5")
Width over tires I 2580 ( 8' 6")
Dump angle J 47
degree (˚)
Roll back angle (carry position) K 46
Lift (with load) 6.0
Cycle time Dump (with load) sec 1.2
Lower (empty) 3.1
Maximum travel speed km/hr (mph) 35.8 (22.2)
Braking distance 12 (39' 4")
m (ft-in)
Minimum turning radius (center of outside tire) 5.2 (17' 1")
Gradeability degree (˚) 30
Brakeout force kg (lb) 12720 (28040)
First gear 6.9 (4.3)
Second gear 11.4 (7.1)
Forward
Third gear 22.7 (14.1)
Travel speed Fourth gear km/hr (mph) 35.8 (22.2)
Reverse Second gear 12.0 (7.5)
1-11
WITH BOLT-ON CUTTING EDGE TYPE BUCKET (HL757XTD-9S)
5650
B
F
I
4320
H
C
K
G
40
52
D
0
636 0
0 E
A
7579S2SE03-1

Struck 2.3 (3.0)
Heaped 2.7 (3.5)
Tread F 2050 ( 6' 9")
Dump clearance at 45˚ G 3270 (10' 9")
Dump angle J 47
degree (˚)
Lower (empty) 3.1
m (ft-in)
Forward
1-12
2) WITH TOOTH TYPE BUCKET (HL757-9S)
5250
B
F
I
H
3910
C
K
G
40
52
D
0
623 0
5
E
A
7579S2SE02

Struck 2.2 (2.9)
Heaped 2.6 (3.4)
Tread F 2050 ( 6' 9")
Dump angle J 47
degree (˚)
Lower (empty) 3.1
m (ft-in)
Forward
1-13
WITH TOOTH TYPE BUCKET (HL757XTD-9S)
5650
B
F
I
H
4320
C
K
G
40
52
D
0
642 0
0 E
A
7579S2SE02-1

Struck 2.3 (3.0)
Heaped 2.7 (3.5)
Tread F 2050 ( 6' 9")
Dump angle J 47
degree (˚)
Lower (empty) 3.1
m (ft-in)
Forward
1-14
3. WEIGHT
Item kg lb
Front frame assembly 1139 2510
Rear frame assembly 1667 3680
Front fender (LH & RH) 31 68
HL757-9S 550 1210
Counterweight
HL757XTD-9S 840 1850
Cab assembly 780 1720
Engine assembly 485 1070
Transmission assembly 518 1140
Drive shaft (front) 26 57
Drive shaft (center) 22 49
Drive shaft (rear) 13 29
Front axle (include differential) 970 2140
Rear axle (include differential) 760 1680
Tire (20.5-25, 16PR, L3) 203 448
Hydraulic tank assembly 230 507
Fuel tank assembly 219 483
Main pump assembly 40 88
Fan & brake pump assembly 6.5 14.3
Main control valve (2 / 3 spool) 45 / 65 99 / 143
Steering valve (EHPS) 10 22
HL757-9S 980 2160
Boom assembly
HL757XTD-9S 1145 2520
Bell crank assembly 264 580
Bucket link 48 110
2.8 m3 bucket, with bolt on cutting edge 1075 2370
2.6 m3 bucket, with tooth 1060 2340
Boom cylinder assembly 108 238
Bucket cylinder assembly 122 269
Steering cylinder assembly 29 64
Seat 40 88
Battery 44 97
1-15
4. SPECIFICATION FOR MAJOR COMPONENTS
1) ENGINE
Item Specification
Model Cummins QSB6.7
Type 4-cycle turbocharged and charge air-cooled diesel engine
Control type Electronic control
Cooling method Water cooling
Number of cylinders and arrangement 6 cylinders, in-line
Firing order 1-5-3-6-2-4
Combustion chamber type Direct injection type
Cylinder bore × stroke 107×124 mm (4.2"×4.9")
Piston displacement 6730 cc (410cu in)
Compression ratio 17.2 : 1
Rated horse power (Net) 170 hp at 2100 rpm
Maximum torque at 1400 rpm (Net) 82 kgf·m (593 lbf·ft)
Engine oil quantity 18ℓ (4.8 U.S. gal)
Wet weight 485 kg(1069 lb)
High idling speed 2230 ± 50 rpm
Low idling speed 800± 25 rpm
Rated fuel consumption 252 g/kW·hr
Starting motor Nippondenso 228000-7902 (24V-3.7kW)
Alternator Delco Remy 24SI (24V-70Amp)
Battery 2×12V×160Ah
1-16
2) MAIN PUMP
Item Specification
Type Gear pump
Capacity 56+56 cc/rev
Maximum operating pressure 210 kgf/cm2 (2990 psi)
Rated oil quantity 225ℓ/min (59.4 U.S.gpm)
Rated speed 2100 rpm
3) FAN + BRAKE PUMP

Specification
Item
Fan Brake
Type Gear pump
Capacity 19.4 cc/rev 11.9 cc/rev
Maximum operating pressure 120 kgf/cm2 (1710 psi) 150 kgf/cm2 (2130 psi)
Rated oil quantity 39ℓ/min (10.3 U.S.gpm) 24ℓ/min (6.3 U.S.gpm)
Rated speed 2100 rpm
4) MAIN CONTROL VALVE

Item Specification
Type 2 spool
Operating method Hydraulic pilot assist
System pressure 210 kgf/cm2 (2990 psi)
Overload relief valve pressure 240 kgf/cm2 (3410 psi)
5) REMOTE CONTROL VALVE

Item Specification
Type Pressure reducing type
Minimum 6.5 kgf/cm2 (92.4 psi)
Operating pressure
Maximum 22 kgf/cm2 (312.9 psi)
Single operation stroke Lever 80 mm (3.4 in)
1-17
6) CYLINDER
Item Specification
Boom cylinder Bore dia×Rod dia×Stroke Ø140×Ø75×750 mm
Bucket cylinder Bore dia×Rod dia×Stroke Ø160×Ø80×475 mm
Steering cylinder Bore dia×Rod dia×Stroke Ø 70×Ø45×436 mm
7) DYNAMIC POWER TRANSMISSION DEVICES
Item Specification
Model 4WG190
Converter Single-stage, single-phase
Type
Transmission Full-automatic power shift
Transmission Converter stall ratio 2.542 : 1
Gear shift Forward fourth gear, reverse third gear
Control Electrical single lever type, kick-down system
Pump rated flow 105ℓ/min (27.7 U.S.gpm) at 2000 rpm
Drive devices 4-wheel drive
Axle Front Front fixed location
Rear Oscillation ±13˚ of center pin-loaded
Wheels Tires 20.5-25, 16PR (L3)
Travel Four-wheel, wet-disc type, full hydraulic
Brakes
Parking Spring applied, hydraulic released brake on transmission
Type Full hydraulic, articulated
Steering
Steering angle 40˚ to both right and left angle, respectively
1-18
5. TIGHTENING TORQUE OF MAJOR COMPONENT
Torque
No. Descriptions Bolt size
kgf·m lbf·ft
1 Engine mounting bolt, nut (rubber, 2EA) M20×2.5 57.9 ± 8.7 419 ± 63
2 Engine mounting bolt (bracket, 8EA) M12×1.75 10.7 ± 1.6 77.4 ± 11.6
3 Engine mounting bolt (flywheel housing, 12EA) M10×1.5 4.6 ± 0.9 33.3 ± 6.5
Engine
4 Engine mounting bolt (flywheel housing, 4EA) M10×1.5 4.5 ± 0.6 32.5 ± 4.3
5 Radiator mounting bolt M16×2.0 29.7 ± 4.5 215 ± 32.5
6 Fuel tank mounting bolt, nut M16×2.0 29.7 ± 4.5 215 ± 32.5
7 Main pump housing mounting bolt M12×1.75 12.8 ± 3.0 92.6 ± 21.7
8 Fan & brake pump housing mounting bolt M10×1.5 6.9 ± 1.4 50 ± 10.1
9 Main control valve mounting bolt M12×1.75 12.8 ± 3.0 92.6 ± 21.7
10 Steering unit mounting bolt M10×1.5 6.9 ± 1.4 50 ± 10.1
11 Pilot supply unit M8×1.25 2.5 ± 0.5 18.1 ± 3.6
12 Hydraulic Steering valve (EHPS) mounting bolt M8×1.25 2.5 ± 0.5 18.1 ± 3.6
13 system Cushion valve M8×1.25 2.5 ± 0.5 18.1 ± 3.6
14 Brake valve mounting bolt M8×1.25 2.5 ± 0.5 18.1 ± 3.6
15 Cut-off valve mounting bolt M8×1.25 2.5 ± 0.5 18.1 ± 3.6
16 Remote control lever mounting bolt M6×1.0 1.1 ± 0.2 8.0 ± 1.4
17 Safety valve M8×1.25 2.5 ± 0.5 18.1 ± 3.6
18 Hydraulic oil tank mounting bolt M16×2.0 29.7 ± 4.5 215 ± 32.5
19 Transmission mounting bolt, nut (rubber, 2EA) M24×3.0 100 ± 15 723 ± 108
20 Transmission mounting bolt (bracket) M20×2.5 46.3 ± 7.0 335 ± 50.6
21 Power Front axle mounting bolt, nut M27×2.0 135 ± 15 976 ± 108
train
22 system Rear axle support mounting bolt, nut M27×2.0 135 ± 15 976 ± 108
23 Tire mounting nut M22×1.5 79 ± 2.5 571 ± 18.1
24 Drive shaft joint mounting bolt, nut 1/2-20UNF 6.0 ± 0.8 43.4 ± 5.8
25 Counterweight mounting bolt M30×3.5 199 ± 30 1439 ± 216
26 Operator's seat mounting bolt M8×1.25 3.4 ± 0.8 24.6 ± 5
Others
27 Cab mounting bolt (4EA) M30×3.5 199 ± 30 1440 ± 217
28 Cab mounting nut (4EA) M16×2.0 20.5 ± 4.7 148 ± 40
1-19
6. TORQUE CHART
Use following table for unspecified torque.
1) BOLT AND NUT
(1) Coarse thread

8T 10T
Bolt size
kg·m lb·ft kg·m lb·ft
M 6×1.0 0.85 ~ 1.25 6.15 ~ 9.04 1.14 ~ 1.74 8.2 ~ 12.6
M 8×1.25 2.0 ~ 3.0 14.5 ~ 21.7 2.73 ~ 4.12 19.5 ~ 29.8
M10×1.5 4.0 ~ 6.0 28.9 ~ 43.4 5.5 ~ 8.3 39.8 ~ 60
M12×1.75 7.4 ~ 11.2 53.5 ~ 79.5 9.8 ~ 15.8 71 ~ 114
M14×2.0 12.2 ~ 16.6 88.2 ~ 120 16.7 ~ 22.5 121 ~ 167
M16×2.0 18.6 ~ 25.2 135 ~ 182 25.2 ~ 34.2 182 ~ 247
M18×2.5 25.8 ~ 35.0 187 ~ 253 35.1 ~ 47.5 254 ~ 343
M20×2.5 36.2 ~ 49.0 262 ~ 354 49.2 ~ 66.6 356 ~ 482
M22×2.5 48.3 ~ 63.3 350 ~ 457 65.8 ~ 98.0 476 ~ 709
M24×3.0 62.5 ~ 84.5 452 ~ 611 85.0 ~ 115 615 ~ 832
M30×3.0 124 ~ 168 898 ~ 1214 169 ~ 229 1223 ~ 1655
M36×4.0 174 ~ 236 1261 ~ 1703 250 ~ 310 1808 ~ 2242
(2) Fine thread

8T 10T
Bolt size
kg·m lb·ft kg·m lb·ft
M 8×1.0 2.17 ~ 3.37 15.7 ~ 24.3 3.04 ~ 4.44 22.0 ~ 32.0
M10×1.25 4.46 ~ 6.66 32.3 ~ 48.2 5.93 ~ 8.93 42.9 ~ 64.6
M12×1.25 7.78 ~ 11.58 76.3 ~ 83.7 10.6 ~ 16.0 76.6 ~ 115
M14×1.5 13.3 ~ 18.1 96.2 ~ 130 17.9 ~ 24.1 130 ~ 174
M16×1.5 19.9 ~ 26.9 144 ~ 194 26.6 ~ 36.0 193 ~ 260
M18×1.5 28.6 ~ 43.6 207 ~ 315 38.4 ~ 52.0 278 ~ 376
M20×1.5 40.0 ~ 54.0 289 ~ 390 53.4 ~ 72.2 386 ~ 522
M22×1.5 52.7 ~ 71.3 381 ~ 515 70.7 ~ 95.7 512 ~ 692
M24×2.0 67.9 ~ 91.9 491 ~ 664 90.9 ~ 123 658 ~ 890
M30×2.0 137 ~ 185 990 ~ 1338 182 ~ 248 1314 ~ 1795
M36×3.0 192 ~ 260 1389 ~ 1879 262 ~ 354 1893 ~ 2561
1-20
2) PIPE AND HOSE (FLARE type)
Thread size Width across flat (mm) kgf·m lbf·ft
1/4" 19 4 28.9
3/8" 22 5 36.2
1/2" 27 9.5 68.7
3/4" 36 18 130
1" 41 21 152
1-1/4" 50 35 253
3) PIPE AND HOSE (ORFS type)
9/16-18 19 4 28.9
11/16-16 22 5 36.2
13/16-16 27 9.5 68.7
1-3/16-12 36 18 130
1-7/16-12 41 21 152
1-11/16-12 50 35 253
4) FITTING
1/4" 19 4 28.9
3/8" 22 5 36.2
1/2" 27 9.5 68.7
3/4" 36 18 130
1" 41 21 152
1-1/4" 50 35 253
1-21
7. RECOMMENDED LUBRICANTS
Use only oils listed below or equivalent.
Do not mix different brand oil.
Ambient temperature˚C (˚F)
Capacity
Service point Kind of fluid -20 -10 0 10 20 30 40
ℓ (U.S. gal)
(-4) (14) (32) (50) (68) (86) (104)
SAE 30
SAE 10W
Engine oil pan Engine oil 18 (4.8)
SAE 10W-30
SAE 15W-40
SAE 10W-30
Transmission Engine oil 43 (11.4)
SAE 15W-40
Front : 32 (8.5) ★
Axle UTTO Refer to below list
Rear : 24 (6.3)
ISO VG 32
Tank:
124 (32.7)
Hydraulic tank Hydraulic oil ISO VG 46
System:
175 (46)
ISO VG 68
ASTM D975 NO.1

Fuel tank Diesel fuel 294 (77.6)
ASTM D975 NO.2
NLGI NO.1
Fitting
Grease As required
(grease nipple) NLGI NO.2
Mixture of
antifreeze Ethylene glycol base permanent type
Radiator 36 (9.5)
and water
50 : 50
★
·SAE : Society of Automotive Engineers Recommended oil list
·API : American Petroleum Institute - BP TERRAC SUPER TRANSMISSION 10W-30
·ISO : International Organization for Standardization - CASTROL AGRI TRANS PLUS 10W-30
·NLGI : National Lubricating Grease Institute - MOBILFLUID 426
·ASTM : American Society of Testing and Material - SHELL DONAX TD 10W-30
·UTTO : Universal Tractor Transmission Oil - TOTAL DYNATRANS MPV
1-22
GROUP 3 OPERATIONAL CHECKOUT RECORD SHEET
·Owner :
·Date :
·Hours :
·Serial No. :
·Technician :
※ Use this sheet to record operational

checkout results.
Perform the operational check before
installing any test equipment. 75791GE02
OK NOT
Item Comments
OK
1. Monitor indicator and gauge checks (engine OFF)
· Hourmeter and gauge check □ □

· Battery check □ □
· Monitor indicator circuit check □ □
· Cluster turn signals and warning indicator check □ □
2. Transmission, axle and engine, neutral start

switch and reverse warning alarm switch checks
· Transmission control lever and neutral □ □

· Neutral start and reverse warning □ □
· Alarm circuit checks □ □
3. Monitor indicator and gauge checks (engine running)
· Monitor display and alternator output checks □ □

· Monitor bypass circuit and seat belt indicator check □ □
· Monitor primary and secondary level check □ □
· Transmission oil warm up procedure □ □
· Transmission temperature gauge check □ □
1-23
4. Brake system and clutch cut off checks
· Park brake capacity check □ □

· Park brake transmission lockout check □ □
· Service brake pump flow check □ □
· Service brake capacity check □ □
· Brake accumulator precharge check □ □
· Brake system leakage check □ □
· Service brake pedal check □ □
· Service and park brake system drag check □ □
· Clutch cut off check □ □
5. Driving checks
·Transmission oil warm up procedure □ □

·Transmission noise check □ □
·Speedometer check □ □
·Transmission kick down system check □ □
·1st, 2nd, 3rd and 4th speed clutch pack drag check □ □
·Transmission pressure, pump flow and leakage check □ □
·Transmission shift modulation check □ □
·Torque converter check □ □
·Engine power check □ □
6. Hydraulic system checks
·Hydraulic system warm up procedure □ □

·Hydraulic pump performance check □ □
·Pilot control valve boom float check □ □
·Boom down solenoid valve check □ □
·Control valve lift check □ □
·Bucket rollback circuit relief valve check □ □
·Bucket dump circuit relief
Low pressure check □ □
High pressure check □ □
·Boom and bucket cylinder drift check □ □
·Boom down solenoid valve leakage check □ □
·Pilot controller check □ □
·Return to dig check □ □
·Boom height kickout check-if equipped □ □
1-24
7. Steering system checks
·Steering unit check □ □

·Steering system leakage check □ □
·Steering valve (EHPS)
Low check pressure □ □
High check pressure □ □
8. Accessory checks
·Operating lights check □ □

·Work light check □ □
·Brake light check □ □
·Cab light check □ □
·Horn circuit check □ □
·Windshield washer and wiper check □ □
·Defroster blower check □ □
·Heater/Air conditioner blower check □ □
·Heater functional check □ □
·Air conditioner functional check □ □
·Start aid system check □ □
9. Cab components and vandal protection checks
·Cab door latch check □ □

·Cab door hold open latch check □ □
·Cab door release button check □ □
·Cab door lock check □ □
·Cab door window check □ □
·Cab window latch check □ □
·Steering column adjustment check □ □
·Seat and seat belt check □ □
·Air intake filter door check □ □
·Engine side panels check □ □
·Radiator cap access door check □ □
·Frame locking bar check □ □
·Boom lock check □ □
·Service decal check □ □
1-25
SECTION 2 ENGINE

Group 2 Fuel warmer system ------------------------------------------------------------------------------------------ 2-7
Group 3 Engine speed and Stall rpm ----------------------------------------------------------------------------- 2-8
SECTION 2 ENGINE
GROUP 1 STRUCTURE AND FUNCTION
1. STRUCTURE
Exhaust outlet connection

Turbocharger
Air inlet connection

Lifting bracket
Air heating
starting aid
Alternator
Crankcase
breather
Belt tensioner
Vibration damper Injection pump

Fuel filter
Oil level gauge
ECM(Engine control module)
Starter Valve cover Air intake connection
Flywheel housing
Water outlet
Fan drive
Lubricating oil filter

Alternator mounting
Water inlet connection
Oil pan
7577AEG01
· Direct 4-stroke, 6-cylinders, water-cooling and charge air cooled diesel engine in installed, cylinder
block and cylinder head are made of case iron and turbocharger is attached.
2-1
2. SYSTEM DIAGRAMS
The following drawings show the flow through the engine systems.
1) FUEL SYSTEM
7607AEG02
1 From fuel tank 11 Fuel rail

2 Water/fuel separator (not mounted on engine) 12 To injectors
3 ECM cooling plate 13 High-pressure connector
4 To fuel gear pump 14 Injector
5 To fuel filter 15 Fuel return from injectors and fuel rail to fuel
6 Fuel filter head filter head
7 Fuel filter 16 Fuel return from high-pressure pump to fuel
8 To high-pressure pump filter head
9 High-pressure pump 17 To fuel tank
10 To fuel rail
2-2
2) LUBRICATING OIL SYSTEM
7607AEG03
1 Gerotor lubricating oil pump 8 Filter bypass valve

2 From lubricating oil pump 9 Filter bypass valve closed
3 Pressure regulating valve closed 10 Filter bypass valve open
4 Pressure regulating valve open 11 To lubricating oil filter
5 To lubricating oil cooler 12 Full-flow lubricating oil filter
6 To lubricating oil pump supply 13 From lubricating oil filter
7 Lubricating oil cooler 14 Main lubricating oil rifle
(1) Lubrication for the turbocharger
7607AEG04
1 Turbocharger lubricating oil supply 2 Turbocharger lubricating oil drain
2-3
(2) Lubrication for the power components
7607AEG05
1 From lubricating oil cooler 6 To camshaft

2 Main lubricating oil rifle 7 Crankshaft main journal
3 To valve train 8 Oil supply to rod bearings
4 From main lubricating oil rifle 9 Directed piston-cooling nozzle
5 To piston-cooling nozzle 10 To internal lubrication of air compressor
(3) Lubrication for the overhead
7607AEG06
1 Main lubricating oil rifle 4 Rocker lever shaft

2 Rocker lever support 5 Rocker lever bore
3 Transfer slot 6 Rocker lever
2-4
3) COOLING SYSTEM
7607AEG07
1 Coolant inlet 7 Coolant flow to thermostat housing

2 Pump lmpeller 8 Coolant bypass passage
3 Coolant flow past lubricating oil cooler 9 Coolant flow back to radiator
4 Coolant flow past cylinders 10 Bypass closed
5 Coolant flow from cylinder block to cylinder head 11 Coolant bypass in cylinder head
6 Coolant flow between cylinders 12 Coolant flow to water pump inlet
4) AIR INTAKE SYSTEM
7607AEG08
1 Intake air inlet to turbocharger 4 Intake manifold

2 Turbocharger air to charge air cooler (Integral part of cylinder head)
3 Charge air cooler 5 Intake valve
2-5
5) EXHAUST SYSTEM
7607AEG09
1 Exhaust valve 3 Turbocharger

2 Exhaust manifold 4 Turbocharger exhaust outlet
2-6
GROUP 2 F
FUEL
UEL WARMER SYSTEM
1. S
SPECIFICATION
PECIFICATION
1) Operating voltage : 24±4V
2) Power : 350±50W
3) Current : 15A
2. O
OPERATION
PERATION
1) T h e c u r r e n t o f f u e l w a r m e r s y s t e m i s Fuel warmer
automatically controlled without thermostat
according to fuel temperature.
2) At the first state, the 15A current flows to the fuel
warmer and engine may be started in 1~2 Prefilter
minutes.
3) If the fuel starts to flow, ceramic-disk in the fuel
warmer heater senses the fuel temperature to
reduce the current as low as 1.5A.
So, fuel is protected from overheating by this
2507A5MS12
mechanism.
3. E
ELECTRIC
LECTRIC CIRCUIT
CN-60
MASTER SW 40A
3R 104 104 3R 105 FUSE MAXI
3R 102 111 15R 106
80A
3R
15R
CN-95
CS-74 BATT. RY
80R 107 108
80R 109
BATTERY
CR-1
TO STARTER
MCU
AC COMP. OFF SIG_REVERSE FAN
SPARE_LOW_ENGINE OIL LOW

AC CONDENSOR FAN SIGNAL
SPARE_DIGITAL INPUT_LOW
SPARE_DIGITAL INPUT_LOW
BLOWER RUN SIGNAL_DINP
BUCKET POSITION SENSOR

CLUSTER 24V BATTERY
MIRROR,SER.SOCKET2
PRE-HEAT, FUEL WARMER
BOOM POSITION SENSOR

WORK LAMP_FRONT
START KEY SWITCH

SERVICE SOCKET 1
AUDIO/ROOM LAMP
HORN/CONVERTER
WORK LAMP_REAR
AIR-CON/HEATER 1
AIR-CON/HEATER 2
JOYSTICK-DETENT
MCU 24V BATTERY

ECM 24V BATTERY
TCU 24V BATTERY
SPARE_HIGH SOURCE
BACK.STOP LAMP
JOYSTIC_SWITCH
RIDE CONTROL
CIGARLIGHTER
FAN REVERSE
FUEL WARMER
TURN LAMP
HEAD LAMP
FUEL WARMER
WIPER INT SIG
ILL.LAMP
BEACON
SPARE
WIPER
CAN2 LOW
PARK
FUSE BOX
WASH SIG
CAN2 HI
CN-36
10A
20A
20A
20A
20A
10A
20A
30A
20A
30A
20A
20A
20A
20A
20A
10A
20A
20A
10A
10A
20A
30A
10A
20A
20A
20A
10A
5A
A38
B14
B15
A16
A24
B40
B30
A05
A18
A08
A23
A31
A35
A26
24
25
26
27
28
29
30
31
32
33
34
15
16
17
18
19
20
21
22
23
1
2
3
4
5
6
7
8
L 380
CN-58B
CN-5
20
21
22
CR-25 23
86 30 87a 24
B G01A
85 25
87
RW 531
ECM POWER IG 26
86 27
85 87 87a R 530
30 28
ECM POWER RY 29
40
CR-35 31
86 30 87a 32 CN-13 FUEL WARMER
B G01
85 33 1 B
Gr 550
87 MCU POWER IG 30 2 A
RW 531
86 35 3
85 87 87a R 530 CN-96
30 4
POWER RY 5
6
LW 381
Y 370A
Y 370B
H BR ACC ST C
6 7
Y 370
L 380
5 CS-2
8
6
3 5
CR-46
CR-36
2
87
30
87a
85
85 8787a 86
4
B
1
1
5
3
2
4
RW 531
4 3
R 530
0, I
1 5 4
1
H 0 I II
86 30
2 3
RW 531
2
START SWITCH FUEL WARMER RY PREHEAT RY

7579S2EG04
2-7
GROUP 3 ENGINE SPEED & STALL RPM
1. TEST
TEST CONDITION
1) Normal temperature of the whole system
- Coolant : Approx 80˚C (176˚F)
- Hydraulic oil : 45 ± 5˚C (113 ± 10˚F)
- Transmission oil : 75 ± 5˚C (167 ± 10˚F)
2) Normal operating pressure : See page 6-50.
2. SPECIFICATION
SPECIFICATION
Engine speed, rpm (P mode)
Remark
Low idle High idle Pump stall Converter stall Full stall Fan motor
800±25 2230±50 2000±70 2040±70 1620±100 1150±20
3. ENGINE
ENGINE RPM CHECK
Remark : If the checked data is not normal, it indicates that the related system is not working properly.
Therefore, it is required to check the related system pressure : See page 6-50.
1) Pump stall rpm
- Start the engine and raise the bucket
approx 45 cm (1.5 ft) as the figure.
- Press the accelerator pedal fully and
operate the bucket control lever to the
45cm
retract position fully.

- Check the engine rpm at the above
condition.
75792EG01
2) Convertor stall rpm

- Start the engine and lower the bucket on
OFF
the ground as the figure.

L
M H
- Set the clutch cut off mode switch at the Clutch cut off mode switch
OFF position.
- Press the brake pedal and accelerator
pedal fully.
- Shift the transmission lever to the 4th
forward position.
- Check the engine rpm at the above 75792EG02
condition.
3) Full stall rpm
- Start the engine and raise the bucket
OFF
L
approx 45 cm (1.5 ft) as the figure. M H
- Set the clutch cut off mode switch at the Clutch cut off mode switch
OFF position.
- Press the brake pedal and accelerator
45cm
pedal fully .
- Shift the transmission lever to the 4th
forward position and operate the bucket
lever to the retract position fully. 75792EG03
- Check the engine rpm at the above

condition.
2-8

Group 3 Test and Adjustments ---------------------------------------------------------------------------------------- 3-64
Group 4 Disassembly and Assembly ------------------------------------------------------------------------------ 3-66
1. POWER TRAIN COMPONENT OVERVIEW
Transmission Engine
Front axle
Front drive shaft Center drive shaft Rear drive shaft Rear axle
75793PT01
The power train consists of the following components:

·Transmission
·Front, center and rear drive shafts
·Front and rear axles
Engine power is transmitted to the transmission through the torque converter.
The transmission is a hydraulically engaged four speed forward, three speed reverse countershaft type
power shift transmission. A calliper-disc type parking brake is located on the transmission.
The transmission outputs through universal joints to three drive shaft assemblies. The front drive shaft
is a telescoping shaft which drives the front axle. The front axle is mounted directly to the loader frame.
The front and rear axle are equipped with conventional differential as standard (option : limited slip
differential).
The rear axle is mounted on an oscillating pivot.
The power transmitted to front axle and rear axle is reduced by the pinion gear and ring gear of
differential. It then passes from the differential to the sun gear shaft(Axle shaft) of final drive.
The power of the sun gear is reduced by a planetary mechanism and is transmitted through the
planetary hub to the wheel.
3-1
HYDRAULIC CIRCUIT
K4 KR K1 K3 KV K2
P1 F 60 P2 E 55 P3 D 56 P4 C 58 P5 B 53 P6 A 57
B D B D B D B D B D B D
Y1 NFS Y2 NFS Y3 NFS Y4 NFS Y5 NFS Y6 NFS
Pressure
Temp reducing
sensor valve
9+0.5 bar
System
pressure
Valve block control circuit valve
16+2 bar
Filter pressure
differential valve
Converter
Relief Filter
valve
11+2 bar
Oil cooler Bcak

pressure
valve Pump
Bypass 4.3+3 bar
valve 16+2 bar
3 bar
Oil sump
Lubrication Main oil circuit
7607APT18
NFS Follow-on slide P3 Proportional valve clutch K1

D Vibration damper P4 Proportional valve clutch K3
B Orifice P5 Proportional valve clutch KV
P1 Proportional valve clutch K4 P6 Proportional valve clutch K2
P2 Proportional valve clutch KR Y1~Y6 Pressure regulator
Current
Forward Reverse Positions
Engaged No. of the
Speed Neutral on the
clutch measuring
1 2 3 4 1 2 3 valve block
points
Y1 X K4 F 60
Y2 X X X KR E 55
Y3 X X K1 D 56
Y4 X X X K3 C 58
Y5 X X X KV B 53
Y6 X X K2 A 57
Engaged
K1,KV KV,K2 K3,KV K4,K3 KR,K1 KR,K2 KR, K3 - - -
clutch
X : Pressure regulator under voltage
3-2
2. TORQUE CONVERTER
5 1 2 3 4
73033TM00
1 Turbine 3 Pump 5 Input flange

2 Stator 4 Transmission pump
The converter is working according to the Trilok-system, i.e. it assumes at high turbine speed the
characteristics, and with it the favorable efficiency of a fluid clutch.
The converter is designed according to the engine power so that the most favorable operating
conditions are obtained for each installation case.
The Torque converter is composed of 3 main components :
Pump wheel - turbine wheel - stator (reaction member)
These 3 impeller wheels are arranged in such a ring-shape system that the fluid is streaming through
the circuit components in the indicated order.
Pressure oil from the transmission pump is constantly streaming through the converter. In this way, the
converter can fulfill its task to multiply the torque of the engine and at the same time, the heat created in
the converter is dissipated via the escaping oil.
The oil which is streaming out of the pump wheel, enters the turbine wheel and is there inversed in the
direction of flow.
According to the rate of reversion, the turbine wheel and with it also the output shaft is receiving a more
or less high reaction torque. The stator (reaction member), following the turbine, has the task to reverse
the oil streaming out of the turbine once more and to deliver it under the suitable discharge direction to
the pump wheel.
Due to the reversion, the stator receiving a reaction torque.
The relation turbine torque/pump torque is called torque multiplication. This is the higher, the greater
the speed difference of pump wheel and turbine wheel will be.
Therefore, the maximum torque multiplication is created at stationary turbine wheel.
With increasing output speed, the torque multiplication is decreasing. The adaption of the output speed
to a certain required output torque will be infinitely variable and automatically achieved by the torque
converter.
3-3
when the turbine speed is reaching about 80% of the pump speed, the torque multiplication becomes
1.0 i.e. the turbine torque becomes equal to that of the pump torque.
From this point on, the converter is working similar to a fluid clutch.
A stator freewheel serves to improve the efficiency in the upper driving range, in the torque
multiplication range it is backing-up the torque upon the housing, and is released in the clutch range.
In this way, the stator can rotate freely.
Function of a hydrodynamic torque converter (schematic view)
TP = Torque of the pump wheel

TT = Torque of the turbine wheel
TR = Torque of the reaction member (stator)
Pump wheel TR
Turbine wheel
From the engine
TT
TP
To the gearbox
Starting nT = 0
condition 1 1.5 Reaction member 2.5
(stator) Machine standing
still
Intermediate
condition 1 <1.5 <2.5 nT < n engine
Condition in the
coupling point 1 0 1 nT = 0.8n engine
7577APT100
3-4
3. TRANSMISSION
1) LAYOUT
12
11
10
3
15
14
13
8
6
7
16
7577APT03
1 Reverse clutch (KR) 7 Converter side output 12 Inductive transmitter

2 Engine-dependent flange for engine speed
power take-off 8 Output shaft 13 4th clutch (K4)
3 Forward clutch (KV) 9 Transmission pump 14 Converter relief valve
4 2nd clutch (K2) 10 Connection to engine 15 1st clutch (K1)
5 3rd clutch (K3) 11 Converter 16 Parking brake
6 Rear output flange
3-5
2) INSTALLATION VIEW
6 8 3
11
15
14
7
4
2
5 1
12
10 9 13
7577APT02
1 Converter 9 Parking brake

2 Full flow filter 10 Oil drain plug
3 Transportation eye 11 Connection to engine
4 Gearbox mounting pads 12 Output flange-Converter side
5 Mounting possibility emergency steering 13 Output flange-Rear side
pump 14 Temperature switch for oil temperature
6 Breather behind converter
7 Electrical hydraulic transmission control 15 Difference pressure switch for pressure filter
8 Power take-off; Coaxial; Engine dependent
3-6
3) OPERATION OF TRANSMISSION
(1) Forward
① Forward 1st
In 1st forward, forward clutch (KV) and 1st clutch (K1) are engaged.
Forward clutch and 1st clutch are actuated by the hydraulic pressure applied to the clutch piston.
KR KR
KV IN
K4
K2
INPUT
K3 K1
KV
OUT
GEAR PATTERN
K2
K1 K3
K4
OUTPUT OUTPUT
7577APT04 F1
3-7
② Forward 2nd
In 2nd forward, forward clutch (KV) and 2nd clutch (K2) are engaged.
Forward clutch and 2nd clutch are actuated by the hydraulic pressure applied to the clutch
piston.
KR KR
KV IN
K4
K2
INPUT
K3 K1
KV
OUT
GEAR PATTERN
K2
K1 K3
K4
OUTPUT OUTPUT
7577APT05 F2
3-8
③ Forward 3rd
In 3rd forward, forward clutch (KV) and 3rd clutch (K3) are engaged.
Forward clutch and 3rd clutch are actuated by the hydraulic pressure applied to the clutch piston.
KR KR
KV IN
K4
K2
INPUT
K3 K1
KV
OUT
GEAR PATTERN
K2
K1 K3
K4
OUTPUT OUTPUT
7577APT06 F3
3-9
④ Forward 4th
In 4th forward, 4th clutch (K4) and 3rd clutch (K3) are engaged.
4th clutch and 3rd clutch are actuated by the hydraulic pressure applied to the clutch piston.
KR KR
KV IN
K4
K2
INPUT
K3 K1
KV
OUT
GEAR PATTERN
K2
K1 K3
K4
OUTPUT OUTPUT
7577APT07 F4
3-10
(2) Reverse
① Reverse 1st
In 1st reverse, reverse clutch (KR) and 1st clutch (K1) are engaged.
Reverse clutch and 1st clutch are actuated by the hydraulic pressure applied to the clutch piston.
KR KR
KV IN
K4
K2
INPUT
K3 K1
KV
OUT
GEAR PATTERN
K2
K1 K3
K4
OUTPUT OUTPUT
7577APT08 R1
3-11
② Reverse 2nd
In 2nd reverse, reverse clutch (KR) and 2nd clutch (K2) are engaged.
Reverse clutch and 2nd clutch are actuated by the hydraulic pressure applied to the clutch
piston.
KR KR
KV IN
K4
K2
INPUT
K3 K1
KV
OUT
GEAR PATTERN
K2
K1 K3
K4
OUTPUT OUTPUT
7577APT09 R2
3-12
③ Reverse 3rd
In 3rd reverse, reverse clutch (KR) and 3rd clutch (K3) are engaged.
Reverse clutch and 3rd clutch are actuated by the hydraulic pressure applied to the clutch piston.
KR KR
KV IN
K4
K2
INPUT
K3 K1
KV
OUT
GEAR PATTERN
K2
K1 K3
K4
OUTPUT OUTPUT
7577APT10 R3
3-13
4) ELECTRO-HYDRAULIC SHIFT CONTROL WITH PROPORTIONAL VALVE
2 1 3
A A
Y6 Y1
Y5 Y2
B
Y4 Y3
3 6
2 6 1 4 11 9 10
Y5
SECTION A-A SECTION B-B

8 7
73033CV01
1 Pressure reducing valve(9+0.5bar) 7 Intermediate sheet

2 System pressure valve(16+2bar) 8 Duct plate
3 Housing 9 Oscillation damper
4 Cable harness 10 Follow-on slide
5 Cover 11 Pressure regulator
6 Valve block
Transmission control, see schedule of hydraulic circuit, electro-hydraulic control unit and measuring
points at page 3-2, 3-14 and 3-64.
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. Y1), follow-on
slide and vibration damper.
The control pressure of 9 bar for the actuation of the follow-on slides is created by the pressure
reducing valve. The pressure oil (16+2bar) is directed via the follow-on slide to the respective
clutch.
3-14
Due to the direct proportional selection with separated pressure modulation for each clutch, the
pressures 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 are 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 maximum control pressure to 16+2 bar and releases the
main stream to the converter and lubricating circuit.
In the inlet to the converter, a converter satety valve is installed which protects the converter from
high internal pressures (opening pressure 11+2bar).
Within the converter, the oil serves to transmit the power according to the well-known
hydrodynamic principle (see torque converter, page 3-3).
To avoid cavitation, the converter must be always completely filled with oil.
This is achieved by a converter back pressure back-up valve, rear-mounted to the converter, with
an opening pressure of at least 4.3bar.
The oil, escaping out of the converter, is directed to a oil cooler.
The oil is directed from the oil cooler to the transmission and from there to the lubricating oil circuit,
so that all lubricating points are supplied with cooled oil.
In the electro-hydraulic control unit are 6 pressure regulators installed.
5) GEAR SELECTOR (DW-3)

The gear selector is designed for the
mounting on the left side of the steering
column. The positions (speeds) 1 to 4 are F
1
selected by a rotary motion, the driving 4

2
3
N
R
direction Forward (F)-Neutral (N)-Reverse
(R) by tilting the gear selector lever.
The gear selector is also available with
integrated kickdown push button.
For the protection from unintended start off,
a neutral interlock is installed.
N D
Position N - Gear selector lever blocked in
this position.
Position D - Driving. 73033TM17
3-15
6) ELECTRIC CONTROL UNIT
(1) Complete system
1
2
14 12
5
10
4 15 9
3
7
13
2
6
11
8 7609S3PT33
1 Transmission control unit (EST-37A)

2 Kickdown switch
3 Clutch cut off mode switch
4 Transmission shift mode switch
5 Monitor
6 Gear selector (DW-3) with integrated kickdown switch
7 Power supply connection
8 Transmission
9 Cable to inductive transmitter - speed central gear train
10 Cable to inductive transmitter - speed turbine
11 Cable to inductive transmitter - speed engine
12 Cable to speed sensor output and speedometer
13 Cable to plug connection on the electro - hydraulic control unit
14 CAN-Connection
15 Wiring
(2) Description of the basic functions
The powershift transmissions is equipped is electronic transmission control unit (EST-37A),
developed for it.
The system is processing the desire of the driver according to the following criteria.
·Gear determination depending on controller position, driving speed and load condition.
3-16
·Protection from operating errors as far as necessary, is possible via electronic protection
(programming).
·Protection from over-speeds (On the basis of engine and turbine speed).
·Automatic reversing (Driving speed-dependent).
·Pressure cut-off possible(Disconnecting of the drive train for maximum power on the power
take-off).
·Change-over possibility for Auto-/Manual mode.
·Kick down functions possible.
(3) Driving and shifting
- Neutral position :
Neutral position will be selected via the controller.
After the ignition is switched on, the electronics remains in the waiting state. By the position
NEUTRAL of the controller, resp. by pressing the pushbutton NEUTRAL, the EST-37A becomes
ready for operation.
Now, a gear can be engaged.
- Starting :
The starting of the engine has always to be carried out in the NEUTRAL POSITION of the
controller.
For safety reasons it is to recommend to brake the machine securely in position with the parking
brake prior to start the engine.
After the starting of the engine and the preselection of the driving direction and the gear, the
machine can be set in motion by acceleration.
At the start off, the converter takes over the function of a master clutch.
On a level road it is possible to start off also in higher gears.
- Upshifting under load
Upshifting under load will be then realized if the machine can still accelerate by it.
- Downshifting under load
Downshifting under load will be realized if more traction force is needed.
- Upshifting in overrunning condition
In the overrunning mode, the upshifting will be suppressed by accelerator pedal idling position, if
the speed of the machine on a downgrade should not be further increased.
- Downshifting in overrunning condition
Downshiftings in overrunning mode will be then carried out if the machine should be retarded.
If the machine will be stopped and is standing with running engine and engaged transmission,
the engine cannot be stalled. On a level and horizontal roadway it is possible that the machine
begins to crawl, because the engine is creating at idling speed a slight drag torque via the
converter.
It is convenient to brake the machine at every stop securely in position with the parking brake.
At longer stops, the controller has to be shifted to the NEUTRAL POSITION.
At the start off, the parking brake has to be released. We know from experience that at a
converter transmission it might not immediately be noted to have forgotten this quite normal
operating step because a converter, due to its high ratio, can easily overcome the braking
torque of the parking brake.
3-17
Temperature increases in the converter oil as well as overheated brakes will be the
consequences to be find out later.
Neutral position of the selector switch at higher machine speeds (above stepping speed) is not
admissible.
Either a suitable gear is to be shifted immediately, or the machine must be stopped at once.
(4) Independent calibration of the shifting elements (AEB)
The AEB has the task to compensate tolerances (plate clearance and pressure level) which are
influencing the filling procedure of the clutches. For each clutch, the correct filling parameters are
determined in one test cycle for :
·Period of the quick-filling time
·Level of the filling compensating pressure
The filling parameters are stored, together with the AEB-program and the driving program in the
transmission electronics. Because the electronics will be separately supplied, the AEB-cycle
must be started only after the installation of both components in the machine, thus ensuring the
correct mating (Transmission and electronics).
※ It is imperative, to respect the following test conditions :
- Shifting position neutral
- Engine in idling speed
- Parking brake actuated
- Transmission in operating temperature
※ After a replacement of the transmission, the electrohydraulic control or the TCU in the machine,
the AEB-cycle must be as well carried out again.
The AEB-cylcle continues for about 3 to 4 minutes. The determined filling parameters are stored
in the EEProm of the electronics. In this way, the error message F6 shown on the display will be
cancelled also at non-performed AEB.
(5) Pressure cut-off
In order to provide the full engine power for the hydraulic system, the control can be enlarged for
the function of a pressure cut-off in the 1st and 2nd speed. In this way, the pressure in the
powershift clutches will be cut-off, and the torque transmission in the drive train will be eliminated
by it. This function will be released at the actuation of a switch, arranged on the brake pedal.
For a soft restart, the pressure will be build-up via a freely programmable characteristic line.
3-18
4. FAULT CODE
1) MACHINE FAULT CODE
HCESPN FMI Description
Hydraulic oil temperature sensor circuit - Voltage above normal, or shorted to high source (or
3
101 open circuit)
4 Hydraulic oil temperature sensor circuit - Voltage below normal, or shorted to low source
5 Engine cooling fan EPPR valve circuit - Current below normal, or open circuit
145
6 Engine cooling fan EPPR valve bircuit - Current above normal
Boom up lever detent solenoid circuit - Voltage below normal, or shorted to low source (or
4
172 open circuit)
6 Boom up lever detent solenoid circuit - Current above normal
Boom down lever detent solenoid circuit - Voltage below normal, or shorted to low source (or
4
173 open circuit)
6 Boom down lever detent solenoid circuit - Current above normal
Bucket lever detent solenoid circuit - Voltage below normal, or shorted to low source (or open
4
174 circuit)
6 Bucket lever detent solenoid circuit - Current above normal
Engine cooling fan reverse solenoid circuit - Voltage below normal, or shorted to low source (or
4
181 open circuit)
6 Engine cooling fan reverse solenoid circuit - Current above normal
Engine cooling fan reverse driving status signal circuit - Voltage below normal, or shorted to
4
183 low source (or open circuit)
6 Engine cooling fan reverse driving status signal circuit - Current above normal
Emergency steering pump relay circuit - Voltage below normal, or shorted to low source (or
4
187 open circuit)
6 Emergency steering pump relay circuit – Current above normal
0 Steering main pump pressure sensor data above normal range (or open circuit)
1 Steering main pump pressure sensor data below normal range
202
2 Steering main pump pressure sensor data error
4 Steering main pump pressure sensor circuit - Voltage below normal, or shorted to low source
0 Emergency steering pump pressure sensor data above normal range (or open circuit)
1 Emergency steering pump pressure sensor data below normal range
203 2 Emergency steering pump pressure sensor data error
Emergency steering pump pressure sensor circuit - Voltage below normal, or shorted to low
4
source
0 Boom cylinder pressure sensor data above normal range (or open circuit)
1 Boom cylinder pressure sensor data below normal range
204
2 Boom cylinder pressure sensor data error
4 Boom cylinder pressure sensor circuit - Voltage below normal, or shorted to low source
0 Bucket cylinder pressure sensor data above normal range (or open circuit)
1 Bucket cylinder pressure sensor data below normal tange
205
2 Bucket cylinder pressure sensor data error
4 Bucket cylinder pressure sensor circuit - Voltage below normal, or shorted to low source
3-19
3 Fuel level sensor circuit - Voltage above normal, or shorted to high source (or open circuit)
301
4 Fuel level sensor circuit - Voltage below normal, or shorted to low source
Engine coolant temperature sensor circuit - Voltage above normal, or shorted to high source
3
304 (or open circuit)
4 Engine coolant temperature sensor circuit - Voltage below normal, or shorted to low source
310 8 Engine speed signal error – Abnormal frequency or pulse width
318 8 Engine cooling fan speed signal error – Abnormal frequency or pulse width
4 Engine preheat relay circuit – Voltage below normal, or shorted to low source (or open circuit)
322
6 Engine preheat relay circuit - Current above normal
4 Fuel warmer relay circuit - Voltage below normal, or shorted to low source (or open circuit)
325
6 Fuel warmer relay circuit – Current above normal
4 Anti-restart relay circuit - Voltage below normal, or shorted to low source (or open circuit)
327
6 Anti-restart relay circuit – Current above normal
Engine power mode selector circuit – Voltage above normal, or shorted to high source (or
3
346 open circuit)
4 Engine power mode selector circuit – Voltage below normal, or shorted to low source
0 Brake oil pressure sensor data above normal range (or open circuit)
1 Brake oil pressure sensor data below normal range
503
2 Brake oil pressure sensor data error
4 Brake oil pressure sensor circuit – Voltage below normal, or shorted to Low Source
0 Parking oil pressure sensor data above normal range (or open circuit)
1 Parking oil pressure sensor data below normal range
507
2 Parking oil pressure sensor data error
4 Parking oil pressure sensor circuit - Voltage below normal, or shorted to low source
Clutch cut off mode selector circuit – Voltage above normal, or shorted to high source (or
3
551 open circuit)
4 Clutch cut off mode selector circuit – Voltage below normal, or shorted to low source
Transmission shift mode selector circuit – Voltage above normal, or shorted to high source (or
3
552 open circuit)
4 Transmission shift mode selector circuit – Voltage below normal, or shorted to low source
0 Differential lock pressure sensor data above normal range (or open circuit)
1 Differential lock pressure sensor data below normal range
558
2 Differential lock pressure sensor data error
4 Differential lock pressure sensor circuit - Voltage below normal, or shorted to low source
701 4 Hourmeter circuit - Voltage below normal, or shorted to low source
0 Battery voltage high
705
1 Battery voltage low
3-20
707 1 Alternator node I voltage low (or open circuit)
3 Buzzer circuit - Voltage above normal, or shorted to high source
723
4 Buzzer circuit - Voltage below normal, or shorted to low source (or open circuit)
4 Wiper relay circuit - Voltage below normal, or shorted to low source (or open circuit)
727
6 Wiper relay circuit – Current above normal
Boom position sensor signal circuit – Voltage above normal, or shorted to high
3
728 source (or open circuit)
4 Boom position sensor signal circuit – Voltage below normal, or shorted to low source
Bucket position sensor signal circuit – Voltage above normal, or shorted to high
3
source (or open circuit)
729
Bucket position sensor signal circuit – Voltage below normal, or shorted to low
4
source
730 19 APTC heater PWM output duty operation error
830 12 MCU internal memory error
840 2 Cluster communication error
841 2 ECM communication error
842 2 TCU communication error
843 2 APTC communication error
844 2 Monitor communication error
850 2 RCM communication error
3-21
2) ENGINE FAULT CODES
Fault code
J1939 SPN Reason Effect (only when fault code is active)
J1939 FMI
Engine control module critical internal failure - Possible no noticeable performance effects,
111
Bad intelligent device or component. Error engine dying, or hard starting.
629
internal to the ECM related to memory hardware
12
failures or internal ECM voltage supply circuits.
Engine magnetic crankshaft speed/position lost Fueling to injectors is disabled and the engine
115 both of two signals - Data erratic, intermittent, or can not be started.
612 incorrect. The ECM has detected that the
2 primary engine speed sensor and the backup
engine speed sensor signals are reversed.
Intake manifold 1 pressure sensor circuit - Engine power derate.
122 Voltage above normal, or shorted to high source.
102 High signal voltage detected at the intake
3 manifold pressure circuit.
Intake manifold 1 pressure sensor circuit - Engine power derate.
123 Voltage below normal, or shorted to low Source.
102 Low signal voltage or open circuit detected at the
4 intake manifold pressure circuit.
Intake manifold 1 pressure - Data valid but above Engine power derate.
124 normal operational range - Moderately severe
102 level. Intake manifold pressure has exceeded the
16 maximum limit for the given engine rating.
Accelerator pedal or lever position sensor 1 Severe derate in power output of the engine.
131 circuit - Voltage above normal, or shorted to high Limp home power only.
91 source. High voltage detected at accelerator
3 pedal position circuit.
Accelerator pedal or lever position sensor 1 Severe derate in power output of the engine.
132 circuit - Voltage below normal, or shorted to low Limp home power only.
91 source. Low voltage detected at accelerator
4 pedal position signal circuit.
Remote accelerator pedal or lever position Remote accelerator will not operate. Remote
133 sensor 1 circuit - Voltage above normal, or accelerator position will be set to zero percent.
974 shorted to high source. High voltage detected at
3 remote accelerator pedal position circuit.
Remote accelerator pedal or lever position Remote accelerator will not operate. Remote
134 sensor 1 circuit - Voltage below normal, or accelerator position will be set to zero percent.
974 shorted to low source. Low voltage detected at
4 remote accelerator pedal position signal circuit.
Engine oil rifle pressure 1 sensor circuit - Voltage None on performance. No engine protection
135 above normal, or shorted to high source. High for oil pressure.
100 signal voltage detected at the engine oil pressure
3 circuit.
Engine oil rifle pressure 1 sensor circuit - Voltage None on performance. No engine protection
141 below normal, or shorted to low source. Low for oil pressure.
100 signal voltage detected at engine oil pressure
4 circuit.
143 Engine oil rifle pressure - Data valid but below None on performance.
100 normal operational range - Moderately severe
18 level.
Engine coolant temperature 1 sensor circuit - Possible white smoke. Fan will stay ON if
144
Voltage above normal, or shorted to high source. controlled by ECM. No engine protection for
110
High signal voltage or open circuit detected at engine coolant temperature.
3
engine coolant temperature circuit.
3-22
Fault code
J1939 FMI
Engine Coolant Temperature 1 Sensor Circuit - Possible white smoke. Fan will stay ON if
145
Voltage Below Normal, or Shorted to Low controlled by ECM. No engine protection for
110
Source. Low signal voltage detected at engine engine coolant temperature.
4
coolant temperature circuit.
Engine Coolant Temperature - Data Valid but Progressive power derate increasing in
146 Above Normal Operational Range - Moderately severity from time of alert.
110 Severe Level. Engine coolant temperature signal
16 indicates engine coolant temperature is above
engine protection warning limit.
Accelerator Pedal or Lever Position 1 Sensor Severe derate in power output of the engine.
Circuit Frequency - Data Valid but Below Normal Limp home power only.
147
Operational Range - Most Severe Level. A
91
frequency of less than 100 Hz has been
1
detected at the frequency throttle input to the
ECM.
Accelerator Pedal or Lever Position Sensor 1 - Severe derate in power output of the engine.
148 Data Valid but Above Normal Operational Limp home power only.
91 Range - Most Severe Level. A frequency of
0 more than 1500 Hz has been detected at the
frequency throttle input to the ECM.
Engine Coolant Temperature - Data Valid but Progressive power derate increasing in
151 Above Normal Operational Range - Most severity from time of alert. If Engine Protection
110 Severe Level. Engine coolant temperature signal Shutdown feature is enabled, engine will shut
0 indicates engine coolant temperature above down 30 seconds after Red Stop Lamp starts
engine protection critical limit. flashing.
Intake Manifold 1 Temperature Sensor Circuit - Possible white smoke. Fan will stay ON if
153 Voltage Above Normal, or Shorted to High controlled by ECM. No engine protection for
105 Source. High signal voltage detected at intake intake manifold air temperature.
3 manifold air temperature circuit.
Intake Manifold 1 Temperature Sensor Circuit - Possible white smoke. Fan will stay ON if
154 Voltage Below Normal, or Shorted to Low controlled by ECM. No engine protection for
105 Source. Low signal voltage detected at intake intake manifold air temperature.
4 manifold air temperature circuit.
Intake Manifold 1 Temperature - Data Valid but Progressive power derate increasing in
155 Above Normal Operational Range - Most severity from time of alert. If Engine Protection
105 Severe Level. Intake manifold air temperature Shutdown feature is enabled, engine will shut
0 signal indicates intake manifold air temperature down 30 seconds after Red Stop Lamp starts
above engine protection critical limit. flashing.
187 Sensor Supply 2 Circuit - Voltage Below Normal, Engine power derate.
520195 or Shorted to Low Source. Low voltage detected
4 at the sensor supply number 2 circuit.
195 Coolant Level Sensor 1 Circuit - Voltage Above None on performance.
111 Normal, or Shorted to High Source. High signal
3 voltage detected at engine coolant level circuit.
196 Coolant Level Sensor 1 Circuit - Voltage Below None on performance.
111 Normal, or Shorted to Low Source. Low signal
4 voltage detected at engine coolant level circuit.
197 Coolant Level - Data Valid but Below Normal None on performance.
111 Operational Range - Moderately Severe Level.
18 Low coolant level has been detected.
Barometric Pressure Sensor Circuit - Voltage Engine power derate.
221
Above Normal, or Shorted to High Source. High
108
signal voltage detected at barometric pressure
3
circuit.
3-23
Fault code
J1939 FMI
Barometric Pressure Sensor Circuit - Voltage Engine power derate.
222
Below Normal, or Shorted to Low Source. Low
108
signal voltage detected at barometric pressure
4
circuit.
227 Sensor Supply 2 Circuit - Voltage Above Normal, Engine power derate.
520195 or Shorted to High Source. High voltage
3 detected at sensor supply number 2 circuit.
Engine Crankshaft Speed/Position - Data Valid Fuel injection disabled until engine speed falls
234
but Above Normal Operational Range - Most below the overspeed limit.
190
Severe Level. Engine speed signal indicates
0
engine speed above engine protection limit.
Coolant Level - Data Valid but Below Normal Progressive power derate increasing in
235 Operational Range - Most Severe Level. Low severity from time of alert. If Engine Protection
111 engine coolant level detected. Shutdown feature is enabled, engine will shut
1 down 30 seconds after Red Stop Lamp starts
flashing.
237 External Speed Command Input (Multiple Unit
644 Synchronization) - Data Erratic, Intermittent, or
2 Incorrect. Communication between multiple
engines may be intermittent.
238 Sensor Supply 3 Circuit - Voltage Below Normal, Possible hard starting and rough running.
520196 or Shorted to Low Source. Low voltage detected
4 on the +5 volt sensor supply circuit to the engine
speed sensor.
241 Wheel-based vehicle speed - Data erratic, Engine speed limited to ,maximum engine
84 intermittent, or incorrect. The ECM lost the speed without VSS parameter value. Cruise
2 vehicle speed signal. control, gear-down protection, and road speed
governor will not work.
242 Wheel-based vehicle speed sensor circuit Engine speed limited to maximum engine
84 tampering has been detected - Abnormal rate of speed without VSS parameter value. Cruise
10 change. Signal indicates an intermittent control, gear-down protection, and road speed
connection or VSS tampering. g+H53overnor will not work.
245 Fan control circuit - Voltage below normal, or The fan may stay on continuously or not run at
647 shorted to low source. Low signal voltage all.
4 detected at the fan control circuit when
commanded on.
271 Fuel pump pressurizing assembly 1 circuit - Engine will run poorly at idle. Engine will have
1347 Voltage below normal, or shorted to low source. low power. Fuel pressure will be higher than
4 Low signal voltage detected at the fuel pump commanded.
actuator circuit.
Fuel pump pressurizing assembly 1 circuit - Engine will not run or engine will run poorly.
272
Voltage above normal, or shorted to high source.
1347
High signal voltage or open circuit detected at
3
the fuel pump actuator circuit.
281 Fuel pump pressur izing assembly 1 - Engine will not run or possible low power.
1347 Mechanical system not responding properly or
7 out of adjustment.
SAE J1939 multiplexing PGN timeout error - At least one multiplexed device will not
285
Abnormal update rate. The ECM expected operate properly.
639
information from a multiplexed device but did not
9
receive it soon enough or did not receive it at all.
SAE J1939 multiplexing configuration error - At least one multiplexed device will not
286
Out of calibration. The ECM expected operate properly.
639
information from a multiplexed device but only
13
received a portion of the necessary information.
3-24
Fault code
J1939 FMI
SAE J1939 multiplexed accelerator pedal or Engine may only idle or engine will not
287 lever sensor system - received network data In accelerate to full speed.
91 error. The OEM vehicle electronic control unit
19 (VECM) detected a fault with its accelerator
pedal.
SAE J1939 Multiplexing Remote Accelerator The engine will not respond to the remote
288 Pedal or Lever Position Sensor Circuit - throttle. Engine may only idle. The primary or
974 Received Network Data In Error. The OEM cab accelerator may be able to be used.
19 vehicle electronic control unit (VECM) detected
a fault with the remote accelerator.
292 Auxiliary temperature Sensor Input 1 - Special Possible engine power derate.
441 instructions.
14
Auxiliary temperature sensor input 1 circuit - None on performance.
293 Voltage above normal, or shorted to high
441 source. High signal voltage or open circuit
3 detected at the OEM auxiliary temperature
circuit.
Auxiliary temperature sensor input 1 circuit - None on performance.
294 Voltage below normal, or shorted to low source.
441 Low signal voltage detected at the OEM
4 auxiliary temperature circuit.
296 Auxiliary pressure sensor input 1 - Special Possible engine power derate.
1388 instructions.
14
Auxiliary pressure sensor input 1 circuit - None on performance.
297
Voltage above normal, or shorted to high
1388
source. High signal voltage detected at the OEM
3
pressure circuit.
Auxiliary pressure sensor input 1 circuit - None on performance.
1388 Low signal voltage or open circuit detected at
4 the OEM pressure circuit.
319 Real time clock power interrupt - Data erratic, None on performance. Data in the ECM will
251 intermittent, or incorrect. Real time clock lost not have accurate time and date information.
2 power.
Injector solenoid driver cylinder 1 circuit - Engine can possibly misfire or run rough.
Current below normal, or open circuit. High
322 resistance detected on injector number 1 circuit
651 or no current detected at number 1 injector
5 driver or return pin when the voltage supply at
the harness is on.
the harness is on.
the harness is on.
the harness is on.
3-25
Fault code
J1939 FMI
331
resistance detected on injector number 2 circuit
652
or no current detected at number 2 injector
5
driver or return pin when the voltage supply at
the harness is on.
332
resistance detected on injector number 4 circuit
654
or no current detected at number 4 injector
5
driver or return pin when the voltage supply at
the harness is on.
Engine coolant temperature - Data erratic, The ECM will estimate engine coolant
334
intermittent, or incorrect. The engine coolant temperature.
110
temperature reading is not changing with engine
2
operating conditions.
342 Electronic calibration code incompatibility - Out Possible no noticeable performance effects,
630 of calibration. An incompatible calibration has engine dying, or hard starting.
13 been detected in the ECM.
343 Engine control module warning internal No performance effects or possible severe
620 hardware failure - Bad intelligent device or power derate.
12 component. Internal ECM failure.
351 Injector power supply - Bad intelligent device or Possible smoke, low power, engine misfire,
627 component. The ECM measured injector boost and/or engine will not start.
12 voltage is low.
352 Sensor supply 1 circuit - Voltage below normal, Engine power derate.
1079 or shorted to low source. Low voltage detected
4 at sensor supply number 1 circuit.
386 Sensor supply 1 circuit - Voltage above normal, Engine power derate.
1079 or shorted to high source. High voltage detected
3 at sensor supply number 1 circuit.
Engine oil rifle pressure - Data valid but below Progressive power derate increasing in
415 normal operational range - Most severe level. Oil severity from time of alert. If engine protection
100 pressure signal indicates oil pressure below the shutdown feature is enabled, engine will shut
1 engine protection critical limit. down 30 seconds after red stop lamp starts
flashing.
418 Water in fuel indicator - Data valid but above Possible white smoke, loss of power, or hard
97 normal operational range - Least severe level. starting.
15 water has been detected in the fuel filter.
428 Water in fuel indicator sensor circuit - Voltage None on performance. No water in fuel
97 above normal, or shorted to high source. High warning available.
3 voltage detected at the water in fuel circuit.
429 Water in fuel indicator sensor circuit - Voltage None on performance. No water in fuel
97 below normal, or shorted to low source. Low warning available.
4 voltage detected at the water in fuel circuit.
Accelerator pedal or lever idle validation switch - Engine will only idle.
431 Data erratic, intermittent, or incorrect. Voltage
558 detected simultaneously on both idle validation
2 and off-idle validation switches.
Accelerator pedal or lever idle validation circuit - Engine will only idle.
432 Out of calibration. Voltage at idle validation
558 on-idle and off-idle circuit does not match
13 accelerator pedal position.
3-26
Fault code
J1939 FMI
Engine oil rifle pressure - Data erratic, None on performance. No engine protection
435
intermittent, or incorrect. An error in the engine for oil pressure.
100
oil pressure switch signal was detected by the
2
ECM.
Battery 1 voltage - Data valid but below normal Engine may stop running or be difficult to start.
441
operational range - Moderately severe level.
168
ECM supply voltage is below the minimum
18
system voltage level.
Battery 1 Voltage - Data valid but above normal Possible electrical damage to all electrical
442
operational range - Moderately severe level. components.
168
ECM supply voltage is above the maximum
16
system voltage level.
449 Injector metering rail 1 pressure - Data valid but None or possible engine noise associated with
157 above normal operational range - Most severe higher injection pressures (especially at idle or
0 level. light load). Engine power is reduced.
Injector metering rail 1 pressure sensor circuit - Power and or speed derate.
451
Voltage above normal, or shorted to high source.
157
High signal voltage detected at the rail fuel
3
pressure sensor circuit.
Injector metering rail 1 pressure sensor circuit - Power and or speed derate.
452
Voltage below normal, or shorted to low source.
157
Low signal voltage detected at the rail fuel
4
pressure sensor circuit.
Intake manifold 1 temperature - Data valid but Progressive power derate increasing in
488 above normal operational range - Moderately severity from time of alert.
157 severe level. Intake manifold air temperature
16 signal indicates intake manifold air temperature
is above the engine protection warning limit.
497 Multiple unit synchronization switch - Data
1377 erratic, intermittent, or incorrect.
2
523 Auxiliary intermediate (PTO) speed switch None on performance.
611 validation - Data erratic, intermittent, or
2 incorrect.
Auxiliary input/output 2 circuit - Voltage above None on performance.
527 normal, or shorted to high source. High signal
702 voltage or open circuit has been detected at the
3 auxiliary input/output 2 circuit.
528 Auxiliary alternate torque validation switch - None on performance.
93 Data erratic, intermittent, or incorrect.
2
Auxiliary input/output 3 circuit - Voltage above
529
normal, or shorted to high source. Low signal
703
voltage has been detected at the auxiliary input/
3
output 2 circuit.
Injector metering rail 1 pressure - Data valid but The ECM will estimate fuel pressure and
553 above normal operational range - Moderately power is reduced.
157 severe level. The ECM has detected that fuel
16 pressure is higher than commanded pressure.
Injector metering rail 1 pressure - Data erratic, Possibly hard to start, low power, or engine
554 Intermittent, or incorrect. The ECM has smoke.
157 detected that the fuel pressure signal is not
2 changing.
3-27
Fault code
J1939 FMI
Injector metering rail 1 pressure - Data Valid Either the engine will not start or the engine
559 but Below Normal Operational Range - will not have starter lockout protection.
157 Moderately Severe Level. The ECM has
18 detected that fuel pressure is lower than
commanded pressure.
Starter relay driver circuit - Voltage above The engine will not have starter lockout
584
normal, or shorted to high source. Open circuit protection.
677
or high voltage detected at starter lockout
3
circuit.
585 Starter relay driver circuit - Voltage below Engine power derate. The ECM uses an
677 normal, or shorted to low source. Low voltage estimated turbocharger speed.
4 detected at starter lockout circuit.
Turbocharger 1 speed - Data valid but above Amber lamp will light until high battery voltage
595
normal operational range - Moderately severe condition is corrected.
103
level. High turbocharger speed has been
16
detected.
599 Auxiliary commanded dual output shutdown - None or possible engine noise associated with
640 Special instructions. higher injection pressures (especially at idle or
14 light load). Engine power is reduced.
Turbocharger 1 speed - Data valid but below Engine can run rough. Possibly poor starting
687
normal operational range - Moderately severe capability. Engine runs using backup speed
103
level. Low turbocharger speed detected by the sensor. Engine power is reduced.
18
ECM.
689 Engine crankshaft speed/position - Data Engine power derate.
190 erratic, intermittent, or incorrect. Loss of signal
2 from crankshaft sensor.
Turbocharger 1 compressor inlet temperature Engine power derate.
691 circuit - Voltage above normal, or shorted to
1172 high source. High signal voltage detected at
3 turbocharger compressor inlet air temperature
circuit.
Turbocharger 1 compressor inlet temperature Engine will run derated. Excessive black
692
circuit - Voltage below normal, or shorted to low smoke, hard start, and rough idle possible.
1172
source. Low signal voltage detected at
4
turbocharger compressor inlet air tempera
Engine speed / position camshaft and Possible no noticeable performance effects,
crankshaft misalignment - Mechanical system engine dying, or hard starting.
731
not responding properly or out of adjustment.
723
mechanical misalignment between the
7
crankshaft and camshaft engine speed
sensors.
757 Electronic control module data lost - Condition Possible poor starting. Engine power derate.
611 exists. Severe loss of data from the ECM.
31
Engine camshaft speed / position sensor - Possible engine power derate.
778
Data erratic, intermittent, or incorrect. The ECM
723
has detected an error in the camshaft position
2
sensor signal.
Auxiliary equipment sensor input 3 - Root Possible no noticeable performance effects or
779 cause not known. e n g i n e d y i n g o r h a r d s t a r t i n g . Fa u l t
703 information, trip information, and maintenance
11 monitor data may be inaccurate.
3-28
Fault code
J1939 FMI
Power supply lost with ignition on - Data erratic, Engine will shut down.
intermittent, or incorrect. Supply voltage to the
1117 ECM fell below 6.2 volts momentarily, or the
627 ECM was not allowed to power down correctly
2 (retain battery voltage for 30 seconds after key
OFF).
1633 OEM datalink cannot transmit - Data erratic, Engine will only idle.
625 intermittent, or incorrect. Communications
2 within the OEM datalink network is intermittent.
Sensor supply 4 circuit - Voltage above normal, Engine will only idle.
2185 or shor ted to high source. High voltage
520197 detected at +5 volt sensor supply circuit to the
3 accelerator pedal position sensor.
Sensor supply 4 circuit - Voltage below normal, Possibly hard to start, low power, or engine
2186 or shorted to low source. Low voltage detected smoke.
520197 at +5 volt sensor supply circuit to the
4 accelerator pedal position sensor.
Injector metering rail 1 pressure - Data valid but Engine may be difficult to start.
2249 below normal operational range - Most severe
157 level. The ECM has detected that fuel pressure
1 is lower than commanded pressure.
Electric lift pump for engine fuel supply circuit - Engine may be difficult to start.
2265 Voltage above normal, or shorted to high
1075 source. High voltage or open detected at the
3 fuel lift pump signal circuit.
Electric lift pump for engine fuel supply circuit - Possible low power.
1075 Low signal voltage detected at the fuel lift pump
4 circuit.
Electronic fuel injection control valve circuit -Engine may exhibit misfire as control switches
2311 Condition exists. Fuel pump actuator circuit from the primary to the backup speed sensor.
633 resistance too high or too low. Engine power is reduced while the engine
31 operates on the backup speed sensor.
2321 Engine crankshaft speed/position - Data erratic, Possible low power.
190 intermittent, or incorrect. crankshaft engine
2 speed sensor intermittent synchronization.
Engine camshaft speed / position sensor - Data Engine power derate.
2322
erratic, intermittent, or incorrect. Camshaft
723
engine speed sensor intermittent
2
synchronization.
2345 Turbocharger 1 Speed - Abnormal rate of Engine power derate.
103 change. The turbocharger speed sensor has
10 detected an erroneous speed value.
Turbocharger turbine inlet temperature Engine power derate.
2346 (Calculated) - Data valid but above normal
2789 operational range - Least severe level.
15 Turbocharger turbine inlet temperature has
exceeded the engine protection limit.
2347 Turbocharger compressor outlet temperature Engine brake on cylinders 1, 2, and 3 can not
2790 (Calculated) - Data valid but above normal be activated or exhaust brake will not operate.
15 operational range - Least severe level.
2377 Fan control circuit - Voltage above normal, or Variable geometry turbocharger will go to the
647 shorted to high source. Open circuit or high open position.
3 voltage detected at the fan control circuit.
3-29
Fault code
J1939 FMI
2384 VGT actuator driver circuit - Voltage below Variable geometry turbocharger may be in
641 normal, or shorted to low source. Low voltage either the open or closed position.
4 detected at turbocharger control valve circuit.
VGT actuator driver circuit - Voltage above The intake air heaters may be ON or OFF all
2385
normal, or shorted to high source. Open circuit the time.
641
or high voltage detected at turbocharger
3
control valve circuit.
2555 Intake air heater 1 circuit - Voltage above The intake air heaters may be ON or OFF all
729 normal, or shorted to high source. High voltage the time.
3 detected at the intake air heater signal circuit.
2556 Intake air heater 1 circuit - Voltage below Can not control transmission.
729 normal, or shorted to low source. Low voltage
4 detected at the intake air heater signal circuit.
2557 Auxiliary PWM driver 1 circuit - Voltage above Can not control transmission.
697 normal, or shorted to high source. High signal
3 voltage detected at the analog torque circuit.
2558 Auxiliary PWM driver 1 circuit - Voltage below Power derate and possible engine shutdown if
697 normal, or shorted to low source. Low signal engine protection shutdown feature is enabled.
4 voltage detected at the analog torque circuit.
Intake manifold 1 pressure - Data erratic,
2973 intermittent, or incorrect. The ECM has
102 detected an intake manifold pressure signal
2 that is too high or low for current engine
operating conditions.
3-30
3) DEFINITION OF OPERATING MODES
(1) Normal
There's no failure detected in the transmission system or the failure has no or slight effects on
transmission control. TCU will work without or in special cases with little limitations. (See
following table)
(2) Substitute clutch control
TCU can't change the gears or the direction under the control of the normal clutch modulation.
TCU uses the substitute strategy for clutch control. All modulations are only time controlled.
(Comparable with EST 25)
(3) 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.
(4) Transmission-shutdown
TCU has detected a severe failure that disables control of the transmission.
TCU will shut off the solenoid valves for the clutches and also the common power supply (VPS1).
Transmission shifts to neutral. The park brake will operate normally, also the other functions
which use ADM1 to ADM8.
The operator has to slow down the vehicle. The transmission will stay in neutral.
(5) TCU-shutdown
TCU has detected a severe failure that disables control of system.
TCU will shut off all solenoid valves and also both common power supplies (VPS1, VPS2). The
park brake will engage, also functions are disabled which use ADM 1 to ADM 8.
The transmission will stay in neutral.
※ Abbreviations
OC : Open circuit
SC : Short circuit
OP mode : Operating mode
TCU : Transmission control unit
EEC : Electronic engine controller
PTO : Power take off
3-31
4) TRANSMISSION FAULT CODES
Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair
(Hex) possible reason for fault detection
10 Logical error at direction select signal TCU shifts transmission to · Check the cables from TCU to shift
3rd shift lever neutral if selector active lever 3
T C U d e t e c t e d a w r o n g s i g n a l OP mode : Transmission · Check signal combinations of shift
combination for the direction shutdown if lever positions F-N-R
·Cable from shift lever 3 to TCU is broken selector active · If shift lever is a CAN shift lever
·Cable is defective and is contacted to check CAN cable/shifter/device
battery voltage or vehicle ground ※ Fault is cleared if TCU detects a
·Shift lever is defective valid neutral signal for the direction
at the shift lever
11 Logical error at gear range signal TCU shifts transmission to · Check the cables from TCU to shift
TCU detected a wrong signal combination neutral lever
for the gear range OP mode : Transmission · Check signal combinations of shift
·Cable from shift lever to TCU is broken shutdown lever positions for gear range
·Cable is defective and is contacted to ※ Failure cannot be detected in
battery voltage or vehicle ground systems with DW2/DW3 shift lever.
·Shift lever is defective Fault is taken back if TCU detects a
valid signal for the position
12 Logical error at direction select signal TCU shifts transmission to · Check the cables from TCU to shift
TCU detected a wrong signal combination neutral lever
for the direction OP mode : Transmission · Check signal combinations of shift
·Cable from shift lever to TCU is broken shutdown lever positions F-N-R
·Cable is defective and is contacted to ※ Fault is taken back if TCU detects a
battery voltage or vehicle ground valid signal for the direction at the
·Shift lever is defective shift lever
13 Logical error at engine derating device After selecting neutral, · Check engine derating device
TCU detected no reaction of engine while TCU change to OP mode ※ This fault is reset after power up of
derating device active limp home TCU
15 Logical error at direction select signal 2 TCU shifts transmission to · Check the cables from TCU to shift
shift lever neutral if selector active lever 2
TCU detected a wrong signal combination OP mode : Transmission · Check signal combinations of shift
for the direction shutdown if lever positions F-N-R
·Cable from shift lever 2 to TCU is broken elector active ※ Fault is taken back if TCU detects a
·Cable is defective and is contacted to valid neutral signal for the direction
battery voltage or vehicle ground at the shift lever
·Shift lever is defective
17 S.C. to ground at customer specific Customer specific · Check the cable from TCU to
function No. 1 (ride control) customer specific function No. 1
TCU detected a wrong voltage at the device
output pin, that looks like a S.C. to vehicle · C h e ck t h e c o n n e c t o r s f r o m
ground customer specific function No. 1 to
·Cable is defective and is contacted to TCU
vehicle ground · Check the resistance of customer
·Customer specific function No. 1 device specific function No. 1 device
has an internal defect
·Connector pin is contacted to vehicle
ground
※ Some fault codes are not applied to this machine.
3-32
18 S.C. to battery voltage at customer specific Customer specific · Check the cable from TCU to
function No. 1 (ride control) customer specific function No. 1
output pin, that looks like a S.C. to battery · C h e ck t h e c o n n e c t o r s f r o m
voltage customer specific function No. 1 to
·Cable is defective and is contacted to TCU
battery voltage · Check the resistance of customer
·Connector pin is contacted to battery
voltage
19 O.C. at customer specific function No. 1 Customer specific · Check the cable from TCU to
(ride control) customer specific function No. 1
output pin, that looks like a O.C. for this · C h e ck t h e c o n n e c t o r s f r o m
output pin customer specific function No. 1
·C a b l e i s d e fe c t i ve a n d h a s n o device to TCU
connection to TCU · Check the resistance of customer
·Connector has no connection to TCU
21 S.C. to battery voltage at clutch cut off Clutch cut off function is · Check the cable from TCU to the
input disabled sensor
The measured voltage is too high: OP mode : Normal · Check the connectors
·Cable is defective and is contacted to · Check the clutch cut off sensor
battery voltage
·Clutch cut off sensor has an internal
defect
voltage
22 S.C. to ground or O.C. at clutch cut off Clutch cut off function is · Check the cable from TCU to the
input disabled sensor
The measured voltage is too low: OP mode : Normal · Check the connectors
·Cable is defective and is contacted to · Check the clutch cut off sensor
vehicle ground
·Cable has no connection to TCU
·Clutch cut off sensor has an internal
defect
ground or is broken
25 S.C. to batter y voltage or O.C. at No reaction, TCU use · Check the cable from TCU to the
transmission sump temperature sensor default temperature sensor
input OP mode : Normal · Check the connectors
The measured voltage is too high: · Check the temperature sensor
·Cable is defective and is contacted to
battery voltage
·Temperature sensor has an internal
defect
voltage or is broken
3-33
26 S.C. to batter y voltage or O.C. at No reaction, TCU uses · Check the cable from TCU to the
transmission sump temperature sensor default temperature sensor
input OP mode : Normal · Check the connectors
The measured voltage is too low: · Check the temperature sensor
vehicle ground
defect
ground
27 S.C. to batter y voltage or O.C. at No reaction, TCU uses · Check the cable from TCU to the
retarder temperature sensor input default temperature sensor
The measured voltage is too high: OP mode : Normal · Check the connectors
·Cable is defective and is contacted to · Check the temperature sensor
battery voltage
defect
voltage or is broken
28 S.C. to ground at retarder temperature No reaction, TCU uses · Check the cable from TCU to the
sensor input default temperature sensor
The measured voltage is too low: OP mode : Normal · Check the connectors
·Cable is defective and is contacted to · Check the temperature sensor
vehicle ground
defect
ground
31 S.C. to battery voltage or O.C. at engine OP mode : Substitute clutch · Check the cable from TCU to the
speed input control sensor
TCU measures a voltage higher than · Check the connectors
7.00V at speed input pin · Check the speed sensor
battery voltage
·Speed sensor has an internal defect
voltage or has no contact
32 S.C. to ground at engine speed input OP mode : Substitute clutch · Check the cable from TCU to the
TCU measures a voltage less than 0.45V control sensor
at speed input pin · Check the connectors
·Cable/connector is defective and is · Check the speed sensor
contacted to vehicle ground
33 Logical error at engine speed input OP mode : Substitute clutch · Check the cable from TCU to the
TCU measures a engine speed over a control sensor
threshold and the next moment the · Check the connectors
measured speed is zero · Check the speed sensor
·Cable/connector is defective and has · Check the sensor gap
bad contact ※ This fault is reset after power up of
·Speed sensor has an internal defect TCU
·Sensor gap has the wrong size
3-34
34 S.C. to battery voltage or O.C. at turbine OP mode : Substitute clutch · Check the cable from TCU to the
TCU measures a voltage higher than If a failure is existing at · Check the connectors
7.00V at speed input pin output speed, · Check the speed sensor
·Cable is defective and is contacted to TCU shifts to neutral
vehicle battery voltage OP mode : Limp home
35 S.C. to ground at turbine speed input OP mode : Substitute clutch · Check the cable from TCU to the
at speed input pin If a failure is existing at · Check the connectors
·Cable/connector is defective and is output speed, · Check the speed sensor
contacted to vehicle ground TCU shifts to neutral ※ This fault is reset after power up of
·Speed sensor has an internal defect OP mode : Limp home TCU
36 Logical error at turbine speed input OP mode : Substitute clutch · Check the cable from TCU to the
TCU measures a turbine speed over a control sensor
threshold and at the next moment the If a failure is existing at · Check the connectors
measured speed is zero output speed, · Check the speed sensor
·Cable/connector is defective and has TCU shifts to neutral · Check the sensor gap
bad contact OP mode : Limp home
37 S.C. to battery voltage or O.C. at internal OP mode : Substitute clutch · Check the cable from TCU to the
TCU measures a voltage higher than · Check the connectors
7.00V at speed input pin · Check the speed sensor
vehicle battery voltage
38 S.C. to ground at turbine speed input OP mode : Substitute clutch · Check the cable from TCU to the
at speed input pin · Check the connectors
·Cable/connector is defective and is · Check the speed sensor
39 Logical error at internal speed input OP mode : Substitute clutch · Check the cable from TCU to the
TCU measures a internal speed over a control sensor
threshold and at the next moment the · Check the connectors
measured speed is zero · Check the speed sensor
·Cable/connector is defective and has · Check the sensor gap
bad contact ※ This fault is reset after power up of
·Speed sensor has an internal defect TCU
3A S.C. to battery voltage or O.C. at output Special mode for gear · Check the cable from TCU to the
speed input selection sensor
TCU measures a voltage higher than OP mode : S u b s t i t u t e · Check the connectors
12.5V at speed input pin clutch control · Check the speed sensor
·Cable is defective and is contacted to If a failure is existing at
battery voltage turbine speed,
·Cable has no connection to TCU TCU shifts to neutral
·Speed sensor has an internal defect OP mode : Limp home
3-35
3B S.C. to ground at output speed input Special mode for gear · Check the cable from TCU to the
TCU measures a voltage less than 1.00V selection sensor
at speed input pin OP mode : Substitute clutch · Check the connectors
·Cable/connector is defective and is control · Check the speed sensor
contacted to vehicle ground If a failure is existing at
·Speed sensor has an internal defect turbine speed,
TCU shifts to neutral
OP mode : Limp home
3C Logical error at output speed input Special mode for gear · Check the cable from TCU to the
TCU measures a turbine speed over a selection sensor
threshold and at the next moment the OP mode : Substitute clutch · Check the connectors
measured speed is zero control · Check the speed sensor
·Cable/connector is defective and has If a failure is existing at · Check the sensor gap
bad contact turbine speed, ※ This fault is reset after power up of
·Speed sensor has an internal defect TCU shifts to neutral TCU
·Sensor gap has the wrong size OP mode : Limp home
3D Turbine speed zero doesn't fit to other - · Not used
speed signals
3E Output speed zero doesn't fit to other Special mode for gear · Check the sensor signal of output
speed signals selection speed sensor
If transmission is not neutral and the OP mode : Substitute clutch · Check the sensor gap of output
shifting has finished, control speed sensor
TCU measures output speed zero and If a failure is existing at · Check the cable from TCU to the
turbine speed or internal speed not equal turbine speed, sensor
to zero. TCU shifts to neutral ※ This fault is reset after power up of
·Speed sensor has an internal defect OP mode : Limp home TCU
54 DCT1 timeout OP mode : Normal · Check display computer
Timeout of CAN-message DCT1 from · Check wire of CAN-Bus
display computer · Check cable to display computer
·Interference on CAN-Bus
·CAN wire/connector is broken
·CAN wire/connector is defective and
has contact to vehicle ground or battery
voltage
55 JSS timeout TCU shifts to neutral while · Check joystick steering controller
Timeout of CAN-message JSS from joystick steering is active · Check wire of CAN-Bus
joystick steering controller OP mode : Normal · Check cable to joystick steering
·Interference on CAN-Bus controller
voltage
56 Engine CONF timeout OP mode : Substitute · Check engine controller
Timeout of CAN-message engine CONF clutch control · Check wire of CAN-Bus
from engine controller · Check cable to engine controller
voltage
3-36
57 EEC1 timeout OP mode : Substitute · Check EEC controller
Timeout of CAN-message EEC1 from clutch control · Check wire of CAN-Bus
EEC controller · Check cable to EEC controller
voltage
58 EEC3 timeout OP mode : Substitute · Check EEC controller
Timeout of CAN-message EEC3 from clutch control · Check wire of CAN-Bus
EEC controller · Check cable to EEC controller
·CAN wire/connector is defective an has
contact to vehicle ground or battery
voltage
5C Auto downshift signal No reaction · Check cluster controller
CAN signal for automatic downshift is · Check wire of CAN-Bus
defective · Check cable to cluster controller
·Cluster controller is defective
5D Manual downshift signal No reaction · Check cluster controller
CAN signal for manual downshift is · Check wire of CAN-Bus
defective · Check cable to controller
·Cluster controller is defective
5E CCO request signal No reaction · Check cluster controller
CAN signal for CCO request is defective · Check wire of CAN-Bus
·Cluster controller is defective · Check cable to controller
61 AEB request signal No reaction · Check I/O controller, Omron master
CAN signal for AEB request is defective OP mode : Normal · Check wire of CAN-Bus
·I/O controller is defective · Check cable to I/O controller,
·Interference on CAN-Bus Omron master
64 Sarting gear signal No reaction. · Check I/O controller
CAN signal for starting gear is defective TCU uses default starting · Check wire of CAN-Bus
·I/O controller is defective gear · Check cable to I/O controller
(illegal starting gear) OP mode : Normal
65 Engine torque signal OP mode : Substitute · Check engine controller
CAN signal for engine torque is defective clutch control · Check wire of CAN-Bus
·Engine controller is defective · Check cable to engine controller
69 Reference engine torque signal OP mode : Substitute · Check engine controller
CAN signal for reference of engine torque clutch control · Check wire of CAN-Bus
is defective · Check cable to engine controller
·Engine controller is defective
6A Actual engine torque signal OP mode : Substitute · Check engine controller
CAN signal for actual engine torque is clutch control · Check wire of CAN-Bus
defective · Check cable to engine controller
·Engine controller is defective
3-37
6E EEC2 timeout No reaction, TCU uses · Check EEC controller
Timeout of CAN-message EEC2 from default signal accelerator · Check wire of CAN-Bus
EEC controller pedal in idle position · Check cable to EEC controller
·Interference on CAN-Bus OP mode : Normal
voltage
71 S.C. to battery voltage at clutch K1 TCU shifts to neutral · Check the cable from TCU to the
The measured resistance value of the valve OP mode : Limp home gearbox
is out of limit, the voltage at K1 valve is too If failure at another clutch · Check the connectors from TCU to
high is pending the gearbox
·Cable/connector is defective and has TCU shifts to neutral · Check the regulator resistance*
contact to battery voltage OP mode : TCU shutdown · Check internal wire harness of the
·Cable/connector is defective and has gearbox
contact to another regulator output of * See page 3-49
the TCU
·Regulator has an internal defect
72 S.C. to ground at clutch K1 TCU shifts to neutral · Check the cable from TCU to the
is out of limit, the voltage at K1 valve is too If failure at another clutch · Check the connectors from gearbox
low is pending to TCU
contact to vehicle ground OP mode : TCU shutdown · Check internal wire harness of the
·Regulator has an internal defect gearbox
* See page 3-49
73 O.C. at clutch K1 TCU shifts to neutral · Check the cable from TCU to the
The measured resistance value of the OP mode : Limp home gearbox
valve is out of limit If failure at another clutch · Check the connectors from gearbox
·Cable/connector is defective and has no is pending to TCU
contact to TCU TCU shifts to neutral · Check the regulator resistance*
·Regulator has an internal defect OP mode : TCU shutdown · Check internal wire harness of the
gearbox
* See page 3-49
valve is out of limit, the voltage at K2 valve If failure at another clutch · Check the connectors from gearbox
is too high is pending to TCU
the TCU
* See page 3-49
3-38
gearbox
* See page 3-49
the TCU
* See page 3-49
gearbox
* See page 3-49
7D S.C. ground at engine derating device Engine derating will be on · Check the cable from TCU to the
·Cable is defective and is contacted to until engine derating device
vehicle ground TCU power down even if · Check the connectors from engine
·Engine derating device has an internal fault vanishes (Loose derating device to TCU
defect connection) · Check the resistance* of engine
·Connector pin is contacted to vehicle OP mode : Normal derating device
ground ※ Not used
* See page 3-49
7E S.C. battery voltage at engine derating No reaction · Check the cable from TCU to the
device OP mode : Normal engine derating device
·Cable/connector is defective and is · Check the connectors from backup
contacted to battery voltage alarm device to TCU
·Engine derating device has an internal · Check the resistance* of backup
defect alarm device
* See page 3-49
3-39
7F O.C. at engine derating device No reaction · Check the cable from TCU to the
TCU detected a wrong voltage at the OP mode : Normal engine derating device
output pin, that looks like a O.C. for this · Check the connectors from engine
output pin derating device to TCU
·C a b l e i s d e fe c t i ve a n d h a s n o · Check the resistance* of engine
connection to TCU derating device
·Engine derating device has an internal * See page 3-49
defect
the TCU
The measured resistance value of the valve OP mode : Limp home engine derating device
* See page 3-49
83 O.C. at clutch K4 · Check the cable from TCU to the
The measured resistance value of the TCU shifts to neutral gearbox
valve is out of limit OP mode : Limp home · Check the connectors from gearbox
·Cable/connector is defective and has If failure at another clutch to TCU
contact to TCU is pending · Check the regulator resistance*
·Regulator has an internal defect TCU shifts to neutral · Check internal wire harness of the
OP mode : TCU shutdown gearbox
* See page 3-49
the TCU
85 S.C. to ground at clutch KV TCU shifts to neutral · Check the cable from TCU to the
* See page 3-49
3-40
86 O.C. at clutch KV TCU shifts to neutral · Check the cable from TCU to the
·Cable/connector is defective and has is pending to TCU
gearbox
* See page 3-49
87 S.C. to battery voltage at clutch KR TCU shifts to neutral · Check the cable from TCU to the
valve is out of limit, the voltage at KR valve is If failure at another clutch · Check the connectors from gearbox
too high is pending to TCU
contact to another regulator output of the * See page 3-49
TCU
88 S.C. to ground at clutch KR TCU shifts to neutral · Check the cable from TCU to the
is out of limit, the voltage at KR valve is too If failure at another clutch · Check the connectors from gearbox
* See page 3-49
89 O.C. at clutch KR TCU shifts to neutral · Check the cable from TCU to the
gearbox
* See page 3-49
91 S.C. to ground at relay reverse warning Backup alarm will be on · Check the cable from TCU to the
alarm until backup alarm device
TCU detected a wrong voltage at the TCU power down even if · Check the connectors from backup
output pin, that looks like a S.C. to vehicle fa u l t va n i s h e s ( L o o s e alarm device to TCU
ground connection) · Check the resistance* of backup
·Cable is defective and is contact to OP mode : Normal alarm device
vehicle ground * See page 3-49
·Backup alarm device has an internal
defect
ground
92 S.C. to battery voltage at relay reverse No reaction · Check the cable from TCU to the
warning alarm OP mode : Normal backup alarm device
TCU detected a wrong voltage at the · Check the connectors from backup
output pin, that looks like a S.C. to battery alarm device to TCU
voltage · Check the resistance* of backup
·Cable is defective and is contacted to alarm device
battery voltage * See page 3-49
·Backup alarm device has an internal
defect
voltage
3-41
93 O.C. at relay reverse warning alarm No reaction · Check the cable from TCU to the
TCU detected a wrong voltage at the OP mode : Normal backup alarm device
output pin, that looks like a O.C. for this · Check the connectors from backup
output pin alarm device to TCU
·C a b l e i s d e fe c t i ve a n d h a s n o · Check the resistance* of backup
connection to TCU alarm device
·Backup alarm device has an internal * See page 3-49
defect
94 S.C. to ground at relay starter interlock No reaction · Check the cable from TCU to the
TCU detected a wrong voltage at the OP mode : Normal stater interlock relay
output pin, that looks like a S.C. to vehicle · Check the connectors from starter
ground interlock relay to TCU
·Cable is defective and is connection to · Check the resistance* of starter
vehicle ground interlock relay
·Starter interlock relay has an internal * See page 3-49
defect
ground
95 S.C. to battery voltage at relay starter No reaction · Check the cable from TCU to the
interlock OP mode : Normal starter interlock relay
TCU detected a wrong voltage at the · Check the connectors from starter
output pin, that looks like a S.C. to battery interlock relay to TCU
voltage · Check the resistance* of starter
·C a b l e i s d e fe c t i ve a n d h a s n o interlock relay
connection to battery voltage * See page 3-49
·Starter interlock relay has an internal
defect
voltage
96 O.C. at relay starter interlock No reaction · Check the cable from TCU to the
TCU detected a wrong voltage at the OP mode : Normal starter interlock relay
output pin, that looks like a O.C. for this · Check the connectors from starter
output pin interlock relay to TCU
·C a b l e i s d e fe c t i ve a n d h a s n o · Check the resistance* of starter
connection to TCU interlock relay
·Starter interlock relay has an internal * See page 3-49
defect
9A S.C. to ground at conver ter lock up No reaction · Check the cable from TCU to the
clutch solenoid OP mode : Normal converter clutch solenoid
TCU detected a wrong voltage at the · C h e ck t h e c o n n e c t o r s f r o m
output pin, that looks like a S.C. to vehicle converter clutch solenoid to TCU
ground · Check the resistance* of converter
·Cable is defective and is contacted to clutch solenoid
·Conver ter clutch solenoid has an
internal defect
ground
3-42
9B O.C. at converter lock up clutch solenoid Converter clutch always · Check the cable from TCU to the
TCU detected a wrong voltage at the open, retarder not converter clutch solenoid
output pin, that looks like a O.C. for this available · C h e ck t h e c o n n e c t o r s f r o m
output pin OP mode : Normal converter clutch solenoid to TCU
·C a b l e i s d e fe c t i ve a n d h a s n o · Check the resistance* of converter
connection to TCU clutch solenoid
·Conver ter clutch solenoid has an * See page 3-49
internal defect
9C S.C. to battery voltage at converter lock No reaction · Check the cable from TCU to the
up clutch solenoid OP mode : Normal converter clutch solenoid
TCU detected a wrong voltage at the · C h e ck t h e c o n n e c t o r s f r o m
output pin, that looks like a S.C. to battery converter clutch solenoid to TCU
voltage · Check the resistance* of converter
·Cable is defective and has no contacted clutch solenoid
to battery voltage * See page 3-49
·Conver ter clutch solenoid has an
internal defect
voltage
A1 S.C. to ground at difflock or axle No reaction · Check the cable from TCU to the
connection solenoid OP mode : Normal difflock solenoid
TCU detected a wrong voltage at the · Check the connectors from difflock
output pin, that looks like a S.C. to vehicle solenoid to TCU
ground · Check the resistance* of difflock
·Cable is defective and is contacted to solenoid
·Difflock solenoid has an internal defect
ground
A2 S.C. to battery voltage at difflock or axle No reaction · Check the cable from TCU to the
connection solenoid OP mode : Normal difflock solenoid
output pin, that looks like a S.C. to battery solenoid to TCU
voltage · Check the resistance* of difflock
·C a b l e i s d e fe c t i ve a n d h a s n o solenoid
connection to battery voltage * See page 3-49
voltage
A3 O.C. at difflock or axle connection No reaction · Check the cable from TCU to the
solenoid OP mode : Normal difflock solenoid
output pin, that looks like a O.C. for this solenoid to TCU
output pin · Check the resistance* of difflock
·C a b l e i s d e fe c t i ve a n d h a s n o solenoid
connection to TCU * See page 3-49
3-43
A4 S.C. to ground at warning signal output No reaction · Check the cable from TCU to the
TCU detected a wrong voltage at the OP mode : Normal warning device
output pin, that looks like a S.C. to vehicle · Check the connectors from warning
ground device to TCU
·Cable is defective and is contacted to · Check the resistance* of warning
vehicle ground device
·Warning device has an internal defect * See page 3-49
ground
A5 O.C. voltage at warning signal output No reaction · Check the cable from TCU to the
TCU detected a wrong voltage at the OP mode : Normal warning device
output pin, that looks like a O.C. for this · Check the connectors from warning
output pin device to TCU
·C a b l e i s d e fe c t i ve a n d h a s n o · Check the resistance* of warning
connection to TCU device
·Warning device has an internal defect * See page 3-49
A6 S.C. to battery voltage at warning signal No reaction · Check the cable from TCU to the
output OP mode : Normal warning device
TCU detected a wrong voltage at the · Check the connectors from warning
output pin, that looks like a S.C. to battery device to TCU
voltage · Check the resistance* of warning
·Cable is defective and has is contacted device
to battery voltage * See page 3-49
·Warning device has an internal defect
voltage
B1 Slippage at clutch K1 TCU shifts to neutral · Check pressure at clutch K1
TCU calculates a differential speed at OP mode : Limp home · Check main pressure in the system
closed clutch K1. If this calculated value If failure at another clutch · Check sensor gap at internal speed
is out of range, TCU interprets this as is pending sensor
slipping clutch TCU shifts to neutral · Check sensor gap at output speed
·Low pressure at clutch K1 OP mode : TCU shutdown sensor
·Low main pressure · Check signal at internal speed
·Wrong signal at internal speed sensor sensor
·Wrong signal at output speed sensor · Check signal at output speed
·Wrong size of the sensor gap sensor
·Clutch is defective · Replace clutch
TCU calculates a differential speed at OP mode : Limp home Check main pressure in the system
3-44
·Clutch is defective Replace clutch
slipping clutch TCU shifts to neutral · Check sensor gap at turbine speed
·Wrong signal at turbine speed sensor · Check signal at turbine speed
·Clutch is defective Replace clutch
B5 Slippage at clutch KV TCU shifts to neutral · Check pressure at clutch KV
closed clutch KV. If this calculated value If failure at another clutch · Check sensor gap at internal speed
·Low pressure at clutch KV OP mode : TCU shutdown sensor
B6 Slippage at clutch KR TCU shifts to neutral · Check pressure at clutch KR
closed clutch KR. If this calculated value If failure at another clutch · Check sensor gap at internal speed
·Low pressure at clutch KR OP mode : TCU shutdown sensor
B7 Overtemp sump No reaction · Cool down machine
TCU measured a temperature in the oil OP mode : Normal · Check oil level
sump that is over the allowed threshold. · Check temperature sensor
B9 Overspend engine Retarder applies
-
OP mode : Normal
BA Differential pressure oil filter No reaction · Check oil filter
TCU measured a voltage at differential OP mode : Normal · Check wiring from TCU to
pressure switch out of the allowed range differential pressure switch
·Oil filter is polluted · C h e ck d i f fe r e n t i a l p r e s s u r e
·Cable/connector is broken or cable/ switch(Measure resistance)
connector is contacted to battery voltage
or vehicle ground
·Differential pressure switch is defective
3-45
BB Slippage at converter lockup clutch No reaction · Check pressure at converter lockup
TCU calculates a differential speed at OP mode : Normal clutch
closed converter lockup clutch. If this · Check main pressure in the system
calculated value is out of range, TCU · Check sensor gap at engine speed
interprets this as slipping clutch sensor
·Low pressure at converter lockup clutch · Check sensor gap at turbine speed
·Low main pressure sensor
·Wrong signal at engine speed sensor · Check signal at engine speed
·Wrong signal at turbine speed sensor sensor
·Wrong size of the sensor gap · Check signal at turbine speed
·Clutch is defective sensor
· Replace clutch
C0 Engine torque or engine power overload OP mode : Normal
TCU calculates an engine torque or
e n g i n e p o w e r a b o ve t h e d e f i n e d
thresholds
C1 Transmission output torque overload OP mode : Normal
TCU calculates an transmission output
torque above the defined threshold
C2 Transmission input torque overload programmable :
TCU calculates an transmission input No reaction or shift to
torque above the defined threshold neutral
OP mode : Normal
C3 Overtemp converter output No reaction · Cool down machine
TCU measured a oil temperature at the OP mode : Normal · Check oil level
converter output that is the allowed · Check temperature sensor
threshold
C4 S. C. t o g r o u n d a t j oy s t i ck s t a t u s No reaction · Check the cable from TCU to
indicator OP mode : Normal joystick status indicator
TCU detected a wrong voltage at the · Check the connectors from joystick
output pin, that looks like a S.C. to vehicle status indicator to TCU
ground · Check the resistance* of joystick
·Cable is defective and is contacted to status indicator
·Joystick status indicator has an internal
defect
ground
C5 S.C. to battery voltage at joystick status No reaction · Check the cable from TCU to
indicator OP mode : Normal joystick status indicator
TCU detected a wrong voltage at the · Check the connectors from joystick
output pin, that looks like a S.C. to battery status indicator to TCU
voltage · Check the resistance* of joystick
·Cable is defective and is contacted to status indicator
battery voltage * See page 3-49
·Joystick status indicator has an internal
defect
voltage
3-46
C6 O.C. at joystick status indicator No reaction · Check the cable from TCU to
TCU detected a wrong voltage at the OP mode : Normal joystick status indicator
output pin, that looks like a O.C. for this · Check the connectors from joystick
output pin status indicator to TCU
·C a b l e i s d e fe c t i ve a n d h a s n o · Check the resistance* of joystick
connection to TCU status indicator
·Joystick status indicator has an internal * See page 3-49
defect
·Connector pin has no connection to
TCU
D1 S.C. to battery voltage at power supply See fault codes No.21 to · Check cables and connectors to
for sensors 2C sensors, which are supplied from
TCU measures more than 6V at the pin AU1
AU1 (5V sensor supply) · Check the power supply at the pin
AU1(Should be appx. 5V)
· Fault codes No.21 to No.2C may be
reaction of this fault
D2 S.C. to ground at power supply for See fault codes No.21 to · Check cables and connectors to
sensors 2C sensors, which are supplied from
TCU measures less than 4V at the pin AU1
AU1 (5V sensor supply) · Check the power supply at the pin
AU1(Should be appx. 5V)
· Fault codes No.21 to No.2C may be
reaction of this fault
D3 Low voltage at battery Shift to neutral · Check power supply battery
Measured voltage at power supply is lower OP mode : TCU shutdown · Check cables from batteries to TCU
than 18V(24V device) · Check connectors from batteries to
TCU
D4 High voltage at battery Shift to neutral · Check power supply battery
Measured voltage at power supply is OP mode : TCU shutdown · Check cables from batteries to TCU
higher than 32.5V(24V device) · Check connectors from batteries to
TCU
D5 Error at valve power supply VPS1 Shift to neutral · Check fuse
TCU switched on VPS1 and measured OP mode : TCU shutdown · Check cables from gearbox to TCU
VPS1 is off or TCU switched off VPS1 and · Check connectors from gearbox to
measured VPS1 is still on TCU
·Cable or connectors are defect and are · Replace TCU
contacted to battery voltage
·Cable or connectors are defect and are
·Permanent power supply KL30 missing
·TCU has an internal defect
D6 Error at valve power supply VPS2 Shift to neutral · Check fuse
TCU switched on VPS2 and measured OP mode : TCU shutdown · Check cables from gearbox to TCU
VPS2 is off or TCU switched off VPS2 and · Check connectors from gearbox to
measured VPS2 is still on TCU
·Cable or connectors are defect and are · Replace TCU
contacted to battery voltage
·Cable or connectors are defect and are
·Permanent power supply KL30 missing
·TCU has an internal defect
3-47
E3 S.C. to battery voltage at display output No reaction · Check the cable from TCU to the
TCU sends data to the display and OP mode : Normal display
measures always a high voltage level on · Check the connectors at the display
the connector · Change display
·Cable or connectors are defective and
are contacted to battery voltage
·Display has an internal defect
E4 S.C. to ground at display output No reaction · Check the cable from TCU to the
TCU sends data to the display and OP mode : Normal display
measures always a high voltage level on · Check the connectors at the display
the connector · Change display
·Cable or connectors are defective and
are contacted to battery voltage
·Display has an internal defect
E5 Communication failure on DeviceNet Shift to neutral · Check Omron master
OP mode : TCU shutdown · Check wire of DeviceNet-Bus
· Check cable to Omron master
F1 General EEPROM fault No reaction · Replace TCU
TCU can't read non volatile memory OP mode : Normal ※ Often shown together with fault
·TCU is defective code F2
F2 Configuration lost Transmission stay neutral · Reprogram the correct configurat-
TCU has lost the correct configuration and OP mode : TCU shutdown ion for the vehicle (e.g. with cluster
can't control the transmission controller,...)
·Interference during saving data on non
volatile memory
·TCU is brand new or from another
vehicle
F3 Application error Transmission stay neutral · Replace TCU
Something of this application is wrong OP mode : TCU shutdown ※ This fault occurs only if an test
engineer did something wrong in
the application of the vehicle
F5 Clutch failure Transmission stay neutral · Check clutch
AEB was not able to adjust clutch filling OP mode : TCU shutdown ※ TCU shows also the affected clutch
parameters on the display
·One of the AEB-Values is out of limit
F6 Clutch adjustment data lost No reaction, · Execute AEB
TCU was not able to read correct clutch Default values : 0 for AEB
adjustment parameters Offsets used
·Interference during saving data on non OP mode : Normal
volatile memory
·TCU is brand new
F7 Substitute clutch control OP mode : Substitute · Check engine retarder torque
·Transmission input torque wrong clutch control · Check speed sensors
·Engine retarder torque wrong
·Speed signal (s) defective
3-48
5) MEASURING OF RESISTANCE AT ACTUATOR/SENSOR AND CABLE
(1) Actuator
2 G
76043PT19
Open circuit R12 = R1G = R2G = ∞

Short cut to ground R12 = R; R1G = 0, R2G = R or R1G = R, R2G = 0
(For S.C. to ground, G is connected to vehicle ground)
Short cut to battery R12 = R; R1G = 0, R2G = R or R1G = R, R2G = 0
(For S.C. to battery, G is connected to battery voltage)
(2) Cable
UBat
P(Power supply)
TCU
1 2 Actuator/
Sensor
C(Chassis)
Ground
76043PT20
Open circuit R12 = R1P = R1C = R2P = R2C= ∞

Short cut to ground R12 = 0; R1C = R2C = 0, R1P = R2P = ∞
Short cut to battery R12 = 0; R1C = R2C = 0, R1P = R2P = 0
3-49
5. AXLE
1) OPERATION
· The power from the engine passes through torque converter, transmission and drive shafts, and is
then sent to the front and rear axles.
· Inside the axles, the power passes from the bevel pinion to the bevel gear and is sent at right
angles. At the same time, the speed is reduced and passes through the both differentials to the
axle shafts. The power of the axle shafts is further reduced by planetary-gear-type final drives and
is sent to the wheels.
(1) Front axle
2
3
3
2
7609A3PT15
1 Input 2 Output 3 Brake

4 Axle housing
(2) Rear axle
2
3
1
3
2
7609A3PT16
1 Input 2 Output 3 Brake

4 Axle housing
3-50
2) DIFFERENTIAL
(1) Description 3
When the machine makes a turn, the
2 4
outside wheel must rotate faster than the
inside wheel. A differential is a device
which continuously transmits power to the
right and left wheels while allowing them
to turn a different speeds, during a turn.
The power from the drive shaft passes
through bevel pinion (1) and is transmitted
to the bevel gear (2). The bevel gear
changes the direction of the motive force
by 90 degree, and at the same time
reduces the speed. 1
It then transmits the motive force through
the differential (3) to the axle gear shaft 770-3 [3-26(1)]
(4).
(2) When driving straight forward

Pinion gear
When the machine is being driven straight
Side gear Side gear
forward and the right and left wheels are
rotating at the same speed, so the pinion Axle gear shaft
gear inside the differential assembly do
not rotate. The motive force of the carrier
is send through the pinion gear and the
side gear, therefore the power is equally Carrier
transmitted to the left and right axle gear Pinion gear
shaft.
770-3 [3-26(2)]
(3) When turning

Swing
When turning, the rotating speed of the
Pinion gear
left and right wheels is different, so the
Side gear Side gear
pinion gear and side gear inside the
differential assembly rotate in accordance
with the difference between the rotating
speed of the left and right wheels.
T h e p owe r o f t h e c a r r i e r i s t h e n
transmitted to the axle gear shafts. Carrier
Pinion gear Ring gear
770-3 [3-26(3)]
3-51
6. TIRE AND WHEEL
7407APT10
1 Wheel rim 3 O-ring 5 Side ring

2 Tire 4 Lock ring 6 Valve assembly
1) The tire acts to absorb the shock from the ground surface to the machine, and at the same time
they must rotate in contact with the ground to gain the power which drives the machine.
2) Various types of tires are available to suit the purpose. Therefore it is very important to select the
correct tires for the type of work and bucket capacity.
3-52
GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING
1. POWER TRAIN OPERATIONAL CHECKS

This procedure is designed so that the mechanic can make a quick check of the system using a
minimum amount of diagnostic equipment. If you need additional information, read Structure and
function, Group 1.
A location will be required which is level and has adequate space to complete the checks.
The engine and all other major components must be at operating temperature for some checks.
Locate system check in the left column and read completely, following the sequence from left to right.
Read each check completely before performing.
At the end of each check, if no problem is found(OK), that check is complete or an additional check is
needed. If problem is indicated(NOT OK), you will be given repair required and group location.
If verification is needed, you will be given next best source of information :
Chapter 2 : Troubleshooting
Group 3 : Tests and adjustments
3-53
※ Transmission oil must be at operating temperature for these checks.
Item Description Service action

Transmission oil warm-up Start engine. Apply service brakes OK
procedure and release parking brake. Check completed.
Select T/M shift mode switch to
MAN (manual) mode.
Move gear selector lever to 3rd
speed.
Move gear selector lever to forward
"F" position.
Increase engine speed to high idle
AL MAN
for 30 seconds.
AN AH
A
Move gear selector lever to neutral
"N" position and r un for 15
seconds.
1
4
2
3
Repeat procedure until
transmission temperature gauge
arrow points to bar above dial.
Gear selector lever and Move gear selector lever to each OK
neutral lock latch checks position. Check completed.
Engine OFF. 1
NOTE : Gear selector lever position

2
3
4
NOT OK
changes slightly as steer ing
Repair lock or replace
column is tilted.
switch.
FEEL : Lever must move freely
through all positions.
Engage neutral lock.
Apply slight effort to move lever into
forward (F) and reverse (R).
LOOK : Neutral lock must stay
engaged.
Automatic shifting check Start engine. OK
Check completed.
1
2
3
F
N
Move gear selector lever to 4th
4
R
speed.
NOT OK
Turn T/M shift mode switch to AL Go to transmission error
(auto light) mode. code group at page 3-32~
3-48.
Auotmatic sign LOOK : Automatic sign on monitor.
Repair or replace the
Move gear selector lever to forward monitor or harness.
or reverse position.
Increase engine rpm.
LOOK : Speed on monitor must
vary with machine speed.
3-54
Transmission noise Run engine at approximately 1600 OK
check 1
2
rpm. Check completed.
3
Engine running.
4
Drive unit with transmission in each NOT OK

forward and reverse speed. Go to transmission makes
excessive noise, chapter 2
LISTEN : Transmission must not
in this group.
make excessive noise in any range.
Engine rpm must not "lug down" as
unit is shifted between gears.
Transmission "quick shift" Release parking brake and select OK
Release
check T/M shift mode switch to MAN Check completed.
Engine running. (manual) mode.
NOT OK
P
Shift to 2nd forward. Check connector at base

of control valve.
Drive machine at approximately
5km/h and press gear selector lever IF OK
kick down switch or RCV levers Go to transmission
switch once. controller circuit in group 1.
AL MAN
LOOK/FEEL : Transmission must

AN
A
AH
shift to and remain in 1st gear.
Press gear selector lever kick down
switch once.
1
4
2
3
shift back to 2nd gear.
Shift to (3rd or 4th) gear and press
gear selector lever kick down
switch once.
not shift down.
Select T/M shift mode switch to AL
(auto light) mode.
Drive machine at approximately
90% speed of max speed in each
gear (2nd or 3rd or 4th).
Shift to (2nd or 3rd or 4th) gear in
each forward and reverse speed
and press gear selector kick down
lever switch or RCV lever switch
once.
LOOK/FEEL : It shift down quickly
from current gear to one step lower
speed and recover to original
speed quickly when push the
switch one more time. (mode 1)
3-55
LOOK/FEEL : If shifts down from
current gear to one step lower
speed when push the switch
everytime and recover when push
the switch in 1st gear. (mode 2)
Forward, reverse and 4th Park unit on level surface. OK
speed clutch pack drag 1
2
3 Check completed.
Apply service brakes.
4
check
NOT OK
※ Transmission must Move gear selector lever to neutral.
I f u n i t m ove s, r e p a i r
be warmed up for Release
Move gear selector lever to 1st. transmission.
this check.
Engine running. Release parking brake and service
P
brakes.
Run engine at low idle.
LOOK : Unit must not move in
either direction.
NOTE : If unit moves forward,
either the forward pack or the 4th
speed pack is dragging.
Transmission shift Run engine at approximately 1300 OK
modulation check 1
4
2
3 rpm. Check completed.
Engine running.
Put transmission in 1st forward, NOT OK
shift several times from forward to Go to unit shifts too fast,
reverse and reverse to forward. chapter 2 in this group.
Repeat check in 2nd gear.
LOOK : Unit must slow down and
change direction smoothly.
Torque converter check Start engine. Apply service brakes OK
1
4
2
3
and release parking brake. Check completed.
Move gear selector lever to 3rd NOT OK
speed. If stall rpm are too low or
too high, problem may be
Move gear selector control lever to
engine power or torque
forward "F" position.
converter.
Increase engine speed to high idle.
IF OK
LOOK : Torque converter stall rpm Replace transmission
must be within the following range. torque converter.
Stall rpm : 2040±70 rpm
Move gear selector control lever to
neutral "N" position and run for 15
seconds.
3-56
2. TROUBLESHOOTING
1) TRANSMISSION
※ Diagnose malfunction charts are arranged from most probable and simplest to verify, to least likely,
more difficult to verify. Remember the following steps when troubleshooting a problem :
Step 1. Operational check out procedure (See group 3 in section 1.)
Step 2. Operational checks (In this group.)
Step 3. Troubleshooting
Step 4. Tests and/or adjustments (See group 3.)
Problem Cause Remedy

Transmission slippage Low oil level. Add oil.
Wrong oil grade. Change oil.
Restricted transmission pump Remove and clean screen.
suction screen.
Leak in transmission control valve Remove valve and inspect gaskets.
or gasket.
Low transmission pump flow due Do transmission pump flow test.
to worn pump.
Weak or broken pressure regulat- Do transmission system pressure test.
ing valve spring.
Error code on display Something wrong in transmission. Go to transmission error code group at page
3-32~3-48.
3-57
Machine will not move Low oil level. Add oil.
Applied park brake. Check parking brake fuse.
Check continuity to parking brake switch.
No power to transmission contro- Check transmission controller fuse.
ller.
Malfunctioning parking brake Remove and inspect parking brake solenoid
solenoid valve. valve.
Check for power to solenoid valve.
Restricted orifice of PPC valve. Remove orifice and check for contamination
and/or plugging.
(Do not remove valve housing for this purpose.)
Excessive leakage in Do transmission element leakage test using
transmission element. system pressure.
Worn clutch disks. Repair transmission.
Low or no transmission See transmission pressure is low in this group.
pressure.
Service brake will not release. Do brake pedal operational check.
Do service and park system drag checks.
Failed torque converter. Do torque converter stall test.
If engine pulldown in normal, torque converter is
good.
Broken shafts or gears. Drain transmission to determine if large pieces
of metal contamination are present.
Broken drive shafts. Inspect drive shafts and universal joints for
external damage. Repair.
Broken ring or pinion gear. If drive shaft rotate with transmission in gear but
machine does not move, a differential failure is
indicated. Repair.
Machine does not Malfunctioning transmission Check solenoid valve.
engage in low gear control solenoid valve.
Stuck spool in transmission Remove and inspect transmission control valve
control valve. spools.
Stuck PPC valve. Remove end cover to inspect PPC valve.
Replace if necessary.
Malfunctioning transmission Check speed sensor.
speed sensor.
3-58
Transmission pressure is Low oil level. Check transmission oil level and refill if
low (all gears) necessary.
Failed transmission pressure Verify transmission system pressure. Do
switch. transmission system pressure test.
Plugged suction strainer. Transmission pump may be noisy if transmission
suction screen is clogged. Drain transmission.
Remove and clean suction screen.
Also, check condition of transmission filter.
Stuck transmission pressure Remove transmission pressure regulating valve.
regulating valve or broken spring. Inspect for damage (See transmission control
valve).
Failed control valve gasket. Inspect transmission control valve for external
leakage. Remove control valve.
Inspect or replace gasket.
Stuck PPC valve. Remove end cover to inspect modulation spool
and check torque on cap screws retaining
control valve to transmission.
Tr a n s m i s s i o n s y s t e m Failed transmission pump. Do pump flow test.
pressure is low (one or
Failed transmission control valve Inspect transmission control valve for external
two gears)
gasket. leakage. Remove control valve.
Inspect or replace gasket.
Leakage in clutch piston or seal Disassemble and repair.
ring.
Transmission shifts too Low oil level (aeration of oil). Add oil.
low
Low transmission pressure. Do transmission system pressure test.
Restricted transmission pump Remove and clean screen.
suction screen.
Low transmission pump flow. Do transmission pump flow test.
Excessive transmission Do transmission element leakage test using
element leakage. system pressure.
Stuck PPC valve. Remove end cover to inspect modulation spool.
Restricted PPC valve orifice. Remove orifice and inspect for contamination
and /or plugging.
Restricted oil passages between Remove control valve and inspect oil passage.
control valve and transmission
elements.
Incorrect transmission oil. Change oil (SAE 10W-30/15W-40)
3-59
Transmission shifts too Wrong transmission controller. Check if transmission controller has been
fast changed
System pressure too high. Do transmission system pressure test.
Stuck PPC valve. Remove and inspect PPC valve.
Replace if necessary. Also remove end cover
to inspect PPC valve and control valve housing.
Stuck or missing check valves. Inspect transmission control valve.
Missing O-r ing from end of Remove orifice and inspect port for O-ring.
modulation orifice.
Broken piston return spring. Disassemble and inspect clutch.
Incorrect transmission oil. Change oil (SAE 10W-30/15W-40).
Machine "creeps" War ped disks and plates in Check transmission.
in neutral transmission.
Transmission hydraulic High oil level. Transmission overfilled or hydraulic pump seal
system overheats leaking.
Low oil level. Add oil.
Wrong oil grade. Change oil.
Park brake dragging. Check for heat in park brake area.
Pinched, restricted or leaking lube Check cooler lines.
lines.
Machine operated in too high Operate machine in correct gear range.
gear range.
Malfunction in temperature gauge I n s t a l l t e m p e ra t u r e s e n s o r t h e ve r i f y
or sensor. temperature.
Do tachometer/temperature reader installation
procedure.
Restricted air flow through oil Do radiator air flow test.
cooler or radiator.
Failed oil cooler bypass valve (In Disassemble and inspect.
thermal bypass valve).
Failed thermal bypass valve. Remove thermal bypass valve and check to see
if machine still overheats. Do transmission oil
cooler thermal bypass valve test.
Internally restricted oil cooler. Do oil cooler restriction test.
Leakage in transmission hydraulic Do transmission system pressure, element
system. leakage test.
Malfunction in converter relief Do converter out pressure test.
valve.
Low transmission pump output. Do transmission pump flow test.
3-60
Excessive transmission Too low engine low idle. Check engine low idle speed.
noise (Under load or no
Wo r n p a r t s o r d a m a g e d i n Remove transmission suction screen. Inspect
load)
transmission. for metal particles.
Repair as necessary.
Warped drive line between engine Inspect drive line.
and torque converter.
Low or no lube. Do converter-out and lube pressure test. Do
transmission pump flow test.
Foaming oil Incorrect type of oil. Change oil.
High oil level. Transmission overfilled or hydraulic pump seal
leaking.
Low oil level. Add oil.
Air leak on suction side of pump. Check oil pickup tube on side of transmission.
Oil ejected from dipstick Plugged breather. Inspect breather on top of transmission.
Replace.
Machine vibrates Aerated oil. Add oil.
Low engine speed. Check engine speed.
Fa i l e d u n i ve r s a l j o i n t s o n Check universal joints.
transmission dr ive shaft or
differential drive shafts.
Machine lacks power and Engine high idle speed set too Check high idle adjustment.
acceleration low.
Incorrect transmission oil. Change oil.
Aerated oil. Add oil.
Low transmission pressure. Do transmission system pressure test.
Warped transmission clutch. Do transmission clutch drag checks.
Torn transmission control valve Inspect gasket.
gasket.
Brake drag. Do brake drag check.
Failed torque converter. Do torque converter stall speed test.
Low engine power. Do engine power test.
Torque conver ter stall Aerated oil. Put clear hose on thermal bypass outlet port.
RPM too high Run machine to check for bubbles in oil.
Stuck open converter relief valve. Do converter-out pressure test.
Leakage in torque converter seal. Do converter-out pressure test.
Torque converter not Replace torque converter.
transferring power (Bent fins,
broken starter).
3-61
Torque conver ter stall Low engine power. Do engine power test.
RPM too low
Mechanical malfunction. Remove and inspect torque converter.
Transmission pressure Low oil level. Add oil.
light comes ON when
Cold oil. Warm oil to specification.
shifting from forward to
reverse (all other gears Leak in reverse pack. Do transmission pressure, pump flow, and
OK) leakage check.
Transmission pressure Cold oil. Warm oil to specification.
light comes ON for each
No time delay in monitor. Do monitor check.
shift
Restriction in modulation orifice. Remove orifice and inspect for restriction and/or
plugging.
Stuck PPC valve. Remove and inspect.
Low transmission pressure circuit. Do transmission system pressure test.
Leak in transmission pressure Do converter out pressure test.

circuit.
Failed transmission pump. Do transmission pump flow test.
Clogged filter. Inspect filter. Replace.
3-62
2) DIFFERENTIAL / AXLE
Differential low on oil External leakage. Inspect axle and differential for leaks.
Excessive differential Low oil level in differential. Check oil. Remove drain plug and inspect for
and/or axle noise metal particles in differential case.
Disassemble and determine cause.
Incorrect type of oil. Change oil
Dragging brakes. Do brake check.
Failed pinion bearing. Remove and inspect pinion.
Check to ensure pinion housing was indexed.
Incorrect gear mesh pattern Remove pinion gear housing and inspect ring
between ring and pinion gear. and pinion gear.
Failed differential pinion gears Remove differential housing drain plug and
and/or cross shafts. inspect for metal particles. Disassemble and
inspect.
Failed axle bearing. Do axle bearing adjustment check.
M e c h a n i c a l fa i l u r e i n a x l e Remove differential. Inspect, repair.
planetary.
Oil seeping from outer Excessive end play in axle. Do axle bearing adjustment check.
axle seal
Worn outer bearing and/or cup. Disassemble and inspect outer axle bearing,
cup, spacer, and seal. Replace, if necessary.
Overfilled differential. Check differential oil return system for
excessive internal restriction.
Axle overheats Low differential oil. Add oil.
Overfilled differential. See differential overfills with oil in this group.
Brake drag. See brakes drag in this group.
3) DRIVE LINE
E x c e s s i v e d r i v e l i n e Yokes not in line on drive shafts. Inspect. Align drive shaft yokes.
vibration or noise
Worn front drive line support Inspect, repair.
bearing.
Bent drive shaft. Inspect all drive shafts. Replace.
Loose yoke retaining nuts (drive Inspect. Replace.
shafts wobble at high speed).
Rear axle oscillating support. Inspect, repair.
Lack of lubrication. Lubricate with proper grade of grease.
3-63
GROUP 3 TESTS AND ADJUSTMENTS
1. TRANSMISSION MEASURING POINTS AND CONNECTIONS

The measurements have to be carried out at hot transmission (about 80~95˚C).
48 47 21
16
15
52,63 54
34
65 51 68
69 49
H J
K G
57 A F
60
B E
53 55
C D
58 56
VIEW X
7607APT14
1) OIL PRESSURE AND TEMPERATURE

Port Description Size
51 Converter inlet-opening pressure (11+2 bar) H M10×1.0
52 Converter outlet-opening pressure (4.3+3 bar) M14×1.5
53 Forward clutch (16+2 bar) KV B M10×1.0
55 Reverse clutch (16+2 bar) KR E M10×1.0
56 1st clutch (16+2 bar) K1 D M10×1.0
57 2nd clutch (16+2 bar) K2 A M10×1.0
58 3rd clutch (16+2 bar) K3 C M10×1.0
60 4th clutch (16+2 bar) K4 F M10×1.0
63 Converter outlet temperature 100˚C, short-time 120˚C M14×1.5
65 System pressure (16+2 bar) K M10×1.0
3 - 64
2) DELIVERY RATES
15 Connection to the oil cooler 1 5/6″-12UNF-2B
16 Connection from the oil cooler 1 5/6″-12UNF-2B
3) INDUCTIVE TRANSMITTER AND SPEED SENSOR

21 Inductive transmitter n turbine M18×1.5
34 Speed sensor n output and speedometer -
47 Inductive transmitter n central gear train M18×1.5
48 Inductive transmitter n engine M18×1.5
54 Filter contamination switch M14×1.5
4) CONNECTIONS
49 Plug connection on the hydraulic control unit -
68 Pilot pressure (option) J M16×1.5
69 System pressure (option) G M16×1.5
3-65
GROUP 4 DISASSEMBLY AND ASSEMBLY
1. CONTROL VALVE
1) DISASSEMBLY
(1) Illustration on the right shows the comple-
te control unit.
73073CV001
(2) Mark the installation position of the

different covers, the housing and cable
harness with the valve housing.
73073CV002
(3) Loosen socket head screws.

S e p a ra t e d u c t p l a t e, 1 s t g a s ke t ,
intermediate plate and 2nd gasket from
the valve housing.
Box spanner 5873 042 002
73073CV003
(4) Remove retaining clip.
73073CV004
3-66
(5) Loosen socket head screws.
Separate cover from housing and cable
harness.
73073CV005
(6) Disassemble opposite cover.

Disconnect pressure regulator and
remove cable harness.
73073CV006
(7) Loosen socket head screws, remove

fixing plate and pressure regulators (3EA).
73073CV007
(8) Loosen two socket head screws and

locate housing provisionally, using
adjusting screws (housing is under spring
preload).
Now, loosen remaining socket head
screws.
Adjusting screws 5870 204 036
73073CV008
3-67
(9) Separate housing from valve housing by
loosening the adjusting screws uniformly.
73073CV009
(10) Remove components.
73073CV010
(11) Remove opposite pressure regulators,

housing as well as components accord-
ingly.
73073CV011
3-68
2) ASSEMBLY
※ Check all components for damage and
renew if necessary.
Prior to the installation, check free travel of
all moving parts in the housing.
Spools can be exchanged individually.
Oil the components prior to the assembly.
Insert diaphragms with the concave side
showing upward until contact is obtained.
※ Installation position, see arrows.
73073CV015
(1) Illustration on the right shows the following

components.
1 Vibration damper
2 Follow-on slide
3 Pressure reducing valve
73073CV016
(2) Install components according to figure (1).

※ Preload compression spring of the follow-
on slides and locate spool provisionally by
means of cylindrical pins Ø5.0 mm
(assembly aid), see arrows.
73073CV017
(3) Install two adjusting screws.

Assemble gasket (arrow 1) and housing
cover. Now, position the housing cover
uniformly, using adjusting screws, until
contact is obtained and remove cylindrical
pins (assembly aid) again (see the next
figure).
※ Pay attention to the different housing covers.
Install recess Ø15 mm (arrow 2), facing
the spring of the pressure reducing valve. 73073CV018
3-69
73073CV019
(4) Fasten housing cover by means of socket

head screws.
·Torque limit : 0.56 kgf·m (4.06 lbf·ft)
73073CV020
(5) Introduce pressure regulators and fix by

means of fixing plates and socket head
screws.
※ Install fixing plate, with the claw showing
downward.
Pay attention to the radial installation
position of the pressure regulators, see
figure.
Box spanner 5873 042 002 73073CV021
Pre assemble opposite side

(6) Illustration on the right shows the following
components.
1 Main pressure valve
2 Follow on slide
3 Vibration damper
73073CV022
3-70
(7) Install components according to figure (6).
Preload compression springs of the
follow-on slides and locate spool
provisionally by means of cylindrical pins
Ø5.0 mm (assembly aid), see arrows.
Install two adjusting screws.
Assemble gasket (arrow 1) and housing
cover, and position them uniformly against
shoulder, using adjusting screws.
※ Pay attention to the different housing 73073CV023
covers-install the recess Ø19 mm (arrow
2), facing the main pressure valve.
Now, fasten housing cover by means of
socket head screws.
Remove cylindrical pins (assembly aid)
again.
(8) Introduce pressure regulators and fix by

means of fixing plates and socket head
screws.
※ Install fixing plates, with the claw showing
downward.
Pay attention to the radial installation
position of the pressure regulators, see
figure.
Box spanner 5873 042 002 73073CV024
(9) Introduce cable harness and connect

pressure regulators (6EA).
※ Pay attention to the installation position of
the cable harness, ass also markings
(See figure (2), page 3-66).
73073CV025
3-71
(10) Introduce female connector against
shoulder, with the groove facing the guide
nose of the cover.
Install gasket (arrow) and fasten cover by
means of socket head screws.
73073CV026
(11) Fix female connector by means of

retaining clamp, see figure.
Install opposite cover.
73073CV027
(12) Install two adjusting screws and mount

gasket Ⅰ.
※ Pay attention to the different gaskets, see
on the right figure and (15).
73073CV028
Intermediate plate-Version with screens

(13) Insert screws (6EA) flush mounted into
the bore of the intermediate plate, see
arrow.
※ Pay attention to the installation position-
screws are showing upward (facing the
duct plate).
73073CV029
3-72
(14) Mount intermediate plate, with the
screens showing upward.
73073CV030
(15) Mount gasket Ⅱ.
73073CV031
(16) Mount duct plate and fasten it uniformly by

73073CV032
(17) Equip screw plug (8EA) with new O-rings

and install them.
※ The installation of the hydraulic control
unit is described, starting from page
3-123.
73073CV033
3-73
2. POWERSHIFT TRANSMISSION
Fasten transmission of the assembly car.
Assembly car 5870 350 000
Strips 5870 350 063
Support 5870 350 090
75773TM050
1) DISASSEMBLY
(1) Separate hydraulic control unit and duct
plate from gearbox housing
① Loosen two socket head screws and
install adjusting screws.
Now, loosen remaining socket head
screws and separate valve housing from
duct plate.
Adjusting screws (M6) 5870 204 063
Box spanner 5873 042 002 75773TM051
② Remove both gaskets and intermediate

plate.
Loosen socket head screws as well as
hexagon nuts and separate duct plate
from gearbox housing.
Now, remove gasket.
75773TM052
③ Pull converter safety valve out of the

housing bore.
75773TM053
3-74
(2) Converter
① Loosen hexagon head screws and
separate diaphragm from the converter.
75773TM060
② Loosen hexagon head screws and

separate drive shaft from the diaphragm.
75773TM061
③ Remove inductive transmitter (engine).
75773TM062
④ Loosen hexagon head screws and

remove converter bell.
75773TM063
3-75
(3) Hydraulic pump
① Loosen socket head screws.
75773TM064
② Apply separating device on the gear

teeth runout of the stator shaft and pull
pump (Compl.) by means of two leg
puller carefully out of the housing bores.
Separating device 5870 300 024
Two leg puller 5870 970 004
75773TM065
③ Separate hydraulic pump from stator

shaft.
Separate control disk from pump.
※ If traces due to running in should be
encountered in the pump housing or on
the control disk, the complete pump has
to be renewed.
Now, lay on control disk again and fix it
by means of grooved pins (2EA).
75773TM066
④ Loosen socket head screws as well as

two hexagon head screws and remove
oil feed housing.
Now, remove gasket.
75773TM067
3-76
(4) Converter back pressure valve
① Preload compression spring and remove
lock plate.
Remove released components.
75773TM068
② Loosen hexagon head screws.

Remove cover and gasket.
75773TM069
(5) Remove output, input and clutches

① Remove lock plate, loosen hexagon head
screws and pry converter side output
flange off the shaft.
Now, pry shaft seal out of the housing
bore.
Tilt transmission 180˚ and remove rear
side output flange accordingly.
Pry bar 5870 345 065
75773TM075
② Remove speed sensor as well as both

inductive transmitters (arrows).
75773TM076
3-77
③ Loosen hexagon nuts and remove both
covers (arrows).
Loosen screw connection (housing/
housing cover).
75773TM077
④ Drive both cylindrical pins out (arrows).
75773TM078
※ The following figures show the common

removal of all clutches.
The removal of single clutches without
use of the special tool (handles 5870
260 010) is due to the installation
conditions extremely difficult.
Besides there is the danger of injuries.
⑤ Locate all clutches by means of handles
in the housing cover.
Install eye bolts and hang in the lifting 75773TM080
device.
Handle (6 pieces needed) 5870 260 010
Eye bolt (M20, 2EA) 0636 804 003
Eye bolt (M16, 1EA) 0636 804 001
Puller device 5870 000 017
Lifting chain 5870 281 047
3-78
⑥ Separate housing cover along with
clutches from the gearbox housing, using
lifting device.
75773TM081
⑦ Fasten housing cover on the assembly

car.
Assembly car 5870 350 000
Clamping bracket 5870 350 089
75773TM082
⑧ Loosen socket head screws and remove

output shaft as well as the two oil
collecting plate.
75773TM083
⑨ Pull off tapered roller bearing.

Remove opposite tapered roller bearing
accordingly.
Grab sleeve 5873 002 038
Basic set 5873 002 001
75773TM084
3-79
⑩ Tilt housing cover 180。.
Illustration on the right shows the
arrangement of the single clutches and
the input in the housing cover.
AN Input
KV Clutch-Forward
KR Clutch-Reverse
K1 Clutch-1st speed
K2 Clutch-2nd speed
K3 Clutch-3rd speed
75773TM085
K4 Clutch-4th speed
⑪ Remove handles (see figure).

Handles 5870 260 010
75773TM086
⑫ Lift clutch K4 a bit by means of pry bars

and remove clutch K1.
75773TM087
⑬ Remove clutch K2.
75773TM088
3-80
⑭ Remove clutch K3.
75773TM089
⑮ Lift clutch KV and KR by means of pry

bars and remove clutch K4.
Pry bar 5870 345 065
75773TM090
16Lift clutch KV and clutch KR as well as

input together out of the housing cover.
Remove bearing outer races out of the
housing bores.
※ If contrary to the recommendation the
tapered roller bearings of the clutches as
well as of the input and output will not be
renewed, the allocation (bearing inner
races to bearing outer races) must at
least be maintained. 75773TM091
Mark bearing inner race and bearing

outer race accordingly to each other.
17 Tilt housing cover 90。.

Squeeze circlip out and separate pump
shaft from housing cover.
75773TM092
3-81
18 Squeeze rectangular ring out (arrow)
and press ball bearing from the shaft.
75773TM093
(6) Disassemble clutch KV and KR

※ The following figures show the disassem-
bly of clutch KV.
① The disassembly of clutch KR is similar.
Squeeze rectangular ring out (arrow).
75773TM095
② Pull tapered roller bearing from the shaft.

accordingly.
Basic set 5873 001 000
75773TM096
③ Squeeze circlip out.
75773TM097
3-82
④ Separate plate carrier from the shaft.
Three leg puller 5870 971 003
75773TM098
⑤ Squeeze snap ring out and remove plate

pack.
75773TM099
⑥ Preload compression spring, squeeze

snap ring out and remove components.
Assembly aid 5870 345 088
75773TM100
⑦ Lift piston by means of compressed air

out of the cylinder bore and remove it.
75773TM101
3-83
⑧ Remove both O-rings (arrows).
75773TM102
⑨ Lift idler gear a bit by means of pry bare.
75773TM103
⑩ Apply puller and separate idler gear from

the clutch shaft.
Pry bar 5870 345 065
Puller 5870 971 003
75773TM104
⑪ Squeeze circlip out and remove ball

bearing.
※ The disassembly of clutch KR has to be
carried out accordingly.
75773TM105
3-84
(7) Disassemble clutch K1, K2 and K3
※ The following figures show the disassem-
bly of clutch K3.
The disassembly of the clutches K1 and
K2 is similar.
① Squeeze rectangular ring out.

Pull tapered roller bearing from the shaft.
Remove the opposite tapered roller
bearing accordingly.
Grab sleeve(Bearing 33800) 5873 001 059
Grab sleeve(Bearing 39500) 5873 002 038
Basic set 5873 001 000
Basic set 5873 002 001
75773TM110
② Remove running disk, axial needle cage

and axial washer.
75773TM111
③ Remove idler gear.
75773TM112
3-85
④ Remove both needle bearings as well as
the axial bearing (complete).
75773TM113
⑤ Squeeze snap ring out and remove plate

pack.
75773TM114
⑥ Preload cup-spring pack and squeeze

snap ring out.
75773TM115
⑦ Squeeze circlip into the groove of the

plate carrier.
Apply puller on the circlip and pull plate
carrier from the clutch shaft.
Puller 5870 970 004
Circlip 0630 502 053
75773TM116
3-86
(8) Disassemble clutch K4
① Squeeze rectangular ring out (arrow).
75773TM120
② Pull tapered roller bearing from the shaft.

accordingly.
Basic set 5873 001 000
75773TM121
③ Squeeze circlip out and separate plate

carrier from the shaft.
Three leg puller 5870 971 003
75773TM122
④ Squeeze snap ring out and remove plate

pack.
75773TM123
3-87
⑤ Preload cup-spring pack and squeeze
snap ring out.
Remove piston.
75773TM124
⑥ Lift piston by means of compressed air

out of the cylinder bore and remove it.
75773TM125
⑦ Take off the idler gear and remove

release components.
※ The separation of shaft and gear is not
possible (shrink fit).
75773TM126
3-88
(9) Disassemble drive shaft
① Squeeze rectangular ring out.
Pull off tapered roller bearing.
accordingly.
Basic set 5873 002 001
Basic set 5873 002 006
75773TM130
② If necessary, press turbine shaft out of

the drive shaft.
※ The turbine shaft is axially fixed with a
snap ring which will be destroyed at the
pressing out.
75773TM131
3-89
2) REASSEMBLY
(1) Install oil tubes
※ To ensure the correct installation of the oil
tubes, the use of the indicated special tool
is imperative.
① Insert suction pipe (1), pressure pipes (2)

and pressure pipelubrication (3) into the
housing bores.
Fasten suction and pressure pipes by
75773TM140
② Tilt housing 180。.

Roll suction as well as pressure pipes
(arrows) into the housing bores, using
special tool.
The pipe end must be maximally plane
with the housing face.
If necessary, equalize projection of pipe.
Rolling tool 5870 600 003
Rolling tool 5870 600 007 75773TM141
③ Inser t O-rings (2EA/pipe) into the

annular grooves of the two oil tubes and
oil them.
75773TM142
3-90
④ Assemble both oil tubes (arrows) until
contact is obtained.
Equip screw plug with new O-ring and
install it.
·Torque limit : 14.3 kgf·m (103 lbf·ft)
75773TM143
⑤ Insert both oil tubes (arrows) into the

housing cover, tilt housing cover 180。
and roll oil tubes into the housing bores.
※ The tube end must be maximally plane
with the housing face.
If necessary, equalize projection of the
tube.
75773TM144
⑥ Mount studs (M8×25).

Wet screw in thread with loctite (type No.
262).
Equip plugs (arrows) with new O-rings
and install them
·Torque limit(M16×1.5) : 4.1 kgf·m
(29.5 lbf·ft)
(36.9 lbf·ft) 75773TM145

(59.0 lbf·ft)
⑦ Insert sealing cover, with the recess

showing upward.
※ Wet contact face with loctite (type No.
262).
75773TM146
3-91
(2) Reassemble clutch KV and KR
※ The following figure show the reassembly
of the clutch KV. The reassembly of the
clutch KR has to be carried out
accordingly.
Preassemble plate carrier
① Check function of the purge valve.
※ Ball must not stick, if necessary, clean
with compressed air.
75773TM150
② Insert both O-ring (arrows) scrollfree into

the grooves of the piston and oil.
Introduce piston until contact is obtained.
※ Pay attention to the installation position,
see figure.
75773TM151
③ Install disk, compression spring and

guide ring.
75773TM152
④ Preload compression spring and fix it by

means of snap ring.
75773TM153
3-92
Plate pack KV, KR
※ The plate arrangement respectively
stacking of clutch KV and KR is identical.
⑤ The following draft shows the installation
position of the components. 2.7
+0.2
mm
1 Plate carrier 5
3
2 Piston
3 Outer plate-one sided coated (1 piece) 6 2
4 Inner plates (10 pieces)
5 Outer plates-coated on both sides
7
(10 pieces)
1
6 Snap ring (optional s = 2.1~4.2 mm) 4
7 End shim
Effective number of friction surfaces = 20
※ Install outer plate 3 with the uncoated
side facing the piston.
Install on the end-shim side two outer 76043PT07
and inner plates each.
Adjust plate clearence : 2.7+0.2 mm

※ For the adjustment of the plate clearance
are snap rings of different thickness
available.
To ensure a faultless measuring result,
install plates for the moment without oil.
⑥ Introduce plate pack according to the
upper draft.
75773TM155
⑦ Lay on the end shim and squeeze the

snap ring in (e.g. s = 2.55 mm)
75773TM156
3-93
⑧ Press on end shim with about 100N (10
kg), apply dial indicator and set it at zero.
75773TM157
⑨ Now, push the end shim by means of

screw driver against snap ring until
contact is obtained (upward) and read
plate clearance on the dial indicator.
※ In case of a deviation from the required
plate clearance, correct with
corresponding snap ring (s=2.1~4.2 mm).
After the adjustment of the plate
clearance has been carried out, remove
the plate pack, oil plates and install it 75773TM158
again.
※ Use oil SAE 10W-30/15W-40.
Magnetic stand 5870 200 055
Dial indicator 5870 200 057
⑩ Introduce idler gear until all inner plates

are accommodated.
※ This step makes the later assembly of
the idler gear easier.
Now, remove the idler gear again.
75773TM159
3-94
⑪ Mount stud (arrow).
Wet screw-in thread with loctite (type
No.241).
·Torque limit (M10) : 1.7 kgf·m
(12.5 lbf·ft)
75773TM160
⑫ Inser t ball bearing until contact is

obtained and fix by means of circlip.
75773TM161
⑬ Assemble needle bearing.
75773TM162
⑭ Press idler gear against shoulder.

※ Support it on the bearing inner race.
75773TM163
3-95
⑮ Heat inner diameter of plate carrier
(about 120˚C).
Hot air blower 220V 5870 221 500
75773TM164
16 Assemble preassembled plate carrier

until contact is obtained.
75773TM165
17 Locate plate carrier axially by means of

circlip.
75773TM166
18Check function of clutch by means of

compressed air.
※ At correctly installed components, the
closing resp. opening of the clutch is
clear audible.
75773TM167
3-96
Press tapered roller bearing against
shoulder.
Install opposite tapered roller bearing
accordingly.
75773TM168
Squeeze rectangular rings in (arrow) and

let them snap in.
75773TM169
(3) Reassemble clutch K1, K2 and K3

※ T h e fo l l o w i n g f i g u r e s s h o w t h e
reassembly of clutch K3.
The reassembly of the clutches K1 and
K2 has to be carried out accordingly.
① Install stud (arrow).
※ Wet screw in thread with loctite (type No.
241).
(12.5 lbf·ft) 75773TM175
② Heat inner diameter of plate carrier.
75773TM176
3-97
③ Assemble plate carrier until contact is
obtained.
75773TM177
④ Check function of the purge valve

※ Ball must not stick, if necessary clean
Insert both O-rings (arrows) scrollfree
into the grooves of the piston and oil.
75773TM178
⑤ Introduce piston until contact is obtained.

see figure.
75773TM179
⑥ Lay on cup spring pack and guide ring.

※ Pay attention to the stacking of the cup
springs, see the next draft.
75773TM180
3-98
⑦ Preload cup spring pack and fix it by
means of snap ring.
75773TM181
※ The plate arrangement of clutch K1 is

identical with clutch K2 and K3.
In this connection see the following drafts.
Plate pack K1
1 Plate carrier +0.2
2 Piston 2.4 mm
3 Outer plate-one side coated (1 piece)
5
4 Inner plates (9 pieces) 3
5 Outer plates-on both sides coated
2 6
(9 pieces)
6 Snap ring (optional s=2.1~4.2 mm)
7
7 End shim
Effective number of friction surfaces = 18 1 4

side facing the piston. 76043PT08
Plate pack K2 and K3

1 Plate carrier 1.8
+0.2
mm
2 Piston
3 Outer plate-one side coated (1 piece) 5
3
4 Inner plates (7 pieces)
5 Outer plates-on both side coated 2 6
(7 pieces)
6 Snap ring (optional s= 2.1~4.2 mm) 7
7 End shim 1 4

76043PT13
Install on the end-shim two outer and
inner plates each.
3-99
Adjust plate clearance
Plate clearance clutch K1 2.4+0.2 mm
Plate clearance clutch K2 and K3
1.8+0.2 mm
are snap rings with different thickness
available.
install the plates for the moment without
oil. 75773TM185
Introduce plate pack according to drafts /

page 3-99.
⑧ Lay on the end shim and squeeze circlip

in (e.g. s = 3.1 mm).
75773TM186
⑨ Press on the end shim with about 100N

(10 kg), apply dial indicator and set it at
zero.
75773TM187
3-100
⑩ Now, push the end shim by means of
contacts is obtained (upward) and read
plate clearance, correct with correspond-
ing snap ring (s = 2.1~4.2 mm).
clearance has been carried out, remove
the plate pack, oil plates and install it 75773TM188
again.
Use oil SAE 10W-30/15W-40.
⑪ Assemble runing disk 1 (55×78×5),

axial needle cage 2 and axial washer 3
(55×78×1).
Install running disk 1, with the chamber
facing the axial needle cage.
75773TM189
⑫ Assemble both needle bearings.
75773TM190
3-101
⑬ Introduce idler gear until all inner plates
are accommodated.
75773TM191
⑭ Assemble axial washer 3 (55×78×1),

axial needle cage 2 and running disk 1
(55×78×5).
※ Install running disk 1, with the chamfer
facing the axle needle cage.
※ Only if the running disk in overlapping
with the shaft collar is ensured that all
inner plates are accommodated.
75773TM192
⑮ Press tapered roller bearing against

shoulder.
Press opposite tapered roller bearing
against shoulder.
75773TM193
16Check function of the clutch by means of

compressed air.
closing respectively opening of the clutch
is clearly audible.
75773TM194
3-102
17 Squeeze rectangular ring in(Arrow) and
let it snap in.
Install opposite rectangular r ing
accordingly.
75773TM195
(4) Reassemble clutch K4

① Undercool shaft (about -80˚C), heat gear
(about +120˚C) and assemble it until
75773TM200
② Fix gear axially by means of circlip.

Set of external pliers 5870 900 015
75773TM201
③ Install stud (arrow).

※ Wet screw-in thread with loctite (type No.
241).
(12.5 lbf·ft)
75773TM202
3-103
④ Check function of the purge valve.
※ Ball must not stick, if necessary clean
Insert both O-ring (arrow) scrollfree into
the grooves of the piston and oil them.
75773TM203
⑤ Introduce piston until contact is obtained.

see figure.
75773TM204
⑥ Install cup-spring pack and guide ring.

※ Pay attention to the stacking of the cup
springs, see draft, page 3-105.
75773TM205
⑦ Preload cup-spring pack and fix it by

means of snap ring.
75773TM206
3-104
Plate pack K4
※ The following draft shows the installation
position of the components. +0.2
1.2 mm
1 Plate carrier
2 Piston 5
3
3 Outer plate-one side coated (1 piece)
4 Inner plates (5 pieces) 6 2
5 Outer plates-coated on both sides
(5 pieces) 7
6 Snap ring (optional s = 2.1~4.2 mm) 4 1
7 End shim
76043PT14
Adjust plate clearance = 1.2+0.2mm

are snap rings of different thickness
available.
install plates for the moment without oil.
⑧ Introduce plate pack according to the
draft.
75773TM210
⑨ Lay on end shim and squeeze snap ring

in (e.g. s = 3.4 mm).
75773TM211
3-105
⑩ Press on the end shim with about 100N
(10 kg), apply dial indicator and set it at
zero.
75773TM212
⑪ Now, push the end shim by means of

contacts is obtained (upward) and read
plate clearance, correct with
corresponding snap ring (s = 2.1~4.2
mm).
clearance has been carried out, remove 75773TM213
the plate pack, oil plates and install it

again.
※ Use oil SAE 10W-30/15W-40.
⑫ Introduce idler gear until all inner plates

are accommodated.
※ This step makes the later assembling of
the idler gear easier.
Now, remove idler gear again.
75773TM214
3-106
⑬ Assemble both axial washers as well as
needle case.
※ Upper and lower axial washer have the
same thickness (55×78×1).
75773TM215
⑭ Assemble both needle bearings.
75773TM216
⑮ Assemble idler gear.
75773TM217
16Assemble axial washer 3 (55×78×1),

needle cage 2 and running disk 1
(55×78×5).
※ Install running disk 1, with the chamfer
facing the needle cage.
75773TM218
3-107
17Heat inner diameter of the plate carrier
(about 120˚C).
Assemble preassembled plate carrier
until all inner plates are accommodated.
※ Use safety gloves.
75773TM219
18 Fix plate carrier axially by means of

circlip.
75773TM220
19Check function of the clutch by means of

compressed air.
closing respectively opening of the clutch
is clearly audible.
75773TM221
20 Press tapered roller bearing against

shoulder.
Install opposite tapered roller bearing.
75773TM222
3-108
Squeeze rectangular ring in (arrow) and
let it snap in.
Install opposite rectangular ring.
75773TM223
(5) Preassemble drive shaft

① Undercool the drive shaft (about -80˚C),
heat the gear (about +120˚C) and
assemble it until contact is obtained.
75773TM225
② Fix gear axially by means of circlip.
75773TM226
③ Squeeze snap ring into groove of the

turbine shaft.
75773TM227
3-109
④ Introduce turbine shaft until the snap ring
snaps into the groove of the drive shaft
turbine shaft is axially fixed.
75773TM228
⑤ Press tapered roller bearing against

shoulder.
Now, squeeze rectangular ring into the
groove of the drive shaft and let it snap
in.
Install opposite tapered roller bearing.
75773TM229
(6) Preassemble and install output

① Lay on screening plate
75773TM230
② Heat tapered roller bear ing and

assemble it until contact is obtained.
Install opposite tapered roller bearing
accordingly.
75773TM231
3-110
③ Insert all bearing outer races into the
bearing bores of the housing.
Install O-ring (arrows).
※ At the use of already run bearings, pay
attention to the allocation of the bearing
outer races, see also note/page 3-81.
AN Input
KV Clutch-Forward
KR Clutch-Reverse
K1 Clutch-1st speed
K2 Clutch-2nd speed 75773TM232
K3 Clutch-3rd speed
K4 Clutch-4th speed
AB Output
④ Lay on screening plate.
75773TM233
⑤ Insert preassembled output shaft.

Fix screening plates by means of socket
head screws.
·Torque limit (M8/8.8) : 2.3 kgf·m
(17.0 lbf·ft)
75773TM234
3-111
(7) Install preassembled drive shaft and
clutches
① Insert all bearing outer races into the
bearing bores of the housing cover.
※ At the use of already run bearings, pay
attention to the allocation of the bearing
outer races, see also note/page 3-81.
AN Input
KV Clutch-Forward
KR Clutch-Reverse
K1 Clutch-1st speed
K2 Clutch-2nd speed
K3 Clutch-3rd speed
K4 Clutch-4th speed
AB Output 75773TM235
※ Prior to the installation of the clutches

and the drive shaft, grease rectangular
rings and align them centrally.
② Insert clutch KR, drive shaft and clutch
KV together into the housing cover.
75773TM236
③ Lift drive gear and position clutch K4.
75773TM237
3-112
④ Install clutch K3.
75773TM238
⑤ Position clutch K2.
75773TM239
⑥ Lift clutch K4 and position clutch K1.
75773TM240
⑦ Illustration on the right shows the

installation position of the single clutches
in the housing cover.
Grease rectangular rings (arrows) and
align them centrally.
75773TM241
3-113
⑧ Fix all clutches by means of handles.
Handle (6 pieces needed) 5870 260 010
75773TM242
⑨ Tilt housing cover 180。.

Install eye bolts (arrows).
Eye bolt (M20, 2EA) 0636 804 003
Eye bolt (M16, 1EA) 0636 804 001
Puller device 5870 000 017
75773TM243
⑩ Grease O-rings of the two oil tubes.

We t m o u n t i n g fa c e w i t h s e a l i n g
compound loctite (type No.574).
Position preassembled housing cover by
means of lifting device carefully on the
gearbox housing until contact is
obtained.
※ Pay attention to the overlapping of the oil
tubes with the bores in the housing
cover. 75773TM244
⑪ Remove handles again.
75773TM245
3-114
⑫ Install both cylindrical pins centrally to
the housing face.
75773TM246
⑬ Fasten housing cover by means of

hexagon head screws.
·Torque limit (M10/8.8) : 4.7kgf·m
(33.9lbf·ft)
※ Pay attention to position of the fixing
plate, see Arrow.
75773TM247
(8) Install pump shaft (power take off)

① Install ball bearing.
Squeeze rectangular ring in (arrow) and
let it snap in.
75773TM248
② Grease rectangular ring, align it centrally

and introduce pump shaft until contact is
obtained.
75773TM249
3-115
③ Fix pump shaft by means of circlip.
75773TM250
④ Insert O-ring (arrow) into the annular

groove of the oil feed covers.
75773TM251
⑤ Fasten both covers (arrows) by means of

hexagon nuts (Use plain washers).
·Torque limit : 2.3kgf·m(17.0lbf·ft)
75773TM252
(9) Install output flanges

① Install shaft seal with the sealing lip
facing the oil chamber.
※ At the use of the prescribed driver, the
exact installation position is obtained.
Wet rubber coated outer diameter with
spirit.
Grease sealing lip.
Driver 5870 048 213
75773TM255
3-116
② Assemble output flange.
Insert O-ring (arrow) into the gap of drive
flange and shaft.
75773TM256
③ Fasten output flange by means of disk

and hexagon head screws.
(33.9 lbf·ft)
75773TM257
④ Fix hexagon head screws by means of

lock plate.
Driver 5870 057 009
Handle 5870 260 002
Install converter side output flange
accordingly.
75773TM258
(10) Converter back pressure valve

① Illustration on the right shows the
components of the conver ter back
pressure valve.
1 Piston
2 Compression spring
3 Pressure plate
4 Lock plate
※ Install pressure plate with the spigot
(Ø6 mm) facing the lock plate. 75773TM260
3-117
② Introduce components according to
figure (10) ①, preload and fix by means
of lock plate.
Equip plug(Arrow) with new O-ring and
install it.
·Torque limit (M14×1.5) : 2.5 kgf·m
(18.4 lbf·ft)
75773TM261
(11) Oil feed housing-Transmission pump

① Install two adjusting screws (arrows) and
lay on gasket.
75773TM262
② Lay on oil feed housing and fix it

provisionally by means of socket head
screws.
※ Screw socket head screws only in until
contact is obtained do not tighten.
75773TM263
③ Install two adjusting screws and

introduce stator shaft until contact is
obtained.
※ Pay attention to the overlapping of the
bores.
75773TM264
3-118
④ Insert O-ring (arrow) into the annular
groove and oil it.
75773TM265
⑤ Introduce transmission pump (complete)

and put it by means of socket head
screws (for the moment without O-rings)
evenly against shoulder.
Now, remove socket head screws again.
75773TM266
⑥ Equip socket head screws with new

O-ring (arrow).
※ Grease O-rings.
75773TM267
⑦ Fasten transmission pump by means of

socket head screws.
75773TM268
3-119
⑧ Fasten oil feed housing by means of
socket head screws and hexagon head
screws (2 pieces).
·Torque limit
- Socket head screw : 2.3 kgf·m
(16.6 lbf·ft)
- Hexagon head screw : 4.7 kgf·m
(33.9 lbf·ft)
※ Pay attention to the position of the fixing
plate, see Arrow. 75773TM269
Box spanner (Torx, TX-40) 5873 042 004
(12) Engine connection-Converter

① Fasten converter bell by means of
hexagon head screws.
(50.1 lbf·ft)
75773TM270
② Screw drive shaft and diaphragm

together.
(84.8 lbf·ft)
75773TM271
③ Fasten diaphragm by means of hexagon

head screws on the converter.
(84.8 lbf·ft)
※ Insert hexagon head screws with loctite
(type No.262).
75773TM272
3-120
④ Introduce converter until contact is
obtained.
※ Pulse disk of the converter must be
positioned centrally to the bore of the
inductive transmitter, see Arrow.
Only in this way will be ensured that the
converter is perfectly introduced.
75773TM273
75773TM274
⑤ Inser t ball bearing until contact is

obtained and fix it by means of circlip.
75773TM275
⑥ Assemble housing cover.

Install drive flange, lay on disk an pull
cover by means of hexagon head screws
evenly against shoulder.
(25.1 lbf·ft)
※ Pay attention to the radial installation
position of the cover, see figure.
75773TM276
3-121
⑦ Fix hexagon head screws by means of
lock plate.
Driver 5870 057 010
Handle 5870 260 002
75773TM277
⑧ Fasten cover by means of hexagon head

screws and nuts on the converter bell.
·Torque limit (M10/838) : 4.7 kgf·m
(33.9 lbf·ft)
75773TM278
⑨ Mount gasket and fasten cover by

means of hexagon head screws.
(17.0 lbf·ft)
75773TM279
(13) Converter safety valve

① Insert converter safety valve (complete)
into the housing hose.
75773TM280
3-122
(14) Mount duct plate and hydraulic control
unit
① Install components according to the
following draft.
(17.0 lbf·ft)
5
※ Pay attention to the installation position 3 4
of the different gaskets, see draft.
2
1 Gasket 1
2 Duct plate
3 Gasket
4 Intermediate plate
5 Gasket
76043PT21
Box spanne 5873 042 004
② Equip screw plug (arrow) with new

O-ring and install it.
(21.7 lbf·ft)
75773TM282
③ Fasten hydraulic control unit (HSG-94)

by means of socket head screws.
(7.0 lbf·ft)
Box spanner (Torx Tx-27) 5873 042 002
75773TM283
3-123
(15) Install plugs and oil level tube
① Equip both plugs (arrows) with new
O-rings and install them.
(36.9 lbf·ft)
(59.0 lbf·ft)
75773TM284
② Install oil level tube (arrow).

※ Mount new gasket.
(25.1 lbf·ft)
75773TM285
③ Install cover plate (arrow 1).

※ Install new gasket.
(17.0 lbf·ft)
Equip screw plug (arrow 2) with new
O-ring and install it.
(103 lbf·ft)
75773TM286
3-124
(16) Speed sensor and inductive transmitters
① The figures show the installation position
of the single inductive transmitters and
the speed sensor.
34 Speed sensor
n-Output and speedometer
21 Inductive transmitter
n-Turbine
n-Central gear train 75773TM290
n-Engine
② Grease O-rings and install speed sensor

as well as inductive transmitters.
(Socket head screw/Speed sensor)
(Inductive transmitter)
75773TM291
③ Install breather (arrow).

75773TM292
3-125
3. FRONT AXLE
1) DISASSEMBLY
(1) Disassembly output and brake
① Fix axle to assembly truck.
Assembly truck 5870 350 000
Fixtures 5870 350 077
Clamping brackets 5870 350 075
Support 5870 350 125
※ Before clamping the axle fully turn in the 7609AAX001
support. Position axle first onto the two

fixtures, secure with clamping brackets
and then unbolt the support until contact
with the axle is obtained.
② Loosen screw plugs (3EA, see AX002

and AX003) and drain oil from the axle.
7609AAX002
7609AAX003
3-126
③ Remove the breather valve (see arrow).
※ To avoid any damage, the breather valve
must be removed when separating the
output.
7609AAX004
④ Secure the output with the lifting device

and loosen hexagon screws.
Then separate the output assy from the
axle housing.
Load carrying device 5870 281 043
※ Fix the load carrying device with a wheel
nut.
7609AAX005
⑤ Pull stub shaft and sun gear shaft.

※ Pay attention to potentially releasing
shim.
7609AAX006
⑥ Fix output to assembly truck.

Fixture 5870 350 113
7609AAX007
3-127
⑦ Use a lever to remove the cover from the
output shaft.
7609AAX008
⑧ Loosen locking screws and remove the

releasing cover.
7609AAX009
⑨ Press planetary carrier with a two-armed

puller out of the profile of the output
shaft.
7609AAX010
⑩ Lift the planetary carrier out of the brake

housing by means of the lifting device.
Rear axle
(planetary carrier with 3 planetary gears)
Inner extractor 5870 300 019
Eye bolt 5870 204 073
Front axle
7609AAX011
Eye nut 5870 204 076
3-128
⑪ Pull the tapered roller bearing from the
planetary carrier.
Rapid grip 5873 014 016
Basic tool 5873 004 001
7609AAX012
⑫ Disengage retaining ring.
7609AAX013
⑬ Pull off planetary gear.
7609AAX014
⑭ Lift the end plate out of the brake

housing.
7609AAX015
3-129
⑮ Lift the disk package out of the brake
housing.
7609AAX016
16 Loosen hexagon screws, remove

releasing cover and cup spring.
7609AAX017
17 Mount breather valve and press piston

out of the brake housing by means of
compressed air.
7609AAX018
18 If necessary, remove guide ring, back-up

rings and grooved rings out of the
annular grooves of the brake housing
(see arrows).
※ For the installation position of the single
parts please also refer to the following
sketch.
7609AAX019
3-130
1 Brake housing
2 Guide ring
3 Back-up ring
4 Grooved ring
5 Grooved ring
6 Back-up ring
7 Slide ring seal
8 Output shaft
7609AAX020
19 Lift the brake housing from the output

shaft by means of the lifting device.
7609AAX021
20 Use a lever to remove the slide ring seal

from the brake housing.
If necessary, force out both bearing outer
rings.
Resetting device 5870 400 001
7609AAX022
3-131
21 Use a lever to remove the slide ring seal
from the output shaft.
Resetting device 5870 400 001
7609AAX023
22 Pull the tapered roller bearing from the

output shaft.
Rapid grip 5873 014 013
Basic tool 5873 004 001
7609AAX024
3-132
(2) Disassembly axle housing
① Secure axle housing with the lifting
device and loosen the hexagon screws.
Then separate the axle housing from the
axle drive housing.
※ Pay attention to releasing differential.
7609AAX025
② Loosen the threaded connections and

remove the releasing brake tube.
7609AAX026
③ Loosen screw neck.
7609AAX027
④ Pull the bearing outer ring out of the

bearing hole and remove the shim
behind.
Then remove the O-ring (see arrow).
7609AAX028
3-133
(3) Disassembly input
① Use the lifting device to lift the differential
out of the axle drive housing.
Load carrying fixture 5870 281 083
※ Disassembly of the differential is
described as of page 3-137.
7609AAX029
② Pull the bearing outer ring (see arrow)

out of the housing hole and remove the
shim behind.
7609AAX030
③ Press piston (see arrow) out of the axle

housing (see subsequent figure) by
means of compressed air.
※ This operation is only necessary for the
hydraulic lock differential (option).
7609AAX031
7609AAX032
3-134
④ Heat slotted nut by means of hot air
blower.
※ Slotted nut is secured with loctite (type
No. : 262).
7609AAX033
⑤ Loosen slotted nut and remove the shim

behind.
Slotted nut wrench 5870 401 139
Clamping device 5870 240 002
7609AAX034
⑥ Pull the input flange from the input pinion

and use a lever to remove the shaft seal
behind from the axle drive housing.
7609AAX035
⑦ Press input pinion from the axle drive

housing and remove the releasing
tapered roller bearing.
Extractor 5870 000 065
Hexagon screw (2EA) AA00 331 360
7609AAX036
3-135
⑧ Remove spacer ring and pull the tapered
roller bearing from the input pinion.
Gripping device AA00 684 425
Basic tool 5873 002 000
7609AAX037
⑨ If necessary, force both bearing outer

rings out of the axle drive housing.
7609AAX038
3-136
(4) Disassembly differentials
Disassembly hydraulic lock differential
(option)
① Remove axial roller cage (arrow).
7609AAX039
② Pull both tapered roller bearings from the

differential.
Crown wheel side
Basic tool 5873 002 001
Opposite side
Basic tool 5873 002 001
Reduction 5873 003 011 7609AAX040
Pressure piece 5870 100 075
③ Preload the differential by means of the

press, loosen the hexagon screws and
remove the releasing housing cover.
7609AAX041
④ Preload the housing cover/compression

spring by means of the press and
disengage the retaining ring.
Then remove sliding sleeve and
compression spring from the housing
cover.
7609AAX042
3-137
⑤ Remove single parts.
2 3
1
1 Pressure piece 4
2 Cage
5
3 Lever (12EA)
4 Disk carrier
5 Disk package
7609AAX043
⑥ Preload differential by means of the

press, loosen locking screws and
housing cover.
7609AAX044
⑦ Remove axle bevel gear with thrust

washers from the differential housing.
7609AAX045
⑧ Force out both slotted pins.
7609AAX046
3-138
⑨ Force out both differential axles (short)
and remove the releasing spider gears
with thrust washers from the differential
housing.
7609AAX047
⑩ Pull the differential axle (long) and

remove the releasing spider gears with
thrust washers from the differential
housing.
7609AAX048
⑪ Remove the axle bevel gear and the

shim behind.
7609AAX049
⑫ Press crown wheel from the differential

carrier.
7609AAX050
3-139
Disassembly conventional differential
(standard)
① Pull both tapered roller bearings from the
differential.
Basic tool 5873 002 001
7609AAX051
② Preload the differential by means of the

press, loosen the hexagon screws and
remove the releasing housing cover.
7609AAX052
③ Preload the differential by means of the

housing cover.
7609AAX053
④ Remove axle bevel gear with thrust

washers from the differential housing.
7609AAX054
3-140
⑤ Force out both slotted pins.
7609AAX055
⑥ Force out both differential axles (short)

and remove the releasing spider gears
with thrust washers from the differential
housing.
7609AAX056
⑦ Pull the differential axle (long) and

remove the releasing spider gears with
thrust washers from the differential
housing.
7609AAX057
⑧ Remove the axle bevel gear and the

shim behind.
7609AAX058
3-141
⑨ Press crown wheel from the differential
carrier.
7609AAX059
Disassembly limited slip differential

(option)
① Pull both tapered roller bearings from the
differential.
Basic tool 5873 002 001
7609AAX060
② Preload the differential by means of the

housing cover.
7609AAX061
③ Lift the axle bevel gear with pressure

ring, disk package and thrust washers
out of the differential housing.
7609AAX062
3-142
④ Remove spider shafts and axle bevel
gears (see figure) out of the differential
housing.
7609AAX063
⑤ Remove the second axle bevel gear.
7609AAX064
⑥ Lift the pressure ring out of the differential

housing and remove the disk package
and thrust washers behind.
7609AAX065
⑦ Press crown wheel from the differential

carrier.
7609AAX066
3-143
(5) Reassembly differentials
Reassembly hydraulic lock differential
(option)
① Mount two locating pins and press the
heated crown wheel onto the differential
housing until contact is obtained.
Locating pins 5870 204 040
7609AAX067
② Insert thrust washer into the differential

housing.
7609AAX068
③ Insert axle bevel gear.
7609AAX069
④ Insert spider gears with thrust washers

into the differential housing and fix them
with the spider shaft (long).
※ Thrust washers must be positioned with
the tabs (see arrow) being located in the
recesses of the differential housing.
7609AAX070
3-144
⑤ Insert spider gears with thrust washers
with the two spider shafts (short).
1 2
the tabs (see arrow 1) being located in
the recesses of the differential housing.
※ Pay attention to radial installation position
of the spider shafts (fixing holes, arrow
7609AAX071
2).
⑥ Fix spider shafts (short) with slotted pins.

※ Flush mount slotted pins.
7609AAX072
⑦ Mount second axle bevel gear.
7609AAX073
⑧ Fix the thrust washers into the housing

cover by means of grease.
7609AAX074
3-145
⑨ Mount two adjusting screws and insert
the housing cover until contact with the
differential housing is obtained.
Preload the differential by means of the
press and bolt with new locking screws.
·Tightening torque (M16/12.9) :

40.8 kgf·m (295 lbf·ft) 7609AAX075
⑩ Install compression spring onto the

sliding sleeve.
7609AAX076
⑪ Insert the premounted sliding sleeve into

the housing cover.
Preload the compression spring by
means of the press and engage the
retaining ring into the annular groove of
the sliding sleeve.
7609AAX077
Setting of disk package

⑫ Premount single parts according to the
adjacent sketch.
1 Housing cover
2 Pressure piece
3 Cage
4 Lever (12EA)
5 Disk carrier
6 Pressure ring
7 Inner disks
8 Outer disks (optional) 7609AAX078
9 Snap ring
※ For the number of disks and the disk
arrangement please refer to the relating
parts manual.
3-146
⑬ Preload disk package with an axial force
of F = 50+30 kN.
Then check the setting dimension "A" =
1.05±0.1 mm from the collar of the
differential cover to the plane face of the
outer disk (see also below sketch).
Load cell 5870 700 004
※ Any deviation from the specified setting 7609AAX079
dimension must be corrected with a

corresponding outer disk.
A = Setting dimension = 1.05±0.1 mm

B = Contact face
⑭ To obtain a correct measuring result :
T h e h o u s i n g c ove r m ay o n l y b e
supported on the contact face (B).
Ensure that the assembly fixture is only
supported on the disk package and not
on the disk carrier (5).
7609AAX080
⑮ Position housing cover onto pressure

piece (see arrow).
Insert two hexagon screws into the
housing cover to radially fix the disk
package.
7609AAX081
16 Position the premounted differential with

the lifting device onto the housing cover
and preliminarily fix with hexagon
screws.
Lifting device AA00 331 446
7609AAX082
3-147
17 Preload the differential by means of the
press and the pressure piece.
Then finally tighten the housing cover
with hexagon screws.
18.9 kgf·m (136 lbf·ft)
7609AAX083
18 Heat both tapered roller bearings and

insert until contact is obtained.
※ Adjust tapered roller bearing after
cooling down.
7609AAX084
19 Fix axial roller cage (see arrow) to the

sliding sleeve by means of grease.
7609AAX085
3-148
Reassembly conventional differential
(standard)
7609AAX086

housing.
7609AAX087
③ Insert axle bevel gear.
7609AAX088
④ Insert spider gears with thrust washers

with the spider shaft (long).
the tabs (see arrow) being located in the
recesses of the differential housing.
7609AAX089
3-149
⑤ Insert spider gears with thrust washers
with the two spider shafts (short).
1 2
the tabs (see arrow 1) being located in
the recesses of the differential housing.
of the spider shafts (fixing holes, arrow
7609AAX090
2).
⑥ Fix spider shafts (short) with slotted pins.

※ Flush mount slotted pins.
7609AAX091
7609AAX092
⑧ Fix the thrust washers into the housing

7609AAX093
3-150
⑨ Mount two adjusting screws and insert

40.8 kgf·m (295 lbf·ft) 7609AAX094
⑩ Attach the housing cover and preload the

differential with the press.
Then fix the housing cover with hexagon
screws.
18.9 kgf·m (136 lbf·ft)
7609AAX095
⑪ Heat both tapered roller bearings and

cooling down.
7609AAX096
3-151
Reassembly limited slip differential
(option)
7609AAX097

housing.
7609AAX098
③ Mount outer and inner disks in

alternating order, starting with an outer
disk.
※ The installation clearance of the internal
parts is corrected by mounting outer
disks with different thicknesses.
The difference in thickness between
the left and the right disk package
7609AAX099
must only be 0.1 mm at maximum.
④ Place the pressure ring.
7609AAX100
3-152
⑤ Insert the axle bevel gear until contact is
obtained and install the inner disks with
the teeth.
7609AAX101
⑥ Preassemble the differential spider and

insert it into the differential housing/into
the pressure ring.
7609AAX102
7609AAX103
⑧ Insert the second pressure ring into the

differential housing.
7609AAX104
3-153
⑨ Mount outer and inner disks in
alternating order, starting with an inner
disk.
The installation clearance of the internal
parts is corrected by mounting outer
disks with different thicknesses.
The difference in thickness between
the left and the right disk package
7609AAX105
must only be 0.1 mm at maximum.
Determine the installation clearance

0.2~0.7 mm
⑩ Measure dimension I, from the mounting
face of the differential housing to the
plane face of the outer disk.
Dimension I e.g. . . . . . . . . . . . . . 44.30 mm
7609AAX106
⑪ Measure dimension II, from the contact

face of the outer disk to the mounting
face on the housing cover.
Dimension II e.g. . . . . . . . . . . . . 43.95 mm
CALCULATION EXAMPLE :
Dimension I . . . . . . . . . . . . . . . . 44.30 mm
Dimension II . . . . . . . . . . . . . . . - 43.95 mm
Difference = disk clearance = 0.35 mm
7609AAX107
※ Any deviation from the required

installation clearance is to be corrected
with corresponding outer disks (s = 2.7, s
= 2.9, s = 3.0, s = 3.1, s = 3.2, s = 3.3 or
s = 3.5 mm), taking care that the
difference in thickness between the left
and the right disk package must only be
0.1 mm at maximum.
3-154
⑫ Fix the thrust washers into the housing
7609AAX108
⑬ Mount two adjusting screws and insert


40.8 kgf·m (295 lbf·ft) 7609AAX109
⑭ Heat both tapered roller bearings and

cooling down.
7609AAX110
3-155
(6) Reassembly input
※ If crown wheel or input pinion are
damaged, both parts must be jointly
replaced.
In case of a new installation of a
complete bevel gear set pay attention to
an identical mating number of input
pinion and crown wheel.
Determination of shim thickness to obtain

a correct contact pattern
※ The following measuring procedures
must be carr ied out with utmost
accuracy.
Inaccurate measurements lead to an
incorrect contact pattern requiring an
additional disassembly and reassembly
of input pinion and differential.
① Read dimension I from the axle drive

housing.
221, 10
Dimension I e.g. . . . . . . . . . . . 221.10 mm
7609AAX111
② Read dimension II (pinion dimension).

Dimension II e.g. . . . . . . . . . . . 181.00 mm
7609AAX112
3-156
③ Determine dimension III (bearing width).
Dimension III e.g. . . . . . . . . . . . . 39.10 mm
CALCULATION EXAMPLE “A„ :
Dimension I . . . . . . . . . . . . . . . 221.10 mm
Dimension II . . . . . . . . . . . . . . - 181.00 mm
Dimension III . . . . . . . . . . . . . - 39.10 mm
Difference = shim s = 1.00 mm
7609AAX113
Reassembly of input pinion

④ Undercool the external bearing outer ring
and insert it into the axle drive housing
Driver tool 5870 058 079
Handle 5870 260 004
7609AAX114
⑤ Insert the determined shim e.g. s =

1.00 mm into the housing hole.
7609AAX115
⑥ Undercool the internal bearing outer ring

and bring it into contact position in the
housing hole by using the assembly
fixture.
Assembly fixture 5870 345 080
7609AAX116
3-157
⑦ Heat the tapered roller bearing and insert
it into the input pinion until contact is
obtained.
7609AAX117
Setting of rolling torque of input pinion

bearing 0.15~0.41 kgf
kgf·m
m (1.11~2.95 lbf
lbf·ftft)
(without shaft seal)
⑧ Insert spacer (e.g. s = 8.18 mm).
※ According to our exper ience the
necessary rolling torque is obtained
when reusing the spacer which has been
removed during disassembly (e.g. s =
7609AAX118
8.18 mm).
A later check of the rolling torque,
however, is absolutely necessary.
⑨ Insert the preassembled input pinion into

the axle drive housing and insert the
heated tapered roller bearing until
7609AAX119
⑩ Press the protection plate onto the input

flange (see arrow) until contact is
obtained.
※ Do not fit the shaft seal until the contact
pattern has been checked.
7609AAX120
3-158
⑪ Insert input flange and fix it by means of
disk and slotted nut.
·Tightening torque :
122 kgf·m (885 lbf·ft)
※ Preliminarily mount slotted nut without
loctite. 7609AAX121
While tightening rotate the input pinion

several times in both directions.
⑫ Check rolling torque (0.15~0.41 kgf·m)

without shaft seal).
※ When installing new bearings try to
achieve the upper value of the rolling
torque.
I n c a s e o f d ev i a t i o n s f r o m t h e
necessary rolling torque correct with a
corresponding spacer (AX118, page
7609AAX122
3-158) as specified below.
Insufficient rolling torque
install thinner spacer ring
Excessive rolling torque
install thicker spacer ring
⑬ Grease O-rings (2EA, see arrows) and

insert them into the annular grooves of
the piston.
※ Operation figure AX123 and AX124 is
only necessar y for hydraulic lock
differential (option).
7609AAX123
⑭ Insert piston (see arrow) into the bearing

7609AAX124
3-159
Determination of shims for setting of
b e a r i n g r o l l i n g t o r q u e ( d i f fe r e n t i a l
housing) and backlash (bevel gear set)
※ Determine the required shims on the
basis of the read value (deviation/test
dimension) and the corresponding
specifications of the table below :
(KRS – SET – RIGHT)
(KRS = bevel gear set) 7609AAX125
⑮ Deviation see crown wheel rear side.

※ The test dimension “101„ is stamped into
the crown wheel rear side. If no + or –
deviation is indicated, this value
corresponds to the actual value “0” in the
table below.
According to this value, the required
shims are allocated in the table below.
7609AAX126
A ny + o r – d ev i a t i o n o f t h e t e s t
dimension caused by production is also 1 Axle housing
marked on the crown wheel rear side 2 Shim (crown wheel side)
(e.g. - 20 or - 10 or 10 or 20). 3 Shim (differential carrier side)
In accordance with this deviation, the 4 Axle housing
required shims are allocated in the table
below.
Shims for differential

Crown wheel marking - 20 - 10 - 10
Deviation - 0.2 - 0.1 0 0.1
Shim
Differential cage side 0.7 0.8 0.9 1.0
Shim thickness
Shim
ZGAQ-04367 ZGAQ-04167 ZGAQ-04168 ZGAQ-04169
Hydraulic lock differential
Shim
ZGAQ-04368 ZGAQ-03896 ZGAQ-03897 ZGAQ-03898
Conventional, L/slip differential
Shim
Crown wheel side 1.3 1.2 1.1 1.0
Shim thickness
Shim ZGAQ-04369 ZGAQ-03900 ZGAQ-03899 ZGAQ-03898
3-160
16 Insert the determined shim (e.g. s =
0.9 mm) into the hole of the axle housing
and adjust the bearing outer ring (see
arrow) until contact is obtained.
7609AAX127
17 Cover some drive and coast flanks of the

crown wheel with marking ink.
Then insert the premounted differential
into the axle drive housing.
7609AAX128
18 Insert the determined shim (e.g. s =

1.1 mm) into the hole of the axle housing
and adjust the bearing outer ring (see
arrow) until contact is obtained.
7609AAX129
19 Mount two locating pins and bring the

axle housing into contact position with
the axle drive housing by means of the
lifting device.
Then preliminarily fix the axle housing
with 4 hexagon screws.
57.1 kgf·m (413 lbf·ft) 7609AAX130
※ Preliminarily mount the axle housing

without O-ring.
3-161
Leakage test of lock
20 Pressurize the lock (p = 1 bar), close
shut-off valve and remove air line.
No noticeable pressure loss is allowed
to occur within 10 sec.
※ This operation is only necessary for
hydraulic lock diferential (option).
7609AAX131
21 By rotating the input flange, roll crown

wheel over the input pinion in both
directions several times.
Then remove the axle housing again and
lift the differential out of the axle drive
housing.
Compare the obtained contact pattern.
In case of any contact patter n 7609AAX132
deviation, a measuring error was
made when determining the shim
(AX115, page 3-157), which must be
corrected by all means.
22 After the contact pattern check insert the

differential again into the axle drive
housing.
7609AAX133
3-162
Reassembly of shaft seal (figure
AX134~136)
23 Loosen the slotted nut and pull the input
flange from the input pinion.
7609AAX134
24 Mount the shaft seal with the seal lip

showing to the oil chamber.
※ The exact installation position of the
shaft seal is obtained when using the
specified driver tool.
※ Wet the outer diameter of the shaft seal
with spirit directly before installation and 7609AAX135
fill the space between seal and dust lip
with grease.
25 Insert input flange and finally tighten by

means of disk and slotted nut.
※ Cover the thread of the slotted nut with
loctite (type no. : 262).
7609AAX136
3-163
(7) Reassembly axle housing
① Grease O-ring (see arrow) and insert it
into the axle housing.
7609AAX137
② Mount two locating pins and bring the

axle housing into contact position with
the axle drive housing by using the lifting
device.
Then fix the axle housing by means of
hexagon screws.
57.1 kgf·m (413 lbf·ft)
7609AAX138
※ After assembling the axle housing
secure the axle with clamping brackets.
③ Mount fitting.
3.67 kgf·m (26.6 lbf·ft)
7609AAX139
④ Grease O-ring and insert it into the

annular groove of the brake tube (see
arrow).
7609AAX140
3-164
⑤ M o u n t b ra ke t u b e w i t h t h r e a d e d
connection and hexagon nut (see arrow).
10.2 kgf·m (73.8 lbf·ft)
7609AAX141
⑥ Provide screw plug with a new O-ring

and fit it.
Flush mount slotted pins.
5.1 kgf·m (36.9 lbf·ft)
7609AAX142
3-165
(8) Reassembly output and brake
① Pull in wheel stud into the output shaft
Wheel stud puller-basic tool
5870 610 001
Insert (M22×1.5) 5870 610 002
Special tool may only be used for repair
solution when exchanging individual 7609AAX143
wheel studs with mounted output shaft.
When using a new output shaft, mount
the wheel studs with the press.
② Heat tapered roller bearing and insert it

into the output shaft until contact is
obtained.
7609AAX144
③ Wet O-ring of slide ring seal and locating

hole with spirit.
Snap new slide ring seal (part 1) into the
output shaft.
Then mount new slide ring seal (part 2)
accordingly into the brake housing.
※ For the installation position of the seal
please also refer to sketch, page 3-168. 7609AAX145
※ The surface of the slide ring seal may not

have any grooves, scratches or other
types of damage.
Take care that the sealing surface is
parallel to the housing face.
The O-rings must be mounted evenly
into the locating hole and must not bulge
out of the hole.
R i s k o f i n j u r y - M e t a l r i n g s h ave
7609AAX146
extremely sharp edges.
Wear protective gloves.
3-166
④ Insert both bearing outer rings (see
arrows) into the brake housing until
7609AAX147
⑤ Insert the premounted brake housing by

means of the lifting device over the
output shaft until contact is obtained.
※ Before clamping the seal rings (slide ring
seal) to installation dimension, clean the
sliding surfaces and apply an oil film.
We recommend to use a leather cloth
soaked with oil.
7609AAX148
⑥ Insert back-up rings and grooved rings

into the annular grooves of the brake
housing (see arrows).
※ Pay attention to the installation position;
please also refer to sketch, page 3-168.
7609AAX149
⑦ Clean the annular groove of the brake

housing with spirit.
Then insert the guide ring into the
annular groove (see also the following
sketch) and fix it with loctite (type No. :
415) at its extremities (see arrows).
※ The full circumference of the guide ring
must be in an exact contact position.
7609AAX150
※ Upon installation the orifice of the guide
ring must show upwards (12 o’clock).
3-167
1 Brake housing
2 Guide ring
3 Back-up ring
4 Grooved ring
5 Grooved ring
6 Back-up ring
7 Slide ring seal
8 Output shaft
7609AAX151
⑧ Flush-mount the slotted pins (6EA) into

the holes of the piston.
7609AAX152
⑨ Insert the piston into the brake housing

and carefully install with the fixing device
Fixing device AA00 680 530
※ Sufficiently oil seal surface of piston/
back-up rings, grooved rings and guide
ring.
7609AAX153
3-168
⑩ Insert disk and cup spring with the
convex side showing upwards into the
piston.
7609AAX154
⑪ Insert cover and fix it by means of

hexagon screws.
3.47 kgf·m (25.1 lbf·ft)
7609AAX155
⑫ Mount outer and inner disks.

※ For the number of disks and the disk
arrangement please refer to the relating
parts manual.
7609AAX156
⑬ Insert end plate.
7609AAX157
3-169
⑭ Press stop bolt into the planetary carrier
1 Stop bolt
2 Planetary carrier
7609AAX158
⑮ Insert the cylindrical roller bearing into

the planetary gear – for this purpose 1
press the cylindrical roller bearing 2
through the packaging sleeve until the 3
snap ring engages into the annular
groove of the planetary gear. 4
※ Use packaging sleeve to facilitate
assembly.
7609AAX159
1 Cylindrical roller bearing
2 Packaging sleeve
3 Snap ring
4 Planetary gear
16 Heat bearing inner rings and insert the

premounted planetary gears with large
radius facing the planetary carrier
(downwards) until contact is obtained.
※ Adjust bearing inner rings after cooling
down.
Then fix planetary gears by means of
retaining rings.
7609AAX160
17 Heat tapered roller bearing and install it

to the planetary carrier until contact is
obtained.
7609AAX161
3-170
18 Wet front face (contact face bearing
inner ring, arrow 1) and profile (teeth,
arrow 2) in the output shaft with anti-
corrosive agent.
7609AAX162
19 Align disk package centrally and radially.

Then insert the planetary carrier by
means of the lifting device into the teeth
of the output shaft.
Rear axle
Eye bolt 5870 204 073
7609AAX163
Front axle
Eye nut 5870 204 076
Setting of gap width output shaft /

planetary carrier
20 Bring planetary carrier with measuring
disk and three old locking screws, which
were removed during disassembly, into
contact position.
20.4 kgf·m (148 lbf·ft)
7609AAX164
Measuring disk AA00 360 730
21 Pivot output 180˚ and measure gap

width from the output shaft to the
planetary carrier (see also subsequent
sketch).
Gap width e.g. . . . . . . . . . . . . . . . 0.21 mm
Then remove the locking screws and the
measuring disk again.
7609AAX165
3-171
1 Planetary carrier
2 Output shaft
X Gap width
7609AAX166
22 Select the cover (optional) on the basis

of the following table.
Determined gap Offset to be used
P/No.
width (Delta) on the cover
0.30~0.24 mm 0.13±0.01 mm ZGAQ-04137
0.239~0.18 mm 0.07±0.01 mm ZGAQ-04370
0.179~0.10 mm 0.0 mm ZGAQ-03909
※ Cover (ZGAQ-04370) has an offset of
0.07 mm on one side and an offset of 7609AAX167
0.13 mm on the other side.

※ Offset 0.13 mm is visually marked with an
annular groove (see arrow).
23 Insert the cover with the offset e.g.

0.07 mm showing to the planetary carrier
and tighten with new locking screws.
※ When using the cover with offset
0.07 mm, the groove (figure AX167) must
be visible when the cover is installed.
※ Tighten locking screws successively with
a tightening torque of 20.4 kgf·m (148
lbf·ft). 7609AAX168
Then retighten the locking screws

successively with a tightening torque of
51 kgf·m (369 lbf·ft).
24 Install O-ring (see arrow 1) to the cover.
Then wet contact face (arrow 2).
※ Use new cover and O-ring. 2
7609AAX169
3-172
25 Insert the cover into the output shaft until
7609AAX170
Set the axial play of the sun gear shaft

0.5~2.0 mm
26 Deter mine dimension I, from the
mounting face of the brake housing to
the front face of the stop bolt.
Dimension I e.g. . . . . . . . . . . . . . 19.75 mm
Gauge blocks 5870 200 066
Straightedge 5870 200 022 7609AAX171
27 Insert stub shaft into the teeth of the axle

bevel gear until contact is obtained.
※ Pay attention to the installation position ;
mount the stub shaft with the long teeth
showing to the differential.
7609AAX172
28 Insert the sun gear shaft until contact is

obtained.
7609AAX173
3-173
29 Measure dimension II, from the front face
of the sun gear shaft to the mounting
surface of the axle housing.
Dimension II e.g. . . . . . . . . . . . . 17.15 mm
Straightedge 5870 200 022
7609AAX174
Dimension I . . . . . . . . . . . . . . . 19.75 mm
Dimension II . . . . . . . . . . . . . . - 17.15 mm
Difference . . . . . . . . . . . . . . . . . 2.60 mm
Required axial play e.g. . . . . - 1.00 mm
Difference = shim e.g. s = 1.60 mm
30 Insert sun gear shaft into the planetary

carrier.
7609AAX175
31 Fix determined shim (s) e.g. s = 1.60 mm

with grease into the sun gear shaft.
7609AAX176
3-174
32 Fix O-ring (see arrow) with grease into
the countersink of the brake housing.
7609AAX177
33 Grease O-ring (see arrow) and install it

to the axle housing.
7609AAX178
34 Mount two adjusting screws and use the

lifting device to bring the output into
contact position with the axle housing.
Then fix the output by means of hexagon
screws.
39.8 kgf·m (288 lbf·ft)
Adjusting screws (M18×15) 7609AAX179
5870 204 029
※ Fix load carrying device with wheel stud.
35 Mount breather (see arrow).
7609AAX180
3-175
Check brake hydraulics for leakages
※ Before starting the test, completely breathe
the brake hydraulics.
Then pressurize the brake temporarily (5EA)
with p = 100 bar max.
High-pressure test :
Build up test pressure p = 100-10 bar max
and close connection to HP pump via shut- 7609AAX181
off valve.
A pressure drop of max 2 % (2 bar) is
permissible during a 5-minute testing time.
Low-pressure test :
Reduce test pressure p = 5 bar and close
shut-off valve.
No pressure drop is allowed during a
5-minute testing time.
Test media :
Engine oil SAE 10W
HP pump 5870 287 007
Clutch 0501 207 939
Reduction (M18×1.5) 5870 950 161
Oil collector bottle 5870 286 072
C h e ck o p e ra b i l i t y o f hy d ra u l i c l o ck
differential (opt)
Build up pressure p = 20 bar max and close
connection to HP pump via shut-off valve.
Lock on :
When rotating the input flange, both outputs
must have the same direction of rotation.
Lock off :
7609AAX182
When rotating the input flange, one side has
no movement or has the opposite direction of
rotation.
Prior to putting the axle into operation, fill it
with oil according to the related lubrication
and maintenance instructions.
3-176
4. REAR AXLE
1) DISASSEMBLY - OUTPUT/BRAKE 4
5
1 Input 2 3 4
2 Output
3 Brake
1 3 2
4 Axle housing
5 Axle drive housing
7577AAXR001
① Mount axle on assembly truck.

※ Special tool
Supporting bracket (2EA) 5870 350 106
7577AAXR002
② Drain oil from axle.

※ Use suitable reservoir - environmental
protection.
7577AAXR003
③ Drain oil from both outputs.

※ Use suitable reservoir - environmental
protection.
7577AAXR004
3-177
(1) Disassembly output assy/brake :
For any replacement of components you
can remove the output assy (with brake)
as one unit.
- In this context refer to work steps on
page 3-178~186.
- Figure 7577AAXR007~009 and
assembly steps on page 3-192~196.
Please consider, however, that multi discs
of the brake must be replaced on both 7577AAXR005
outputs each.
(2) Replacement combi seal ring (output) :

The combi seal ring (output) can also
be replaced on the installed axle - for
this purpose remove output shaft.
※ For the installation of the combi seal ring -
refer to work steps on page 3-185 figure
7577AAXR030~7577AAXR 032.
※ Special tool
Pry bar 5870 345 071 7577AAXR006
(3) Output/brake :
① Disassemble brake tube.
7577AAXR007
② Take up output by means of a lifting

bracket.
Loosen bolted connection (output/axle
housing) and separate output from axle
housing.
※ Pay attention to releasing end plate and
multi-discs.
※ Special tool
Lifting bracket 5870 281 043 7577AAXR008
3-178
③ Remove stub shaft and sun gear shaft.
※ Pay attention to shim (placed in sun gear
shaft) and mark allocation of shim to sun
gear shaft and output side-assembly aid.
※ In certain cases the stub shaft/sun gear
shaft could get stuck in the axle housing
(gearing of axle bevel gear/differential).
7577AAXR009
④ Mount output assy on assembly truck. 1 2 3

Remove end plate (1), brake breather
valve (2) and screw neck (3).
※ Special tool
Fixture 5870 350 112
7577AAXR010
⑤ Remove lid (with O-ring).

※ Special tool
Pry bar 5870 345 071
7577AAXR011
⑥ Loosen locking screws and remove lid.

Pay attention to releasing planetary
carrier-risk of accident.
7577AAXR012
3-179
⑦ Lift compl. planetary carrier out of brake
housing.
※ Special tool
Eye nut 5870 204 073
7577AAXR013
⑧ Snap out retaining ring.

※ Special tool
7577AAXR014
⑨ Pull off planetary gear.

Disassemble the remaining planetary
gears in the same way.
※ Special tool
Three-armed puller 5870 971 002
7577AAXR015
3-180
⑩ Pull bearing inner ring off the planetary
carrier.
※ Special tool
Basic tool 5870 003 001
7577AAXR016
⑪ Take disc package out of brake housing.
7577AAXR017
⑫ Loosen threaded joint.
7577AAXR018
⑬ Remove lid, cup spring and disk.
7577AAXR019
3-181
⑭ Lift piston off with lever.
※ Special tool
Adjusting device 5870 400
001
7577AAXR020
⑮ Remove sealing elements (arrows - also

refer to below sketch) from annular
grooves of brake housing.
7577AAXR021
To the sketch :
1 Brake housing
2 Guide ring 1
3 Support ring 2
4 Grooved ring 3
5 Grooved ring 4
5
6 Support ring
6
7577AAXR022
3-182
16 Lift brake housing off the output shaft by
means of lifting device.
※ Special tool
Eyebolts 5870 204 071
7577AAXR023
17 Remove screw neck (1) and breather 1 2

valve (2).
7577AAXR024
18 Lift off shaft seal by lever and remove

both bearing outer rings from brake
housing - if required.
※ Special tool
Pry bar 5870 345 071
7577AAXR025
3-183
19 Pull bearing inner ring from output shaft.
※ Special tool
Rapid grip 5873 014 016
Basic tool 5873 004 001
7577AAXR026
20 If required - disassemble wear sleeve

(arrow) of combi seal ring.
7577AAXR027
3-184
2) REASSEMBLY - OUTPUT/BRAKE 3
1
1 Planetary carrier
2 Brake housing
3 Disc package 4 2
4 Piston 4
5 Combi seal ring
6 Output shaft
※ Special tool 6
5
7577AAXR028
Fixture 5870 350 112
Close apertures of oil supply holes with

plugs.
※ Special tool
Hand tool 5870 320 014
Ratchet wrench 5870 320 018
(1) Installation combi seal ring

(figure 757AAXR030~032) :
① Mount shaft seal (part I/combi seal ring)
7577AAXR029
considering installation dimension X-see
detailed sketch figure 7577AAXR031.
※ Wet contact faces of shaft seal /brake
housing with spirit right before assembly
- assembly aid.
※ Grease shaft seal around the dust and
sealing lips.
※ Observe plane installation position of
shaft seal. use the specified driver to
ensure an exact shaft seal installation
position.
7577AAXR030
※ Special tool
1 Brake housing
2 Output shaft
3 Shaft seal (part I) 1
combi seal ring
4 Wear sleeve (part II)
3
X = installation dimension/shaft seal Detail Z :
4.1 + 0.2 mm 3
Y = installation dimen./wear sleeve
2.6 + 0.2 mm
4
2
4
7577AAXR031
3-185
② Apply sealing agent (Loctite no. 574) on
contact faces of wear sleeve/output shaft
and mount wear sleeve (part I/combi
seal ring) considering installation
dimension Y - see detailed sketch figure
7577AAXR031.
※ Special tool
Pressing device 5870 506 172
7577AAXR032
(2) Output shaft/brake housing

① Mount heated bearing inner ring until
contact.
※ Adjust bearing inner ring after cooling
down.
7577AAXR033
② Press outside bearing outer ring into

brake housing until contact
※ Special tool
7577AAXR034
③ Press inside bearing outer ring into brake

housing until contact.
※ Special tool
7577AAXR035
3-186
④ Position preassembled brake housing on
the output shaft.
※ Special tool
Eyebolts 5870 204 071
7577AAXR036
⑤ Insert sealing elements (arrows) into

annular grooves of brake housing paying
attention to installation position and
arrangement - in this context refer to 2 3
figure 7577AAXR028. 4
Guide ring installation : 5
6
Clean annular groove of brake housing
with spirit.
Then insert guide ring into annular
groove - Ensure an exact contact 7577AAXR037
position of the whole guide r ing

circumference - after wards stick guide
ring with glue (Loctite no. 415) on its
endpoints.
※ Ensure a correct installation position of
the guide ring - Endpoints of guide ring
to be in 12 o'clock position in the axle
installed in the machine (radial position in
brake housing - area of brake oil supply
and vent hole).
1 Brake housing
1
2 Guide ring
3 Support ring
4 Grooved ring 2
5 Grooved ring 3
6 Support ring 4
5
6
7577AAXR038
3-187
⑥ Flush - mount slotted pins (for installation
position refer to arrow) into the piston if
not disassembled, adjust adequately
(flush-fitting).
7577AAXR039
⑦ Oil sealing/sliding surface of piston and

sealing elements (W - 10 oil).
Carefully bring piston in contact position.
7577AAXR040
⑧ Inser t disc, cup spring and lid

considering the installation position - see
detail-sketch.
1 Disc Detail sketch :
2 Cup spring
6 3 4
3 Lid
4 Hex screw
5 Brake housing
6 Piston 1 2
7 Slotted pin 7 5 7577AAXR041
⑨ Fix lid with hex screws evenly until

contact is obtained (cup spring pre-load).
Finally tighten hex screws.
· Tightening torque (M8/10.9) :
3.47 kgf·m (25.1 lbf·ft)
7577AAXR042
3-188
⑩ Mount heated bearing inner ring until
contact.
※ Adjust bearing inner ring after cooling
down.
7577AAXR043
⑪ Apply anti-corrosive agent on spline

2
(arrow-1).
Only for assembly of a new planetary
carrier or if disassembled :
Insert shim (arrow-2) into planetary
carrier until contact.
1
7577AAXR044
⑫ Insert pre-assembled planetary carrier.
※ Special tool
Lifting device 5870 281 082
7577AAXR045
⑬ Fix planetary carrier with disc and new

locking screws.
※ Do not reuse locking screws - just one -
time installation is permitted.
7577AAXR046
3-189
⑭ Evenly tighten locking screws crosswise
- while rotating the brake housing in both
directions several times (roller setting).
7577AAXR047
⑮ Apply a screw safety marking paint on

correctly installed locking screws.
7577AAXR048
16 Mount O-ring (arrow) on lid.
7577AAXR049
17 Insert pre-assembled lid into output

shaft.
※ Special tool
Plastic hammer 5870 280 004
7577AAXR050
3-190
(3) Brake
4
1 Outer disc s = 2.0 mm
2 Outer disc s = 4.0 mm
1
3 Inner disc (lined disc)
4 End plate
※ Possible other versions could have a 3
2
deviating equipment (number and
arrangement of single discs), the
illustration in the relating spare parts list
fo r m s t h e b a s i s fo r t h e r e q u i r e d 1
equipment. 7577AAXR051
① Insert disc package, considering disc

arrangement and installation position of
outer discs-see sketch 7577AAXR051.
7577AAXR052
② Insert end plate (Item 4) fix by means of

grease-assembly aid.
※ Ensure radial installation position -
driving tabs of end plate must be
positioned in recessed grooves of the
brake housing.
※ Special tool
Locating screw 5870 204 078
7577AAXR053
※ Make leakage test on brake hydraulics

- see page 3-196.
3-191
Only for assembly of new parts :
Install cylindrical roller bearing into 3
planetary gear by pressing roller bearing
into planetar y gear by means of
assembly sleeve (arrow) until snap ring 2
engages into annular groove of planetary
gear. 1
1 Planetary gear
2 Roller bearing (with bearing inner ring
7577AAXR054
/cylindical rollers/axial discs and snap
ring)
3 Assembly sleeve
③ Heat up planetary gears and mount to

the pin of the planetary carrier until
contact is obtained, with the large radius/
bearing inner ring showing downwards
(arrow).
※ Adjust bearing after cooling down.
7577AAXR055
④ Fix planetary gears with retaining ring.
※ Check contact position of retaining ring

on groove base and readjust, if required.
※ Special tool
7577AAXR056
(4) Axial play setting of sun gear shaft :

4
1 Planetary carrier 3
2 Stop pin
3 Brake housing
4 Axle housing
5 Sun gear shaft
6 Shim (s = optional)
7 Stub shaft
X = axial play-sun gear shaft 0.5~2.0 mm 1 2 5 6 7
7577AAXR058
3-192
① Determine dimension I from mounting
face (brake housing/axle housing) to stop
pin.
Dimension I e. g . . . . . . . . . . . 21.25 mm
※ Special tool
Digital-depth gauge 5870 200 072
Straightedge 5870 200 022
7577AAXR059
② Mount stub shaft with fitted sun gear

shaft (without shim) into differential/axle
bevel gear until contact.
7577AAXR060
③ Determine dimension II from mounting

face (brake housing/axle housing) to
front face/sun gear shaft.
Dimension II e. g. . . . . . . . . . . 19.00 mm
Dimension I . . . . . . . . . . . . . . 21.25 mm
Dimension II . . . . . . . . . . . . . - 19.00 mm
Difference . . . . . . . . . . . . . . . . 2.25 mm
Required axial play e.g. (average) . . . . . . 7577AAXR061
- 1.25mm
Result = shim required e.g . . . . ........
s = 1.00mm
④ Pull stub shaft with sun gear shaft out of

axle housing. 1
Insert determined shim (s) (2) into sun 2

gear shaft (1) and mount stub shaft (3).
3
7577AAXR062
3-193
(5) Reassemble output assy
① Fix disc package by means of locating
screw - assembly aid.
※ Special tool
Locating screw 5870 204 078
7577AAXR063
② Oil O-ring and mount on collar of axle

housing.
7577AAXR064
③ Take up output by means of lifting bracket.

Mount pre-assembled sun gear/stub shaft
into teeth of planetary gears.
※ Special tool
Lifting bracket 5870 281 043
7577AAXR065
④ Bring output assy into contact position

with axle housing - by mounting the stub
shaft into the gearing of the axle bevel
gear/differential.
※ Pay attention to end plate - see figure
7577AAXR053, page 3-191.
7577AAXR066
3-194
⑤ Connect output with axle housing evenly
by means of hex screws.
·Tightening torque (M18x1.5/10.9) :
39.8 kgf·m (288 lbf·ft)
7577AAXR067
⑥ Install screw plug (1) with new O-ring. 2

·Tightening torque (M24×1.5) : 3
1
5.1 kgf·m (36.9 lbf·ft)
Mount breather valve (2).
0.61 kgf·m (4.4 lbf·ft)
Install screw neck (3) with new O-ring.
3.7 kgf·m (26.6 lbf·ft)
7577AAXR068
⑦ Install brake tube (1). 2
·Tightening torque : 1
Screw nut (2) : 10.2 kgf·m (73.8 lbf·ft)
Cylindrical screw (3) (M8/8.8) :
2. 3 kgf·m (17.0 lbf·ft)
7577AAXR069
3-195
(6) Make leakage test on brake hydraulics
Prior to starting the test, completely
breathe brake hydraulics.
High-pressure test :
Build up testing pressure p = 100-10 bar
max and close connection to HP pump by
means of a shutoff valve. A pressure drop
by max 3% (3 bar) is permissible during a
5 minute test duration.
7577AAXR070
Low-pressure test :
Reduce testing pressure to p = 5 bar and
close shut-off valve again.
No pressure drop is permitted during a 5
minute test duration!
※ Special tool
HP-pump 5870 287 007
Straight screw-in connection
0637 842 518
Measuring fitting (M18x1.5) 5870 950 139
Oil collector bottle 5870 286 072
3-196
3) DISASSEMBLY - DIFFERENTIAL/INPUT
(1) Differential
① Mount axle on assembly truck.
※ Special tool
Supporting bracket (2EA) 5870 350 106
7577AAXR002
※ The following illustration shows the removal

of the differential in the course of a
complete disassembly of the axle.
To remove the differential, however, it is
possible to separate the axle half assy
(axle housing with output) from the axle
drive housing.
Secure axle by means of a support
(arrow) - risk of accident.
② Take up axle housing half on crown
wheel side with lifting chain (see figure
757AAXR072) and loosen bolted
connection (axle housing/axle drive
housing). 7577AAXR071
※ Special tool
Eyebolts 5870 204 071
③ Separate axle housing from axle drive

housing.
※ Pay attention to releasing axial roller ring
and differential.
※ Pay attention to releasing stub shaft and
sun gear shaft with inserted shim (sun
gear shaft - clearance).
Mark allocation of shim versus sun gear
shaft/stub shaft and output side -
7577AAXR072
assembly aid.
3-197
(2) Input :
For axle version with pivot bearing only
(figure 7577AAXR073) :
① Loosen bolted connection and pull off
bearing flange.
7577AAXR073
② Heat up hex nut (Loctite locking

compound) by means of hot air blower.
disassembly aid.
※ Special tool
Hot air blower 230 V 5870 221500
Hot air blower 115 V 5870 221501
7577AAXR074
③ Fix input flange by means of a clamping

fork, loosen hex nut.
Secure axle by means of a support -
risk of accident.
※ Special tool
Clamping fork 5870 240 025
7577AAXR075
④ Remove disc and pull-off flange.

Remove screen sheet from output
flange, if required.
7577AAXR076
3-198
⑤ Lift shaft seal off.
※ Special tool
Pry bar 5870 345 071
7577AAXR077
⑥ Press input pinion out by means of press-

off tool and remove releasing bearing
inner ring.
※ Special tool
Press-off tool 5870 280 044
7577AAXR078
⑦ Remove spacer ring from pinion.
7577AAXR079
⑧ Pull bearing inner ring off the pinion.

※ Special tool
Basic tool 5873 002 001
7577AAXR080
3-199
⑨ Pull-off outside bearing outer ring.
※ Special tool
Internal extractor 5870 300 019
Counter support 5870 300 020
7577AAXR081
⑩ Force bearing outer ring out of inner

bearing hole - pay attention to shim
behind (contact pattern/bevel gear set).
※ Mark shim (thickness/position and
bearing allocation) - assembly aid.
7577AAXR082
3-200
4) REASSEMBLY
EASSEMBLY - INPUT / DIFFERENTIAL
14 2 13
(1) Input
1 Axle drive housing 1 3
2 Input pinion
3 Tapered roller bearing
4
4 Shim for contact pattern (bevel gear set)
5
5 Spacer ring (bearing roll.torque/pinion
bearing) 12 6
6 Tapered roller bearing 10 8 7
7 Shaft seal 11 9
8 Protection plate
9 Input flange
7577AAXR083
10 Disc
11 Hex nut
12 Bearing flange (only for axle version with pivot bearing)
13 Axle housing/part I
14 Axle housing/part II (crown-wheel side)
※Depending on the version - crown wheel and bevel pinion may be mounted as a bevel gear set
(for production reasons, crown wheel and pinion are paired and show an identical pairing number
- see figure 7577AAXR086) or as single parts - the respective version has to be taken from the
specification of the corresponding spare parts list.
If a bevel gear set is specified, the crown wheel must only be replaced together with the pinion.
Only for assembly of new parts or if

disassembled :
① Mount O-ring on axle housing/part I and
install axle drive housing - pay attention
to radial installation position!
·Tightening torque (M 18×1.5/10.9) :
39.8 kgf·m (288 lbf·ft)
7577AAXR084
3-201
Determine shim for pinion position
required to obtain an optimum contact
pattern on the bevel gear set (crown
wheel/pinion) :
② We recommend to reinstall the shim
found during disassembly (e.g. S = 1.20
mm see disassembly instructions, page
3-200, figure 7577AAXR082.) into the
inner bearing hole/pinion bearing.
7577AAXR085
※ The contact pattern required on the bevel gear set, however, is decisive. If this is not achieved -
see contact pattern check on page 3-209, correct the pinion position with a corresponding shim.
※ As an alternative, a basic setting of the required pinion position can be made, e.g. when
assembling a new part - as shown below (figure 7577AAXR086 ~ 088).
Basic setting of pinion position :

③ Read dimension I = production
dimension/axle drive housing (from axle
center to bearing contact/inner bearing
hole) from the axle drive housing
(position see arrow).
Dimension I e.g . . . . . . . . . . . 182.81 mm
7577AAXR086
④ Read pinion dimension X (pinion basic

dimension e.g. = 148) from pinion, or
determine it in case of a + or -deviation
from pinion dimension due to production
(value concerned is marked by hand on 7 +0.1
the pinion, e.g.+ 0.1).
148
Pinion dimension X (without + or
-deviation value) = 148.0 mm
Pinion dimen. X with indication of + 0.1
deviation = 148.1 mm 7577AAXR087
Pinion dimen. X with indication of - 0.1

deviation = 147.9 mm
Dimension II (pinion dim. X) e.g . . . .
148.00 mm
※ Pairing number e.g. 7 - only for version
with bevel gear set - see note figure
7577AAXR083.
3-202
⑤ Determine dimension III bearing width,
ensure here that the rollers are located
without any play (rotate bearing inner
ring in both directions several times -
roller setting).
Since the installed roller bearing is
subject to a pre-load in installation
position, deduct an experience value of
-0.05 mm.
Dimension III = e.g. . . . . . . . . . . . . . .
33.67 mm - 0.05 mm = 33.62 mm
CALCULATION EXAMPLE e.g. :
Dimension I . . . . . . . . . . . . . 182.81 mm
Dimension II + III (148.00 + 33.62) . . . . . 7577AAXR088
- 181.62 mm
Result . . . . . . . . . . . . . . . . . . = 1.19 mm
Required shim S = 1.20 mm
⑥ Insert determined shim into the hole of
the axle drive housing - see figure
7577AAXR085.
※ Special tool
Digital-depth gauge 5870 200 072
⑦ Undercool bearing outer ring (see arrow)
and bring it into contact position in the
inner bearing hole/pinion bearing by
means of the fixture.
※ Special tool
Assembly fixture 5870 345
049
7577AAXR089
⑧ Install outside bearing outer ring/pinion

bearing
※ Special tool
Assembly fixture 5870 345 049
7577AAXR090
3-203
⑨ Mount heated bearing inner ring until
contact position and adjust after cooling-
down.
7577AAXR091
Set rolling torque of input pinion

bearing 0.11~0.23 kgf·m
kgf m (without shaft
seal) :
⑩ Mount spacer ring (s = optional).
※ We recommend to reinstall the spacer
ring found during disassembly (e.g. s =
8.7 mm).
If the originally installed shim was
replaced (contact pattern/bevel gear set)
7577AAXR079
- see page 3-202, figure 7577AAXR085,
also install a spacer ring adjusted by the
same correction value.
※ The required bearing rolling torque of
0.11~0.23kgf·m (without shaft seal),
however, is decisive, in case it is not
achieved - see bearing rolling torque
check (figure 7577AAXR094), correct
the bear ing rolling torque with a
corresponding shim.
⑪ Insert pre-assembled input pinion, mount

heated bearing inner ring until contact is
obtained.
7577AAXR092
3-204
⑫ Mount flange, fix with disc and hex nut.
※ While tightening - rotate pinion in both
directions several times (roller setting).
·Tightening torque (M36×1.5) :
71.4 kgf·m (516 lbf·ft)
※ Special tool
7577AAXR093
Check rolling torque of the pinion

bearing.
Bearing rolling torque (without shaft
seal) 0.11~0.23 kgf·m
kgf m
⑬ Try to achieve upper value.
rolling torque correct it with a
corresponding spacer ring (see figure
7577AAXR079/page 3-204). 7577AAXR094
※ Special tool
Torque wrench 5870 203 031
Reducing adapter ¼" to ½"
5870 656 056
Reducing adapter ½" to ¾"
5870 656 057
3-205
Contact pattern check of bevel gear
set
⑭ Cover some tooth flanks of crown wheel
with marking ink (contact pattern check).
7577AAXR095
⑮ Insert pre-assembled differential.

※ Special tool
7577AAXR096
16 Position axle housing/crown wheel side

(without O-ring) on axle drive housing.
pay attention to radiale installation
position!
※ Special tool
Eyebolts 5870 204 071
7577AAXR097
17 Bring axle housing to contact position by

means of hex. screw and temporarily fix
it.
Rotate differential several times in both
directions - roller setting (also see figure
7577AAXR099).
·Tightening torque (M 18/10.9) :
39.8 kgf·m (288 lbf·ft)
7577AAXR098
3-206
18 Roll input pinion over crown wheel in
both directions (coast - drive flank
meshing - contact pattern).
※ Special tool
7577AAXR099
19 Disassemble differential.
Compare contact pattern to examples –
page 3-209.
※ If contact pattern differs considerably,
use a suitable shim for correction (see
figure 7577AAXR085, page 3-202).
7577AAXR100
20 If disassembled :
Insert shim(s) (2) into sun gear shaft (1)
and mount stub shaft (3).
※ If position was not allocated, as specified 1
in disassembly instructions on page 2

3-201, figure 7577AAXR072 and sun
gear shaft clearance (see page 3-192, 3
figure 7577AAXR58~62) must be set on
both output sides.
7577AAXR101
21 Insert preassembled stub shafts into

both outputs (considering allocation to
the correct output side).
7577AAXR102
3-207
22 Remount differential - by mounting stub
shaft into gearing of axle bevel gear
(differential).
※ Special tool
7577AAXR103
23 Position axial roller ring on differential

and fix by means of grease (assembly
aid).
7577AAXR104
24 Oil O-ring (arrow) and mount it.

Position complete axle half on the axle
drive housing-by mounting the stub shaft
into the gearing of the axle bevel gear
(differential).
of output towards axle drive housing!
※ Special tool
7577AAXR105
Eyebolts 5870 204 071
25 Fix axle housing finally by means of hex

screws.
Rotate differential several times in both
directions - roller setting.
·Tightening torque (M 18/10.9) :
39.8 kgf·m (288 lbf·ft)
7577AAXR098
3-208
※ BACKLASH
ACKLASH CHECK
- Applied the paint (or red lead) on the surface of several bevel gear teeth.
- Turn the pinioin gear and check the contact pattern.
Correct pattern
WTHAX16 WTHAX17
Concave side Convex side
※ ADJUSTMENT
DJUSTMENT
Incorrect pattern : high contact
WTHAX18 WTHAX19
- Reduce the distance (-)
(-)
WTHAX20
3-209
Incorrect pattern, low contact
WTHAX21 WTHAX22
- Add the distance (+)
(+)
WTHAX23
3-210

Group 2 Operational Checks and Troubleshooting -------------------------------------------------------- 4-31
Group 4 Disassembly and Assembly ------------------------------------------------------------------------------ 4-40
1. OUTLINE
※ The brakes are operated by a pressure compensated, closed center hydraulic system.
Flow is supplied by a fixed displacement, gear type brake pump.
BRAKE SYSTEM
The fixed displacement brake pump supplies flow to the cut-off valve for service brake circuit and
park brake circuits. It flows to three accumulator. The accumulator has a gas precharge and an
inlet check valve to maintain a pressurized volume of oil for reserve brake applications.
Oil through the accumulator flows to the brake valves. The brake valve is a closed center design,
dual circuit operated by a pedal.
The front and rear brakes will operate simultaneously with only one brake pedal depressed.
The differential contains annular brake piston and double sided disk.
Brake pump flow also goes to the parking brake solenoid valve in cut-off valve.
The brake system contains the following components:
·Brake pump
·Parking brake solenoid valve in cut-off valve
·Cut-off valve
·Brake valve
·Accumulators
·Pressure switches
4-1
FULL POWER HYDRAULIC BRAKE
SYSTEM
ADVANTAGES - The full power hydraulic Response time
brake system has several advantages over Full power brake actuation VS
Air/Hydraulic brake actuation
traditional brake actuation systems. These
systems are capable of supplying fluid to a 1000
range of very small and large volume
service brakes with actuation that is faster 900
than air brake systems. Figure represents 800
a time comparison between a typical air/ Brake pressure
700 (Full power)
Brake torque(lb·in)
hydraulic and full power hydraulic brake
actuation system. 600
Brake pressure
Full power systems can supply significantly 500 (Air/hydraulic)
higher brake pressures with relatively low Brake torque
400
reactive pedal forces. The reactive pedal (Air/hydraulic)
force felt by the operator will be proportional 300
Brake torque
to the brake line pressure being generated. 200 (Full power)
This is referred to as brake pressure
modulation. 100
Another key design feature of full power
0 1 2 3 4
systems is the ability to control maximum
brake line pressure. In addition, because Time(seconds)
these systems operate with hydraulic oil,
filtration can be utilized to provide long
component life and low maintenance
operation.
Because these systems are closed center,
by using a properly sized accumulator,
emergency power-off braking that is
identical to power-on braking can be
achieved. These systems can be either
dedicated, where the brake system pump
supplies only the demands of the brake
system or non-dedicated, where the pump
supplies the demands of the brake system
as well as some secondary down stream
hydraulic device.
Another important note is that all seals
within these system must be compatible
with the fluid medium being used.
4-2
2. HYDRAULIC CIRCUIT
FRONT 39 REAR
18 PS
BL1 BR1 BL2 BR2

8
T1 P1 T2 P2
40
T/M
17 17
16 7 B1 A1 B2 A2
A3
19
PS T1
PS
PS1
PS
19
T
Parking brake
P
Return line MCV
solenoid
20
Steering system RCV lever
Fan drive moter
2
23
Return line
24 Return line
26 21
25
7579S4BS01
2 Fan & brake pump 18 Pressure sensor 24 Hydraulic tank

7 Cut off valve 19 Pressure sensor 25 Return filter
8 Brake valve 20 Line fiter 26 Bypass valve
16 Accumulator 21 Oil cooler 39 Axle
17 Accumulator 23 Air breather 40 Parking brake at T/M
4-3
1) SERVICE BRAKE RELEASED
FRONT
39 REAR
18 PS
BL1 BR1 BL2 BR2

8
40 T1 P1 T2 P2
T/M
17 17
16 7 B1 A1 B2 A2
A3
19
PS T1
PS
PS1
PS
19
P T Return line MCV
20
Fan drive moter
2 1
23
Return line
24 Return line
26 21
25
7579S4BS02
When the pedal of brake valve (8) is released, the operating force is eliminated by the force of the
spring, and the spool is returned.
When the spool removes up, the drain port is opened and the hydraulic oil in the piston of axles
return to the tank (24).
Therefore, the service brake is kept released.
4-4
2) SERVICE BRAKE OPERATED
FRONT 39 REAR
18 PS
BL1 BR1 BL2 BR2
8
T1 P1 T2 P2
40
T/M
17 17
16 7 B1 A1 B2 A2
A3
19
PS T1
PS
PS1
PS
19
P T Return line MCV
20
Fan drive moter
2 1
23
Return line
24 Return line
26 21
25
7579S4BS03
When the pedal of brake valve (8) is depressed, the operating force overcomes the force of the
spring, and is transmitted to the spool. When the spool moves down, the inlet port is opened, and
at the same time the hydraulic oil controlled the pressure level by the cut-off valve (7) enters the
piston in the front and rear axles. Therefore, the service brake is applied.
4-5
3) PARKING BRAKE RELEASED
FRONT 39 REAR
18 PS
BL1 BR1 BL2 BR2

8
T1 P1 T2 P2
40
T/M
B
17 17 A
P
16 7 B1 A1 B2 A2
Parking brake switch
A3
19
PS
PS
T1
PS1
PS
19
Parking brake
P T Return line MCV
solenoid
20
Fan drive moter
2 1
23
Return line
24 Return line
26 21
25
7579S4BS04
When the parking brake switch is pressed A position, the solenoid valve is energized and the
hydraulic oil controlled the pressure level by the cut-off valve enters the parking brake. It overcomes
the force of the spring and pushes the piston rod. This releases the brake.
Therefore, the hydraulic oil pressure is applied to the parking brake piston through the solenoid
valve and the parking brake is kept released.
4-6
4) PARKING BRAKE OPERATED
FRONT 39 REAR
18 PS
BL1 BR1 BL2 BR2

8
T1 P1 T2 P2
40
T/M
B
17 17 A
P
16 7 B1 A1 B2 A2
Parking brake switch
A3
19
PS T1
PS
PS1
PS
19
Parking brake
P T Return line MCV
solenoid
20
Fan drive moter
2 1
23
Return line
24 Return line
26 21
25
7579S4BS05
When the parking brake switch is pressed B position, the solenoid valve is deenergized and the
valve open the drain port.
At the same time, the hydraulic oil in the parking brake return to the tank through the solenoid
valve. When the piston rod is returned by the force of the spring, the parking brake is applied.
4-7
3. BRAKE PUMP (+FAN PUMP)
1) STRUCTURE
5
9
12
13
14
11
1
Brake pump
11
14
13
12
18
19 7
20
2 17
10 18
17
18 6
8 15
16
23
22 18
12
13
14
11
3
11
14
13
Fan pump 12
7609S4BS06
1 Shaft gear 9 Spacer 17 Dowel pin

2 Driven gear 10 Rear cover 18 D-ring
3 Joint drive gear 11 Bush block 19 Bolt
4 Driven gear 12 Bushing 20 Washer
5 Connector 13 Seal 22 Name plate
6 Front cover 14 Back up seal 23 Rivet
7 Front housing 15 Retainer seal
8 Rear housing 16 Snap ring
This gear pump have a maximum delivery pressure of 150 kgf/cm2.

The pressure loaded type gear pump is designed so that the clearance between the gear and the
bushing can be automatically adjusted according to the delivery pressure. Therefore, the oil leakage
from the bushing is less than that in the case of the fixed bushing type under a high discharge pressure.
Consequently, no significant reduction of the pump delivery occurs, even when the pump is operated
under pressure.
4-8
2) PRINCIPLE OF OPERATION
(1) Mechanism for delivering oil
The drawing at r ight shows the
operational principle of an external gear
pump in which two gears are rotating in
mesh.
The oil entering through the suction port Suction Discharge
is trapped in the space between two gear
teeth, and is delivered to the discharge
port as the gear rotates.
Except for the oil at the bottom of the gear
teeth, the oil trapped between the gear
teeth, is prevented from returning to the
suction side with the gears in mesh.
Since the gears are constantly delivering
oil, the oil delivered to the discharge port
is forced out of the port.
The amount of discharge increases with
the speed of rotation of the gear.
If there is no resistance in the oil passage
into which the discharged oil flows, the oil
merely flows through the passage,
producing no increase in pressure.
If however, the oil passage is blocked with
something like a hydraulic cylinder, there
will be no other place for the oil to flow, so
the oil pressure will rise. But the
pressure which rises in this way will never
go higher, once the hydraulic cylinder
piston starts moving because of the oil
pressure.
As described earlier, the pump produces
the oil flow, but not the oil pressure. We
can therefore conclude that pressure is a
consequence of load.
In other words, the pressure depends on
a counterpart.
(770-3ATM) 4-9
4-9
(2) Internal oil leakage
Oil leaks from a place under higher
pressure to a place under lower pressure,
provided that a gap or a clearance exists
in between.
In the gear pump, small clearances are
provided between the gear and the case
and between the gear and the side plate
to allow the oil to leak out and to serve as
a lubricant so that the pump will be rge
protected from seizure and binding. ischa
D
The drawing at right shows how the
leaked oil flows in the pump. As such,
there is always oil leakage in the pump
from the discharge side (under higher
pressure) to the suction side. The delivery
n
of the pump is reduced by an amount uctio
S
equal to the pump discharge.
In addition, the delivery of the pump will
also decrease as the amount of oil
leakage increases because of expanded
radial clearance resulting from the wear of
pump par ts, the lower oil viscosity
resulting from increases in the oil
temperature, and the initial use of low
(770-3ATM) 4-10
viscosity oil.
4-10
(3) Forces acting on the gear
The gear, whose outer surface is
subjected to oil pressure, receives forces
jointing towards its center.
Due to the action of the delivery pressure,
the oil pressure in higher on the delivery
side of the pump, and due to suction
pressure, is lower on the suction side. In
the intermediate section, the pressure will
gradually lower as the position moves
from the delivery side to the suction side. Drive gear
This phenomenon is shown in the
drawing at right.
In addition, the gears in mesh will receive Suction Discharge
interacting forces. side side
These forces pushing the gears toward
the suction side are received by the
bearings. Since the gears are pressed Driven gear
toward the suction side by these forces,
the radial clearance becomes smaller on
the suction side in the case. In some
pumps, the clearance may become zero, Pressure distribution
thus allowing the gear teeth and the case
to come into light contact.
For this reason, an excessive increase in
the delivery pressure must be avoided,
since it will produce a large force which
will act on the gears, placing an overload
on the bearings, and resulting in a
shortened service life of the bearing or
(770-3ATM) 4-11
interference of the gear with the case.
4-11
4. BRAKE VALVE
1) STRUCTURE
17-2
18
17-3,17-4
17-1,17
19
23 22
24
21
2
33
20 8,31,32
9
25 29
25
16 14
15 7
5 13
30
12 6
10
26
11
3
1 4
7607B4BS07
1 Lower body 13 Spring guide 21 Torsion spring

2 Upper body 14 Snap ring 22 Snap ring
3 Spool 15 Du bushing 23 Hexagon bolt
4 Plug 16 Pedal plate 24 Hexagon nut
5 Holder 17 Pedal assy 25 Bolt
6 Lower spring 17-1 Pedal 26 Spring washer
7 Upper spring 17-2 Lock plate 29 Plate washer
8 Main spring 1 17-3 Hexagon bolt 30 Snap ring
9 Spring retainer 1 17-4 Plate washer 31 Spring retainer 2
10 O-ring 18 Rubber cover 32 Main spring 2
11 O-ring 19 Bellows 33 Taper plug
12 Oil seal 20 Lock pin 1
4-12
2) OPERATION
BL1 BR1 BL2 BR2
T1 P1 T2 P2
Hydraulic circuit
Port Port name Port size

P1, P2 Pressure port PF 3/8
T1
BL1 T1, T2 Return port PF 3/8
P1
BR1, BR2 Brake cylinder port PF 3/8
BR1
BL1, BL2 Pressure switch port PF 1/4
BL2 T2
P2
BR2
7607B4BS08
· Brake pressure specification : 80 ± 5 bar (1160 ± 70 psi)
4-13
(1) Purpose
The purpose of the brake valve is to sensitively increase and decrease the braking pressure
when the brake pedal is actuated.
(2)
2) Ready position
When the braking system is ready for operation, its accumulator pressure acts directly on ports
(P1, P2) of the brake valve. A connection is established between ports (BR1, BR2) and ports (T1,
T2) so that the wheel brakes ports (BR1, BR2) are pressureless via the returns ports (T1, T2).
(3) Partial braking
(3
When the brake valve is actuated, an amount of hydraulic pressure is output as a ratio of the foot
force applied.
The spring assembly (8) beneath pedal plate (16) is designed in such a way that the braking
pressure changes depending on the angle. In the lower braking pressure range, the machine can
be slowed sensitively.
When the braking process is commenced, the upper spool is mechanically actuated via spring
assembly (8), and the lower spool is actuated hydraulically by spool. As spools (3) move
downward, they will first close returns (T1, T2) via the control edges, thus establishing a
connection between accumulator ports (P1, P2) and ports (BR1, BR2) for the wheel brake
cylinders. The foot force applied now determines the output braking pressure. The control spools
(3) are held in the control position by the force applied (spring assembly above the spools and the
hydraulic pressure below the spool (balance of forces).
After output of the braking pressure, spools (3) are in a partial braking position, causing ports (P1,
P2) and ports (T1, T2) to close and holding the pressure in ports (BR1, BR2).
(4) Full braking position
(4
When pedal is fully actuated, end position of the brakes is reached and a connection established
between accumulator ports (P1, P2) and brake cylinder ports (BR1, BR2). Returns (T1, T2) are
closed at this point.
When the braking process is ended, a connection is once again established between brake
cylinder ports (BR1, BR2) and return ports (T1, T2), closing accumulator ports (P1, P2).
The arrangement of spools in the valve ensures that even if one braking circuit fails the other
remains fully operational. This is achieved by means of the mechanical actuation of both spools
and requires slightly more pedal travel.
(5) Limiting the braking pressure
Pedal restriction bolt (23) on pedal plate (16) is used to limit the braking pressure.
(6) Failure of a circuit
In the event of the lower circuit failing, the upper circuit will remain operational. Spring assembly
(8) will mechanically actuate spool. In the event of the upper circuit failing, the lower circuit will
remain operational since the lower spool (3) is mechanically actuated by spring assembly (8) and
spool (3).
(7) Installation requirements
Return lines (T1, T2) must be connected directly to the tank.
The connecting lines must be installed is such a way as to permit proper bleeding.
4-14
(8) Maintenance of the brake valve
No special maintenance beyond the legal requirements is necessary.
When using high-pressure cleaners on the machine, please make sure that the water jet is not
aimed directly at the brake valve (to prevent damaging the bellows).
For safety reasons the whole of the brake valve must be replaced if parts other than those
listed above are damaged.
(9) Repair work
(9
When working on the braking system, always make sure that there is absolutely no pressure
in the system. Even when the engine is switched off there will be some residual pressure in
the system.
※ When doing repair work, make sure your environment is very clean.
Immediately close all open ports on the components and on pipes using plugs.
(10) Replacing the complete actuating mechanism
Carefully clamp the unit vertically in a fixture. The actuating mechanism can be removed by taking
out the three bolts. Make sure that spring assembly (8) does not fall out. When installing the new
actuating mechanism, make sure that spring assembly (8) is fitted in the right order. Tighten the
four bolts (25).
(11) Replacing the pedal cover
Pedal cover (18) is simply pulled of by hand. The new pedal cover is pushed over pedal (17) and
tightened manually. Fasten the bellows with the strap retainers.
(12) Replacing the bellows
To change bellows (19) it is advisable to remove pedal (17). For this purpose, loosen snap ring
(22) and knock out pin (20) using a mandrill. When knocking out the bolt, make sure that the
mandrill is applied to the side of the bolt without a knurl. Remove pedal (17) and bellows (19).
Now fit the new bellows and proceed in reverse order as described above. The upper portion of
bellows is fastened to piston, its lower portion to pedal plate (16) secure the bellows using clamps.
4-15
5. CUT-OFF VALVE
1) STRUCTURE
3 4
5 C B
D D
P PS1
A A
C B
SECTION A - A SECTION B - B
1 2
2
B1 A1 A2 B2
A3
PS
A1 A2 T1
B
PS T1
PS1
B1 B2
P T
A3
B 5 1
SECTION C - C SECTION D - D HYDRAULIC SYMBOL

7707ABS06
1 Cut-off valve 4 Coil

2 Relief valve 5 Solenoid valve
3 Check valve
2) OPERATION
When the pump works, the oil under the pressure flows into P port.
The oil in P port is stored in the accumulator on A3 port.
As the pressure on P line rises to 150 bar, the cut off valve (1) starts cut-offing and the oil in the P
port is unloaded. The pressure on P line goes down 120 bar by the minute leakage from valve and
other factors.
At this pressure, the cut-off valve starts cut-ining.
This process is repeated in the regular period of 30~40 seconds.
4-16
6. BRAKE ACCUMULATOR
1) STRUCTURE
81L1-0003 81L1-0004
Item
(item16) (item17)
Diameter 138 mm 110 mm
Mounting height 187 mm 164 mm
Norminal volume 1.0ℓ 0.75ℓ
B Priming pressure 50 kgf/cm2 50 kgf/cm2

Operating medium Oil Oil
A Operating pressure Max 200 kgf/cm2 Max 150 kgf/cm2

Thread M22×1.5 M18×1.5
C
Priming gas Nitrogen Nitrogen
A Fluid portion C Diaphragm
D B Gas portion D Valve disk
75794BS09
2) OPERATION
(1) Purpose
Fluids are practically incompressible and are thus incapable of accumulating pressure energy. In
hydropneumatic accumulators, the compressibility of a gas is utilized to accumulate fluid. The
compressible medium used in the accumulators is nitrogen.
In braking systems, the purpose of the accumulators is to store the energy supplied by the
hydraulic pump. They are also used as an energy reserve when the pump is not working, as a
compensator for any losses through leakage, and as oscillation dampers.
(2) Operation
(2
The accumulator consists of a fluid portion (A) and a gas portion (B) with a diaphragm (C) as a
gas-tight dividing element. The fluid portion (A) is connected to the hydraulic circuit, causing the
diaphragm accumulator to be filled and the gas volume to be compressed as the pressure rises.
When the pressure falls, the compressed gas volume will expand, thus displacing the
accumulated pressure fluid into the circuit.
The diaphragm bottom contains a valve disk (D) which, if the diaphragm accumulator is
completely empty, closes the hydraulic outlet, thus preventing damage to the diaphragm.
3) Installation requirements
(3)
The accumulators can be fitted in the hydraulic circuit, directly on a component or in blocks on
suitable consoles.
They should be fitted in as cool a location as possible.
Installation can be in any position.
4-17
(4) Maintenance of the accumulator
The accumulator should be checked annually. It should be replaced if the initial gas pressure has
fallen by more than 30% (please refer to Performance testing and checking of the accumulator).
(5) Disposal of the accumulator
Before the accumulator is scrapped, its gas filling pressure must be reduced. For this purpose,
drill a hole through gas chamber (B) using a drill approx. 3mm in diameter. The gas chamber is
located on the side opposite the threaded port above the welding seam around the center of the
accumulator.
※ Wear safety goggles when doing this job.
(6) Performance testing and checking of the accumulator
The accumulator is gradually pressurized via the test pump; until the initial gas pressure is
reached, the hydraulic pressure in the accumulator will rise abruptly. This is apparent from gauge
M. If the initial gas pressure is more than 30% below the prescribed value, the accumulator needs
to be replaced. If the measuring process needs to be repeated, wait for intervals of 3 minutes
between the individual tests. Any accumulator whose initial gas pressure is insufficient must be
scrapped following the instructions under Disposal of the accumulator
accumulator.
The amount of initial gas pressure can also be checked from the vehicle. Start the vehicle's
engine. The pump will now supply oil to the accumulators. Until the initial gas pressure is
reached, the hydraulic pressure in the accumulator will rise abruptly. This is apparent from the
gauge in the cab. If the initial gas pressure is more than 30% below the prescribed value, that
initial pressure lies outside the permissible range for at least one of the accumulators fitted in the
vehicle. This accumulator can be traced only by using the method described above, i.e. all
accumulators have to be individually tested. The accumulator whose initial gas pressure is
insufficient must be replaced and scrapped following the instruction under Disposal of the
accumulator.
accumulator
Accumulator
Pressure gauge(M)
Ball valve for

shutting off pump flow
Safety valve
Ball valve for

reducing pressure
75794BS10
(7) Repair work

When working on the braking system, always make sure that there is absolutely no
pressure in the system. Even when the engine in switched off there will be some residual
pressure in the system.
For safety reasons the accumulators need to be replaced as a whole if damaged.
4-18
7. PRESSURE SENSORS
1) STRUCTURE
Connector
Connector
H1
H1
H2 H2
G G
PARKING, CHARGING BRAKE STOP & CLUTCH CUT OFF
7579S4BS15
2) TECHNICAL DATA
H1 H2 Adjusting range Actuating pressure Voltage
Item Medium G
mm mm kgf/cm2 kgf/cm2 V
Parking pressure
Oil PF 1/4" 46.5 11 0 ~ 200 100 ± 5 Max 30
sensor
Charging pressure
Oil PF 1/4" 46.5 11 0 ~ 200 100 ± 5 Max 30
sensor
Brake stop & clutch cut
Oil PF 1/4" 46.5 11 1 ~ 100 5±1 Max 30
off pressure sensor
4-19
2) OPERATION
(1) Purpose
The pressure switches are used to visually or audibly warn the driver of the pressure within the
system.
(2) Make contact / circuit closer
The pressure switch can be fitted in the braking system or directly on one of its components.
The system pressure acts on an absorption area within the switch, making an electrical contact
as the pressure on that area is increased. The resulting current is used to activate a warning
facility, for instance.
(3) Break contact / circuit breaker
The pressure switch can be fitted in the braking system or directly on one of its components.
The system pressure acts on a absorption area within the switch, breaking an electrical contact
as the pressure on that area is increased. The current is now broken, e.g. to deactivate a warning
facility.
(4) Installation requirements
No special measures need to be taken.
(5) Maintenance of the pressure switch
When using high-pressure cleaners on the vehicle, please make sure that the water jet is not
directed at the pressure switch (corrosion of contacts).
(6) Repair work
When working on the braking system, always make sure that there is absolutely no
pressure in the system. Even when the engine is switched off there will be some residual
pressure in the system.
※ For safety reasons the pressure switch needs to be replaced as a whole if damaged.
4-20
8. PARKING BRAKE SYSTEM
1) STRUCTURE
12
9 1
13
10
11
9 2
8
7
3
5
6 4
7609A4BS21
1 Housing 6 Piston 11 Adjusting screw

2 Pressure ring 7 Lining pad 12 Lining spring
3 Pressure bolt 8 Lining pad 13 Counter nut
4 Setting screw 9 Guiding pin
5 Plate spring pack 10 Rubber buffer
4-21
2) OPERATION
The two identical lining pads (7, 8) slide on the guide surfaces on the top of the housing and are
held in position by a lining spring (12). The brake itself is directly fixed on the gearbox with the two
guide pins (9).
The brake is positioned axially using the rubber buffers (10) between the brake housing (1) and the
guide pins (9), and the setting screw (11).
When the brake is actuated (= closed) a clamping force is created on the lining pads (7, 8) which is
transmitted to the brake disc. Under the force of the plate spring pack (5), the piston (6), together
with the adjusting screw (4), the pressure bolt (3) and the lining pad (7) are moved towards the
brake disc. When the lining pad (7) comes into contact with the brake disc, the reaction force
displaces the brake on the guide pins (9), against the spring force of the rubber buffers (10), until
the second lining pad (8) is also pressed against the brake disc.
The braking effect (braking torque) is dependent upon the frictional values of the brake linings.
The brake is released by complete pretensioning of the plate spring pack (5). The piston (6) is
moved back by the required minimum release pressure to the stop on the pressure ring (2).
During this process the brake positions itself, depending upon the setting, by the two rubber buffers
(10) up to contact with the setting screw (11). An equal air gap must be guaranteed on both sides
of the brake disc when set correctly.
The clamping force is reduced by wear of the lining pads (7, 8) and the brake disc.
The brake must then be readjusted.
4-22
3) FITTING AND SETTING INSTRUCTIONS
7
8
4
9
10
7 1
2
5
7609A4BS22
1 Lock nut 5 Screw cap 9 Piston

2 Setting screw 6 Pressure bolt 10 Spring pack
3 Adjusting screw 7 Guiding bolt
4 Counter nut 8 Bleeding screw
※ The fitting or adjusting must always be carried out when the brake is cold.
(1) Fitting the brake
① Rotate the screw cap (5) in a counter-clockwise direction and unscrew it.
② Release the lock nut (1) and turn the adjusting screw (2) counter-clockwise until the pressure
bolt (6) contacts the piston (9) with the flat surface.
③ Slide the brake over the brake disc in this condition.
④ Screw the two guide pins (7) into the gearbox.
⑤ Connect the pressure.
⑥ Apply the required release pressure (min. 130 bar) to the brake in order to pre-tension the plate
spring pack (10) completely, up to the stop.
⑦ Carry out bleeding of the brake using the bleed valve (8) .
4-23
(2) Clearance adjusting
① Insert a setting gauge on both sides between the brake lining carrier and brake disc and hold
them in position.
※ The thickness of the setting gauge must be adjusted to the desired air gap.
Clearance Setting gauge

Min. 0.5 mm 0.25 mm
Nominal clearance 1.0 mm 0.50 mm
Max. 1.5 mm 0.75 mm
② Turn the adjusting screw (2) in a clockwise direction until the two setting gauges are clamped
between the brake lining carriers and the brake disc.
③ Hold the adjusting screw (2) in position and lock using the lock nut (1).
※ The application pressure for clamping the setting gauges must be selected so that both gauges
can be removed using a small amount of force after locking in position.
④ Release the counter nut (4) and then turn the setting screw (3) in a clockwise direction until the
end surface of the setting screw (3) is in contact with the surface provided for setting.
⑤ Hold the setting screw (3) in position and lock using the counter nut (4).
⑥ Remove the setting gauges from both sides of the brake disc.
※ The fitting procedure for the brake and the setting of the desired air gap is now complete.
The brake is ready for use.
⑦ Turn the screw cap (5) in a clockwise direction and tighten hand-tight.
※ The brake should be actuated and released several times to check that it is functioning properly.
7
8
4
9
10
7 1
2
5
7609A4BS22
4-24
(3) Adjusting instructions
① Place the machine on flat ground and secure against rolling away.
② Release the parking brake by application of the required release pressure (min. 130 bar).
③ Rotate the screw cap (5) in a counter-clockwise direction and unscrew it.
④ Release the lock nut (1) of the setting screw (2).
⑤ Insert a setting gauge on both sides between the brake lining carrier and brake disc and hold
them in position.
※ The setting gauge must be selected in accordance with the table under (2) "Clearance adjusting".
⑥ Turn the setting screw (2) in a clockwise direction until the two setting gauges are clamped
between the brake lining carriers and the brake disc.
⑦ Apply the lock nut (1) to the setting screw (2).
※ The application pressure for clamping the setting gauges must be selected so that both gauges
can be removed using a small amount of force after locking in position.
⑧ Release the counter nut (4) and then turn the adjusting screw (3) in a clockwise direction until
the end surface of the adjusting screw (3) is in contact with the surface provided for setting.
⑨ Hold the adjusting screw (3) in position and lock using the counter nut (4).
⑩ Remove the setting gauge from both sides of the brake disc.
※ The adjustment of the desired air gap is now complete. The brake is ready for use.
⑪ Turn the screw cap (5) in a clockwise direction and tighten hand-tight.
※ Actuate the brake valve several times and check the holding effect of the parking brake on a
suitable incline or a suitable gradient.
7
8
4
9
10
7 1
2
5
7609A4BS22
4-25
4) EMERGENCY RELEASE OF THE PARKING BRAKE
In the event of a failure in pressure supply the parking brake can be released mechanically in the
following way :
G
2
5
7609A4BS23
1 Lock nut S Peg spanner

2 Setting screw G Ring spanner
5 Screw cap
(1) Secure the machine against rolling away.

(2) Rotate the screw cap (5) in a counter-clockwise direction and unscrew it.
(3) Release the lock nut (1) and unscrew it back to the end of the setting screw (2).
(4) Rotate the setting screw (2) in a clockwise direction until the brake disc is completely free.
※ For emergency release a torque of min 7.1 kgf·m (51.6 lbf·ft) is required on the setting screw (2).
(5) Screw on the lock nut (1) up to contact with the piston and apply a slight locking force to the
setting screw (2).
(6) Screw on the screw cap (5) in a clockwise direction by a few threads. (dirt ingress protection)
※ In this condition the machine has no parking brake facility and thus must be protected from rolling
away by different means. The brake must be adjusted before recommissioning.
4-26
5) MAINTENANCE AND REPAIR WORK
(1) Maintenance and replacement of the lining pads
The brake, particularly the brake lining carriers, must be visually inspected at regular intervals.
If the remaining lining thickness is too thin, these intervals must be reduced accordingly to
prevent extensive damage to the brake or the brake disc.
Once the minimum remaining lining thickness of 1.0~1.5 mm per brake lining carrier is reached,
the brake lining carrier must be replaced in accordance with the following instructions :
3 1
S1
4 2
S
5
7609A4BS24
1 Lock nut 5 Screw cap

2 Setting screw S Peg spanner
3 Pressure bolt S1 Screwdriver
4 Piston R Ring spanner
③ Rotate the screw cap (5) in a counter-clockwise direction and unscrew it.
⑤ Rotate the setting screw (2) in an counter-clockwise direction until the pressure bolt (3) can be
pushed completely into the piston (4) .
⑥ Unscrew (lever) the pressure bolt (3) with a suitable screwdriver until it contacts the piston (4).
4-27
5
1
7609A4BS25
1 Counter nut 4 Lining pad

2 Adjusting screw 5 Lining spring
3 Lining pad
⑦ Release the counter nut (1) and unscrew the adjusting screw (2) from the brake housing.
※ The lining spring (5) is pre-tensioned. The lining spring (5) must be held in position with a
suitable tool whilst removing the adjusting screw (2).
⑧ Remove the lining spring (5).
⑨ Remove the two lining pads (3, 4) from the lining compartment in the brake housing.
※ If there is no possibility of changing the brake lining carriers (3, 4) as described above (not
enough space), the brake must be removed completely.
※ Check the pressure line. A pressure line which is too short must be unscrewed in order to permit
removal of the brake.
An emergency release of the parking brake must be carried out before releasing the pressure
line.
⑩ Replace the lining pads (3, 4).
⑪ The lining spring (5) must be pushed in position with a suitable tool whilst screwing in the
adjusting screw (2).
※ If you removed the brake completely because of a lack of space you must carry out fitting of the
brake.
※ After changing the lining pads (3, 4), or repair to them, the brake must be adjusted in
accordance with 3) FITTING AND SETTING INSTRUCTION.
4-28
(2) Replacing the seals
B
3
10
2
1
8 4
9 5
7
6
7609A4BS26
1 Piston 5 Circlip 9 Plate spring pack

2 Setting screw 6 Sealring 10 Dust protection cap
3 Lock nut 7 Pressure ring A Detail sealring
4 Housing 8 Pressure bolt B Detail sealring
Leaking seals must be replaced in accordance with the following instructions :

※ If the brake cannot be pressurised with the required release pressure (min. 130 bar) because of
excessive leaks, the parking brake MUST be released using the emergency procedure. See 4)
Emergency release of the parking brake.
③ Rotate the screw cap in a counter-clockwise direction and unscrew it.
⑤ Rotate the setting screw (2) in an counter-clockwise direction until the pressure bolt (8) can be
pushed completely into the piston (1).
⑥ Unscrew (lever) the pressure bolt (8) with a suitable screwdriver until it contacts the piston (1).
⑦ Actuate the brake valve and dissipate the existing release pressure down to 0 bar.
※ The plate spring pack (9) is now fully de-tensioned.
⑧ Unscrew the pressure line and remove the brake completely.
⑨ Remove the circlip (5) and remove the pressure ring (7) from the housing (4).
⑩ Remove the plate spring pack (9) and the piston (1).
⑪ Always replace both the seals (A, B).
4-29
※ Observe the fitting direction of the grooved rings and use a suitable fitting needle with rounded
edges to fit the new grooved rings. Take care - there is a danger of injury.
※ Carry out re-fitting of the individual parts into the brake in reverse order. Apply a light coat of
fitting fluid lubricant to the sliding and sealing surfaces of the piston when fitting.
⑫ If necessary, also replace the dust protection cap (10).
※ The dust protection cap (10) has a vulcanised-in steel ring which is used to press it into the
opening in the brake housing (4).
In order to replace this you will need to "lever it out" with a suitable tool and then replace with a
fitting fixture by pressing it into the housing (4).
⑬ Fit the brake onto gearbox.
(3) General instructions
Any faults or damage detected on parts not listed here must, of course, be rectified or replaced
by genuine parts.
B
3
10
2
1
8 4
9 5
7
6
7609A4BS26
4-30
1. OPERATIONAL CHECKS
This procedure is designed so the mechanic can make a quick check of the system using a minimum
amount of diagnostic equipment. If you need additional information, read structure and function
function,
Group 1.
At the end of each check, if no problem is found (OK), that check is complete or an additional check is
needed. If problem is indicated (NOT OK), you will be given repair required and group location.
If verification is needed, you will be given next best source of information:
Chapter 2 : Troubleshooting
Group 3 : Tests and adjustments
4-31
※Hydraulic oil must be at operating temperature for these checks (refer to page 6-48).

Parking brake capacity Start engine. OK
check Check completed.
Fasten seat belt.
Seat belt must be worn
NOT OK
while doing this check to Release parking brake and put
Inspect parking brake. Go
prevent possible injury transmission in 2nd gear forward.
to group 3.
when machine stops
Drive machine at 8 km/hr and
suddenly.
switch parking brake ON.
ON LOOK/FEEL : Machine must
Release
come to a stop within 2 meters (6
feet) when parking brake is
P
engaged at 8 km/hr.
Transmission must shift to neutral.
Parking brake Turn parking brake to ON. OK
transmission lockout Check completed.
Place transmission in 1st forward.
check
P
NOT OK
Engine running. Slowly increase engine speed to
Go to transmission control
high idle.
circuit in section 3.
LOOK : Machine must not move.
4-32
Service brake pump flow Stop engine. OK
Operate brake pedal approximately
※ Hydraulic oil must be at
20 times. NOT OK
operating temperature
Start engine and run at low idle. Check for brake circuit
for the check.
leakage.
Engine OFF. Record number of seconds
required for low brake pressure Go to next page.
indicator lamp to go out.
IF OK
LOOK : Indicator lamp must go out I n s t a l l a c a p o n l i n e
in less than 4 seconds from time connected to inlet of brake
engine starts. valve and repeat pump
flow check.
NOTE : Indicator will not come on
approximately 1 second after If time does not decrease,
starting engine. check for wor n brake
pump.
Service brake capacity Turn clutch cut-off mode switch OK
check OFF. Check completed.
OFF
Engine running.
Apply service brakes, release park NOT OK
L
M H
brake and put transmission in 2nd Check brake pressure.
forward.
IF OK
Increase engine speed to high idle. Inspect brake disk.
LOOK : Machine may not move or
P
move at a very slow speed.

Repeat check three times to ensure
accurate results.
4-33
Brake accumulator S t a r t a n d r u n e n g i n e fo r 3 0 OK
precharge check seconds. Check completed.
※The axles and hydraulic
Stop engine and turn start switch to NOT OK
oil must be at operating
ON and wait 5 seconds. Make sure brake pedal is
temperature for this
not binding and keeping
check. NOTE : Engine oil pressure lamp
brakes partially engaged.
will be on due to no engine oil
pressure. Bleed brakes in group 3.
Count the number of times the C h e c k b r a k e s y s t e m
brake pedal can be fully depressed pressure.
before the low brake pressure
NOT OK
warning lamp comes ON.
If light comes ON with
LOOK : Warning lamp must come e n g i n e r u n n i n g ,
ON in 1~5 applications. accumulator has lost it's
charge. Inspect and
Start engine and operate at low
recharge accumulator.
idle.
Observe cluster while applying
brake pedal with maximum force.
LOOK/LISTEN : Brake pressure
indicator must not come ON.
Brake system leakage Start engine and wait 30 seconds. OK
Stop engine.
NOT OK
Wait 2 minutes.
If brake leakage is
Turn start switch to ON and wait 5 indicated with brakes
seconds. released, check leakage at
accumulator inlet check
LOOK : Brake oil pressure warning
valve and brake valve. If
lamp must not come ON within 2
brake leakage is indicated
minutes after stopping engine.
with brakes applied, check
for leakage at brake valve
and brake pistons.
Check individual
component leakage.
4-34
S e r v i c e b ra ke p e d a l Slowly depress brake pedal. OK
Listen for a hissing noise that
indicates oil is flowing to brake NOT OK
pistons. Inspect for debris under
brake pedal.
LISTEN/FEEL : A hissing noise
must be heard when pedal is
depressed.
Service and parking Position machine on gradual slope. OK
brake system drag Check completed.
Lower bucket approximately 50 mm
checks
(2 in) from ground.
Engine running NOT OK
Release parking and ser vice Adjust park brake.
brakes.
NOT OK
LOOK : Machine must move or
Check floor mat interfer-
coast.
P
ence to pedal or debris

NOTE : If machine does not move, build-up.
check brake pedals to be sure they
fully release when feet are removed IF OK
from pedals. Check for brake pressure
when brake is released.
Drive machine at high speed for
about 5 minutes.
Go to brake pressure test.
Brake drag is indicated if brake
areas in differential case are hot.
NOTE : Observe parking brake.
If disk is hot, parking brake drag is
indicated.
Clutch cut-off check Place clutch cut-off mode switch in OK
L position. Check completed.
Release parking brake. NOT OK
Adjust clutch cut-off switch.
Run engine at half speed in 1st
forward.
Firmly depress brake pedal.
F E E L : Tr a n s m i s s i o n m u s t
disengage when brake pedal is
depressed at 30% of pedal stroke.
OFF
NOTE : Clutch cut-off mode switch

L
M H
can be selected to operator
preference to match your loading
needs.
4-35
2. TROUBLESHOOTING
1) SERVICE BRAKE
Diagnose malfunction charts are arranged from most probable and simplest to verify, to least likely,
more difficult to verify. Remember the following steps when troubleshooting a problem :
Step 1. Operational check out procedure (see section 1)
Step 2. Operational checks (in this group)
Step 4. Tests and adjustments (see group 3)

Poor or no brakes Brake accumulator charge low. Do brake accumulator check.
Brake pump standby pressure Do brake pump standby pressure test.
low.
Brake pressure low. Do brake valve pressure test.
Air in system. Bleed brakes.
Worn brake surface material. Inspect brake surface material.
Leakage in brake valve. Do brake valve leakage test.
Leakage in brake piston seal. Check for an over filled differential.
Apply brakes and check for leakage from check
plug.
※It is normal for the oil level to be slightly
above the check plug.
Aggressive brakes Internal restriction in circuit. Remove lines and components.
Brake valve malfunction. Disassemble and inspect.
Low oil level. Check oil level.
Brakes drag Brake pedal not retur ning Inspect floor mat and pedal.
properly.
Debris holding valve partially Do brake valve pressure test.
open in brake valve.
Warped brake disk. Inspect brake disk.
Stuck brake piston. Repair.
Brakes lock up Brake valve malfunction. Clean or replace brake valve.
4-36
Brakes chatter Air in brake system. Do brake bleed procedure.
Worn brake surface material. Inspect brake surface material.
Wrong oil in differential. Drain.Refill.
H i s s i n g n o i s e w h e n Leakage in brake valve, or brake Do brake system leakage test.
brake pedal is held with piston.
engine stopped
Brake pressure warning M a l f u n c t i o n i n b r a k e l o w Replace switch.
light will not go out or pressure warning switch.
stays on excessively long
Brake accumulator pressure too Recharge accumulator.
after start-up
low.
L ow b r a ke p u m p s t a n d by Do brake pump standby pressure test.
pressure setting.
Leakage in pressure reducing Do pressure reducing valve manifold leakage
manifold block. test.
Leakage in brake system. Do brake system components leakage tests.
Worn brake pump. Do brake pump flow test.
Leakage in par king brake Do parking brake pressure test.
solenoid.
2) PARKING BRAKE MALFUNCTIONS

Brake will not hold Pads not adjusted correctly. Adjust parking brake.
Malfunctioning parking brake Inspect and replace.
solenoid.
Worn brake disk and / or brake Disassemble, inspect, repair.
pads.
Brake piston hangs up in bore. Remove and inspect. Repair.
Brake disk overheats Pads out of adjustment. Adjust parking brake.
Brake not released. Release parking brake.
Disassemble, inspect brake.
Repair if necessary.
Inspect for loosen or broken lines between brake
pressure switch and indicator on dash.
Parking brake indicator in Faulty wiring or switch. Inspect for loose or broken lines between brake
monitor does not come pressure switch and indicator on dash.
on when brake applied Inspect for a faulty indicator on dash. Replace if
necessary.
Brake will not apply Pads out of adjustment. Adjust parking brake.
Malfunctioning wiring, switch, or Check electric circuit.
solenoid.
Restriction between brake valve Remove hose and inspect. Replace.
and brake.
4-37
1. PARKING BRAKE PERFORMANCE

1) MEASUREMENT
EASUREMENT CONDITION
(1) Tire inflation pressure : Specified pressure
(2) Road surface : Flat, dry, paved surface
with 1/5 (11˚20') gradient.
(3) Machine : In operating condition 20%
gradient 11 20'
Item Standard valve
Parking brake Keep machine on 20%
performance (11˚20') gradient 75794BS17
2) MEASURING PROCEDURE
(1) Start the engine and drive the machine
straight up a 1/5 gradient with the bucket
unloaded.
(2) Depress the service brake, place the gear
selector lever in neutral, then stop the
engine.
(3) Turn the parking brake switch ON, then 20%
11 20' gradient
slowly release the service brake pedal
and the machine must be kept stopped.
※ The measurement must be made with
the machine facing either up or down
75794BS18
the slope.
2. ADJUSTMENT OF PARKING BRAKE

(1) External brake inspection
·Inspect for wear of brake pad
(2) Refer to the PARKING BRAKE SYSTEM Lock nut

on the page 4-21.
Setting screw
7609A4BS27
4-38
3. HYDRAULIC BRAKE BLEEDING PROCEDURE
Escaping fluid under pressure can
penetrate the skin causing serious injury.
Avoid the hazard by relieving pressure
before disconnecting hydraulic or other
lines. Tighten all connections before
applying pressure.
Search for leaks with a piece of cardboard.
Protect hands and body from high
pressure fluids.
※ If an accident occurs, see a doctor Breather vent
Air breather
immediately. Any fluid injected into the skin
must be surgically removed within a few
hours or gangrene may result. Breather vent
Doctors unfamiliar with this type of injury
should reference a knowledgeable medical
source.
Two people are required to bleed brake A
system oil, one to operate brake valve and
other to open and close bleed screws.
1) Install frame locking bar. Engage parking
brake.
2) Put a clear plastic tube on bleed screw to
route low to hydraulic oil tank filler tube or
container (A).
3) Start engine and run at low idle.
4) Push and hold brake pedal down until
brake bleeding procedure is complete.
※ If bubbles continue for more than 2
minutes, stop bleeding procedure. Safety lock bar
Check for and correct problem, then
continue.
5) Open on bleed screw on differential and
axle assembly until hydraulic oil starts to
flow. Close bleed screw when oil is free of
air. Release brake pedal.
6) Repeat steps 1)~5) for each bleed screw.
7) Push either brake pedal and hold down.
7579S4BS19
8) Check hydraulic oil level.
4-39
1. BRAKE PUMP
1) MAIN
AIN ASSEMBLY
Inlet
2
Brake pump
3
6
Outlet A
B
2
1 C
5
D
4
13
Inlet
A 12
7
8 11
Outlet
7
10
Fan pump
14
Assembly direction of bushing block
7609S4BS07
1 Housing sub assy 6 Multi spacer 11 Rear cover

2 Bushing block sub assy 7 Bush block sub assy 12 Washer
3 Shaft gear 8 Joint drive gear 13 Bolt
4 Driven gear 9 Driven gear 14 Connector
5 Front cover sub assy 10 Housing sub assy
4-40
(1) Prepare all parts and clean it.
(2) Prepare M10 torque wrench, oil pump and 1, 2, 5, 7, 10 sub assembly status.
(3) When you assemble, front cover sub assy (5) is based on a front view.
(4) Main assembly order
① Front cover sub assy (5) is based on a front view in drawing, check sense of rotation (CW) and
assembling shaft gear's upper direction.
② At first, one of bushing block sub assy (2) point to same position of figure. After you assemble
drive gear (3) and driven gear (4), you assemble bushing block sub assy (2).
③ Put oil on the assembled parts (2, 3, 4), lubrication for the gear to rotate and assemble front
cover sub assy (5) to A direction.
④ Check the outlet port based on housing sub assy (1) drawing and contamination of part's inside.
Coated oil parts are assembled in the direction vertical and horizontal.
⑤ Assemble multi spacer(6) as shown in the figure and connector (14) put in joint drive gear's(8)
hole.
⑥ One of bush block sub assy(7) point to same position of figure.
After you assemble joint drive gear(8) and driven gear(9), you assemble bush block sub assy.
⑦ Put oil on the assembled parts (7,8,9), lubrication for the gear to rotate assemble multi
spacer(6) to A axis direction.
⑧ Check the outlet port based on housing sub assy(10) drawing and contamination of part's inside.
Coated oil parts are assembled in the direction verticcal and horizontal.
⑨ Assemble rear cover(11) as shown in the figure.
⑩ Washer(12) put in bolt(13), assemble in order of A-D-B-C and tighten bolts same order using
toque wrench
·Tightening torque : 5.1±0.5 kgf·m (36.9±3.7 lbf·ft)
(5) Complete assembly.
(6) Dissembly is assembly's order in reverse.
(7) You proceed running-in using performance test device.
(8) Install it, and use.
4-41
2) SUB ASSEMNLY
※ Beware of scratches, damages and foreign
materials.
※ Grease must have good lubricity and
viscosity.
※ You must prepare snap ring tool and
retainal seal special tool.
(1) Fron
Frontt cover assy
1
① After enough grease on the surface of Direction B
retainal seal (2). It is assembled front
cover (1) using retainal seal special tool. 2
3
※ Lip's direction toward A direction should
be assembled and because of the risk of
Direction A
damage should be used only special tool.
② After you put snap ring tool in 2 holes of Direction A Lip
snap ring (3), grasp it and snap ring (3) is

assembled front cover's (1) groove using
Direction B
snap ring tool. 7407B4BS20
(2) Housing assy

① After enough grease on the surface of 1
D-rings (2), those should be assembled
grooves of housing's (1) both sides 2
closely.
2
※ A side of D-ring (2) should be assembled
side of housing (1) closely.
Face A
7407B4BS21
(3) Bushing block assy

① After enough grease on the surface of
channel seal (2), it should be assembled 2
groove of bushing block (1). 3
※ A side of channel seal(2) should be
assembled side of bushing block (1)
1
closely.
② After enough grease on the surface of
back-up seal (3), it should be assembled
groove of channel seal (2).
Face B Face A
※ A side of back-up seal (3) should be
assembled inside of channel seal (2)
closely. 7407B4BS22
4-42
3) RUNNING-IN
Pressure gauge
Test unit Variable

restrictor
Microbic filter
Flow
meter
Relief valve
Strainer
Tank
(730TM-3C)4-48
(1) A unit which has been re-assembled with either new gears, bushes or body, must be carefully
run-in before it is subjected to full working conditions.
(2) Ideally this should be done on a test rig (see figure) where pressure can be gradually applied and
any wipings from the body cut-in arrested by filters.
(3) It is recommended that the unit is run-in at 1500 rpm, initially, at zero pressure for one minute then
in stages with the pressure increased by 500 psi every minute, until maximum rated pressure has
been attained. Frequently check the system temperature, ensuring that it does not exceed the
maximum permissible figure of 80˚C. If the temperature exceeds the system or unit specification
the test must be delayed and operated off-load until acceptable temperatures are obtained.
4-43
Group 1 Structure and Function ---------------------------------------------------------------------------------- 5-1

Group 2 Operational Checks and Troubleshooting ---------------------------------------------------- 5-15
Group 3 Tests and Adjustments ----------------------------------------------------------------------------------- 5-23
Group 4 Disassembly and Assembly -------------------------------------------------------------------------- 5-30
1. OUTLINE
The steering system of this machine consists of a variable displacement piston pump supplying a
load sensing steering system and an closed center loader system.
The components of the steering system are :
·Steering pump
·Steering valve (EHPS)
·Steering unit
·Cushion valve
·Steering cylinders
The steering pump, the first pump of main pump, draws hydraulic oil from the hydraulic tank.
Outlet flow from the pump flows to the priority valve of steering valve. The priority valve of steering
valve preferentially supplies flow, on demand, to the steering unit. When the machine is steered, the
steering unit routes flow to the steering cylinders to articulate the machine.
When the machine is not being steered, or if pump flow is greater than steering flow, the priority valve
supplies flow to the loader system.
That is, output flow from the steering pump enters into the main control valve for the operation of the
attachment.
5-1
10
33
6 CL CR
Priority valve spool Ps
Ts
EF P LS T
L R
5
MCV
P T
RCV lever
Brake system Fan drive moter
1
Return line
23
29 PS Return line
28 M1
A P1
24 Return line
29
M2 26 21
PS
25
P2
27
M
7579S5SE01
1 Main pump (steering) 23 Air breather 28 Check block (option)

5 Steering unit 24 Hydraulic tank 29 Pressure sensor (option)
6 Steering valve (EHPS) 25 Return filter 33 Cushion valve
10 Steering cylinder 26 Bypass valve
21 Oil cooler 27 Motor pump (option)
5-2
1) NEUTRAL
10
33
6 CL CR
D Ts
EF P LS T
L R
5
MCV
P T
RCV lever
2 1 A
Return line
23
Return line
24 Return line
26 21
25
7609S5SE02
· The steering wheel is not being operated so control spool (G) does not move.
· The oil from the steering pump (A) enters port P of the priority valve in steering valve (EHPS) and the
inlet pressure oil moves the spool (D) to the right.
· Almost all of pump flow goes to the loader system (main control valve) through the EF port and partly
flows into the hydraulic tank (24) through the spool (M).
5-3
2) LEFT TURN
10
33
6 CL CR

CF
Ts
EF P LS T
·
L R
5
·
·
MCV
P T ·
RCV lever
2 1
Return line
23
Return line
24 Return line
26 21
25
7609S5SE03
When the steering wheel is turned to the left, the pressure oil from the steering unit fill on the left side
chamber of main steering spool (M), and main steering spool moves to the right in the direction.
At the same time of moving of main steering spool, LS signal will be blocked. Refer to page 5-8.
If LS signal of main steering spool is blocked, it cause to increase pressure of right chamber of priority
valve and then priority valve to be pushed to left side.
Consequently, oil will flow via CF of priority valve to main spool. That oil will push steering cylinder rod
out and it will cause wheel loader to be steered to left side.
The rate of movement of main steering spool is concluded as flow rate, which is kept in left chamber
from steering unit. Furthermore the rate controls speed of movement for cylinder.
5-4
3) RIGHT TURN
10
33
6 CL CR

CF
Ts
EF P LS T
L R
5
MCV
P T
RCV lever
2 1
Return line
23
Return line
24 Return line
26 21
25
7609S5SE04
· When the steering wheel is turned to the right, the pressure oil from the steering unit fill on the right
side chamber of main steering spool (M), and main steering spool moves to the left in the direction.
· At the same time of moving of main steering spool, LS signal will be blocked. Refer to page 5-9.
· If LS signal of main steering spool is blocked, it cause to increase pressure of right chamber of priori-
ty valve and then priority valve to be pushed to left side. Consequently, oil will flow via CF of priority
valve to main spool. That oil will push steering cylinder rod out and it will cause wheel loader to be
steered to right side.
· The rate of movement of main steering spool is concluded as flow rate, which is kept in right cham-
ber from steering unit. Furthermore the rate controls speed of movement for cylinder.
5-5
3. STEERING VALVE (EHPS ; Electro Hydraulic Power Steering)
1) STRUCTURE
1 6
L CL CR R
CL CR
T TS Steering
valve Shock valves
block
LS EF P PS Suction valves
L
Main spool
R
S3
KV2
KV1
7 2 8 3 9 4 10 11 5 12
EF 12bar
CF Ps
Pressure
30bar reducing
valve Ts
EF P LS T
Hydraulic circuit
13 14
15 17
18
16
7607SE11
1 To tank 7 From steering unit L port 13 Relief valve

2 To emergency system 8 Shock & suction valve (left side) 14 Check valve
3 To main control valve 9 To steering cylinder (left side) 15 Main steering spool
4 From main pump 10 To steering cylinder (right side) 16 Pressure reducing valve
5 To steering unit P port 11 Shock & suction valve (right side) 17 Metering spool
6 From steering unit T port 12 From steering unit R port 18 Priority spool
5-6
2) OPERATION
(1) Neutral
CL CR
Shock valves
Suction valves 15
KV1 S3 KV2 17
16
18A CF Ps
Pressure L R
reducing
valve
Ts P T
LS P EF T
18
7607SE12
· In neutral position, the oil will pass from the pump across the integrated priority valve (18) in the
steering valve for discharge through the EF port. When the steering unit is in neutral, flow through
it is blocked and all flow through the priority valve (18) in steering valve is directed out the EF port
and passed to the main control valve.
· When the engine is turned off, the priority valve spool (18) is pushed to the right by the spring. The
passage to the EF port is blocked while the passage to the CF port is open.
· When the machine is started, EF port of the steering valve may be connected to the working
hydraulic. Maximum pressure on the EF port = 210 bar.
· The operating pressure in the loader system has not effected on the operation of the priority
valve(18) of steering valve. Independently of operation of the loader actuated in relief, the priority
valve(18) will not shift until the machine is steered.
· A part of flow through the priority valve spool (18) will flow to P port of steering unit through pres-
sure reducing valve. Also flow as pilot signal of steering through the priority valve spool (18) pass-
es from the P port through the dynamic orifice and into the LS line. It flows to the tank through the
LS orifice in main spool.
· In neutral position, the main spool will be in its center position. This means that knocks and
impacts from the cylinder are not transmitted to the steering unit. The steering valve is thus of the
non-reaction type.
5-7
(2) Turning left
CL CR
Shock valves
Suction valves 15
KV1 S3 KV2 17
16
18A CF Ps
Pressure L R
reducing
valve
P T
Ts
LS P EF T
18
7607SE13
· When the steering wheel is turned to the left, the pressure oil from the steering unit fill on the left
side chamber of main steering spool (15), and main steering spool (15) moves to the right in the
direction.
· At the same time of moving of main steering spool (15), LS signal will be blocked.
· If LS signal of main steering spool (15) is blocked, it cause to increase pressure of left chamber of
priority valve (18A) and then priority valve (18) to be pushed to right side.
Consequently, oil will flow via CF of priority valve to main spool. That oil will push steering cylinder
rod out and it will cause wheel loader to be steered to left side.
· The rate of movement of main steering spool (15) is concluded as flow rate, which is kept in left
chamber from steering unit. Furthermore the rate controls speed of movement for cylinder.
· When the cylinder reaches to end position, pressure of oil flowing through main steering spool (15)
will get to be increased. If the oil pressure increase up to relief pressure to be set, relief valve will
be activated. It result in decreasing pressure of left chamber of priority valve (18A), and will push
priority valve(18) to right side. Then, oil flow to cylinder will be blocked.
5-8
(3) Turning right
CL CR
Shock valves
Suction valves 15
KV1 S3 KV2 17
16
18A CF Ps
Pressure L R
reducing
valve
P T
Ts
LS P EF T
18
7607SE14
· When the steering wheel is turned to the right, the pressure oil from the steering unit fill on the right
side chamber of main steering spool (15), and main steering spool (15) moves to the left in the
direction.
· At the same time of moving of main steering spool (15), LS signal will be blocked.
· If LS signal of main steering spool (15) is blocked, it cause to increase pressure of left chamber of
priority valve (18A) and then priority valve (18) to be pushed to right side. Consequently, oil will
flow via CF of priority valve to main spool. that oil will push steering cylinder rod out and it will
cause wheel loader to be steered to right side.
· The rate of movement of main steering spool (15) is concluded as flow rate, which is kept in right
chamber from steering unit. Furthermore the rate controls speed of movement for cylinder.
· When the cylinder reaches to end position, pressure of oil flowing through main steering spool (15)
will get to be increased. If the oil pressure increase up to relief pressure to be set, relief valve will
be activated. It result in decreasing pressure of left chamber of priority valve (18A), and will push
priority valve (18) to right side. Then, oil flow to cylinder will be blocked.
5-9
(4) Pressure reducing valves
1 2 3
7607SE15
· Pressure reducing valve is a valve, which is supplying pilot oil to steering unit.
That is one of advantage of steering system adopting steering valve.
· Pressure reducing valves are pressure-limiting devices that limit pressure in one portion of a circuit
while leaving system pressure unaffected.
Pressure reducing valves allow flow to pass from (1) to (2) until the pressure at (1) reaches the pre-
determined setting, at which point the spool shifts to restrict input flow from (1) (reducing mode) or
to open flow from (2) to (3) (relieving mode) as needed to maintain the regulated pressure at (2).
(5) Relief valve
1 2 3 4 5
7607SE16
1 Plastic plug 4 Thrust pad

2 Adjustment screw 5 Valve seat
3 Spring
The relief valve is inside the steering valve, and set the maximum circuit pressure of the steering
circuit.
When the steering valve is being actuated, if the steering circuit goes up above the set pressure of
this valve, oil will be relieved, the priority valve spool will be actuated, and the oil will be flow to EF
port.
5-10
4. STEERING UNIT
1) STRUCTURE
1 7
2 8
3 9
4 10
A A
5
11
6
12
SECTION A - A
7607SE17
1 Bearing 5 Gear wheel 9 Spool

2 Neutral position spring 6 Gear rim 10 Check valve
3 Cross pin 7 Sleeve 11 Distributor plate
4 Housing 8 Cardan shaft 12 End cover
2) OPERATION
The steering unit consists of a rotary valve and a rotary meter.
Via a steering column the steering unit is connected to the steering wheel of the machine.
When the steering wheel is turned, oil is directed from the steering system pump via the rotary
valve (spool and sleeve) and rotary meter (gear wheel set) to the cylinder ports L or R, depending
on the direction of turn. The rotary meter meters the oil flow to the steering cylinder in proportion to
the angular rotation of the steering wheel.
Spool (9) is connected directly to the drive shaft of steering wheel. It is connected to sleeve (7) by
cross pin (3) (not in contact with the spool when the steering wheel is at neutral) and neutral posi-
tion spring (2).
Cardan shaft(8) is meshed at the top with cross pin (3) and forms one unit with sleeve (7).
At the same time, it is meshed with gear rim (5) of the gerotor set by spline.
There are four ports in valve body. They are connected to the pump circuit, tank circuit, and the
head, and left and right steering cylinder. In addition, the pump port and tank port are connected
inside the body by the check valve. Therefore, if there is any failure in the pump of engine, oil can
be sucked in directly from the tank through the check valve.
5-11
5. CUSHION VALVE
1) STRUCTURE
B A
B A
13
16 15 5 14 8 1 2 3 6 7 5 4
17 13 12 11 10 9
SECTION B - B SECTION A - A
7607SE18
1 Housing 7 Back ring 13 Plug

2 Poppet 8 Orifice 14 Plug
3 Spring 9 Plug 15 Spring
4 Valve seat 10 O-ring 16 Poppet
5 O-ring 11 Spring 17 Plug
6 O-ring 12 Spool
5-12
2) OPERATION
L R
B A
B A
16 8 2 3
Check valve Pilot valve

section section
Main valve
section
SECTION B - B SECTION A - A
12 11 9
7607SE19
The cushion valve is a valve that eliminates steering jerk motion. It makes a higher pressurized oil to
flow into another line in order to prevent the shock on steering system.
The pressure by rapid supplied pressurized oil from R port is higher than the spring (3) force, so it press
and open the poppet (2). Then the oil flows to the central groove of the spool (12), and flows to L port
through the poppet of the check valve (16) on L port side.
At this time, this pressurized oil flows to the pressure area of the plug (9) through the orifice (8), and this
force is higher than the spring (11) force plus the oil pressure on L port side, so the spool (12) is shifted
to the right. The flow of the supplied oil to L port side through the poppet (2) from R port side is trapped.
The flow of this instant oil makes the function of the cushion. After this operation, the normal steering
operation is not affected because this valve is not operated any longer.
Also, for the response of the pressure when the operation is slow as a cushion effect is not required, the
spool (12) is closed before the poppet (2) is opened, so this valve is not operated.
5-13
6. STEERING CYLINDER
1) STRUCTURE
5,4 3 12 7,6 8 11,10 9 2 1 13 17 20 14 15 16 18,19
7579S5SE05
1 Tube assembly 8 Buffer ring 15 Wear ring

2 Rod assembly 9 Bushing 16 Nylon nut
3 Gland 10 O-ring 17 O-ring
4 Dust wiper 11 Back up ring 18 Spherical bearing
5 Retaining ring 12 O-ring 19 Retaining ring
6 Rod seal 13 Piston 20 O-ring
7 Back up ring 14 Piston seal
2) OPERATION
This machine use to cross connected cylinder for steering operation.
The steering cylinder use a gland(3) to remove piston and sealed seals. Dust wiper (4) located on
the in side of the gland protects cylinder inner parts from dust. The piston (13) is fastened to the rod
(2).
The piston uses a single wear ring (15) with a piston seal (14) to seal between the piston and tube.
The gland seals against the tube with two O-rings. The rod is sealed against the gland with a rod
seal (6).
5-14
This procedure is designed so the service man can make a quick check of the steering system using
a minimum amount of diagnostic equipment. If you need additional information, prefer to structure
and function in group 1.
Locate system check in the left column and read completely, following this sequence from left to right.
At the end of each check, if no problem is found (OK), that check is complete or an additional check
is needed. If problem is indicated (NOT OK), you will be give repair required and group location. If
verification is needed, you will be give next best source of information :
·Chapter 2 : Troubleshooting
·Group 3 : Tests and adjustments
5-15
Steering unit check Run engine at low idle. OK
Check completed.
A
Turn steering wheel until frames are
at maximum right (A) and then left NOT OK
B
(B) positions. Go to next check.
L O O K : Fra m e s mu s t m ove
smoothly in both directions.
When steering wheel is stopped,
frames must stop.
FEEL : Excessive effort must not be
required to turn steering wheel.
NOTE : It is normal for steering to
drift from stops when steering
wheel is released.
Steering system leakage Turn steering wheel rapidly until OK
check frames are against stop. Check completed.
Heat hydraulic oil to Left Right
Hold approximately 2 kg on steer- NOT OK
operating temperature.
ing wheel. Do steering system leakage
Run engine at high idle.
test in group 3 to isolate the
Count steering wheel revolutions
leakage.
for 1 minute.
Repeat test in opposite direction.
LOOK : Steering wheel should
rotate less than 7 rpm.
NOTE : Use good judgment;
Excessive steering wheel rpm does
not mean steering will be affected.
Priority valve (in steering Park machine on a hard surface. OK
valve) low pressure Check completed.
Hold brake pedal down.
check
NOT OK
Do steering valve (EHPS)
Steer machine to the right and left pressure test in group 3.
as far as possible.
LOOK : Machine must turn at least
half way to the right and left stops.
Priority valve (in steering Steer to steering stop and release OK
valve) high pressure steering wheel. Check completed.
check
Roll bucket back and hold over NOT OK
relief and observe engine rpm. Priority pressure is set too
high. Do steering valve
Turn steering wheel to steering
(EHPS) pressure test in
stop and hold, observe engine rpm.
group 3.
LOOK : Steering stall engine rpm
must be higher than hydraulic stall
rpm.
5-16
2. TROUBLESHOOTING
※ Diagnose malfunction charts are arranged from most probable and simplest to verify, to least
likely, more difficult to verify. Remember the following steps when troubleshooting a problem :
Step 1. Operational check out procedure (see group 3 in section 1)
Step 2. Operational checks (in this group)

No steering Low oil level. Add recommended oil.
Failed steering pump. Remove and inspect return filter for
metal pump particles.
Failed main pump drive. Do main pump flow test.
Stuck priority valve spool. Remove and inspect priority valve spool.
Broken priority valve spring. Remove and inspect spring.
Relief valve in steering valve stuck open. Do relief cartridge leakage test in group 3.
No hydraulic functions Stuck open system relief valve. Replace relief valve.
steering normal Locked safety valve. Unlock safety valve.
Plugged pilot line filter. Inspect and replace.
Failed hydraulic pump. Remove and inspect the pump.
Low secondary pressure of RCV. Check the pressure and replace if nec-
essary.
5-17
Slow or hard steering Too much friction in the mechanical parts of Lubricate bearings and joints of steering
the machine. column or repair if necessary.
Check steering column installation.
Cold oil. Warm the hydraulic oil.
Low priority valve pressure setting. Do priority valve pressure test.
Clean or replace cartridge in steering valve.
Worn hydraulic pump. Do hydraulic pump performance check .
Sticking priority valve spool. Remove and inspect.
Broken priority valve spring. Remove and inspect.
C o n s t a n t s t e e r i n g t o Air in system. Check for foamy oil.
maintain straight travel
Leakage in steering system. Do steering system leakage check.
Worn steering unit. Do steering system leakage check.
Do steering unit neutral leakage test in
group 3.
Leaf spring without spring force or broken. Replace leaf springs.
Spring in double shock valve broken. Replace shock valve.
Gear wheel set worn. Replace gear wheel set.
Cylinder seized or piston seals worn. Replace defects parts.
S l o w s t e e r i n g w h e e l Leakage in steering unit gerotor. Do steering system leakage check.
movement will not cause
Worn steering unit gerotor. Do steering leakage check.
any frame movement
Steering wheel can be Leakage in steering system. Do steering system leakage check.
turned with frames
against steering stop
Steering wheel turns with Broken steering column or splined cou- Remove and inspect.
n o r e s i s t a n c e a n d pling.
causes no frame move-
Lack of oil in steering unit. Start engine and check steering operation.
ment
Leakage in steering system. Do steering system leakage test in group 3.
5-18
Erratic steering Air in oil. Check for foamy oil.
Low oil level. Add recommended oil.
Sticking priority valve spool. Remove and inspect spool.
Loose cylinder piston. Remove rod to inspect piston.
Damaged steering unit. Remove and inspect.
Spongy or soft steering Air in oil. Check for foamy oil.
Low oil level. Add recommended oil.
Free play at steer ing Loose steering wheel nut. Tighten.
wheel
Worn or damaged splines on steering col- Inspect.
umn or unit.
Steering unit binding or Binding in steering column or misalignment Inspect.
steering wheel does not of column.
immediately retur n to
High return pressure. Check for a pinched or damaged return
neutral when released
line.
Contamination in steering unit. Inspect hydraulic filter for contamination.
Repair cause of contamination. Flush
hydraulic system.
Large particles of contamination in steering Inspect hydraulic filter for contamination.
unit. Repair cause of contamination. Flush
hydraulic system.
Steering unit locks up Worn or damaged steering unit. Repair or replace steering unit.
Abrupt steering wheel Improperly timed gerotor gear in steering Time gerotor gear.
oscillation unit.
Steering wheel turns by Lines connected to wrong port. Reconnect lines.
itself
Vibration in steering sys- High priority valve setting. Do priority valve pressure test.
tem or hoses jump
Neutral position of steer- Steering column and steering unit out of Align the steering column with steering unit.
ing wheel cannot be line.
obtained, i.e. there is a
Too little or no play between steering col- Adjust the play and, if necessary, shorten
tendency towards
umn and steering unit input shaft. the splines journal.
"motoring"
Pinching between inner and outer spools. Contact the nearest service shop.
5-19
"Motoring" effect. Leaf springs are stuck or broken and have Replace leaf springs.
The steering wheel can therefore reduced spring force.
turn on its own.
Inner and outer spools pinch, possibly due Clean steering unit or contact the nearest
to dirt. service shop.
Return pressure in connection with the Reduce return pressure.
reaction between differential cylinder and
steering unit too high.
Oil is needed in the tank. Fill with clean oil and bleed the system.
Steering cylinder worn. Replace or repair cylinder.
Gear wheel set worn. Replace gear wheel set.
Spacer across cardan shaft forgotten. Install spacer.
5-20
Backlash Cardan shaft fork worn or broken. Replace cardan shaft.
Leaf springs without spring force or broken. Replace leaf springs.
Worn splines on the steering column. Replace steering column.
"Shimmy" effect. The Air in the steering cylinder. Bleed cylinder.
steered wheels vibrate. Find and remove the reason for air collec-
(Rough tread on tires tion.
gives vibrations)
Mechanical connections or wheel bearings Replace worn parts.
worn.
High priority valve setting pressure. Set pressure as regular value.
Steering wheel can be One or both shock valves are leaky or are Clean or replace defective of missing
turned slowly in one or missing in steering valve. valves.
both directions without
the steered wheels turn-
ing.
Steering is too slow and Insufficient oil supply to steering unit, pump Replace pump or increase number of revo-
heavy when trying to turn defective or number of revolutions too low. lutions.
quickly.
Relief valve setting too low. Adjust valve to correct setting.
Relief valve sticking owing to dirt. Clean the valve.
Spool in priority valve sticking owing to dirt. Clean the valve, check that spool moves
easily without spring.
Too weak spring in priority valve. Replace spring by a stronger.
"Kick back" in steering Fault in the system. Contact authorized man or shop.
wheel from system. Kicks
from wheels.
5-21
Heavy kick-back in steer- Wrong setting of cardan shaft and gear- Correct setting as shown in this manual.
ing wheel in both direc- wheel set.
tions.
urning the steering wheel Hydraulic hoses for the steering cylinders Connect lines to correct ports.
activates the steered have been switched around.
wheels opposite.
Hard point when starting Spring force in priority valve too weak. Replace spring by a stronger.
to turn the steering wheel
Oil is too thick (cold). Let motor run until oil is warm.
Too little steering force Pump pressure too low. Correct pump pressure.
(possibly to one side
Too little steering cylinder. Fit a larger cylinder.
only).
Piston rod area of the differential cylinder Fit cylinder with thinner piston rod or 2 dif-
too large compared with piston diameter. ferential cylinders.
Leakage at either input Shaft defective. Replace shaft seal.
shaft, end cover, gear-
Screws loose. Tighten screws.
wheel set, housing or top
part. Washers or O-rings defective. Replace.
5-22
1. HYDRAULIC OIL CLEAN UP PROCEDURE USING PORTABLE FILTER CADDY

※ Service equipment and tool.
·Portable filter caddy
·Two 3658 mm (12 ft) × 1" I.D. 100R1
hoses with 3/4 M NPT ends
·Quick disconnect fittings
·Discharge wand
·Various size fittings and hoses
※ Brake system uses oil from hydraulic oil
tank. Flush all lines in the steering sys-
tem.
Disassemble and clean major compon-
ents for steering system.
Steering components may fail if steering
system is not cleaned after hydraulic oil
tank contamination.
1) If hydraulic system is contaminated due to
a major component failure, remove and dis-
assemble steering cylinders to clean debris
from cylinders.
2) Install a new return filter element. Clean fil-
ter housing before installing new element.
※ For a failure that creates a lot of debris,
remove access cover from hydraulic oil
tank. Drain and clean hydraulic oil tank of
fill the specified oil to hydraulic oil tank
through upper cover.
3) To minimize oil loss, pull a vacuum in
hydraulic oil tank using a vacuum pump.
Connect filter caddy suction line to drain
port at bottom of hydraulic oil tank using
connector. Check to be sure debris has not
closed drain port.
4) Put filter caddy discharge line into hydraulic
oil tank filter hole so end is as far away from
drain port as possible to obtain a through
cleaning of oil.
5-23
5) Start the filter caddy. Check to be sure oil
is flowing through the filters.
Operate filter caddy approximately 10 min-
utes so oil in hydraulic oil tank is circulated
through filter a minimum of four times.
※ Hydraulic oil tank capacity 175ℓ(46 U.S.
gal).
Leave filter caddy operating for the next
steps.
6) Start the engine and run it at high idle.
※ For the most effective results, cleaning
procedure must start with the smallest
capacity circuit then proceed to the next
largest capacity circuit.
7) Operate all functions, one at a time, through
a complete cycle in the following order:
clam, steering, bucket, and boom. Also
include all auxiliary hydraulic functions.
Repeat procedure until the total system
capacity has circulated through filter caddy
seven times, approximately 30 minutes.
Each function must go through a minimum
of three complete cycles for a through
cleaning for oil.
※ Filtering time for machines with auxiliary
hydraulic functions must be increased
because system capacity is larger.
8) Stop the engine. Remove the filter caddy.
9) Install a new return filter element.
10) Check oil level in hydraulic oil tank ; Add oil
if necessary.
5-24
2. TEST TOOLS
1) CLAMP-ON ELECTRONIC TACHOMET-
ER INSTALLATION
· Service equipment and tools
B
Tachometer
A : Clamp on tachometer.
Remove paint using emery cloth and
C
connect to a straight section of injec-
tion line within 100 mm (4in) of pump.
Finger tighten only-do not over tighten. D
B : Black clip (-). Connect to main
frame. A
C : Red clip (+). Connect to transducer.
D : Tachometer readout. Install cable. 75795SE32
2) DIGITAL THERMOMETER INSTALLATION

· Service equipment and tools
Digital thermometer
A : Temperature probe.
Fasten to a bare metal line using a A
C
tie band. Wrap with shop towel.
B
B : Cable.
C : Digital thermometer.
75795SE33
3) DISPLAY MONITOR TACHOMETER

The display monitor tachometer is accurate
enough for test work. Unit
75793CD03
5-25
3. STEERING SYSTEM RESTRICTION TEST
· SPECIFICATION
Oil temperature 45±5˚C (113±9˚F)
Engine speed High idle
Maximum pressure 4.5MPa (45 bar, 640psi)
at steering valve (EHPS)
· GAUGE AND TOOL
Gauge 0~7 MPa (0~70 bar, 0~1000 psi) 2EA
· This test will check for restrictions in the
steering system which can cause overheat-
Steering pump
ing of hydraulic oil.
1) Install temperature reader.
(see temperature reader installation proce- Fitting
dure in this group).
2) Heat hydraulic oil to specifications.
(see hydraulic oil warm up procedure at
P
page 6-48).
3) Connect fitting and install gauge.
Do not operate steering or loader funct-
ions or test gauge may be damaged.
4) Run engine at specification and read pres-
sure gauges.
If pressure is more than specification at the
steering valve, inspect steering valve for a
priority valve spool. Make sure orifice
plugs installed in ends of priority valve spool. 7607SE24
5-26
4. STEERING UNIT LEAKAGE TEST
· SPECIFICATION
Maximum leakage 7.5ℓ/min (2 gpm)
· GAUGE AND TOOL Cap fitting
Temperature reader
T
Measuring container (approx. 20ℓ) L
R
Stop watch
1) Install frame locking bar to prevent machine
from turning.
(see temperature reader installation proce-
page 6-48).
4) Disconnect return hose from fitting.
Install cap fitting.
5) Run engine at specifications. Rotate
steering wheel against locking bar using
approximately 1.2 kgf·m of force.
Measure oil flow from return hose for 1
minute.
Safety lock bar
6) Leakage is greater than specifications,
repair or replace steering unit.
75795SE11
5-27
5. STEERING VALVE (EHPS) PRESSURE TEST
· SPECIFICATION
Oil pressure 21±0.5 MPa
(210±5 bar, 3050±72 psi)
· GAUGE AND TOOL Relief valve
Gauge 0~35 MPa (0~350 bar, 0~5000 psi)
CL
CR
Temperature reader
1) Connect gauge to test port.
2) Install temperature reader (see installation
procedure in this group).
3) Install frame locking bar.
4) Heat hydraulic oil to specifications (see
hydraulic oil warm up procedure at page
Test port
6-48).
5) Run engine at specifications and turn
steering wheel rapidly hold approximately
22N (5lb force) pressure on wheel with
frames locked.
※ If steering wheel is turned slowly, it will
continue to with the frames locked.
This will give an incorrect pressure read-
ing.
If steering wheel continues to turn rapidly
with the frames locked, steering system
leakage is indicated.
6) Read pressure gauge. This is the steering Safety lock bar
valve relief pressure.
7) If pressure in not to specification, turn
adjusting screw in relief cartridge using a
hex head wrench (6 mm) to adjust pressure.
If pressure cannot be adjusted to specifica-
tion, disassemble and inspect steering 75795SE12
valve.
5-28
6. STEERING VALVE (EHPS) RELIEF
CARTRIDGE LEAKAGE TEST
· SPECIFICATION
Engine speed High idle Relief valve
Maximum leakage 1mℓ/min (16 drops per min)
A
· GAUGE AND TOOL
Temperature reader T B
Ts
Measuring container
Stop watch
(see temperature reader installation proce-
page 6-48).
3) Install plug (A) in Ts port.
Disconnect line from T port on steering
valve. Install plug in line.
4) Connect line (B) to steering valve.
5) Start engine and run at specification.
6) Measure oil leakage from T port.
7607SE21
7) If leakage is more than specification, disas-
semble and inspect relief cartridge for dam-
age or debris.
5-29
1. STEERING UNIT
1) STRUCTURE
3 8
11
4
9
2
13
14
12
15
13
17
18
21
20
7607SE10
1 Dust seal 8 Ring 15 Gearwheel set

2 Housing, spool, sleeve 9 Cross pin 17 End cover
3 Ball 11 Cardan shaft 18 Washer
4 Thread bushing 12 Set of springs 20 Screw with pin
5 O-ring 13 O-ring 21 Screw
7 Bearing assembly 14 Distributor plate
5-30
2) TOOLS
(1) Holding tool + Guide ring
7607SE08
(2) Assembly tool for O-ring and kin-ring.
7607SE09
(3) Assembly tool for lip seal.
(780-3A) 5-69(3)
(4) Assembly tool for cardan shaft.
(780-3A) 5-69(4)
5-31
(5) Assembly tool for dust seal.
(780-3A) 5-70(1)
(6) Torque wrench 0~7.1 kgf·m

(0~54.4 lbf·ft)
13 mm socket spanner
6, 8 mm and 12 mm hexagon sockets
12 mm screwdriver
2 mm screwdriver
13 mm ring spanner
6, 8 and 12 mm hexagon socket spanners
Plastic hammer
(780-3A) 5-70(2)
Tweezers
5-32
3) TIGHTENING TORQUE AND HYDRAULIC CONNECTIONS
(1) Hydraulic connections
L: Left port
R: Right port
T: Tank
TLPR
P: Pump
(780-3A) 5-71
(2) Tightening torque

Max. tightening torque [ kgf·m (lbf·ft) ]
Screwed
connection With cutting With copper With aluminum With O - ring
edge washer washer
1/4 BSP.F 4.1 (29.7) 2.0 (14.5) 3.1 (22.4) -
3/8 BSP.F 6.1 (44.1) 2.0 (14.5) 5.1 (36.9) -
1/2 BSP.F 10.2 (73.8) 3.1 (22.4) 8.2 (59.3) -
7/16-20 UNF - 2.0 (14.5) - -
3/4-16 UNF - 6.1 (44.1) - -
M 12×1.5 4.1 (29.7) 2.0 (14.5) 3.1 (22.4) 2.0 (14.5)
M 18×1.5 7.1 (51.4) 2.0 (14.5) 5.1 (36.9) 5.1 (36.9)
M 22×1.5 10.2 (73.8) 3.1 (22.4) 8.2 (59.3) 7.1 (51.4)
5-33
4) DISASSEMBLY
(1) Disassemble steering column from
steering unit and place the steering unit in
the holding tool.
Screw out the screws in the end cover (6-
off plus one special screw).
(780-3A) 5-72(1)
(2) Remove the end cover, sideways.
(780-3A) 5-72(2)
(3) Lift the gearwheel set (with spacer if

fitted) off the unit.
Take out the two O-rings.
(780-3A) 5-72(3)
(4) Remove cardan shaft.
(780-3A) 5-72(4)
5-34
(5) Remove distributor plate.
(780-3A) 5-73(1)
(6) Screw out the threaded bush over the

check valve.
(780-3A) 5-73(2)
(7) Remove O-ring.
(780-3A) 5-73(3)
(8) Take care to keep the cross pin in the

sleeve and spool horizontal. The pin can
be seen through the open end of the
spool. Press the spool inwards and the
sleeve, ring, bearing races and needle
bearing will be pushed out of the housing
together.
(780-3A) 5-73(4)
5-35
(9) Take ring, bearing races and needle
bearing from sleeve and spool. The outer
(thin) bearing race can sometimes "stick"
in the housing, therefore check that it has
come out.
(780-3A) 5-74(1)
(10) Press out the cross pin. Use the special

screw from the end cover.
(780-3A) 5-74(2)
※ A small mark has been made with a

pumice stone on both spool and sleeve
close to one of the slots for the neutral
position springs (see drawing).
If the mark is not visible, remember to
leave a mark of your own on sleeve and
spool before the neutral position springs
are disassembled.
(780-3A) 5-74(3)
(11) Carefully press the spool out of the sleeve.
(780-3A) 5-74(4)
5-36
(12) Press the neutral position springs out of
their slots in the spool.
(780-3A) 5-75(1)
(13) Remove dust seal and O-ring.
(780-3A) 5-75(2)
(14) The steering unit is now completely

disassembled.
(780-3A) 5-75(3)
※ Cleaning
Clean all parts carefully in Shellsol K or
the like.
※ Inspection and replacement
Replace all seals and washers. Check all
par ts carefully and make any
replacements necessary.
※ Lubrication
Before assembly, lubricate all parts with
hydraulic oil.
5-37
(1) Place the two flat neutral position springs
in the slot.
Place the curved springs between the flat
ones and press them into place.
7607SE06
(2) Line up the spring set.
(780-3A) 5-76(4)
(3) Assemble the spool/sleeve and make sure

the marks on spool and sleeve are
opposite each other (see drawing page
5-36).
(780-3A) 5-76(1)
(4) Press the springs together and push the

neutral position springs into place in the
sleeve.
(780-3A) 5-77(2)
5-38
(5) Line up the springs and center them.
(780-3A) 5-77(3)
(6) Guide the ring down over the sleeve.

※ The ring should be able to move-free of
the springs.
(780-3A) 5-77(4)
(7) Fit the cross pin into the spool / sleeve.
(780-3A) 5-78(1)
(8) Fit bearing races and needle bearing.

(See the next page)
(780-3A) 5-78(2)
5-39
※ Assembly pattern for standard bearings
1
1 Outer bearing race 2
2 Needle bearing 3
3 Inner bearing race
4 Spool
5 Sleeve * 4
* The inside chamfer on the inner bearing

race must face the inner spool. 5
7607SE07
Installation instruction for O-ring

(9) Turn the steering unit until the bore is
horizontal. Guide the outer part of the
assembly tool into the bore for the spool /
sleeve.
(780-3A) 5-78(4)
(10) Grease O-ring with hydraulic oil and place

them on the tool.
(780-3A) 5-79(1)
(780-3A) 5-79(2)
5-40
(11) Hold the outer part of the assembly tool in
the bottom of the steering unit housing
and guide the inner part of the tool right to
the bottom.
(780-3A) 5-79(3)
(12) Press and turn the O-ring into position in

the housing.
(780-3A) 5-79(4)
(13) Draw the inner and outer parts of the

assembly tool out of the steering unit
bore, leaving the guide from the inner part
in the bore.
(780-3A) 5-80(1)
Installation instructions for lip seal

(14) Lubricate the lip seal with hydraulic oil and
place it on the assembly tool.
(780-3A) 5-80(2)
5-41
(780-3A) 5-80(3)
(15) Guide the assembly tool right to the

bottom.
(780-3A) 5-80(4)
(16) Press and turn the lip seal into place in

the housing.
(780-3A) 5-81(1)
(17) With a light turning movement, guide the

spool and sleeve into the bore.
※ Fit the spool set holding the cross pin
horizontal.
(780-3A) 5-81(2)
5-42
(18) The spool set will push out the assembly
tool guide. The O-ring are now in position.
(780-3A) 5-81(3)
(19) Turn the steering unit until the bore is

vertical again. Put the check valve ball
into the hole indicated by the arrow.
(780-3A) 5-81(4)
(20) Screw the threaded bush lightly into the

check valve bore. The top of the bush
must lie just below the surface of the
housing.
(780-3A) 5-82(1)
(21) Grease the O-ring with mineral oil approx.

viscosity 500 cSt at 20˚C.
(780-3A) 5-82(2)
5-43
(22) Place the distributor plate so that the
channel holes match the holes in the
housing.
(780-3A) 5-82(3)
(23) Guide the cardan shaft down into the bore

so that the slot is parallel with the
connection flange.
(780-3A) 5-82(4)
(24) Place the cardan shaft as shown - so that

it is held in position by the mounting fork.
(780-3A) 5-83(1)
(25) Grease the two O-rings with mineral oil

approx. viscosity 500 cSt at 20˚C and
place them in the two grooves in the gear
rim. Fit the gearwheel and rim on the
cardan shaft.
(780-3A) 5-83(2)
5-44
(26) Important
Fit the gearwheel (rotor) and cardan shaft
so that a tooth base in the rotor is
positioned in relation to the shaft slot as
shown.
Turn the gear rim so that the seven
through holes match the holes in the
housing.
(780-3A) 5-83(3)
(27) Fit the spacer, if any.
(780-3A) 5-83(4)
(28) Place the end cover in position.
(780-3A) 5-84(1)
(29) Fit the special screw with washer and

place it in the hole shown.
(780-3A) 5-84(2)
5-45
(30) Fit the six screws with washers and insert
them. Cross-tighten all the screws and
the rolled pin.
·Tightening torque : 3.1±0.6 kgf·m
(22.4±4.3 lbf·ft)
(780-3A) 5-84(3)
(31) Place the dust seal ring in the housing.
(780-3A) 5-84(4)
(32) Fit the dust seal ring in the housing using

special tool and a plastic hammer.
(780-3A) 5-85(1)
(33) Press the plastic plugs into the connection

ports.
※ Do not use a hammer!
(780-3A) 5-85(2)
5-46
2. STEERING CYLINDER
1) STRUCTURE
5,4 3 12 7,6 8 11,10 9 2 1 13 17 20 14 15 16 18,19
7579S5SE05
1 Tube assembly 8 Buffer ring 15 Wear ring

2 Rod assembly 9 Du bushing 16 Nylon nut
4 Dust wiper 11 Back up ring 18 Spherical bearing
5 Retaining ring 12 O-ring 19 Retaining ring
6 Rod seal 13 Piston 20 O-ring
7 Back up ring 14 Piston seal
5-47
2) TOOLS AND TIGHTENING TORQUE
(1) Tools
Tool name Remark
Wrench For gland
(-) Driver Small and large sizes
Torque wrench Capable of tightening with the specified torques
(2) Tightening torque

Torque
Part name Item Size
kgf·m lbf·ft
Gland 3 M75×2 70±7 506±50.6
Piston 16 M27×2 75±8 542±57.9
5-48
3) DISASSEMBLY
(1) Remove cylinder head and piston rod
① Hold the clevis section of the tube in a
vise.
※ Use mouth pieces so as not to damage
the machined surface of the cylinder
tube. Do not make use of the outside
piping as a locking means.
② Pull out piston rod (2) about 200 mm (7.8

in). Because the piston rod is rather
heavy, finish extending it with air
pressure after the oil draining operation. mm
0
20
7577ASE30
③ Loosen and remove the gland (3).

※ Cover the extracted piston rod (2) with
rag to prevent it from being accidentally
damaged during operation.
3
2
7577ASE31
④ Draw out gland (3) and piston rod (2)

assembly together from cylinder tube (1). 1
※ Since the piston rod assembly is heavy Lift
in this case, lift the tip of the piston rod
(2) with a crane or some means and
draw it out. However, when piston rod 3
(2) has been drawn out to 2
Oil pan
approximately two thirds of its length, lift Pull straight
it in its center to draw it completely. sideways
7577ASE39
5-49
※ Note that the plated surface of piston rod
(2) is to be lifted. For this reason, do not
use a wire sling and others that may
damage it, but use a strong cloth belt or
a rope.
⑤ Place the removed piston rod assembly

on a wooden V-block that is set level.
※ Cover a V-block with soft rag.
Piston rod assy
Wooden block
75795SE40
(2) Remove piston and gland assembly

① Remove the piston nut (16).
17 13 16
② Remove piston assembly (13) and
O-ring (17).
7577S5SE20
③ Remove the gland (3) assembly from

Lift with a crane
piston rod (2).
※ If it is too heavy to move, move it by Plastic 5,4 7,6 8 9
striking the flanged part of gland (3) with hammer
a plastic hammer. Pull straight
※ Pull it straight with gland assembly lifted
with a crane.
Exercise care so as not to damage the
lip of rod bushing (9) and packing (4, 5, 3
2 7577S5SE21
6, 7, 8) by the threads of piston rod (2).
5-50
(3) Disassemble the piston assembly
① Remove wear ring (15) and piston seal 17 14 15
(14).
Remove O-ring (17).
※ Exercise care in this operation not to
damage the grooves.
7577S5SE22
(4) Disassemble gland assembly

① Remove back up ring (11), and O-ring 5,4 12 7,6 8 11,10
(10).
② Remove O-ring (12).
③ Remove snap ring (5) and dust wiper (4).
④ Remove back up ring (7), rod seal (6)
and buffer ring (8).
※ Exercise care in this operation not to
damage the grooves.
75795SE23
※ Do not remove seal and ring, if does not
damaged.
5-51
4) ASSEMBLY
(1) Assemble gland assembly
※ Check for scratches or rough surfaces if
found smooth with an oil stone.
① Coat the inner face of gland (3) with
hydraulic oil.
7607B5SE34
② Coat dust wiper (4) with grease and fit

Press here(Straight down)
dust wiper (4) to the bottom of the hole of
dust wiper. Metal
At this time, press a pad metal to the 4
metal ring of dust seal.
③ Fit retaining ring (5) to the stop face.
7607B5SE24
④ Fit back up ring (7) and rod seal (6), and

buffer ring (8) to corresponding grooves,
in that order.
※ Coat each packing with hydraulic oil
Wrong Right
before fitting it.
※ Insert the backup ring until onside of it is
inserted into groove.
7577ASE42
※ Rod seal (6) has its own fitting direction.

Therefore, confirm it before fitting them. Push bar
※ Fitting rod seal (6) up side down may
damage its lip. Therefore check the
correct direction that is shown in figure.
7577ASE43
5-52
⑤ Fit back up ring (11) to gland (3).
※ Put the back up ring in the warm water of 12 3 11,10 9
30~50˚C.
⑥ Fit O-ring (10, 12) to gland (3).
⑦ Fit bushing (9) to gland (3).
7607B5SE26
(2) Assemble piston assembly

※ Check for scratches or rough surfaces.
① If found smooth with an oil stone.
Coat the outer face of piston (13) with
hydraulic oil.
13
7577S5SE27
② Fit piston seal (14) to piston.

※ Put the piston seal in the warm water of
60~100˚C for more than 5 minutes. 14
※ After assembling the piston seal, press
its outer diameter to fit in.
7577S5SE28
③ Fit wear ring (15) to piston (13).

④ Fit O-ring (17) to piston (13). 17 15
13
7577S5SE36
5-53
(3) Install piston and gland assembly
① Fix the piston rod assembly to the work Grand assembly
bench. Piston rod
② Apply hydraulic oil to the outer surface of
piston rod (2), the inner surface of piston
and gland (3).
③ Insert gland assembly to piston rod (2).
7577S5SE37
④ Fit piston assembly to piston rod (2).

⑤ Tighten the piston nut (16) to piston rod 2 Piston assy 16
(2).
· Tightening torque : 75±8 kgf·m
(542±57.9 lbf·ft)
7577S5SE26
(4) Overall assembly

Fix with a bar
① Place a V-block on a rigid work bench.
Mount the cylinder tube assembly on it
Lift
and fix the assembly by passing a bar
through the clevis pin hole to lock the
assembly. Straight
② Insert the piston rod assembly in to the
cylinder tube assembly, while lifting and
moving the piston rod assembly with a Apply liquid packing
7577ASE46
crane.
※ Be careful not to damage piston seal by
thread of cylinder tube.
③ Fit gland to the tube.
Tube
·Tightening torque : 70±7 kgf·m
(506±50.6 lbf·ft) Piston rod
Wrench
Gland
7577ASE38
5-54
3. CENTER PIVOT PIN
1) CONSTRUCTION
Figure shows the construction of the center pivot pin assembly. This assembly serves to connect
the front frame with the rear frame; two sets of assemblies are provided, one each for the upper
and lower parts. The numbers in parentheses following the parts name denote the item numbers
shown in the figure in the disassembly and assembly procedures.
8 12,13 11 6 5 21
10
16
18,13
2
1
3,4 20
20 17
1
3,4
8 7
14,15
21 9 16 12,13
UPPER LOWER
7579S5SE15
1 Bearing 8 Plate 15 Shim (0.5T)

2 Cover 9 Pin 16 Bushing
3 Shim (0.1T) 10 Seal 17 Cover
4 Shim (0.5T) 11 Seal 18 Hexagon bolt
5 Pin 12 Hexagon bolt 20 Front frame
6 Collar 13 Hardened washer 21 Rear frame
7 Collar 14 Shim (0.1T)
5-55
2) DISASSEMBLY
After supporting the front frame and the
rear frame as horizontally as possible using
wood blocks and jacks, disassemble as
fo l l o w s : I n o r d e r t o fa c i l i t a t e t h e
disassembly/assembly of the center pivot
pins, remove the drive shaft, hydraulic line
and steering cylinder first.
(1) Maintain the horizontal level of front frame
(20) and rear frame (21), and then 12
8
remove hexagon bolt (12) and plate (8).
(2) Take out upper pin (9) to the downside
using a metal punch. 20
21
7579S5SE16
(3) Maintain the front frame horizontal level,

remove hexagon bolts (12) and then 5
21
remove the plate (8) and shims (14, 15).
(4) Take out lower pin (6) to the upside using
a metal punch carefully.
20
(5) Jack up or lifting the front frame (20) 7
slightly, the collar (7) protrudes over the
rear frame. 8
Remove the collar (7). 14,15
12
(6) Lift the frame by passing the slinging wire 7579S5SE17
rope at four positions of front frame, in
order to separate it from the rear frame.
(7) Support the front frame safely.
5-56
(8) Remove bolt (18) and then take out cover
(2) and shims (3, 4). 18 11 2
(9) Take out dust seal (11) from the cover (2).
3,4
(10) Remove the bearing (1), and dust seal
(11).
1
11
7579S5SE18
(11) Remove bolt (18) and then take out cover

(17) and shims (3, 4). 10 6
(12) Take out the dust seal (10) from the cover 1
(17).
(13) Remove the bearing (1), collar (6) and
dust seal (10). 3,4
17 10 18
7579S5SE19
3) INSPECTION
(1) Check the bearing sliding surface for excessive wear, scorching or scratches; replace if
necessary.
(2) Replace all dust seals (10, 11) with new ones.
(3) Grind any pins (5, 9) dented with an oilstone or replace any pins abrasive excessively.
(4) Check inside cover (2, 17) and collar (6, 7) for dents or scratches; if any damage is found, correct
with a grinder or replace.
(5) The serviceable limit of pins and bushings is shown in the table below.
Unit : mm
Std Serviceable limit
Item No. Name Remedy
dimension Outer dia Inner dia Clearance
6, 10 Pin 74.5
1 Tapered roller bearing 75 75.5 0.8 Replace
7, 8 Collar 75.5
12, 13 Dust seal When removed Replace
5-57
4) ASSEMBLY
8 12,13 11 6 5 21
10
16
18,13
2
1
20
3,4
Clearance A
3,4
1 20
17
8 7
14,15
21 9 16 12,13
UPPER LOWER
7579S5SE20
Assemble the center pivot group by reversing the order of disassembly while paying close attention
to the following.
(1) Put the dust seal (10, 11) into cover (2, 17) and front frame (20).
※ Apply grease to the lip of the dust seal. Insert the dust seal so that the dust seal lip faces out and
punch four places on the outer circumference of the seal to lock it.
(2) Lower the temperature of the lower bearing cup to -75±5˚C (-103±9˚F ) and install it to front
frame until it contacts the bottom of the frame.
(3) Coat lightly with oil and install lower bearing in bore in front frame. Coat lightly with oil and install
upper bearing in bore in upper front frame.
(4) Position the cover (2, 17) and hold in place with bolt (12). At this time, adjust shims (3, 4) to press
the shoulder of bearing (1) against retainer.
ㆍ Adjustment method of clearance A
① Install bearing and cover without shim (3, 4)
Install four of bolt (12) so that each bolt is seperated by 90 degrees.
ㆍTightenig torque : 0.8~1.0 kgfㆍm (5.8~7.2 lbfㆍft)
② Adjust shims in order to control the clearance A.
ㆍClearance A : Below 0.1 mm
ㆍShim thickness : 0.1 mm, 0.5 mm
5-58
(5) Apply grease to lower collar (7) and insert it to the lower of roller bearing.
(6) After setting the bearing so that its upper surface is horizontal, tighten the all the bolt (14).
After tightening, confirm that tapered roller bearing moves lightly ; if does not move smoothly, add
shims (3, 4).
ㆍTightening Torque : 9.8~15.8 kgfㆍm (70.9~114lbfㆍft)
ㆍApply loctite #243.
(7) Move the front frame and join it to the rear frame so that match the pin hole at the center.
(8) Apply grease to pin (9), bushing (16) and insert it into tapered roller bearing (1).
(9) Apply grease to lower collar (7) and insert it to the lower of roller bearing through rear frame (21).
(10) Apply grease to pin (5) and insert it into tapered roller bearing (1).
(11) Before tightening bolt (12), adjust shims (14, 15) in order to control the clearance between the
plate (8) and rear frame (21).
ㆍAdjustment method of clearance B
① Install pin (5) and plate (8) without shim (14, 15).
Install four of bolt (14) so that each bolt is seperated by 90 degrees.
ㆍTighting torque : 0.8~1.0 kgfㆍm (5.8~7.2 lbfㆍft)
② Adjust shims in order to control the clearance B.
ㆍClearance B : 0.1~0.2 mm
ㆍShim thickness : 0.1 mm, 0.5 mm
(12) Tighten the all the bolts (12).
ㆍTightening Torque : 9.8~15.8 kgfㆍm (70.9~114 lbfㆍft)
ㆍApply loctite #243.
5) TROUBLESHOOTING
Trouble Probable cause Remed
Shock is felt when steering Capscrew for fixing steering valve is loose Retighten
Faulty center pivot pin mounting bolts Retighten
Center pivot pins have worn out Readjust or replace
Faulty hydraulic system See hydraulic system
Shock is felt when moving Fault fixing of connecting capscrews Retighten
backward or forward
Center pins have worn out Readjust or replace
Bearings of support unit have worn out Retighten
Drive shaft damaged See drive system
Faulty transmission See transmission system
5-59
Group 1 Structure and Function ----------------------------------------------------------------------------------- 6-1

Group 2 Operational Checks and Troubleshooting ----------------------------------------------------- 6-33
Group 3 Tests and Adjustments ----------------------------------------------------------------------------------- 6-44
Group 4 Disassembly and Assembly --------------------------------------------------------------------------- 6-59
1. HYDRAULIC SYSTEM OUTLINE

The loader hydraulic system is a pilot operated, open center system which is supplied with flow from
the fixed displacement main hydraulic pump.
The polit control system is a low pressure, closed center hydraulic system which is supplied with flow
from the first(steering) pump.
The loader system components are :
·Main pump
·Main control valve
·Bucket cylinder
·Boom cylinders
·Pilot supply unit
·Remote control valve (Pilot control valve)
·Safety valve
The pilot supply unit consists of the pressure reducing valve, relief valve and accumulator.
Flow from the main hydraulic pump not used by the steering system leaves the steering valve EF
port.
It flows to the inlet port plate of mono block type main control valve.
The main control valve is open center system which routes flow to the boom, bucket or auxiliary
cylinders (not shown) when the respective spools are shifted.
Flow from the steering pump is routed to the pilot supply unit where the steering pump outlet
pressure is reduced to pilot circuit pressure. The pilot supply unit control valve flow to the remote
control valve.
The remote control valve routed flow to either end of each spool valve section in the main control
valve to control spool stroke.
A accumulator mounted on pilot supply unit supplies a secondary pressure source to operated
remote control valve so the boom can be lowered if the engine is off.
The return circuit for the main hydraulic system have return filter inside the hydraulic tank. The return
filter uses a filter element and a bypass valve. The bypass valve is located in the upside of filter.
6-1
FRONT
AXLE
LH
10 RH
11 12 30
REAR
31
33
LH RH
Sp
4 T P
B.D/F B.U IN OUT
18 PS 6 CL CR
T
A B
BL1 BR1 BL2 BR2
8
32 PS 1 3 4 2 1.1 2.1
L
40 T1 P1 T2 P2
R 3 T
T/M
B3
A3 BOOM UP BOOM DOWN

b3
17 17 Ps
a3
B2 15
Ts
16 7 A2 ROLL BACK DUMP A

B1 A1 B2 A2
EF P LS T b2
a2
A3 L R
19 5
F2
PS
14
PS
T1 B1
A1 AUX
B b1
a1 F1
PS1
PS
19 U 13
P T
P
20 P T
T
P1 P2
2 1
29 23
PS
28 M1
A
29 M2
P1
24 T P
26 21 C
PS
25
P2
27 22
M
7579S6WE01
1 Main pump 13 Pilot supply unit 24 Hydraulic tank

2 Fan & brake pump 14 Line filter 25 Return filter
3 Main control valve 15 Safety valve 26 Bypass valve
4 Remote control valve 16 Accumulator 27 Pump motor (opt)
5 Steering unit 17 Accumulator 28 Check valve (opt)
6 Steering valve 18 Pressure sensor 29 Pressure sensor (opt)
7 Cut off valve 19 Pressure sensor 30 Ride control valve (opt)
8 Brake valve 20 Line filter 31 Accumulator (opt)
10 Steering cylinder 21 Oil cooler 32 Pressure sensor (opt)
11 Bucket cylinder 22 Fan motor 33 Cushion valve
12 Boom cylinder 23 Air breather 40 Parking brake on T/M
6-2
3. WORK EQUIPMENT HYDRAULIC CIRCUIT
11 12 4 T P
B.D/F B.U IN OUT
LH RH
1 3 4 2 1.1 2.1
3 T
B3

b3
a3
B2
15
A2 ROLL BACK DUMP A
b2
a2
F2
B1 14
A1 AUX.
b1
a1 F1
U 13
P
T
Steering valve(EHPS) EF port
P1 P2
Steering system
Brake system
1
Return line
23
24 T P
26 21 C
25
22
7579S6WE02
1 Main pump 13 Pilot supply unit 24 Hydraulic tank

3 Main control valve 14 Line filter 25 Return filter
4 Remote control valve 15 Safety valve 26 Bypass valve
11 Bucket cylinder 21 Oil cooler
12 Boom cylinder 23 Air breather
6-3
1) WHEN THE RCV LEVER IS IN THE RAISE POSITION
11 12 4 T P
B.D/F B.U IN OUT
LH RH
1 3 4 2 1.1 2.1
3 T
B3

b3
a3
B2
15
A2 ROLL BACK DUMP A
b2
a2
F2
B1 14
A1 AUX.
b1
a1 F1
U 13
P
T
P1 P2
Steering system
Brake system
1
Return line
23
24 T P
26 21 C
25
7579S6WE03
· When the RCV lever (4) is pulled back, the boom spool is moved to raise position by pilot oil
pressure from port 3 of RCV.
· The oil from main pump (1) flows into main control valve (3) and then goes to the large chamber of
boom cylinder (12) by pushing the load check valve of the boom spool.
· The oil from the small chamber of boom cylinder (12) returns to hydraulic oil tank (24) through the
boom spool at the same time.
· When this happens, the boom goes up.
6-4
2) WHEN THE RCV LEVER IS IN THE LOWER POSITION
11 12 4 T P
B.D/F B.U IN OUT
LH RH
1 3 4 2 1.1 2.1
Make up valve
3 T
B3

b3
a3
B2
15
A2 ROLL BACK DUMP A
b2
a2
F2
B1 14
A1 AUX.
b1
a1 F1
U 13
P
T
P1 P2
Steering system
Brake system
1
Return line
23
24 T P
26 21 C
25
7579S6WE04
· When the RCV lever (4) is pushed forward, the boom spool is moved to lower position by pilot
pressure.
· The oil from main pump (1) flows into main control valve (3) and then goes to small chamber of
boom cylinder (12) by pushing the load check valve of the boom spool.
· The oil returned from large chamber of boom cylinder (12) returns to hydraulic tank (24) through
the boom spool at the same time.
· When the lowering speed of boom is faster, the return oil from the large chamber of boom cylinder
combines with the oil from the pump through the make up valve, and flows into the small chamber
of the cylinder.
This prevents cylinder cavitation by the negative pressure when the pump flow cannot match the
boom down speed.
6-5
3) WHEN THE RCV LEVER IS IN THE FLOAT POSITION
11 12 4 T P
B.D/F B.U IN OUT
LH RH
1 3 4 2 1.1 2.1
3 T
B3

b3
a3
B2
15
A2 ROLL BACK DUMP A
b2
a2
F2
B1 14
A1 AUX.
b1
a1 F1
U 13
P
T
P1 P2
Steering system
Brake system
1
Return line
23
24 T P
26 21 C
25
7579S6WE05
· When the RCV lever (4) is pushed further forward from the lower position, the pilot pressure
reaches to 13~15bar, then the boom spool is moved to floating position.
· The work ports (A3), (B3) and the small chamber and the large chamber are connected to the
return passage, so the boom will be lowered due to it's own weight.
· In this condition, when the bucket is in contact with the ground, it can be move up and down in
accordance with the shape of the ground.
6-6
4) WHEN THE RCV LEVER IS IN THE DUMP POSITION
11 12 4 T P
B.D/F B.U IN OUT
LH RH
1 3 4 2 1.1 2.1
3 T
B3

b3
a3
B2
15
A2 ROLL BACK DUMP A
b2
a2
F2
B1 14
A1 AUX.
b1
a1 F1
U 13
P
T
P1 P2
Steering system
Brake system
1
Return line
23
24 T P
26 21 C
25
7579S6WE06
· If the RCV lever (4) is pushed right, the bucket spool is moved to dump position by pilot oil pressure
from port 2 of RCV.
· The oil from main pump (1) flows into main control valve (3) and then goes to the small chamber of
bucket cylinder (11) by pushing the load check valve of the bucket spool.
· The oil at the large chamber of bucket cylinder (11) returns to hydraulic tank (24).
· When this happens, the bucket is dumped.
· When the dumping speed of bucket is faster, the oil returned from the large chamber of bucket
cylinder combines with the oil from the pump, and flows into the small chamber of the cylinder.
This prevents cylinder cavitation by the negative pressure when the pump flow cannot match the
bucket dump speed.
6-7
5) WHEN THE RCV LEVER IS IN THE ROLL BACK (retract) POSITION
11 12 4 T P
B.D/F B.U IN OUT
LH RH
1 3 4 2 1.1 2.1
3 T
B3

b3
a3
B2
15
A2 ROLL BACK DUMP A
b2
a2
F2
B1 14
A1 AUX.
b1
a1 F1
U 13
P
T
P1 P2
Steering system
Brake system
1
Return line
23
24 T P
26 21 C
25
7579S6WE07
· If the RCV lever (4) is pulled left, the bucket spool is moved to roll back position by pilot oil pressure
from port 4 of RCV.
· The oil from main pump (1) flows into main control valve (3) and then goes to the large chamber of
bucket cylinder by pushing the load check valve of the bucket spool.
· The oil at the chamber of bucket cylinder (11) returns to hydraulic tank (24).
· When this happens, the bucket roll back.
6-8
6) WHEN THE RCV LEVER IS IN THE HOLD POSITION
11 12 4 T P
B.D/F B.U IN OUT
LH RH
1 3 4 2 1.1 2.1
3 T
B3

b3
a3
B2
15
A2 ROLL BACK DUMP A
b2
a2
F2
B1 14
A1 AUX.
b1
a1 F1
U 13
P
T
P1 P2
Steering system
Brake system
1
Return line
23
24 T P
26 21 C
25
7579S6WE08
· The oil from main pump (1) flows into main control valve (3)
In this time, the bucket spool, the boom spool and the boom float spool are in neutral position, then
· the oil supplied to main control valve (3) returns into hydraulic tank (24) through center bypass
circuit of each spool.
· In this condition, each cylinder keeps the neutral position, so the boom and the bucket is holded.
6-9
4. MAIN PUMP
1) STRUCTURE
21
20
4
3 5
23
13
11 12 P2
22
19
15
8
7 14
6
S
17
18
P1
9
16
8 15
7 14
6 13
12
11
10
S Inlet 2 1/2" SAE
P1, P2 Outlet 1" SAE
1
2 7607S6WE29
1 Shaft seal 9 Front drive gear 17 Spline coupling

2 Adapter 10 Front driven gear 18 Rear driven gear
3 Washer 11 Wearplate 19 Rear drive gear
4 Bolt 12 O-ring seal 20 Stud
5 Flange 13 Back up seal 21 Flanged nut
6 Back up seal 14 Interface seal 22 Rear body
7 O-ring seal 15 Dowel 23 O-ring
8 Wearplate 16 Front body
6-10
2) OPERATION
The main hydraulic pump is a fixed displacement gear type pump. The pump is drive at engine
speed by the transmission. The pump shafts are supported by shaft seal (1) adapter (2), front body
(16) and rear body (22). The wearplate (8, 11) are located between the gear surface and adapter
(1), rear body (22) and front body (16).
As the drive gear (9) and (19) turns the idler gears (10, 18), the gear teeth come out of mesh. Oil
flows from the hydraulic tank through the inlet into the cavity between the gear teeth. As the gears
continue to rotate, the oil becomes trapped between the gear teeth and front body (16).
The trapped oil is then carried to the pump outlet. Oil is forced out the outlet to supply the hydraulic
function. As the gears re-mesh, they form a seal to prevent oil from flowing between the gears and
back to the inlet.
The pump uses outlet pressure oil to load the wearplate (8, 11) against the gear faces. This
controls internal leakage to maintain pump displacement.
Outlet pressure fills the area bounded by the pressure balance moulded seals (6, 7) to force the
wearplate against the high pressure area or the gear faces.
6-11
5. REMOTE CONTROL VALVE
1) STRUCTURE
33 34 30 31
29
20 32
24 25
23 27
22 26
21 28
18 17
19 16
14 15
9 13
5 11
4 12
8 10
7 3
6 2
44
43 1,35
42 45
38,39,40,41 36,37,38,39
7607B6WE28
1 Body 16 Bushing 31 Nut

2 O-ring 17 Rod 32 Boot
3 Plug 18 Magnet 33 Handle assy
4 Spring 19 Plate 34 Nut
5 Spring seat 20 Joint assy 35 Plug
6 Spool 21 Joint assy 36 6 pin connector
7 Spring seat 22 Plate 37 Rear holder
8 Spring 23 Washer 38 Terminal
9 Stopper 24 Nut 39 Seal wire
10 Plug 25 Plug 40 2 pin connector
11 Rod seal 26 Nut 41 Rear holder
12 O-ring 27 Set screw 42 Clip band
13 Push rod 28 Nut 43 Connector
14 Plate 29 Nut 44 O-ring
15 Rod stopper 30 Handle bar 45 O-ring
6-12
2) OPERATION
T P
B.D/F B.U IN OUT
33
1 34 2
HYDRAULIC CIRCUIT
(3 Electromagnetic locks)
32
Electromagnetic lock
21
17
18
13
(1) Hydraulic functional principle 8
Pilot devices with end position locks operate as
direct operated pressure reducing valves. 4
They basically comprise of handle (33), four
pressure reducing valves, body (1) and locks. 6
Each pressure reducing valve comprises of a
control spool (6), a control spring (8), a return 1
spring (4), push rod (13) and rod (17).
At rest, handle (33) is held in its neutral position by
return springs (4). Ports (1, 2, 3, 4) are connected 7607B6WE27
to tank port T via drilling.

When handle (33) is deflected, rod (17) is pressed against return spring (4) and control spring (8).
Control spring (8) initially moves control spool (6) downwards and closes the connection between
the relevant port and tank port T. At the same time the relevant port is connected to port P via
drilling. The control phase starts as soon as control spool (6) finds its balance between the force
from control spring (8) and the force, which results from the hydraulic pressure in the relevant port
(ports 1, 2, 3 or 4).
Due to the interaction between control spool (6) and control spring (8) the pressure in the relevant
port is proportional to the stroke of rod (17) and hence to the position of handle (33).
This pressure control which is dependent on the position of the handle (33) and the
characteristics of the control spring permits the proportional hydraulic control of the main
directional valves and high response valves for hydraulic pumps.
A rubber boot (32) protects the mechanical components in the housing from contamination.
6-13
(2) End position lock
Only those control ports, for which it is necessary to hold the handle in a deflected position are
equipped with end position locks.
Electromagnetic lock
When this threshold is overcome, a joint assy (21) contacts the magnet (18); if the magnet (18) is
energized, then handle (33) is held in its end position by magnetic force.
This lock is released automatically when the solenoid is deenergized.
6-14
6. MAIN CONTROL VALVE
1) STRUCTURE
16
17
24
19
18
30
3
19
15
20
24
2
1
20
20
21
22
23
14 16
19 17
21
22
37 23
32 20
25
26 31 19
28 33
25
36 27 28 26
7607B6WE45
29 27
1 Block 20 O-ring 29 Plug

2 Spool assembly 21 Pilot cap (C) 30 Make up valve
3 Spool assembly 22 Guide plug 31 Cover
14 Main relief valve 23 O-ring 32 O-ring
15 Pilot cap (A) 24 Overload relief valve 33 Socket bolt
16 Nipple 25 Check 36 Plug
17 O-ring 26 Spring 37 Check
18 Pilot cap (B) 27 O-ring
19 Wrench bolt 28 Back up ring
6-15
STRUCTURE
a3 A3 B3 b3
a2 A2 B2 b2
a1 A1 B1 b1
B3
A3 Boom up Boom down
b3
a3 Floating
B2
A2 Roll back Dump
b2
a2
B1
A1 Aux
b1
a1
21MPa
P
Hydraulic circuit
7607B6WE10

P From main pump 1″ Split flange
T To hydraulic tank 1-1/4″Split flange
A2, B2 To bucket cylinder port 1″ Split flange
A3, B3 To boom cylinder port 1″ Split flange
a3, b3 Boom pilot port PF 3/8″ Fitting
a2, b2 Bucket pilot port PF 3/8 O-ring boss
6-16
2) BOOM SECTION OPERATION
(1) Spool in neutral
T
LH RH
B3
b3
a3
B2
A2 Roll back Dump
b2
a2
T
Center bypass passage Tank passage
a3 Boom b3
Main relief valve
7607WE11
When the boom plunger is in neutral position, oil from the pump flows to the tank through the
center bypass line.
The cylinder port (A3, B3) are shut off from the high pressure feed passage and tank passage by
the boom plunger.
6-17
(2) Boom raise position
T
LH RH
B3
A3 Boom up
b3
a3 Load
check
valve
B2
A2 Roll back Dump
b2
a2
Load check valve High pressure feed passage

A3 B3
a3 b3
7607WE12
When the pilot pressure is led to the port (a3), the boom plunger is switched, and shut off center
bypass passage.
Oil from the pump flows to the cylinder port (A3) through the load check valve and oil from the
cylinder flows into the tank passage through the cylinder port (B3).
※ Load check valve
When the load pressure is higher than the pump pressure, the load check shuts off the passage
between the high pressure feed passage and the center bypass passage and prevents the reverse
flow from the cylinder.
6-18
(3) Boom lower position
T
LH RH
B3
A3 Boom down
b3
a3 Load
check
valve
B2
A2 Roll back Dump
b2
a2
High pressure feed passage Load check valve

A3 B3
a3 b3
Tank passage Center bypass passage
7607WE13
When the pilot pressure is led to the port (b3), the boom plunger is switched, and shut off center
bypass passage. Oil from the pump flows to the cylinder port (B3), through the load check valve
and oil from the cylinder flows into the tank passage through the cylinder port (A3).
6-19
(4) Boom float position
T
LH RH
B3
A3 Boom float
b3
a3
B2
A2 Roll back Dump
b2
a2
High pressure feed passage

(bridge line) A3 B3
Tank passage
Center bypass passage
7607WE14
When the boom plunger is located in float position, the oil from the pump flows to the tank through
the center bypass line.
The cylinder port (A3) is connected to the tank passage, and the cylinder port (B3) is connected to
the tank passage, and the cylinder port (B3) is connected to the tank passage through the bridge
line. And then the both cylinder port is in float condition.
6-20
3) BUCKET SECTION OPERATION
(1) Spool in neutral
B3
b3
a3
B2
A2 Roll back Dump
b2
a2
T
a2 Bucket b2
Main relief valve
7607WE15
When the bucket plunger is in neutral position, oil from the pump flows to the tank through the
center bypass line.
To cylinder port (A2, B2) are shut off from the high pressure feed passage and tank passage by the
bucket plunger.
6-21
(2) Bucket rollback position
B3
b3
a3
B2
A2 Roll back
b2
a2 Load
check
valve
Load check valve High pressure feed passage

A2 B2
a2 b2
7607WE16
When the pilot pressure is led to the port (a2), the bucket plunger is switched, and shut off center
bypass passage.
Oil from the pump flows to the cylinder port (A2) through the load check valve and oil from the
cylinder flows into the tank passage through the cylinder port (B2).
※ Load check valve
When the load pressure is higher than the pump pressure, the load check shuts off the passage
between the high pressure feed passage and the center bypass passage and prevents the reverse
flow from the cylinder.
6-22
(3) Bucket dump position
B3
b3
a3
B2
A2 Dump
b2
a2 Load
check
valve
High pressure feed passage Load check valve

A2 B2
a2 b2
Tank passage Center bypass passage
7607WE17
When the pilot pressure is led to the port (b2), the bucket plunger is switched, and shut off center
bypass passage.
Oil from the pump flows to the cylinder port (B2) through the load check valve and oil from the
cylinder flows into the tank passage through the cylinder port (A2).
6-23
4) Main relief valve
Main poppet(A)
· The relief valve is installed between pump
Pilot poppet(B) d1
circuit and tank circuit in the main control Spring(C) d2
valve housing and keeps system pressure
to setting pressure.
· Oil from the pump port (P) enters into the P
chamber (3) through the orifice (2) of the

main poppet (A). T
As d2<d1, main poppet (A) is securely 4 3 2 1
seated.
· When the pressure reaches the preset Pilot poppet(B) d1

Spring(C) d2
force of the spring (C), the pilot poppet (B)
opens. Oil flow around pilot poppet (B) and
flows into the tank passage (T) through the
side hole (4). P
T
4
· As oil flows from the pump port (P) to the d1

Main poppet(A) d2
tank passage (T) through the orifice (2) of
the main poppet (A), the pressure of the
chamber (3) comes to lower than that of
P
the pump port.
Then the main poppet (A) is lifted and
pressured oil flows into the tank passage. T
3 2 1
7607WE18
6-24
5) Port relief valve
The port relief valve is installed between
cylinder port and tank passage. Main poppet(B) Pilot poppet(D)
It protects the actuator from abnormal Piston(A) d1 Spring(C)
d2
pressure, due to outer force or sudden
block of cylinder pressure. Cylinder
The port relief valve is the type of built-in port
make-up function.
1 2 T 3 Circular 4
passage
7607WE19
(1) Overload relief function Pilot poppet(D)

① When the pressure reaches the preset Spring(C)
force of the spring (C), the pilot poppet
(D) is lifted and pressured oil flows into
Cylinder
the tank passage. port
T Circular 4
passage
7607WE20
② As oil flows from the cylinder port to the 5
tank passage through the orifice (2) of

the piston (A), the pressure of the
chamber (3) comes to lower than that of Pilot poppet(D)
the cylinder port. Then the piston(A) is Piston(A)
lifted and seated to the pilot poppet (D).

Oil from the cylinder port flows to the tank Cylinder
passage through the orifice (5) of the port
pilot poppet (D), side hole (4) and the
circular passage.
T
1 2 3 Circular 4
passage
7607WE21
6-25
7. PILOT OIL SUPPLY UNIT
1) STRUCTURE
5
1
P
2
U
T
6
P2 2
7607B6WE46
3MPa
U
P1 From steering pump 3/4-16UNF
4.5MPa P2 Pluging 3/4-16UNF

U Supply to RCV lever 9/16-18UNF
P1 T T To hydraulic tank 9/16-18UNF
HYDRAULIC CIRCUIT 7807AWE49
1 Manifold complete 4 Accumulator

2 Reducing valve 5 Gasket
3 Seal kit 6 Relife valve
(2) OPERATION
The pilot supply manifold reduces the pressure from the high pressure circuit to a low pressure
circuit in order to supply the remote control valve.
The accumulator satisfies short term peak power demands and is a source of emergency power
in case of main circuit pressure failures.
The unit consists of the housing, the accumulator(4), the relief valve (6), the check valve and the
reducing valve (2).
The flow path is from the high pressure circuit through port P2 to the pressure reducing valve (2).
The pressure is reduced in the reducing valve (2) and oil passes the check valve into the
accumulator (4) and to the port U, which is connected with the remote control valve.
The pressure relief valve (6) protects the pilot circuit in case of the reducing valve (2) failures or
external increase of pressure.
6-26
8. BOOM AND BUCKET CYLINDER
The boom cylinders are two unit and the bucket cylinder is one unit. They use a bolt on rod guide.
The piston (12) threads on to the rod (2) and is retained by a nut (18) and set screw (19).
The piston seals against the tube (1) with piston seal (15). Two wear rings (16) are located on each
side of the piston seal.
The gland (3, the rod guide) seals against the tube with an O-ring (10). The cylinder thread seals
against the rod with a lip type buffer ring (7) and a rod seal (5). A dust wiper (8) cleans the rod when
it is retracted.
1) BOOM CYLINDER
9,8 6,5 3 7 24 11,10 4 21 2 22 25,26,27 12 17 15 16 19 18 23
13,14 28,29
20 1
7579S6WE26
1 Tube assembly 11 Back up ring 21 Pipe assembly

2 Rod assembly 12 Piston 22 Pipe assembly
4 Bushing 14 Back up ring 24 Bolt
5 Rod seal 15 Piston seal 25 Spring washer
6 Back up ring 16 Wear ring 26 Bolt
7 Buffer ring 17 Dust ring 27 Pipe clamp
8 Dust wiper 18 Lock nut 28 Bushing
9 Snap ring 19 Set screw 29 Dust seal
10 O-ring 20 Bolt
6-27
2) BUCKET CYLINDER
9,8 3 6,5 7 11,10 4 2 25 13,14 12 17 15 16 19 18 27,29
26,28 20 21 1 22 24 23
7577S6WE20
1 Tube assembly 11 Back up ring 21 Pipe assembly

2 Rod assembly 12 Piston 22 Pipe assembly
4 Bushing 14 Back up ring 24 Bolt
5 Rod seal 15 Piston seal 25 Band assembly
6 Back up ring 16 Wear ring 26 Pin bushing
7 Buffer ring 17 Dust ring 27 Pin bushing
8 Dust wiper 18 Lock nut 28 Dust seal
9 Snap rin 19 Set screw 29 Dust seal
10 O-ring 20 Bolt
6-28
9. HYDRAULIC OIL TANK
1) STRUCTURE
· The oil from the hydraulic tank is sent from the pump through main control valve to the cylinders.
In the return circuit, the oil from various parts merges.
· A part of oil is cooled in the oil cooler, passes through the hydraulic filter and returns to the
hydraulic tank (1).
· If the hydraulic return oil filter becomes clogged, return filter bypass valve (6) acts to allow the oil
to return directly to the hydraulic tank (1). This prevents damage to the hydraulic filter (5). The
bypass valve (6) is also actuated when negative pressure is generated in the circuit.
15 11,13 4 9
A
7
A
3 6
5
SECTION A - A
2,8
12,14 15 10
7579S6WE22
1 Hydraulic tank wa 9 Socket bolt

2 Pipe wa 10 Bolt
3 Sight gauge 11 Cover
4 Air breather 12 Cover
5 Element assembly 13 O-ring
6 Bypass valve 14 O-ring
7 Spring 15 Bolt
8 O-ring
6-29
2) RETURN OIL FILTER BYPASS VALVE
(1) When the filter is clogged

Bypass valve (1) is opened and the oil
returns directly to the tank without passing 1
through the filter.
·Bypass valve set pressure : 1.36kgf/cm2

(19.3psi)
From MCV
7607B6WE47
6-30
3) AIR BREATHER
The air breather is equipped with the
capacity to perform three functions
simultaneously-as an air filter, breathing
valve, and as a lubrication opening.
(1) Preventing negative pressure inside the
Air breather
tank
The tank is a pressurized sealed type, so
negative pressure is formed inside the
hydraulic tank when the oil level drops
during operations. When this happens,
the difference in pressure between the
tank and the outside atmospheric
pressure opens the poppet in the
breather, and air from the outside is let
into the tank or prevent negative pressure.
(2) Preventing excessive pressure inside
the tank
When the hydraulic cylinder is being
used, the oil level in the hydraulic system
increases and as temperature rises. If
the hydraulic pressure rises above the set
pressure, breather is actuated to release
the hydraulic pressure inside the tank. 7579S6WE27
6-31
10. ACCUMULATOR
The accumulator is installed at the pilot oil
supply unit. When the boom is left the
raised position, and the control levers are
operated with the engine stopped the
pressure of the compressed nitrogen gas
inside the accumulator sends pilot pressure
to the control valve to actuate it and allow 1
the boom and bucket to come down under 2
their own weight. 3
Type of gas Nitrogen gas (N2)

Volume of gas 0.75ℓ(0.2 U.S.gal)
Charging pressure of gas 16 kg/cm2 (228 psi)
Max actuating pressure 128 kg/cm2 (1820 psi) 1 Diaphragm
2 Steel pressure vessel
3 Closure button
7803AWE56
6-32
This procedure is designed so the mechanic can make a quick check of the system using a minimum
amount of diagnostic equipment. If you need additional information, read structure and function,
Group 1.
At the end of each check, if no problem is found (OK), that check is complete or an additional check is
needed. If problem is indicated (NOT OK), you will be given repair required and group location.
If verification is needed, you will be given next best source of information:
·Chapter 2 : Troubleshooting
·Group 3 : Tests and adjustments
6-33

Hydraulic system warm-up Hold a hydraulic function over OK
procedure relief to heat oil. (don't keep relief Check completed.
condition over 5 seconds at a time)
Refer to page 6-51. Periodically cycle all hydraulic
functions to distribute warm oil.
Repeat procedure until oil is at
FEEL : Hydraulic reservoir must be
uncomfortable to hold your hand
against.
(approximately 40 ~50˚C)
Hydraulic pump With bucket flat on ground, actuate OK
performance check boom raise. Time how long it takes Check completed.
to raise boom to full height.
Heat hydraulic oil to NOT OK
operating temperature. LOOK : Boom must raise to full Go to priority valve (in
Run engine at high idle. height in less than 7 seconds. steer ing valve) high
pressure check at page
5-28.
IF OK
Do steering system
leakage check at page
5-29.
IF OK
Do main hydraulic pump
flow test at page 6-49.
Control valve lift check With bucket partially dumped, OK
Run machine at low idle. lower boom to raise front of Check complete.
machine.
NOT OK
Slowly move boom control lever Repair lift checks in loader
( R C V l eve r ) t o b o o m l owe r control valve.
position.
Slowly move bucket control lever
to bucket dump position.
LOOK : Boom must not raise
before moving down.
Bucket must not rollback before
dumping.
6-34
Bucket rollback circuit relief Position bucket at a 45˚ angle OK
valve check against an immovable object. Check complete.
Engage transmission in 3rd speed NOT OK
forward. Replace boom lower
check valve.
LOOK : Bucket angle must not
change.
Bucket dump circuit relief Raise front of machine which OK
valve low pressure check bucket at 45˚ angle. Go to next check.
Backdrag with bucket while NOT OK
observing bucket angle. Do loader system and
circuit relief valve test at
LOOK : Bucket must not rollback
page 6-50.
Pilot control valve float With the bucket partially dumped, OK
check lower boom to raise front of Check complete.
machine.
Run engine at low idle. NOT OK
Push control lever to the float
Do pilot control valve
detent position and release lever.
pressure test in group 3.
LOOK : Front of machine lower to
the ground and valve must remain
in float position when lever is
released.
Boom cylinder and S e t t h e b o o m a n d b u c k e t OK

bucket cylinder drift horizontal, then stop the engine. Check complete.
check
S t o p t h e e n g i n e, wa i t fo r 5 NOT OK
Heat hydraulic oil to minutes, then start measuring. Go to next check.
operating temperature. B
Measure the amount the lift and
dump cylinder rods retract during 5
A minutes. (loaded bucket)
A : Retraction of boom cylinder
rod
B : Retraction of bucket cylinder
rod
Boom cylinder must drift less than
15 mm
Bucket cylinder must drift less than
23 mm
6-35
Boom cylinder leakage Dump bucket until teeth or cutting OK
check edge is per pendicular to the Drift is approximately the
ground. same between first and
Heat hydraulic oil to
second measurement.
operating temperature. Raise boom until cutting edge is
about 1 m (3 ft) above ground.
Repair loader control valve
Stop engine. Measure drift from or circuit relief valve.
tooth or cutting edge to ground for
1 minute. NOT OK
If drift is considerably less
Wait 10 minutes.
on second measurement,
Measure drift from tooth or cutting repair cylinder.
edge to ground for 1 minute.
LOOK : Compare the drift rate
between the first measurement
and the second measurement.
Bucket cylinder leakage Raise bucket about 1 m (3 ft) off OK
check ground with bucket level. Drift is approximately the
same between first and
Heat hydraulic oil to Stop engine. Place a support
second measurement.
operating temperature. under boom.
Measure drift from tooth or cutting Repair loader control valve
edge to ground for 1 minute. or circuit relief valve at
page 6-57.
Wait 10 minutes.
Measure drift from tooth or cutting NOT OK
edge to ground for 1 minute. Drift is considerably less
on second measurement.
LOOK : Compare the drift rates
between the first measurement
Repair cylinder.
and the second measurement.
Check valve of safety Put bucket level and position about OK
valve leakage check 1.2 m (4 ft) above ground. Check complete.
Heat hydraulic oil to Place a piece of tape on cylinder
NOT OK
operating temperature. rod at least 51 mm (2 in) from rod
Check or replace safety
guide.
valve.
Run engine at low idle in safety-
release position.
LOOK : Bucket must not drift up.
Pilot control valve Stop engine. Turn key switch to OK
OFF position. Check completed.
(RCV lever) check
Move control lever to all positions
NOT OK
and then release.
Repair pilot control valve.
LOOK : Lever must return to
neutral when released from all
positions.
6-36
Bucket leveler Position bucket fully dumped just OK
(positioner) check above ground level. Check complete.
Run engine at low idle. Move control lever to bucket NOT OK
leveler detent position and release. Do bucket leveler checks.
LOOK : Bucket must rollback to
the level position and control lever
must return to neutral.
If bucket is in a rolled back position
when key is turned ON, control
lever must be returned to neutral
manually if placed in the bucket
leveler detent position.
After bucket is dumped once,
bucket leveler will work normally.
Boom height kickout Position bucket flat on ground. OK
check Check complete.
Move control lever to boom raise
Run engine at low idle. detent position and release. NOT OK
Do boom height kickout
LOOK : Boom must raise to the
check.
set height and stop.
Control lever must return to
neutral.
Cycle time check Function Operating condition. Maximum cycle time
H e a t h y d r a u l i c o i l t o Boom raise Bucket flat on ground to full height. 6.0sec
Boom lower Full height to level ground. 3.1sec
Bucket dump Boom at full height. 1.2sec
Bucket rollback Boom at full height. 1.6sec
Steering [No. of Frame stop to frame stop. 4.0 turns
turns]
OK
Check complete.
NOT OK
Go to slow hydraulic
functions in group 2.
6-37
※MEASURING BOOM AND BUCKET CYCLE TIME
1) MEASUREMENT CONDITION
·Coolant temperature : Inside operating range
·Steering position : Neutral
·Hydraulic temperature : 40~50˚C
·Bucket : Unloaded
·Engine speed : High idling
2) MEASURING TOOL
· Stop watch (1EA)
3) MEASURING PROCEDURE
(1) LIFTING TIME OF BOOM Lifting time of boom
Set the bucket near the maximum tilt back

position and at the lowest position on the
ground. Raise the bucket and measure
the time taken for bucket to reach the
maximum height of the boom.
75796WE25
(2) LOWERING TIME OF BOOM

Set the bucket horizontal with the boom at Lowering time of boom
the maximum height, lower the bucket and
measure the taken for the bucket to reach
the lowest position on the ground.
75796WE26
(3) DUMPING TIME OF BUCKET

Raise the boom to the maximum height Dumping time of bucket
Rollback time of bucket
and measure the time taken for the bucket
to move from the maximum tilt back
position to the maximum dump position
(4) ROLL BACK TIME OF BUCKET
Raise the boom to the maximum height
and measure the time taken for the bucket
to reach the maximum tilt back position. 75796WE27
6-38
2. TROUBLESHOOTING
※ Diagnose malfunction charts are arranged from most probable and simplest to verify, to least
likely, more difficult to verify. Remember the following steps when troubleshooting a problem :
Step 1. Operational check out procedure (see section 1)

Step 2. Operational checks (see group 2)
Noisy hydraulic pump Low oil supply or wrong viscosity. Fill reservoir with recommended oil.
Plugged or pinched suction line. Clean or replace line.
Air in oil. Check for foamy oil. Tighten
connections.
Replace O-rings and or lines.
Plugged suction strainer. Inspect and clean strainer in reservoir.
Loose or missing hydraulic line clamps. Tighten or replace clamps.
Hydraulic lines in contract with frame. Inspect and repair.
Worn or damaged pump. Do hydraulic pump performance check
in group 2. Do hydraulic pump flow test
in group 3.
No or Slow hydraulic Failed or worn hydrualic pump. Do performance check.
functions
Cold oil. Warm oil up.
Slow engine speed. Adjust engine speed.
Check high idle speed.
Suction line air leak. Check for foamy oil.
Low oil supply. Add recommended oil.
Wrong oil viscosity. Use recommended oil.
Oil leaking past cylinders or control Check cylinder drift in group 2.
valve.
Blocked or damaged line. Inspect lines.
Faulty pilot control valve (RCV). Do pilot control valve (RCV) pressure
test in group 3.
Binding loader control valve (MCV) Inspect valve.
spool.
Faulty steering valve (EHPS). Check priority valve, orifice of steering
valve (EHPS) specification.
6-39
No steering or hydraulic Low oil level. Add recommended oil.
function
Failed hydraulic pump. Remove and inspect return filter for
metal pump particles.
No hydraulic functions Failed hydraulic pump. Remove and inspect return filter for
steering normal metal pump particles, or replace the
pump.
Failed line filter. Remove and inspect line filter for RCV.
Faulty safety valve. Safety valve leakage test or ON, OFF
function test.
Stuck open port relief valve. Replace relief valve.
Boom float function Low pilot control pressure. Do pressure reducing valve pressure
does not work test in group 3.
Faulty pilot control valve (RCV). Replace relief valve.
Loader control valve (MCV) spool Do pressure reducing valve pressure
binding in bore. test in group 3.
One hydraulic function Faulty pilot control valve (RCV). Do pilot control valve pressure test.
does not work. Inspect and repair valve.
Stuck open port relief valve. Replace relief valve.
Oil leaking past cylinder packings. Do boom and bucket cylinder leakage
test in group 3.
Blockage in oil lines or valve. Inspect lines for damage.
Disconnect and inspect lines for internal
blockage.
Loader control valve (MCV) spool stuck Inspect and repair valve.
in bore.
Low hydraulic power Leakage within work circuit. Do cylinder drift check in group 2.
Low system relief valve (main relief Do loader system and port relief valve
valve) setting. pressure test in group 3.
Low port relief valve setting. Do loader system and port relief valve
pressure test in group 3.
Leaking system relief valve. Remove and inspect valve.

Worn hydraulic pump. Do hydraulic pump performance check
in group 2.
Faulty pilot control valve (RCV). Do pilot control valve pressure test in
group 3.
6-40
Function drifts down Leaking cylinders. Do cylinder leakage checks in group 3.
Leaking seals in circuit relief valve (port Inspect seals. Replace relief valve.
relief valve) or valve stuck open.
Leaking loader control valve (MCV). Repair or replace valve section.
Boom drifts up Leakage in boom down spool. Remove and inspect boom down spool.
Boom down does not Safety valve not operated. Operate valve.
work (engine off)
Stuck pilot control valve. Inspect.
Faulty line filter. Remove and inspect filter.
Accumulation not operated. Inspect.
MCV spool stuck. Inspect and repair valve.
Oil overheats Low oil viscosity in hot weather. Use recommended oil.
Excessive load. Reduce load.
Holding hydraulic system over relief. Reduce load.
Leakage in work circuit. Do boom and bucket cylinder leakage
test in group 3.
Plugged fins in oil cooler. Inspect and clean oil cooler.
Internally plugged oil cooler. Do hydraulic oil cooler restriction test.
Incorrect system or circuit relief valve Do loader system and circuit relief valve
setting. pressure test in group 3.
Restriction in oil lines or loader control Inspect for dented or kinked lines.
valve (MCV).
Malfunctioning steering valve. Do hydraulic system restriction test in
group 3.
Leaking system main relief valve. Do hydraulic system restriction test in
group 3.
Remove and inspect valve and seals.
Worn hydraulic pump (internal leakage). Do hydraulic pump performance check
in group 2.
Function drops before Stuck open lift check valve. Do control valve lift check in group 2.
raising when valve is
activated
6-41
Hydraulic oil foams Low oil level. Add recommended oil.
Wrong oil. Change to recommended oil.
Water in oil. Change oil.
Loose or faulty suction lines (air leak in Tighten or install new lines.
system).
Remote control valve Leaking plunger seals. Remove, inspect and replace plunger
(RCV) leaking seals.
※ Followings are general precautions for the hydraulic system and equipment.
1) Every structure has its limit of strength and durability. The relief valve is installed to limit the
pressure on the hydraulic equipment and protect various parts of the wheel loader from possible
damage. Therefore, never change the preset pressure of the relief valve unless absolutely
necessary.
2) Since the hydraulic equipment is built with precision, the presence of only the slightest amount of
dust and / or other particles in the hydraulic circuit might cause wear and/or damage, resulting in
unstable functions and/or damage, resulting in unstable functions and/or unexpected accidents.
Therefore, always keep hydraulic oil clean. Periodically, check the filter in the return circuit and
replace the element as necessary.
3) Extract about 200cc of hydraulic oil from the tank as a sample every 6 months. If possible, have it
analyzed by a specialist to confirm that the oil can still be used. Never extract the oil for sampling
until the oil temperature has become the normal operating temperature. Since the replacement
period varies depending on operating conditions, refer to Operator's Manual and change oil.
4) Should the equipment get damaged due to the presence of metal particles and/or foreign matter in
the circuit drain out the hydraulic oil and carry out flushing. Also, replace the filter element and
clean the hydraulic tank. Change the hydraulic oil entirely.
5) When checking the filter, if found metal particles in the element, drain out the hydraulic oil entirely,
flush the whole circuit, and then fill with new oil. The presence of metal particles may indicate
internal damage to the equipment. In such a case, check carefully before flushing, and repair or
replace as required.
6) To add and/or change the hydraulic oil, always use recommended oil. (Refer to the list of
recommended oils and lubricants at page 1-22, Recommended lubricants.
lubricants.) Never mix oil of
different makes of kinds.
7) To change the hydraulic oil, use a clean vessel and funnel for pouring it into the tank. Never use
cloth because it might cause the presence of lint in the circuit.
8) When removing the hydraulic equipment, be sure to put plugs or caps on hoses, tube lines and
ports. Also, enter mating marks for later identification.
6-42
9) Disassemble and/or assemble the hydraulic equipment only in a clean place free of dust. When
disassembling, be careful about the interchangeability of parts, and clean the disassembled parts
with pure and clean mineral cleansing oil. Clean the internal passages as well. After the parts
have dried, wipe them off with a clean lint-free cloth.
10) When overhauling the hydraulic equipment replace all O-rings, backup rings, etc. with new ones.
Assemble O-rings with grease or vaseline applied.
11) After installing the equipment, add more hydraulic oil to make up for that lost during disassembly.
12) Tighten joints correctly. Loose joints will cause the hydraulic oil to leak. If the oil leaks, the tank oil
level drops and air gets sucked in, so the pump will break down. Also loose joints in suction lines
will take air in and might cause abnormal noise, malfunction or damage to pumps.
6-43
1. HYDRAULIC OIL CLEAN UP PROCEDURE USING PORTABLE FILTER CADDY

※ Service equipment and tool
·Portable filter caddy
·Two 4000 mm × 1in 100R1 Hoses
·Quick disconnect fittings.
·Discharge wand
·Various size fittings.
※ Brake system uses oil from hydraulic oil
tank. Flush all lines in the brake, pilot,
steering system and cut off system.
Disassemble and clean major
components for brake and steering
system. Remove and clean pilot caps
from main control valve.
Brake and steering components may fail
if brake and steering system is not
cleaned after hydraulic oil tank
contamination.
1) If hydraulic system is contaminated due to
a major component failure, remove and
disassemble steering cylinders to clean
debris from cylinders.
2) Install a new return filter element. Inspect
filter housing before installing new element.
※ For a failure that creates a lot of debris,
remove access cover from hydraulic oil
tank. Drain and clean hydraulic oil tank of
fill the specified oil to hydraulic oil tank
through upper cover.
3) To minimize oil loss, pull a vacuum in
hydraulic oil tank using a vacuum pump.
Connect filter caddy suction line to drain
port at bottom of hydraulic oil tank using
connector. Check to be sure debris has not
closed drain port.
4) Put filter caddy discharge line into hydraulic
oil tank filler hole so end is as far away from
drain port as possible to obtain a thorough
cleaning of oil.
6-44
5) Start the filter caddy. Check to be sure oil is
flowing through the filters.
Operate filter caddy approximately 10
minutes so oil in hydraulic oil tank is
circulated through filter a minimum of four
times.
※ Hydraulic oil tank capacity : 175 ℓ(46
U.S. gal)
Leave filter caddy operation for the next
steps.
6) Start the engine and run it at high idle.
※ For the most effective results, cleaning
procedure must start with the smallest
capacity circuit then proceed to the next
largest capacity circuit.
7) Operate all functions, one at a time,
through a complete cycle in the following
order: Clam, steering, bucket, and boom.
Also include all auxiliary hydraulic functions.
Repeat procedure until the total system
capacity has circulated through filter caddy
seven times, approximately 30 minutes.
Each function must go through a minimum
of three complete cycles for a through
cleaning for oil.
※ Filtering time for machines with auxiliary
hydraulic functions must be increased
because system capacity is larger.
8) Stop the engine. Remove the filter caddy.
9) Install a new return filter element.
10) Check oil level in reservoir; Add oil if
necessary.
6-45
2. BOOM HEIGHT KICKOUT ADJUSTMENT
1) Lift the boom up to a desired height, set the
boom control lever at hold, then stop the
engine.
Be careful lest work equipment fall down.
Put the hydraulic safety lock lever in the Boom
LOCK position.
Proximate switch
7707WE20
2) Loosen nuts and bolts then tighten them

after adjusting the plate or proximate switch Bolt
so that it comes in contact with the center Nut
of the probe of the proximate switch.
Boom
Plate
7707WE21
3) Loosen the nuts so that a clearance

between the plate and the probe of the
proximate switch are maximum 6 mm. Max 6mm
Boom
7707WE22
4) Start the engine. Position the bucket on the

Neutral
ground. Then lift the bucket to a desired
Detent position
height by using the control lever and
release the hand.
Confirm the lever automatically returns to
the neutral position and the boom (the
bucket) stop at the adjusted position.
7609S4OP26
6-46
3. TEST TOOLS
1) CLAMP-ON ELECTRONIC TACHOMETER
INSTALLATION
·Service equipment and tools
B
Tachometer
A : Clamp on tachometer.
Remove paint using emery cloth and
C
connect to a straight section of injection
line within 100 mm (4 in) of pump. Finger
Tighten only-do not over tighten. D
B : Black clip ( - ). Connect to main frame.
C : Red clip (+). Connect to transducer. A
D : Tachometer readout. Install cable.
75795SE32
2) DIGITAL THERMOMETER INSTALLATION

·Service equipment and tools
Digital thermometer
A : Temperature probe.
Fasten to a bare metal line using a tie A
band. Wrap with shop towel. C
B : Cable. B
C : Digital thermometer.
75795SE33
3) DISPLAY MONITOR TACHOMETER

The display monitor tachometer is accurate
enough for test work.
75795SE35
6-47
4. HYDRAULIC OIL WARM UP PROCEDURE
1) Install temperature reader (see temperature
reader installation procedure in this group).
2) Run engine at high idle.

3) Hold a hydraulic function over relief to heat
the oil.
4) Periodically cycle all hydraulic functions to

distribute warm oil.
5) Heat oil to test specification (approx. 45˚C).
※ Ride control system (option)

Attention B
A
1) Before carrying out any maintenance work
the accumulators must be unloaded (zero
pressure).
2) For this, loosen the nut (4) and bolt (B)
counterclockwise with 10 mm spanner.
※ The accumulator will be unloaded (zero
pressure) in less than a minute.
3) The lifting system must firstly be secured
against lowering.
Ride control valve
7607S6WE28
4) After carrying out maintenance work, screw
the bolt (B) and nut (A).
·Tightening torque
A : 2.04 kgf·m (14.8 lbf·ft)
6-48
5. MAIN HYDRAULIC PUMP FLOW TEST
· SPECIFICATION
Engine speed 2100±25 rpm
Test pressure 210±5 bar (2990 psi)
Maximum pump flow 225ℓ/min (59.4 U.S.gpm)
· FLOW METER GAUGE AND TOOL
Gauge 0~35 MPa (0~350 bar, 0~5000 psi) Flow meter
Temperature reader
To MCV
1) Make test connections.
(see temperature reader installation procedure
in this group)
(see hydraulic oil warm up procedure in this
group)
4) Run engine at test specifications.
5) Close flow meter loading valve to increase
pressure to test specifications.
6) Read flow meter.
7) If flow is below specifications, check suction
line and suction pressure for abnormality
before removing pump. 7607WE29
6-49
6. LOADER
L ADER SYSTEM AND PORT RELIEF
VALVE PRESSURE TEST
· SPECIFICATION
Oil temperature (40~50˚C)
Relief valve Engine speed Relief pressure
210±10 kg/cm2 U
System (M) High T
(2990±140 psi)
Boom 240±10 kg/cm2
Low Boom
raise (U) (3410±140 psi)
Bucket
Bucket 240±10 kg/cm2
Low
rollback (R) (3410±140 psi) P
R
Bucket 240±10 kg/cm2
Low
dump (D) (3410±140 psi)
M D
· Gauge and tool
Gauge 0~35 MPa (0~350 bar, 0~5000 psi)
M : System (main) relief valve
R : Bucket rollback relief
D : Bucket dump relief
U : Boom raise relief
1) Install fitting and pressure gauge to test
port in pump delivery line.
P
(see temperature reader installation
procedure in this group)
T
group)
4) To check the system relief (M), run engine
at high idle. Lower boom to bottomed Main pump
position.
Slowly activate boom down function while
watching pressure gauge. If pressure is not
to specification, loosen lock nut on system
relief valve (M) and adjust to specification. 7607WE30
6-50
※ Do not adjust the system relief valve
above 210 kg/cm2 (2990 psi). Damage to
the pump will result from excessive
pressure settings.
6-51
7. HYDRAULIC SYSTEM RESTRICTION
TEST
· SPECIFICATION
Maximum pressure 2 MPa (20 bar, 285 psi)
at steering valve (EHPS).
Maximum pressure at main control valve
1 MPa (10 bar, 145 psi)
· GAUGE AND TOOL
Gauge 0~7 MPa (0~70 bar, 0~1000 psi) 2EA
This test will check for restrictions in the
hydraulic system which can cause
overheating of hydraulic oil.
P
(see temperature reader installation
procedure in this group)
group)
3) Connect fitting and gauge to steering valve.
4) Connect fitting and gauge to main control
valve.
Do not operate steering or loader funct-
ions or test gauge may be damaged.
5) Run engine at specification and read
pressure gauges.
T
loader control valve, check for a kinked,
dented or obstructed hydraulic line. Check
loader control valve for a binding spool.
steering unit, inspect neutral condition of
the steering unit and steering valve for a
stuck spool. Make sure orifice plugs are
installed in ends of priority valve spool.
Check for plugged orifice in priority valve
and dynamic signal orifice on steering valve
body. 7607WE31
6-52
8. LOADER CYLINDER DRIFT TEST
· SPECIFICATION B
Boom horizontal
Bucket horizontal
Bucket loaded A
Item Standard value
Retraction of boom
15 mm
cylinder rod A : Retraction of bucket cylinder rod
Retraction of bucket B : Retraction of boom cylinder rod
23 mm
cylinder rod
· GAUGE AND TOOL
Stop watch
Temperature reader
Put the hydraulic safety lock lever in the
lock position.
Do not go under the work equipment.
1) Set the boom and bucket horizontal, then
stop the engine.
2) Stop the engine, wait for 5 minutes, then
start measuring.
3) Measure the amount the boom and bucket
cylinder rods retract during 15 minutes.
7577AWE31
6-53
9. BOOM AND BUCKET CYLINDER LEAKAGE TEST
· SPECIFICATION
Engine speed Low idle
Maximum leakage 15 mℓ/min (1/2 oz/min)
· GAUGE AND TOOL
Temperature reader
Stop watch
Measuring container
1) Fasten temperature sensor to head end
port of cylinder to be tested. Cover sensor
with a shop towel.
2) Heat hydraulic oil to specifications (see
hydraulic oil warm up procedure in this
group).
Never work under raised equipment
unless it is supported with a hoist or
support stands.
3) Full extend the cylinder to be tested. If
testing the boom cylinders, restrain boom in
the fully raised position using a hoist or a
stand.
※ Check cylinders for leakage in the fully
extended position only. In the retracted
position contacts the end of the cylinder
and seals off piston seal leakage.
4) Remove and plug cylinder rod end hose or
line.
5) Run engine at slow idle. Activate control
lever to extend cylinder for 1 minute over
relief while measuring leakage for open
port.
If leakage is within specification, excessive
cylinder drift is caused by leakage in the
(770-3ATM) 6-56
loader control valve or circuit relief valve.
6-54
10. PILOT CONTROL VALVE P
PRESSURE
RESSURE TEST
· SPECIFICATION
Engine speed Low idle
Begin metering 1/4" of lever travel
Pressure in detent :
Boom float detent 1.9 MPa (19 bar)
Pressure at detent position :
Boom power down 19~22bar
Boom raise 19~22bar
Bucket rollback 19~22bar
Bucket dump 19~22bar
· GAUGE AND TOOL
Gauge 0~7 MPa (0~70 bar, 0~1000 psi)
As the control lever is moved from neutral,
the pilot pressure will suddenly jump up to
approximately 5.8bar at 1/4in. travel. The
pressure should then increase smoothly to
the specification at the FEEL position (or
3/4 lever travel), and then jump up about
430psi as the lever is moved into detent.
This test will determine if adequate pilot
pressure is available to move the loader
control valve spools.
※ The FEEL position is when lever is
moved to feel the ramp of the detent
before lever passes into detent position.
1) Lower boom to ground.
2) Connect gauge to the pilot pressure port of
function to be checked.
3) Install temperature reader (see temperature
reader installation procedure in this group).
4) Heat hydraulic oil to specification (see
hydraulic oil warm up procedure in this
7607B6WE41
group).
6-55
11. PILOT OIL SUPPLY UNIT P
PRESSURE
RESSURE TEST
· SPECIFICATION
Engine speed Low idle and stop
Pilot pressure setting
30~35 bar (430~500 psi)
Relief valve setting pressure 45 bar
Accumulator precharging pressure 16 bar
· GAUGE AND TOOL
Gauge 0~7 MPa (0~70 bar, 0~1000 psi)
The pilot supply unit consist of the pressure
reducing valve, the relief valve and an
accumulator. This regulates pressure to the
pilot control circuit.
1) Connect gauge to test port on the screw
coupling.
2) I n s t a l l t e m p e r a t u r e r e a d e r ( S e e
temperature reader instakkation procedure
in this group).
3) Heat hydraulic oil to specification (see
U
hydraulic oil warm up procedure in this T P2
group).
4) Run engine at loe idle for 1 minute and stop
engine, wait for 5 minutes, Then start
measuring.
5) If pressure in not within specifiactions,
replace valve.
7707WE26
6-56
12. CYCLE TIME TEST
· SPECIFICATION
Function Operating conditions Maximum cycle time (seconds)
Boom raise Bucket flat on ground to full height 6.0
Boom lower (float) Full height to ground level 3.1
Bucket dump Boom at full height 1.2
Bucket rollback Boom at full height 1.6
Steering (number of turns) Frame stop to stop 4.0 turns
Hydraulic pump performance cycle time.

Function Operating conditions Maximum cycle time (seconds)
Bucket flat on ground to full height
Boom raise 10
while holding steering over relief
6-57
13. HYDRAULIC OIL FILTER INSPECTION
PROCEDURE
1) Lower the bucket to the ground, stop the
engine, move the control lever back and
forth several times, and clean all over the
upper surface of the hydraulic oil tank.
2) Remove the bolts and take out the filter
case cover and O-ring.
3) Remove the spring and bypass valve.
4) Remove the filter element from the tank. Cover
O-ring
5) Check the element and the filter case Spring
bottom for debris. Excessive amounts of By-pass valve
brass and steel particles can indicate a Return filter
failed hydraulic pump or a pump failure in
process. A rubber type of material can
indicated cylinder packing or other packing
failure.
※ The hydraulic oil filter in the filter case of
the hydraulic oil tank should be replaced
every 250 operating hours or more often.
When the filter element is replaced,
please keep as follows.
(1) Clean the inside of the filter case.
(2) Place new element in the proper positions
inside the filter case.
(3) Install the bypass valve and spring.
Make sure the element stand upright, and
check for complete contact of the element
bottom with the filter case bottom.
(4) Install the O-ring and filter case covers.
Tighten them with bolt. Replace the
7579S6WE60
O-ring with new one if damaged.sa
6-58
1. MAIN PUMP
1) STRUCTURE
21
20
4
3 5
23
13
11 12
22
19
15
8
7 14
6
17
18
9
16
8 15
7 14
6 13
12
11
10
1
2
7607WE33
1 Shaft seal 9 Front drive gear 17 Spline coupling

2 Adapter 10 Front driven gear 18 Rear driven gear
3 Washer 11 Wearplate 19 Rear drive gear
4 Bolt 12 O-ring seal 20 Stud
5 Flange 13 Back up seal 21 Flanged nut
6 Back up seal 14 Interface seal 22 Rear body
7 O-ring seal 15 Dowel 23 O-ring
8 Wearplate 16 Front body
6-59
2) DISASSEMBLY
21
20
4
3 5
23
13
11 12
22
19
15
8
7 14
6
17
18
9
16
8 15
7 14
6 13
12
11
10
1
2
7607WE33
※ Plug all ports prior to cleaning and disassembling pump to prevent ingress of debris or
contamination.
※ Clean the pump thoroughly with a solvent, ensuring no loose debris or contamination remains on
the unit.
※ Mark each interface and then separate into individual pump sections.
(1) Securely clamp pump horizontally on one port face, ensuring that no damage is sustained to the
port face and remove the stud (20) and nut (21).
(2) Remove the front adaptor (2) from the body (16) using a pulling tool centred on the drive shaft (9).
※ Under NO circumstances attempt to prise or chisel cover from body as such action could
damage the machined sealing faces.
(3) Remove and discard the shaft seal (1) from adaptor making sure that no damage is sustained to
the surface of the seal bore.
(4) Unclamp pump and place it vertically with drive shaft up.
(5) Before removing wearplate from the body mark it using a soft pencil or a felt-tip pen to ensure
correct reassembly. Remove wearplate (8) complete with O-ring seal (7) and back up seal (6).
6-60
DISASSEMBLY
21
20
4
3 5
23
13
11 12
22
19
15
8
7 14
6
17
18
9
16
8 15
7 14
6 13
12
11
10
1
2
7607WE33
(6) Mark the gears using a soft pencil or felt-

tip pen to ensure assembly in the same
relative position, see figure on the right,
then withdraw the drive shaft/gear (9) and
driven gear (10) separately to prevent
jamming.
(7) Again, to ensure correct assembly, mark
remaining wearplate (11) using a soft
pencil or a felt-tip pen. Remove wearplate 7607WE34
from body complete with O-ring seal (12)
and back up seal (13).
(8) Discard interface seal (14).
(9) Having separated into individual pumps,
proceed as per paragraph (1)~(7).
6-61
3) MANDATORY REPLACEMENT PARTS
Discard all seals including interface seals, shaft seals, wear plate seals and back up seals. Fit new
seals on reassembly. Wearplates should also be replaced with new items from seal kit.
4) HANDLING/STORAGE
HANDLING/STORAGE
While disassembling pump, ensure no surfaces are scored or marked in any way. A rubber
surfaced table will be beneficial. All components must be placed in a clean, dry and safe area.
Leakage will be created by scratches on components. If parts are to be left for any period ensure
they are not exposed to dirt, dust and corrosion. Keep gears separate from each other in protective
boxes.
5) INSPECTION
INSPECTION OF PARTS
Wash all parts in a solvent and dry.
(1) Adaptor housing and cover
The pump must be replaced if the damage listed is present.
Feature Damage
Corrosion, nicks or burrs (slight burrs can be removed using and
Surfaces
india stone)
Machined sealing lnterfaces Scores, cracks or corrosion
Bearing Loose
(2) Gears
Feature Damage
Corrosion, nicks or burrs (slight burrs can be removed using an
Surfaces lndia stone).
Wear due to seal (s)
Journals Pitting, wear, sufficient wear to change outside diameter
Tooth Cracks or heavy scoring or chipped
Splines/keyways Distortion of wear
End faces Wear, cracks
6-62
(3) Floating wear plates
Feature Damage
Corrosion, nicks or burrs, amounts of scoring,erosion
Surfaces
or any cracks, discoloration caused by overheating
Removing burrs or minor scoring from

Scoring of wear plate.
end faces and teeth of the gears.
(4) Bolts/Studs
The pump should be replaced if the damage listed is present.
Feature Damage
Corrosion, nicks or burrs (slight burrs can be removed
Surfaces using an lndia stone), cracks or scoring,
distortion or damage to thread form
(5) Plain bearings

Feature Damage
Surfaces Cracks or socring
PTEF Coating Worn-bronze, sub-layer showing
Bearing Loose in housing/cover
(6) Coupling
This must be replaced if damage listed is present.
Feature Damage
Surfaces Corrosion, nicks or burrs, erosion, cracks or pitting
Splines Distorted or badly worn
6-63
6) ASSEMBLY
21
20
4
3 5
23
13
11 12
22
19
15
8
7 14
6
17
18
9
16
8 15
7 14
6 13
12
11
10
1
2
7607WE33
※ It is critical that the wearplates are assembled into the pump with regard to the following:
-The seal side of the wearplate must be adjacent to the adaptor or body.
-The high pressure side of the wearplate must be adjacent to the outlet port.
※ This must take place in a clean dry area, ensuring that all parts are clean and free from
contamination or loose particles. Lightly oil all surfaces.
(1) Place body vertically with gear pockets upper most.
(2) Slide wearplate (11) complete with O-ring seal (12) and back up seal (13) down through the
housing to the bottom of the gear pockets.
※ Be sure to refit the wearplate the same as that marked from this position during disassembly.
(3) Fit the gears (18,19) within the housing taking care to replace as marked, with the teeth
reassembled to their original related position.
(4) Fit the wearplate (8) complete with O-ring seal (7) and back up seal (6).
※ Be sure to refit the wearplate the same as that marked from this position during disassembly.
6-64
ASSEMBLY
21
20
4
3 5
23
13
11 12
22
19
15
8
7 14
6
17
18
9
16
8 15
7 14
6 13
12
11
10
1
2
7607WE33
(5) Fit new interface seal (14) into groove in body.

(6) Proceed as per paragraph (1)~(5).
(7) Fit adaptor (2) over the drive gear (9) and fit stud (22).
(8) Securely clamp unit and tighten nut(21) to half torque and then full torque.
·Tightening torque : 23.2 kgf·m (168 lbf·ft)
(9) Fit shaft seal (1) using appropriate tooling, in correct position and orientation.
(10) Pour a little clean hydraulic oil into the ports.
6-65
2. MAIN CONTROL VALVE
1) STRUCTURE
89
11
37
32
33
34 24
23 22
7 35 22
17 23
24
36 21
20 17
19
18 3 24
11 17 23
22
2 12
16
5 1
4 12
12
13
6 1514
21
11 9
8
31 13
25 1514
26 12
27 25
26 11
28 27 39
30 28 38
29 40
7607WE35
1 Housing assembly 15 O-ring 29 Cap

2 Plunger assembly 16 Plunger 30 Cap
3 Plunger assembly 17 Guide 31 Check
4 O-ring 18 Spring 32 Cap
5 O-ring 19 Spacer 33 Guide
6 Main relief assembly 20 Nipple 34 Spacer
7 Cover 21 Port relief assembly 35 Spring
8 Nipple 22 O-ring 36 Plunger
9 O-ring 23 Back up ring 37 Make up assembly
10 Cover 24 O-ring 38 Cover
11 Socket bolt 25 Check 39 O-ring
12 O-ring 26 Spring 40 Bolt
13 Cover 27 O-ring
14 Plug 28 Back up ring
6-66
2) GENERAL PRECAUTIONS
(1) Clean room with no dust is recommended for maintenance. Because hydraulic components are
precision, and have minute clearance. Tool and wash-oil must be clean, too. Handle them
carefully.
(2) At removing control valve from the machine, wash around the piping port, and neither dust nor
water should go into inside with plugging. It is same at attaching the machine.
(3) Prepare the required parts by checking structure figure before assembly. There are parts which
are supplied with only sub-assembly part, so check the parts list before assembly.
3) PRECAU
PRECAUTIONS
TIONS FOR DISASSEMBLY
(1) Handle the components carefully not to drop them or bump them with each other as they are
made with precision.
(2) Do not force the work by hitting or twisting as burred or damaged component may not be
assembled or result in oil leakage or low performance.
(3) When disassembled, tag the components for identification so that they can be reassembled
correctly.
(4) Once disassembled, O-ring and back-up rings are usually not to be used again (remove them
using a wire with its end made like a shoe-horn. Be careful not to damage the slot).
(5) If the components are left disassembled or half-disassembled, they may get rust from moisture or
dust. If the work has to be interrupted, take care to prevent rust and dust.
4) PREC
PRECAUTIONS
AUTIONS FOR REASSEMBLY
(1) Take the same precautions as for disassembly.
(2) When assembling the components, remove any metal chips or foreign objects and check them
for any burrs or dents. Remove burrs and dents with oil-stone, if any.
(3) O-rings and back-up rings are to be replaced with new ones, as a rule.
(4) When installing O-rings and back-up rings, be careful not to damage them (apply a little amount
of grease for smoothness).
(5) Tighten the bolts and caps with specified torque.
5) SPEC
SPECIAL
IAL TOOL
· HOLDER
Material : copper
41 Hex : Division
100
28.2
7607WE36
6-67
※ Regarding to change the main plunger
We can not supply the main plunger,
because the plunger is fit for valve
housing.
So, do not change the plunger at the field.
If changing plunger must be needed, then
tell us model name of control valve and Name plate
serial number written at its nameplate.
7607WE37
6) BUCKET PLUNGER AND ACCESSORY PLUNGER

※ Reassemble in the opposite order to disassemble.
※ To reassemble correctly, attach an identification tag immediately after parts are removed.
(1) Remove hexagon socket bolts (1) then

remove cover (2).
·Hexagon socket bolt
Width across flat : 8 mm
Tightening torque : 5.1 kgf·m (36.8 lbf·ft)
※ Reassembly
Install cover (2), after making sure that Stopper plug
O-ring is placed on the edge of the 2 1 Cover
housing hole. 7607WE38
(2) Pull out spool assembly from housing.

※ Do not pull out the spool all at once.
Pull slowly while fitting in the housing
hole.
※ Reassembly
Set the key groove of the plunger with the
stopper plug of the cover.
7607WE39
(3) Set the spool between holders and

loosen plunger cap (3) by using vise. Holder
·Plunger cap
※ Set the spool between holders and clamp 3
them by a vise after degreasing the spool
and holders as a special tool.
7607WE40
6-68
(4) Remove the plunger cap (3), spring guide
(4), spring (6) and sleeve (5).
※ Spring is different from boom section
spring. 3
4
5
6
4
7607WE41

remove cover (9) after remove plug (7).
·Plug (7)
Width across flat : 19 mm 7
Tightening torque : 8.2 kgf·m (59.0 lbf·ft) O-ring
·Hexagon socket bolt (8)
Tightening torque : 5.1 kgf·m (36.8 lbf·ft) 8
※ Make sure that O-ring is on the face of 7607WE42

housing.
7) BOOM PLUNGER
remove cover (2).
·Hexagon socket bolt
※ Reassembly
Install cover (2), after making sure that 2 1
O-ring is placed on the edge of the housing 7607WE43
hole.
(2) Pull out spool assembly from housing.

※ Do not pull out the spool all at once.
Pull slowly while fitting in the housing
hole.
※ Reassembly
Set the key way of the plunger to the
stopper plug of the cover.
7607WE44
6-69
(3) Set the spool between holders and
Holder
loosen plunger cap (3) by using vise.
·Plunger cap
※ Set the spool between holders and clamp 3
them by a vise after degreasing the spool
and holders as a special tool.
7607WE45
(4) Remove the plunger cap (3), spring guide

(4), spring (6), sleeve (5) and spring guide
(7).
※ Spring is different from the other section 3
spring. 4
5
6
7
7607WE46

remove cover (10) after remove plug (8).
·Plug (8)
Tightening torque : 8.2 kgf·m (59.0 lbf·ft) O-ring
·Hexagon socket bolt (9)
9
※ Confirm that O-ring is put to end face of 7607WE47
housing.
8) MAIN RELIEF VALVE

(1) Loosen cap (1) and remove the main relief 2 1
cartridge from the body.
·Cap (1)
3 4 5
7607WE48
6-70
(2) Loosen hex nut (2), and remove adjust
screw (3), spring (4) and pilot poppet (5).
·Hex nut (2)
2 5
·Adjust screw (3) 4
3
7607WE49
(3) Pull out sleeve (9), and remove orifice (6),

spring (7) and main poppet (8).
7
6
9
8
7607WE50
※ Do not disassemble pilot seat, because

the pilot seat is assembled with pressure.
6 7 8 9
Pilot seat
7607WE51
6-71
(5) RESETTING THE RELIEF PRESSURE
Cap Adjust spring(C)
Adjust screw(A) Pilot poppet(B)
7607WE52
※ If setting pressure is mistaken, hydraulic unit may be destroyed and danger may be caused.
Do not raise by any means more than the pressure decided for every model.
Tempolary assembly and setting
① Check the position of setting pressure 0 MPa.
Set adjusting screw (A) temporarily in the position that pilot poppet (B) contacts to pilot seat.
Then pressure adjusting spring (C) begins to be effective.
② Install the main relief valve which is set temporarily to main body.
Tighten cap with torque wrench.
·Tightning torque : 10.2 kgf·m (73.8 lbf·ft)
To set pressure
① Attach exact pressure gauge at exit of pump or gauge port of control valve.
② Operate the pump with rated speed.
③ Operate plunger either boom or bucket at full stroke and check the pressure.
④ Turn adjusting screw (A) (right turn) and set pressure with checking pressure gauge.
·One quarter turn of adjusting screw (A) equals about 4 MPa.
·Setting pressure 20.6 MPa (210 kgf/cm2) at 220ℓ/min.
·Relief is very sensitivity. So, do not turn adjusting screw (A) suddenly.
⑤ Tighten lock nut with torque wrench holding adjusting screw.
·Tightning torque : 3.3 kgf·m (23.6 lbf·ft)
※ Operate plunger and check the setting pressure, again.
6-72
9) PORT RELIEF VALVE
Adjusting screw
※ Do not disassemble adjusting screw.
It’s impossible to readjust setting pressure
exactly on the machine.
(1) Loosen sleeve (1) and remove relief valve.
·Sleeve (1)
6 5 4 3 1 2
※ Install to original position. 7607WE53
(2) Loosen and remove relief seat sub-

assembly (2). And remove spring (3),(4)
piston (5), and main poppet (6).
·Relief seat (2)
Width across flat : 36 mm 4 2
3
6
7607WE54
10) MAKE UP VALVE

(1) Loosen sleeve (1) and remove relief valve.
·Sleeve (1)
4 3 1 2
7607WE55
(2) Remove cap (2) and pull out spring (3),

poppet (4).
·Cap (2)
Tightening torque : 10.2 kgf·m
(73.8 lbf·ft) 2
3
4
7607WE56
6-73
11) LOAD CHECK VALVE
2
2 1 1
3 4 3
- Bucket for 2-spools valve - Bucket for 3-spools valve

- Aux for 3-spools valve
- Boom for 2 & 3-spools valve
7607WE57
Example for explanation : Bucket section of 3-spools valve (double check)
(1) Remove cap (1) pull out spring (2), check

(3) and (4)
·Cap (2)
Tightening torque : 25.5 kgf·m (184 lbf·ft)
4
※ When reassembly ;
2
Be careful for the back-up ring not to
protrude.
3
※ Only Bucket section has double check. 7607WE58
6-74
3. REMOTE CONTROL VALVE
1) STRUCTURE
33
10
42 12
34 11
30 13
9
31 5
38,39,40,41
6
32
29
24 4
23
25
1,3,4 1
4
22 3 2 7
26
3
21 27
28 2
2
1,3,4 4 1
3 2
20
1
4 1
19
3 2
17 35
44 44
16 16
18 15 43
1,3,4
43
2
36,37,38,39
14 45
45
7607B6WE48
1 Body 13 Push rod 25 Plug 37 Rear holder

2 O-ring 14 Plate 26 Nut 38 Terminal
3 Plug 15 Rod stopper 27 Set screw 39 Seal wire
4 Spring 16 Bushing 28 Nut 40 2 Pin connector
5 Spring seat 17 Rod 29 Nut 41 Rear holder
6 Spool 18 Magnet 30 Handle bar 42 Clip band
7 Spring seat 19 Plate 31 Nut 43 Connector
8 Spring 20 Joint assy 32 Boot 44 O-ring
9 Stooper 21 Joint assy 33 Handle assy 45 O-ring
10 Plug 22 Plate 34 Nut
11 Rod seal 23 Washer 35 Plug
12 O-ring 24 Nut 36 6 Pin connector
6-75
2) DISASSEMBLY
(1) Remove the boots (32) and loosen nut
(31).
· Tool : spanner 19 mm
7607BRCV01
7607BRCV02
(2) Remove nut (29).
7607BRCV03
6-76
(3) Disassemble plate kit.
7607BRCV04
(4) Remove rod (17).
7607BRCV05
(5) Remove joint assembly (20).

· Tool : Spanner 17 mm
7607BRCV06
(6) Disassemble plate (19).
7607BRCV07
6-77
(7) Disassemble magnet (18) and rod stopper
(15).
7607BRCV08
(8) Disassemble plate (14).
7607BRCV09
(9) Disassemble plug kit.
7607BRCV10
(10) Disassemble spring (4) and spool kit.
7607BRCV11
6-78
(11) Disassemble plug (2).
· Tool : Wrench 10 mm
7607BRCV12
6-79
3) ASSEMBLY
(1) Coat oil on O-ring and mount plug (3) into
body assembly (1).
7607BRCV13
(2) Tighten the plug (3).

· Tool : Wrench 10 mm
· Tightening torque : 30±3 kgf·m
(217±21.7 lbf·ft)
7607BRCV14
(3) Assemble spring (4).
7607BRCV15
(4) Assemble spool kit.
7607BRCV16
6-80
(5) Assemble plug kit.
7607BRCV17
(6) Assemble plate (14).
7607BRCV09
(7) Assemble magnet (18) at port 1, 3 and 4.

Assemble rod stopper (15) at port 2.
Important
7607BRCV19
(8) Confirm port 2 on the bottom of the body.
7607BRCV20
6-81
(9) Assemble plate (19).
7607BRCV21
(10) Assemble joint assembly (20) and put

grease on joint pin lightly.
· Tools : spanner 17 mm
· Tightening torque (M16) :
45±4.5 kgf·m (325±32.5 lbf·ft)
7607BRCV22
7607BRCV23
(11) Assemble rod (17).
7607BRCV24
6-82
(12) Assemble plate kit.
Put a bit of grease on rod (17) and Joint
(21).
7607BRCV04
(13) Assemble nut (29).

· Tightening torque :
40±4 kgf·cm (289±28.9 lbf·ft)
7607BRCV03
7607BRCV02
6-83
(14) Assembled nut (31).
· Tightening torque (M12) :
40±4 kgf·cm (28±28.9 lbf·ft)
7607BRCV01
(15) Assemble the boots (32).
7607BRCV25
6-84
Group 1 Component Location ----------------------------------------------------------------------------------------- 7-1

Group 2 Electrical Circuit -------------------------------------------------------------------------------------------------- 7-3
Group 3 Monitoring System --------------------------------------------------------------------------------------------- 7-21
Group 4 Electrical Component Specification ------------------------------------------------------------------ 7-48
Group 5 Connectors --------------------------------------------------------------------------------------------------------- 7-55
Group 6 Troubleshooting -------------------------------------------------------------------------------------------------- 7-75
GROUP 1 COMPONENT LOCATION
1. LOCATION 1
15
Cab ceiling LH side
3
12
24 23
5
4 21
22
14 16
6 7 8 9 10 11 12 13 17 18 19 20
7579S7EL02
1 Beacon switch (opt) 9 Hazard switch 17 Starting switch

2 Rear wiper / washer switch 10 T/M shift mode switch 18 Engine mode switch
3 Mirror defrost switch 11 Clutch cut off mode switch 19 Parking brake switch
4 Emergency test switch (opt) 12 Multi function switch 20 Ride control switch (opt)
5 Fan control switch 13 Horn switch 21 Machine control unit (MCU)
6 Main light switch 14 Monitor 22 T/M control unit (TCU)
7 Work lamp switch 15 Radio & USB player 23 Engine control unit (ECU)
8 Kick down switch 16 Aircon & heater switch 24 USB socket
7-1
2. LOCATION 2
3 3 2 4
OFF
11 12 5
13
6 7 8 9 10
7609S7EL02-1
1 Head lamp 6 Start relay 11 Camera (opt)

2 Horn 7 Fuel sender 12 Work lamp
3 Proximity switch 8 Battery relay 13 Number plate lamp
4 Work lamp 9 Battery
5 Master switch 10 Rear combi lamp
7-2
CAB ROOF HARNESS
·ELECTRICAL
PTC
AC HARNESS
1
2
3
HI
OPTION
WIPER
RELAY
REAR
CN-244A
STEER
WITH PTC
LOW
AC
HORN
HEAT
RELAY
WIPER
RELAY
WIPER
RELAY
TIMER
DIFF.
LAMP
LOCK
LAMP
REAR
WORK
MIRROR
RELAY
UNIT
WORK
FRONT
RELAY
EMERGENCY
A
B
C
M
AC SYSTEM GND
FLASHER
BLOWER RELAY
SW2
2
2
2
2
2
2
1
1
1
1
1
1
GND 1
86
86
85
85
AC 24V
ILLUMINATION
WIPER SWITCH
WIPER SWITCH
WIPER SWITCH
Pf
NC
NC
B
E
MIRROR HEAT
MIRROR HEAT SWITCH
AC CONTROLLER B+
BEACON LAMP
NC
NC
NC
NC
NC
WORK LAMP FRONT

WORK LAMP FRONT
EMERGENCY TEST SW
AC OPERATE SIGNAL
SWITCH ATT. COM

REVERCE SW_RETURN
WORK LAMP REAR

WORK LAMP REAR
3
3
3
3
3
3
SWITCH ATT. LOCK
5
5
5
5
5
5
SWITCH ATT. UNLOCK
BOOM POSITION SELECT
WIPER SWITCH
NC
REVERCE SW_AUTO
BUCKET POSITION SLCT

CASSETTE_IG
CASSETTE/ROOM LAMP
REVERCE SW_ON
CASSETTE_ILLUMINATION
PTC POWER
30
30
AC COMP
REVERSE FAN SIGNAL
G
IG
A
Hi 4
2
3
Lo 5
4
4
4
4
4
4
4
3
OUT
87 87a
87 87a
1
3
2
4
4
4
2
2
2
2
2
2
6
1
1
1
1
1
1
5
3
3
3
3
3
3
14
7
13
5
10
10
1
87a
87a
4
3
2
1
5
5
5
5
5
5
15
13
14
15
2
4
4
4
4
4
4
9
5
3
6
8
3
12
11
12
11
B 85
86
86
8
1
6
9
7
1
85
85
30
30
L 87
E 86
87
87
A
2
2
1
B
7
4
6
C
2
5
8
3
CN-7
CR-79
CN-102
CR-4
CR-2
CR-3
CR-55
CN-244
CR-26
CR-7
CR-37
CN-245
CR-11
CN-11
CN-9
CR-56
L
L
L
L
L
L
B
Y
V
B
B
Y
Y
Y
B
B
V
Y
B
Y
B
Y
B
V
B
V
R
R
R
R
R
G
G
G
W
W
W
W
W
W
W
W
Br
Br
Br
Br
Gr
Gr
Gr
Gr
Gr
Or
5L
5B
WITHOUT PTC
BW
VW
BW
RW
RW
RW
RW
YOr
BrW
OrW
300
314
315
310
307
306
311
YW 214
211
462
467
460
230
245
242
140
144
141
GW 130
134
131
436
435
GW 500
RW 501
251
250
254
460
WOr 120
254
251
293
333
332
335
GOr 771
RW 770
520
LW 590
YOr 160
332
333
790
791
114
233
234
235
160
237
G02
G02
G01
G01
G08
G09
310B
310A
ROr 210A
230A
WOr 420A
426A
300A
300B
440D
WOr 690C
G01F
G01E
G01C
G01D
G01G
ELECTRICAL CIRCUIT (1/2) :
240 2.0
G11 2.0
141 1.25
131 1.25
131 1.25
230 0.85
2.0
2.0
2.0
2.0
2.0
0.85
314
315
307
310
311
211
462
245
242
144
134
GROUP 2 ELECTRICAL CIRCUIT
W 307
440A
1 WIPER MOTOR-LOW
R 315
2 WIPER MOTOR-HI
G 311
43 WIPER RY_LOW
Y 310
4 WIPER SW_LOW
520
590
160
Br 314
42 WIPER SW_HI
Y 629
9 RS232 RX 2-MONITOR
L 623
10 RS232 TX 2-MONITOR
GBr 624
37 PROGRAM DUMP-MONITOR
Y 625
CR-59 38 RS232 RX-CLUSTER
Br 422 L 626
86 30 87a 39 RS232 TX-CLUSTER
B G01 RY 627
85 50 PROGRAM DUMP-CLUSTER
RIDE-
87
OrW 216
86
85 87 87a
CONTROL
Br 217 L 251A
SPEED RY
30 13 MIRROR HEATED
Gr 650
14 CLUSTER_BATT. 24V
Or 570C
CR-60 18 SHIFT LEVER_IG
V 580
86 30 87a 27 CLUSTER_ IG
L 425 RW 935
85 6 LAMP-JOYSTICK STR
RIDE-
Br 217 GOr 930
87 15 TCU_ED6-NEU.
W 426 LW 920
86 16 TCU_ED5-REV.
85 87 87a
CONTROL
LOr 421 BrW 910
30 17 TCU_ED4-FWD.
435 WOr 451A
21 SHIFT LEVER_KD
425 ROr 915
CR-58 22 TCU_ED1
426 GrW 925
2 3 4 23 TCU_ED2
G 193 193 VOr 905
1 24 TCU_ED3
BrW 191 540
5
RELAY
Or 190
2
BACK-UP
1 5 4 190A OrW 150 1.25
3
Or MAIN SWITCH_ILL
33
G 180 2.0
TO SHEET 2 OF 2
34 MAIN SWITCH_HEAD
CR-63 LOr 154
35 MAIN SWITCH_ILL
191 YW 214
2 3 4 19 HORN RY
B G01B 436 YOr 184 1.25
1 31 MULTI_HEAD LAMP_LOW
LOr 200 200 R 187 1.25
RELAY
5 32 MULTI_HEAD LAMP_HI
GW 202 202
2
1 5 4 Or 190B
3
STOP LAMP
CR-25
RW 501
86 30 87a 30 FLASHER_L
B G01A B 795
85 12 GROUND_SHIELD
Y 620 L 790
87 7 CAN2 LOW
RELAY
RW 531 Y 791
86 8 CAN2 HI
85 87 87a R 530B LOr 303
30 40 MCU_INT
Gr 305 305
ECM POWER
41 MCU & WASHER
Gr 305A
CR-35
Br 300C
86 30 87a 45 FUSE BOX
B G01 Y 134
85 46 WORK LAMP SWITCH
Gr 550 2.0 VW 144
87 47 WORK LAMP SWITCH
RELAY
RW 531 531 Or 505
POWER
86 28 RH TURN
85 87 87a R 530 2.0 530A GOr 506
30 29 LH TURN
534 BrW 740
57 5V_POWER
WOr 690
CR-38 58 GND_SENSOR
LOr 754
2 3 4 59 TM MODE
R 540 BW 755
CAN2 BUS
1 60 CLUTCH_MODE
335
305
LW 538A
G02A
G02B
5
Or 570 G16
RELAY
2 1
1 5 4 Or 570 RY 627
1
1
2
2
4
NEUTRAL
3
CN-22
L 626
PUMP
3
CN-103
M
M
538 Y 625
CN-127C
WASHER
CR-5 2
86 30 87a
VW 539 539 G16
85 1
G 535 GBr 624
87 4
RELAY
LW 538 L
SAFETY
86
623 3
85 87 87a GOr 534
CN-127B
Y 629 CN-126
30 2
G16
D BATTERY(-)
BW 560
CR-46 J BATTERY(+)
G 993E
86 30 87a E CAN_Hi
L 380 V 994E
85 F CAN_Lo
FUEL
2LW 381 Y 791
87 G CAN2_Hi
RELAY
SERVICE TOLL
Y 370A L 790
86 H CAN2_Lo
WARMER
85 87 87a 2Y 370
30
G16 1
R 781 786
2 B MCU_RS232_RX
Br 782 787
CR-36 3 C MCU_RS232_TX
CONNECTOR_MCU & CAN
W 780 785
2 3 4 4 A MCU_RS232 P_DUMP
CAN BUS
GOr 371 371

1
Y 370B
RELAY
5
RW 372 372
2
CN-127
1 5 4
PRE-HEAT
CN-127A
Y 373 373
3
CN-58A
G16B
A13 GND(MAIN)
CN-36 G16A
A14 GND(MAIN)
10A BEACON WOr 120 Or 660
15 B38 ELEC. STEER MAIN PUMP PS
20A WORK LAMP_FRONT GW 130 2.0 V 661
MCU
16 B27 ELEC. STEER PUMP PS

20A MIRROR,SER.SOCKET2 RW 280
17 A33 SPARE_D_IN_HIGH
20A ILL.LAMP OrW 150 150 W 306
18 B02 WIPER RY
20A HEAD LAMP G 180 2.0 180
19 B01 BUZZER
10A BACK.STOP LAMP Or 190 154 GW 671
20 B07 SPEED PULSE_TCU
20A HORN/CONVERTER ROr 210 LW 538
21 A34 NEUTRAL SIG
30A AIR-CON/HEATER 1 L 230 2.0 VW 539
22 B03 ANTI-RESTART RELAY
20A FUEL WARMER Gr 250 1.25 V 467
23 B12 ELEC. STEERING PUMP RELAY
30A CIGARLIGHTER G 260 260 Y 423
24 A32 RIDE CONT. ON
W 112 8.0 210 BrW 424
A22 RIDE CONT. AUTO
280 G 993
A07 CAN(1)-H
20A SERVICE SOCKET 1 R 270 270 V 994
25 A17 CAN(1)-L
20A SPARE B 995
26 A04 CAN_SHIELD(GROUND)
20A WORK LAMP_REAR Y 140 2.0 R 672
27 B26 BRAKE OIL LOW PS
20A WIPER Br 300 VW 675
28 B37 PARKING OIL LOW PS
20A PARK ROr 340
29 B16 SPARE_D_OUT_HIGH
10A JOYSTICK-DETENT V 360 360
30 B39 BOOM DOWN PR SNENSOR
30A PRE-HEAT, FUEL WARMER Y 370 440
31 B29 BOOM UP PR SNENSOR
20A FAN REVERSE, ATT. LW 390 R 394
32 B04 REVERSE FAN CONTROL
10A RIDE CONTROL WOr 420 RW 358
33 B21 DIFFERTIAL LOCK PR SIGNAL
10A JOYSTIC_SWITCH Gr 440 Br 680
34 A03 +24V PRESSURE SNESOR
112 LW 705
B25 FUEL SENDOR
Y 112A 8.0 112A W 710
B35 HYD TEMP SENDER
103 ROr 715
B36 ALT LEVEL
G 720
B10 COOLING FAN EPPR-
20A TURN LAMP GW 500 V 721
1 B20 COOLING FAN EPPR+
5A CASSETTE/ROOM LAMP Gr 520 B 730
2
30A START KEY SWITCH R 530 2.0 570 YW 725
3 A36 AIR FILTER
10A TCU 24V BATTERY ROr 600 600 WOr 690A 690
4 B11 GROUND_SENSOR
20A ECM 24V BATTERY W 610 2.0 B 655
5 B17 TACHO SENSOR(+)_REMOTE FAN
20A MCU 24V BATTERY GW 630 230 W 656
6 B18 TACHO SENSOR(-)_REMOTE FAN
10A AIR-CON/HEATER 2 BrW 240 2.0 240 B 730
7 B24 SPARE_ENGINE COOLANT TEMP
10A CLUSTER 24V BATTERY Gr 650 G16
8 B13 SPARE_PREHEATER RELAY
520
A05 SPARE_DIGITAL INPUT_LOW
3R 103 160 L 790
A18 CAN2 LOW
590 Y 791
7-3
A08 CAN2 HI
LOr 303
A23 WIPER INT SIG
610 Gr 305
A31 WASH SIG
621
A38 SPARE_DIGITAL INPUT_LOW
L 380
B14 FUEL WARMER
Y 620 Gr 235
A35 AC CONDENSOR FAN SIGNAL
20A ECM_IG Br 621 W 234
9 B15 AC COMP. OFF SIG_REVERSE FAN
Gr 550 630 Or 233
A16 BLOWER RUN SIGNAL_DINP
10A MCU BW 560 560
10 A24 SPARE_HIGH SOURCE
A26 SPARE_LOW_ENGINE OIL LOW
10A TCU Or 570 570B
11 B40 BOOM POSITION SENSOR
570C
B30 BUCKET POSITION SENSOR
10A CLUSTER V 580 580 BrW 740
12 A01 REF. POWER +5V
650
A37 MECHANICAL ENGINE SELECT
10A CASSETTE LW 590 BW 560
13 A11 POWER IG(+24V)
A12 BATTERY POWER(+24V)
10A SPARE GW 630
14 A02 BATTERY POWER(+24V)
LOr 154
B09 DETENT CONTROL_BUCKET
5A ILLUMINATION 1 YOr 160 160A
35 B08 DETENT CONTROL_BOOM UP
390
B19 DETENT CONTROL_BOOM DOWN
5A ILLUMINATION 2 Or 170 170
36 A30 COUNT_WEIGHT_SET SWITCH
A39 SPARE_ENGINE SPEED SENSOR
BrW 740
A29 SPARE-DIGITAL INPUT-LOW
WOr 690B
A40 SPARE_SPEED PULSE
CS-55 LOr 754
B31 TM MODE SELECT SIG
B G21 BW 755
12 B28 CLUTCH CUT OFF_SLT SIG
2 1 BW 261
2 B32 ENGINE POWER MODE SELEET
Y 423 BrW 740
10 B22 SPARE_PR SIGNAL
4 Br 217 WOr 690
8 9 B05 SPARE_HOUR METER
10 8 B06 SPARE_D_OUT_HIGH
3 WOr 690C
7 A28 SPARE-DIGITAL INPUT-LOW
7 6 WOr 420
6 B33 SPARE-DIGITAL INPUT-LOW
9 423 RW 770
B23 REVERSE FAN MODE-ON
BrW 424 424 GOr 771
4 B34 REVERSE FAN MODE-AUTO
LOr 421
3 A15 BOOM POSITION SELECT SIGNAL
RIDE CONTROL SW
Or 170F
1 A25 BUCKET POSITION SELECT SIGNAL
12 11 W 780
11 A27 PROGRAM DUMP
R 781
A19 RS-232(1) RX
CS-17 Br 782
A09 RS-232(1) TX
B G21B WOr 757
12 A21 RS-232 GND
12
Or 170B Br 758
11 A10 RS-232(2) TX
R 759
10 A20 RS-232(2) RX
10
8
9 CN-134 A06 SPARE-DIGITAL INPUT-HIGH
4
ROr 340C Or 570A
8 1
9
ROr 340B Or 800
7
7 2
3
W 801 CN-58B
4
3
LW 350 CN-157
PARKING SW
6
DIAGNOSTIC
4
Y 352 B G17
3 1 VM1-GND
G17A
1 2 VM2-GND 14
11
12
Or 800
15 SDDK-DIAGNOSTIC 16
W 801
18 EUPR-DIAGNOSTIC 33
TCU
CS-79 Or 570A
6 NC 34
12
B G21A Y 352
21 ED10-PARKING BRAKE SW(+) 35
1
12
Or 170C 354 Y 353

1 66 ED9 DIFF. LOCK SWITCH 40
Y 353 353 YW 354
9 29 ED11 47
G 993
2 0 1
10 25 CANF_H 48
0,2
Or 570D V 994
5 26 CANF_L 50
4
B 995 995
6 28 VGS-CAN SHIELD 53
6
9: AUTO
GW 671
7 36 SD4-SPEED METER CLUSTER 54
600A
3: MANUAL
10 3
8 23 VPE1-CONTINUANCE 24V 58
5
YW 354 ROr 600 600

3 68 VPE2-CONTINUANCE 24V 60
9
DIFF. LOCK SW
Or 570 570
4 45 VPI-POWER IG 61
Or 170 B 810 810
11 3 VMG1-SPEED PICK-UP COM 27
11
12
W 820
19 EF1-SPEED PICK-UP ENG
B 810A
27 CANF_T
RW 825
CN-125 41 EF2-SPEED PICK-UP TURBIN
GW 630 B 810B 850A
BATTERY(+) 1 12 VPS1-GEAR BOX VPS1(+)
BW 560 WOr 830
KEY IG(24V) 2 42 EF3-SPEED PICK-UP GEAR
G 840
NC 3 4 VMG2-SPEED SENSOR OUTPUT
UNIT
R 759 V 845
SERIAL "1"_L(RX) 4 62 EF4-SPEED SENSOR(SIG)
Br 758 VW 850 850
REMOTE
SERIAL "1"_H(TX) 9 13 VPS1-GEAR BOX VPS1(+)

WOr 757 ROr 855
GROUND 5 17 ER3-SW FILTER RESTRICTION
GOr 860
NC 49 ER2-SENSOR TEMP CONVERTER
MANAGEMENT
B G21 OrW 865

GROUND 12 32 AIP3-GEAR BOX Y3
YOr 870
39 ER1-GEAR BOX TEMP
WOr 875
CR-41 46 VMGA2-GEAR BOX TEMP(COM)
B G19 BrW 880
86 30 87a 51 AIP6-GEAR BOX Y6
LW 743 743 Gr 885
85 55 AIP4-GEAR BOX Y4
YW 890
V 360 LOr 895
85 87 87a VOr 900
30
VOr 366 10 AIP2-GEAR BOX Y2
BOOM UP RY
VOr 905
20 ED3-SHIFT LEVER-X1A-B3
CR-40 BrW 910
43 ED4-SHIFT LEVER X2B-FWD
86 30 87a ROr 915
OrW 746 746 63 ED1-SHIFT LEVER X1C-B1
85 LW 920
B G19 64 ED5-SHIFT LEVER X2C-REV
87 GrW 925
V 360 65 ED2-SHIFT LEVER X1B-B2
86 GOr 930
85 87 87a 67 ED6-SHIFT LEVER X2D-NEU
GrW 365
BUCKET RY
30 WOr 451A 451

22 ED7-SHIFT LEVER-X1D-KD
DO-5 RW 935
7 ADM2-JOYSTICK SELECT LAMP(-)
1
GrW 365 WOr 449
CAN BUS
31 ED13-REV-JOYSTICK
2
V 360 DO-4 LOr 447
30 ED12-NEU-JOYSTICK
366 VOr 1 GrW 448
44 ED8-FWD-JOYSTICK
360 V 2 VOr 450
NC 14 59 ED15-JOYSTICK SELLECTER(+)
WOr 451
NC 15
V 360 360 W 426
24V(DETEND) 1 8 VPS2-RIDE CONT. RY(+)
Gr 440 440 R 540
24V(HANDLE) 9 52 ADM1-START INTERLOCK RY(-)
WOr 449 449 G 193
REV 2 5 ADM4-REVERSE DRIVE RY(-)
GrW 448 448 700 L 425
FWD 3 57 ADM5-RY RIDE CONT.(-)
LOr 447 447 945 Y 435
CN-246
NEUTRAL 4 11 ADM6-RY DIFF LOCK(-)

VOr 450 450 940 L 940
JOYSTICK SELECT 10 24 VMGA1-GROUND_BRAKE PEDAL
WOr 451 451 G 945
KICK DOWN 8 37 AU1-+5V SUPPLY_BRAKE PEDAL
Y 700
BOOM DOWN(-) 7 38 EU1-SIGNAL SENSOR_BRAKE PEDAL
GrW 365 W 426A
BUCKET(-) 6
VOr 366
BOOM UP(-) 5
JOYSTICK LEVER
COUNT_WEIGHT SW16
YW 214B
HORN SWITCH 11
Or 170D
ILLUMINATION 12
B G19
FNR SWITCH 13
CN-160
8.0
8.0
5.0
L
Y
W
280
270
210
260
B G21
L
B
Y
B
B
B
V
V
V
V
B
V
Y
B
V
R
R
R
R
R
R
R
G
G
G
G
G
W
W
W
W
W
W
W
W
W
W
W
Br
Br
Br
Gr
Or
Or
Gr
Or
Or
Gr
LW
LW
LW
LW
YW
VW
VW
YW
RW
RW
LOr
RW
RW
RW
RW
RW
LOr
GW
VOr
YOr
YOr
YOr
ROr
ROr
GOr
GOr
GOr
BrW
BrW
BrW
OrW
WOr
WOr
OrW
WOr
OrW
B G19
EARTH
GOr 534
531
530
531
531
2LW 381
350
112
112
112
112
103
202
610
621
945
940
746
743
360
211
462
394
141
506
505
170
390
184
187
191
200
535
216
422
237
245
242
373
371
372
890
900
865
885
895
880
850
870
860
855
875
112
112
675
672
700
830
825
820
810
845
840
660
661
715
705
725
710
721
720
730
680
358
740
436
656
655
570B
440A
160A
426A
810B
810A
690A
995C
994C
993C
B G22
B
B
B
B
B
R
R
R
2.0
G
Or
3.0
3.0
3.0
3.0
3.0
3.0
3.0
RW
B G20
3
3
9
8
7
6
9
8
7
6
4
1
4
1
5
5
2
2
220
ROr 210
260
220
280
270
WOr 690
BW 261
BrW 740
G22
G20
G20
48
47
46
45
44
43
36
41
40
39
38
37
32
35
34
33
42
31
30
29
28
27
26
25
24
23
22
21
20
14
13
15
17
16
19
18
12
11
10
13
60
20
44
26
56
55
54
53
52
51
50
49
48
47
46
45
43
42
41
36
29
37
22
21
23
24
33
35
34
32
31
30
58
28
27
57
25
38
40
39
59
19
18
17
16
15
14
12
11
10
CN-5
CN-6
170E
G22B
G22A
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
1
HORN
2 2
2
2
1 1
1
5
4
2
6
1
3
A
B
C
SHIELD
CL-2
CS-2
PARKING
AC R/DRY
AC R/DRY
TUU_GND
AC COMP.
CN-139
TCU_(5V+)
CN-172
CN-171
CS-80
B
FUSE MAXI
FUSE MAXI
FUSE MAXI
FUSE MAXI
FUSE MAXI
FUSE MAXI
FUSE MAXI
CN-138
ECM-J1939-
STOP LAMP
REAR LAMP
ECM-J1939+
1
SENSOR_24V
0, I
12V
24V
START RELAY
TUN LAMP_LH
2.5
FUEL SENDER
BACK BUZZER
TUN LAMP_RH
GND
SERVICE
MAIN PUMP PS
ALTERNATOR I
GROUND_MCU
HEAD LIGHT HI
SERVICE
GEAR BOX - Y1
GEAR BOX - Y2
GEAR BOX - Y3
GEAR BOX - Y4
GEAR BOX - Y5
GEAR BOX - Y6
FUEL WARMER
ATT. LOCK SOL
PILOT CUT-OFF
ECM POWER IG
DIFF. LOCK SOL
REF. POWER 5V
GEAR BOX TEMP
SOCKET SOCKET
HEAD LIGHT LOW
PRE-HEAT RELAY
ATT. UNLOCK SOL
ECM BATTERY 24V

ECM-J1939 SHIELD
GEAR BOX VPS1(+)

TEMP CONVERTER
HYD TEMP SENSER
12V
STEERING PUMP PS
4
RIDE CONTROL SOL.
FAN SPEED SENSOR

FAN SPEED SENSOR
SPEED SENSOR_24V
FILTER RESTRICTION
SENSOR_STOP LAMP
JUMP WIRE-JOYSTICK
AIR CLEANER SWITCH
BOOM UP PR SENSOR
ECM-AIR HEATER OUT
H0 I
BATTERY RELAY(DO-1)
SEERING PUMP RELAY
SEERING PUMP RELAY
GEAR BOX TEMP(COM)

SPEED SENSOR_VMG2
3
2
6
5
V
SPEED SENSOR_EF4(2)
24V
PRO-PORTIONAL VALVE
PRO-PORTIONAL VALVE
PRO-PORTIONAL VALVE
H
PROXIMITY SWITCH_24V
C BR ACC
BOOM POSITION SWITCH
TURBIN PICK-UP SENSER

TURBIN PICK-UP SENSER
FAN REVERSAL SOL _24V
BOOM DOWN PR SENSOR
ENGINE PICK-UP SENSOR

ENGINE PICK-UP SENSOR
ECM-AIR HEATER RETURN
BUCKET POSITION SWITCH

FAN PROPORTIONAL VALVE
FAN PROPORTIONAL VALVE
REAR COMBI_ILLUMINATION
REAR COMBI_ILLUMINATION
INTER GEAR PICK-UP SENSOR

INTER GEAR PICK-UP SENSOR
FAN REVERSAL SOL CONTORL
PRESSURE SENSOR_JOYSTICK
CLUTCHBRAKE PEDALSENSING
24V_SENSOR-CLUTCH CUT-OFF
CIGAR
BRAKE OIL PRESSURE SENSING
DIFFERENTIAL SHIFT PR SENSOR
PARK BRAKE PRESSURE SENSING

RIDE CONTROL PRESSURE SENSOR
12V SOCKET
SWITCH
SWITCH
START KEY
FRAME HARNESS
DC/DC CONVERTER
ECONO MODE
7579S7EL01
·ELECTRICAL
ELECTRICAL CIRCUIT (2/2)
OFF IDLE
5
CN-99 USB PLAYER(WITH H./FREE) POWER CONNECT SUB CONNECTOR
LINEAR THROTTLE
3 990A A A
AUTO REVERSE FAN SW EMERGENCY TEST SW
991A
REMOCON GND
CN-162
12
12
12
5
B RESISTOR 4 3
SPK FRT RH+

2
SPK FRT LH+

SPK FRT RH-
THROTTLE
SPK FRT LH-

G 647
REMOCON+
6 C B CN-20 0,2
BACK UP+
TEL MUTE
AUX_GND
ASSEMBLY
USB GND
YOr 646 G56
ANT 12V
CN-93
USB D+
1
USB 5V
5 2
USB D-
AUX_R
AUX_L
Or 645 YOr 646 213
GND
ACC
ILL+
4 1 OFF IDLE SW 1 2 0 1
ILL-
CN-27A
NC
NC
NC
NC
CS-73
CS-75
GW 644 Or 645
11
4 11
3
4
6 10
CN-27
9
3 11 ON IDLE SW 8 7
ON IDLE L 643 W 642 HORN
10
11
12
11
10
12
10
11
12
13
14
15
16
2 CN-25
9
4
8
1
2
3
4
5
6
7
1
2
3
4
5
6
7
1
3
3
1
23 ACCEL POSITION RETURN
6 W 642 L 643 G56A
1 9 ACCEL POSITION SIGNAL 2
WOr
OrW
GW 644 213A
GOr
YOr
RW
LW
RW
22 ACCEL POSITION SUPPLY 1
WOr
Or
BW
GOr
W
Gr
R
B
B
G 647
CN-6 34 SWITCH RETURN
G 990 G 990 213 CL-3
ECM-J1939+ 7 46 J1939(+)
V 991 V 991 179
G60D
G60C
Lo
G60E
ECM-J1939- 8 47 J1939(-) 6
163C
163B
163A
B 992 B 992 189A
G60
G60
774
696
775
461
591
523
524
521
163
525
526
513
514
515
516
517
518
519
ECM-J1939 SHIELD 9 37 J1939 SHIELD 4 Hi
RW 375 RW 375
PRE-HEAT RELAY 10 40 AIR-HEATER OUTPUT 5
GOr 374 GOr 374 172 172 SPEAKER
PRE-HEAT RELAY 11 42 AIR-HEATER RETURN 3 C
G56B
1 2 E CN-23
ABL
31 ALTERNATE TORQUE
LH
510 510 T
526 WOr
2 1 1
262 524
3 32 COOLANT LEVEL RETURN 2
262 G CL-4
4 28 COOLANT LEVEL
622 CN-10 179 179 CS-1
5 39 POWER IG 6 Lo CN-24
RH
6 23
189 189
4 Hi
HEAD R 522 525 W 1
ECU LIGHT 523
774
696
775
22 5 2
NC 13
Br 622
CN-94 21
162 162
3 C
-RH
W 611 2.0 611 W G56C DOOR S.W
2 E CN-7
ABL
NC 57 4 BATT (+) 20
2.0 611A W 509 509 T CL-1 163 YOr 1
3 BATT (+) 19 1 FUSE_ILLUMINATION
5B G55 2.0 G55B 591 LW
2 BATT (-) 18 3 3 FUSE-CASSETTE
2.0 G55A Gr 521A 521 Gr
1 BATT (-) 17 2 4 FUSE_ROOM LAMP
WOr 694 G60I 696 WOr
7 CN-100 1 5 MCU_RETURN
Gr 466 CN-29 2
GOr 510 742 742 BrW MG651032 774 RW
SEERING PUMP RELAY 52 2 1 B 7 MCU_REVERSE_MANUAL
R 463 R 243 Or 172 694A ROOM LAMP 775 GOr
SEERING PUMP RELAY 53 3 2 Pa 3 3 E 8 MCU_REVERSE_AUTO
V 663 V 238 R/DRY OrW 509 745 745 LW LH W 132
STEERING PUMP PS 55 1 1 4 4 S 1 9 NC
Or 662 YOr 179 G61
MAIN PUMP PS 56 5 CD-1 5
BOOM KICK OUT WORK 2 10 NC
684 W 711 711 R 189 694
4 2 C
HYD. TEMP
6
LAMP CL-5 11 NC
693A 693C YOr 162 CN-101
6 1 1 12 NC
W 213 742 FRONT W 132A
CD-10 8 1 B 1 13 NC
CN-19 YW 726 726 BrW 742 694 G61A
Pa 9 3 E 2 15 NC
WOr 693 693 AIR-CLEANER LW 745 748 748 RH
10 4 S CL-6 2 NC-NC
OrW 748 W 132 1.25 142 RW
CD-2 11
BUCKET LEVELER 6 WORK LAMP RELAY
B 657 693D B G56 1.25 1.25 132 W
FAN SPEED SENSOR_MCU 24 1 12 14 WORK LAMP RELAY
WORK LAMP FRONT

W 658 LW 706 706 FUEL SENDER B W 133 W 133
FAN SPEED SENSOR_MCU 23 2 13 CD-41 1
R 243 Or 432 695 G62
G57
AC RELAY 14 14 1 Pa 2
RIDE
S S + -
V 238 OrW 646 433
AC RELAY 16 CN-154(GRAY) 16 CONTROL 2 BOOM DOWN CL-35
W 711 G 722 722 Br 432 645 P./SWITCH
MCU_HYD TEMP SENSER 46 2 15 3
1.25
YW 726 V 723 723 FAN PROPORTIONAL V/V CN-141 W 133A
MCU_AIR CLEANER SWITCH 47 1 4 1
B 731 432 Or 433 G62A
CN-155(BLACK) 1 2
OPTION
LW 706 LW 391 391 646 OrW 645 CN-136
MCU_FUEL SENDER 48 2
FAN REVERSE SOL
2 CL-36
G 722 R 393 393 432 Br 432 432
MCU_FAN PROPORTIONAL VALVE 42 1 3 2 RIDE SOL
V 723 G57 G58 G58 RW 142 RW 142
WORK LAMP REAR

MCU_FAN PROPORTIONAL VALVE 43 4 1 CONT.VALVE 1
B 731 CD-73 694 WOr 695 G63
MCU_SHIELD 41 5 2
R 393 657 B
FAN REVERSAL SOL CONTORL 29 1 6 CL-32 CN-9
LW 391 658 W FAN PICK-UP 1.25 133 W
FAN REVERSAL SOL _24V 30 2 2 WORK LAMP RELAY
BrW 192 RW 142A 461 BW 1
BACK BUZZER RELAY 40 1 EMERGENCY RELAY
LOr 201 G63A 330 Br
STOP LAMP RELAY 39 2 3 FUSE-WIPER
RW 143 CN-250 CN-14 CN-14 CN-249 336 OrW
RELAY_WORK LMAP 33 CL-33 4 WASHER TANK
YOr 161 B 607 606 B 613 613 331 RW
CAMERA
FUSE_ILLUMINATION 31 2 1 1 1 SHD 5 REAR WIPER MOTOR
GOr 508 V 609 607 B 612 612 334 G
TURN LAMP_LH 35 4 2 2 2 GND 7 REAR WIPER MOTOR
Or 171 B 606 608 W 615 615 L 252
FUSE_ILLUMINATION 32 1 3 3 3 SIG 9 MIRROR HEAT CONT.
OrW 507 W 608 609 V 614 614
TURN LAMP_RH 34 3 4 4 4 24V 6 NC
5 5 14 NC
253 V
6 6 10 MIRROR HEAT CONT.
WOr 693
GROUND_MCU 45 CN-10 CL-23 11 NC
336
253
330
334
331
Br 684 161A RW 143 143 RW 146 146A 121 WOr
MCU_24V 36 1 12 12 1 12 FUSE_BEACON
508A 2
G71B
2 13 NC
171A
3 CL-22 WORK LAMP RH CL-7 15 NC
507A 146 R 122
YOr 185 185
4
B G70 1.25 G70 B G71A
1
WORK LAMP LH BEACON M
2
G64B
8 NC
G71
MULTI_HEAD LIGHT LOW 28
R 188 188
5 11 11 2 LAMP 1
MULTI_HEAD LIGHT HI 27 6 B G54 2.0 CL-21
693B 171B Or 174 174 CR-39
7 10 10 2 FROM BATT. RY
519
513
518
517
516
515
514
W 212 212 G71 465 L 252
G60M
G60N
HORN 54 8 1 2
G60L
G60J
YOr 163H
YOr 163K
RH
YOr 163J
BrW 741 741 CN-65 464 G64
334
331
OrW 336
330
253
122
WOr 121
MCU_REF. POWER 5V 26 9 1
MCU_BOOM POSITION SENSOR 44
LW 744 744
10
G54
1
BACK BUZZER
NUMBER PLATE LAMP CN-19 M MIRROR CN-150
OrW
OrW 747 747 BrW 192 192 374
GOr
Or
RW
RW
LW
MCU_BUCKET POSITION SENSOR 20 11 2 5 MOTOR RY
Or
HEATER
Br
W
G
R
B
B
Gr 465 L 252A
50 12 2 2
CN-27B
R 464 LH G64A
CL-16
CS-35
CS-76
CS-23
13 CD-40
3
1
3
1
3
1
2
1
ATT. UNLOCK SWITCH 3
5
4
3
1
10
10
9
10
9
8
51
12
12
12
11
11
11
10
571 Or 171 687 687
G62
G61
G64
G60
14
171 Br
A
- S+
4 C 4 Pa CN-149 8 7 8 7
Br 430 430 OrW 507 507 REAR V 664 664 1 10 3 I 0 11 1 11 1 11
RIDE CONTROL RELAY 17 15 3 T COMBI 1 B ELEC. STR PUMP PS
USB +(5V)
OrW 647 647 G54D 695 695
AUX GND
USB GND
WOr
RIDE CONTROL RELAY 18 16 RH 6 C
USD D+
2 E
AUX S2
AUX S1
USD D-
LOr 201 201 G63
17 1 S CD-39
687A 0,I
18 CL-15 A
- S+
YOr 161 161 374 Pa 12 5 8 12 12 10 4 9 3 12 12 10 4 9 3 12
NC 38 19 4 C B MAIN PUMP PS
20
GOr 508 508 REAR 695A REAR WIPER SW MIRROR HEATER SW BEACON SW USB PORT
NC 37 3 T C
G54E COMBI
BOOM UP SENSOR_MCU 21 21 2 E
201A LH
BOOM DOWN SENSOR_MCU 22 22 1 S EMERGENCY STEERING
23 THER_ AMBIENT RELAY(HI)
INCAR FET
NC 59 MISTER(+) TEMP ACT'R
CN-13 CN-96 MODE-1 ACT'R MODE-1 ACT'R INTAKE ACT'R SENSOR SENSOR
BLOWER
L 384 2.0 2.0 384 L
3
1
NC 58 1 B 2 7 2 7 2 7 2 7
1 4 1 4 1 4 1 4
L 384A 2.0 B G53 2.0 1.25 G53 B M M M M
4
2
2
A
5 5 5 5
3
FUEL HEATER CN-28
1
1
5
6
7
5
6
7
5
6
7
5
6
7
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
2
3
2
12
CN-13 Gr 247 1.25 247 AC-2 AC-22
5 2
Gr 246 246 Y 377 1.25 G53B AC COMP.
RY
BY
BW
BY
AC COMP. 15 5 6 1 NC 10 10
Y 376 376 G 537 1.25
PRE-HEAT RELAY 12 6 7 CN-80 NC 5 5
G 536 536 ROr 717 1.25 CR-24
2.0
2.0
2.0
2.0
START RELAY 19 7 8 15W 707 NC 14 14
ROr 716 716 RS-1 377
MCU_ALTERNATOR I 49 8 NC 6 6 CN-11
ROr 717A 961 B BW 2.0 BW
3 2 15R 709 PREHEATER GND 1 1 1 1 1 GND(CONTROLLER)
RESISTOR 3W/300 RW 718 1.25 964 YOr 4
RY RY
12 1 TAIL(+) 4 4 4 8 ILLUMINATION
382B L 963 RW RW 2.0 RW
1 PREHEATER BATTERY(+) 3 3 3 3 5 FUSE(Battery)
382A L RELAY 988 W L L
2 ALTERNATOR CN-74 REVERSE FAN 13 13 13 13 4 REVERSE_MCU
CR-23 CN-45 962 R R R
NC 4 5W 727 IG2 2 2 2 2 3 FUSE(IG)
G53A M 965 G RG LY
U
FI 3
ROr 717 537 5R 728
M ACT'R REF 7 7
968 BW
7 7
GB YW
6 DPS(COMPRESSOR)
L 2 SENSOR GND 8 8 8 8 7 CONDENSOR FAN
969 GW Y BR
~3 P 1
B+
THERMISTER(+) 9 9 9 9 2 BLOWER_SIGNAL
G 718 START RELAY 708 966 R 11
YL
B+ INCAR SENSOR 11 11 11
AIR CON
AC & HEATER CONTROLLER

708 15 R STARTER 970 OrW 12
YB
AMBIENT SENSOR 12 12 12
109 80R
FROM BATTERY RELAY 983 YW YW
CONDENSER FAN 18 18 18 18
WIF CD-45 987 Y 17
LY
COMPRESSOR 17 17 17
W 713 1.25 986 LW BY
2 2 WATER IN FUEL FET_F/BACK 16 16 16 16
R 712 1.25 HARNESS-CUMMINS 985 YW BR
1 1 (HL757-9SB) BLOWER RELAY_LO 15 15 15 15
984 BOr BL
FET_GATE 14 14 14 14
982 LW LW
MODE-2 ACT'R_PBR 12 12 12 12
981 Y LB
MODE-2 ACT'R_FOOT 11 11 11 11
980 LW LR
CD-3 MODE-2 ACT'R_DEF 10 10 10 10
684 Br Br 682 682A BRAKE ACC. PS
979 WOr LgW
A
- S+
3 3 Pa MODE-1 ACT'R_PBR 9 9 9 9
674 978 BW 8
LgB
B MODE-1 ACT'R_FOOT 8 8 8
693 WOr WOr 692 692A 977 Gr 7
LgR
5 5 C MODE-1 ACT'R_VENT 7 7 7
L 941 941 L L 942 976 Y 6
BrW
TCU_VMGA1(24) 60 6 6 TEMP ACT'R_PBR 6 6 6
G 946 946 G W 947 975 G 5
BrB
TCU_AU1(37) 25 9 9 TEMP ACT'R_WARM 5 5 5
974 BOr 4
BrR
TEMP ACT'R_COOL 4 4 4
673 R R 674 973 L 3
LW
1 1 INTAKE ACT'R_PBR 3 3 3
CD-26 972 BW 2
LB
INTAKE ACT'R_REC 2 2 2
CN-5 682 971 WOr 1
LR
A
- S+
Pa INTAKE ACT'R_FRE 1 1 1
676 VW VW 677 677 PARKING
4 4 B NC 13 13 13 13
CN-160
Br 662 2.0 692 PS
JOYSTICK SELECT 10
16
11
13
14
15
12
4
6
5
1
3
2
C
8
FUSE_JOYSTIC SW 9
7
FUSE BOX_IG 16
W 611 2.0 AC-1 AC-11
FUSE BOX_IG 17 CD-4
3L 382 942
RELAY_BUCKET
FUEL WARMER REALY 33 7 7 1 Pa
ILLUMINATION
S S + -
RELAY_BOOM
HORN RELAY
947
KICK DOWN
2 STOP LAMP
R 673 203 GW GW 204 204
NEUTRAL
MCU_BRAKE OIL LOW PRESSURE 13 8 8 3 CLUTCH CUT-OFF
VW 676 701 Y Y 702 702
FWD
GND
MCU_PARKING PRESSURE 14 2 2 4
REV
24V
NC
NC
NC
NC
Y 701
TCU_EU1(38) 15 10 10 STOP LAMP &
G50B B B G51
363 GrW
442 WOr
11 11 CLUTCH CUT-OFF PS
362 VOr
441 Gr
G19 B
12 12
369 V
GW 359 LW LW 351 CN-71
STOP LAMP RELAY 20 13 13
G51
14 14 1
351
SWITCH PILOT CUT OFF 29 15 15 2
LW 359
SWITCH PARKING 30 PARKING SOL
CN-12
NC 31 SHIFT LEVER
NC 42
AD7
AD6
AD5
AD4
AD3
AD2
AD1
CD-46 MONITOR CLUSTER
VM
VP
CN-110
ED
841 G
B1
AS
B3
B2
1
R
V
846 V SPEED SENSOR OUTPUT MULTI FUNCTION SWITCH 1
2 2 1 442
LAMP_JOYSTICK STR SELECTED
2 1
571 Or 2
Y 7
F
NC 34 3
B 5
WB 8
BG 3
BW 2
NC 35 CD-17 G19
4 3
811 B 6
CAMERA 0_INPUT_SIDE
Lo
CAMERA SIGNAL SHILD
1 4 BK- BK+ 3 362

821 W ENG. PICK-UP 5
OUTPUT SIGNAL
O
363
L
2
2 1
L
CAMERA 0_INPUT
CAMERA 3_INPUT
CAMERA 2_INPUT
CAMERA 1_INPUT
4
PROGRAM DUMP
MIRROR HEATED
5 BO- BO+ 2
PROGRAM DUMP
Lo Hi F
RS232 PC SHILD
B+
C
X1
RS232_SHILED
X2
ILLUMINATION
ILLUMINATION
Or 571 571 CD-27(GRAY) 3
AD5(R) C
D
A
D
C
B
4 3
FUSE_TCU 1 369
CAN2-SHILD
CAN2-SHILD
6 FL- FL+ 1
HIGH BEAM
RS232 RXD
RS232 TXD
G 841 812 BW 2
CAN2 LOW
CAN2 LOW
BATT. 24V
BATT. 24V
BATT. 24V
RS232 RX
RS232 TX
O
RH TURN
TCU_VMG2(04) 2
LH TURN
AD6(N)
1
AD4(F)
O J
TURBIN PICK-UP
I
GND_B+
CAN2 HI
CAN2 HI
GND_IG
AD1
AD2
AD3
V 846 826 RW 1
BWG C
IG 24V
IG 24V
ED1(VP)
2 1
Hi
TCU_EF4(62)
J
3
AD7(KD)
HO
2
STANDARD
I
GND
N
GND
B 811 CN-114
NC
NC
NC
NC
TCU_VMG1(03)
RW
4
BVi
BY
FRONT WIPER
Gr
W 821
W
CN-57
CN-56
G
4 3
L
TCU_EF1(19) 5 CD-47(BLACK)
BW 812 813 BOr
6
2
6
1
3
5
4
INTER
14
18
16
14
11
12
13
16
19
17
13
12
11
17
18
10
19
15
20
10
15
20
TCU_VMG1(03) 6 2
8
6
6
2
1
1
7
4
5
4
3
2
D
9
K
RW 826 831 WOr
TCU_EF2(41) 7 1 GEAR PICK-UP
BOr 813
GOr
GBr
CS-5A
CS-11
RW
SHIFT CLUTCH
CS-12
RY
B G50 1.25
4
5
2
TCU_VMG1(03)
5
8
1
3
Or
Or
4
1
3
2
7
Or
R
R
Y
Y
B
WOr 831
L
L
V
TCU_EF3(42) 9 MASTER SW CN-60 MODE CUT-OFF
GOr
YOr
YOr
LOr
RW
YW
SWITCH SWITCH
LW
B
CS-74 3R
Pf
JOYSTICK STEERING 10 40A
Gr
Or
Gr
Or
5 Lo
153E
251A
Br
Br
4 Hi
G
105
R
V
Y
104 104 3R
G15
G15
G15
G15
FUSE MAXI
187
790
791
624
596
594
592
650
650
580
790
791
935
625
626
627
505
506
650
580
153
629
623
JOYSTICK STEERING 11
2
3
1
M10 3R 102 111 15R 106 HAZARD SW ILL. HEAD LAMP SW WORK LAMP SW
JOYSTICK STEERING 12
CN-158
12
12
12
CN-159
X1
182
184
187
180
214
303
305
314
311
317
300
501
505
506
X2
12
12
12
3R
10
D
D
B
A
B
A
15R
0.5
0.5
4
9
80A
V
4
4
RW 532
4
CONT_JOYSTICK_INTPU1 18
M5 CN-95
WOr
GrW
BrW
RW 541
GOr
ROr
VOr
LW
3
CONT_JOYSTICK_SENSOR(-) 19
570C Or
G
R
3W 111F
L
CR-1
2
FUSE 21
3W 111A 532 80R 107 108 CS-41
1
11
11
451A
11
CS-42
CS-36
CS-59
CS-21
1
7
9
7
9
7
FUSE 22
930
920
910
915
925
905
10
11
11
11
12
12
12
C
CN-21
B
A
A
9
9
6
2
1
6
5
1
3
1
3
1
3
7
3W 111B G50 80R 109
FUSE 25
B
BATTERY
OrW
WOr
WOr
BrW
BrW
3W 111C
GOr
YOr
RW
LOr
LOr
LOr
LOr
VW
BW
LW
FUSE 26
Or
W
BATT. RY
G
R
R
B
B
3W 111D
G15
596
594
592
580
FUSE 27
3W 111E 15R 111 532A
FUSE 28 2
TO STARTER
153D
153A
153B
G50A
G14
G14
G14
G14
307
315
317
310
505
506
501
501
150
182
180
154
153
134
144
154
154
740
754
690
740
755
690
1
NC 23 DO-2
G14 1.25
B G15 1.25
RW 541
START KEY SWITCH 37
3R 102
FUSE 24
CD-48
ROr 856 856
TCU_ER3(17) 39 1
B
876B FILTER RESTRICTION

629 0.5
0.5
0.5
795 0.5
790 0.5
791 0.5
935 0.5
625 0.5
626 0.5
251A 0.5
NC 32 2 Pa
570C
WOr 451A
307
315
310
623
GBr 624
627
650
580
GOr 930
LW 920
BrW 910
ROr 915
GrW 925
VOr 905
505
GOr 506
501
214
LOr 303
305
314
311
300
YOr 184
187
OrW 150
180
154
134
144
LOr 754
BrW 740
BW 755
WOr 690
CD-49
876A
G15
G15
2 C
580
592
596
580
592
594
GOr 861 861 TEMP CONVERTER

RW
RW
LOr
YW
VW
RY
TCU_ER2(49) 40 1
Or
Or
Or
Gr
Br
Br
W
G
R
R
Y
Y
L
CN-112
9
7
8
6
1
4
2
10
37
12
38
39
50
13
14
27
15
16
17
18
21
22
23
24
28
29
30
19
40
41
42
43
45
31
32
33
34
35
46
47
59
57
60
58
W
B
V
B
B
V
B
L
16
WOr 876 876
CN-250A
TCU_VMGA2(46) 38 9 VMGA2
CN-250
CLUTCH_MODE
FUSE BOX_ILL
WORK LAMP RY_FRONT

WIPER MOTOR-LOW
WORK LAMP RY_RELAY

YOr 871 871
WIPER MOTOR-HI
TCU_ED4-FWD.
WIPER MOTOR-HI&LOW
TCU_ED1
TCU_ED2
TCU_ED3
FUSE BOX_HEAD
RH TURN
SHIELD_GROUND
HEAD LAMP_LOW
TCU_JOYSTCIK STR
MCU-SERIAL_H
TCU_ED6-NEU.
MCU-SERIAL_L
TCU_ED5-REV.
PROGRAM DUMP 2
WIPER RY_LOW
LH TURN
RS232_TX
TM_SHIFT_MODE
FLASHER_L
RS232 RX 2
GND_SENSOR
MIRROR HEATED
5V_POWER
1
1
2
4
2
4
ILL
RS232 TX 2
RS232 RX
FUSE BOX_TCU
FUSE BOX_BATT. 24V
FUSE BOX_BATT. IG
RS232 P_DUMP
HORN RY
TCU_KD
HEAD LAMP_HI
MCU_INT
TCU_ER1(39) 41
WIPER RY_HI
TEMP
MCU & WASHER
FUSE BOX
8
VW 851 851 FWD REV
TCU_VPS1(12,13) 36 7 VPS1(+)
BrW 881 881 1 2 3 4 1 2 3
TCU_AIP6(51) 43 6 Y6
LOr 896 896 Y5
TCU_AIP5(09) 44 5 Y5
Gr 886 886 Y2
TCU_AIP4(55) 45 4 Y4 Y3
OrW 866 866
TCU_AIP3(32) 46 3 Y3 Y6
VOr 901 901 VOr
TCU_AIP2(10) 47 2 Y2 Y4
TCU_AIP1(56) 48
YW 891 891 YW
1 Y1 Y1 TO SHEET 1 OF 2
GEARBOX
7579S7EL01-1
7-4
MEMORANDUM
7-5
1. ILLUMINATION CIRCUIT
1) OPERATING FLOW
Fuse box [CN-36 (18)] Illumination switch [CS-21 (3)] Switch ON, 1st step
[CS-21 (9)] Work and hazard switch, cluster, monitor indicator lamp ON
[CS-21 (7)] Fuse box [CN-36 (35)] Switch indicator lamp
I/conn [CN-6 (31)]
LH Combi clearance lamp ON [CL-15 (4)]
I/conn [CN-10 (1)] RH Head lamp ON [CN-4 (3)]
Fuse box [CN-36 (36)] Switch indicator lamp
I/conn [CN-6 (32)]
RH Combi clearance lamp ON [CL-16 (4)]
I/conn [CN-10 (3)] LH Head lamp ON [CL-3 (3)]
2) CHECK POINT
Engine Key switch Check point Voltage
① - GND (switch input)
OFF ON ② - GND (switch output) 20~25V
③ - GND (to light)
※ GND : Ground
7-6
ILLUMINATION CIRCUIT
CLUSTER
R
ILLUMINATION 17
CN-56
MONITOR
R
ILLUMINATION 18
CN-57 FUSE BOX

BEACON 10A
1 15
ILL & HEAD LAMP SW WORK LAMP_FRONT 20A
16
12 11
1
2 MIRROR,SER.SOCKET2 20A
17
OrW OrW ILL.LAMP 20A
3 18
4 HEAD LAMP 20A
19
BACK.STOP LAMP 10A
6 20
6 LOr HORN/CONVERTER 20A
7
4 21
AIR-CON/HEATER 1 30A
R 22
9 9
FUEL WARMER 20A
3
7 23
R CIGARLIGHTER 30A
11
12 1 B 24
12
LOr
CS-21
YOr ILLUMINATION 1 5A
35
WORK LAMP SW HAZARD SW
12 11 11 12
Or ILLUMINATION 2 5A
1 1 36
3 3
CN-36
4 4
LOr
6
6 LOr 7
3
7 7
4 9
8
4
9 9 9 8
3 10
7 10
R R
11 11
12 1 B 1 12
12 12
CS-36 CS-41
CN-6
1
2
3
4
26
27
HEAD LIGHT-LH
Lo 6 3 28
Hi 4
5
29
Or
C 3
B 30
E 2
ABL
YOr YOr
T 1 1 31
CL-3 Or Or
2 32
HEAD LIGHT-RH 3 33
Lo 6 3 4 34
Hi 4
5
YOr 5 35
C 3
E
B CN-10 59
2
ABL
T 1
60 ALL SWITCH INDICATOR LAMP ON
CL-4
3 CN-14
1
REAR COMBI-LH
C 4
YOr 2
T 3
B 3
E 2
S 1
4
CL-15 3 5
REAR COMBI-RH 11
Or
CL-21
NUMBER
C 4 10 2
PLATE
T 3 1
B LAMP
E 2
S 1
CL-16
7579S7EL03
7-7
2. HEAD LIGHT CIRCUIT
1) OPERATING FLOW
Fuse box [CN-36 (19)] Head light switch [CS-21 (6)] Light switch ON, 2nd step [CS-21 (4)]
Multi function switch [CS-11 (8)]
Multi function switch MIDDLE [CS-11(7)] I/conn [CN-6 (28)] I/conn [CN-10 (5)]
LH Head light low beam ON [CL-3 (6)]
RH Head light low beam ON [CL-4 (6)]
Multi function switch DOWN [CS-11(6)] I/conn [CN-6 (27)] I/conn [CN-10 (6)]
LH Head light high beam ON [CL-3 (4)]
RH Head light high beam ON [CL-4 (4)]
Cluster high beam pilot lamp ON [CN-56 (5)]
2) CHECK POINT

① - GND (switch input)
② - GND (switch output)
③ - GND (multi function input)
④ - GND (multi function output)
OFF ON 20~25V
⑤ - GND (multi function output)
⑥ - GND (low beam)
⑦ - GND (high beam)
⑧ - GND (passing B+)
※ GND : Ground
7-8
HEAD LIGHT CIRCUIT
FUSE BOX
ILL & HEAD LAMP SW BEACON 10A
15
12 11
2 WORK LAMP_FRONT 20A
1 16
MIRROR,SER.SOCKET2 20A
3 17
YOr
4 ILL.LAMP 20A
18
G G HEAD LAMP 20A
6 19
6 7 BACK.STOP LAMP 10A
4 20
HORN/CONVERTER 20A
9 9 21
3 AIR-CON/HEATER 1 30A
7
22
12
11 1 FUEL WARMER 20A
1 23
12
CIGARLIGHTER 30A
CS-21 24
YOr ILLUMINATION 1 5A
35
1
2 36
1 3 CN-36
6 2 4
3 26
R R
HEAD LIGHT-LH 4 27
YOr YOr YOr
Lo 6 5 28
R
Hi 4
5
6 29
Or
C 3
B 7 30
E 2
ABL
YOr YOr
T 1 8 31
CL-3 7 9
Or 32 Or
10 33
11 34
HEAD LIGHT-RH
YOr 12 35
Lo 6
R
Hi 4
13 59
5
YOr
C 3
B
14 60
E 2
ABL
T 1 15 CN-6
CL-4 16
CN-10
4
YOr
YOr
R
G
5
3 8
R
CS-11
CN-56
16
14
19
18
17
13
12
11
10
20
15
8
7
6
5
4
3
2
1
9
8
6
7
1
4
3
2
LAMP_JOYSTICK STR SELECTED
4BWG
W
6
Hi
C
MIRROR HEATED
PROGRAM DUMP
RS232 PC SHILD
ILLUMINATION
Hi Lo
CAN2-SHILD
HIGH BEAM
CAN2 LOW
BATT. 24V
RS232 RX
RS232 TX
B+
RH TURN
LH TURN
C
CAN2 HI
F
IG 24V
L
R
GND
O
GND
L
R
NC
NC
NC
Y 7 Lo
B 5
WB 8
CLUSTER
BG 3
BW 2
MULTI FUNCTION SWITCH
7579S7EL04
7-9
3. WORK LIGHT SWITCH
1) OPERATING FLOW
※ Illumination switch : ON position (1st step)
(1) Work lamp switch ON (1st step)
ILL & head lamp switch [CS-21 (9)] Work lamp switch indicate lamp ON
Work lamp switch [CS-36 (7)→(3)]
Front work lamp relay [CR-3 (2)→(5)] I/conn [CN-7 (14)]
LH Front work lamp ON [CL-5 (1)]
RH Front work lamp ON [CL-6 (1)]
(2) Work lamp switch (2nd step)
Work lamp switch [CS-36 (6) → (4)] Rear work lamp relay [CR-55 (2)→(5)]
I/conn [CN-6 (33)] I/conn [CN-14 (12)] LH Rear work lamp ON [CL-22 (1)]
RH Rear work lamp ON [CL-23 (1)]
2) CHECK POINT
① - GND (work lamp power input)
② - GND (work lamp power output)
OFF ON 20~25V
③ - GND (front work lamp)
④ - GND (rear work lamp)
※ GND : Ground
7-10
WORK LIGHT SWITCH
FUSE BOX
1
BEACON 10A
15
2 GW WORK LAMP_FRONT 20A
16
3 MIRROR,SER.SOCKET2 20A
17
4 ILL.LAMP 20A
18
HEAD LAMP 20A
5 19
RW RW BACK.STOP LAMP 10A
6 20
HORN/CONVERTER 20A
7 21
8 22
FUEL WARMER 20A
23
9 CIGARLIGHTER 30A
24
10
3 11
SERVICE SOCKET 1 20A
12 25
SPARE 20A
13 26
W W W Y WORK LAMP_REAR 20A
27
FR WORK 1 14
B WIPER 20A
LAMP-LH 2 28
CL-5 15 PARK 20A
29
W CN-7 JOYSTICK-DETENT 10A
30
FR WORK 1 PRE-HEAT, FUEL WARMER 30A
B
LAMP-RH 2 31
FAN REVERSE, ATT 20A
CL-6 32
RIDE CONTROL 10A
33
OPTION JOYSTIC_SWITCH 10A
1 34
CL-35
W W W
1 2 CN-36
B
2
3
FR WORK LAMP
4
W FUSE BOX
1
B 5 LOr
2
5A
CL-36 6 ILLUMINATION 1
35
7
CL-32
RW ILLUMINATION 2 5A
1 8 36
B
2
9 CN-36
RR WORK LAMP
10
RW
1
2
B 11 2 FR WORK LAMP RY
CL-33 12 4 3 2
B
1
13 W
5
4 14
Y
2
GW 4 5 1
3
8 15
CR-3
RW 9 CN-9
RR WORK 1
B
1
LAMP-LH 2 10 31 RR WORK LAMP RY
CL-22 B B 4 3 2
11 32 B
1
RW RW RW RW RW RW
RR WORK 1 12 33 5
B VW
LAMP-RH 2 2
CN-14 34 Y
CL-23 3 4 5 1
35 CR-55
59
2
60
WORK LAMP SW 1
CN-6
12 11
1
3
Y
4
VW
6
LOr
6 7
LOr
4
9 9
3
7
R
11
12 1
12
B
CS-36
ILL & HEAD LAMP SW
12 11
1
3
4 CLUSTER
R 17 ILLUMINATION
6
6 LOr CN-56
7
4
MONITOR
R R
9 9 18 ILLUMINATION
3
7 CN-57
R
11
12 1
12
B
CS-21 7579S7EL05
7-11
4. STARTING CIRCUIT
1) OPERATING FLOW
Battery(+) terminal Fusible link [CN-60] Master switch [CS-74]
I/conn [CN-5 (24)] Fuse box [CN-36] Start switch [CS-2(1)]
ECM power relay [CR-25(30)]
Power relay [CR-35(30)]
※ The gear selector lever is neutral position. It is necessary condition before the starting.
The gear selector has an output signal which is activated whenever the shift lever is in the neutral
position. This signal can be used to control a relay and prevent engine from starting whenever the shift
lever is not in the neutral position.
(1) When start key switch is in ON position
Start switch ON Start switch [CS-2(2)] I/conn [CN-5(37)] Master switch [CS-74]
Battery relay [CR-1]
Battery relay operating (All power is supplied with the electric component)
Start switch [CS-2 (3)] ECM power relay [CR-25 (30)→(87)]
Fuse box [CN-36 (9)] I/conn [CN-5 (16)]
ECM [CN-93(39)]
Power relay [CR-35(30)→(87)]
Fuse box [CN-36 (10)] MCU [CN-58A (A11)]
Fuse box [CN-36 (11)] TCU [CN-157 (45)]
(2) When start key switch is in START position

Start switch START [CS-2 (6)] Start safety relay [CR-5 (30)→(87)] I/conn [CN-6 (19)]
I/conn [CN-13(7)] Start relay [CR-23] +
Starter (terminal B and M connector of start motor)
2) CHECK POINT

① - GND (battery B+)
② - GND (fusible link)
③ - GND (start key B terminal)
④ - GND (start key BR terminal)
Running ON 20~25 V
⑤ - GND (i/conn CN-5 (37))
⑥ - GND (start key C terminal)
⑦ - GND (start safety relay output)
⑧ - GND (start key ACC terminal)
※ GND : Ground
※ ECM : Electronic control module
※ MCU : Machine control unit
7-12
STARTING CIRCUIT
2
MASTER SW CN-60
3R 104 3R 105
MONITOR CLUSTER 3R 15R 106
CN-95
RW
FUSIBLE LINK
RW
CAMERA 0_INPUT_SIDE
FUSE BOX USB PLAYER
10A BEACON CS-74 BATTERY RY
CAMERA 0_INPUT
15 RW 80R
REMOCON GND
20A WORK LAMP_FRONT
SPK FRT RH+

16
SPK FRT LH+

SPK FRT RH-
SPK FRT LH-
HIGH BEAM
REMOCON+
BATT. 24V
BATT. 24V
BATT. 24V
20A MIRROR,SER.SOCKET2
RH TURN
BACK UP+
TEL MUTE
LH TURN
17 1 B 80R BATTERY
ANT 12V
IG 24V
IG 24V
20A ILL.LAMP
18
GND
ACC
2
ILL+
CR-1
ILL-
CN-127
NC
NC
NC
20A HEAD LAMP
CN-250A
CN-57
CN-56
CN-250
19
3 DO-2 1
10A BACK.STOP LAMP RW
10
11
12
13
14
15
16
8
5
1
2
3
4
5
6
7
9
2
4
3
2
3
1
1
4
3
2
4
4
20 2
20A HORN/CONVERTER 14 B
21 1
30A AIR-CON/HEATER 1 15
LW
22
V
V
20A
STARTER
FUEL WARMER 16
23
M
24
30A CIGARLIGHTER
17 M
W START RY
21 5W
B B+
22
20A SERVICE SOCKET 1 G CN-45
25 5R
20A SPARE 23
26
20A WORK LAMP_REAR 24 CR-23
27
20A WIPER 25 R ALTERNATOR
28
20A PARK, PILOT CUT
29 26 1 B+
~ G
10A JOYSTICK-DETENT 2
27 Or 1 P
30
30A PRE-HEAT, FUEL WARMER 3 ROr L 3
2
31 28
20A FAN REVERSE, ATT CD-46 3 FI U
32 36
10A RIDE CONTROL 4 NC
33
10A JOYSTIC_SWITCH 37 CN-74
34
38 RESISTOR
Y RW
CN-5 5 1
CN-7
ROr 3W/300
3
1
4
2
2
RS-1
20A TURN LAMP
1 CN-13
5A CASSETTE/ROOM LAMP
2 1 1
30A START KEY SWITCH R 32 COOLANT LEVEL RETURN
3 G
2 2
10A TCU 24V BATTERY 28 COOLANT LEVEL
4
20A ECM 24V BATTERY 3 3 39 POWER IG
5
20A MCU 24V BATTERY 4 12 CN-93
6 ECM
10A AIR-CON/HEATER 2
7 5 5
10A
CN-94
CLUSTER 24V BATTERY 6 W
8 6 4 BATT (+)
W
19 7 3 BATT (+)
3R
20 2 BATT (-)
8
1 BATT (-)
21
22
CD-41
23
CN-10 CN-141 1
24
1 1 2 Pa
25
9
20A ECM_IG Br 2 2 3
26
Gr 3 3 4
46
10A MCU BW 4 4 S S + -
10
47
12 5
10A TCU Or 48
11 13 6
49
14
10A CLUSTER V
12 59 15 X2
60
V AD5(R) C
10A CASSETTE LW D
13 AD4(F) B
CN-6 C
B AD6(N) D
10A SPARE B
14 A A
ED1(VP)
CN-159 X1
5A ILLUMINATION 1 AD7(KD) D
35
8 3 AD1 C
5A AD2 B
ILLUMINATION 2
36
GOr
ROr
4
VW
BW
RW
LW
GOr
RW
Or
Or
6 AD3 A
BW
R
R
CN-36
RW
RW
GOr
AD7
VW
LW
Gr
LW
G
R
R
Y
B
Or
Or
CN-134
CN-157
CN-125
CS-2
R
68
45
ADM1-START INTERLICK RY(-) 52

63
64
65
67
22
CN-58A
7 AS AD6
3
8
7
A11
A34
ANTI-RESTART RLY B03
B36
12
1
3
4
5
2
9
1
2
3
4
5
6
3
2
6
5
4
R AD5
ED6-SHIFT LEVER X2D-NEU

VMG1-SPEED PICK-UP ENG
ED5-SHIFT LEVER X2C-REV
ADM2-JOYSTICK SELECT LAMP(-)

ED7-SHIFT LEVER-X1D-KD
CR-38
CR-5
CR-35
CR-25
ED1-SHIFT LEVER X1C-B1
SERIAL "1"_H(TX)
ED2-SHIFT LEVER X1B-B2
VPE2-CONTINUANCE 24V
SERIAL "1"_L(RX)
B DIAGNO- V AD4
87a 85 87 86 30 87a 85 87 86 30 4 1 5 2 3 87a 85 87 86 30
VPS2-RIDE CONT.RT(+)
POWER IG(24V)
0, I
1
B3 AD3
BATTERY(+)
STIC
KEY IG(24V)
NETURAL SIG
87a 87a 4 87a
GROUND
GROUND
B2 AD2
ALT LEVEL
VPI-POWER IG
30 87 30 87 2 5 30 87 B1 AD1
NC
NC
86 85 86 85 3 1 86 85
H 0 I II
4 3 2 1 4 3 2 1 4 3 2 1 ED
4
6
5
3
2
H
C ST ACC BR REMOTE N R F
K VP
POWER RY ECM POWER RY NETURAL RY SAFETY RY START SWITCH MANAGEMENT D VM
OUTPUT SIGNAL
MCU
TCU UNIT GEAR SELECTOR LEVER
7579S7EL06
7-13
5. CHARGING CIRCUIT
When the starter is activated and the engine is started, the operator releases the key switch to the
ON position.
Charging current generated by operating alternator flows into the battery through the battery relay
(CR-1).
The current also flows from alternator to each electrical component and controller through the fuse
box.
1) OPERATING FLOW
(1) Warning flow
Altermator [CN-74 (2)] I/conn [CN-13 (8)] I/conn [CN-6 (49)] MCU [CN-58A (B36)]
Cluster charge warning lamp ON
(2) Charging flow
Alternator Starter [CN-45 (B+)] Battery relay [CR-1]
Battery(+) terminal Charging
Fusible link [CN-60] Master switch [CS-74] I/conn [CN-5 (24)]
Fuse box [CN-30)]
Fusible link [CN-95] I/conn [CN-5 (21, 22, 25~28)] Fuse box [CN-36]
2) CHECK POINT

① - GND (battery)
② - GND (battery relay)
③ - GND (alternator B+)
OFF ON 20~28V
④ - GND (alternator 2)
⑤ - GND (MCU)
⑥ - GND (fuse box)
※ GND : Ground
※ MCU : Machine control unit
7-14
CHARGING CIRCUIT
6
MASTER SW CN-60
3R 104 3R 105
3R 8W 106
CN-95
RW FUSIBLE LINK
FUSE BOX
10A BEACON
15
20A WORK LAMP_FRONT CS-74
16
17
20A ILL.LAMP
18
20A HEAD LAMP
19
10A BACK.STOP LAMP BATTERY
20 BATTERT RY
20A HORN/CONVERTER 1 RW
21 80R
30A AIR-CON/HEATER 1 2
22
20A FUEL WARMER B 80R
3
23
30A CIGARLIGHTER
1
24 4 CR-1
W 2
21
20A
22
SERVICE SOCKET 1
25
20A
23
SEAT HEAT/AIR
26
20A WORK LAMP_REAR 24
27
20A WIPER 25 RW
28 2
20A PARK
B
29
26 1
10A JOYSTICK-DETENT
27 DO-2
30
30A PRE-HEAT, FUEL WARMER
31 28
20A FAN REVERSE, ATT
32 36
10A RIDE CONTROL
33
10A JOYSTIC_SWITCH
37
34
38
Y 47
48
20A
CN-5
TURN LAMP
1
5A AUDIO/ROOM LAMP STARTER
2
30A START KEY SWITCH M
3
10A TCU 24V BATTERY
M
4 START RY
20A ECM 24V BATTERY 5W
5
20A
B+
MCU 24V BATTERY
6 CN-45
10A AIR-CON/HEATER 2 5R
7
8
10A CLUSTER 24V BATTERY
CR-23 3
3R
R ALTERNATOR
1 1 B+
~ G
2 2 1 P
ROr L 3
2
3 3
3 FI U
4 4
46
4 4 NC
5 CN-74
20A ECM_IG
9 47 6
RESISTOR
48 7 RW
10A MCU 1
10 ROr 3W/300
49 8 2
RS-1
11
10A TCU 50 CN-13
59
10A CLUSTER
12 60
10A
CN-6
CASSETTE
13
ROr
14
10A SPARE 5
CN-58A
5A ILLUMINATION 1
B36
35
5A ILLUMINATION 2
36
CN-36
ALT LEVEL
MCU
7579S7EL07
7-15
6. ELECTRIC PARKING CIR
CIRCUIT
CUIT
1) OPERATING FLOW
(1) Parking OFF
Fuse box[CN-36 (29)] Parking switch OFF [CS-17 (8)→(4)] I/conn [CN-5 (30)]
I/conn [CN-12 (13)]
OFF ON
Parking solenoid [CN-71] ON (activated)
P
Parking brake released (by hydraulic pressure)
[CS-17 (7)→(3)] T/M control unit[CN-157 (21)]
(2) Parking ON
Fuse box [CN-36 (29)] Parking switch ON Parking solenoid [CN-71] OFF
Parking brake applied [By spring force]
2) CHECK POINT
① - GND (parking switch input)
Running ON ② - GND (parking switch output) 20~25V
③ - GND (parking solenoid)
※ GND : Ground
7-16
ELECTRIC PARKING CIRCU
CIRCUIT
IT
FUSE BOX
ILLUMINATION 1 5A
35
36
PARKING SW 1
B
12
12
Or
1
11 SERVICE SOCKET 1 20A
10 25
10
SEAT HEAT/AIR-RIDE 20A

26
8
9
ROr
4
WORK LAMP_REAR 20A

8 27
ROr
9
7 WIPER 20A
7
28
3
ROr PARK 20A

29
LW V JOYSTICK-DETENT 10A
4 30
Y PRE-HEAT, FUEL WARMER 30A
3 31
1 FAN REVERSE, ATT 20A
11
12
32
RIDE CONTROL 10A
CS-17 2 10A
33
JOYSTIC_SWITCH
34
BOOM UP RY
B
86 30 87a CN-36
LW
85
87
V
86
85 87 87a VOr
30 TCU
CR-41 1 VM1-GND
BUCKET RY 2 VM2-GND
86 30 87a 15 SDDK-DIAGNOSTIC
OrW 18 EUPR-DIAGNOSTIC
85
B Y
6 NC
87 21 ED10-PARKING BRAKE SW(+)
V
86 66 ED9 DIFF. LOCK SWITCH
85 87 87a GrW
30
Y 37 AU1-+5V SUPPLY_BRAKE PEDAL
CR-40 38 EU1-SIGNAL SENSOR_BRAKE PEDAL
DO-5 CN-157
GrW
1
V
2
DO-4
VOr
1
V
OrW
2
BrW
LW
LW
Y
JOYSTICK LEVER
CN-5
CN-6
16
20
21
25
26
44
45
33
47
48
30
31
32
14
29
13
3
15
1
1
2
NC 14
NC 15
V
24V(DETEND) 1
LW
Y
24V(HANDLE) 9
REV 2
FWD 3
LW
NEUTRAL 4
Y
JOYSTICK SELECT 10
CN-12
CN-10
KICK DOWN 8
10
10
11
12
13
14
15
11
12
7
3
8
9
6
1
7
8
9
2
2
4
5
BOOM DOWN(-) 7
GrW
BUCKET(-) 6
VOr
5
OrW
BOOM UP(-)
BrW
LW
LW
COUNT_WEIGHT SW 16
Y
HORN SWITCH 11
Or
ILLUMINATION 12
B
FNR SWITCH 13
CN-160
CIGAR LIGHTER
3
Or
Y
B
LW
CD-4
CN-71 B
BUCKET LEVELER
CL-2
1
2
3
4
BOOM KICK OUT
CN-101
CN-100
1
1
3
4
1
3
4
2
Pa
B
E
S
B
E
S
SS + -
STOP LAMP & PARKING SOL
CLUTCH CUT-OFF PS
7579S7EL08
7-17
7. WIPER AND WASHER CIRCUIT
1) OPERATING FLOW
Fuse box[CN-36 (28)] Wiper relay Hi [CR-4 (3)→(4)] I/conn [CN-4 (4)]
Front wiper motor [CN-21 (1)]
Wiper relay Lo [CR-26 (5), (2)]
Multi function switch [CS-12 (6)]
I/conn [CN-9 (3)] Rear wiper & washer switch [CS-35 (3)]
Rear wiper motor [CN-102 (1)]
(1) Front washer switch ON
① Washer switch ON [CS-12(6)→(2)] Front washer [CN-22 (1)] Washer operating
MCU [CN-58A (A31)→(B02)] Front wiper relay Lo
[CR-26 (5)→(3)] Front wiper motor [CN-21 (5)]
Wiper motor operating (low)
(2) Front wiper switch ON
① INT position
Wiper switch ON [CS-12 (6)→(1)] MCU [CN-58A (A23)→(B02)] Wiper relay Lo [CR-26 (5)→(3)]
Front wiper motor [CN-21(5)] Front wiper motor intermittently operating
② Lo position
Wiper switch ON [CS-12 (6)→(4)] Wiper relay Lo [CR-26 (4)→(3)] Front wiper motor [CN-21 (5)]
Front wiper motor operating (low)
③ Hi position
Wiper switch ON [CS-12 (6)→(3)] Wiper relay Hi [CR-4(3)→(5)] Front wiper motor [CN-21 (4)]
Front wiper motor operating (high)
(3) Auto-parking (when switch OFF)
Switch OFF Fuse box [CN-36 (28)] Wiper relay Hi [CR-4 (3)→(4)] Front wiper motor
[CN-21 (1)→(2)] Multi function switch [CS-12 (5)→(4)] Wiper relay Lo [CR-26 (4)→(3)]
Front wiper motor [CN-21 (5)] Wiper motor stop
(4) Rear wiper and washer switch
① Wiper switch ON (1st step)
Wiper switch ON [CS-35 (3)→(8)] I/conn [CN-9 (5)] Rear wiper motor [CN-102(5)]
Rear wiper motor operating
② Washer switch ON (2nd step)
Washer switch ON [CS-35 (3)→(5)] I/conn [CN-9 (4)] Rear washer tank [CN-103(1)]
Washer operating
2) CHECK POINT
Condition Check point
① - GND (front wiper switch power input) ⑥ - GND (wiper relay power input)
Engine : Stop ② - GND (rear wiper switch power input) ⑦ - GND (front washer power output)
Key switch : ON ③ - GND (wiper relay power input) ⑧ - GND (rear washer power output)
Voltage : 20~25V ④ - GND (front wiper motor Lo power input) ⑨ - GND (front wiper motor power output)
⑤ - GND (front wiper motor High power input) ⑩ - GND (rear wiper motor power output)
※ GND : Ground
7-18
WIPER AND WASHER CIRCUIT
WASHER
PUMP
CN-103
CN-22
2
1
1
2
OrW
FUSE BOX
Gr
B
B
25
20A
1 SPARE
26
WORK LAMP_REAR 20A
2 27
Br Br Br WIPER 20A
3 28
OrW OrW PARK 20A
4 29
JOYSTICK-DETENT 10A
RW RW 30
REAR WIPER 5 PRE-HEAT, FUEL WARMER 30A
B 31
12
6
12
FAN REVERSE, ATT. 20A

1
11 G G 32
G
10 7 RIDE CONTROL 10A
33
5
JOYSTIC_SWITCH 10A
RW 8
10 3
8 34
8
9
10 CN-36
OrW
0,I
5 10
I 0
Br 11
3
1 12
11
12
8 13 Y
WIPER RY HI
CS-35 4
B 3 2
2 14
R
1
5
15 Br
2
Br
CN-9 3 4 5 1
CR-4
3
WIPER RY LO
G
4 3 2
W
1
Y
FRONT WIPER 5
Y Y Y
3E 1 2
G LW W
2Pf 2 3 4 5 1
B B
1B 3
L R B CR-26
R 4 W
4 Hi 5
M
5 Lo 6
CN-21
6
5
4
REAR WIPER
Br
1 3E
G
2 2Pf
B
9 3 1B
4
LOr
LW
RW
Gr
Br
Br
G
5 4 Hi
7 6 5 Lo
M
1 CN-102
CS-11
CS-12
CS-5
CN-58A
WIPER INT SIG A23
A31
B02
1
2
3
4
5
6
8
7
6
5
4
3
2
1
HO
RW
BVi
BY
4BWG
Gr
W
G
L
WIPER RLY
Y
6
2
6
1
3
5
WASH SIG
C
Hi
J
C
W
II
II
J
Hi Lo
I
O
B+
C
MCU
F
L
R
O
L
R
Y 7 Lo
B 5
WB 8
BG 3
BW 2
7579S7EL09
7-19
HAZARD, TURN AND ROTARY CIRCUIT
11 FUSE BOX
WOr WOr WOr BEACON 10A
12 15
WORK LAMP_FRONT 20A
13 20A
16
MIRROR,SER.SOCKET2
17
14 ILL.LAMP 20A
18
15 HEAD LAMP 20A
19
CN-9 BACK.STOP LAMP 10A
20
HORN/CONVERTER 20A
21
22
1 FUEL WARMER 20A
23
2 CIGARLIGHTER 30A
24
3
4
CL-16 33 GW TURN LAMP 20A
C 4 1
OrW CASSETTE/ROOM LAMP 5A
T 3
B
34 2
E 2 START KEY SWITCH 30A
S 1
35 10A
3
TCU 24V BATTERY
36 4
REAR COMBI,RH ECU 24V BATTERY 20A
5
59 MCU 24V BATTERY 20A
6
60 AIR-CON/HEATER 2 10A
7
10A
CL-15 CN-6 CLUSTER 24V BATTERY
8
C 4
GOr
T 3
B
E 2 CN-36
S 1
REAR COMBI,LH
FLASHER UNIT
RW
87 L
GW
85 B G
B
86 E
CR-11
CLUSTER
8 PROGRAM DUMP
7 NC
6 MIRROR HEATED
5 HIGH BEAM
Or
4 RH TURN
GOr
3 LH TURN
2 BATT. 24V
ILL & HEAD LAMP 1 IG 24V
SW : ON(1st step) CN-56
GOr
RW
Or
CS-11
8
7
6
5
4
3
2
1
WOr
GOr
RW
RW
YOr
YOr
4BWG
Or
W
R
B
R
B
6
CL-7
CS-23
CS-41
7
3
1
3
1
8
4
9
9
10
10
12
12
11
11
1
2
Hi
C
1 8 7 11 1 8 7 11
Hi Lo
BEACON
B+
C
LAMP
F
L
R
O
L
R
12 10 4 9 3 12 12 10 4 9 3 12
Y 7 Lo
BEACON LAMP SWITCH HAZARD SWITCH

B 5
WB 8
BG 3
BW 2
7579S7EL10
7-20
GROUP 3 MONITORING SYSTEM
1. CLUSTER
1) STRUCTURE
The cluster consists of gauges, lamps and LCD as shown below, to warn the operator in case of
abnormal machine operation or conditions for the appropriate operation and inspection.
· Gauges : Indicate operating status of the machine.
· Warning lamps : Indicate abnormality of the machine.
· Pilot lamps : Indicate operating status of the machine.
· LCD : Indicates selected the driving speed and direction.
※ The cluster installed on this machine does not entirely guarantee the condition of the
machine. Daily inspection should be performed according to chapter 6, M MAINTENANCE.
AINTENANCE.
※ When the cluster provides a warning immediately check the problem, and perform the
required action.
Speedometer Emergency warning lamp

Left turning pilot lamp Right turning pilot lamp
T/M oil temperature gauge Hyd oil temp gauge
Engine coolant temperature gauge Fuel gauge
Lamps (See page 7-23) Lamps (See page 7-23)

LCD (See page 7-28) Battery volt meter
7579S7EL20
2) GAUGE
(1) Speedometer
Unit ① The speedometer displays the speed of machine in mph and
km/h.
※ The unit ((km/h
km/h or mph
mph)) can be set by the display set up menu
of the monitor and selected unit is displayed.
Refer to page 7-40.
75793CD03
7-21
(2) Fuel gauge
① This gauge indicates the amount of fuel in the fuel tank.
② Fill the fuel when the indicator moves red range or lamp blinks
in red, refuel as soon as possible to avoid running out of fuel.
※ If the gauge indicates below red range even though the
machine is on the normal condition, check the electric device
Red
75793CD04 as that can be caused by the poor connection of electricity or
sensor.
(3) Engine coolant temperature gauge

Red ① This gauge indicates the temperature of coolant.
·White range : 40~104˚C (104~219˚F)
·Red range : Above 104˚C (219˚F)
White ② If the indicator is in the red range or lamp blinks in red, turn
OFF the engine and check the radiator and engine.
75793CD05
(4) Transmission oil temperature gauge

Red ① This gauge indicates the temperature of transmission oil.
·White range : 40~107˚C (104~225˚F)
White ② If the indicator is in the red range or lamp blinks in red, it
means the transmission is overheated. Be careful that the indi-
cator does not move into the red range.
75793CD06
(5) Hyd oil temperature gauge

Red ① This gauge indicates the temperature of hydraulic oil.
·White range : 40~105˚C (104~221˚F)
White ② If the indicator is in the red range or lamp blinks in red, reduce
the load on the system.
③ If the gauge stays in the red range, stop the machine and check
75793CD08
the cause of the problem.
(6) Battery volt meter

① This gauge indicates the voltage in the charging system when
the engine is running.
24V 30V
② If the indicator is below 24V, it means that the electricity is being
20V 36V discharged. If the indicator is above 30V, an unusually high volt-
age may damage the alternator. Check the charging system in
both cases.
75793CD07
7-22
3) WARNING LAMPS
Emergency warning lamp Hydraulic oil temperature

T/M oil temperature warning lamp warning lamp
Engine overheat warning lamp Fuel level warning lamp
T/M error warning lamp

Air cleaner warning lamp Battery charging warning lamp
Engine oil pressure warning lamp Steering warning lamp(Emergency)
Steering warning lamp(Primary) Brake fail warning lamp
7609S3CD09
(1) Emergency warning lamp

① This warning lamp blinks and the buzzer sounds when commu-
nication error occur between monitor and MCU.
② When this warning lamp blinks, machine must be checked and
service immediately.
75793CD95
(2) Engine overheat warning lamp

① This lamp is turned ON when the temperature of coolant is over
the normal temperature (106˚C, 223˚F).
② Check the cooling system when the lamp is ON.
77073CD17
(3) Transmission oil temperature warning lamp

① This lamp informs the operator that transmission oil is above the
specified temperature.
② When this lamp lights up during operation, stop the engine and
check the machine.
75793CD35
7-23
(4) Hydraulic oil temperature warning lamp
① This warning lamp operates and the buzzer sounds when the
temperature of hydraulic oil is over 105˚C (221˚F).
② Check the hydraulic oil level when the lamp is turned ON.
③ Check for debris between oil cooler and radiator.
77073CD21
(5) Fuel level warning lamp

① This warning lamp lights ON when the fuel level is low.
Refuel the machine as soon as possible.
77073CD23
(6) Transmission error warning lamp

① This lamp lights ON and the LCD display show the error codes
when an error occurs in the transmission.
② Immediately pull the machine to a convenient stop. Stop the
engine. Investigate the cause.
※ Consult a HYUNDAI dealer to investigate the cause.
77073CD19
※ Do not operate until the cause has been corrected.
(7) Air cleaner warning lamp

① This lamp lights ON when the filter of air cleaner is clogged.
② Check the filter and clean or replace it when the lamp is ON.
77073CD20
(8) Engine oil pressure warning lamp

① This lamp is comes ON after starting the engine because of the
low engine oil pressure.
② If the lamp comes ON during engine operation, shut OFF engine
immediately. Check engine oil level.
77073CD18
7-24
(9) Steering warning lamp
① Primary
This lamp indicates that the primary steering has failed. When
the indicator comes on and the action alarm sounds, steer the
machine immediately to a convenient location and stop the
machine. Stop the engine and investigate the cause.
※ Do not operate the machine until the cause has been cor-
77073CD66
rected.
② Emergency
This lamp indicates the emergency steering system is active.
※ Immediately pull the machine to a convenient stop and stop
the engine.
※ The emergency steering system can be manually tested.
77073CD15
Refer to page 7-45.
(10) Battery charging warning lamp

① This lamp is ON when key ON, it is turned OFF after starting the
engine.
② Check the battery charging circuit when this lamp comes ON,
during engine operation.
77073CD22
(11) Brake fail warning lamp

① The lamp lights ON when the oil pressure of service brake drops
below the normal range.
② When the lamp is ON, stop the engine and check for its cause.
※ Do not operate until any problems are corrected.
77073CD16
7-25
4) PILOT LAMPS
Warming up pilot lamp Seat belt pilot lamp

Mirror defrost pilot lamp Fuel warmer pilot lamp
Preheater pilot lamp High beam pilot lamp
Parking brake pilot lamp
Fan reverse pilot lamp
Maintenance pilot lamp Clutch cut off pilot lamp

Ride control pilot lamp(Auto)
Ride control pilot lamp(On)
7609S3CD10
(1) Warming up pilot lamp

① This lamp is turned ON when the coolant temperature is below
30˚C (86˚F).
② The automatic warming up is cancelled when the engine coolant
temperature is above 30˚C, or when 10 minutes have passed
since starting the engine.
75793CD31
(2) Seat belt pilot lamp

① This lamp lights ON for the first five seconds after starting the
engine.
75793CD17
(3) Mirror defrost pilot lamp

① This lamp comes ON when mirror defrost switch is pressed.
※ Refer to page 7-44 for details.
7807A3CD11
7-26
(4) High beam pilot lamp
① This lamp works when the illuminating direction is upward.
② This lamp comes ON when the dimmer switch is operated, e.g.,
when passing another vehicle.
77073CD12
(5) Preheat pilot lamp

① This lamp lights ON when start switch is turned clockwise to the
ON position. Light will turn off after approximately 5~45 sec-
onds, depending on engine temperature, indicating that preheat-
ing is completed.
② When the lamp goes out the operator should start cranking the
77073CD14 engine.
(6) Parking brake pilot lamp

① When the parking brake is actuated, the lamp lights ON.
※ Check the lamp is OFF before driving.
77073CD13
(7) Maintenance pilot lamp

① This lamp will be ON when the consuming parts are needed
to change or replace. It means that the change or replace-
ment interval of the consuming parts remains below 30
hours.
② Check the message in maintenance information of the moni-
tor menu. Also, this lamp lights ON for 3 minutes when the
75793CD32
start switch is ON position.
(8) Clutch cut off pilot lamp

① This lamp lights ON when the clutch cut off mode switch is
positioned L, M, H.
※ Refer to page 7-45.
77073CD65
7-27
(9) Ride control pilot lamp (option)
① Auto ride control
This lamp lights ON when push in the bottom of the ride control
switch (auto position).
75793CD33
② Manual ride control

This lamp lights ON when push in the top of the ride control
switch (manual position)
75793CD34
(10) Fan reverse pilot lamp

① This lamp lights ON when the fan control switch is pressed.
7707A3CD40
(11) Fuel warmer pilot lamp

① This lamp is turned ON when the coolant temperature is below
10˚C (50˚F ) or the hydraulic oil temperature 20˚C (68˚F ).
② The automatic fuel warming is cancelled when the engine
coolant temperature is above 60˚C and the hydraulic oil tem-
perature is above 45˚C since the start switch was ON position.
21093CD43
5) LCD
Type 1 (1) The LCD can be used with the gear selector.
It indicates speed and driving direction.
2
3 No Symbol Meaning Remark
2
Forward, reverse, neutral
1 1 1, 2, 3, 4 Actual gear display Actual gear
75793CD39
P Parking brake mode active
2 , Forward, reverse Automatic mode
3 Gear range display Automatic mode
7-28
2. MONITOR
·The monitor is adjustable.

- Vertical : 14˚
- Horizontal : 30˚
Vertical
Main display
Horizonta
l
Menu button Enter button
Left move button Right move /

buzzer stop button
Camera / ESC button
75793CD23
1) BUTTONS
(1) Menu button
① Main display to main menu, main menu to main display.
② AEB cancel button in AEB setting.
75793CD90
(2) Left move button

① Move in menu (left, up).
75793CD91
(3) Camera / ESC button

① Enter rear camera mode in main display.
② Cancel button except in main display (move previous menu).
75793CD92
(4) Right move / Buzzer stop button

① Move in menu (right, down).
② Buzzer stop.
75793CD93
(5) Enter button

① Select menu (enter).
② AEB cancel button in AEB setting.
75793CD94
7-29
2) MAIN MENU
Main display
1 3
6
7
4 Main menu
5
8
10 Press
9
TYPE A (default)
2 8
9
5
10
6
7
TYPE B 75793CD11
1 Buzzer 5 Select gear 9 Hour meter, odometer

2 Clock 6 Engine mode 10 Monitoring
3 Wiper speed 7 Transmission mode
4 Actual gear 8 Engine rpm
※ Display type can be changed by operator. See page 7-40.
(1) Structure
No Main menu Sub menu Description
Engine speed Engine warming up, Engine speed
Kick down Mode 1 (down/up), Mode 2 (down only)
Wiper speed 4 steps
1
Fan-auto mode Interval and time setting
MODE AEB AEB setting
75793CD12
Speed meter Pulse setting
Fault code Active, logged fault (machine, ECU, TCU)
Machine monitoring Hyd temp, Battery, Coolant temp
T/M oil temp
2
Monitoring history Hour meter, ODO meter
MONITORING
75793CD13
Machine security ESL system setting, Change password

Maintenance Replacement, Change interval (oils and filters)
Machine information Version, Status
3
Service contact Service contact
MANAGEMENT Service menu S/W download
75793CD14
Clock Clock
Display Brightness setting (Manual/Automatic)
Type display (A or B type)
4
Unit Temp (˚F/˚C), Distance (km/mile), Pressure (bar, Mpa, kgf/m2, psi)
DISPLAY SET UP Rear camera Reverse mode, Active camera, Display order
75793CD13
Language 12 languages
7-30
(2) Mode
① Engine speed
75793CD16
75793CD16A 75793CD16B
Set low idling speed
75793CD16C 75793CD16D
② Kick down
75793CD17
75793CD17A
· Mode 1 (down/up) : Press kick down button once, shift down and press button again, shift up.
· Mode 2 (down only) : Press kick down button every time, shift to lower gear respectively.
③ Wiper speed
75793CD18
· Setting wipe speed 1 to 4.
75793CD18A
④ Fan-auto mode
75793CD110
75793CD111 75793CD112
· Select reverse interval or reverse time.

· Set reverse interval (30~300 min) or reverse time (30~300 sec).
※ Default : Interval (60 min), time (120 sec)
※ Refer to page 7-44, fan control switch.
7-31
⑤ AEB
Actual gear window
75793CD19
75793CD19A
· AEB mode controls the disk clearance of the transmission, automatically.

· To start AEB setting, press and hold for 3 seconds.
· To cancel AEB setting, press , or .
· If "OK" in actual gear window, press , or to complete AEB setting.
· Display during AEB mode
Symbol Meaning
ST Start AEB
K1~K4, KV, KR Calibrating clutch K1~K4, KV or KR respectively
OK* Calibration for all clutches finished
Spanner and Kx* Kx couldn't be calibrated, AEB finished

Engine speed too low
△E
- Raise engine speed
Engine speed too high
▽E
- Lower engine speed
Transmission oil temperature too low
△T
- Heat up transmission
Transmission oil temperature too high
▽T
- Cool down transmission
FO* Output speed not zero
FN* Shift lever not in neutral position
FP* Parking brake not applied
* : Transmission stays in neutral, you have to restart the TCU (ignition off/on).
⑥ Speed meter
75793CD20
75793CD20B 75793CD20A
· Press and hold for 3 seconds.

· To change the pulse value, press or .
· To change the position, press .
※ Only for the serviceperson.
7-32
(3) Monitoring
① Fault code
75793CD23
75793CD23C 7709S3CD23D
75793CD23E 7709S3CD23
7709S3CD23G
75793CD23H 75793CD23I
75793CD23J
· Monitor the fault code of the Machine / ECU / TCU .

※ Not define will be indicated in case of that there's no fault.
7-33
② Machine monitoring
75793CD24
7709S3CD24A 7709S3CD24B
· Monitor the status of the machine.

· To check the item in main display, choose it and press .
· The right icon shows ON / OFF status.
③ Record monitoring
75793CD25
75793CD25A 75793CD25C
· Hour meter
- Total : total hour meter
To show the item in the main display, select "ON"
and press (this item could not reset).
- Latest : the latest hour meter after reset.
and press . 75793CD25D
To reset the latest hour meter, select "initializing" and

press .
75793CD25F 75793CD25H
· ODO meter
- Total : total ODO meter
and press (this item could not reset).
- Latest : the latest ODO meter after reset.
and press .
75793CD25J
To reset the latest odometer, select "initializing" and
press .
7-34
(4) Management
① Machine security
75793CD26
75793CD26A 75793CD26B
· ESL system setting

- ESL : Engine Starting Limit
- ESL mode is designed to be a theft deterrent or will pre-
vent the unauthorized operation of the machine.
- If the ESL mode was selected Enable, the password will
be required when the start switch is turned ON.
- Disable : Not used ESL function
Enable : The password is required whenever the 75793CD26C
operator start engine.

Interval mode : The password is required when the opera-
tor start engine first. But the operator can
restart the engine within the interval time
without inputting the password.
The interval time can be set maximum 2
days.
※ Default password : 00000
* 75793CD26D
· Interval setting
- If set interval setting to 5 minutes,
ESL system is activated after 5
minutes.
Therefore, the password does not
need to restart engine within 5
minutes. 75793CD26J 75793CD26K
7-35
· Change password
- Input 5 to 10 digits and press *.
75793CD26G 75793CD26H
Enter the current password.
75793CD26L
Enter the new password.
75793CD26N 75793CD26M
The new password is stored Enter the new password
in the MCU. again.
7-36
② Maintenance
75793CD27
75793CD27A 75793CD27B
75793CD27D 75793CD27C
· Alarm ( ) : Warning
Replacement : The elapsed time will be reset to zero.
Change cycle : The change or replace cycle can be changed in the unit of 50 hours.
· To change cycle, press or .
· Change or replace interval
No Item Interval
1 Engine oil 500
★1
2000
2 Hydraulic oil ★2
5000
3 Pilot line filter element 250
4 Hydraulic oil return filter 250
5 Engine oil filter 500
6 Fuel filter element 500
7 Fuel pre-filter 500
8 Hydraulic tank air breather 250
9 Radiator coolant 2000
10 Transmission oil and filter 1000
11 Axle oil (front and rear) 1500
★1
: Conventional hydraulic oil
★2
: Hyundai genuine long life hydraulic oil
7-37
③ Machine information
75793CD28
75793CD28A 7579S3CD28B
75793CD28C 75793CD28D
· Version
- Software versions of MCU, cluster and monitor can be
checked.
· Status info
- The machine status can be checked.
75793CD28E
④ Service contact
75793CD29
75793CD29A 75793CD29B
· The phone number of the service man can be checked and changed.
⑤ Service menu
75793CD30
75793CD30A 75793CD30B
· The software of monitor can be downloaded.
7-38
(5) DISPLAY SET UP
① Clock
75793CD32
75793CD32A
· To set time, press or .

· To move position, press .
② Display
· Brightness setting
75793CD33
75793CD33A
75793CD33B 75793CD33C
Manual (1st~8th step)
75793CD33D 75793CD33E
Auto (day / night)

※ If "Automatic" is chosen, brightness for day and night can be differently set up. Also by
using the bar in lower side, users can define which time interval belongs to day and night.
(in bar figure, gray area represents night time while white shows day time)
7-39
· Display type
75793CD33F 75793CD33G 75793CD33H

A type
75793CD33I
B type
③ Unit
75793CD34
75793CD34A 75793CD34B
· Temperature : ˚C ↔ ˚F
· Distance : km ↔ mile
· Pressure : bar ↔ Mpa ↔ kgf/m2 ↔ psi
7-40
④ Rear camera
75793CD35
75793CD35A 75793CD35B
75793CD35C 75793CD35D
75793CD35E 75793CD35F
· Reverse mode
- If transmission engages the reverse gear (R1~R3), the camera mode is displayed
automatically in main display.
· Active camera
- Three cameras can be installed on the machine.
- The display order can be set by this menu.
· If the camera was not equipped, this menu is not useful.
· In main display, if the button is pushed, the first ordered display camera will be viewed.
⑤ Language
75793CD36
75793CD36A 75793CD36B
· User can select preferable language and all display are changed the selected language.
7-41
3. SWITCHES
Cab ceiling LH side
Mirror defrost switch(option) A
M
Rear wiper/washer switch
Beacon switch(option) M
USB socket Fan control switch

Emergency test switch(opt)
Main light switch

Work lamp switch
Kick down switch
Hazard switch Engine mode switch
T/M shift mode switch Parking brake switch
Clutch cut off mode switch Ride control switch(opt)
Multi function switch
P
Horn button
Starting switch
7709S3CD29
1) STARTING SWITCH
(1) There are three positions, OFF, ON and START.
· (OFF) : None of electrical circuits activate.
· (ON) : All the systems of machine operate.
· (START) : Use when starting the engine.
Release key immediately after starting.
※ If you turn ON the starting switch in cold weather, the fuel warm-
77073CD41
er is automatically operated to heat the fuel by sensing the cool-
ant temperature. Start the engine in 1~2 minutes after turning
ON the starting switch. More time may take according to ambi-
ent temperature.
※ Key must be in the ON position with engine running maintain
electrical and hydraulic function and prevent serious machine
damage.
7-42
2) HAZARD SWITCH
(1) Use for parking, or loading the machine.
ON
OFF (2) Both turn signal lights will flash simultaneously.
※ If the switch is left ON for a long time, the battery may be dis-
charged.
75793CD42
3) PARKING BRAKE SWITCH

Safety button (1) When the switch is pressed to ON position, the parking brake will
ON start to operate and the cluster warning lamp will comes ON.
Release
Lock
(2) Press the release position in order to disengage the parking brake.
Unlock
※ When operating the gear selector lever, be sure to release the
P
parking brake. If the machine is operated with the parking brake

75793CD44 engaged, the brake will overheat and may cause the brake sys-
tem to go out of order.
※ This switch can be set to ON or Release position only when the
safety button is pulled to the unlock position.
4) MAIN LIGHT SWITCH

(1) This switch use to operates the clearance lamp and head light by
two step.
·First
First step : Clearance lamp and cluster illumination lamp
comes ON. Also, all indicator lamp of switches
come ON.
·Second
Second step : Head light comes ON.
75793CD45
5) WORK LAMP SWITCH

(1) This switch use to operates the front and rear work lamps by two
step.
·First
First step : Front work lamp located on the cab comes ON.
·Second
Second step : Rear work lamp located on the cowl comes ON.
75793CD46
6) REAR WIPER AND WASHER SWITCH

(1) The switch use to operates the rear wiper and washer by two step.
OFF ·First
First step : The rear wiper operates.
ON
·Second
Second step : The washer liquid is sprayed and the rear wiper is
operated only while pressing. If release the switch,
return to the first step position.
75793CD47
7-43
7) FAN CONTROL SWITCH
(1) This switch use to control the cooling fan.
OFF
AUTO (2) This switch has three positions.
MANUAL ·AUTO
UTO : The fan automatically work in reverse according to set
up interval and time.
·OFF
OFF : Only forward rotation is possible.
75793CD49
·MANUAL
MANUAL : The fan rotates reverse only while pressing this position.
If release the switch, return to the OFF position.
(3) On pressing the switch, the indicator lamp is turned ON.
8) MIRROR DEFROST SWITCH (option)

(1) If the mirror defrost switch is pressed in condition of key ON, it oper-
ates for 15 minutes. After 15 minutes, the defrost function stops
automatically.
(2) One more pressing the switch in operation also stops defrost func-
tion.
(3) On pressing the switch, the indicator lamp is turned ON.
75793CD48
9) BEACON SWITCH (option)

(1) This switch turns ON the rotary light on the cab.
75793CD50
10) RIDE CONTROL SWITCH (option)

OFF (1) AUTO
MANUAL Press in the bottom of the ride control switch in order to turn on the
AUTO automatic ride control. The automatic ride control automatically
turns on when the travel speed exceeds a preset speed of approxi-
mately 7 km/h. The automatic ride control automatically shuts off dur-
75793CD51 ing low speed travel (below 7 km/h).
(2) MANUAL
(2
Press in the top of the ride control switch in order to turn on the sys-
tem for ride control regardless speed. The ride control will smooth
the ride of the machine during travel.
(3) OFF
(3
Press the ride control switch to the middle position in order to turn
off the system for the ride control.
7-44
11) EMERGENCY TEST SWITCH (option)
(1) The emergency steering system can be manually tested. Push the
switch in order to determine if the emergency steering and the
emergency steering lamp are functional.
M
(2) When the switch is pressed, the emergency steering pump motor
will run. The emergency steering lamp will light. If the emergency
75793CD52
steering lamp does not light, do not operate the machine.
12) ENGINE MODE SWITCH

(1) The operator can adjust the machine's performance with this dial
S switch.
E P
· P (Power) : Maximum power output for hard digging operation
or hill climb.
· S (Standard) : General digging and loading operation.
· E (Econo) : Maximum fuel efficiency for general loading.
75793CD57
13) CLUTCH CUT OFF MODE SWITCH

(1) Four modes are available for operator's preference and job condition.
L M · OFF : The clutch cut off function is disable.
OFF H · L (Low) : The clutch is disengaged early for short-distance
and rapid loading.
· M (Medium) : The clutch is disengaged normally for general dig-
ging and loading operation.
· H (High) : The clutch is disengaged lately for slope ground.
M mode (2) The clutch cut off functions of the left brake pedal depend on the
L mode
position of the left brake pedal and the position of the clutch cut off
mode switch.
H mode Positions for clutch cut off function
Left brake pedal

Clutch cut off mode switch L M H
75793CD58 Left brake pedal L, M, H M, H H
14) TRANSMISSION SHIFT MODE SWITCH

(1) Four modes are available for operator's preference and job
A
.
. AN
AL
.
condition.
MAN AH
· MAN (Manual) : Machine is operated by selected gear on
lever.
· AL (Auto Light) : Automatic shifting point is fast for long-dis-
tance transportation and fuel efficiency.
75793CD59
· AN (Auto Normal) : Automatic shifting point is normal without
automatic kick-down to 1st gear for general
digging and loading operation.
· AH (Auto Heavy) : Automatic shifting point is normal with auto-
matic kick-down to 1st gear for more power-
ful operation.
7-45
15) HORN BUTTON
Horn button (1) If you press the button on the top of the multifunction switch, the
horn will sound.
7609S3CD16
16) CAB LAMP SWITCH

(1) This switch turns ON the cab room lamp.
DOOR ON ① DOOR
The lamp comes ON when the door is opened.
When the door is closed the lamp is OFF.
② ON
This switch is used to turn the lamp ON or OFF.
75793CD63
17) USB SOCKET

(1) MP3 files are played when a USB device is connected to the USB
port.
(2) In addition, the AUX port enables headphone and other devices.
AUX USB
HB1003CD63
18) KICK DOWN SWITCH

Kick down switch (1) Manual mode
It is effective 2nd speed to 1st speed only and recover to 2nd speed
quickly when push the switch one more time.
(2) Automatic mode
① Mode 1 (down/up)
It shifts down quickly from current gear to one step lower speed by
pushing the switch and recover to current speed quickly when push
7609S3CD24
the switch one more time.
② Mode 2 (down)
It shifts down from current gear to one step lower speed when
push the switch every time.
The kick down function is released in only 1st speed.
※ Refer to page 7-31 for the kick down setting.
※ The normal autoshift function continues after the kick down
switch is released.
7-46
19) MULTI FUNCTION SWITCH
O J ⅠⅡ (1) Front wiper and washer switch
① When the switch is in J position, the wiper moves intermittently.
② When placed in Ⅰ or Ⅱ position, the wiper moves continuously.
③ If you push the grip of the lever, washer liquid will be sprayed and
the wiper will be activated 2-3 times.
73033CD29
※ Check the quantity of washer liquid in the tank. If the level of
the washer liquid is LOW, add the washer liquid (in cold, winter
days) or water. The capacity of the tank is 1 liter.
Up (2) Dimmer switch

① This switch is used to turn the head lights direction.
M
② Switch positions
Down ·Up : To flash for passing
·Middle : Head lights low beam ON
73033CD30 ·Down : Head lights high beam ON
③ If you release the switch when it's in up position, the switch will
return to middle.
Left turning (3) Turning switch

① This switch is used to warn or signal the turning direction of the
machine to other vehicles or equipment.
② Push the lever up for turning left, pull the lever down for turning
Right turning right.
73033CD31
7-47
GROUP 4 ELECTRICAL COMPONENT SPECIFICATION
Part name Symbol Specifications Check item
Gravity
12V × 160Ah 1.280 over : over charged
Battery
(2EA) 1.280 ~ 1.250 : normal
1.250 below : discharged
Rated load : 24V Coil resistance

Battery relay 100A (continuity) breaked : approx 50Ω
1000A (30seconds) connected :∞Ω
CR-1
Resistance between ring termi-

Fusible link 24V nal and each connector pin
0Ω: normal
CN-60 (40A)
CN-95 (80A)
H BR ACC ST C
23 56
H 0 I II 4
Resistance between each pin
B-BR : 24V 1A
Key off : ∞Ω(for each pin)
Start key 0, I 1
B-ACC : 24V 10A
B Key on : 0Ω(for pin 1-2 & 1-3)
B-ST : 20V 40A
1 2 3 4 5 6 Start : 0Ω(for pin 1-5)
CS-2
A
- S +
Pa
B
Voltage
Pressure sensor C - Pin A, B : 24V
Pin B, C : 1~5V
CD-3 CD-26
CD-39 CD-40
T/M filter 1 Resistance

N.O Type
pressure switch 2 Pa ∞Ω: normal (open)
CD-48
7-48
1
Parking brake Resistance
2 24V 1A
solenoid normal : 15~25Ω
CN-71
Air cleaner Pa Max load : 6W Resistance

pressure switch N.O Type ∞Ω: normal (open)
CD-10
Ride control 2 ※ Check LED lamp

valve / Fan sole- 1 24V 1.2A ※ Check resistance
noid about 24Ω
CN-136 CN-154 CN-155
Resistance at fuel levels

full level : 200Ω
1 9/12 level : 500Ω
Fuel sender -
2 6/12 level : 800Ω
3/12 level : 1100Ω
CD-2
empty : 1300Ω
1 2 1
Resistance at normal position
Relay 2
3 24V 20A about 200Ωbetween pin 1-3
(4pin)
4 4 3 ∞Ω between pin 2-4
AC RY(H1)
CR-2 CR-26 AC RY1
CR-5 CR-30 AC RY2
30
87a 87 85
86 Resistance
87
normal : about 160Ω
Relay 85
87a 30 86 24V 20A (for pin 85~86)
(5pin)
0Ω(for pin 30~87)
CR-5 CR-25 CR-35 CR-37
CR-40 CR-41 CR-46 CR-59 ∞Ω(for pin 30~87)
CR-60 CR-79
7-49
2 3 4
1 Resistance
5
2
normal : about 160Ω
Relay 1 5 4
3 24V 20A (for pin 1~2)
(5 pin)
CR-2 CR-3 CR-4 CR-7 0Ω(for pin 3~4)
CR-26 CR-36 CR-38 CR-55 ∞Ω(for pin 3~5)
CR-58 CR-63
2 Resistance
Hydraulic C
- normal : ∞Ω
temperature 1
105。C over : 0Ω
CD-1
1 Resistance
Speaker 4Ω 20W
2 normal : 4Ω
CN-23(LH)
CN-24(RH)
7
3
1
10
4
12
9
11
1 8 7 11 Resistance at switch off position

Switch ∞Ωbetween pin 1-5 and 2-6
24V 8A
(Locking type) 12 10 4 9 3 12 0Ωbetween pin 5-7 and 6-8
CS-17 CS-23
CS-41 CS-76
12
12
Resistance at switch off position

3
4
Switch
∞Ωbetween pin 1-5 and 2-6
(Non-locking 24V 8A
1
11
9
7
0Ωbetween pin 5-7 and 6-8

11
12
type)
9
4
6
1
3
CS-21 CS-36
Work lamp
1
Work lamp, 24V 65W
2
Room lamp, Number plate lamp Resistance
Numbaer plate CL-1CL-21
CL-1 CL-6
CL-32CL-22 24V 10W normal : 1.2Ω
lamp CL-5 CL-22 CL-33CL-23
CL-5 CL-21
Room lamp
CL-6 CL-23 CL-36
24V 10W
7-50
M 24V 70W Resistance

Beacon lamp
(H1 TYPE) normal : 1.1Ω
CL-7
2 24V
24V Resistance
DC/DC 1 GND 12V 3A 8.8Ω(for pin A-B)
Converter 3 12V
12V
7.7Ω(for pin B-C)
CN-138
Operation by external power

source
Horn 24V 2A - conncet 24V power to (+)
CN-20 CN-25 terminal
- ground the (-) terminal
2 Resistance
PA
Receiver dryer 24V 2.5A 0Ω: 2.1±0.3~27±2kgf/cm²
1
∞Ω: ~2.1±0.3, 27±2~kgf/cm²
CN-29
REMOCON GND
SPK FRT RH+
SPK FRT LH+

SPK FRT RH-
SPK FRT LH-
REMOCON+
Resistance
BACK UP+
TEL MUTE
ANT 12V
Radio & USB

24V 20W+20W Power ON : 4Ω+4Ω
GND
GND
ACC
ILL+
ILL-
NC
NC
player
(for pin 1-6, 4-8)
10
11
12
13
14
15
16
8
1
2
3
4
5
6
7
CN-27
24V 0.5A Resistance

Back up buzzer
110dB normal : 5.2Ω
CN-65
7-51
M 1 Resistance
Washer pump 2 24V 2.5A normal : 26.4 Ω
(for pin1-2)
CN-103
CN-22 (FR)CN-22
CN-103 (RR)
E 3 1
Pf 2 2
B 1 3
4 24V 1.5A
Hi 4 5
Wiper motor Lo 5 6
2-speed -
M
Auto parking
CN-21 (FR) CN-102 (RR)
B
A Coil resistance
Cigar lighter 24V 5A 1.4W
1 normal : about 1MΩ
CL-2
B+
G
1 P
3~
2 L
U
Voltage
Alternator 3 FI 24V 70A
4 NC normal : 24~28V
CN-74
M
Nippondenso
Starter Operating or not
24V-3.7kW
B+ M
CN-45
1 Resistance
Aircon
24V 79W
compressor normal : 13.4Ω
CN-28
7-52
Coil resistance
normal : 1-2Ω
Start relay 24V 300A Switch connection
∞Ωat normal open position
CR-23 0Ωwhen engaged
M Resistance at each switch posi-

1
Blower 24V 9.5A tion
2 normal : 0.5-2Ω
Resistance
Door switch 24V 2W
normal : about 5MΩ
CS-1 CS-55
3 E
G 24V
2 B
Flasher unit 1 L
85 ~ 190 C/M -
50dB
CR-11
6 Lo
4 Hi 24V 75W/70W
5 (H4 TYPE) Resistance
Head lamp 3 C
E
24V 4W normal : a fewΩ
2
ABL
1 T (T4W)
CL-3 CL-4
4 C
24V 5W
3 T
Combi lamp (R5W)
2 E -
(rear) 2×24V 21W
1 S
(P21W)
CL-15 CL-16
7-53
Continuous capaci-
ty :
Master switch 180Amp -
Push in capacity :
1000Amp
CS-74
2
24V 200mA
Warning buzzer 1 -
90±5dB (ℓm)
CN-26
Resistance
Preheater 24V 200A
0.25~0.12Ω
CN-80
A A
B Resistance
Resistor 4W
C B A - B : 120Ω
CN-99
7-54
GROUP 5 CONNECTORS
1. CONNECTOR DESTINATION
Connector No. of Connector part No.
Type Destination
number pin Female Male
CN-5 DEUTSCH 48 I/conn (Frame harness-Main harness) DRB16-48SAE-L018 DRB12-48PAE-L018
CN-6 DEUTSCH 60 I/conn (Frame harness-Main harness) DRB16-60SBE-L018 DRB12-60PBE-L018
CN-7 AMP 15 I/conn (Main harness-Cab harness) 2-85262-1 368301-1
CN-9 AMP 12 I/conn (Cab harness-Main harness) 2-85262-1 368301-1
CN-10 DEUTSCH 23 I/conn (Frame harness-Front harness) HD34-24-23PE HD36-24-23SE
CN-11 DEUTSCH 8 I/conn (Main harness-Aircon harness) DT06-8S DT04-8P
CN-12 AMP 15 I/conn (Frame harness-Bottom harness) 2-85262-1 368301-1
CN-13 DEUTSCH 12 I/conn (Frame harness-Engine harness) DT06-12S DT04-12P
CN-14 DEUTSCH 12 I/conn (Frame harness-Grill harness) DT06-12S DT04-12P
CN-19 Econoseal J 6 I/conn (Emer steer harness-Front harness) S816-006002 S816-106602
CN-20 DEUTSCH 2 Horn DT06-2S -
CN-21 AMP 6 Front wiper motor 936257-1 -
CN-22 KET 2 Front washer tank MG640605 -
CN-23 KET 2 Speaker (LH) 7123-1520 -
CN-24 KET 2 Speaker (RH) 7123-1520 -
CN-25 DEUTSCH 2 Horn DT06-2S -
CN-26 250 2 Warning buzzer S810-002202 -
CN-27 MK II 16 Radio and USB player PK145-16017 -
CN-27A MK II 8 USB connector 174984-2 -
CN-28 NMWP 1 Aircon compressor PB625-01027 -
CN-29 KET 2 Receiver drier MG640795 -
CN-36 - - Fuse box 21Q7-10910 -
CN-45 Ring term - Starter R14-12 ST 710246-2
CN-56 AMP 20 Cluster 174047-2 -
CN-57 AMP 20 Monitor 174047-2 -
CN-58A DEUTSCH 40 MCU DRC26-40-SA -
CN-58B DEUTSCH 40 MCU DRC26-40-SB -
CN-60 MTA 2 Fusible link (40A) 07.00910 03.21000
CN-65 DEUTSCH 2 Back up buzzer DT06-2S -
CN-71 DEUTSCH 2 Parking solenoid DT06-2S-EP06 -
CN-74 PACKARD 4 Alternator 1218-6568 -
CN-83 NMWP 2 Aircon fan PB625-02027 -
CN-93 DEUTSCH 50 ECM DRC26-50S-04 -
7-55
Type Destination
CN-94 DEUTSCH 4 ECM power DTP06-4S-EP06 -
CN-95 MTA 2 Fusible link (80A) 07.00960 03.21000
CN-96 - 2 Fuel heater 1530-0027 -
CN-99 DEUTSCH 2 Resister DT04-3P-EP10 -
CN-100 Econoseal J 3 Boom kick out S816-003002 S816-103002
CN-101A Econoseal J 3 Bucket leveler - S816-103002
CN-102 AMP 6 Rear wiper motor 936257-1 -
CN-103 KET 2 Rear washer tank MG640605 -
CN-112 - 16 Gear box 21L7-60290 -
CN-114 - 6 Joy stick 1-480704-0 -
CN-126 DEUTSCH 9 Data link HD10-9-96P -
CN-136 AMP 2 Ride control solenoid 85202-1 -
CN-138 250 3 DC/DC Converter S810-003202 -
CN-139 250 2 12V socket S810-002202 -
CN-141 Econoseal J 6 I/conn (Ride control harness-Front harness) S816-006002 S816-106002
CN-149 DEUTSCH 2 Mirror heat (LH) DT04-2S-EP06 DT04-2P-E005
CN-150 DEUTSCH 2 Mirror heat (RH) DT04-2S-EP06 DT04-2P-E005
CN-154 AMP 2 Fan speed solenoid 85202-5 -
CN-155 AMP 2 Fan reverse solenoid 85202-1 -
CN-157 AMP 60 T/M control unit 962175 -
CN-158 PACKARD 4 Gear shift lever - 1201-0974
CN-159 PACKARD 4 Gear shift lever 1201-5797 -
CN-162 Econoseal J 6 Pedal S816-006602 -
CN-249 DEUTSCH 4 Camera DT06-4S DT06-4P
CN-250 Econoseal J 4 Rear view camera S816-004002 S816-104002
Relay
CR-1 Ring term - Battery relay S820-104002 -
CR-2 AMP 5 Horn relay VCFM-1002 -
CR-3 AMP 5 Front work lamp relay VCFM-1002 -
CR-4 AMP 5 Wiper relay (Hi) VCFM-1002 -
CR-5 HELLA 5 Safety relay 8JA003526-001 -
CR-7 AMP 5 Aircon relay VCFM-1002 -
CR-11 HELLA 5 Flasher unit 8JA003526-001 -
CR-23 Ring term - Start relay ST 710289-2 ST 710384-2
CR-24 Shur 1 Preheater relay S822-014000 -
CR-25 HELLA 5 ECM power relay 8JA003526-001 -
7-56
Type Destination
CR-26 AMP 5 Wiper relay (low) VCFM-1002 -
CR-36 AMP 5 Preheater relay VCFM-1002 -
CR-39 Ring term - Emergency steering pump relay S820-104000 -
CR-46 HELLA 5 Fuel warmer relay 8JA003526-001 -
CR-55 AMP 5 Rear work lamp relay VCFM-1002 -
CR-56 KET 4 Mirror heat relay MG610047-1 -
CR-58 AMP 5 Back up relay VCFM-1002 -
CR-63 AMP 5 Stop lamp relay VCFM-1002 -
Switch
CS-1 Shur 1 Door switch S822-014004 -
CS-2 SWP 6 Start key switch S814-006000 -
CS-5 Shur 1 Horn switch S822-014000 -
CS-11 SWP 8 Multi function switch S814-008000 -
CS-12 SWP 6 Multi function switch S814-006000 -
CS-17 SWF 12 Parking switch 589790 -
CS-21 SWF 12 Main light switch 589790 -
CS-23 SWF 12 Beacon switch 589790 -
CS-35 SWF 12 Rear wiper 589790 -
CS-36 SWF 12 Work lamp switch 589790 -
CS-41 SWF 12 Hazard switch 589790 -
CS-42 DEUTSCH 3 Clutch cut off dial switch - DT06-3S-E008
CS-55 SWF 12 Ride control switch 589790 -
CS-59 DEUTSCH 3 Transmission shift dial switch - DT06-3S-E008
CS-73 SWF 12 Fan reverse switch 589790 -
CS-74 RING TERM 4 Master switch ST710287-2 S820-205000
CS-75 SWF 12 Emergency steering test switch 589790 -
CS-76 SWF 12 Mirror heater switch 589790 -
CS-80 DEUTSCH 3 Econo mode dial switch DT06-3S-E008 -
7-57
Type Destination
Light
CL-1 KET 3 Room lamp MG651032 -
CL-2 250 3 Cigar lighter S810-003202 -
CL-3 DEUTSCH 6 Head light (LH) DT06-6S -
CL-4 DEUTSCH 6 Head light (RH) DT06-6S -
CL-5 DEUTSCH 2 Work light (LH) DT06-2S-EP06 -
CL-6 DEUTSCH 2 Work light (RH) DT06-2S-EP06 -
CL-7 250 2 Beacon lamp S810-002202 -
CL-15 SWP 4 Combi lamp (RR, LH) S814-004000 -
CL-16 SWP 4 Combi lamp (RR, RH) S814-004000 -
CL-21 SWP 2 Numberplate lamp S814-002000 -
CL-22 DEUTSCH 2 Work light (LH) DT06-2S -
CL-23 DEUTSCH 2 Work light (RH) DT06-2S -
CL-24 SWP 2 Turn lamp (LH) S814-002000 -
CL-25 SWP 2 Turn lamp (RH) S814-002000 -
CL-30 KET 2 Room lamp MG610392 -
CL-32 DEUTSCH 2 Rear work light (RH) DT06-2S-EP06 DT04-2P-E005
CL-33 DEUTSCH 2 Rear work light (LH) DT06-2S-EP06 DT04-2P-E005
Sensor, sender
CD-1 AMP 2 Hyduaulic oil temp sendor 85202-1 -
CD-2 SWP 2 Fuel sendor S814-002000 -
CD-3 DEUTSCH 3 Brake fail pressure switch DT06-3S -
CD-4 DEUTSCH 4 Stop lamp/Clutch cut off pressure switch DT06-4S-EP06 -
CD-5 PACKARD 3 Clutch cut off pressure switch - 12015793
CD-10 Ring term 2 Air cleaner switch GP890469 -
CD-17 AMP 2 Engine pick-up sensor 85202-1 -
CD-26 DEUTSCH 3 Parking pressure switch DT06-3S -
CD-27 AMP 2 Turbin pick up sensor 85202-1 -
CD-39 DEUTSCH 3 Main pump pressure switch DT06-3S -
CD-40 DEUTSCH 3 Steering pump pressure switch DT06-3S -
CD-41 DEUTSCH 4 Boom down pressure switch DT06-4S -
CD-45 DEUTSCH 2 WIF sensor DT06-2S-EP06 -
CD-46 AMP 3 Output speed sensor 282087 -
CD-47 AMP 2 Gear chain senser 85202-5 -
CD-48 AMP 2 Oil filter 282080 -
CD-49 AMP 2 Converter sensor 85202-1 -
CD-73 AMP 2 Speed sendsor 174352-2 -
7-58
2. CONNECTION TABLE FOR CONNECTORS
1) 58-L TYPE CONNECTOR
No. of
Receptacle connector (female) Plug connector (male)
pin
1 1
S813-030100 S813-130100
1 2 1 2
S813-030200 S813-130200
7-59
2) PA TYPE CONNECTOR
No. of
pin
2 5 1 3
1 3 2 5
S811-005002 S811-105002
3 7 1 4
1 4 3 7
S811-007002 S811-107002
4 9
1 5
1 5
4 9
S811-009002 S811-109002
5 11 1 6
11
1 6 5 11
S811-011002 S811-111002
7-60
No. of
pin
6 13 1 7
13
1 7 6 13
S811-013002 S811-113002
1 9
8 17
17
1 9 8 17
S811-017002 S811-117002
110 21 1 11
21
1 11 1
10 21
S811-021002 S811-121002
7-61
3) J TYPE CONNECTOR
No. of
pin Receptacle connector (female) Plug connector (male)
1 2
1
2 12
S816-002001 S816-102001
2 3 1
3 1 2
S816-003001 S816-103001
3 1 4 2
4 2 3 1
S816-004001 S816-104001
8 5 2
6 3 1
8 5 2 6 3 1
S816-008001 S816-108001
7-62
4) SWP TYPE CONNECTOR
No. of
pin Receptacle connector (Female) Plug connector (male)
1 1
S814-001000 S814-101000
2 1
1 2
S814-002000 S814-102000
3 1
2 1 23
S814-003000 S814-103000
2 4 1 3
1 3 2 4
S814-004000 S814-104000
7-63
No. of
3 6 1 4
3 6
1 4
S814-006000 S814-106000
4 8 1 5
4 8
1 5
S814-008000 S814-108000
4 12 1 9
12
4 12
1 9
S814-012000 S814-112000
3 14 11
1
14
1 11 3 14
S814-014000 S814-114000
7-64
5) CN TYPE CONNECTOR
No. of
1 1
S810-001202 S810-101202
2 2
1 1
S810-002202 S810-102202
3 2
1 2 1 3
S810-003202 S810-103202
2 4 1 3
1 3 2 4
S810-004202 S810-104202
7-65
No. of
3 6 1 4
1 4 3 6
S810-006202 S810-106202
4 8 1 5
1 5 4 8
S810-008202 S810-108202
7-66
6) ITT SWF CONNECTOR
No. of
10
1 12
11
SWF589790
7) HW090 SEALED CONNECTOR

No. of
6 3
4
6
6189-0133
8) MWP02F-B CONNECTOR
No. of
2 1
2
PH805-02028
7-67
9) AMP ECONOSEAL CONNECTOR
No. of
12
1
12
13 24
36
25
24 36 1
13
36
25
344111-1
344111-1 344108-1
344108-1
10) AMP TIMER CONNECTOR

No. of
85202-1
11) AMP 040 MULTILOCK CONNECTOR

No. of
12 1 6
7 12
174045-2
7-68
12) KET 090 WP CONNECTORS
No. of
2 1
MG640795
13) ITT SWF CONNECTOR

No. of
2
10
1 10
SWF593757
14) MWP NMWP CONNECTOR

No. of
1
1
NMWP01F-B
7-69
15) DEUTSCH DT CONNECTORS
DT 06 - 3S - ★★★★
Modifications (see below)

Number of contacts (P : Pin, S : Socket)
04 : Receptacle, 06 : Plug
Deutsch connetors
※ Modification
E003 : Standard end cap - gray
E004 : Color of connector to be black
E005 : Combination - E004 & E003
EP04 : End cap
EP06 : Combination P012 & EP04
P012 : Front seal enhancement - connectors color to black for 2, 3, 4 & 6pin
No. of
1 2 2 1
2
DT06-2S DT04-2P
2 1 1 2
3 3
DT06-3S DT04-3P
4 1 1 4
3 2 2 3
DT06-4S DT04-4P
7-70
No. of
6 1 1 6
4 3 3 4
DT06-6S DT04-6P
4 5 5 4
1 8
8 1
DT06-8S DT04-8P
7 6
6 7
12
1 12 12 1
DT06-12S DT04-12P
7-71
16) ECONOSEAL J TYPE CONNECTORS
No. of
S816-001002 S816-101002
1 2 1
2
S816-002002 S816-102002
S816-003002 S816-103002
S816-004002 S816-104002
7-72
No. of
S816-006002 S816-106002
S816-008002 S816-108002
10
S816-010002 S816-110002
12
S816-012002 S816-112002
7-73
No. of
15
368301-1 2-85262-1
17) METRI-PACK TYPE CONNECTOR

No. of
pin
12040753
18) DEUTSCH MCU CONNECTOR

No. of
Receptacle connector (Female) Plug connector (Male)
pin
5
1 6
11 1
10
2
3
11 4
5
21
6
40 21 31
32
7
8
9
33 10
34
35
31 36
37
20
30
20
38
39
35 40
36
30
40
DRC26-40SA/B/C
7-74
GROUP 6 TROUBLESHOOTING
1. WHEN STARTING SWITCH IS TURNED ON, CLUSTER AND MONITOR LAMP DOES NOT
LIGHT UP
·Before carrying out below procedure, check all the related connectors are properly inserted and the
fuse [CN-36] No.12 is not blown out and ON/OFF of bulb.
·After checking, connect the disconnected connectors again immediately unless otherwise
specified.
Cause Remedy
YES
Defective cluster Replace
Check voltage Defective monitor Replace
between CN-56
(1), CN-57(1) and
chassis
Disconnection in Repair or
NO
wiring harness or replace
poor contact (after clean)
between CN-56
(1), CN-57 (1)
and fuse No. 12
MONITOR
CN-57
CLUSTER
FUSE[CN-36]
1
No.12
CN-56
Check voltage
YES 20 ~ 30 V
NO 0V
7609A7EL24
7-75
2. WHEN BATTERY LAMP LIGHTS UP (engine is started)
·Before carrying out below procedure, check all the related connectors are properly inserted.
specified.
Cause Remedy
YES
Check voltage Defective Replace
YES controller
between CN-58A
(B36) and chassis
NO Disconnection in Repair or replace
Voltage : 27.5~30V wiring harness or (after clean)
poor contact
Check voltage between CN-58A
YES between CN-6
(B36) and CN-6 (49)
(49) and chassis
YES
Voltage : 26~30V Disconnection in Repair or replace
wiring harness or (after clean)
Check voltage poor contact
Check voltage between CN-13 between CN-13
NO
between (8) and chassis (8) and CN-6 (49)
alternator
terminal "2" and Disconnection in Repair or replace
chassis NO
Voltage : 26~30V poor contact
Starting switch : ON
between CN-13
(8) and alternator
terminal " 2 "
Defective alternator Replace

NO
CONTROLLER(MCU)
49
ALTERNATOR
B36 8 " 2 " TERMINAL
CN-6 CN-13
CN-58A
Check valtage
YES 20 ~ 30 V
NO 0V 75797EL30
7-76
3. WHEN PARKING SOLENOID DOES NOT WORK
fuse [CN-36] No.29 is not blown out.
·After checking, connect the disconnected connectors again immediately unless otherwise specified.
Cause Remedy
YES
Defective parking Replace
Check voltage brake solenoid
YES between CS-17
Check voltage (4) and chassis
YES Disconnection in Repair or replace
between CN-5
Voltage : 20~30V NO wiring harness or (after clean)
(30) and chassis
Check voltage
poor contact
between CN-71 Voltage : 20~30V
between CS-17
(2) and chassis
(4) and CN-5 (30)
Parking switch : ON-OFF YES
Voltage : 20~30V Disconnection in Repair or replace
poor contact
Check voltage between CN-12
between CN-12 (13) and CN-5
NO
(13) and chassis
(30)
Voltage : 20~30V
Disconnection in Repair or replace
NO
poor contact
between CN-12
(13) and CN-71
(2)
YES
Difective parking Replace
Check voltage
switch
between CS-17
NO
(7) and chassis
Voltage : 20~30V NO
poor contact
between CS-17
(7) and Fuse
No.29
PARKING SWITCH
8 FUSE [CN-36]
7
4 No.29
CN-5 CN-12
CS-17
30 13 2
1
CN-71
7609A7EL31
7-77
4. TRANSMISSION IS NOT RETURNED TO NEUTRAL WHEN PARKING BRAKE IS APPLIED
fuse [CN-36] No.29 is not blown out.
specified.
Cause Remedy
YES
Defective T/M Replace
control unit
Check voltage YES

between CN-157
(21) and chassis
poor contact
Starting switch : ON Check voltage between CN-157
Parking switch : ON between CS-17
Voltage : 20~30V NO (3) and chassis (21) and CS-17(3)
YES
Voltage : 20~30V Defective switch Replace
Parking switch : ON Check voltage
between CS-17
NO
(7) and chassis
NO
Voltage : 20~30V wiring harness or (after clean)
poor contact
between CS-17 (7)
and fuse No.29
PARKING SWITCH
8 FUSE[CN-36]
7
3 No.29
T/M CONTROL UNIT
CS-17
21
CN-157
Check resistance
YES MAX 1Ω
7609A7EL32
NO MIN 1MΩ
7-78
5. MACHINE DOES NOT TRAVEL
fuse [CN-36] No.11 (transmission controller) is not blown out.
specified.
·Wiring diagram : See page 7-17.
Cause Remedy
YES
Defective clutch Replace
cut-off mode
Check resistance
YES switch
between CD-4
and chassis
Is there continuity
NO
between CN-157
(38) and chassis? Defective T/M Replace
NO
control unit
Is voltage between
Defective T/M Replace
CN-157(21) and NO
chassis 20-28V? control unit
Starting switch : ON YES

Parking switch : OFF Defective Replace
Clutch cut-off parking switch
switch : ON Is there continuity
between CS-17(3)
YES
and chassis?
Disconnection Repair or replace

NO
wiring harness (after clean)
or poor contact
between CN-157
(21) and CS-17 (3)
Check resistance
YES MAX 1Ω
NO MIN 1MΩ
7-79
6. WHEN STARTING SWITCH IS TURNED ON, WIPER MOTOR DOES NOT OPERATE
fuse No.28 is not blown out.
specified. FUSE BOX
25
SEAT HEAT/AIR-RIDE 20A
26
WORK LAMP_REAR 20A
27
Cause Remedy Br WIPER 20A
28
PARK, PILOT CUT
YES 20A
29
Check voltage Defective front Replace JOYSTICK-DETENT 10A
30
30A
YES between front wiper motor PRE-HEAT, FUEL WARMER
31
FAN REVERSE, ATT. 20A
wiper motor and RIDE CONTROL 10A
32
chassis Poor connection of Replace JOYSTIC_SWITCH 10A

33
Check voltage Voltage : 20~30V

NO 34
YES chassis
between CN-21(5) Starting switch : ON CN-36
Wiper switch : 1st
and chassis
Voltage : 20~30V
WIPER RY HI
Starting switch : ON Disconnection in Repair or replace Y
4
Wiper switch : 1st NO 3 2
YES Check voltage
B
1
wiring harness or (after clean) R
between CS-12 Br
5
(4) and chassis poor contact Br
2
3 4 5 1
between CN-21(5) CR-4
Voltage : 20~30V and CR-26(3)
Starting switch : ON WIPER RY LO
Wiper switch : OFF G
4 3 2
W
1
Y
FRONT WIPER 5
Y Y Y
3E 1 2
G LW W
Defective wiper Repair or replace 2Pf
B
2
B 3 4 5 1
NO 1B
L
3
R CR-26
Check voltage switch or (after clean) R
4
W
4 Hi 5
CS-12 (6) disconnection in M
5 Lo 6
CN-21
wiring harness or CN-102
Voltage : 20~30V poor contact
Wiper switch : 1st
between CS-12(4)
and CR-26(4)

NO
wiring harness or (After clean)
LOr
LW
Gr
Br
Br
G
poor contact
between CS-12(6)
and fuse [CN-36]
CS-11
CS-12
CS-5
CN-58A
WIPER INT SIG A23
A31
B02
1
2
3
4
5
6
8
7
6
5
4
3
2
1
No.28
HO
RW
BVi
BY
4BWG
Gr
W
G
L
WIPER RLY
Y
6
2
6
1
3
5
WASH SIG
C
Hi
J
C
W
II
II
J
Hi Lo
I
O
B+
C
MCU
F
L
R
O
L
R
Y 7 Lo
B 5
WB 8
BG 3
BW 2
7609A7EL33
7-80
7. WHEN STARTING SWITCH "ON" DOES NOT OPERATE
·Before carrying out below procedure, check all the related connectors are properly inserted and
and the fuse No.3 is not blown out.
·After checking, connect the disconnected connectors again immediately unless otherwise MASTER SW CN-60
3R 105
specified. 3R 106
Cause Remedy CN-95

RW
YES RW FUSIBLE LINK
Check voltage Defective cable Repair or replace CS-74 BATTERY RY

RW 80R
YES between assembly (after clean)
B 80R
CN-60(1) and BATTERY
chassis CR-1
Short circuit or Replace DO-2
Voltage : 20~30V NO RW
2
Check voltage defect of fusible B
YES FUSE BOX
1
between CR-1 link or defective 10A BEACON 19 To starter
and chassis 15
20A WORK LAMP_FRONT
battery relay 16 20
Voltage : 20~30V 17 21
20A ILL.LAMP
18
20A
22
HEAD LAMP
Disconnection in Repair or replace 19
23
NO 10A BACK.STOP LAMP
Check voltage wiring harness (after clean)
20
20A HORN/CONVERTER 24
21
YES between CS-2 30A AIR-CON/HEATER 1 25
(1)[and CS-2(2)] or poor contact 22
20A FUEL WARMER
23 26
and chassis between CS-2 30A CIGAR LIGHTER
24 27
Voltage : 20~30V W
(2) - CN-5(37)- 28
20A TURN LAMP 36
CS-74-CR-1. 1
5A RADIO/ROOM LAMP 37
2
30A START KEY SWITCH R
3 38
10A TCU 24V BATTERY
Disconnection in Repair or replace 4 47
Check voltage NO 5
20A ECM 24V BATTERY
48
wiring harness (after clean) 20A MCU 24V BATTERY
and specific 6
20A AIR-CON/HEATER 2 CN-5
gravity of battery or poor contact 7
10A CLUSTER 24V BATTERY
8
Specific gravity : MIN 1.28

b e t we e n f u s e 3R
Voltage : MIN 24V No. 3 and CS-2 CN-36
(1) or defect of
start switch
Battery capacity Repair or replace

NO
too low (after clean)
RW
R
CS-2
2
6
5
4
1
B
0, I
1
H 0 I II
4
6
5
3
2
H
C ST ACC BR
START SWITCH
7579S7EL34
7-81
FUSE BOX
1
8. WHEN STARTING SWITCH IS TURNED ON, WORK LAMP DOES NOT LIGHTS UP 2
BEACON 10A
15
GW WORK LAMP_FRONT 20A
16
·Before carrying out below procedure, check all the related connectors are properly inserted, and 3 MIRROR,SER.SOCKET2 20A
17
4 ILL.LAMP 20A
the fuse [CN-36] No. 16, 27 is not blown out. HEAD LAMP 20A
18
5 19
·After checking, connect the disconnected connectors again immediately unless otherwise 6 BACK.STOP LAMP 10A
20
HORN/CONVERTER 20A
specified. 7
21
8 22
FUEL WARMER 20A
23
9 CIGARLIGHTER 30A
24
10
Cause Remedy 11
YES 12 SERVICE SOCKET 1 20A
Defective lamp Replace 25
YES Check voltage SEAT HEAT/AIR-RIDE 20A

13 26
between each FR WORK 1
W
14
Y WORK LAMP_REAR 20A
27
B WIPER 20A
lamp and chassis LAMP,LH 2
15
28
Disconnection in Repair or replace CL-5 PARK 20A
29
NO
Check voltage Voltage : 20~30V wiring harness or (after clean) FR WORK 1
W CN-7 JOYSTICK-DETENT 10A
30
Starting switch : ON poor contact B PRE-HEAT, FUEL WARMER 30A
between LAMP,RH 2 31
YES CL-6 FAN REVERSE, ATT. 20A
CN-7(14), between CL-6 (2), RIDE CONTROL 10A

32
33
CN-6(33) and CL-5 (2), CL-22 OPTION JOYSTIC_SWITCH 10A
1 34
chassis (2), CL-23 (2) and CL-35
W
LOr
1 2
Check voltage Voltage : 20~30V CN-7 (14), CN-6 2
B ILLUMINATION 1 5A
35
3
between Starting switch : ON (33). FR WORK LAMP
4 ILLUMINATION 2 5A
36
W
YES CR-3(5), 1
B 5
CR-55(5) and Disconnection in Repair or replace 2 CN-36
NO CL-36 6
chassis wiring harness or (after clean)
7
poor contact CL-32
RW
Voltage : 20~30V 1 8
Starting switch : ON between CN-7 2
B
Check voltage (14) -CR-3 (5) and
9
RR WORK LAMP
between CN-6 (33) - CR-55 RW
10
1
CR-3(3), (5) 2
B 11 FR WORK LAMP RY
CR-55(3) and CL-33 12
B
4 3 2
1
chassis Defective work Replace relay
13 W
5
Y
Voltage : 20~30V NO 14 2
lamp relay GW
3 4 5 1
Starting switch : ON 15
RR WORK 8 CR-3
YES LAMP,LH CN-9
Disconnection in Repair or replace 1
RW 9
B RR WORK LAMP RY
wiring harness or (after clean) 2 10 31
RR WORK CL-22 4 3 2
Check voltage poor contact 11 32 B
LAMP,RH 1
RW RW
between CR-3 (3), 12 33
between fuse 1
B VW
5
2 2
NO [CN-36] No. 16, CR-55 (3) and fuse CN-14 34 Y
CL-23 3 4 5 1
[CN-36] No. 16, 27 35 CR-55
27 and chassis
59
Voltage : 20~30V
Starting switch : ON Short circuit of Replace WORK LAMP SW
60
NO CN-6
fuse 12 11
1
3
Y
4
VW
6
LOr
6 7
LOr
4
9 9
3
7
R
11
12 1
12
B
CS-36
ILL & HEAD LAMP SW
12 11
1
3
4 CLUSTER
R 17 ILLUMINATION
6
6 LOr CN-56
7
4
MONITOR
R R
9 9 18 ILLUMINATION
3
7 CN-57
R
11
12 1
12
B
7579S7EL35
CS-21
7-82

HL740 9S

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CONTENTS

FOREWORD -------------------------------------------------------------------------------------------------------------------------- 0-1

Group 1 Safety Hints -------------------------------------------------------------------------------------------------------- 1-1

Group 1 Structure and Function -------------------------------------------------------------------------------------- 2-1

SECTION 3 POWER TRAIN SYSTEM

Group 1 Structure and Function -------------------------------------------------------------------------------------- 3-1

SECTION 4 BRAKE SYSTEM

Group 1 Structure and Function -------------------------------------------------------------------------------------- 4-1

SECTION 5 STEERING SYSTEM

Group 1 Structure and Function -------------------------------------------------------------------------------------- 5-1

Group 1 Structure and Function -------------------------------------------------------------------------------------- 6-1

SECTION 7 ELECTRICAL SYSTEM

Group 1 Component Location --------------------------------------------------------------------------------------- 7-1

Structure and function

2. Convert 550 mm into inches.

0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

Kilogram to Pound 1kg = 2.2046lb

0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84

0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378

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

0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980

7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1

14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0

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

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

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

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

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

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

Group 1 Safety Hints --------------------------------------------------------------------------------------------------------1-1

FOLLOW SAFE PROCEDURE

WEAR PROTECTIVE CLOTHING

WARN OTHERS OF SERVICE WORK

USE HANDHOLDS AND STEPS

Be careful of slippery conditions on platforms,

WORK IN CLEAN AREA

PROTECT AGAINST FLYING DEBRIS

PROTECT AGAINST NOISE

SUPPORT MACHINE PROPERLY

SERVICE COOLING SYSTEM SAFELY

HANDLE FLUIDS SAFELY-AVOID FIRES

BEWARE OF EXHAUST FUMES

REMOVE PAINT BEFORE WELDING OR

SERVICE MACHINE SAFELY

STAY CLEAR OF MOVING PARTS

AVOID HEATING NEAR PRESSURIZED

PREVENT BATTERY EXPLOSIONS

USE TOOLS PROPERLY

damaged rims or missing lug bolts and nuts.

USE PROPER LIFTING EQUIPMENT

DISPOSE OF FLUIDS PROPERLY

LIVE WITH SAFETY

Bucket Tire Head light Hydraulic tank Air cleaner Radiator

Boom Boom cylinder Main control valve Battery Counterweight

Description Unit Specification

Description Unit Specification

Description Unit Specification

Description Unit Specification

3) FAN + BRAKE PUMP

4) MAIN CONTROL VALVE

5) REMOTE CONTROL VALVE

7) DYNAMIC POWER TRANSMISSION DEVICES