Hyundai HL780-3A

WHEEL LOADER HYUNDAI HL780-3A
HL780-3A Service Manual Open index screen
CONTENTS
Foreword
SECTION 1 GENERAL
Group 1 Safety Hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Group 2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Group 3 Operational checkout record sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
SECTION 2 ENGINE
Group 1 Structure and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
SECTION 3 POWER TRAIN SYSTEM

Group 1 Structure and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Group 2 Operational checks and troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59
Group 3 Tests and adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71
Group 4 Disassembly and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-74
SECTION 4 BRAKE SYSTEM

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
Group 4 Electrical component specification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39
Group 5 Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-48
Group 6 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-61
FOREWORD
1. STRUCTURE
This service manual has been prepared as an aid to improve the quality of repairs by giving the
serviceman an accurate understanding of the product and by showing him the correct way to perform
repairs and make judgements. Make sure you understand the contents of this manual and use it to
full effect at every opportunity.
This service manual mainly contains the necessary technical information for operations performed in
a service workshop.
For ease of understanding, the manual is divided into the following sections.
Structure and function

This group explains the structure and function of each component. It serves not only to give an
understanding of the structure, but also serves as reference material for troubleshooting.
Operational checks and troubleshooting
This group explains the system operational checks and troubleshooting charts correlating problem to
remedy.
Tests and adjustments
This group explains checks to be amide before and after performing repairs, as well as adjustments to
be made at completion of the checks and repairs.
Disassembly and assembly
This section explains the order to be followed when removing, installing, disassembling or assembling
each component, as well as precautions to be taken for these operations.
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Contact your HYUNDAI distributor for the latest information.
0-1
2. HOW TO READ THE SERVICE MANUAL
Distribution and updating Revised edition mark(①②③…)
Any additions, amendments or other changes When a manual is revised, an edition mark is
will be sent to HYUNDAI distributors. recorded on the bottom outside corner of the
Get the most up-to-date information before you pages.
start any work.
Revisions
Filing method Revised pages are shown at the list of revised
1. See the page number on the bottom of the pages on the between the contents page and
page. section 1 page.
File the pages in correct order.
2. Following examples shows how to read the Symbols
page number. So that the service manual can be of ample
Example 1 practical use, important places for safety and
3-3 quality are marked with the following symbols.
Section number (3. Power train
system)
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 55mm into inches.
(1) Locate the number 50 in the vertical column at the left side, take this as ⓐ, then draw a
horizontal line from ⓐ.
(2) Locate the number 5 in the row across the top, take this as ⓑ, then draw a perpendicular line
down from ⓑ.
(3) Take the point where the two lines cross as ⓒ. This point ⓒ gives the value when converting
from millimeters to inches. Therefore, 55mm = 2.165 inches.
2. Convert 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 55mm
(2) (Carry out the same procedure as above to convert 55mm to 2.165 inches.
(3) The original value (550mm) was divided by 10, so multiply 2.165 inches by 10(move the decimal
point one place to the right) to return to the original value.
This gives 550mm = 21.65 inches.
Millimeters to inches ⓑ
1mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
ⓒ
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
ⓐ
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
0-3
Millimeters to inches 1mm = 0.03937 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
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
kgm to lb・ft 1kg・m = 7.233lb・ft
0 1 2 3 4 5 6 7 8 9
7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1

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

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

-37.2 -35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

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

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

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

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

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

-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 172 347.0
0-8
CONTENTS
SECTION 1 GENERAL
Group 1 Safety Hints 1-1
Group 2 Specifications 1-10
Group 3 Operational Checkout Record Sheet 1-22
SECTION 2 ENGINE
Group 1 Structure and Function 2-1

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

Group 3 Tests and Adjustments 4-31


Group 1 Component Location 7-1
Group 2 Electrical Circuit 7-3
Group 3 Monitoring System 7-23
Group 4 Electrical Component Specification 7-39
Group 5 Connectors 7-47
Group 6 Troubleshooting 7-61
SECTION 1 GENERAL
Group 1 Safety Hints 1-1

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

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

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

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

D S
IA IS
-O
G
N
OPERATE
USE HANDHOLDS AND STEPS

Falling is one of the major causes of personal
injury.
When you get on and off the machine, always
maintain a three point contact with the steps and
handrails and face the machine. Do not use
any controls as handholds.
Never jump on or off the machine. Never mount
or dismount a moving machine.
Be careful of slippery conditions on platforms,
steps, and handrails when leaving the machine.
1-1
PREPARE FOR EMERGENCIES
Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors,
ambulance service, hospital, and fire
department near your telephone.
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.
PROTECT AGAINST FLYING DEBRIS

Guard against injury from flying pieces of metal
or debris; wear goggles or safety glasses.
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.
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.
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.
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.
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.
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.
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.
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.
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.
STAY CLEAR OF MOVING PARTS

Entanglements in moving parts can cause
serious injury.
To prevent accidents, use care when working
around rotating parts.
1-5
AVOID HIGH PRESSURE FLUIDS
Escaping fluid under pressure can penetrate the
skin causing serious injury.
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten
all connections before applying pressure.
Search for leaks with a piece of cardboard.
Protect hands and body from high pressure
fluids.
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.
AVOID HEATING NEAR PRESSURIZED FLUID

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

Keep sparks, lighted matches, and flame away
from the top of battery. Battery gas can
explode.
Never check battery charge by placing a metal
object across the posts. Use a volt-meter or
hydrometer.
Do not charge a frozen battery; it may explode.
Warm battery to 16°C (60°F ).
1-6
PREVENT ACID BURNS
Sulfuric acid in battery electrolyte is poisonous.
It is strong enough to burn skin, eat holes in
clothing, and cause blindness if splashed into
eyes.
Avoid the hazard by:
1. Filling batteries in a well-ventilated area.
2. Wearing eye protection and rubber gloves.
3. Avoiding breathing fumes when electrolyte is
added.
4. Avoiding spilling of dripping electrolyte.
5. Use proper jump start procedure.
If you spill acid on yourself:
1. Flush your skin with water.
2. Apply baking soda or lime to help neutralize
the acid.
3. Flush your eyes with water for 10-15
minutes. Get medical attention immediately.
If acid is swallowed:
1. Drink large amounts of water or milk.
2. Then drink milk of magnesia, beaten eggs,
or vegetable oil.
3. Get medical attention immediately.
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.
Do not use U.S. measurement tools on metric
fasteners. Avoid bodily injury caused by slipping
wrenches.
Use only recommended replacement parts.(See
Parts catalogue.)
1-7
SERVICE TIRES SAFELY
Explosive separation of a tire and rim parts can
cause serious injury or death.
Do not attempt to mount a tire unless you have
the proper equipment and experience to
perform the job.
Always maintain the correct tire pressure. Do
not inflate the tires above the recommended
pressure. Never weld or heat a wheel and tire
assembly. The heat can cause an increase in
air pressure resulting in a tire explosion.
Welding can structurally weaken or deform the
wheel.
When inflating tires, use a clip-on chuck and
extension hose long enough to allow you to
stand to one side and not in front of or over the
tire assembly. Use a safety cage if available.
Check wheels for low pressure, cuts, bubbles,
damaged rims or missing lug bolts and nuts.
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.
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.
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.
LIVE WITH SAFETY

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

Make certain all parts are reinstalled correctly if
the roll-over protective structure (ROPS) is
loosened or removed for any reason. Tighten
mounting bolts to proper torque.
The protection offered by ROPS will be impaired
if ROPS is subjected to structural damage, is
involved in an overturn incident, or is in any way
altered by welding, bending, drilling, or cutting.
A damaged ROPS should be replaced, not
reused.
1-9
GROUP 2 SPECIFICATION
1. MAJOR COMPONENTS
Tooth Bucket Tire Head light Hydraulic tank Air cleaner Radiator
Boom Bucket cylinder Main control valve Step Battery Counterweight
Bucket link Bell crank Steering cylinder Cab Precleaner Muffler Engine
Front axle Boom cylinder Main pump Transmission Rear axle Fuel tank
7803ASE01
1-10
2. SPECIFICATIONS
1) WITHOUT TOOTH AND CUTTING EDGE TYPE BUCKET

B
F
I
J
6220
4560
H
3621
K
C
G
40
761 6430
D
5
E 2472
A
7803ASE02
Description Unit Specification
Operating weight kg(lb) 28880(63670)

Struck 4.1(5.4)
Bucket capacity m3(yd3)
Heaped 4.8(6.3)
Overall length A 9280(30' 5")
Overall width B 3450(11' 4")
Overall height C 3750(12' 4")
Ground clearance D 475( 1' 7")
Wheelbase E mm(ft-in) 3700(12' 2")
Tread F 2440( 8' 0")
Dump clearance at 45° G 3434(11' 3")
Dump reach at 45° H 1407( 4' 7")
Width over tires I 3220(10' 7")
Dump angle J 47
Degree (°)
Roll back angle(Carry position) K 48
Lift(With load) 6.3
Cycle time Dump(With load) sec 1.3
Lower(Empty) 3.5
Maximum travel speed km/hr(mph) 34.7(21.6)
Braking distance 12(39' 4")
m(ft-in)
Minimum turning radius(Center of outside tire) 6.43(21' 1")
Gradability Degree (°) 30
First gear 7.1(4.4)
Second gear 12.5(7.8)
Forward
Third gear 19.7(12.3)
Fourth gear 34.7(21.6)
Travel speed km/hr(mph)
First gear 7.1(4.4)
Reverse
1-11
2) BOLT-ON CUTTING EDGE TYPE BUCKET
B
F
I
J
6220
4560
H
3621
K
C
G
40
765 6430
D
5
E 2472
A
7803A2SE03

Struck 4.3(5.6)
Heaped 5.1(6.7)
Tread F 2440( 8' 0")
Dump reach at 45° H 1440( 4' 7")
Dump angle J 47
Degree (°)
Lift(With load) 6.3
Lower(Empty) 3.5
m(ft-in)
First gear 7.1(4.4)
Forward
First gear 7.1(4.4)
Reverse
1-12
3) WITH TOOTH TYPE BUCKET
B
F
I
J
6220
4560
H
3621
K
C
G
40
774 6430
D
0
E 2472
A
7803A2SE04

Struck 4.1(5.4)
Heaped 4.8(6.3)
Tread F 2440( 8' 0")
Dump reach at 45° H 1568( 5' 2")
Dump angle J 47
Degree (°)
Lift(With load) 6.3
Lower(Empty) 3.5
m(ft-in)
First gear 7.1(4.4)
Forward
First gear 7.1(4.4)
Reverse
1-13
3. WEIGHT
Item kg lb
Front frame assembly 2825 6228

Rear frame assembly 3531 7785
Front fender(LH & RH) 42 93
Counterweight 1200 2646
Cab assembly 1000 2205
Engine assembly 984 2169
Transmission assembly 835 1841
Drive shaft(Engine to transmission) 14 31
Drive shaft(Front) 44 97
Drive shaft(Center) 46 101
Drive shaft(Rear) 27 60
Front axle(Include differential) 1550 3417
Rear axle(Include differential) 1550 3417
Tire(4EA) 430 948
Hydraulic tank assembly 253 558
Fuel tank assembly 500 1102
Main pump assembly 37 82
Steering pump assembly 24 53
Main control valve 94 207
Flow amplifier 29 64
Boom 2070 4564
Bell crank 263 580
Bucket link 55 121
5.1m3 bucket, with bolt on cutting edge 2670 5886
4.8m3 bucket, with tooth 2540 5600
4.7m3 bucket, without tooth and cutting edge 2250 4960
Boom cylinder assembly(2EA) 290 639
Bucket cylinder assembly(2EA) 150 331
Steering cylinder assembly(2EA) 65 143
Seat 40 88
Battery 55 121
1-14
4. SPECIFICATION FOR MAJOR COMPONENTS
1) ENGINE
Item Specification
Model Cummins QSM 11-C

Type 4-cycle turbocharged, charge air cooled diesel engine
Control type Electronic control
Cooling method Water cooling
Number of cylinders and arrangement 6 cylinders, in-line
Firing order 1-5-3-6-2-4
Combustion chamber type Direct injection type
Cylinder bore × stroke 125×147mm(4.92"×5.79")
Piston displacement 10800cc(659cu in)
Compression ratio 16.3:1
Rated gross horse power 340ps at 2100rpm
Maximum gross torque at 1400rpm 174kgf・m(1255lbf・ft)
Engine oil quantity 38ℓ (10 U.S. gal)
Wet weight 984kg(2170lb)
High idling speed 2130 ± 50rpm
Low idling speed 800 ± 50rpm
Rated fuel consumption 147.8g/ps・hr
Starting motor Delco Remy 42MT(24V)
Alternator Delco Remy 22SI(24V-70Amp)
Battery 2×12V×200Ah
1-15
2) MAIN PUMP(+BRAKE PUMP)
Specification
Item
Main pump Brake pump
Type Fixed displacement double vane pump
Capacity 98.3cc/rev 15.9cc/rev
Maximum operating pressure 210kgf/cm2(2987psi) 150kgf/cm2(2130psi)
Rated oil quantity 193ℓ/min(51U.S.gpm) 31.3ℓ/ min(8.3U.S.gpm)
Rated speed 2100rpm
3) STEERING PUMP
Item Specification
Type Fixed displacement single vane pump

Capacity 136cc/rev
Maximum operating pressure 210kgf/cm2(2987psi)
Rated oil quantity 280ℓ/min(74U.S.gpm)
Rated speed 2100rpm
4) MAIN CONTROL VALVE
Item Specification
Type 2 spool
Operating method Hydraulic pilot assist
Main relief valve pressure 210kgf/cm2(2987psi)
Overload relief valve pressure(Boom) 250kgf/cm2(3556psi)
Overload relief valve pressure(Bucket) 230kgf/cm2(3271psi)
5) REMOTE CONTROL VALVE
Item Specification
Type Pressure reducing type

Minimum 5.8kgf/cm2(82.5psi)
Operating
Maximum 19kgf/cm2(270psi)
Single operation stroke Lever 70mm(2.8in)
6) CYLINDER
Item Specification
Boom cylinder Bore dia×Rod dia×Stroke Ø200×Ø110×863mm

Bucket cylinder Bore dia×Rod dia×Stroke Ø160×Ø80×580mm
Steering cylinder Bore dia×Rod dia×Stroke Ø110×Ø55×480mm
1-16
7) DYNAMIC POWER TRANSMISSION DEVICES
Item Specification
Model ZF 40H005
Torque converter
Type Single-stage, single-phase
Model ZF 4WG310
Type Full-automatic power shift
Transmission Gear shift Forward fourth gear, reverse third gear
Electrical single lever type, kick-down system,
Adjustment
Automatic kick down from 2nd to 1st gear
Drive devices 4-wheel drive
Axle Front Front fixed location
Rear Oscillation 13°of center pin-loaded
Wheels Tires 29.5-25, 22PR(L3)
Travel Four-wheel, wet-disc type, full hydraulic
Brakes Spring applied, hydraulic released brake on front
Parking
axle
Type Full hydraulic, articulated
Steering
Steering angle 40°to both right and left angle, respectively
1-17
5. TIGHTENING TORQUE
The torques given are standard figures. Any figures specifically described in this manual has priority.
1) BOLT AND NUT
(1) Coarse thread
8T 10T
Bolt size
kgf・m lbf・ft kgf・m lbf・ft
M 6 × 1.0 0.85 ~ 1.25 6.15 ~ 9.04 1.14 ~ 1.74 8.2 ~ 12.6
M 8 × 1.25 2.0 ~ 3.0 14.5 ~ 21.7 2.73 ~ 4.12 19.7 ~ 29.8
M10 × 1.5 4.0 ~ 6.0 28.9 ~ 43.4 5.5 ~ 8.3 39.8 ~ 60
M12 × 1.75 7.4 ~ 11.2 53.5 ~ 79.5 9.8 ~ 15.8 71 ~ 114
M14 × 2.0 12.2 ~ 16.6 88.2 ~ 120 16.7 ~ 22.5 121 ~ 167
M16 × 2.0 18.6 ~ 25.2 135 ~ 182 25.2 ~ 34.2 182 ~ 247
M18 × 2.5 25.8 ~ 35.0 187 ~ 253 35.1 ~ 47.5 254 ~ 343
M20 × 2.5 36.2 ~ 49.0 262 ~ 354 49.2 ~ 66.6 356 ~ 482
M22 × 2.5 48.3 ~ 63.3 350 ~ 457 65.8 ~ 98.0 476 ~ 709
M24 × 3.0 62.5 ~ 84.5 452 ~ 611 85.0 ~ 115 615 ~ 832
M30 × 3.5 124 ~ 168 898 ~ 1214 169 ~ 229 1223 ~ 1655
M36 × 4.0 174 ~ 236 1261 ~ 1703 250 ~ 310 1808 ~ 2242
(2) Fine thread

8T 10T
Bolt size
kgf・m lbf・ft kgf・m lbf・ft
M 8 × 1.0 2.17 ~ 3.37 15.7 ~ 24.3 3.04 ~ 4.44 22.0 ~ 32.0
M10 × 1.25 4.46 ~ 6.66 32.3 ~ 48.2 5.93 ~ 8.93 42.9 ~ 64.6
M12 × 1.25 7.78 ~ 11.58 76.3 ~ 83.7 10.6 ~ 16.0 76.6 ~ 115
M14 × 1.5 13.3 ~ 18.1 96.2 ~ 130 17.9 ~ 24.1 130 ~ 174
M16 × 1.5 19.9 ~ 26.9 144 ~ 194 26.6 ~ 36.0 193 ~ 260
M18 × 1.5 28.6 ~ 43.6 207 ~ 315 38.4 ~ 52.0 278 ~ 376
M20 × 1.5 40.0 ~ 54.0 289 ~ 390 53.4 ~ 72.2 386 ~ 522
M22 × 1.5 52.7 ~ 71.3 381 ~ 515 70.7 ~ 95.7 512 ~ 692
M24 × 2.0 67.9 ~ 91.9 491 ~ 664 90.9 ~ 123 658 ~ 890
M30 × 2.0 137 ~ 185 990 ~ 1338 182 ~ 248 1314 ~ 1795
M36 × 3.0 192 ~ 260 1389 ~ 1879 262 ~ 354 1893 ~ 2561
1-18
2) PIPE AND HOSE
Thread size Width across flat(mm) kgf・m lbf・ft

1/4" 19 3 21.7
3/8" 22 4 28.9
1/2" 27 5 36.2
3/4" 36 12 86.8
1" 41 14 101
3) FITTING
Thread size Width across flat(mm) kgf・m lbf・ft
1/4" 19 4 28.9
3/8" 22 5 36.2
1/2" 27 6 43.4
3/4" 36 13 94.0
1" 41 15 109
1-19
4) TIGHTENING TORQUE OF MAJOR COMPONENT
No. Items Size kgf・m lbf・ft
1 Engine mounting bolt, nut(Rubber, 4EA) M24×3.0 100 ± 15.0 723± 108
2 Engine mounling bolt(Fly wheel housing, 8EA) M16×2.0 19.4 ± 3.0 140± 21.7
3 Engine Engine mounting bolt(Gear housing, 6EA) M10×1.5 4.6 ± 0.7 33.3± 5.1
4 Radiator mounting bolt M12×1.75 12.3 ± 2.5 89.0± 18.1
5 Fuel tank mounting bolt, nut M20×2.5 57.9 ± 8.7 419± 62.9
6 Main pump housing mounting bolt M16×2.0 29.7 ± 4.5 215± 32.5
7 Steering pump housing mounting bolt M16×2.0 29.7 ± 4.5 215± 32.5
8 Main control valve mounting bolt M12×1.75 12.8 ± 3.0 92.6± 21.7
9 Steering unit mounting bolt M10×1.5 6.9 ± 1.4 49.9± 10.1
10 Flow amplifier mounting bolt M10×1.5 6.9 ± 1.4 49.9± 10.1
Hydraulic
11 system Brake valve mounting bolt M8×1.25 2.5 ± 0.5 18.1± 3.6
12 Cut-off valve mounting bolt M8×1.25 2.5 ± 0.5 18.1± 3.6
13 Remote control lever mounting bolt M6×1.0 1.1±0.2 8.0± 1.4
14 Pilot supply unit mounting bolt M8×1.25 2.5 ± 0.5 18.1± 3.6
15 Safety valve M8×1.25 2.5 ± 0.5 8.1± 3.6
16 Hydraulic oil tank mounting bolt M20×2.5 57.9 ± 8.7 419 ± 62.9
17 T/M bolt, nut(Rubber, 4EA) M24×3.0 100 ± 15.0 723 ± 108
18 T/M bolt(Converter cover, 4EA) M16×2.0 18.4 ± 2.0 133± 14.5
19 Power train Front axle mounting bolt, nut M33×2.0 225 ± 25.0 1627±181
20 system Rear axle support mounting bolt, nut M33×2.0 225 ± 25.0 1627±181
21 Tire mounting nut M22×1.5 79 ± 2.5 571± 18
22 Drive shaft joint mounting bolt, nut 1/2-13UNC 12.3 ± 2 89.0± 14
23 Counterweight mounting bolt M30×3.5 199 ± 29.9 1439±216
24 Others Operator's seat mounting bolt M8×1.25 3.4 ± 0.8 24.6± 5
25 ROPS Cab mounting bolt(4EA) 1.25-12UNF 126 910
1-20
6. 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 38(10.0)
SAE 10W-30
SAE 15W-40
SAE 10W-30
Transmission Oil 43(11.4)
SAE 15W-40
Front : 60(15.9)
Axle Gear oil SAE 80W-90LSD/API GL-5
Rear : 60(15.9)
Tank: ISO VG 32
185(48.9)
Hydraulic tank Hydraulic oil ISO VG 46
System:
235(62.1) ISO VG 68
ASTM D975 NO. 1

Fuel tank Diesel fuel 470(124)
ASTM D975 NO. 2
NLGI NO. 1
Fitting
Grease As required
(Grease nipple)
NLGI NO. 2
Mixture of
antifreeze
Radiator 65(17.2) Ethylene glycol base permanent type
and water
50 : 50
1-21
GROUP 3 OPERATIONAL CHECKOUT RECORD SHEET
・Owner :
・Date :
・Hours :
・Serial No. :
・Technician :
※ Use this sheet to record operational

checkout results.
Perform the operational check before
installing any test equipment.
OK NOT
Item Comments
OK
1. Monitor indicator and gauge checks(Engine OFF)
・ Hourmeter and gauge check

・ Battery check
・ Monitor indicator circuit check
・ Monitor turn signals and warning indicator check
2. Transmission, axle and engine linkages, neutral start

switch and reverse warning alarm switch checks
・ Transmission control lever and neutral

・ Neutral start and reverse warning
・ Alarm circuit checks
・ Engine speed control linkage check
3. Monitor indicator and gauge checks(Engine running)
・ Monitor display and alternator output checks

・ Monitor bypass circuit and seat belt indicator check
・ Monitor primary and secondary level check
・ Transmission oil warm up procedure
・ Transmission temperature gauge check
1-22
4. Brake system and clutch cut off checks
・ Park brake capacity check

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

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

・Hydraulic pump performance check
・Pilot control valve boom float check
・Boom down solenoid valve check
・Control valve lift check
・Bucket rollback circuit relief
・Valve check
・Bucket dump circuit relief valve
・Low pressure check
・High pressure check
・Boom and bucket cylinder drift check
・Boom down solenoid valve leakage check
・Pilot controller check
・Return to dig check
・Boom height kickout check-if equipped
1-23
7. Steering system checks
・Steering valve check

・Steering system leakage check
・Flow amplifier
Low check pressure
High check pressure
8. Accessory checks
・Operating lights check

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

・Cab door hold open latch check
・Cab door release button check
・Cab door lock check
・Cab door window check
・Cab window latch check
・Steering column adjustment check
・Seat and seat belt check
・Air intake filter door check
・Engine side panels check
・Radiator cap access door check
・Frame locking bar check
・Boom lock check
・Service decal check
1-24
SECTION 2 ENGINE

Group 2 Engine fault code information(For QSM11) 2-14
SECTION 2 ENGINE
GROUP 1 STRUCTURE AND FUNCTION
1. STRUCTURE
Air intake manifold

Engine coolant vent
Exhuast manifold
Corrosion resistor
Dipstick
Coolant inlet
Filler cap
Oil filter
Oil pan sump heater
Oil drain
Electronic control module(ECM) Air intake connection

Lifting bracket Blowby measurement
ECM coolant plate

Compressor
mounting location
Fly wheel
Fuel inlet to pump
Engine support
Oil pan
Side oil drain
・ 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. COMPONENTS
1) The ECM receives information from various
components in the QSM system.
2) The temperature sensors are a two-wire

type sensor with a 5 volt supply and signal
return. The ECM registors temperature
chages as the voltage drops across this
circuit.
3) The Coolant Temperature Sensor is mount-

ed in the thermostat housing. Its input is
required to properly control engine timing,
and to control the operation of the fan
clutch. This sensor also provides input to
the engine protection system.
4) The Intake Air Temperature Sensor is

mounted on the rear of the intake manifold.
Its input is required by the engine protection
system, as well as for engine control
purposes.
2-2
5) The Oil Temperature Sensor is mounted in
the main oil rifle. It provides input to the
engine protection system.
6) The Engine Position Sensor, or EPS, is a

magnetic pick-up type device that uses the
detection of 24 specially machined
surfaces, on the back side of the camshaft
gear, to monitor engine speed.
A unique "tooth" indicates number one
cylinder at top dead center compression
stroke, for injection timing purposes.
7) The pressure sensors are a three-wire type

sensor with a 5 volt supply, a signal wire,
and a return. Although pressure sensors
use an analog signal similar to the
temperature sensors, the electronics built
into the sensor require that separate signal
and return wires be used.
8) The oil Pressure Sensor is mounted in the

main oil rifle. Like the oil temperature
sensor, it provides input information to the
engine protection system.
2-3
9) The Boost Pressure Sensor is mounted
next to the intake manifold temperature
sensor. Its input is crucial to the precise
electronic control of fuel metering.
10) An Ambient Air Pressure sensor provides

altitude input information to the ECM for
altitude derate purposes.
11) The vehicle Control Data Link Connector

provides a means of connecting the QSM
system with other onboard microprocessor-
based systems, such as an anti-skid braking
system.
This connector, however, is not designed to
be used with a diagnostic tool such as
INSITE. INSITE and other diagnostic tools
should only be connected to the Service
Data Links located on the OEM Harness or
the Service Data Link mounted on the
engine next to the ECM.
2-4
12) Engines with QSM systems will have a
service data link mounted next to the ECM.
This additional data link was added
because new calibration procedures require
that the key switch must be off during
calibration transfer. But many OEM
harnesses have a small amount of voltage
across the data link connection even with
the key off.
The OEM harness data link can be used for
all service tool operations except
transferring calibrations. Only the engine-
mounted data link should be used for
calibration transfer.
13) A 21-pin OEM connector is part of the

Engine Harness. The keyswitch, diagnostic
switch, coolant level sensor, fan control
signals, and data link wires pass through
the Engine Harness and the OEM
connections.
14) The throttle pedal assembly is supplied by

the OEM. This assembly includes a base
plate, dual return springs, idle validation
switch, foot pedal, wiring harness, and a
potentiometer, or "pot".
No mechanical linkage exists between the
foot pedal and the engine.
2-5
15) The potentiometer provides a DC voltage
signal proportional to pedal angle
displacement.
The ECM sees this voltage signal as an
indication of throttle position.
16) The Idle Validation Switch provides

verification independent of throttle pot
movement that the pedal is, or is not, in the
idle position. This scheme allows the ECM
to detect potential throttle assembly
problems. The Idle Validation Switch can
be a separate mechanical or an integrated
switch with the potentiometer.
17) The tachometer output-signal connector

can provide the engine RPM signal to the
vehicle tachometer.
18) In this section we'll review the major

components of the QSM Hydromechanical
Subsytem.
The QSM system fuel supply pump is
mounted to the air compressor assembly
and, like the air compressor, is driven by the
engine through the accessory drive.
2-6
19) It's a gear-type pump, using one-and-a-
quarter-inch gears.
The pressure regulator is set at
approximately 150 psi.
20) The ECM is mounted on a cooling plate.

During engine operation, fuel circulates
through the one-pass unit, absorbing heat
generated by the ECM electronics.
21) The electronically controlled injector is

substantially different from standard PT
injectors. The most apparent difference is
the addition of a solenoid valve near the top
of the injector.
Controlled by the ECM, it determines the
amount of fuel metered, as well as injection
timing.
22) As mentioned earlier, the QSM injector

uses camshaft actuation to build adequate
pressure for injection.
・ Lower Overhead Force and Cam Stress
・ Improved Injection Train Component Life
・ Shorter Heat Release during Combustion
・ Lower Emissions
・ Improved Fuel Economy
2-7
23) The QSM injector includes the top stop
shim; injector control valve; spring guide;
timing chamber; bias spring; metering
plunger; pressure relief valve; closed nozzle
subassembly, with its cup, needle valve and
return spring; metering check valve;
metering spill port; fuel drain passage; fuel
supply passage; timing plunger; bottom
stop shim; return spring; and the top stop
assembly.
24) To better understand the operation of the

injector, let's study a simplified version.
Here we can see the timing plunger, top
stop hardware, return spring, injector
control valve, metering spill port, pressure
relief valve, fuel supply passage, metering
check valve, closed-nozzle subassembly,
metering plunger, bias spring, timing spill
port, and the bottom stop shim.
25) At the start of metering, the metering

plunger and the timing plunger are at the
lower limits of their travel. The injector
control valve is closed.
26) As the camshaft rotates, the timing plunger

return spring forces the timing plunger
upward.
Fuel flows past the metering checkball and
into the metering chamber. This flow
continues as long as the timing plunger is
moving upward, and the injector control
valve is closed.
Supply pressure, acting on the bottom of
the metering piston, forces it to maintain
contact with the timing plunger.
2-8
27) The ECM determines the end of metering
by signaling the injector control valve to
open.
28) Fuel at supply pressure then flows into the

timing chamber, thereby stopping metering-
piston travel.
During this time, the bias spring ensuress
that the metering plunger remains
stationary, that it does not drift upward as
the timing plunger moves upward. This
same force against the metering plunger
results in enough fuel pressure below the
piston to keep the metering check ball
seated.
A precisely metered quantity of fuel is now
trapped in the metering chamber. This
determines the quantity of fuel that will be
injected.
29) The timing plunger continues to move

upward, and the timing chamber fills with
fuel.
2-9
30) Now the timing plunger begins its
downward travel. Initially, the injector
control valve remains open, allowing fuel to
flow from the timing chamber, through the
injector control valve, to the fuel supply
passage.
31) At the appropriate time, as determined by

the ECM, the injector control valve closes,
trapping fuel in the timing chamber. This
trapped fuel acts as a solid hydraulic link
between the timing plunger and metering
plunger.
32) As a result, the metering plunger is forced

to move down-ward with the timing plunger.
Because the fuel is trapped, the downward
force on the timing plunger is transferred to
the metering plunger, thereby increasing
pressure in the metering chamber.
33) When this pressure reaches approximately

5000 psi, the needle valve begins to be
forced upward.
Continued downward movement of the
timing plunger and metering plunger results
in steadily increasing fuel pressure. The
result is that fuel is forced past the needle
valve, through the spray holes, and into the
combustion chamber.
2-10
34) Injection continues until the spill passage of
the metering plunger passes the metering
spill port.
Metering-chamber pressure drops rapidly,
allowing the needle valve to close abruptly.
This action results in a positive end of
injection. The positive end of injection
prevents dribble, and results in cleaner
burning.
It is also at this point that the pressure relief
valve "pops off" thereby reducing the effects
of the high pressure "spike" that occurs at
the time of metering spill. The relief valve
passage connects to the fuel drain line.
35) Immediately after the metering spill port is

opened, the upper edge of the metering
plunger passes the timing spill port.
36) This action allows the fuel in the timing

chamber to be spilled back to the fuel drain
as the timing plunger completes its
downward movement.
This completes the injection cycle.
2-11
37) To summarize QSM system operation, the
injector is camshaft-actuated to achieve
high pressures.
38) Opening the injector control valve

terminates metering, which results in a
precise amount of fuel to be injected.
Closing the injector control valve controls
the start of injection. This injection "timing"
can be varied over a wide range of values.
39) By varying the amount of time the injector

control valve remains open, and remains
closed, the ECM is able to maintain precise
and independent control of metering and
timing values. This process allows the
system to meet engine demands resulting
from a wide range of operating conditions.
40) When fuel pressure exceeds that of the

needle valve return spring, the needle valve
opens and injection begins.
Injection ends when the pressure drops to
less than this opening pressure.
2-12
41) The primary diagnostic tool for use with the
QSM system will be the INSITE computer
based diagnostic tool.
Echek and Compulink cartridges will be
available for use with QSM.
2-13
GROUP 2 ENGINE FAULT CODEINFORMATION(FOR QSM11)
Fault code No. Reason Effect(only when fault code is active)

Error internal to the ECM related to memory Engine will not start.
111 hardware failures or internal ECM voltage
supply circuits.
No engine speed signal detected at both Engine will die and will not start.
115 engine position sensor circuits.
No engine speed signal detected from one of None on performance.
121 the engine position sensor circuits.
High voltage detected on the intake manifold Derate in power output of the engine.
122 pressure circuit.
Low voltage detected on the intake manifold Derate in power output of the engine.
High voltage detected at the throttle position Severe derate(power and speed). Limp home
131 signal circuit. power only.
Low voltage detected at the throttle position Severe derate(power and speed). Limp home
132 signal circuit. power only.
High voltage detected at the remote throttle None on performance if remote throttle is not
133 position signal circuit. used.
Low voltage detected at the remote throttle None on performance if remote throttle is not
134 position signal circuit. used.
High voltage detected at the oil pressure No engine protection for oil pressure.
135 circuit.
Low voltage detected at the oil pressure No engine protection for oil pressure.
141 circuit.
Oil pressure signal indicates oil pressure Progressive power and speed derate with
below the low oil pressure engine protection increasing time after alert. If engine protection
143 limit. shutdown feature is enable, engine will shut
down 30 seconds after red lamp starts
flashing.
High voltage detected at the coolant Possible white smoke. Fan will stay on if
temperature circuit. controlled by the electronic control module
144 (ECM). No engine protection for coolant
temperature.
Low voltage detected at the coolant Possible white smoke. Fan will stay on if
145 temperature circuit. controlled by electronic control module (ECM).
No engine protection for coolant temperature.
A frequency of less then 100Hz was detected Calibration dependent power and speed
147 at the frequency throttle signal pin of the derate.
actuator harness connector at the ECM.
A frequency of more than 100Hz was detected Calibration dependent power and speed
148 at the frequency throttle signal pin of the derate.
actuator harness connector at the ECM.
Coolant temperature signal indicates coolant Progressive power derate with increasing time
151 temperature above 104°C(220°F). after alert. If engine protection shutdown
feature is enabled, engine will shut down 30
seconds after red lamp starts flashing.
High voltage detected at the intake manifold Possible white smoke. Fan will stay on if
Low voltage detected at the intake manifold Possible white smoke. Fan will stay on if
Intake manifold temperature signal indicates Progressive power derate with increasing time
temperature above 87.8°C(190°F). after alert. If engine protection shutdown
155 feature is enabled, engine will shut down 30
Low voltage detected on the ECM voltage Engine will run derated. No engine protection
187 supply line to some sensors(VSEN2 supply). for oil pressure and coolant level.
2-14
Additional machine diagnostic codes have None on engine performance.
211 been logged. Check other ECM’s for
diagnostic codes.
High voltage detected at the oil temperature No engine protection for oil temperature.
212 circuit.
Low voltage detected at the oil temperature No engine protection for oil temperature.
213 circuit.
Oil temperature signal indicates oil temperate Progressive power derate with increasing time
above 123.9°C(225°F). after alert. If engine protection shutdown
214 feature is enabled, engine will shut down
30sec after the red lamp starts flashing.
Low oil level was detected in the CentinelTM None on performance. CentinelTM deactivated.
219 makeup oil tank.
High voltage detected at the ambient air Derate in power output of the engine.
Low voltage detected at the ambient air Derate in power output of the engine.
Incorrect voltage detected at the CentinalTM None on performance. CentinelTM deactivated.
223 actuator circuit by the ECM.
High voltage detected on the ECM voltage Engine will run derated. No engine protection
227 supply line to some sensors(VSEN2 supply). for oil pressure and coolant level.
Engine speed signal indicates engine speed is Fuel shutoff valve closes until engine speed
234 greater than 2730 rpm. falls to 2184 rpm.
Coolant level signal indicates coolant level is Progressive power derate with increasing time
below the normal range. after alert. If engine protection shutdown
235 feature is enabled, engine will shut down 30
Duty cycle of the throttle input signal to the All engines(primary and secondary) are shut
primary or secondary engine for multiple unit down with increasing time after alert if hard-
237 synchronization is less than 3 percent or more coupled. Only secondary engines are shut
than 97 percent. down with increasing time after alert if soft-
coupled.
The ECM lost the vehicle speed signal. Engine speed limited to maximum engine
speed without vehicle speed sensor parameter
241 value Cruise Control. Gear-Down Protection
and Road Speed Governor will not work
(automotive only).
Invalid or inappropriate vehicle speed signal Engine speed limited to maximum engine
detected. Signal indicates an intermittent speed without vehicle speed sensor parameter
242 connection or VSS tampering. value Cruise Control. Gear-Down Protection
and Road Speed Governor will not work
(automotive only).
Less than 6 VDC detected at fan clutch circuit The fan may stay on at all times.
245 when on. Indicates an excessive current draw
from the ECM or faulty ECM output circuit.
Less than 6 VDC detected at FSO circuit when The ECM turns off the FSO supply voltage.
254 on. Indicates an excessive current draw from The engine will shut down.
the ECM or a faulty ECM output circuit.
Externally supplied voltage detected going to None on performance. Fuel shutoff valve
255 the fuel shutoff solenoid supply circuit. stays open.
The ECM expected information from a At least one multiplexed device will not operate
285 multiplexed device but did not receive it soon properly.
enough or did not receive it at all.
The ECM expected info from a multiplexed At least on multiplexed device will not operate
286 device but only received a portion of the properly.
necessary information.
The machine vehicle electronic control unit The engine will only idle.
287 (VECU) detected a fault with its throttle pedal.
2-15
The machine vehicle electronic control unit The engine will not respond to the remote
288 (VECU) detected a fault with its remote throttle. throttle.
High voltage detected at the machine No engine protection for machine temperature.
293 temperature sensor signal pin of the 31-pin
machine connector.
Low voltage detected at the machine No engine protection for machine temperature.
294 temperature sensor signal pin of the 31-pin
machine connector.
An error in the ambient air pressure sensor Engine is derated to no air setting.
295 signal was detected by the ECM.
High voltage detected at the machine pressure No engine protection for machine pressure.
297 sensor signal pin of the 31-pin machine
connector.
Low voltage detected at the machine pressure No engine protection for machine pressure.
298 sensor signal pin of the 31-pin machine
connector.
Engine shutdown by device other than key No action taken by the ECM.
switch before proper engine cool down
299 resulting in filtered load factor above maximum
shutdown threshold.
Current detected at No.1 injector when voltage Current to injector is shut off.
311 is turned off.
Current detected at No.5 injector when voltage Current to injector is shut off.
312 is turned off.
Current detected at No.3 injector when the Current to injector is shut off.
313 voltage is turned off
Current detected at No 6 injector when the Current to injector is shut off.
314 voltage is turned off.
315 voltage is turned off.
Real time clock lost power. None on performance. Data in the ECM will
319 not have accurate time and date information.
321 voltage is turned on.
No current detected at No.1 injector when the Current to injector is shut off.
Severe loss of data from the ECM. Possible no noticeable performance effects
OR engine dying OR hard starting. Fault
341 information, trip information and maintenance
monitor data may be inaccurate.
Internal ECM error. Possible none on performance or severe
343 derate.
A frequency greater than calibrated threshold Calibration dependent power and speed
349 was detected at the tail shaft governor signal derate.
pin of the 31-pin machine connector.
Low voltage detected on the ECM voltage Engine is derated to no air setting.
352 supply line to some sensors (VSEN 1 supply).
2-16
High voltage detected on the ECM voltage Engine is derated to no air setting.
386 supply line to some sensors (VSEN 1 supply).
High voltage detected on the ECM voltage Engine will only idle.
387 supply line to the throttle(VTP supply).
Oil pressure signal indicates oil pressure Progressive power derate with increasing time
below the very low oil pressure engine from alert. If engine protection shutdown
415 protection limit. feature is enabled, engine will shut down 30
Water has been detected in the fuel filter. Possible white smoke, loss of power, or hard
418 starting.
An error in the intake manifold pressure Engine is derated to no air setting.
419 sensor signal was detected by the ECM.
Voltage detected simultaneously on both the No engine protection for coolant level.
422 coolant level high and low signal circuits OR
no voltage detected on both circuits.
Communication between the ECM and the None on performance. J1939 devices may
426 J1939 data link has been lost. not operate.
428 High voltage detected at water-in-fuel sensor. None on performance.
429 Low voltage detected at water-in-fuel sensor. None on performance.
431 Voltage detected simultaneously on both the None on performance.
idle validation off-idle and on-idle circuits.
Voltage detected at idle validation on-idle Engine will only idle.
circuit when voltage at throttle position circuit
432 indicates the pedal is not at idle OR voltage
detected at idle validation off-idle circuit when
voltage at throttle position circuit indicates the
pedal is at idle.
Voltage signal at intake manifold pressure Derate to no air setting.
433 circuit indicates high intake manifold pressure
but other engine characteristics indicate intake
manifold pressure must be low.
Supply voltage to the ECM fell below 6.2 VDC Possible no noticeable performance effects
434 for a fraction of a second OR the ECM was not OR possibility of engine dying OR hard
allowed to power down correctly (retain battery starting. Fault information, trip information and
voltage for 30 seconds after key off). maintenance monitor data may be inaccurate.
435 An error in the oil pressure sensor signal was None on performance. No engine protection
detected by the ECM. for oil pressure.
441 Battery voltage below normal operating level. Possible no noticeable performance effects
OR possibility of rough idle.
442 Battery voltage below normal operating level. None on performance.
Low voltage detected on the ECM voltage Engine will only idle.
443 supply line to the throttle(s) (VTP supply).
Auxiliary speed frequency on input pin Engine will only idle.
489 indicated that the frequency is below a
calibration dependent threshold.
Less than 17.0 VDC detected at the dual No action taken by the ECM.
527 output A signal pin of the 31-pin machine
connector.
528 output B signal pin of the 31-pin machine
connector.
529 output B signal pin at the ECM.
No voltage detected simultaneously on both Engine will only idle.
551 the idle validation off-idle and on-idle circuits.
High voltage detected at the fuel inlet Fuel inlet restriction monitor deactivated.
581 restriction sensor signal pin.
2-17
Low voltage detected at the fuel inlet restriction Fuel inlet restriction monitor deactivated.
582 sensor signal pin
Restriction has been detected at the fuel pump Fuel inlet restriction monitor warning is set.
583 inlet.
High battery voltage detected by the battery Yellow lamp will be lit until high battery voltage
596 voltage monitor feature. condition is corrected.
ICONTM has restarted the engine three times Yellow lamp will be lit until low battery voltage
within three hours due to low battery voltage condition is corrected. The ECM may
(automotive only) OR low battery voltage increase idle speed and deactivate idle
597 detected by the battery voltage monitor decrement switch if idle speedup is enabled.
feature. The engine will run continuously if ICONTM is
active (automotive only).
Very low battery voltage detected by the Red lamp lit until very low battery voltage
598 battery voltage monitor feature. condition is corrected.
Engine shutdown by operator before proper No action taken by the ECM.
611 engine cool down resulting in filtered load
factor above maximum shutdown threshold.
A power imbalance between cylinders was Engine may have rough idle or misfire.
951 detected by the ECM.
2-18

1. POWER TRAIN COMPONENT OVERVIEW
Transmission Upper drive shaft Engine
Front axle Front drive shaft Center drive shaft Rear drive shaft Rear axle
The power train consists of the following components:

・Transmission
・Front, center, rear and upper drive shafts
・Front and rear axles
Engine power is transmitted to the transmission through the torque converter.
The transmission is a hydraulically engaged four speed forward, three speed reverse countershaft type
power shift transmission. A calliper-disc type parking brake is located on the front axle.
The transmission outputs through universal joints to three drive shaft assemblies. The front drive shaft
is a telescoping shaft which drives the front axle. The front axle is mounted directly to the loader frame.
The front axle is equipped with limited slip differential.
The rear axle is mounted on an oscillating pivot. The rear axle is equipped with limited slip differential.
The power transmitted to front axle and rear axle is reduced by the pinion gear and ring gear of
differential. It then passes from the differential to the sun gear shaft(Axle shaft) of final drive.
The power of the sun gear is reduced by a planetary mechanism and is transmitted through the
planetary hub to the wheel.
3-1
HYDRAULIC CIRCUIT
KR K4 K1 K3 KV K2
F 55 E 60 D 56 C 58 B 53 A 57
P1 P2 P3 P4 P5 P6
B D B D B D B D B D B D
Y1 Y2 NFS Y3 NFS Y4 NFS Y5 Y6 NFS

NFS NFS
Pressure
Temp reducing
sensor valve
9 bar
System
pressure
valve
Valve block control circuit 16+2 bar
Converter
Filter
Relief
valve
11 bar
Oil cooler Pressure
holding Pump
valve 16+2 bar
Bypass 5 bar
valve Pressure switch
1.5 bar 5.5 bar Coarse filter
Lubrication
Oil sump
Main oil circuit
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 KR P6 Proportional valve-clutch K2
P2 Proportional valve-clutch K4 Y1~Y6 Pressure regulator
Speed
Pressure Positions No. of the
Engaged
regulator Forward Reverse Neutral on the measuring
clutch points
active valve block
1 2 3 4 1 2 3
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
1 3 5 4
1 Turbine 3 Pump 5 Input shaft

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

TT = Torque of the turbine wheel
TR = Torque of the reaction member(Stator)
Pump wheel TR
Turbine wheel
From the engine
TT
TP
To the gearbox
Starting
condition 1 Reaction member nT = 0
1.5 2.5
(Stator) Machine stopped
Intermediate
condition 1 <1.5 <2.5 nT < n engine
Condition shortly
before the converter 1 1 nT = 0.8n engine
clutch is closed. 0
Turbine wheel is running with

about the same speed as
pump wheel.
3-4
3. TRANSMISSION
1) LAYOUT
1 2 3 4
KV K1
KR K2
K4 K3
10
13 12 11
1 Torque converter 8 Clutch axle-KR/K2

2 Breather 9 Clutch axle-K4/K3
3 Electro-hydraulic shift control 10 Output flange (Rear side)
4 2nd power take off 11 Output shaft
5 Transmission pump 12 Output flange (Converter side)
6 1st power take off 13 Countershaft
7 Clutch axle-KV/K1
3-5
2) INSTALLATION VIEW
1 2 7 8 9 10 14 15 16 17 18 19 20
3 4 5 6 11 2' 12 13 21 22 23 24
1 Breather 12 Cover
2 Transmission suspension M16 13 Output flange
2' Transmission suspension M20 14 Pressure oil line clutch K2
3 Attachment possibility for an oil filler 15 Pressure oil line clutch KR
tube with oil dipstick. 16 Pressure oil line clutch KV
4 Output flange 17 1st power take off
5 Oil drain plug 18 2nd power take off
6 Coarse filter 19 Pressure oil line clutch K3
7 Input flange 20 Pressure oil line clutch K1
8 Converter bell 21 Lubricating oil line S2 clutch K4/K3
9 Lifting lug 22 Lubricating oil line S1 clutch KR/K2
10 Electrohydraulic shift controller 23 Emergency steering pump connection(Option)
11 Gearbox housing 24 Pressure oil line clutch K4
3-6
3) OPERATION OF TRANSMISSION
(1) Forward
① Forward 1st
In 1st forward, forward clutch and 1st clutch are engaged.
Forward clutch and 1st clutch are actuated by the hydraulic pressure applied to the clutch piston.
INPUT
KV K1
KR K2
K4 K3
OUTPUT OUTPUT
3-7
② Forward 2nd
In 2nd forward, forward clutch and 2nd clutch are engaged.
Forward clutch and 2nd clutch are actuated by the hydraulic pressure applied to the clutch piston.
INPUT
KV
K1
KR K2
K4 K3
OUTPUT OUTPUT
3-8
③ Forward 3rd
In 3rd forward, forward clutch and K3(3rd) clutch are engage.
Forward clutch and 3rd clutch are actuated by the hydraulic pressure applied to the clutch piston.
INPUT
KV K1
KR K2
K4 K3
OUTPUT OUTPUT
3-9
④ Forward 4th
In 4th forward, 4th clutch and 3rd clutch are engaged.
4th clutch and 3rd clutch are actuated by the hydraulic pressure applied to the clutch piston.
INPUT
KV K1
KR K2
K4 K3
OUTPUT OUTPUT
3-10
(2) Reverse
① Reverse 1st
In 1st reverse, reverse clutch and 1st clutch are engaged.
Reverse clutch and 1st clutch are actuated by the hydraulic pressure applied to the clutch piston.
INPUT
KV K1
KR K2
K4 K3
OUTPUT OUTPUT
3-11
② Reverse 2nd
In 2nd reverse, reverse clutch and 2nd clutch are engaged.
Reverse clutch and 2nd clutch are actuated by the hydraulic pressure applied to the clutch piston.
INPUT
KV K1
KR K2
K4 K3
OUTPUT OUTPUT
3-12
③ Reverse 3rd
In 3rd reverse, reverse clutch and 3rd clutch are engaged.
Reverse clutch and 3rd clutch are actuated by the hydraulic pressure applied to the clutch piston.
INPUT
KV K1
KR K2
K4 K3
OUTPUT OUTPUT
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
1 Pressure reducing valve(9bar) 7 Intermediate plate

2 Main pressure valve(16+2bar) 8 Duct plate
3 Housing 9 Vibration damper
4 Cable harness 10 Follow-on slide
5 Cover 11 Pressure regulator
6 Valve block
Transmission control, see schedule of measuring points, hydraulic schematic and electro-hydraulic
control unit at page 3-2, 3-14 and 3-72.
The six clutches of the transmission are selected via the 6 proportional valves P1 to P6. The
proportional valve(Pressure regulator unit) consists of pressure regulator(e.g. Y6), 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 will be considered:
- Speed of engine, turbine, central gear train and output.
- Transmission temperature.
- Shifting mode(Up-, down-, reverse shifting and speed engagement out of neutral).
- Load condition(Full and part load, traction, overrun inclusive consideration of load cycles during
the shifting).
The main pressure valve is limiting the 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 convert safety valve is installed which protects the converter from high
internal pressures(Opening pressure 11bar).
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 pressure holding valve, rear-mounted to the converter , with an
opening pressure of at least 5bar.
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 there to the lubricating oil circuit so that
all lubricating points are supplied with cooled oil.
In the electro-hydraulic control unit there are 6 pressure regulators installed.
5) GEAR SELECTOR(DW-3)
The gear selector is designed for the

mounting on the left side of the steering
column. By a rotative motion, the positions F
(Speeds) 1 to 4 are selected by tilting the

1
2 N
3
4
lever, the driving direction Forward(F)- R
Neutral(N)-Reverse(R).
The gear selector is also available with
integrated kickdown push button.
For the protection from unintended start of f,
a neutral interlock is installed :
Position N - Gear selector lever blocked in N D
this position.
Position D - Driving.
3 - 15
6) TRANSMISSION ERROR DISPLAY
(1) Function
The display can be used with the gear selector(DW -3). It indicates speed and driving direction as
well as the activated kickdown.
When driving in the automatic mode, a bar indicator gives additionally also information about the
selected driving range; The automatic range is symbolized by arrows above and below the bar
indicator. In case of possible errors in the system, a wrench appears on the display , combined
with indication of the error number. Also sporadically occurring errors can be indicated.
e f d Left side Right side
h S
T
O
P
b a c Central side g 7803A3CD33
a, f Automatic range(up and down shifting)

1 Bars
b, c, d, e Preselected gear
2 Left side For the moment still without function
On the two alphanumeric 16-segment display, the electric control

Central and
3 unit issues the actual state of gear and driving direction. Besides,
Right side
a two digit error code will be indicated via these two segment
4 Spanner g Electronic control unit recognized an error, is flashing
5 Letters STOP h Immediate stop is required(At the moment not activated)
(2) Abbreviations
OC : Open circuit
SC : Short circuit
OP mode : Operating mode
TCU : Transmission control unit
EEC : Electronic engine controller
PTO : Power take off
3 - 16
(3) Display during operation
Symbol Meaning Remarks
F, N, R Actual gear and direction

Central side shows actual gear
1, 2, 3, 4 Right side shows actual direction
NN Not neutral, waiting for neutral To engage a gear, first move shift selector to
(Central and right side) after power up or a severse fault neutral position and again to F to R position
1 bar Manual mode lst gear
2 bar Manual mode 2nd gear
4 bars and 2 arrows Automatic mode a, f
Arrows(a, f) flashing Kick down mode active
Transmission neutral Cold start phase
Bars flashing Downshift mode active
Spanner flashing At least on fault active Select neutral to get fault code displayed
Changes between actual gear/direction while
Warning torgue converter
WT driving, in neutral only displayed if no fault is
temperature
detected(spanner)
WS Warning sump temperature driving, in neutral only displayed if no fault is
detected(spanner)
WE Warning high engine speed driving, in neutral only displayed if no fault is
detected(spanner)
Transmission in neutral until parking brake is
Direction F or R selected while released.
PN
parking brake engaged Machine starts to move after release of
parking brake.
Direction F or R selected while
F or R flashing Gear will engage when turbine speed drops
turbine speed is to high
EE flashing
No communication with display
(central and right side)
3 - 17
(4) Display during AEB mode
Symbol Meaning Remarks
PL AEB-Starter is plugged at the

diagnostic plug
ST AEB-Starter-button is pressed
K1~K4, KV, KR Calibrating clutch K1~K4, KV
or KR respectively
- And Kx Wait for start, initialization of
clutch Kx, x : 1, 2, 3, 4, V, R
≡ And Kx Fast fill time determination of
clutch Kx
= And Kx Compensating pressure
determination of clutch Kx
OK Calibration for all clutches Transmission stays in neutral, you have to restart the
finished TCU(Ignition off/on) after removing AEB-Starter
STOP AEB cancled(Activation Transmission stays in neutral, you have to restart the
stopped) TCU(Ignition off/on)
STOP and Kx AEB stopped, clutch Kx can't Transmission stays in neutral, you have to restart the
be calibrated TCU(Ignition off/on)
Spanner and Kx Kx couldn't be calibrated, AEB Transmission stays in neutral, you have to restart the
finished TCU(Ignition off/on)
△E Engine speed too low,
- Raise engine speed
▽E Engine speed too high,
- Lower engine speed
△T Transmission oil temperature
too low,
- Heat up transmission
▽T Transmission oil temperature
too high,
- Cool down transmission
FT Transmission temperature not Transmission stays in neutral, you have to restart the
in defined range during TCU(Ignition off/on)
calibration
FB Operating mode not NORMAL Transmission stays in neutral, you have to restart the
or transmission temperature TCU(Ignition off/on)
sensor defective or storing of
calibrated values to EEPROM
has failed
FO Output speed not zero Transmission stays in neutral, you have to restart the
TCU(Ignition off/on)
FN Shift lever not in neutral Transmission stays in neutral, you have to restart the
position TCU(Ignition off/on)
FP Park brake not applied Transmission stays in neutral, you have to restart the
TCU(Ignition off/on)
STOP AEB-Starter was used incorrect Transmission stays in neutral, you have to restart the
or is defective. Wrong device TCU(Ignition off/on)
or wrong cable used
3 - 18
(5) DEFINITION OF OPERATING MODES
① Normal
There's no failure detected in the transmission system or the failure has no or slight ef fects 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.
3 - 19
(6) Table of fault codes
Fault code Int. code Meaning of the fault code
(Hex) (Dec) possible reason for fault detection Reaction of the TCU Possible steps to repair Remarks
11 48 Logical error at gear range signal TCU shifts transmission to •Check the cables from TCU to Failure cannot be detected in
TCU detected a wrong signal combination neutral shift lever systems with DW2/DW3 shift
for the gear range OP-mode : Transmission •Check signal combinations of lever
•Cable from shift lever to TCU is broken shutdown shift lever positions for gear Fault is taken back if TCU
•Cable is defective and is contacted to range detects a valid signal for the
battery voltage or vehicle ground position
•Shift lever is defective
12 46 Logical error at direction select signal TCU shifts transmission to •Check the cables from TCU to Fault is taken back if TCU
TCU detected a wrong signal combination neutral shift lever detects a valid signal for the
for the direction direction at the shift lever
•Cable from shift lever to TCU is broken OP-Mode : Transmission •Check signal combinations of
•Cable is defective and is contacted to shutdown shift lever positions F-N-R
battery voltage or vehicle ground
13 95 Logical error at engine derating device After selecting neutral, TCU •Check engine derating device This fault is reset after power
TCU detected no reaction of engine while change to OP mode limp home up of TCU
derating device active
15 176 Logical error at direction select signal 2 shift TCU shifts transmission to •Check the cables from TCU to Fault is taken back if TCU
lever neutral if selector active shift lever 2 detects a valid neutral signal
TCU detected a wrong signal combination OP mode : Transmission •Check signal combinations of for the direction at the shift
for the direction shutdown if selector shift lever positions F-N-R lever
•Cable from shift lever 2 to TCU is broken active
•Cable is defective and is contacted to
battery voltage or vehicle ground
16 178 Logical error at axle connection OP mode : Normal •Check the cables from TCU to
Feedback axle connection measured by TCU feedback axle connection switch
and output signal axle connection don't fit •Check signals of the feedback
•Axle can't be connected or disconnected axle connection switch
due to mechanical problem
•One of the cables from feedback axle
connection switch to TCU is broken
3-20
21 32 S.C. to battery voltage at clutch cut off input Clutch cut off function is disabled •Check the cable from TCU to
The measured voltage is too high: OP mode : Normal the sensor
•Cable is defective and is contacted to •Check the connectors
battery voltage •Check the clutch cut off sensor
•Clutch cut off sensor has an internal defect
•Connector pin is contacted to battery voltage
22 29 S.C. to ground or O.C. at clutch cut off input Clutch cut off function is disabled •Check the cable from TCU to
The measured voltage is too low: OP mode : Normal the sensor
•Cable is defective and is contacted to •Check the connectors
vehicle ground •Check the clutch cut off sensor
•Cable has no connection to TCU
•Clutch cut off sensor has an internal
defect
•Connector pin is contacted to vehicle
ground or is broken
23 S.C. to battery voltage at load sensor input Retarder function is affected •Check the cable from TCU to Availability of retarder
The measured voltage is too high: TCU uses default load the sensor depends on default load
•Cable is defective and is contacted to OP mode : Normal •Check the connectors
battery voltage •Check the load sensor
•Load sensor has an internal defect •Check the assembly tolerances
•Connector pin is contacted to battery voltage of load sensor
24 S.C. to ground or O.C. at load sensor input Retarder function is affected •Check the cable from TCU to Availability of retarder
The measured voltage is too low: TCU use default load the sensor depends on default load
•Cable is defective and is contacted to OP mode : Normal •Check the connectors
vehicle ground •Check the load sensor
•Cable has no connection to TCU •Check the assembly tolerances
•Load sensor has as internal defect of load sensor
ground or is broken
3-21
25 33 S.C. to battery voltage or O.C. at transmission No reaction, TCU use default •Check the cable from TCU to
sump temperature sensor input temperature the sensor
The measured voltage is too high: OP mode : Normal •Check the connectors
•Cable is defective and is contacted to •Check the temperature sensor
battery voltage
•Temperature sensor has an internal defect
•Connector pin is contacted to battery
voltage or is broken
26 30 S.C. to battery voltage or O.C. at transmission No reaction, TCU uses default •Check the cable from TCU to
sump temperature sensor input temperature the sensor
The measured voltage is too low: OP mode : Normal •Check the connectors
vehicle ground
ground
27 76 S.C. to battery voltage or O.C. at retarder No reaction, TCU uses default •Check the cable from TCU to
temperature sensor input temperature the sensor
battery voltage
28 74 S.C. to ground at retarder temperature No reaction, TCU uses default •Check the cable from TCU to
sensor input temperature the sensor
vehicle ground
•Connector pin is contacted to vehicle ground
3-22
27 76 S.C. to battery voltage or O.C. at converter No reaction, TCU uses default •Check the cable from TCU to
output temperature sensor input temperature the sensor
battery voltage
28 74 S.C. to ground at converter output No reaction, TCU uses default •Check the cable from TCU to
temperature sensor input temperature the sensor
vehicle ground
31 38 S.C. to battery voltage or O.C. at engine OP mode : Substitute clutch control •Check the cable from TCU to
speed input the sensor
TCU measures a voltage higher than 7.00 V •Check the connectors
at speed input pin •Check the speed sensor
battery voltage
•Speed sensor has an internal defect
voltage or has no contact
32 34 S.C. to ground at engine speed input OP mode : Substitute clutch control •Check the cable from TCU to
TCU measures a voltage less than 0.45V at the sensor
speed input pin •Check the connectors
•Cable/connector is defective and is •Check the speed sensor
contacted to vehicle ground
3-23
33 42 Logical error at engine speed input OP mode : Substitute clutch control •Check the cable from TCU to This fault is reset after power
TCU measures a engine speed over a the sensor up of TCU
threshold and the next moment the •Check the connectors
measured speed is zero •Check the speed sensor
•Cable/connector is defective and has bad •Check the sensor gap
contact
•Sensor gap has the wrong size
34 39 S.C. to battery voltage or O.C. at turbine OP mode : Substitute clutch control •Check the cable from TCU to
speed input If a failure is existing at output the sensor
TCU measures a voltage higher than 7.00V speed, •Check the connectors
at speed input pin TCU shifts to neutral •Check the speed sensor
•Cable is defective and is contacted to OP mode : Limp home
vehicle battery voltage
35 35 S.C. to ground at turbine speed input OP mode : Substitute clutch control •Check the cable from TCU to This fault is reset after power
TCU measures a voltage less than 0.45 V at If a failure is existing at output the sensor up of TCU
speed input pin speed, •Check the connectors
•Cable/connector is defective and is TCU shifts to neutral •Check the speed sensor
contacted to vehicle ground OP mode : Limp home
36 43 Logical error at turbine speed input OP mode : Substitute clutch control •Check the cable from TCU to
TCU measures a turbine speed over a If a failure is existing at output the sensor
threshold and at the next moment the speed, •Check the connectors
measured speed is zero TCU shifts to neutral •Check the speed sensor
•Cable/connector is defective and has bad OP mode : Limp home •Check the sensor gap
contact
3-24
37 40 S.C. to battery voltage or O.C. at internal OP mode : Substitute clutch control •Check the cable from TCU to
speed input the sensor
TCU measures a voltage higher than 7.00V •Check the connectors
at speed input pin •Check the speed sensor
vehicle battery voltage
38 36 S.C. to ground at turbine speed input OP mode : Substitute clutch control •Check the cable from TCU to
TCU measures a voltage less than 0.45 V at the sensor
speed input pin •Check the connectors
•Cable/connector is defective and is •Check the speed sensor
39 44 Logical error at internal speed input OP mode : Substitute clutch control •Check the cable from TCU to This fault is reset after power
TCU measures a internal speed over a the sensor up of TCU
threshold and at the next moment the •Check the connectors
measured speed is zero •Check the speed sensor
•Cable/connector is defective and has bad •Check the sensor gap
contact
3A 41 S.C. to battery voltage or O.C. at output Special mode for gear selection •Check the cable from TCU to
speed input OP mode : Substitute clutch control the sensor
TCU measures a voltage higher than 12.5 V If a failure is existing at turbine •Check the connectors
at speed input pin speed, •Check the speed sensor
•Cable is defective and is contacted to TCU shifts to neutral
battery voltage OP mode : lamp home
3-25
3B 37 S.C. to ground at output speed input Special mode for gear selection •Check the cable from TCU to
TCU measures a voltage less than 1.00V at OP mode : Substitute clutch control the sensor
speed input pin If a failure is existing at turbine •Check the connectors
•Cable/connector is defective and is speed, •Check the speed sensor
contacted to vehicle ground TCU shifts to neutral
•Speed sensor has an internal defect OP mode : lamp home
3C 45 Logical error at output speed input Special mode for gear selection •Check the cable from TCU to This fault is reset after power
TCU measures a turbine speed over a OP mode : Substitute clutch control the sensor up of TCU
threshold and at the next moment the If a failure is existing at turbine •Check the connectors
measured speed is zero speed, •Check the speed sensor
•Cable/connector is defective and has bad TCU shifts to neutral •Check the sensor gap
contact OP mode : lamp home
3D 71 Turbine speed zero doesn't fit to other - - Not used

speed signals
3E 72 Output speed zero doesn't fit to other Special mode for gear selection •Check the sensor signal of This fault is reset after power
speed signals OP mode : Substitute clutch control output speed sensor up of TCU
If transmission is not neutral and the shifting If a failure is existing at turbine •Check the sensor gap of
has finished, speed, output speed sensor
TCU measures output speed zero and TCU shifts to neutral •Check the cable from TCU to
turbine speed or internal speed not equal to OP mode : lamp home the sensor
zero.
3-26
71 22 S.C. to battery voltage at clutch K1 TCU shifts to neutral •Check the cable from TCU to * See Chapter (7)
The measured resistance value of the valve is OP mode : Limp home the gearbox
out of limit, the voltage at K1 valve is too high If failure at another clutch is •Check the connectors from
•Cable/connector is defective and has pending TCU to the gearbox
contact to battery voltage TCU shifts to neutral •Check the regulator resistance*
•Cable/connector is defective and has OP mode : TCU shutdown •Check internal wire harness of
contact to another regulator output of the the gearbox
TCU
•Regulator has an internal defect
72 10 S.C. to ground at clutch K1 TCU shifts to neutral •Check the cable from TCU to * See Chapter (7)
out of limit, the voltage at K1 valve is too low If failure at another clutch is •Check the connectors from
•Cable/connector is defective and has pending gearbox to TCU
contact to vehicle ground TCU shifts to neutral •Check the regulator resistance*
•Regulator has an internal defect OP mode : TCU shutdown •Check internal wire harness of
the gearbox
73 16 O.C. at clutch K1 TCU shifts to neutral •Check the cable from TCU to * See Chapter (7)
The measured resistance value of the valve OP mode : Limp home the gearbox
is out of limit If failure at another clutch is •Check the connectors from
•Cable/connector is defective and has no pending gearbox to TCU
contact to TCU TCU shifts to neutral •Check the regulator resistance*
the gearbox
is out of limit, the voltage at K2 valve is too If failure at another clutch is •Check the connectors from
high pending gearbox to TCU
•Cable/connector is defective and has TCU shifts to neutral •Check the regulator resistance*
contact to battery voltage OP mode : TCU shutdown •Check internal wire harness of
•Cable/connector is defective and has the gearbox
contact to another regulator output of the
TCU
3-27
the gearbox
the gearbox
TCU
the gearbox
3-28
the gearbox
7A 78 S.C. to battery voltage at converter clutch - - Not used
7B 79 S.C. to ground at converter clutch - - Not used
7C 80 O.C. at converter clutch - - Not used
7D 166 S.C. ground at engine derating device Engine derating will be on until •Check the cable from TCU to * See Chapter (7)
•Cable is defective and is contacted to TCU power down even if fault the engine derating device
vehicle ground vanishes(Loose connection) •Check the connectors from
•Engine derating device has an internal defect OP mode : Normal engine derating device to TCU
•Connector pin is contacted to vehicle ground •Check the resistance* of engine
derating device
7E 168 S.C. battery voltage at engine derating No reaction •Check the cable from TCU to * See Chapter (7)
device OP mode : Normal the engine derating device
•Cable/connector is defective and is •Check the connectors from
contacted to battery voltage backup alarm device to TCU
•Engine derating device has an internal •Check the resistance* of
defect backup alarm device
7F 167 O.C. at engine derating device No reaction •Check the cable from TCU to * See Chapter (7)
TCU detected a wrong voltage at the output OP mode : Normal the engine derating device
pin, that looks like a O.C. for this output pin •Check the connectors from
•Cable is defective and has no connection engine derating device to TCU
to TCU •Check the resistance* of
•Engine derating device has an internal engine derating device
defect
•Connector has no connection to TCU
3-29
TCU
The measured resistance value of the valve is OP mode : Limp home the engine derating device
the gearbox
the gearbox
TCU
3-30
85 14 S.C. to ground at clutch KV TCU shifts to neutral •Check the cable from TCU to * See Chapter (7)
the gearbox
86 20 O.C. at clutch KV TCU shifts to neutral •Check the cable from TCU to * See Chapter (7)
the gearbox
87 27 S.C. to battery voltage at clutch KR TCU shifts to neutral •Check the cable from TCU to * See Chapter (7)
is out of limit, the voltage at KR valve is too high If failure at another clutch is •Check the connectors from
contact to battery voltage TCU shifts to neutral •Check the regulator resistance*
•Cable/connector is defective and has contact OP mode : TCU shutdown •Check internal wire harness of
to another regulator output of the TCU the gearbox
88 15 S.C. to ground at clutch KR TCU shifts to neutral •Check the cable from TCU to * See Chapter (7)
out of limit, the voltage at KR valve is too low If failure at another clutch is •Check the connectors from
the gearbox
89 21 O.C. at clutch KR TCU shifts to neutral •Check the cable from TCU to * See Chapter (7)
the gearbox
3-31
91 1 S.C. to ground at relay reverse warning Backup alarm will be on until •Check the cable from TCU to * See Chapter (7)
alarm TCU power down even if fault the backup alarm device
TCU detected a wrong voltage at the output vanishes(Loose connection) •Check the connectors from
pin, that looks like a S.C. to vehicle ground OP mode : Normal backup alarm device to TCU
•Cable is defective and is contact to vehicle •Check the resistance* of
ground backup alarm device
•Backup alarm device has an internal defect
92 3 S.C. to battery voltage at relay reverse No reaction •Check the cable from TCU to * See Chapter (7)
warning alarm OP mode : Normal the backup alarm device
TCU detected a wrong voltage at the output •Check the connectors from
pin, that looks like a S.C. to battery voltage backup alarm device to TCU
•Cable is defective and is contacted to •Check the resistance* of
battery voltage backup alarm device
•Backup alarm device has an internal
defect
voltage
93 2 O.C. at relay reverse warning alarm No reaction •Check the cable from TCU to * See Chapter (7)
TCU detected a wrong voltage at the output OP mode : Normal the backup alarm device
•Cable is defective and has no connection backup alarm device to TCU
•Backup alarm device has an internal defect backup alarm device
94 4 S.C. to ground at relay starter interlock No reaction •Check the cable from TCU to * See Chapter (7)
TCU detected a wrong voltage at the output OP mode : Normal the stater interlock relay
pin, that looks like a S.C. to vehicle ground •Check the connectors from
•Cable is defective and is connection to starter interlock relay to TCU
vehicle ground •Check the resistance* of
•Starter interlock relay has an internal defect starter interlock relay
ground
3-32
95 6 S.C. to battery voltage at relay starter No reaction •Check the cable from TCU to * See Chapter (7)
interlock OP mode : Normal the starter interlock relay
pin, that looks like a S.C. to battery voltage starter interlock relay to TCU
•Cable is defective and has no connection •Check the resistance* of
to battery voltage starter interlock relay
•Starter interlock relay has an internal defect
96 5 O.C. at relay starter interlock No reaction •Check the cable from TCU to * See Chapter (7)
TCU detected a wrong voltage at the output OP mode : Normal the starter interlock relay
•Cable is defective and has no connection starter interlock relay to TCU
•Starter interlock relay has an internal defect starter interlock relay
97 7 S.C. to ground at park brake solenoid No reaction •Check the cable from TCU to * See Chapter (7)
TCU detected a wrong voltage at the output OP mode : Normal the park brake solenoid
•Cable is defective and is connection to park brake solenoid to TCU
vehicle ground •Check the resistance* of park
•Park brake solenoid has an internal defect brake solenoid
ground
98 9 S.C. to battery voltage at park brake No reaction •Check the cable from TCU to * See Chapter (7)
solenoid Optional : (Some customers) the park brake solenoid
TCU detected a wrong voltage at the output TCU shifts to neutral caused by •Check the connectors from
pin, that looks like a S.C. to battery voltage park brake feed back park brake solenoid to TCU
•Cable is defective and is connection to OP mode : Normal •Check the resistance* of park
battery voltage brake solenoid
•Park brake solenoid has an internal defect
voltage
3-33
99 8 O.C. at park brake solenoid No reaction •Check the cable from TCU to * See Chapter (7)
TCU detected a wrong voltage at the output Optional : Some customers the park brake solenoid
pin, that looks like a O.C. for this output pin TCU shifts to neutral caused by •Check the connectors from
•Cable is defective and has no connection park brake feed back park brake solenoid to TCU
to TCU OP mode : Normal •Check the resistance* of park
•Park brake solenoid has an internal defect brake solenoid
9A 66 S.C. to ground at converter lock up No reaction •Check the cable from TCU to * See Chapter (7)
clutch solenoid OP mode : Normal the converter clutch solenoid
pin, that looks like a S.C. to vehicle ground converter clutch solenoid to
•Cable is defective and is contacted to TCU
vehicle ground •Check the resistance* of park
•Converter clutch solenoid has an internal brake solenoid
defect
9B 67 O.C. at converter lock up clutch solenoid Converter clutch always open, •Check the cable from TCU to * See Chapter (7)
TCU detected a wrong voltage at the output retarder not available the converter clutch solenoid
pin, that looks like a O.C. for this output pin OP mode : Normal •Check the connectors from
•Cable is defective and has no connection converter clutch solenoid to
to TCU TCU
•Converter clutch solenoid has an internal •Check the resistance* of park
defect brake solenoid
9C 68 S.C. to battery voltage at converter lock No reaction •Check the cable from TCU to * See Chapter (7)
up clutch solenoid OP mode : Normal the converter clutch solenoid
pin, that looks like a S.C. to battery voltage converter clutch solenoid to
•Cable is defective and has no contacted TCU
to battery voltage •Check the resistance* of
•Converter clutch solenoid has an internal converter clutch solenoid
defect
3-34
9D 81 S.C. to ground at retarder solenoid No reaction •Check the cable from TCU to * See Chapter (7)
TCU detected a wrong voltage at the output OP mode : Normal the retarder solenoid
•Cable is defective and is contacted to retarder solenoid to TCU
•Retarder solenoid has an internal defect retarder solenoid
ground
9E 82 O.C. at retarder solenoid No reaction •Check the cable from TCU to * See Chapter (7)
TCU detected a wrong voltage at the output OP mode : Normal the retarder solenoid
•Cable is defective and has no connection retarder solenoid to TCU
•Retarder solenoid has an internal defect retarder solenoid
9F 83 S.C. to battery voltage at retarder No reaction •Check the cable from TCU to * See Chapter (7)
solenoid OP mode : Normal the retarder solenoid
pin, that looks like a S.C. to battery voltage retarder solenoid to TCU
to battery voltage retarder solenoid
•Retarder solenoid has an internal defect
3-35
A1 84 S.C. to ground at difflock or axle No reaction •Check the cable from TCU to * See Chapter (7)
connection solenoid OP mode : Normal the difflock solenoid
pin, that looks like a S.C. to vehicle ground difflock solenoid to TCU
vehicle ground difflock solenoid
•Difflock solenoid has an internal defect
A2 85 S.C. to battery voltage at difflock or axle No reaction •Check the cable from TCU to * See Chapter (7)
connection solenoid OP mode : Normal the difflock solenoid
pin, that looks like a S.C. to battery voltage difflock solenoid to TCU
to battery voltage difflock solenoid
•Difflock solenoid has an internal defect
A3 86 O.C. at difflock or axle connection solenoid No reaction •Check the cable from TCU to * See Chapter (7)
TCU detected a wrong voltage at the output OP mode : Normal the difflock solenoid
•Cable is defective and has no connection difflock solenoid to TCU
•Difflock solenoid has an internal defect difflock solenoid
A4 96 S.C. to ground at warning signal output No reaction •Check the cable from TCU to * See Chapter (7)
TCU detected a wrong voltage at the output OP mode : Normal the warning device
•Cable is defective and is contacted to warning device to TCU
•Warning device has an internal defect warning device
3-36
A5 97 O.C. voltage at warning signal output No reaction •Check the cable from TCU to * See Chapter (7)
TCU detected a wrong voltage at the output OP mode : Normal the warning device
•Cable is defective and has no connection warning device to TCU
•Warning device has an internal defect warning device
A6 98 S.C. to battery voltage at warning signal No reaction •Check the cable from TCU to * See Chapter (7)
output OP mode : Normal the warning device
pin, that looks like a S.C. to battery voltage warning device to TCU
•Cable is defective and has is contacted to •Check the resistance* of
battery voltage warning device
•Warning device has an internal defect
voltage
3-37
B1 60 Slippage at clutch K1 TCU shifts to neutral •Check pressure at clutch K1

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

sensor
•Replace clutch

sensor
•Replace clutch
3-38

•Low main pressure OP mode : TCU shutdown •Check sensor gap at turbine
•Wrong signal at turbine speed sensor •Check signal at internal speed
•Clutch is defective •Check signal at turbine speed
sensor
•Replace clutch
B5 64 Slippage at clutch KV TCU shifts to neutral •Check pressure at clutch KV

clutch KV. If this calculated value is out of If failure at another clutch is system
•Low pressure at clutch KV TCU shifts to neutral speed sensor
sensor
•Replace clutch
B6 65 Slippage at clutch KR TCU shifts to neutral •Check pressure at clutch KR

clutch KR. If this calculated value is out of If failure at another clutch is system
•Low pressure at clutch KR TCU shifts to neutral speed sensor
sensor
•Replace clutch
3-39
B7 87 Overtemp sump No reaction •Cool down machine

TCU measured a temperature in the oil OP mode : Normal •Check oil level
sump that is over the allowed threshold. •Check temperature sensor
B8 88 Overtemp retarder TCU disables retarder •Cool down machine

TCU measured a temperature in the retarder OP mode : Normal •Check oil level
oil that is over the allowed threshold •Check temperature sensor
B9 89 Overspend engine Retarder applies -

OP mode : Normal
BA 90 Differential pressure oil filter No reaction •Check oil filter

TCU measured a voltage at differential OP mode : Normal •Check wiring from TCU to
pressure switch out of the allowed range differential pressure switch
•Oil filter is polluted •Check differential pressure
•Cable/connector is broken or cable/ switch(Measure resistance)
connector is contacted to battery voltage
or vehicle ground
•Differential pressure switch is defective
BB 172 Slippage at converter lockup clutch •Check pressure at converter

TCU calculates a differential speed at closed lockup clutch
converter lockup clutch. If this calculated •Check main pressure in the
value is out of range, TCU interprets this as system
slipping clutch •Check sensor gap at engine
•Low pressure at converter lockup clutch speed sensor
•Low main pressure •Check sensor gap at turbine
•Wrong signal at engine speed sensor speed sensor
•Wrong signal at turbine speed sensor •Check signal at engine speed
sensor
•Replace clutch
3-40
BD 169 S.C. to ground at engine brake solenoid No reaction •Check the cable from TCU to * See Chapter (7)
TCU detected a wrong voltage at the output OP mode : Normal engine brake solenoid
•Cable is defective and is contacted to engine brake solenoid to TCU
vehicle ground •Check the resistance* of engine
•Engine brake solenoid has an internal brake solenoid
defect
BE 171 S.C. to battery voltage at engine brake No reaction •Check the cable from TCU to * See Chapter (7)
TCU detected a wrong voltage at the output OP mode : Normal the engine brake solenoid
pin, that looks like a S.C. to battery voltage •Check the connectors from
•Cable is defective and is contacted to engine brake solenoid to TCU
battery voltage •Check the resistance* of engine
•Engine brake solenoid has an internal defect brake solenoid
BF 170 O.C. at engine brake No reaction •Check the cable from TCU to * See Chapter (7)
TCU detected a wrong voltage at the output OP mode : Normal the engine brake solenoid
•Cable is defective and has no connection engine brake solenoid to TCU
to TCU •Check the resistance* of engine
•Engine brake solenoid has an internal brake solenoid
defect
3-41
C3 91 Overtemp converter output No reaction •Cool down machine

TCU measured a oil temperature at the OP mode : Normal •Check oil level
converter output that is the allowed threshold •Check temperature sensor
C4 129 S.C. to ground at joystick status indicator No reaction •Check the cable from TCU to *See chapter (7)
TCU detected a wrong voltage at the output OP mode : Normal joystick status indicator
•Cable is defective and is contacted to joystick status indicator to TCU
•Joystick status indicator has an internal joystick status indicator
defect
C5 131 S.C. to battery voltage at joystick status No reaction •Check the cable from TCU to *See chapter (7)
indicator OP mode : Normal joystick status indicator
pin, that looks like a S.C. to battery voltage joystick status indicator to TCU
battery voltage joystick status indicator
•Joystick status indicator has an internal
defect
C6 130 O.C. at joystick status indicator No reaction •Check the cable from TCU to *See chapter (7)
TCU detected a wrong voltage at the output OP mode : Normal joystick status indicator
•Cable is defective and has no connection joystick status indicator to TCU
•Joystick status indicator has an internal joystick status indicator
defect
•Connector pin has no connection to TCU
3-42
D1 54 S.C. to battery voltage at power supply See fault codes No.21 to 2C •Check cables and connectors Fault codes No.21 to No.2C
for sensors to sensors, which are supplied may be reaction of this fault
TCU measures more than 6V at the pin AU1 from AU1
(5V sensor supply) •Check the power supply at the
pin AU1(Should be appx. 5V)
D2 55 S.C. to ground at power supply for See fault codes No.21 to 2C •Check cables and connectors Fault codes No.21 to No.2C
sensors to sensors, which are supplied may be reaction of this fault
TCU measures less than 4V at the pin AU1 from AU1
(5V sensor supply) •Check the power supply at the
pin AU1(Should be appx. 5V)
D3 53 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
than 18V(24V device) TCU
•Check connectors from
batteries to TCU
D4 52 High voltage at battery Shift to neutral •Check power supply battery

Measured voltage at power supply is higher OP mode : TCU shutdown •Check cables from batteries to
than 32.5V(24V device) TCU
•Check connectors from
batteries to TCU
D5 57 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
VPS1 is off or TCU switched off VPS1 and TCU
measured VPS1 is still on •Check connectors from
•Cable or connectors are defect and are gearbox to TCU
contacted to battery voltage •Replace TCU
•Cable or connectors are defect and are
•Permanent power supply KL30 missing
•TCU has an internal defect
3-43
D6 58 Error at valve power supply VPS2 Shift to neutral •Check fuse

TCU switched on VPS2 and measured OP mode : TCU shutdown •Check cables from gearbox to
VPS2 is off or TCU switched off VPS2 and TCU
measured VPS2 is still on •Check connectors from
•Cable or connectors are defect and are gearbox to TCU
contacted to battery voltage •Replace TCU
•Cable or connectors are defect and are
•Permanent power supply KL30 missing
•TCU has an internal defect
3-44
E1 91 S.C. battery voltage at speedometer - - Not used

output
E2 92 S.C. to ground or O.C at speedometer - - Not used

output
E3 S.C. to battery voltage at display output No reaction •Check the cable from TCU to
TCU sends data to the display and OP mode : Normal the display
measures always a high voltage level on the •Check the connectors at the
connector display
•Cable or connectors are defective and are •Change display
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
TCU sends data to the display and OP mode : Normal the display
measures always a high voltage level on the •Check the connectors at the
connector display
•Cable or connectors are defective and are •Change display
contacted to battery voltage
•Display has an internal defect
E5 93, 104 Communication failure on DeviceNet Shift to neutral •Check Omron master
OP mode : TCU shutdown •Check wire of DeviceNet-Bus
•Check cable to Omron master
E5 104 DISPID1 timeout TCU select parameter set with •Check display controller
Timeout of CAN-massage DISPID1 from ID0 •Check wire of CAN-Bus
display controller OP mode : Limp home •Check cable display controller
•Interference on CAN-Bus
•CAN wire/connector is defective
•Can wire/connector is defective and has
contact to vehicle ground or battery voltage
3-45
F1 51 General EEPROM fault No reaction •Replace TCU Often shown together with
TCU can't read non volatile memory OP mode : Normal fault code F2
•TCU is defective
F2 56 Configuration lost Transmission stay neutral •Reprogram the correct

TCU has lost the correct configuration and OP mode : TCU shutdown configuration for the vehicle
can't control the transmission (e.g. with cluster controller,...)
•Interference during saving data on non
volatile memory
•TCU is brand new or from another vehicle
F3 59 Application error Transmission stay neutral •Replace TCU This fault occurs only if an test
Something of this application is wrong OP mode : TCU shutdown engineer did something wrong
in the application of the vehicle
F5 173 Clutch failure Transmission stay neutral •Check clutch TCU shows also the affected
AEB was not able to adjust clutch filling OP mode : TCU shutdown clutch on the display
parameters
•One of the AEB-Values is out of limit
F6 174 Clutch adjustment data lost No reaction, •Execute AEB

TCU was not able to read correct clutch Default values : 0 for AEB
adjustment parameters Offsets used
•Interference during saving data on non OP mode : Normal
volatile memory
•TCU is brand new
3-46
(7) Measuring of resistance at actuator/sensor and cable
① Actuator
2 G
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 Actuator/
2 Sensor
C(Chassis)
Ground
Open circuit R12 = R1P = R1C = R2P = R2C= ∞

Short cut to ground R12 = 0; R1C = R2C = 0, R1P = R2P = ∞
Short cut to battery R12 = 0; R1C = R2C = 0, R1P = R2P = 0
3 - 47
7) ELECTRIC CONTROL UNIT
(1) Complete system
8
10
5 11
4
3
12
6
13
14
1
16
15
7
1 Gear selector(DW-3)
2 Display
3 Clutch cut off switch
4 Full automatic switch
5 Control unit(EST-37)
6 Filter
7 Power supply connection
8 Kickdown switch
9 Wiring
10 Cable to speed sensor output and speedometer
11 Cable to temperature measuring point behind the converter
12 Cable to plug connection on the electrohydraulic control unit
13 Cable to inductive transmitter speed engine
14 Cable to inductive transmitter speed turbine
15 Cable to inductive transmitter speed central gear train
16 Transmission
(2) Description of the basic functions
The powershift transmission will be equipped with the electronic transmission control unit(EST-37),
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 - 48
・Protection from operating error as far as necessary, is possible via electronic protection.
・Protection from overspends(On the basis of engine and turbine speed).
・Automatic reversing(Driving speed-dependent).
・Pressure cut off possible.
・Change-over possibility for Auto/manual mode.
・Downshifting functions possible.
(3) Gearshifts
The control unit(EST-37) is shifts the required speeds fully-automatically under consideration of
the following criteria.
・Gear selector position
・Driving speed
・Load level
At the same time, the following speeds are picked up by the control unit(EST-37).
・n Engine
・n Turbine
・n Central gear train
・n Output
- Neutral position
Neutral position is selected through the gear selector.
After the ignition is turned on, the electronics remains in the waiting state; By the position neutral
of the gear selector , respectively by pressing on the key neutral, the control unit(EST -37)
becomes ready for operation.
Now, a speed can be engaged.
- Speed engagement
In principle, the speed, adapted to the driving speed(At standing, or rolling machine), will be
engaged. The engagement is realized in dependence on load and rotational speed.
- Upshifting under load
Upshifting under load will be then realized if the machine can still accelerate by it.
- Downshifting under load
Downshifting under load will be realized if more traction force is needed.
- Upshifting in coasting condition
In the coasting condition, the upshifting will be suppressed if the speed of the machine on a slope
shall not be further increased.
- Downshifting in coasting condition
Downshiftings in the coasting condition will be realized if the machine shall be retarded.
- Reversing
At speeds below the reversing limit, direct reversing can be carried out at any time in the speeds
1F 1R and 2F 2R(As a rule, this is the maximum driving speed of the 2nd speed).
3 - 49
Reversings in the speeds 3 and 4 are realized dependent on the driving speed.
- Above the programmed reversing limit, the machine is braked down by downshifts of the
electronic control unit(EST-37) to the permitted driving speed, and only then, the reversing into
the correspondingly preselected speed will be carried out.
- Below the permitted driving speed, the reversing is carried out immediately.
(4) Specific kickdown function
By means of the kickdown-button, integrated in the gear selector , it is at any time possible to
select in the speeds 2F and 2R(i.e. position 2 of the gear selector , at automatic mode also in the
2nd speed of the automatic range) the 1st speed by a short touch. This kickdown state can be
cancelled by :
1. Pressing the kickdown-button again
2. Realization of a reversal operation
3. Change of the gear selector position by the following modification
Gear selector(DW-3) - (Rotation) of the driving position 1...4.
The kickdown function will be always terminated by shifting to neutral.
(5) Clutch cut off
Especially at wheel loaders, the clutch cut off can be activated through a switch signal. It is
interrupting the power flow in the transmission as long as this signal is active. Besides, this
function can be used for the transmission-neutral shifting at applied hand brake or as emergency-
stop(In this case, a restarting is only possible through the gear selector-neutral position).
3 - 50
5. AXLE
1) OPERATION
・ The power from the engine passes through torque converter , transmission and drive shafts, and is
then sent to the front and rear axles.
・ Inside the axles, the power passes from the bevel pinion to the bevel gear and is sent at right
angles. At the same time, the speed is reduced and passes through the both dif ferentials 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
3
2
1 Final drive 2 Differential 3 Axle
(2) Rear axle
1 Final drive 2 Differential 3 Axle
3 - 51
2) LIMITED SLIP DEFFERENTIAL(FRONT AND REAR)
(1) Structure
1 Roller bearing 6 Axle shaft

2 Input flange 7 Pinion gear
3 Bevel gear set 8 Clutch
4 Differential housing 9 Side gear
5 Adjusting screw 10 Pinion shaft
3 - 52
(2) Operation
No driving When driving
N F
Ramp
Pinion shaft F
7803ASPT16
When the differential case is rotated, pinion shaft is moved up on the ramp by the resistance force of
tires as the figure, and then force P is generated. This force P becomes the engaging force of clutch.
① When travelling straight(equal resistance from road surface to left and right tires). Under this
condition, both clutch are engaged and the left and right side gears are driveb wutg tge sane
firce.
② When travelling on soft ground(Resistance from road surface to right tire is smaller). At rotating
speed of right tire becomes faster than left due to the smaller resistance of right tive, right clutch
is engaged and torque of faster rotating right axle shaft is added to left axle shaft through
diffenenting gear case.
3 - 53
3) DIFFERENTIAL
(1) Description
3
When the machine makes a turn, the
2 4
outside wheel must rotate faster than the
inside wheel. A dif ferential is a device
which continuously transmits power to the
right and left wheels while allowing them
to turn a different speeds, during a turn.
The power from the drive shaft passes
through bevel pinion(1) and is transmitted
to the bevel gear(2). The bevel gear
changes the direction of the motive force
by 90 degree, and at the same time
reduces the speed. 1
It then transmits the motive force through
the differential(3) to the axle gear shaft(4).
(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.
(3) When turning Swing

When turning, the rotating speed of the Pinion gear
left and right wheels is dif ferent, so the Side gear Side gear
pinion gear and side gear inside the
differential assembly rotate in accordance
with the difference between the rotating
speed of the left and right wheels.
The power of the carrier is then
Carrier
transmitted to the axle gear shafts.
Pinion gear Ring gear
3 - 54
4) TORQUE PROPORTIONING DIFFERENTIAL
(1) Function
① Because of the nature of their work, 4-
wheel-drive loaders have to work in
places where the road surface is bad.
In such places, if the tires slip, the ability
to work as a loader is reduced, and also
the life of the tire is reduced.
The torque proportioning dif ferential is
installed to overcome this problem.
In structure it resembles the differential of
an automobile, but the dif ferential pinion
gear has an odd number of teeth.
Because of the dif ference in the
resistance from the road surface, the
position of meshing of the pinion gear
and side gear changes, and this changes
the traction of the left and right tires.
(2) Operation Spider rotating

① When traveling straight(Equal direction
resistance from road surface to left and
right tires)
Under this condition, the distances
involving the engaging points between FL FR
right and left side gears and pinion-a and Engaging a b
Engaging
b-are equal and the pinion is balanced as point point
FL×a=FR×b. Thus, FL=FR, and the
right and left side gears are driven with
Left side gear Right side gear
the same force. Pinion
3 - 55
② When traveling on soft ground
(Resistance from road surface to left and
right tires is different)
If the road resistance to the left wheel is
Spider rotating
smaller, the left side gear tends to rotate direction
forward, and this rotation changes the
engaging points between the side gears
and pinion. As a result, the distances
involving the engaging points becomes FL
Small road FR Large road
a>b. The pinion now is balanced as FL resistance a b resistance
×a=FR×b, where FL>FR. The right Engaging Engaging
side gear is driven with a greater force point point
than the left side gear . The torque can
Left side gear Right side gear
be increased by up to about 30 % for Pinion
either side gear.
The pinion therefore does not run idle
and driving power is transmitted to both
side gears until the dif ference between
road resistance to the right and left
wheels reaches about 30%.
3 - 56
5) FINAL DRIVE(Front & rear)
1 Hub carrier assy 8 Outer clutch disc

2 Roller bearing 9 Sun gear shaft
3 Hub 10 Sun gear
4 Ring gear 11 Planetary carrier
5 Piston 12 Planetary gear
6 Tension spring 13 Vent valve
7 Inner clutch disc 14 Axle shaft
(1) To gain a large drive force, the final drive uses a planetary gear system to reduce the speed and
send drive force to the tires.
(2) The power transmitted from the differential through axle shaft(14) to sun gear(10) is transmitted to
planetary gear(12). The planetary gear rotates around the inside of a fixed ring gear(4) and in this
way transmits rotation at a reduced speed to the planetary carrier(11).
This power is then sent to the wheels which are installed to the planetary carriers.
3 - 57
6. TIRE AND WHEEL
1 Wheel rim 3 O-ring 5 Side ring

2 Tire 4 Lock ring 6 Valve assembly
1) The tire acts to absorb the shock from the ground surface to the machine, and at the same time
they must rotate in contact with the ground to gain the power which drives the machine.
2) Various types of tires are available to suit the purpose. Therefore it is very important to select the
correct tires for the type of work and bucket capacity.
3 - 58
GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING
1. POWER TRAIN OPERATIONAL CHECKS

This procedure is designed so that the mechanic can make a quick check of the system using a
minimum amount of diagnostic equipment. If you need additional information, read Structure and
function, Group 1.
A location will be required which is level and has adequate space to complete the checks.
The engine and all other major components must be at operating temperature for some checks.
Locate system check in the left column and read completely, following the sequence from left to right.
Read each check completely before performing.
At the end of each check, if no problem is found(OK), that check is complete or an additional check is
needed. If problem is indicated(NOT OK), you will be given repair required and group location.
If verification is needed, you will be given next best source of information :
Chapter 2 : Troubleshooting
Group 3 : Tests and adjustments
3-59
※ Transmission oil must be at operating temperature for these checks.
Item Description Service action
Transmission oil warm- Start engine. Apply service OK

up procedure brakes and release parking brake. Check completed.
Select full automatic switch to
manual mode.
Move gear selector lever to 3rd
speed.
4
1
3
2
F
N
R
Move gear selector lever to
forward "F" position.
Increase engine speed to high idle
for 30 seconds.
Move gear selector lever to
neutral "N" position and run for 15
seconds.
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 4
1
3
2
F
N
position. Check completed.
R
checks
NOTE : Gear selector lever
Engine OFF. NOT OK
position changes slightly as
Repair lock or replace
steering column is tilted.
switch.
FEEL : Lever must move freely
through all positions.
N D Engage neutral lock.
Apply slight effort to move lever
into forward(F) and reverse(R).
LOOK : Neutral lock must stay
engaged.
Automatic shifting Start engine. OK

check F Check completed.
4
1
3
2 N
R Move gear selector lever to 4th
speed.
NOT OK
Turn full automatic switch ON.
Go to transmission error
code group at page 3-17~
LOOK : Automatic sign on
3-46.
display.
S
Repair or replace the
T
O
P
Move gear selector lever to display or harness.
forward or reverse position.
Increase engine rpm.
LOOK : Speed(2nd~4th) on
display must vary with machine
speed.
3-60
Transmission noise Run engine at approximately OK

check 4
1
3
2
F
N
1600rpm. Check completed.
R
Engine running.
Drive unit with transmission in NOT OK
each forward and reverse speed. Go to transmission makes
excessive noise group 3.
LISTEN : Transmission must not
make excessive noise in any
range.
Engine rpm must not "lug down"
as unit is shifted between gears.
Transmission "quick Release parking brake and select OK

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

shift to and remain in 1st gear.
Press gear selector lever kick
down switch once.
shift back to 2nd gear.
Shift to (3rd or 4th) gear and press
A
gear selector lever kick down

switch once.
not shift down.
Select full automatic switch to
automatic 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.
shift to lower(1st or 2nd or 3rd)
gear respectively.
Press gear selector lever kick
down switch or RCV lever switch
once again.
3-61
LOOK/FEEL : Transmission
must shift to former(2nd or 3rd or
4th) gear.
NOTE : If gear selector lever kick
down switch or RCV lever switch
is pressed twice, transmission
will shift down the immediately
back to former gear.
Forward, reverse and Park unit on level surface. OK
4th speed clutch pack F Check completed.
Apply service brakes.
1
3
2 N
4
R
drag check
NOT OK
※ Transmission must Move gear selector lever to
If unit moves, repair
be warmed up for neutral.
transmission.
this check.
Move gear selector lever to 1st.
Engine running.
Release parking brake and
service brakes.
Run engine at low idle.
LOOK : Unit must not move in
either direction.
NOTE : If unit moves forward,
either the forward pack or the 4th
speed pack is dragging.
Transmission pressure, Run engine at low idle. OK

pump flow, and leakage Check completed.
1
3
2
F
N Release parking brake.
check
4
R
NOT OK
Engine running. Shift transmission to reverse, then
Do transmission leakage
forward, and then to 1st, 2nd, and
test, system pressure test,
3rd speeds.
or pump flow test in group
Wait 5 seconds after each shift 3.
and observe transmission
pressure indicator light.
LOOK : Indicator light must not
come on.
NOTE : If light comes on in one
gear only, leakage is indicated on
that gear.
If light comes on in all gears, low
pump flow or pressure is
indicated.
3-62
Transmission shift Run engine at approximately OK

modulation check 1
3
2
F
N
1300rpm. Check completed.
4
R
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 OK

brakes and release parking brake. Check completed.
1
F
3
2 N
4
R
Move gear selector lever to 3rd NOT OK

speed. If stall rpm are too low or
too high, problem may be
Move gear selector control lever
engine power or torque
to forward "F" position.
converter.
Increase engine speed to high
IF OK
idle.
Replace transmission
LOOK : Torque converter stall torque converter.
rpm must be within the following
range.
Stall rpm : 1950~2050rpm cheek.
Move gear selector control lever
to neutral "N" position and run for
15 seconds.
3-63
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 Remove valve and inspect gaskets.
valve or gasket.
Low transmission pump flow Do transmission pump flow test.
due to worn pump.
Weak or broken pressure Do transmission system pressure test.
regulating valve spring.
Something wrong in Go to transmission error code group at page

Error code on display
transmission. 3-17~3-46.
3-64
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 Check transmission controller fuse.
controller.
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.
3-65
Transmission pressure Low oil level. Check transmission oil level and refill if
is low(All gears) necessary.
Failed transmission pressure Verify transmission system pressure. Do
switch. transmission system pressure test.
Plugged suction strainer. Transmission pump may be noisy if transmission
suction screen is clogged. Drain transmission.
Remove and clean suction screen.
Also, check condition of transmission filter.
Stuck transmission pressure Remove transmission pressure regulating valve.
regulating valve or broken Inspect for damage(See transmission control
spring. valve).
Failed control valve gasket. Inspect transmission control valve for external
leakage. Remove control valve.
Inspect or replace gasket.
Stuck PPC valve. Remove end cover to inspect modulation spool
and check torque on cap screws retaining control
valve to transmission.
Transmission system Failed transmission pump. Do pump flow test.

pressure is low (One or
Failed transmission control Inspect transmission control valve for external
two gears)
valve 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 Remove control valve and inspect oil passage.
between control valve and
transmission elements.
Incorrect transmission oil. Change oil(SAE 10W-30/15W-40)
3-66
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-ring from end of Remove orifice and inspect port for O-ring.
modulation orifice.
Broken piston return spring. Disassemble and inspect clutch.
Incorrect transmission oil. Change oil(SAE 10W-3/15W-40)
Machine "creeps" Warped disks and plates in Check transmission.

in neutral transmission.
Transmission hydraulic High oil level. Transmission overfilled or hydraulic pump seal
system overheats leaking.
Low oil level. Add oil.
Wrong oil grade. Change oil.
Park brake dragging. Check for heat in park brake area.
Pinched, restricted or leaking Check cooler lines.
lube lines.
Machine operated in too high Operate machine in correct gear range.
gear range.
Malfunction in temperature Install temperature sensor the verify temperature.
gauge or sensor. Do tachometer/temperature reader installation
procedure.
Restricted air flow through oil Do radiator air flow test.
cooler or radiator.
Failed oil cooler bypass Disassemble and inspect.
valve(In 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 Do transmission system pressure, element
hydraulic system. leakage test.
Malfunction in converter relief Do converter out pressure test.
valve.
Low transmission pump output. Do transmission pump flow test.
3-67
Excessive transmission Too low engine low idle. Check engine low idle speed.
noise(Under load or no
Worn parts or damaged in Remove transmission suction screen. Inspect
load)
transmission. for metal particles.
Repair as necessary.
Warped drive line between Inspect drive line.
engine 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 Check oil pickup tube on side of transmission.
pump.
Oil ejected from dipstick Plugged breather. Inspect breather on top of transmission.
Replace.
Machine vibrates Aerated oil. Add oil.

Low engine speed. Check engine speed.
Failed universal joints on Check universal joints.
transmission drive shaft or
differential drive shafts.
Machine lacks power Engine high idle speed set too Check high idle adjustment.
and acceleration low.
Incorrect transmission oil. Change oil.
Aerated oil. Add oil.
Low transmission pressure. Do transmission system pressure test.
Warped transmission clutch. Do transmission clutch drag checks.
Torn transmission control valve Inspect gasket.
gasket.
Brake drag. Do brake drag check.
Failed torque converter. Do torque converter stall speed test.
Low engine power. Do engine power test.
Torque converter stall Aerated oil. Put clear hose on thermal bypass outlet port.
RPM too high Run machine to check for bubbles in oil.
Stuck open converter relief Do converter-out pressure test.
valve.
Leakage in torque converter Do converter-out pressure test.
seal.
Torque converter not Replace torque converter.
transferring power(Bent fins,
broken starter).
3-68
Torque converter stall Low engine power. Do engine power test.

RPM too low
Mechanical malfunction. Remove and inspect torque converter.
Transmission pressure Low oil level. Add oil.

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

light comes ON for each
No time delay in monitor. Do monitor check.
shift
Restriction in modulation orifice. Remove orifice and inspect for restriction and/or
plugging.
Stuck PPC valve. Remove and inspect.
Low transmission pressure Do transmission system pressure test.
circuit.
Leak in transmission pressure Do converter out pressure test.
circuit.
Failed transmission pump. Do transmission pump flow test.
Clogged filter. Inspect filter. Replace.
3-69
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 and
between ring and pinion gear. pinion gear.
Failed differential pinion gears Remove differential housing drain plug and
and/or cross shafts. inspect for metal particles. Disassemble and
inspect.
Failed axle bearing. Do axle bearing adjustment check.
Mechanical failure in axle Remove differential. Inspect, repair.
planetary.
Oil seeping from outer Excessive end play in axle. Do axle bearing adjustment check.
axle seal
Worn outer bearing and/or cup. Disassemble and inspect outer axle bearing, cup,
spacer, and seal. Replace, if necessary.
Overfilled differential. Check differential oil return system for excessive
internal restriction.
Axle overheats Low differential oil. Add oil.

Overfilled differential. See differential overfills with oil in this group.
Brake drag. See brakes drag in this group.
3) DRIVE LINE
Excessive drive line Yokes not in line on drive Inspect. Align drive shaft yokes.
vibration or noise shafts.
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.
3-70
GROUP 3 TESTS AND ADJUSTMENTS
1. CLUTCH CUT-OFF PRESSURE SWITCH TEST

The setting pressure of the clutch cut-off
Brake valve
pressure switch should be suited with the
specification. The rated pressure is 25kgf/cm2.
For the detailed method for pressure adjusting,
refer to page 4-21.
Clutch cut-off
pressure switch
3 - 71
2. TRANSMISSION MEASURING POINTS AND CONNECTIONS
The measurements have to be carried out at hot transmission(About 80~95°C).
5 9 14 28 16 13
A
52 63
58
56
D C
60 E B 53
55 F
G
A
57
49 J H
K
69
30 65
68
15
VIEW B
36 51 29
VIEW A
1) OIL PRESSURE AND TEMPERATURE
Port Description Size
51 In front of the converter-opening pressure(11bar) H M10×1.0

52 Behind the converter-opening pressure(5bar) M14×1.5
53 Forward clutch(16+2bar) KV B M10×1.0
55 Reverse clutch(16+2bar) KR E M10×1.0
56 1st clutch(16+2bar) K1 D M10×1.0
57 2nd clutch(16+2bar) K2 A M10×1.0
58 3rd clutch(16+2bar) K3 C M10×1.0
60 4th clutch(16+2bar) K4 F M10×1.0
63 Behind the converter temperature 100°
C, short-time 120°
C M14×1.5
65 System pressure(16+2bar) K M10×1.0
3 - 72
2) CONNECTIONS
10 Breather M10×1.0
15 Connection to the oil cooler -
16 Connection from the oil cooler -
28 Connection to the filter M42×2.0
29 Connection from the filter M42×2.0
30 Connection from the filter bypass M42×2.0
36 Connection oil filler plug M42×2.0
49 Plug connection on the electro-hydraulic control unit -
68 System pressure(Option) G M16×1.5
69 Control system(Option) J M16×1.5
3) INDUCTIVE TRANSMITTER AND SPEED SENSOR
5 Inductive transmitter n Turbine M18×1.5

9 Inductive transmitter n Central gear train M18×1.5
13 Speed sensor n Output and speedometer -
14 Inductive transmitter n Engine M18×1.5
3-73
GROUP 4 DISASSEMBLY AND ASSEMBLY
1. ELECTRO-HYDRAULIC CONTROL UNIT

1) DISASSEMBLY
(1) Loosen socket head screws and remove
selector housing.
Special tool
Box spanner TX-27 5873 042 002
Figure 1
(2) Separate hose lines from the intermediate

plate. Loosen socket head screws and
separate intermediate plate as well as
gaskets and intermediate sheet from
gearbox housing.
Special tool
Figure 2
(3) Mark installation position of the cable

harness to the valve block.
Figure 3
3-74
(4) Loosen socket head screws.
Separate duct plate, gaskets and
intermediate sheet from the valve block.
Figure 4
(5) Remove retaining clip.
Figure 5
(6) Loosen socket head screws and remove

cover. Demount opposite cover.
Figure 6
(7) Demount pressure regulator and remove

cable harness.
Figure 7
3-75
(8) Loosen socket head screws, remove
retaining plates and demount pressure
regulator.
Figure 8
(9) Loosen two socket head screws and

locate the housing provisionally by means
of adjusting screws.
(Housing is spring-loaded)
Now, loosen the remaining socket head
screws.
Special tool
Adjusting screws 5870 204 036
Figure 9
(10) Separate housing from valve body by

uniform loosening of the adjusting screws.
Special tool
Figure 10
(11) Remove components.
Figure 11
3-76
(12) Remove opposite pressure regulators,
housing as well as components accordingly.
Figure 12
2) ASSEMBLY
Check all components for damage and
renew if necessary. Prior to the
installation, check the free travel of the
moving parts in the housing. Spools can
be exchanged individually. Prior to the
assembly, oil the components.
(1) Insert orifices with the concave side
showing upward, until contact is obtained.
Installation position, see Arrows. Figure 13
(2) The figure on the right shows the following

components :
1 Vibration damper(3x spool and compression
spring)
2 Follow-on slide(3x spool and compression
spring)
3 Pressure reducing valve(1x spool and 1
compression spring) 3 1
2 2
Figure 14
(3) Install components according to Figure 14.

Preload the compression springs of the
follow-on slides and locate the spools
provisionally by means of cylindrical pins
¤“5.0mm(assembly aid), see Arrows/Figure
15.
Figure 15
3-77
(4) Install two adjusting screws.
Line up flat gasket(Arrow) and housing
cover(see Figure16).
Now, bring housing cover by means of
adjusting screws uniformly against
shoulder (Figure 17).
Speial tool
Figure 16
Figure 17
(5) Preload spool and remove the cylindrical

pins(assembly aid) again.
Figure 18
(6) Fasten housing cover by means of socket

head screws.
Torque limit : 0.56kgf¡⁄m (4.06lbf¡⁄ft)
Figure 19
3-78
(7) Introduce pressure regulators and fix them
by means of retaining plates and socket
head screws.
Install retaining plates, with the claw
showing downward. Pay attention to the
radial installation position of the pressure
regulators, see Figure.
Figure 20
Pre-assemble opposite side

(8) The Figure on the right shows the
following components:
1 Main pressure valve(1x spool and com -
pression spring)
2 Follow-on slide(3x spool and compress -
ion spring) 3
1
3 Vibration damper(3x spool and compre - 3
ssion spring) 2 2
Figure 21
(9) Install components according to Figure 21.

Preload compression springs of the follow-
1
on slides and fix the spools provisionally
with cylindrical pins ¤“5mm(assembly aid),
see Arrows.
Install two adjusting screws.
Line up flat gasket(Arrow 1) and housing
cover and bring them uniformly against
shoulder, using adjusting screws. Figure 22
Now, fasten housing cover by means of

socket head screws.
Remove cylindrical pins (assembly aid)
again.
Special tool
3-79
(10) Introduce pressure regulators and fix them
by means of retaining plates and socket
head screws.
Install retaining plates, with the claw
showing downward. Pay attention to the
radial installation position of the pressure
regulators, see Figure.
Torque limit : 0.56kgf¡⁄m(4.06lbf¡⁄ft)
Figure 23
(11) Introduce cable harness and connect

pressure regulators(6EA).
Pay attention to the installation position of
the cable harness, see also markings
(Figure 3).
Figure 24
(12) Mount flat gasket(Arrow).

Introduce femal connector, with the groove
facing the guide nose of the cover, until
contact is obtained.
Fasten cover with socket head screws.
Figure 25
(13) Locate the femal connector by means of

retaining clip.
Install opposite cover.
Figure 26
3-80
(14) Install two adjusting screws and mount
gasket I.
Pay attention to the different gaskets, see
Figure 27 and 30.
Special tool
Adjusting screws M6 5870 204 063
Figure 27
Intermediate plate-Version with strainers :

(15) Insert strainers(6EA) flush-mounted into the
bores of the intermediate plate, see Arrows.
Pay attention to the installation position-
strainers are showing upward (facing the
duct plate).
Figure 28
(16) Mount intermediate plate, with the strainers

showing upward.
Figure 29
(17) Mount gasket II.
Figure 30
3-81
(18) Mount duct plate(Arrow) and fasten it
uniformly by means of socket head
screws.
Special tool
Figure 31
(19) Equip screw plugs(8EA) with new O-rings

and install them.
Figure 32
Attach Hydraulic control unit(Figure

33~40)
(20) Screw orifice into the housing bore(Arrow)
and secure it by means of center punch.
Figure 33
(21) Install connecting fittings 1~6.

Install screw plugs 7.
Torque limit Screw plugs (M10x1): 6
0.61kgf¡⁄m (4.43lbf¡⁄ft) 7
Install always new O-rings.
1 2 3 4 5
Figure 34
3-82
(22) Install two adjusting screws(M8) and
mount housing gasket.
At the following steps(Figure 35~39), pay
attention to the installation positions of the
different gaskets.
Special tool
Figure 35
(23) Mount intermediate plate.
Figure 36
(24) Mount 2nd gasket.
Figure 37
(25) Mount plate and fasten it uniformly by

means of socket head screws.
Torque limit(M8/10.9) :
2.35kgf¡⁄m (17.0lbf¡⁄ft)
Special tool
Figure 38
3-83
(26) Install 2 adjusting screws(M6).
Mount gasket(Arrow).
Special tool
Figure 39
(27) Fasten complete valve block uniformly with

socket head screws(2 pieces M6¡¿105 and
21 pieces M6¡¿80mm).
Pay attention to the position of the two socket
head screws (M6¡¿105), see Arrows.
Special tool
Figure 40
3-84
2. RETARDER
1) DISASSEMBLY
(1) Fasten the complete transmission on the
assembly car.
Special tool
Assembly car 5870 350 000
Clamping bracket 5870 350 071
(2) Tilt gearbox housing 90¡£

.
Remove lock plate.
Loosen hexagon head screws and pull off
input flange.
If only operations on the transmission are
necessary, the complete retarder can be
separated, along with the converter, from
the converter connecting housing by
loosening the screw connection (Figure 56).
Figure 53
(3) Loosen screw plug.
Figure 54
3-85
(4) Loosen the first hexagon head screw and
remove it by means of magnetic rod.
Demount the remaining hexagon head
screws accordingly.
Figure 55
(5) Loosen screw connection.

Mark the radial installation position of the
retarder to the converter connecting housing.
Figure 56
(6) Separate the complete retarder from the

converter connecting housing, using lifting
device.
Special tool
Set of eye bolts 5870 204 002
Figure 57
(7) Loosen socket head screws, separate

spacer ring from stator housing.
Figure 58
3-86
(8) Loosen socket head screws and separate
cover from stator housing.
Figure 59
(9) Drive flange shaft out.

Pay attention to the released components.
Special tool
Plastic mallet 5870 280 004
Figure 60
(10) Separate rectangular ring from rotor.
Figure 61
(11) Remove the rectangular ring on the

opposite side. If necessary, separate the
ring(Arrow) from the rotor.
Figure 62
3-87
(12) Loosen hexagon head screws and
remove thrust ring.
Figure 63
(13) Remove stator ring.

Pay attention to the released components.
Figure 64
(14) Pry shaft seal out of the bore.

Special tool
Pry bar 5870 345 036
Figure 65
(15) Drive ball bearing out.
Figure 66
3-88
2) ASSEMBLY
(1) Insert ball bearing until contact is obtained.
Figure 71
(2) Insert stator ring.
Figure 72
(3) Fasten thrust ring by means of hexagon

head screws.
Torque limit (M8/8.8): 2.35kgf m
(17.0lbf ft
Pay attention to the installation position-
shoulder(Arrow) is showing upward.
Secure hexagon head screws with
Loctite(Type No. 243).
Figure 73
(4) Preassemble dampers(3 pieces)

according to Figure 75 and Figure 76.
The Installation dimension B=1.6+0.5mm
results from the alternating stacking of the
cup spring packs(8 packs with 6 cup
springs each).
Figure 74
3-89
1 Guide pin
2 Cup spring packs(8 packs with 6 cup
springs each)
3 Spring guide
4 Compression spring
5 Spring guide
1 2 3 4 5
Figure 75
(5) Install the preassembled dampers, see

Arrows.
Figure 76
(6) Introduce rectangular ring into the recess

of the rotor(Figure 77) and preload it by
means of cylindrical pins ¤“ 6mm
(assembly aid), see Figure 78.
Install rectangular ring with the marking
"Top" see Arrow, showing upward (to the
prime mover).
Figure 77
Figure 78
3-90
(7) Grease rectangular ring.
Introduce rotor into the stator housing until
contact is obtained and remove cylindical
pins again.
Figure 79
(8) Grease rectangular ring.

Introduce rotor into the stator housing until
contact is obtained and remove cylindical
pins again.
Figure 80
(9) Insert ring into the cover, with the oil

grooves showing downward.
Figure 81
(10) Introduce rectangular ring.

Install rectangular ring with the marking
"Top" see Arrow, showing upward (to the
prime mover).
Figure 82
3-91
(11) Insert O-ring into the annular groove of the
cover(Arrow) and grease it.
Install two adjusting screws and pull cover
uniformly against shoulder, using 3 socket
head screws.
Pay attention to the radial installation
position.
Special tool
Adjusting screws M8 5870 204 011 Figure 83
(12) Fasten cover finally by means of socket

head screws (install flat washers).
Secure socket head screws with Loctite
(Type No. 243).
Torque limit(M8/10.9): 2.35kgf¡⁄m
(17.0lbf¡⁄ft)
Figure 84
(13) Adjust Rotor dimension(distance between

Rotor-Stator ring)=1.5~2.0mm (Figure 85~89):
Line up axial washer s = 1.0mm, axial roller
cage and housing disk s = 5.75mm.
Figure 85
(14) Determine Dimension I from the housing

disk to the mounting face.
Dimension I e.g. 13.10mm
Special tool
Digital depth gauge 5870 200 072
Figure 86
3-92
(15) Determine Dimension II from the mounting
face(flange shaft) to the plane face/stator
(contact face - axial bearing).
Dimension II e.g 14.00mm
EXAMPLE A
Dimension II 14.00 mm
Dimension I -13.10 mm
Difference 0.90 mm
Rotor play e.g. + 1.60 mm
Figure 87
Gives Shim e.g. s = 2.50 mm
(16) Insert housing disk s = 5.75 mm, axial roller

cage and axial washer s = 1.0 mm.
Figure 88
(17) Mount shim s = 2.5 mm(see Example A)
Figure 89
(18) Adjust Axial play - Ball bearing 0.10~0.20mm

(Figure 90~93) :
Check exact contact of ball bearing(Arrow)
once more and place preassembled stator
housing over the plug gauge.
The ball bearing must be resting on the
whole plane face(bearing inner and outer
race).
Special tool Figure 90
Plug gauge 5870 200 106
3-93
(19) Determine Dimension I from the shim to
the bearing inner race.
Dimension I e.g. 25.20 mm
Figure 91
(20) Determine Dimension II from the locating

face (ball bearing) to the contact face (shim).
Dimension II e.g. 25.05 mm
EXAMPLE B1 :
Dimension II - Dimension I = Dimension X
25.05 mm - 25.20 mm = -0.15 mm
¡ Minus dimension(X= -0.15 mm) corresponds
with the pressure.
EXAMPLE B2 : Figure92
Required play -Dimension X = Shim
0.15 - (-0.15) = 0.30 mm
(21) Mount shim s = 0.3 mm(see Example B2)

with grease.
Figure 93
(22) Heat bearing inner race.

Special tool
Hot-air blower 230V 5870 221 500
Figure 94
3-94
(23) Introduce flange shaft until contact is
obtained.
Figure 95
(24) Install shaft seal(Arrow), using driver.

¡ At application of the prescribed driver, the
exact installation position is obtained.
Grease the sealing lip of the shaft seal.
Wet outer diameter with spirit.
¡ Special tool
driver 5870 048 193
Figure96
(25) Grease O-ring(Arrow) and insert it into the

annular groove of the spacer ring.
Figure 97
(26) Fasten spacer ring by means of socket

head screws.
Torque limit(M10/8.8): 3.26kgf m
(23.6lbf ft)
Figure 98
3-95
(27) Insert O-ring(Arrow) into the annular groove
of the converter bell.
Figure 99
(28) Place the complete retarder on the converter

bell until contact is obtained, using lifting
device, and fasten it by means of hexagon
head screws.
¡ Pay attention to the radial installation position
of the retarder.
(58.3lbf¡⁄ft)
¡ Special tool
Figure 100
(29) Fasten rotor and flange shaft on the

converter, using hexagon head screws.
¡ Tighten hexagon head screws uniformly
(180 displaced) as well as secure them with
(33.9lbf¡⁄ft)
Figure 101
(30) Equip screw plug with new O-ring and

install it.
Torque limit (M30 1.5): 9.18kgf¡⁄m
(66.4lbf¡⁄ft)
Figure 102
3-96
(31) Line up shim(s = 1.5 mm).
Figure 103
(32) Install dust plate(Arrow).

¡ Special tool
Driver 5870 506 127
Figure 104
(33) Line up input flange and fasten it by means of

disk and hexagon head screws.
¡ Wet contact face of the disk with Loctite (Type
No. 574).
Torque limit (M10/8.8): 4.69kgf¡⁄m
(33.9lbf¡⁄ft)
Figure 105
(34) Fix hexagon head screws with lock plate.

¡ Special tool
Driver 5870 057 009
Handle 5870 260 002
Figure 106
3-97
3. TRANSMISSION
1) DISASSEMBLY
(1) Fasten the complete transmission on the
assembly car.
Special tool
Assembly car 5870 350 000
Support 5870 350 071
Remove all oil lines.
Figure 120
(2) Loosen hexagon head screws and lift

complete retarder along with converter out
of the converter bell, using lifting device.
¡ Special tool
Lifting chain 5870 281 047
Figure 121
(3) Pull oil feed flange by means of special

device out of the converter bell.
Special tool
Puller device 5870 000 089
Figure 123
(4) Remove converter safety valve(ball+spring,

see Arrow).
Figure 124
3-98
(5) Loosen screw connection(M8 and M12).
Separate converter bell from the
transmission, using lifting device.
Special tool
Lifting chain 5870 281 047
Figure 125
(6) Remove shim.
Figure 126
(7) Remove both rectangular rings(Arrow).
Figure 127
(8) Press input shaft out of the spur gear

bearing. Remove released bearing inner
race and spur gear.
Figure 128
3-99
(9) Press bearing inner race from the input
shaft.
Figure 129
(10) Remove converter pressure back-up

valve.
Figure 130
(11) Pull the complete input shaft out of the

gearbox housing, respective out of the
pump.
Figure 131
(12) Squeeze rectangular ring out (Arrow).
Figure 132
3-100
(13) Separate spur gear from the shaft and
squeeze circlip out (Arrow).
Special tool
Set of pliers 5870 900 016
Figure 133
(14) Pull bearing inner race from spur gear.

Special tool
Grab sleeve 5873 001 020
Basic tool 5873 001 000
Figure 134
(15) Pull bearing inner race from spur gear.

¡ Special tool
Basic tool 5873 001 000
Figure 135
(16) Pull bearing inner race and driver from the

shaft.
¡ Support puller on the end face-input shaft.
Pay attention to the released shims.
¡ Special tool
3-Leg puller 5870 971 002
Figure 136
3-101
(17) Separate bearing inner race from driver.
Pay attention to released washers.
If necessary, squeeze circlips(3EA) out.
Figure 137
Transmission pump
(1) Tilt gearbox housing 180°.

Loosen hexagon head screws and
separate both pump flanges from the
housing.
Figure 138
(2) Loosen socket head screws(M8) and

position puller device. Pull transmission
pump out of the housing bore.
¡ Tapping onto the housing face will help at
the extraction procedure.
¡ Special tool
Puller device 5870 000 089
Figure 139
(3) Pull bearing outer race out of the bore and

remove spacer.
¡ Special tool
Internal puller 5870 300 017
Counter support 5870 300 009
Figure 140
3-102
(4) Loosen socket head screws, demount
pump cover and remove rotor set.
¡ If traces of wear should be encountered in
the pump housing or the housing cover,
the complete pump has to be renewed.
Now, introduce the rotor set, with the
chamfer on the tooth crest showing
downward, and install housing cover
again.
Figure 141
Torque limit(M8/8.8): 2.35kgf¡⁄m (17.0lbf¡⁄ft)
Torque limit(M6/8.8): 0.97kgf¡⁄m (7.0lbf¡⁄ft)
Emergency steering pump

(1) Loosen hexagon head screws and pry the
emergency steering pump out of the
housing.
¡ Special tool
Crow bar 5870 345 071
Figure 142
(2) Remove lock plate.

Loosen hexagon head screws and remove
disk. Pull output flange from the shaft.
Figure 143

.
Loosen hexagon head screws, demount
cover and remove filter.
Figure 144
3-103
Axle disconnection device
(1) Remove lock plate, loosen hexagon head
screws and pull off output flange.
Figure 145
(2) Loosen socket head screws and hexagon

head screws.
¡ Separate axle disconnection device from
the housing, using pry bars.
During the separating procedure, drive the
output shaft by tapping downward.
¡ Special tool
Pry bar 5870 345 071
Plastic mallet 5870 280 004 Figure 146
(3) Disassemble switch and detent pin.
Figure 147
(4) Disassemble switch and detent pin.
Figure 148
3-104
(5) Remove cover as well as circlip and drive
pin out of the bore, using striker.
Remove the released components.
¡ Special tool
Striker 5870 650 001
Figure 149
(6) Remove shaft seal.

Squeeze circlip out and remove spacer as
well as shim.
Now, remove the ball bearing.
Figure 150
3-105
Counter shaft
(1) Remove sealing cover and loosen
hexagon head screws.
Figure 151

.
Drive counter shaft axle by means of striker
out of the housing bore, respective counter
shaft bearing.
¡ Special tool
Striker 5870 650 014
Figure 152
Disassemble Inductive transmitter

(3EA) 14
6 = n-Turbine
39 = n-Central gear train 39
6
14 = n-Engine
Figure 153

.
Loosen hexagon head screws and pull
bearing cover KV/K1 out of the housing bore.
Disassemble bearing cover KR/K2 and
K4/K3 accordingly.
¡ Mark installation position of the bearing
covers.
¡ Special tool
Figure 154
Threaded insert 5870 204 042
3-106
(2) Loosen screw connection and separate
housing cover by means of back-off
screws (Arrows) and lifting device from the
gearbox housing.
¡ During the separating procedure, drive the
output shaft by tapping continuously
downward.
¡ Special tool
Back-off screws 5870 204 005
Figure 155
Lifting device 5870 281 055
(3) Loosen hexagon head screws and remove

cover plate.
Figure 156
Interaxle differential
(1) Lift differential by means of lifting device
out of the gearbox housing.
¡ Special tool
Figure 157
(2) Remove plate and disassemble bearing

inner race.
Figure 158
3-107
(3) Remove plate and disassemble bearing
inner race.
Figure 160
(4) Remove bush.
Figure 161
(5) Squeeze snap ring out and pull output

shaft out of the planet carrier.
Figure 162
(6) Squeeze snap ring out and pull output

shaft out of the planet carrier.
Figure 163
3-108
(7) Pull bearing inner race from the internal
gear.
¡ Special tool
Quick-acting grip 5870 014 014
Basic tool 5873 004 001
Figure 164
(8) Squeeze snap ring out.
Figure 165
(9) Press internal gear and planet carrier out

of the internal gear.
¡ Figure 167 shows the released component.
Figure 166
Figure 167
3-109
(10) Drive roll pins(Arrows) carefully in until
Figure 168
(11) Drive roll pins(Arrows) carefully in until

Figure 169
(12) Press output shaft far enough downward

until the sun gear can be removed, see
also Figure 171.
Figure 170
(13) Squeeze snap ring out(Arrow) and separate

output shaft from planet carrier.
Figure 171
3-110
(14) If necessary, pry baffle ring out of the
planet carrier bore, squeeze snap ring out
(Figure 172) and drive the needle bearing
out (Figure 173).
Figure 172
Figure 173
Disassemble Multi-disk clutches

(1) Disassemble clutch K4/K3, KR/K2 and
KV/K1 by means of lifting device.
¡ At the disassembly of the clutch K4/K3, lift
clutch KR/K2 slightly and displace it in
arrow direction, see Figure on the right.
¡ Special tool
Figure 175
(2) The Figure on the right shows the clutches

in disassembled condition.
K3 K2 K1
K4 KR KV
Figure 176
3-111
(3) Remove counter shaft gear.
Figure 177
Disassemble power take-off

(1) Squeeze circlip out and remove shims.
Figure 178
(2) Lift output shaft by means of pry bar until

the bearing outer race is free.
¡ Special tool
Pry bar 5870 345 036
Figure 179
(3) Take output shaft out of the housing.
Figure 180
3-112
(4) Pull bearing outer race out of the housing
bore.
¡ Special tool
Internal puller 5870 300 007
Figure 181
(5) Pull bearing inner race from the shaft

(Figure 182).
Press opposite bearing inner race from
the shaft.
¡ The separation of shaft and gear is not
possible(shrink fit).
¡ Special tool
Basic tool 5873 001 000 Figure 182
Dismantle Multi-disk clutch-K3/K4

(1) Fasten clutch by means of clamping ring
on the assembly car.
¡ Special tool
Clamping ring 5870 654 022
Figure 185
(2) Pull roller bearing from plate carrier.

¡ Special tool
3-Leg puller 5870 971 002
Figure 186
3-113
(3) Separate spur gear K3 from plate carrier.
Figure 187
(4) Pull bearing inner race from plate carrier.

¡ Special tool
Quick-acting grip 5873 012 012
Basic tool 5873 002 001
Figure 188

Disassemble end shim and plate pack K3.
Figure 189
(6) Tilt plate carrier 90¡£

.
Loosen slotted nut.
¡ Slotted nut is secured with loctite.
To prevent a damage of the thread, heat
the slotted nut prior to loosen it(about
120¡£C).
¡ Special tool
Hook spanner 5870 401 118
Figure 190
3-114
.
Pull off the tapered roller bearing.
¡ Speial tool
Figure 191
(8) Pull spur gear K4 from plate carrier.

¡ Special tool
3-Leg puller 5870 971 003
Figure 192
(9) Remove adjusting ring.
Figure 193
(10) Pull off tapered roller bearing.

¡ Special tool
3-Leg puller 5870 971 002
Figure 194
3-115
Figure 195
(12) Preload compression spring by means of

Special device. Squeeze snap ring out
and remove the released components.
Disassemble opposite components (K3-
side) accordingly.
¡ Special tool
Pressure piece 5870 345 072
Figure 196
(13) Separate both pistons by means of

compressed air from the plate carrier.
Figure 197
Dismantle Multi-disk clutch KR/K2

(1) Fasten clutch by means of clamping ring
(Arrow) on the assembly car.
¡ Special tool
Figure 198
3-116
.
Loosen slotted nut.
To prevent a damage of the thread, heat the
slotted nut prior to loosen it (about 120¡£
C).
¡ Special tool
Figure 199
(3) Pull tapered roller bearing from plate

carrier.
¡ Special tool
Basic tool 5873 002 001
Figure 200
(4) Press spur gear K2 from the plate carrier.

¡ Pay attention to the released plate carrier.
Figure 201
(5) Fix plate carrier by means of clamping ring.

Remove shim.
¡ Special tool
Figure 202
3-117
(6) Pull tapered roller bearing from plate carrier.
¡ Special tool
Basic tool 5873 002 001
Figure 203

Figure 204

Loosen slotted nut.
C).
¡ Special tool
Hot-air blower 115V 5870 221 501 Figure 205

carrier.
¡ Spcial tool
Basic tool 5873 002 001
Figure 206
3-118
(10) Pull tapered roller bearing from plate carrier.
¡ Special tool
Basic tool 5873 002 001
Figure 207
(11) Remove adjusting rings.
Figure 208

Disassemble end shim and plate pack KR.
Figure 209

carrier.
¡ Special tool
Basic tool 5873 002 001
Disassemble both pistons, as described at
Figure 196 and 197.
Figure 210
3-119
Dismantle Multi-disk clutch KV/K1
Fasten clutch by means of clamping ring on
the assembly car. Loosen slotted nut
(Figure 211).
¡ Slotted nut is secured with Loctite.
C ).
¡ Special tool
Figure 211

carrier.
¡ Special tool
Basic tool 5873 001 000
Figure 212
(2) Remove disk
Figure 213
(3) Pull spur gear K1 from plate carrier.

¡ Special tool
3-Leg puller 5870 971 003
Figure 214
3-120
(4) The Figure on the right shows the spur gear
bearing K1. 1
The bearing(1) is only as sub-assembly
available.
¡ If the disassembly of the plate pack-side ball
bearing(Arrow, respective Figure 217 and
218) is necessary, the complete bearing (1)
must be renewed.
Figure 215
(5) Remove bush.
Figure 216
(6) Pull ball bearing from plate carrier(Figure

217 and 218).
¡ Pay attention to the released balls.
¡ Special tool
Pry bar 5870 345 036
Figure 217
Figure 218
3-121
Figure 219

.
Loosen slotted nut.
¡ Slotted nut is secured with Loctite.
To prevent a damage of the thread, heat
the slotted nut prior to loosen it(about
120¡£C).
¡ Special tool
Figure 220

carrier.
¡ Special tool
Basic tool 5873 001 000
Figure 221
(10) Pull spur gear KV from plate carrier.

¡ Special tool
3-Leg puller 5870 971 003
Figure 222
3-122
(11) Remove shim and ring.
Figure 223
(12) Pull tapered roller bearing from plate carrier

(Figure 224).
Squeeze snap ring out.
Disassemble end shim and plate pack KV.
Disassemble both pistons (as described at
Figure 196 and 197).
¡ Special tool
Basic tool 5873 001 000
Figure 224
3-123
2) ASSEMBLY
(1) Install studs (Arrows).
Wet thread with Loctite (Type No. 243).
Figure 230
(2) Line up O-ring(Arrow).

Insert besh into the housing bore until
contact is obtained and fasten it.
Figure 231
Power take-off
(1) Supercool the shaft (about -80¡£ C), heat
gear (+120¡£ C) and line it up, respectively
press it against shoulder.
Figure 232
(2) Press bearing inner race against shoulder.

Press opposite bearing inner race against
shoulder.
Figure 233
3-124
(3) Insert bearing outer race(Arrow) into the
housing bore until contact is obtained.
Figure 234
(4) Position preassembled pto-shaft in the

housing, and insert bearing outer race until
Figure 235
(5) Adjust Axial play-Power take-off bearing-

max 0.10mm by means of shim(s) and
circlip.
Figure 236
(6) Tilt gearbox housing 180¡£.

Insert sealing disk(Arrow), with the
concave side showing downward, into the
housing bore until contact is obtained.
Wet contact face with Loctite(Type No.
262).
Do not damage the centric orifice hole ¤“
0.8mm during the installation of the
sealing disk.
Figure 237
3-125
Reassemble Multi-disk clutch K3/K4
(1) Lift plate carrier, with the K4-side showing
downward, into the clamping ring and fix it.
Now, tilt plate carrier 180¡£.
Insert both roll pins (6 24 and 3.5 24)
flush-mounted into the end face-side bore
of the plate carrier, see Arrow/figure 239.
Figure 239

.
Wet both roll pins (Arrows) with Loctite
(Type No. 262) and install them.
Figure 240
(3) Insert purge valve (Arrow) flush-mounted,

with the chamfer showing downward.
Special tool
Settling tool 5870 320 019
Figure 241
(4) Insert both O-rings scrollfree into the ring

grooves of the piston, see Arrows.
Figure 242
3-126
(5) Oil O-rings and piston bearing surfaces.
Insert piston K3 uniformly until contact is
obtained.
Pay attention to the installation position of

the piston, see Figure.
Figure 243
(6) Introduce intermediate washer and

compression spring.
Figure 244
(7) Lay guide ring, with the chamfer(Arrow)

showing upward, over the compression
spring and line up the snap ring.
Lift plate carrier out of the clamping ring.
Figure 245
(8) Preload compression spring by means of

Special device and squeeze snap ring into the
annular groove of the plate carrier (Arrow).
¡ Special tool
Special device 5870 345 072
Install purge valve, spool and compression
spring on the opposite side(Clutch K4)
accordingly, see Figure 241~246.
Now, lift plate carrier, with the K4-side showing
Figure 246
downward, into the clamping ring and fix it. Tilt
plate carrier 180¡£.
3-127
Multi-disk clutch-K4
¡ The following Draft, respective chart shows the plate stacking and the installation position of the
components.
Item Denomination Quantity S (mm) Comment
1 Plate carrier 1
2 Piston 1
3 Outer plate 2 1.85 One-sided coated
4 Outer plate 5 2.5 Coated on both sides
5 Inner plate 5 3.5
6 Inner plate 1 2.5 ~ 4.0 Optional
7 Snap ring 1 2.55 ~ 3.10 Optional
8 End shim 1
Number of friction surfaces : 12
Plate clearance : 2.2 ~ 2.4mm
¡ Install outer plates Item 3, with the uncoated side facing the piston, respective the end shim.
The respective clutch side can be recognized by the length of the plate carrier, see Draft.
K4 = Dimension X (short plate-carrier side)
K3 = Dimension Y (long plate-carrier side)
3-128
Check Plate clearance - K4 =2.2 ~
2.4mm(Figure 249 ~ 251) :
To ensure a faultless measuring result,
install the plate pack for the present without
oil.
(1) Install the plate pack according to the
Draft, respective chart.
Figure 249
(2) Introduce the end shim and fix it by means of

snap ring.
Figure 250
(3) Press end shim on with about 10kg and

set dial indicator to "Zero".
Now, press end shim against the snap
ring(upward) and read the plate clearance
on the dial indicator.
In case of a deviation from the required
plate clearance = 2.2 ~ 2.4mm, correct
with corresponding inner plate item 6
(optional s = 2.5 to 4.0mm) or and snap
Figure 251
ring item 7(optional).
After the performed adjustment of the
plate clearance, disassemble the plate
pack, oil the plates, and install them again.
Special tool
Magnetic stand 5870 200 055
Dial indicator 5870 200 057
3-129
Preassemble and install Spur gear K4
(Figure 252 ~ 257) :
4 2 1
(4) The Figure on the right shows the 2 3
components of spur gear K4. 1
1 Bearing inner race

2 Bearing outer race
3 Shim(optional, empirical value s = 5.4mm)
4 Spur gear
Figure 252
(5) Check Axial play - Spur gear bearing 0.0 ~

0.05mm
Install components, according to Figure
252. Preload tapered roller bearing with
about 5ton, and determine axial play with
dial indicator.
In case of deviations from the required
axial play, correct with corresponding shim
(Item 3/Figure 252).
Figure 253
(6) Heat bearing inner race and line it up until

Figure 254
(7) Line up the determined shim(see Figure

252 and 253), with the oil groove showing
upward.
Figure 255
3-130
(8) Introduce spur gear until all inner plates are
accommodated.
Figure 256
(9) Heat bearing inner race(spur gear

bearing) and position it against shoulder.
¡ Use protective gloves.
Figure 257

Figure 258
3-131
components.
1 Plate carrier 1
2 Piston 1
5 Inner plate 3 2.5
6 Inner plate 5 3.0
9 End shim 1
¡ Install outer plates item 3, with the uncoated side facing the piston, respective the end shim.
K3 = Dimension Y (long plate-carrier side)
3-132
Check plate clearance K3 = 2.6 ~ 2.8mm
(Figure 260 ~ 262) :
To ensure a faultless measuring result,
install the plates for the present without oil.
Draft, respective the chart.
Figure 260
(2) Introduce the end shim and fix it by means

of snap ring.
Figure 261
(3) Press the end shim on with about 10kg

and set the dial indicator "Zero" (Figure
262). Now, press the end shim against
the snap ring(upward), and read the plate
clearance on the dial indicator.
plate clearance = 2.6~2.8mm, correct with
corresponding inner plate Item 7(optional
s = 2.5~4.0mm) or and snap ring item 8
(optional). Figure 262

pack, oil plates and install them again.
Special tool
3-133
Use protective gloves.
Figure 263
(5) Lift plate carrier out of the clamping ring.

To ensure the exact contact of the
components, preload the bearing with 10
ton.
Support on the lower as well as on the
upper bearing inner race.
Use pressure pieces.
Special tool
Pressure pieces 5870 506 096 Figure 264
(6) Lift plate carrier, with the K4-side showing

Tilt plate carrier 90¡£
.
Wet thread of slotted nut with Loctite (Type
No. 262) and install slotted nut(Figure 265).
¡ Install slotted nut, with the collar( 60mm)
facing the bearing inner race.
¡ Special tool
Hook spanner 5870 401 118 Figure 265
(7) Insert bearing outer race into the spur

gear K3 until contact is obtained.
Figure 266
3-134
(8) Introduce spur gear until all inner plates
are accommodated.
Figure 267
(9) Heat roller bearing and position it against

shoulder.
Figure 268
(10) Introduce bearing inner race.
Figure 269
(11) Check function of the clutches K3 and K4

by means of compressed air.
¡ At correctly installed components, the
closing, respective opening of the clutches
is clearly audible.
Figure 270
3-135
(12) Squeeze in and engage rectangular rings
(3EA, see Arrows).
Figure 271
Reassemble Multi-disk clutch KR/K2

(1) Lift plate carrier, with the KR-side showing
Tilt plate carrier 180¡£.
Insert both roll pins (6¡¿24 and 3.5¡¿24)
flush-mounted into the spur gear-side bore
(Arrow) of the plate carrier.
¡ Special tool
Figure 275

.
Wet both set screws (Arrows) with Loctite
Figure 276
(3) Insert purge valve(Arrow) flush-mounted,

Special tool
Figure 277
3-136
(4) Lay both O-rings scrollfree into the ring
Figure 278

Insert K2 piston uniformly until contact is
obtained.
¡ Pay attention to the installation position of
Figure 279
(6) Introduce intermediate plate and

compression spring
Figure 280

Figure 281
3-137
(8) Lift plate carrier out of the clamping ring .
Preload compression spring by means of
special device and squeeze snap ring into
the annular groove of the plate carrier
(Arrow), see Figure 282.
spring on the opposite side(KR clutch)
accordingly(as Figure 277~282).
Now, lift plate carrier, with the KR-side
showing downward into the clamping ring Figure 282
and fix it.
Tilt plate carrier 180¡£.
¡ Special tool
3-138
Multi-disk clutch-KR
components.
1 Plate carrier 1
2 Piston 1
5 Inner plate 11 2.5
8 End shim 1
¡ Install outer plates Item 3, with the uncoated side facing the piston, respective the end shim.
KR = Dimension Y (long plate-carrier side)
3-139
(1) Check Plate clearance KR = 2.8~3.0mm
(Figure 285~287):
¡ To ensure a faultless measuring result,
Install plate pack according to the Draft,
respective chart.
Figure 285
(2) Introduce end shim and fix it by means of

snap ring.
Figure 286

and set the dial indicator to "Zero".
Now, press the end shim against the snap
ring(upward) and read the plate clearance
corresponding inner plate item 6 (optional
2.5 to 4.0mm) or and snap ring item 7

Special tool
3-140
Preassemble and install Spur gear KR
(Figure 288~296) :
components of spur gear KR.
2 Shims s = 3.0 and s = 3.10mm
( = 6.10mm/Empirical value)
3 Spur gear 4
4 Bearing inner race 1 2 3
Figure 288
(2) Check Axial play - Spur gear bearing

0.0~0.05mm.
Place spur gear over the bearing inner
race.
(S)
Figure 289
(3) Introduce shims(2 pieces/s = 3.0 and s =

3.10mm).
Figure 290
(4) Mount bearing inner race.
Figure 291
3-141
(5) Preload the tapered roller bearing with
about 5 ton and determine the axial play
with dial indicator.
¡ In case of deviations from the required
axial play, correct with corresponding
shims (Item 2/figure 288).
¡ Special tool
pry bar 5870 345 036
Figure 292
(6) Heat bearing inner race and position it

against shoulder.
Figure 293
(7) Introduce the spur gear until all inner

plates are accommodated.
Figure 294
(8) Introduce determined shims (see Figure

289 to 292).
Figure 295
3-142
(9) Heat bearing inner race(spur gear bearing)
and position it against shoulder.
Figure 296
(10) Heat bearing inner race(spur gear bearing)

Figure 297
3-143
components.
1 Plate carrier 1
2 Piston 1
5 Inner plate 3 2.5
6 Inner plate 5 3.0
9 End shim 1
KR = Dimension Y (long plate-carrier side)
3-144
Check plate clearance K2 = 2.6 ~
2.8mm(Figure300 ~ 302) :
¡ To ensure a faultles measuring result,
draft, respective chart.
Figure 300
(2) Introduce end shim and fix it by means of

snap ring.
Figure 301

ring (upward) and read the plate clearance
plate clearance = 2.6 ~ 2.8mm, correct
with corresponding inner plate item
7(optional s = 2.5 ~ 4.0mm) or and snap
ring item 8 (optional).
Figure 302
pack, oil the plates and install them again.
¡ Special tool
3-145
Preassemble and install spur gear K2
(Figure 303 ~ 312) :
1
(1) Supercool gear wheel 1 (about 80¡£ C) and 2
heat gear wheel 2 (about 120¡£ C).
Squeeze snap ring in(Arrow), preload, and
join both parts together by means of
hydraulic press until the snap ring snaps
into the annular groove of the gear wheel 2.
Figure 303
(2) Adjust Axial play - Spur gear bearing 0.05

~ 0.15mm (Figure 304 ~ Example C)
The Figure on the right shows the
components of the spur gearbearing.
1
2 Shim (optional)
3 Spur gear complete
4
2 3
Figure 304
(3) Place spur gear over the bearing inner

race.
Figure 305
(4) Introduce bearing inner race.
Figure 306
3-146
(5) Determine Dimension I (bearing dimension)
¡ Special tool
Digital Depth gauge 5870 200 072
Figure 307
(6) Determine Dimension II (shaft dimension).

Dimension II e.g. 74.14mm
Figure 308
EXAMPLE C
Dimension II e.g. - 74.14mm
Difference = 2.13mm
Axial play e.g. + 0.07mm
Gives shim s = 2.20mm

Figure 309
3-147
accommodated.
Figure 310
(9) Line up shim(e.g. s=2.20mm, see Example).
Figure 311
(10) Heat bearing inner race (spur gear bearing)

and line it up until contact is obtained.
Figure 312
(11) Heat bearing inner race(clutch bearing)

Figure 313
3-148
components, preload bearing with 10 ton.
¡ Support on the lower as well as on the
upper bearing race. Use pressure pieces.
¡ Special tool
Pressure pieces 5870 506 096
Figure 314
Lift plate carrier into the clamping ring and

fix it.
(13) Tilt clutch 90¡£
¡⁄ K2-Side:
Wet thread of slotted nut with Loctite
(Type No. 262) and install it (Figure 315).
¡ Install slotted nut with the chamfer facing
¡⁄ Torque limit : 81.6kgf m(590lbf ft) Figure 315
¡ Special tool
¡⁄ KR-Side:
Wet thread of slotted nut with Loctite (Type
No. 262) and install it.
¡ Install slotted nut, with the collar(¤“76mm)
facing the bea-ring inner race.
¡⁄ Torque limit : 81.6kgf m(590lbf ft)
¡ Special tool
Figure 316
(14) Check function of clutches K3 and K4 by

means of compressed air (Figure 317).
is clearly audible.
Squeeze in and engage rectangular ring
(see Arrows).
Figure 317
3-149
Reassemble Multi-disk clutch KV/K1
(1) Lift plate carrier, with the KV-side showing
Tilt plate carrier 180¡£
.
Insert both roll pins(6 24 and 3.5 24)
flush-mounted into the end face-side bore of
the plate carrier (Arrow).
¡ Special tool
Figure 320

.
Wet both set screws(Arrows) with Loctite
Figure 321
(3) Drive purge valve(Arrow) flush-mounted in,

¡ Special tool
Figure 322
(4) Lay both O-rings scrollfree into the ring

Figure 323
3-150
Insert K1-piston uniformly against shoulder.
Figure 324
(6) Introduce intermediate washer and

compression spring.
Figure 325

Figure 326
(8) Lift the plate carrier out of the clamping ring.

Preload compression spring by means of
Special device and squeeze snap ring into
the annular groove of the plate carrier
(Arrow) - see Figure 327.
spring on the opposite side (KV-clutch)
accordingly.
Now, lift the plate carrier, with the KV-side
showing downward, into the clamping ring
Figure 327
and fix it.
Tilt plate carrier 180
¡ Special tool
3-151
Multi-disk clutch-KV
¡ The following Draft, respective Chart shows the plate stacking and the installation position of the
components.
1 Plate carrier 1
2 Piston 1
5 Inner plate 11 2.5
8 End shim 1
The respective clutch side can be recognized by the length, respective. ¤“ of the plate carrier, see Draft.
KV = Dimension Y (long plate-carrier side, resp. great ¤“)
K1 = Dimension X (short plate-carrier side, resp. small ¤“)
3-152
Check plate clearance KV = 2.8~3.0mm
(Figure 330~332):
Draft, respective chart.
Figure 330

of snap ring.
Figure 331

ring(upward), and read the plate clearance
s = 2.5~4.0) or and snap ring(optional).
After the performed adjustment of the Figure 332
plate clearance disassemble the plate

¡ Special tool
3-153
Pre-assemble and install Spur gear KV
(Figure 335~343):
components of spur gear KV.
2 Bearing outer race
2 1
3 Ring 5
4 Shim(s) optional, empirical value s = 3 4
1 2
1.7mm
Figure 335
5 Spur gear
Check Axial play - Spur gear bearing

0.0~0.05mm.
(2) Install both bearing outer races(2) and
place spur gear over the bearing inner
race.
Figure 336
(3) Introduce shim(s) 4 and ring 3.
Figure 337
(4) Introduce taper roller bearing.
Figure 338
3-154
(5) Preload the tapered roller bearing with
about 5ton.
axial play, correct with corresponding shim
(Item 4 / Figure 335).
¡ Special tool
Pry bar 5870 345 036
Figure 339

against shoulder.
Figure 340
(7) Line up shim (see Figure 335~339) and

ring.
Figure 341

accommodated.
Figure 342
3-155
Figure 343
(10) Heat bearing inner race(clutch bearing)

Tilt plate carrier 180°.
Figure 344
3-156
components.
1 Plate carrier 1
2 Piston 1
5 Inner plate 8 2.5
7 Snap ring 1 2.1~ 2.5 Optional
8 End shim 1
The respective clutch side can be recognized by the length, respective ¤“ of the plate carrier, see Draft.
KV = Dimension Y (long plate-carrier side, respective great ¤“)
K1 = Dimension X (short plate-carrier side, respective small ¤“)
3-157
Check plate clearance K1 = 2.6~2.8mm
(Figure 350~352).
(1) Install plate pack according to the Draft,
respective the Chart.
Figure 350

of snap ring.
Figure 351

ring(upward), and read the plate clearance
2.5~3.5mm) or and snap ring item 7

¡ Special tool
3-158
Pre-assemble and install Spur gear K1
(Figure 353~360):
1
(1) The Figure on the right shows the compone-
nts of spur gear K1.
1 Ball bearing (complete)
2 Snap ring
3 Spur gear
3
¡ Prior to assemble the components, align 2
plate pack by means of the spur gear radially
Figure 353
and center it, see figure 354.
Figure 354
(2) Install snap ring.
Figure 355
(3) Introduce bush, with the end face-side

collar (Arrow) facing the snap ring.
Figure 356
3-159
(4) Press ball bearing in until contact is obtained.
¡ Install ball bearing, with the lubricating groove
(Arrow) showing downward.
Apply the pressing-in tool only on the bearing
outer race.
Figure 357
(5) Heat ball bearing and line it up until contact

is obtained.
¡ Lubricating groove(Arrow) must show
upward.
Figure 358
(6) Line up the bush.
Figure 359
(7) Heat spur gear about 120¡£ C and introduce

it until all inner plates are accommodated.
Figure 360
3-160
(8) Line up shim = 1.2mm.
Figure 361

Figure 362

components, prelaod bearing with 10ton
(Figure 363).
¡ Support on the lower as well as on the
upper bearing inner race.
Use pressure pieces.
¡ Special tool
Pressure pieces 5870 506 096
Figure 363
(11) Lift plate carrier into the clamping ring, fix

and tilt it 90 .
Wet thread of slotted nut with Loctite, (Type
No. 262) and install slotted nut.
¡ Install slotted nut, with the collar facing the
bearing inner race.
¡⁄ Torque limit : 56.1kgf m(40.6lbf m)
Install opposite slotted nut(KV-side)
accordingly. Figure 364
¡ Special tool
3-161
(12) Check function of the clutches KV and K1
by means of compressed air.
is clearly audible.
Figure 365
(13) Squeeze in and engage rectangular rings

(3EA, see Arrows).
Figure 366
3-162
Install Counter shaft gear and Multi-
disk clutches
(1) Adjust Axial play of the Counter shaft gear
bearing 0.0~0.05mm(Figure 366, Exam-
ple D2):
Determine Dimension I (shaft dimension).
¡ Special tool
Figure 367
(2) Measure Dimension II (housing dimension)

from the locating face of the bearing inner
race to the locating face of the axle.
EXAMPLE D1
gives Dimension X 61.05mm
required Axial play e.g. - 0.03mm
Figure 368
gives Installation dimension 61.02mm
Y e.g.
(3) Install both bearing inner races.

Lay preassembled counter haft gear upon
the surface plate and determine
Dimension III (bearing dimension).
Dimension III e.g. 59.52mm
EXAMPLE D2
Dimension Y
(installation dimension) 61.02mm
Dimension III Figure 369
(bearing dimension) - 59.52mm
gives shim e.g. s = 1.50mm
3-163
¡ The assembly of the shim as well as of the
countershaft axle can be performed only
after the installation of the clutches.
(4) Position countershaft gear(along with
bearing inner races), see Figure 370.
Figure 370
(5) Insert bearing outer races KV/K1, KR/K2

and K3/K4 into the housing bores until
contact is obtained, see Arrows.
Figure 371
(6) Position clutch KV/K1, using lifting device.

¡ Special tool
Figure 372
(7) Position clutch KR/K2.
Figure373
3-164
(8) Check installation position of the countershaft
gear(Arrow) once more and correct if
necessary.
Figure 374
(9) Locate the spur gear K3 by means of

Special device and eye bolt (Arrow) axially.
¡ The spur gear fixing prevents the slipping
out of the plates during the lifting into
position of the clutch.
¡ Special tool
Assembly jig 5870 345 033
Eye bolt 5870 204 066
Figure 375
(10) Lift cluth KR/K2 slightly, displace it in

direction of arrow, and position clutch
K3/K4.
Now, remove the Special device again.
Figure 376
3-165
Interaxle differential
(1) Close bores (6EA/Arrows) by means of set
screws.
¡ Insert set screws with Loctite (Type No. 243).
Figure 380
(2) Press needle sleeve in, with the reinforced

shell facing the pressing-in tool until
contact is obtained, and fix it by means of
snap ring.
¡ Special tool
Pressing-in sleeve 5870 506 131
Figure 381
(3) Press the ring in, with the great ¤“ showing

downward, until contact is obtained.
Figure 382
(4) Introduce output shaft and install snap ring

(Arrow).
Position sun gear, with the stepped plane
face facing the snap ring, and introduce
output shaft until the snap ring snaps into
position.
Figure 383
3-166
(5) Fix the sun gear by means of circlip.
Figure 384

components of the planetary gear. 5
1 Thrust washer
2 Needle rollers(30 pieces)
3 Disk
4 Planetary shaft
4
5 Planeary gear
1
¡ Install components 1 to 3. 2
3
1 2
As assembly aid, use grease.
Figure 385
Renew needle rollers only in sets.
(7) Position planetary gear, align centrically

and fix it by means of planetary shaft.
the planetary shaft-cental oil hole showing
shead.
Figure 386
(8) Fix planetary shaft by means of roll pin.

Install the remaining planetary gears.
¡ Drive the roll pins each time in up to the
shaft center, see Arrow.
Figure 387
3-167
(9) Insert planet carrier into the internal gear.
Figure 388
(10) Insert bearing outer race(Arrow) into the

internal gear carrier until contact is
obtained.
Figure 389
(11) Supercool the internal gear carrier and

position it against shoulder.
Figure 390
(12) Fix internal gear carrier by means of snap

ring.
Figure 391
3-168
against shoulder.
Figure 392
(14) Introduce output shaft.
Figure 393
(15) Fix output shaft by means of snap ring.
Figure 394
(16) Squeeze in and engage both rectangular

rings(Arrows).
Figure 395
3-169
(17) Line up the bush(Arrow).
Figure 396

against shoulder.
Figure 397
(19) Insert plate.
Figure 398
(20) Lift the differential into the housing, using

lifting device.
¡ Special tool
Figure 399
3-170
(21) Position upper oil baffle and fasten both oil
baffles by means of hexagon head screws
(5EA) and hexagon nut (1EA).
¡ Mount flat washers.
Secure hexagon head screws with Loctite
(Type No. 243).
¡⁄ Torque limit (M8/8.8):2.35kgf m(17.0lbf ft)
Figure 400
Preassemble and mount Housing cover 1 3

(1) Mount components.
1 Sealing cover(use Loctite Type No. 262)
2
2 Connecting piece(install new sealing ring)
3 Cover plate(install new gasket)
4 Sealing cover(use Loctite Type No. 262)
4
¡ According to the transmission version,
differences concerning components and
their installation positions are possible.
Figure 401
(2) Drive the roll pin(2 8mm) flush-mounted

in, see Arrow.
Equip screw plug with new O-ring and 2
install it, see Arrow 2.
Figure 402
(3) Squeeze both snap rings(Arrow) into the

recess.
Figure 403
3-171
(4) Expand the two snap rings.
Introduce ball bearing, with the annular
groove showing upward, until the upper
snap ring snaps into the groove of the ball
bearing
¡ Special tool
Clamping Pliers 5870 900 026
Figure 404
(5) Insert gear wheel until contact is obtained.

¡ Special tool
Mallet 5870 280 004
Figure 405
(6) Fix gear wheel by means of circlip.

¡ Special tool
Set of external pliers 5870 900 015
Figure 406
Adjust Bearing preload of Differential

bearing 0.0~0.1mm (Figure 407~409) :
(7) Determine Dimension I from the mounting
face to the locating face of the bearing
outer race.
Figure 407
3-172
(8) Mount bearing outer race.
Press bearing outer race uniformly on and
determine Dimension II from bearing outer
race to the mounting face.
¡ Apply several measuring points and
determine the average value.
¡ Special tool
Straightedge 5870 200 022 Figure 408
EXAMPLE E :
dimension II e.g. - 64.00mm
Difference 2.36mm
required Bearing preload e.g. + 0.04mm
gives Shim e.g. s = 2.40mm
(9) Insert shim.
Figure 409
(10) Install bearing outer race
Figure 410
(11) Cover mounting face with sealing

compound Loctite (Type No. 574).
Install two adjusting screws and position
the housing cover on the gearbox housing
until contact is obtained, using lifting de-
vice.
¡ Special tool
Figure 411
3-173
(12) Insert both cylindrical pins(Arrow 1 and 2)
until contact is obtained. 2
Fasten housing cover by means of screw
connection.
Drive roll pin (Arrow 3) flush-mounted in.
1
3
¡⁄ Torque limit(M10/8.8):4.70kgf m(33.9lbf ft)
Figure 412
Figure 413
(14) Introduce shim s = 4.0mm.
Figure 414
(15) Fix ball bearing playfree, using shim and

circlip.
¡ Special tool
Clamping pliers 5870 900 021
Figure 415
3-174
(16) Install shaft seal, with the sealing lip facing
the oil chamber.
Grease sealing lip.
¡ According to the version, different shaft
seals can have been applied.
Outer diameter rubber-coated-wet with
spirit.
Figure 416
Outer diameter metallic-wet with sealing
compound (Loctite, Type No. 574).
¡ Special tool
Driver 5870 048 228
(17) Press screening plate against shoulder.

¡ Special tool
Figure 417
(18) Line up output flange.

Wet contact face of the shim with sealing
compound Loctite(Type No. 574) and
fasten output flange with hexagon head
screws.
Figure 418
(19) Fix hexagon head screws by means of

lock plate.
¡ Special tool
Driver 5870 057 009
Handle 5870 260 002
Figure 419
3-175
Adjust bearing preload-Clutch K3/K4 =
0.00~0.05mm (Figure 420~422) :
(20) Insert bearing inner race into the outer
race.
Housing dimension :
Press the bearing inner race uniformly on,
and determine Dimension I from the
mounting face to the bearing inner race.
Dimension I e.g. 43.82mm Figure 420

Cover dimension :
Determine Dimension II from the mounting
face to the contact/bearing inner race.
Dimension II e.g 42.15mm
¡ Special tool
Straightedge 5870 200 022
Figure 421
EXAMPLE F :
Difference = 1.67mm
Bearing preload e.g. + 0.03mm
gives Shim(s) s = 1.70mm
(21) Line up the shim.
Figure 422

against shoulder.
Figure 423
3-176
(23) Install and grease O-ring(Arrow).
Heat inner diameter of the bearing cover
(bearing seat).
Figure 424
(24) Grease and align rectangular rings(3EA,

Arrows) and align them centrically.
Figure 425
(25) Install two adjusting screws.

Line up the bearing cover by means of
hexagon head screws and pull it uniformly
against shoulder.
¡ Pay attention to the radial installation
position, see markings(Arrows).
Figure 426
Adjust bearing preload of Clutch

KR/K2 = 0.00~0.05mm (Figure 427~430)
(26) Insert bearing outer race until contact is
obtained.
Figure 427
3-177
Housing dimension :
Determine Dimension I from bearing outer
race to mounting face.
Figure 428
Cover dimension :
Determine Dimension II from the
contact/bearing outer race to the mounting
face.
¡ Special tool
Figure 429
EXAMPLE G :
Dimension I e.g. - 15.68mm
Difference = 1.78mm
(27) Make shim adhere with assembly grease
in the cover. Install O-ring (Arrow).
Figure 430
(28) Grease and align rectangular rings

(Arrows) centrically.
Figure 431
3-178
(29) Pull bearing cover uniformly against
shoulder.
position, see markings (Arrows).
Figure 432
Adjust bearing preload of the clutch

KV/K1 = 0.00~0.05mm (Figure 433~436):
(30) Lay bearing outer race over the bearing
inner race.
Housing dimension :
Press the bearing outer race uniformly on,
and determine Dimension I from the
mounting face to the bearing outer race.
Dimension I e.g : 52.67mm Figure 433

(31) Insert ring, with the chamfer showing

downward, into the bearing cover.
Figure 434
Cover dimension :
Determine Dimension II from the mounting
face to the ring.
¡ Special tool
Figure 435
3-179
EXAMPLE H :
Difference = 1.92mm
(32) Insert shim.
Figure 436
(33) Insert bearing outer race until contact is

obtained.
Line up O-ring (Arrow).
Figure 437
(34) Grease and align the rectangular rings

(Arrow) centrically.
Figure 438
(35) Insert the bearing cover until contact is

obtained and fasten by means of hexagon
head screws.
position, see markings (Arrows).
¡ Special tool
Figure 439
3-180
Install Countershaft axle
(1) Tilt gearbox housing 180
Align countershaft gear centrically.
Install adjusting screw (Figure 440).
¡ Special tool
Figure 440
(2) Supercool pin.

Make determined shim (see page 3-181)
adhere with grease.
Figure 441
(3) Insert pin until contact is obtained.

Figure 442
(4) Remove adjusting screw and fix bolt by

means of hexagon head screw.
¡ Wet thread of hexagon head screw with
Loctite (Type No. 243).
Figure 443
3-181
(5) Drive the sealing covers(Arrows) in, with
the concave side showing downward,
flush-mounted to the housing face.
¡ Wet contact face with Loctite (Type No.
262).
Figure 444
Install Emergency steering pump

Insert O-ring(Arrow) into the annular
groove and grease it.
Figure 445
(2) Introduce emergency steering pump until

contact is obtained and fasten it by means
of hexagon head screws.
¡ Wet thread of hexagon head screw with
Figure 446
Hydraulic pump
(1) Press needle sleeve(Arrow) against
shoulder, with the reinforced shell facing
the pressing-in tool.
¡ Special tool
Pressing-in tool 5870 058 041
Figure 447
3-182
(2) Insert disk s = 1.3mm and position bearing
outer race against shoulder.
Figure 448
(3) Install and grease O-ring (Arrow).
Figure 449
(4) Supercool the pump to about - 80 C.

Install two adjusting screws and introduce
pump until contact is obtained.
position.
¡ Use Protective gloves.
¡ Special tool
Figure 450
(5) Install O-ring(Arrow) and mount pump

flange.
Figure 451
3-183
(6) Fasten pump flange, respective the pump
by means of hexagon head screws.
¡ Wet thread of the two hexagon head
screws, (Position, see Arrows) with Loctite
(Type No. 243) (through holes).
Figure 452
(7) Insert O-ring(Arrow) into the annular

groove and grease it. Fasten pump flange
(Power take-off) with hexagon head
screws.
Figure 453
3-184
Axle disconnection
Figure 460
(2) Adjust ball bearing by means of disk s =

4.0mm, shim(optional) and circlip playfree.
Figure 461
(3) Position compression spring, piston and

shift fork.
¡ Stop screw as well as rectangular ring will
be installed later.
Figure 462
(4) Introduce pin until contact is obtained and

fix it by means of circlip.
Now, close bore with cover.
the pin-thread for extraction is showing
outward.
Wet contact face of the sealing cover with
Figure 463
3-185
(5) Insert disk, with the chamfer(Arrow)
showing upward.
Figure 464
(6) Preload compression spring, install sliding

blocks and sliding sleeve.
¡ Pay attention to the sliding sleevegreat
chamfer on the outer diameter showing
downward.
Figure 465
Adjust Shifting travel by means of

Measuring device (Figure 466~470):
(7) Insert stop screw into the measuring
device.
¡ Special tool
Measuring device 5870 200 107
Figure 466
(8) Line up measuring device and position it

on the mounting face until contact is
obtained.
¡ Special tool
Measuring device 5870 200 107
Figure 467
3-186
(9) Determine Dimension I, see Figure on the
right.
Dimension I.g. 32.90mm
¡ Special tool
Figure 468
(10) Mount flat gasket and determine Dimens-

ion II from the mounting fase to the bore
root (stop face/socket head screw).
Figure 469
EXAMPLE I :
Difference = 1.60mm
Adjusting dimension + 1.00mm
¡ Adjusting dimension = 1.0mm, gives the
required shifting travel.
(11) Line up shim(s) s = 2.6mm(Arrow) and

install socket head screw.
¡ Wet thread of socket head screw with
Figure 470
3-187
(12) Line up rectangular ring(VITON) into the
ring groove of the piston (Arrow) and oil it.
Figure 471
(13) Install switch :

1 Lock
2 Sealing ring (s=1.5mm)
3 Switch
1
Figure 472
(14) Install two adjusting screws and mount flat

gasket.
Heat ball bearing, introduce axle
disconnection device carefully and position
it uniformly against shoulder, using
hexagon head screws and socket head
screws.
¡ Special tool
Figure 473
(15) Insert both socket head screws(Arrows)

until contact is obtained.
Tighten hexagon head screws and socket
head screws.
Figure 474
3-188
(16) Insert perforated plate(1) and filter insert(2)
into the housing bore(Arrow/Figure 476).
Close bore, till the assembly of the
hydraulic oil feed, by means of plug(3).
1
2
1
Figure 475
Figure 476
(17) Install shaft seal (Arrow), with the sealing

lip facing the oil chamber.
¡ At application of the prescribed driver(s),
(S)
the exact installation position is obtained.
Grease sealing lip.
Outer diameter rubber-coated : wet with
sprit.
Outer diameter metallic : wet with sealing
compound loctite(Type No. 574).
Figure 477
¡ Special tool
Driver 5870 048 228
3-189
(18) Press screening plate(Arrow) against
shoulder.
¡ Special tool
Pressure piece. 5870 506 126
Figure 478
(19) Line up output flange.

Wet contact face of the disk with sealing
compound Loctite(Type No. 574) and
fasten output flange with hexagon head
screws.
Figure 479
(20) Fix hexagon head screws by means of

lock plate.
¡ Special tool
Drive 5870 057 009
Handle 5870 260 002
Figure 480
Filter
(6) Introduce filter into the housing bore.
¡ Oil sealing ring (Arrow).
Figure 471
3-190
(2) Fasten cover by means of hexagon head
screws (mount flat washers).
¡ Install new O-ring (Arrow).
Figure 482
(3) Equip screw plugs(1 and 2) with new O-ring

and install them.
Mount gasket and fasten cover plate(3) by
2
means of hexagon head screws.
¡⁄ Torque limit(screw plugs):14.3kgf m
3
(103lbf ft) 1
Figure 483
Input shaft (Power take-off-Pump)

(1) Tilt gearbox housing 180¡£ .
Squeeze V-rings(3EA) into the recess of
the driver(internal splines).
Install fitting key(Arrow).
Figure 484
Adjust gap dimension = 0.50mm

(Driver/Input shaft) (Figure 485~489) :
1 Driver
2 Input shaft
Figure 485
3-191
(2) Line up the disk s = 1.90mm and position
bearing inner race against shoulder.
Figure 486
(3) Determine Dimension I from the bearing

inner race to the end face/driver.
Figure 487
(4) Determine Dimension II (A-B).

II
B
A
Figure 488
EXAMPLE J
Difference = 1.00mm
Required gap dimension + 0.50mm
3-192
(5) Line up shim(s).
Figure 489
(6) Position driver against shoulder and fix it by

means of clamping disk and socket head
screw.
Figure 490
(7) Press bearing inner race against shoulder.
Figure 491
(8) Squeeze circlip in(Arrow) and line up the

drive gear.
Figure 492
3-193
(9) Squeeze circlip in(Arrow) and engage it.
Figure 493
(10) Introduce preassembled input shaft until

¡ Pay attention to the overlapping of the fitting
key with the fitting key groove.
Figure 494
Adjust axial play of the Input shaft

bearing = 0.0~0.05mm (Figure 495~497):
(11) Mount flat gasket.
Mount bearing outer race, press it uniformly
on and determine Dimension I from the
mounting face(gasket) to the bearing outer
race.
¡ Apply several measuring points and Figure 495
(12) Measure Dimension II from the mounting

face/converter bell to the locating
face/bearing outer race.
¡ Special tool
Gauge blocks 5870 200 080
Figure 496
3-194
EXAMPLE K :
Difference = 1.04mm
Axial play e.g. - 0.04mm
(13) Insert shim and position bearing outer
race until contact is obtained.
Figure 497
Input - Converter bell

(1) Insert bearing outer race into the housing
bore until contact is obtained and install
bearing inner race, see Arrow.
Figure 498
(2) Introduce spur gear(Arrow). starting from

the side, with the long collar showing
upward, and bring it in position.
Figure 499
(3) Insert both roll pins(¤“2.5 and ¤“1.5mm)

flush-mounted into the bore (Arrow) of the
input shaft.
Figure 500
3-195
(4) Supercool the input shaft and introduce it
Figure 501

Figure 502
(6) Position bearing outer race against

shoulder.
Figure 503
Adjust Axial play of the Drive gear

bearing = 0.03 ~ 0.07mm (Figure 504 ~
Example):
(7) Measure Dimension I from the mounting
face to the bearing outer race.
¡ Special tool
Figure 504
3-196
(8) Mount gasket(Arrow) and determine
Dimension II from the mounting face to the
locating face of the bearing outer race.
EXAMPLE K :
Difference = 1.10mm
Axial play e.g. - 0.05mm Figure 505
¡ Assembly of the shim, see Figure 508.
¡ Special tool
Gauge blocks 5870 200 067
(9) Insert needle sleeve(Arrow), with the

reinforced shell facing the pressing-in tool
¡ Special tool
Driver 5870 058 051
Handle 5870 260 002
Figure 506
(10) Install two adjusting screws and mount

gasket (Arrow 1).
Install converter safety valve(disk,
compression spring and ball), see Arrow
2.
Squeeze both rectangular rings into the
annular grooves of the input shaft and
engage them (Arrow3).
Now, grease rectangular rings and align
them centrically.
Figure 507
¡ Special tool
3-197
(11) Supercool oil feed flange, (about -80¡£
C)
and make shim s= 1.05mm (see page 3-
197) adhere with assembly grease in the
bearing bore.
Figure 508
(12) Introduce supercoiled oil feed flange until

position.
Figure 509
(13) Mount flat gasket(Arrow) and install

bearing cover.
position.
Figure 510
(14) Wet thread of the screw-in sleeves (1 and

2) with Loctite (Type No. 262) and install
the two screw-in sleeves.
Equip screw plugs(3 and 4) with new O-
rings and install them. 4
¡⁄ Torque limit(10¡¿1):2.55kgf m(18.4lbf ft)

¡⁄ Torque limit(M14¡¿1.5):3.57kgf¡⁄m(25.8lbf¡⁄ft) 2
1 3
Figure 511
3-198
Converter pressure back-up valve
(Figure 512 and 513):
(15) Drive roll pin (6¡¿50mm) into the bore until
Figure 512
(16) Introduce spool and compression spring.

Equip screw plug with new O-ring and
install it.
¡⁄ Torque limit : 13.3kgf m(95.9lbf ft)
Figure 513
(17) Remove input shaft and heat housing

bore (about 120¡£
C).
¡ Carry out the following steps(Figure
515~517) in immediate chronological
order.
¡ Special tool
Preheating sleeve 5870 801 003
Figure 514
(18) Grease rectangular ring(Arrow) and align

it centrically. Introduce input shaft until
¡ Pay attention to the overlapping of the
fitting key with the fitting key groove.
Figure 515
3-199
(19) Install two adjusting screws and mount flat
gasket (Arrow 1).
Lay O-ring(Arrow 2) into the annular
groove. 1
¡ Special tool
2
Figure 516
(20) Introduce converter bell by means of lifting

device until contact is obtained.
¡ Slight rotary motions of the input shaft will
facilitate the sliding in.
Protect the splines from damage.
Pay attention to the radial installation
position.
¡ Special tool
Figure 517
(21) Fasten converter bell by means of hex

head screws.
Figure 518
(22) Insert O-ring(Arrow) into the annular

groove of the converter bell.
Figure 519
3-200
(23) Grease rectangular ring(Arrow) and align
it centrically.
Figure 520
(24) Introduce retarder along with converter

against shoulder, using lifting device and
fasten it by means of head screws.
position. Binding are the Specifications of
the Vehicle Manufacturer, respective the
markings applied at the disassembly.
¡ Special tool
Figure 521
(25) Tilt transmission 90¡£

.
Insert pot flush-mounted to the housing
face.
¡ Wet sealing surface with Loctite (Type No.
262).
Figure 522
(26) Install breather (Arrow).
Figure 523
3-201
(27) Equip screw plug(Arrow 1) with new O- 2
ring and install it.
Install the two retaining plates(Arrows 2).
1 2
Figure 524
(28) Mount hydraulic control unit.

Install all oil lines.
¡ The line routing is different according to the
design. In this connection, pay attention to
the Perspective Illustrations of the
corresponding Spare Parts List.
Inductive transmitters and Speed

sensor
(1) The following drafts are showing the
installation position of the single inductive
transmitters and the speed sensor. Figure 528
6 Inductive transmitter n-Turbine

14 Inductive transmitter n-Engine
39 Inductive transmitter n-Central gear
train
31 Speed sensor n-Output and
Speedometer
Figure 529
3-202
¡ The following Figures describe the
assembly, respective setting of the
inductive transmitter n-Engine(14).
The assembly of the inductive transmitter
n-Turbine(6) and n-Central gear train(39)
has to be carried out accordingly.
¡ Pay attention to the different Setting
dimensions X.
Inductive transmitter n-Engine(14)
Figure 530
X = 0.5+0.3mm
Inductive transmitter n-Turbine (6)
X = 0.5+0.3mm
Inductive transmitter n-Centr.gear train(39)
X = 0.3¡ 0.1 mm
Set Dimension X by means of

adjusting disk(s)(Figure 531~536):
(2) Measure Dimension I from the contact
face to the screw-in face on the inductive
transmitter.
Figure 531
(3) Rotate counting disk radially until one

tooth tip is central to the inductive
transmitter bore.
Screw the plug gauge in until contact is
obtained.
Position anvil on the tooth tip until contact
is obtained and lock it by means of set
screw (Figure 532 and 533).
¡ Special tool
Plug gauge 5870 200 104 Figure 532
3-203
¡ Special tool
Plug gauge 5870 200 104
Figure 533
(4) Screw the plug gauge out and determine

Dimension II (see also Figure 533).
Figure 534
EXAMPLE M1
Dimension X (0.5+3mm) e.g. - 0.60mm
gives installation s = 29.50mm
dimension A
EXAMPLE M2 :
Installation dimension A e.g. - 29.50mm
gives adjusting disk(s) s = 0.50mm
(5) Line up the corresponding adjusting

disk(s) and wet thread(Arrow) with
Figure 535
3-204
(6) Install inductive transmitter n-Engine(14),
see Arrow.
¡⁄ Torque limit : 3.06kgf m(22.1lbf ft)
¡ Set and install the inductive transmitter n-
Turbine(6) and n-Central gear train (39)
accordingly.
Pay attention to the different setting
dimension.
Installation position of the single inductive
Figure 536
transmitters.
Install Speed sensor n-Output/Speedo -

meter(31) (Figure 540~545):
¡ Setting dimension X = 1.0+0.5mm
Figure 540
(7) The Figure on the right shows the speed

sensor (Hall sensor). 1
1 Speed sensor
2 O-ring
3 Setting plate(s)
2 3
Figure 541
(8) Determine Dimension I from the housing

face to the spur gear K3.
Figure 542
3-205
(9) Measure Dimension II from the contact
face to the mounting face.
¡ Special tool
Figure 543
EXAMPLE N1
Dimension X (1.0 mm) e.g. - 1.20mm
+0.5
gives Installation s = 38.00mm

dimension
EXAMPLE N2
Installation dimension A e.g. - 38.00mm
Figure 544
gives Setting plate(s) s = 1.00mm
Line up setting plates (2EA, s = 0.5mm)
and grease O-ring.
Fasten speed sensor by means of

socket head screw.
¡⁄ Torque limit(M8/8.8) : 2.35kgf m(17.0lbf ft)
¡ Installation position of the speed sensor.
¡ Prior to the commissioning of the Transm-
ission, carry out the oil filling according to
the Operating Instructions.
Figure 545
3-206
3. AXLE
1) FINAL DRIVE
(1) DISASSEMBLY
¤ Loosen oil drain plug and drain oil.
AX002
¤Ł Loosen hexagon head screws and lift off

the planetary carrier.
AX003
¤Ø Squeeze out circlip and pull off the

planetary gears.
Remove thrust washer.
AX004
¤ŒPull sun gear along with inner plate

carrier from the stub shaft, respectively
out of the plate pack.
AX005
3-207
¤º Loosen locking screws and remove ring
from the inner plate carrier.
AX006
¤ Squeeze out circlip.
AX007
¤ Remove backing plate and plate pack.
AX008
¤ Remove thrust washer.
AX009
3-208
¤ Remove lock plate.
AX010
¤ Loosen and remove slotted nut.
AX011
¤æ Pull stub shaft out of the axle housing.
AX012
¤ Separate complete hub from hub carrier.
AX013
3-209
¤ Lift internal gear and internal gear carrier
out of the hub.
Remove released spacer.
AX014
¤ Unhook return springs.
AX015
¤ı Take out the piston and remove sealing

components.
AX016
§ Pull off tapered roller bearing from the

internal gear carrier.
AX017
3-210
§æ Pry shaft seal out of the hub and remove
AX018
§ If required drive out and remove the two

bearing outer races.
AX019
§ Remove bleeder valve.
AX020
§ Loosen hexagon head screws and

separate the hub carrier from the axle
housing.
AX021
3-211
(2) ASSEMBLY
Hub carrier
¤ Fasten hub carrier on the axle housing by
means of hexagon head screws.
¡ Pay attention to the installation position.
Cover flange-mounted surface with
sealing compound.
AX022
¤Ł Pull the wheel studs into the hub bores,

using a special device.
AX023
¤Ø Drive both bearing outer races firmly

against shoulder.
AX024
¤Œ Guide the bearing inner race over the

end of the hub carrier until contact is
obtained.
AX025
3-212
¤º Guide hub over the end of the hub carrier.
AX026
¤ Heat bearing inner race and place it firmly

against shoulder.
AX027
¤ Assemble spacer s=5.4mm(Empirical

value).
¡ If hub carrier, hub as well as internal gear
carrier are not renewed we recommend
to install the existing spacer again.
Decisive, however, is the rolling
resistance of the wheel bearing, see
figure ¤ , page 3-214.
AX028
¤ Screw installer over the threads of the

hub carrier.
Guide complete internal gear over the
hub carrier splines and fix the hub.
AX029
3-213
¤ Tighten slotted nut by continuous turning
of the hub.
¡⁄Torque limit : 204~224kgf m
(1475~162 3lbf ft).
AX030
Rolling resistance of the wheel bearing

¤ T = F¡¿R, from that results : Tractive
Force F=T/R
T = Rolling resistance in kgf m
F = Tractive Force kgf
R = Radius in m
AX031
Nominal value/Bearing rolling moment :

¡⁄1.4~2.0kgf m(10.3~14.8 lbf ft)
¡ For already run-in bearings try to find the
lower value.
If the required rolling resistance is not
obtained correct by means of a
corresponding spacer(Figure ¤ ).
After adjustment of the wheel bearing
remove hub again.
Hub
¤ Insert bearing inner race into the hub.
AX032
3-214
¤Ł Cover outside of shaft seal with Loctite
and drive it in.
¡ Installation depth(7.0~7.8mm) is
determined by the special tool.
If necessary, heat cover plate prior to
assemble the hub and install it.
AX033
¤Ø Guide hub over the hub carrier end

carefully against shoulder.
AX034
Complete internal gear carrier

3 2 1
Pre-assemble piston
¤Œ The draft on the left shows the installation
position of the back-up sealing elements.
1 = Back-up ring
2 = Packing ring
3 = U-section ring
¤º Clean the piston with spirit.

Stick on support ribbons at two points by Stick on
means of Loctite. The support ribbons
must adhere exactly around the whole
circumference. Remove any sticking
residues.
3-215
¤ Install packing rings(2) and U-section
rings(3).
¡ Pay attention to the installation position,
see draft ¤ Œ,page 3-215.
AX037
¤ Insert piston into the installer(S).

¡ Lubricate sealing and back-up elements,
(Use W-10 oil).
AX038
¤ Insert piston with installer into the internal

gear carrier.
position,(Openings for return springs).
With installed condition, the support
ribbon openings must show upwards.
AX039
¤ Press piston carefully against shoulder,

using clamping plate and two-leg puller.
AX040
3-216
¤ Engage return springs (With lug showing
outwards) on the circlip and assemble it
in the internal gear carrier.
position of the circlip(See arrow).
AX041
¤æ Insert 2nd circlip and engage return

springs.
position of the circlip.
AX042
¤ Insert O-ring into the groove of the

internal gear carrier and grease it slightly.
Mark the location of the oil supply holes
on the face, (See arrow).
AX043
Assemble internal gear carrier

¤ Screw installer over the threads of the
hub carrier. Assemble the spacer
determined in Figure ¤ , page 3-216.
AX044
3-217
¤Ł Guide O-ring over the hub carrier and
insert it into the groove.
Mark the radial location of the oil supply
bores on the face(See arrows).
AX045
¤Ø Guide the complete internal gear over the

splines of the hub carrier. At the same
time pay attention to the overlapping of
the oil holes(Hub carrier, internal gear
carrier)(See arrows).
¡ During this step, it is absolutely
necessary to respect the centrical
location of the hub in order to make a
correct assembly of the internal gear-
internal gear carrier possible, and to
AX046
avoid a damage of the two O-rings.
¤Œ Tighten slotted nut by continuous turning

of the hub finally.
¡⁄ Torque limit : 204~224kgf m
(1475~ 1623lbf ft)
AX047
¤º Install lock plate and secure slotted nut.
AX048
3-218
¤ Assemble stub shaft until contact is
obtained.
AX049
¤ Screw oil seal with inner plate carrier.

¡⁄Torque limit : 5.1kgf m(36.9lbf ft)
AX050
¤ Install thrust washer.
AX051
¤ Guide the inner plate carrier(Along with

the sun gear) upon the stub shaft splines.
AX052
3-219
Adjust plate clearance according to the
following table :
Plate clearance
Number of Number of -piston stroke in
inner plates friction faces (mm)
2 4 1.6~2.0
3 6 2.4~2.8
4 8 3.2~3.6
5 10 4.0~4.4
¤ Determine piston stroke

(Nominal value 2.4~2.8mm)
Squeeze in circlip and place it against
shoulder towards the outside.
Determine dimension A from the flange-
mounted surface/hub to the plane
surface/piston.
Dimension A e.g. 121.50mm
¡ Pay attention to the correct location of the
piston against the internal gear carrier.
AX053
¤æ Measure dimension B from the flange-

mounted surface/hub to the inner plane
surface of the circlip.
Dimension B e.g. 75.20mm
AX054
¤ Outer plate : 4¡¿4.5mm

Dimension C e.g. 18.00mm
AX055
3-220
¤ Inner plate : 3¡¿4.5mm
Dimension D e.g. 13.50mm
AX056
¤ Dimension E = Backing plate

Dimension E e.g. 18.00mm
AX057
¤ı Example
Dimension A 121.50mm
Dimension B -75.20mm
Dimension C -18.00mm
Dimension D -13.50mm
Dimension E -12.00mm
Difference = Plate clearance 2.80mm
¡ If the required plate clearance according
to the Table, page 3-220, is not obtained,
correct with corresponding outer plate.
If necessary, mount thinner outer plates
on the piston side, respectively backing
plate side.
3-221
§ Install alternating outer and inner
plates(Starting with one outer plate).
AX058
§æ The illustration on the right shows the

required arrangement of the outer plates.
AX059
§ Insert backing plate-stepped plane

surface is showing outwards.
AX060
§ Fix the plate pack by means of circlip.
AX061
3-222
§ Heat planetary gear and place it upon the
planetary carrier.
¡ Pay attention to the installation position,
large radius of the bearing inner race
showing to the planetary carrier
(Downwards).
AX062
§ı Squeeze in circlip.
AX063
Determine end play of the sun-gear

shaft(Nominal value 0.3~0.6mm)
(Try to find the higher value).
§ Place sun gear and plate carrier against
shoulder.
AX064
§ Determine dimension B from the flange-

mounted surface to the thrust washer.
¡ For the measurement, lay thrust washer
into the planetary carrier.
AX065
3-223
§ł Example
Dimension A 6.00mm
Dimension B -5.50mm
Required end play =0.50mm
of the sun-gear shaft
¡ Remove thrust washer again and make it
adhere with Loctite.
§ø Insert new O-ring into the ring groove of

the planetary carrier(Arrow).
AX066
§œ Assemble planetary carrier until contact

is obtained.
AX067
§ß Tighten hexagon head screws.
AX068
3-224
Check tightness of the brake hydraulic
system
¡ Bleed the brake.
After having applied the brake for about
10 times carry out the following pressure
test.
Using a suitable pressure apparatus
(Lukas or similar) with stopcock build up
an actuating pressure of 120 bar.
Close the stopcock and pressurize the
brake for 5 minutes with this pressure.
After this time, the pressure may have
dropped to 117 bar only.
§ Afterwards, build up a pressure of 5 bar

and close the stopcock.
Within 5 minutes there may be no
pressure break.
Install bleeder valve.
AX069
§ Tighten oil drain plug.

¡⁄Torque limit : 5.1kgf m(36.9lbf ft)
¡ Before the axle is put into Service, pay
attention to the Lubrication Instructions,
page3-195.
AX070
3-225
2) DIFFERENTIAL CARRIER
(Version with screwed bearing caps)
(1) DISASSEMBLY
Remove the two stub shafts prior to
separate the differential carrier from the
axle housing, see figure ¤ ~¤Ø.
¤ Drain oil from the final drive and the axle

housing. Loosen hexagon head screws
and separate planetary carrier from the
hub, using eye hook.
AX071
¤Ł Pull inner plate carrier(Along with sun

gear) from the stub shaft.
AX072
¤Ø Pull stub shaft out of the axle housing.

Squeeze out circlip and remove the plate
pack.
¡ This step is necessary to make the later
installation of the inner plate carrier
possible.
AX073
3-226
¤Œ Loosen hexagon head screws and
axle housing.
AX074
¤º Fasten the differential carrier in the

assembly jig.
Remove lock wire and drive roll pins out.
AX075
¤ Loosen adjusting nuts.
AX076
¤ Loosen hexagon head screws and

remove the two bearing caps.
¡ Mark bearing caps with housing, see
arrow.
AX077
3-227
¤ Remove adjusting nuts.
Remove differential assembly from the
axle carrier.
AX078
Differential
¤ Pull the two bearing inner races of the
tapered roller bearing from the differential
case halves.
AX079
¤Ł Mark housing cover with differential.

Clamp the differential case halves, loosen
the locking screws.
AX080
¤Ø Back off the cover.

¡ Pay attention to the released thrust
washer.
AX081
3-228
¤Œ Take all components of the multi-disk
self-locking differential out of the
differential case.
AX082
¤º Press crown wheel from the differential

case.
AX083
Drive unit
¤ Unlock slotted nut or hexagon head
screw(According to the version) and
remove lock plate.
AX084
¤Ł Loosen slotted nut or hexagon

nut(According to the version) and remove
it along with washer.
AX085
3-229
¤Ø Pull off the drive flange.
AX086
¤Œ Pry out the shaft seal.
AX087
¤º Press drive pinion out of the axle carrier.

¡ Pay attention to the released tapered
roller bearing.
AX088
¤ Remove spacer from the drive pinion

end.
AX089
3-230
¤ Press tapered roller bearing from the
drive pinion, using grab sleeve(See
arrow.).
AX090
¤ If necessary, drive the two bearing outer

races out of the axle carrier bores.
AX091
(2) Assembly
¡ If crown wheel or drive pinion are
damaged, the two parts must be
renewed as a set.
If a new complete crown wheel set is
installed, pay attention that crown wheel
4
and drive pinion have the same mating
3
c
numbers.
When replacing a complete crown wheel
set or axle carrier, pay attention to the 3
b
Draft.
x
1
2
Determine thickness of shim-to obtain
a correct contact pattern
¡ The following measuring operations must
be carried out with utmost care.
Inexact measurements would cause an
incorrect contact pattern and require a
renewed disassembly and assembly of
the drive pinion as well as the
differential(Partial) after the contact
pattern has been taken, page3-196.
3-231
Install adjusting pieces(3) and fasten the
two bearing caps provisionally.
Install stop washer(2) and measuring
pin(1) and introduce measuring shaft(4)
(See draft).
CK-Drive
1 = Measuring pin
2 = Stop washer
3 = Adjusting piece
4 = Measuring shaft
¤ Determine gap(Dimension b) between

measuring pin and measuring shaft with
feeler gauge.
Dimension b e.g. 0.70mm
EXAMPLE ¥
Dimension a(=measuring piston)
166.80mm
Dimension b +0.70mm
Dimension c (1/2'“measuring shaft)
+15.00mm
AX092
¤Ł Measure bearing width.

Bearing width e.g. 33.50mm
AX093
¤Ø Read pinion dimension.

Pinion dimension e.g. 148.0-0.2 147.80mm
EXAMPLE ¥–
Bearing width 33.50mm
Pinion dimension +147.80mm
gives dimension X1 181.30mm
AX094
3-232
EXAMPLE ¥†
Dimension X 182.50mm
Dimension X1 -181.30mm
Difference = Shim thickness s=1.20mm
Now, remove bearing caps, shims,
measuring shaft and measuring pin
again.
¤Œ Lay shim(s = 1.20mm) into the housing

bore.
AX095
¤º Undercool bearing outer race and press

it firmly against shoulder.
Install the drive flange side bearing outer
race correspondingly.
AX096
¤ Heat bearing inner race, guide it over the

drive pinion end until contact is obtained.
¡ Pay attention to a correct contact, reset
after the cooling.
3-233
Adjust rolling resistance of the drive
pinion bearing
¤ Nominal value : DK/CK 0.11~0.23kgf m
HK 0.15~0.31kgf m
LK/RK 0.31~0.46kgf m
Lay measuring ring over the drive pinion
collar.
¡ Configuration and description of the
measuring ring, see below draft.
AX098
Draft for the determination of the spacer :

1 = Measuring ring 30¡£ 3¡¿
12
2 = Roll pin(Set of 3, each spaced for 0¡
£
120¡£)
¡ Dimension X = Thickness of spacer.
2 1
X
¤Ł If necessary(According to the version),

insert hexagon head screws into the
drive flange bores and press the dust
shield upon the collar of the drive flange.
AX099
¤Ø Insert the drive pinion into the axle carrier

and assemble the heated bearing inner
AX100
3-234
¤Œ Guide drive flange over the drive pinion
splines.
Apply washer and tighten slotted nut until
the required rolling resistance is obtained.
¡ When tightening, make several full
revolutions of the drive pinion in both
senses, and check the rolling resistance
continuously.
AX101
¤º Loosen slotted nut, pull off drive flange

and remove the pinion again.
Take off measuring ring and determine
dimension X (See draft, page 3-234).
Dimension X e.g. s=8.55mm
¡ Dimension X corresponds to the
thickness of the spacer to be installed.
Lay spacer(e.g. s = 8.55mm) instead of
the measuring ring over the drive pinion
end.
AX102
Install drive pinion again.
¤ Replace drive flange, apply washer and

tighten slotted nut.
¡⁄Torque limit : RK 112kgf m
LK 122kgf m
CK 71kgf m
senses.
AX103
¤ Check rolling resistance.

¡ If the required rolling resistance is not
obtained correct again with one
corresponding spacer.
AX104
3-235
¤ Remove the drive flange and install the
shaft seal.
¡ Pay attention to the contact.
If the shaft seal outer diameter is rubber-
coated, the sealing face must be wetted
with spirit.
Otherwise use sealing compound Loctite
Fill cavity between sealing lip and dust lip
with grease.
AX105
¤ Replace drive flange, assemble washer

and tighten slotted nut, respectively
hexagon nut(According to the version)
finally.
LK 122kgf m
CK 71kgf m
¡ The securing of the slotted nut,
respectively hexagon nut(According to
the version) is carried out after the
AX106
contact pattern is taken.
Differential
¤ Heat the crown wheel, center and fasten
it provisionally.
AX107
¤Ł Insert the two thrust washers into the

differential case half.
¡ Mount the brass washer on top with the
lubricating groove facing the side gear.
AX108
3-236
¤Ø Insert circlip and install drive pin.
AX109
¤Œ Assemble alternating outer and inner

plates, starting with one outer plate.
¡ Number and installation position of the
outer and inner plates, see
corresponding spare parts lost
(According to the version).
The total height(Thickness) of the plate
pack must be equal on both differential
sides. Plate thickness of outer plates
may be different.
AX110
¤º Mount pressure ring.
AX111
¤ Insert side gear and assemble inner

plates at the same time.
AX112
3-237
¤ Insert the complete differential spider.
AX113
¤ Replace the second side gear.
AX114
¤ Install the second pressure ring and

insert all drive pins.
position of the pressure ring.
AX115
¤ Assemble alternating inner and outer

plates, starting with one inner plate.
¡ Number and installation position of the
inner and outer plates, see corresponding
lost of spare parts(According to the
version).
AX116
3-238
Determine plate clearance
¤æ Differential case :
Measure dimension A from the flange-
mounted surface to the outer plate.
AX117
¤ Housing cover :
Determine dimension B from the contact
face(Outer plate) to the flange-mounted
surface.
AX118
¤ EXAMPLE
Dimension A 3.40mm
Dimension B -3.10mm
¡ The prescribed end play(=plate
clearance) is 0.2~0.8mm, whilst the lower
value should be found.
The end play is corrected by installing
outer plates of corresponding thickness,
whilst the plate thickness must be equal
on both differential sides.
¤ Make the two thrust washers adhere with

grease in the housing cover.
AX119
3-239
¤ıFasten the housing cover by means of
locking screw.
¡ Pay attention to the installation position -
see markings.
Only single use of the locking screws is
admitted.
AX120
§ Heat the two bearing inner races and

place them against shoulder.
AX121
§æ Install the two bearing outer races and

insert the differential assembly into the
housing.
Now, fix the differential by means of the
adjusting nuts.
AX122
§ Install the two bearing caps and tighten

them by means of hexagon head screw.
¡ Pay attention to the marking(Arrow).
AX123
3-240
Adjustment of the bearing preload and
the backlash
§ Apply dial indicator right angled on the
outer diameter of the tooth flank/crown
wheel.
Adjust the adjusting nut on the crown
wheel side until the required backlash-
see value engraved on the crown wheel
outer diameter- is obtained.
AX124
§ Screw in the adjusting nut(Opposite the

crown wheel side) until the differential
bearing is free of play.
Now, tighten adjusting nut further for 2
notches to obtain the required bearing
preload of the differential bearing
0.3~0.4kgf m.
Check backlash again and correct if
necessary.
¡ At this step make several full revolutions
AX125
of the differential.
Determine yoke width ;
e.g. CK 258+0.1mm
§ı Apply dial indicator on the plane

face/crown wheel, make at least one
revolution of the crown wheel and record
the run-out.
Admitted run-out maximum 0.08mm.
AX126
§ Check contact pattern on the crown

wheel : Cover some tooth flanks of the
crown wheel with gear marking
compound. Roll the crown wheel over
the drive pinion to and fro. Take the
contact pattern and compare it with Page
"Examples of contact patterns", page 3-
196.
AX127
3-241
§ In case of a greater contact pattern
deviation a spacing error has been made
during the assembly of the drive pinion
which must be absolutely corrected.
Fix the two adjusting nuts by means of
toll pins, respectively cotter pins
(According to the version).
AX128
§ł Secure hexagon head screws of the

bearing cap fastening against getting
loose by means of lock wire('“1.6mm).
AX129
§ø Tilt differential carrier.

Insert lock plate firmly against shoulder
and caulk it on the drive flange, using a
suitable tool.
AX130
§œCover flange-mounted surface with

sealing compound Loctite.
Screw in two adjusting screws and place
the differential carrier against the axle
housing until contact is obtained.
AX131
3-242
§ß Fasten differential carrier on the axle
housing by means of hexagon head
screws.
¡ Cover hexagon head screws with
AX132
¡ Now, install the stub shafts again and

complete the final drive.
Before the axle is put into service, pay
attention to the lubrication instruction,
page 3-282.
3-243
(Version with cast-on bearing caps)
(1) DISASSEMBLY
¡ Remove the two stub shafts prior to
axle housing, see figure¤ ~¤Œ.

hub, using eye bolt.
AX133
¤Ł Pull inner plate carrier(Along with sun

gear) from the stub shaft.
AX134
¤Ø Pull stub shaft out of the axle housing.
AX135
3-244
¤Œ Squeeze out circlip and remove plate
pack.
¡ This step is necessary to allow the later
installation of the inner plate carrier.
AX136
¤º Loosen hexagon head screws and

axle housing, using back-off screws.
AX137
Differential
¤ Fasten the differential carrier in the
assembly jig.
Drive out the roll pin on the crown wheel
side.
AX138
¤Ł Loosen and remove adjusting nut.
AX139
3-245
¤ØLift differential and remove bearing outer
race.
AX140
¤Œ Tilt axle carrier 180¡£

.
Drive out roll pin(Opposite the crown
wheel side), remove adjusting nut and
bearing outer race(See figure).
AX141
¤º Pull off bearing inner race from the

housing cover, respectively differential
case.
AX142
¤ Mark housing cover with differential case.

Loosen locking screws.
AX143
3-246
¤ Separate housing cover from differential
case and pull it out of the axle carrier.
AX144
¤ Lift differential carrier out of the axle

carrier.
AX145
¤ Take all components of the multi-disk

differential case.
AX146
¤ Clamp the differential housing.

Loosen locking screws and separate the
crown wheel from the differential case.
AX147
3-247
Drive unit
¤ Unlock slotted nut or hexagon nut
(According to the version) and remove
lock plate.
AX148
¤Ł Loosen slotted nut or hexagon nut

(According to the version) and remove it
along with washer.
AX149
¤Ø Pull off drive flange.
AX150
¤Œ Pry out shaft seal.
AX151
3-248
¤º Drive the drive pinion out of the axle
carrier.
roller bearing.
If necessary, drive the two bearing outer
races out of the axle carrier bores.
AX152
¤ Pull spacer from the drive pinion end.
AX153
¤ Press tapered roller bearing from drive

pinion -using grab sleeve, see arrow.
AX154
(2) ASSEMBLY
renewed as a set.
numbers.
set or axle carrier, pay attention to the
Draft.
3-249
¡ The following measuring operations must 4
be carried out with utmost care. 3
c
renewed disassembly and assembly of 3
b
1
the drive pinion as well as the
a
differential(Partial) after the contact 2
pattern has been take, page 3-196.
Install adjusting pieces(3) and fasten the

Install thrust washer(2) and measuring
(See draft).

measuring pin and measuring shaft with
feeler gauge.
EXAMPLE ¥
Dimension a(=measuring pin) 226.00mm
Dimension b +0.70mm
Dimension c (1/2'“measuring shaft)
+15.00mm
AX155

AX156
3-250
Pinion dimension e.g. 198-0.1 197.90mm
EXAMPLE ¥–
AX157
EXAMPLE ¥†
Difference = Shim thickness s =1.35mm
¤Œ Lay shim(According to the example s =

1.35mm) into the housing bore.
AX158
¤º Undercool bearing outer race and press it

firmly against shoulder.
AX159
3-251
AX160

pinion bearing
HK 0.15~0.31kgf m
collar.
AX161
Draft for the determination of the spacer : 3

1 = Measuring ring(S) 30¡£ ¡¿1
20
¡£
2 = Roll pin(Set of 3, each spaced for
120¡£)
2 1
X
¤ If necessary(According to the version),

insert hexagon head screws into the drive
flange bores and press the dust shield
upon the collar of the drive flange.
AX162
3-252
¤ Insert the drive pinion into the axle carrier
and assemble the heated bearing inner
AX163
¤ Apply washer and tighten slotted nut until

the required rolling resistance is obtained.
senses, and check the rolling resistance
continuously.
AX164
¤æ Loosen slotted nut, tighten drive flange

and remove the pinion again.
Take off measuring ring and determine
Dimension X e.g. s =7.79mm
end. Install drive pinion again.
AX165
¤ Replace drive flange, apply washer and

HK/LK 122kgf m
DK/CK 71kgf m
senses.
3-253
¤ Check rolling resistance
AX166
¤ Install shaft seal.

If the outer diameter of the shaft seal is
rubber-coated, wet the sealing lip with
spirit. Otherwise use the sealing
compound Loctite. Fill cavity between
sealing lip and dust lip with grease.
Without figure.
Place dust shield over the axle carrier
collar ( '“ 160mm) until contact is
¡ obtained.
AX167
For version with additional dust shield
only.
¤ı Replace drive flange.

Assemble washer and tighten slotted nut,
the version) finally.
HK/LK 122kgf m
DK/CK 71kgf m
AX168
Differential
¤ Heat the crown wheel and place it against
the differential case half until contact is
obtained.
Clamp differential case by means of
press.
Tighten locking screws.
¡ Only single use of the locking screws is
admitted.
AX169
3-254
¤Ł Press bearing inner race firmly against
shoulder.
AX170
¤Ø Lay the two thrust washers into the

¡ Mount brass washer on top with the
AX171
¤Œ Lay snap ring into the ring groove, see

arrow.
AX172
¤º Insert drive pin, see arrow.
AX173
3-255
¤ Assemble alternating outer and inner
¡ Number and installation position of outer
and inner plates, see corresponding list of
spare parts(According to the version).
may be different.
AX174
¤ Replace pressure ring.
AX175

AX176
¤ insert the differential spider assembly.
AX177
3-256
¤ Replace second side gear.
AX178
¤æ Install second pressure ring and insert all

drive pins.
AX179

¡ Number and installation position of inner
and outer plates, see corresponding list
of spare parts(According to the version).
AX180

¤ Differential case :
AX181
3-257
¤ Housing cover :
surface.
AX182
EXAMPLE
Dimension A 4.00mm
Dimension B -3.80mm
value has to be found.
The end play is corrected by the
installation of outer plates of
corresponding thickness, whilst the plate
pack thickness must be equal on both
differential sides.
¤ı Insert pre-assembled differential case half

in the axle carrier.
AX183
§ Make the two thrust washers adhere with

AX184
3-258
§æ Lay housing cover over the differential
case.
¡ Pay attention to the installation position -
see markings.
AX185
§ Fasten the housing cover by means of

locking screws.
admitted.
AX186
§ Heat bearing inner race and place it

against the housing cover until contact is
obtained.
AX187
§ Insert bearing outer race into the bearing

bore and fix it by means of adjusting nut.
AX188
3-259
§ıTilt axle carrier 180¡£
.
Insert the crown wheel side bearing outer
race into the bearing bore and fix it for the
present with the second adjusting nut.
AX189
Adjustment backlash and bearing

preload
wheel.
Adjust the adjusting nut on the crown
wheel side until the required backlash-
see value engraved on the crown wheel
outer diameter- is obtained.
AX190
§ Screw in the adjusting nut(Opposite the

bearing is free of play.
Now, tighten adjusting nut further for 2
notches to obtain the required bearing
preload of the differential bearing
0.3~0.4kgf m.
necessary.
¡ At this step make several revolutions of
AX191
the differential.
Determine yoke width.
§łApply dial indicator on the plane

face/crown wheel, make at least one
revolution of the crown wheel and record
the run-out.
AX192
3-260
§ø Check contact pattern on the crown
wheel : Cover some tooth flanks of the
crown wheel with gear marking
compound.
Roll the crown wheel over the drive
pinion to and fro.
Take the contact pattern and compare it
with Page "Examples of contact
patterns", page 3-283.
In case of a greater contact pattern
AX193
deviation, a spacing error has been made
during the assembly of the drive pinion,
§œ Secure the two adjusting nuts.
AX194
§ß Tilt differential carrier.

Insert lock plate until contact is obtained
and caulk it on the drive flange.
AX195
3-261
§ Cover flange-mounted surface with
AX196
§ Fasten differential carrier on the axle

housing by means of hexagon head
screws.
¡ Cover threads hexagon head screws with
sealing compound.
AX197
¡ Now, install stub shafts again and

Before the axle is put into service pay
attention to the lubrication instructions
page, page 3-282.
3-262
(Version with screwed and cast-on bearing
caps)
(1) DISASSEMBLY
¡ Remove the two stub shafts prior to
axle housing, see figure ¤ ~¤Ø.

hub, using eye bolt.
AX200
¤Ł Pull inner plate carrier along with sun

gear from the stub shaft.
AX201
¤Ø Pull stub shaft out of the axle housing,

squeeze out circlip and remove the plate
pack.
¡ This step is necessary to allow the later
installation of the inner plate carrier.
AX202
3-263
¤Œ Loosen hexagon head screws and
axle housing.
AX203
¤º Fasten the differential carrier in the

assembly jig.
Drive out the roll pin.
AX204
¤ Remove lock wire and lock plate.
AX205
¤ Loosen and remove the two adjusting

nuts.
AX206
3-264
¤ Loosen hexagon head screws and
remove bearing caps.
AX207
¤ Lift the differential assembly out of the

axle carrier.
¡ Pay attention to the released bearing
outer races.
AX208
Differential
¤ Pull off the two bearing inner races from
the housing cover, respectively differential
case.
AX209
¤Ł Mark housing cover with differential case,

loosen locking screws.
AX210
3-265
¤Ø Take all components of the multi-disk
differential case.
AX211
¤Œ Clamp the differential case half.

Loosen locking screws and separate the
crown wheel from the differential case.
AX212
Drive unit
¤ Unlock slotted nut and remove lock plate.
AX213
¤Ł Loosen slotted nut or hexagon nut

(According to the version) and remove it
along with washer.
AX214
3-266
¤Ø Pull off drive flange.
AX215
¤Œ Pry out shaft seal.
AX216
¤º Press drive flange out of the axle carrier.

roller bearing.
AX217
¤ Pull spacer from the drive pinion end.
AX218
3-267
¤ Separate the tapered roller bearing from
the drive pinion.
AX219
¤ If necessary, drive the two bearing outer

races out of the axle carrier.
AX220
(2) ASSEMBLY
renewed as a set.
4
3
c
numbers.
set or axle carrier, pay attention to the
3
b
Draft. 1
x
2
¡ The following measuring operations must
be carried out with utmost care.
renewed disassembly and assembly of
the drive pinion as well as of the
differential(Partial) after the contact
pattern is taken(Figure§ø, page3-260).
3-268
¡ Install adjusting pieces(3) and fasten the
Mount stop washer(2) and measuring
(See draft, page 3-268).
Special tools
1 = Measuring pin
2 = Stop washer
3 = Adjusting piece
4 = Measuring shaft

measuring piston and measuring shaft
with feeler gauge.
EXAMPLE ¥
Dimension a(=measuring piston)
224.00mm
Dimension b +2.50mm
Dimension c (=1/2'“measuring shaft)
+15.00mm
AX221

AX222

Pinion dimension e.g. 198-0.15 197.85mm
EXAMPLE ¥–
AX223
3-269
EXAMPLE ¥†
Difference = Shim thickness s =1.20mm
¤Œ Lay shim(According to the example s =

1.20mm) into the housing bore.
AX224
¤º Undercool bearing outer race and place it

firmly against shoulder.
AX225

AX226
3-270
pinion bearing
HK 0.15~0.31kgf m
collar.
AX227
Draft for the determination of the spacer :

1 = Measuring ring(S) 30¡£ 3¡¿
12
2 = Roll pin(Set of 3, each spaced for 0¡
£
120¡£)
2 1
X
¤ŁIf necessary(According to the version),

insert hexagon head screws into the drive
flange bores and press dust shield over
the drive flange collar.
AX228
¤Ø Insert drive pinion into the axle carrier and

assemble heated bearing inner race until
AX229
3-271
¤Œ Guide drive flange over the drive pinion
splines. Apply washer and tighten
slotted nut, respectively hexagon nut
(According to the version) until the
required rolling resistance is obtained.
¡ When tightening, make several
senses and check the rolling resistance
continuously.
AX230
¤º Loosen slotted nut, pull off drive flange

and remove pinion again.
Remove measuring ring and determine
Dimension X e.g. s =7.97mm
end. Install drive pinion again.
AX231
¤ Replace drive flange, mount washer and

¡⁄Torque limit : DK/CK 71kgf m
RK 112kgf m
HK/LK 122kgf m
¡ When tightening, make several
senses.
AX232
¤ Check rolling resistance.

AX233
3-272
¤ Remove drive flange and install shaft
seal.
¡ Pay attention to the contact.
If the outer diameter of the shaft seal is
rubber-coated, wet the sealing lip with
spirit. Otherwise use the sealing
compound Loctite. Fill the cavity
between sealing lip and dust lip with
grease.
AX234
¤ Replace drive flange.

Assemble washer and tighten slotted nut,
the version) finally.
¡⁄Torque limit : DK/CK 71kgf m
RK 112kgf m
HK/LK 122kgf m
AX235
Differential
¤ Heat crown wheel and place it against the
differential case half until contact is
obtained.
Clamp the differential case by means of
press and tighten locking screws.
admitted.
AX236
¤Ł Press the bearing inner race firmly

against shoulder.
AX237
3-273
¤Ø Lay the two thrust washers into the
¡ Mount brass washer on top with the
AX238
¤Œ Lay snap ring into the ring groove, see

arrow.
AX239
¤º Insert drive pin, see arrow.
AX240
¤ Assemble alternating outer and inner

¡ Number and installation position of outer
and inner plates, see corresponding list
of spare parts.
may be different.
AX241
3-274
¤ Replace pressure ring.
AX242

AX243
¤ insert the differential spider assembly.
AX244
¤ Replace second side gear.
AX245
3-275
¤æ Install second pressure ring and insert all
drive pins.
AX246

¡ Number and installation position of inner
and outer plates, see corresponding list
of spare parts.
AX247

¤ Differential case :
AX248
¤ Housing cover :
surface.
AX249
3-276
EXAMPLE
Dimension A 3.40mm
Dimension B -3.10mm
value should be found.
The end play is corrected by the
installation of outer plates of
corresponding thickness whilst the plate
pack thickness must be equal on both
differential sides.
¤ıMake the two thrust washers adhere with

AX250
§ Lay housing cover over the differential

case and fasten it by means of locking
screws.
¡ Pay attention to the installation position-
see markings.
Only single use of locking screws is
admitted.
AX251
§æHeat bearing inner race and position it on

the housing cover until contact is
obtained.
AX252
3-277
§ Insert 1st bearing outer race into the
housing and fix it provisionally by means
of adjusting nut.
AX253
§ Mount 2nd bearing outer race and insert

the differential assembly into the axle
carrier.
AX254
§ Fix the crown wheel side bearing outer

race by means of the second adjusting
nut provisionally.
AX255
§ı Replace bearing caps and tighten

hexagon head screws.
AX256
3-278
Adjust backlash and bearing preload
wheel.
Adjust adjusting nut on the crown wheel
side until the required backlash-see value
engraved on the crown wheel outer
diameter- is obtained.
AX257
§ Screw in adjusting nut(Opposite the

bearing is free of play. Now, tighten
adjusting nut further for 2 notches to
obtain the required bearing preload of the
differential bearing 0.3~0.4 kgf m
necessary.
¡ At this step make several revolutions of
the differential.
AX258
Determine yoke width.
Yoke width e.g. 358.00mm +0.05max.
§łApply dial indicator on the plane

face/crown wheel.
Make at least one revolution of the crown
wheel and record the run-out.
AX259
§øCover some tooth flanks of the crown

wheel with gear marking compound.
Roll the crown wheel over the drive pinion
to and fro.
Take the contact pattern and compare it
with Page "Examples of contact
patterns", page 3-283.
In case of a greater contact pattern
deviation, a spacing error has been made
during the assembly of the drive pinion,
AX260
3-279
§œ Secure adjusting nuts.
AX261
§ß Secure adjusting nut and hexagon head

screws according to the figure on the
right.
AX262
§ Tilt differential carrier.

Insert lock plate until contact is obtained
and caulk on the drive flange.
AX263
§ Cover flange-mounted surface with

AX264
3-280
¡ Now, install stub shafts again and
Before the axle is put into service, pay
attention to the lubrication instructions,
page, page 3-282.
3-281
LUBRICATION INSTRUCTIONS
The basis for a correct lubrication of all axles and their parts is a horizontal plane of installation in
every direction. (An inclined position of the differential carrier up to 5¡£is tolerable).
Place the machine in a horizontal position. All lubricating points must be cleaned carefully before
refilling.
Drain oil only immediately after a longer run.
Oil level ..
1. Wheel end : Turn wheel hubs until the word "Olstand" can be read in a horizontal position. Fill
6) EXAMPLES OF CONTACT PATTERNS FOR THE GLEASON GEAR-TOOTH SYSTEM
(1) Coast side(Concave)
(2) Drive side(Convex)
3-283

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 four 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.
The brake system contains the following components:
・Brake pump
・Parking brake solenoid valve
・Cut off valve
・Brake valve
・Accumulators
・Pressure switches
4-1
FULL POWER HYDRAULIC BRAKE
SYSTEM
ADVANTAGES - The full power hydraulic Response time
brake system has several advantages over Full power brake actuation VS
Air/Hydraulic brake actuation
traditional brake actuation systems. These
systems are capable of supplying fluid to a 1000
range of very small and large volume
service brakes with actuation that is faster 900
than air brake systems. Figure represents 800
a time comparison between a typical Brake pressure
700 (Full power)
Brake torque(lb・in)
air/hydraulic and full power hydraulic brake
actuation system. 600
Brake pressure
Full power systems can supply significantly 500 (Air/hydraulic)
higher brake pressures with relatively low Brake torque
400
reactive pedal forces. The reactive pedal (Air/hydraulic)
force felt by the operator will be proportional 300
Brake torque
to the brake line pressure being generated. 200 (Full power)
This is referred to as brake pressure
modulation. 100
Another key design feature of full power
0 1 2 3 4
systems is the ability to control maximum
brake line pressure. In addition, because Time(Seconds)
these systems operate with hydraulic oil,
filtration can be utilized to provide long
component life and low maintenance
operation.
Because these systems are closed center,
by using a properly sized accumulator,
emergency power-off braking that is
identical to power-on braking can be
achieved. These systems can be either
dedicated, where the brake system pump
supplies only the demands of the brake
system or non-dedicated, where the pump
supplies the demands of the brake system
as well as some secondary down stream
hydraulic devise.
Another important note is that all seals
within these system must be compatible
with the fluid medium being used.
4-2
2. HYDRAULIC CIRCUIT
FRONT 28 REAR
19 29
17
20
8 2.4 2.1 2.5 2.2
5.1 1.1 5.2 1.2
A
16
15 15 P T
15
21 22 23
7
15
27
28
Steering system
18
1
MCV RCV Lever

Return line
5
21
2 1
Return line
23
24
25
26 27 22
1 Steering pump 18 Pressure switch 25 Hydraulic oil tank

2 Main pump 19 Pressure switch 26 Return filter
7 Cut off valve 20 Pressure switch 27 Bypass valve
8 Brake valve 21 Line filter 28 Axle
15 Accumulator 22 Oil cooler 29 Parking brake
16 Parking brake solenoid valve 23 Check valve
17 Pressure switch 24 Air breather
4-3
1) SERVICE BRAKE RELEASED
FRONT 28 REAR
19
17
20
8 2.4 2.1 2.5 2.2
5.1 1.1 5.2 1.2
A
16
15 15 P T
15
21 22 23
7
15
27
28
Steering system
18
1
MCV RCV Lever

Return line
5
21
2 1
Return line
23
24
25
26 27 22
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 exhaust port is opened and the hydraulic oil in the piston of axles
return to the tank(25).
Therefore, the service brake is kept released.
4-4
2) SERVICE BRAKE OPERATED
FRONT REAR
19
17
20
2.4 2.1 2.5 2.2
8
1.1 5.1 1.2 5.2
A
16
15 15 P T
15
21 22 23
7
15
27
28
Steering system
18
1
MCV RCV Lever
Return line
5
21
2 1
Return line
23
24
25
26 27 22
When the pedal of brake valve(8) is depressed, the operating force overcomes the force of the
spring, and is transmitted to the spool. When the spool moves down, the inlet port is opened, and
at the same time the hydraulic oil controlled the pressure level by the cut off valve(7) enters the
piston in the front and rear axles. Therefore, the service brake is applied.
4-5
3) PARKING BRAKE RELEASED
FRONT 28 REAR
19 29
17
20
8 2.4 2.1 2.5 2.2
5.1 1.1 5.2 1.2
A
16
15 15 P T
15
21 22 23
7
15
27
28
Steering system
18
1
MCV RCV Lever

Return line
5
21
2 1
Return line
23
24
25
26 27 22
When the parking brake switch is pushed, the solenoid valve(16) is energized and the hydraulic oil
controlled the pressure level by the cut off valve(7) enters the parking brake(29). It overcomes the
force of the spring and pushes the piston. This releases the brake.
Therefore, the hydraulic oil pressure is applied to the parking brake piston through the solenoid
valve(16) and the parking brake(29) is kept released.
4-6
4) PARKING BRAKE OPERATED
FRONT 28 REAR
19 29
17
20
8 2.4 2.1 2.5 2.2
5.1 1.1 5.2 1.2
A
16
15 15 P T
15
21 22 23
7
15
27
28
Steering system
18
1
MCV RCV Lever

Return line
5
21
2 1
Return line
23
24
25
26 27 22
When the parking brake switch is pushed once more, the solenoid valve(16) is deenergized and the
valve open the exhaust port.
At the same time, the hydraulic oil in the parking brake(29) return to the tank through the solenoid
valve(16). When the piston is returned by the force of the spring, the parking brake is applied.
4-7
3. BRAKE PUMP
1) STRUCTURE
2 4-12 4-11 4-13 4-8
1 4-10 4-6 4-5 4-7 4-3 4-2
1 Cap screw 4-4 Dowel pin 4-9 Dowel pin

2 End cap 4-5 Cam ring 4-10 Pressure plate
4-2 Lock pin 4-6 Vane 4-11 Seal
4-3 Port plate 4-7 Vane holdout pin 4-12 Seal
4-8 Rotor assy 4-13 Back up ring
2) OPERATION
The pumping operation of this unit(each cartridge) is obtained by providing a fixed interior cam
surface and a rotating inner member(rotor) containing vanes which held in contact with the inner
cam surface. As the rotor is rotated by the drive shaft, the vanes are urged outward against the
outward sloping cam surface, forming a cavity at the inlet ports of the port plates. Atmospheric
pressure and suction created by the expanding cavity between the rotating vanes fill the inlet cavity
with fluid.
As the rotation continues and the vanes that had previously moved outward and now have fluid
trapped between them and the port plates, follow the inward slope of the cam which decreases the
cavity containing the trapped fluid and discharges the fluid at system pressure through the pressure
port openings in the port plates.
The rotating portion of the unitized cartridges feature the use of pressure actuated vanes which are
urged against the cam ring by pins located in the bottom of each rotor vane slot. Initial force to
bring the vanes in contact with the cam ring contour during start up is provided by centrifugal force.
When pumping operation starts and pressure is established, fluid under pressure fills the pin cavity
through the feed holes.
The feed holes open to the pressure port twice every revolution. All other times they are closed off
by the port plate. This pressure under the pin provides the force necessary to keep the vanes in
contact with the cam countour.
3) DISASSEMBLY AND ASSEMBLY : SEE page 6-60.
4-8
4. BRAKE VALVE
1) STRUCTURE
13,15
11
12
7
8,9
10,14
37
6
5
3 2
1
4 17
19 36
20 18
24
21
23
25
27 28
26 30
29
31
32
33
34
35
1 Base plate 13 Rivet 27 Ring

2 Bushing 14 Pin 28 Spool
3 Nut 15 Pedal cover 29 Retainer
4 Screw 17 Guide pin 30 Spring
5 Piston 18 Spring 31 Spool
6 Bellows 19 Washer 32 Spring
7 Pin 20 Cap 33 Snap ring
8 Bracket 21 Spring 34 Washer
9 Bracket 23 Cap 35 Plug
10 Retaining ring 24 Ball 36 Bolt
11 Plate 25 Spring 37 Bolt
12 Pedal 26 Housing
4-9
2) OPERATION
Set of springs
Upper spool
5.1
2.4 2.1
1.1
Lower spool
5.2
2.5 2.2
1.2
Leading edges
2.4
5.1
1.1 2.1
2.5
5.2
1.2 2.2
4-10
(1) Purpose
The purpose of the brake valve is to sensitively increase and decrease the braking pressure when
the brake pedal is actuated.
(2) Ready position
When the braking system is ready for operation, its accumulator pressure acts directly on ports
(1.1, 1.2) of the brake valve. A connection is established between ports(2.1, 2.2) and ports(5.1,
5.2) so that the wheel brakes ports(2.1, 2.2) are pressureless via the returns ports(5.1, 5.2).
(3) Partial braking
When the brake valve is actuated, an amount of hydraulic pressure is output as a ratio of the foot
force applied.
The spring assembly(21) beneath base plate(1) 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(28) is mechanically actuated via
spring assembly(21), and the lower spool(31) is actuated hydraulically by spool(28). As spools
(28 and 31) move downward, they will first close returns(5.1, 5.2) via the control edges, thus
establishing a connection between accumulator ports(1.1, 1.2) and ports(2.1, 2.2) for the wheel
brake cylinders. The foot force applied now determines the output braking pressure. The control
spools(28 and 31) 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(28 and 31) are in a partial braking position, causing
ports(1.1, 1.2) and(5.1, 5.2) to close and holding the pressure in ports(2.1, 2.2).
(4) Full braking position
When pedal(12) is fully actuated, end end position of the brakes is reached and a connection
established between accumulator ports(1.1, 1.2) and brake cylinder ports(2.1, 2.2). Returns (5.1,
5.2) are closed at this point.
When the braking process is ended, a connection is once again established between brake
cylinder ports(2.1, 2.2) and return ports(5.1, 5.2), closing accumulator ports(1.1, 1.2).
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(37) on base plate(1) below pedal(12) 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
(21) will mechanically actuate spool(28). In the event of the upper circuit failing, the lower circuit
will remain operational since the lower spool(31) is mechanically actuated by spring assembly(21)
and spool(28).
(7) Installation requirements
Return lines(5.1, 5.2) must be connected directly to the tank.
The connecting lines must be installed is such a way as to permit proper bleeding.
4-11
(8) Maintenance of the brake valve
No special maintenance beyond the legal requirements is necessary.
When using high-pressure cleaners on the machine, please make sure that the water jet is not
aimed directly at the brake valve(To prevent damaging the bellows).
For safety reasons the whole of the brake valve must be replaced if parts other than those
listed above are damaged.
(9) Repair work
When working on the braking system, always make sure that there is absolutely no
pressure in the system. Even when the engine is switched off there will be some residual
pressure in the system.
※ When doing repair work, make sure your environment is very clean.
Immediately close all open ports on the components and on pipes using plugs.
(10) Replacing the pedal cover
Pedal cover(15) is simply pulled of by hand. The new pedal cover is pushed over pedal(12) and
tightened manually. Fasten the bellows with the strap retainers.
(11) Replacing the complete actuating mechanism
Carefully clamp the unit vertically in a fixture. The actuating mechanism can be removed by
taking out the four bolts(36) below base plate(1). Make sure that spring assembly (21) does not
fall out. When installing the new actuating mechanism, make sure that spring assembly (21) is
fitted in the right order. Tighten the four bolts(36).
(12) Replacing the bellows
To change bellows(6) it is advisable to remove pedal(12). For this purpose, loosen retaining ring
(10) and knock out pin(14) 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(12) and bellows(6).
Now fit the new bellows(6) and proceed in reverse order as described above. The upper portion
of bellows(6) is fastened to piston(5), its lower portion to base plate(1) secure the bellows using
clamps.
(13) Replacing the grooved ring
Carefully clamp the unit vertically in a fixture. Unscrew plug(35) and pull spool(28 and 31) out
downwards. Check the spools for damage. If they are found to be damaged, the whole brake
valve needs to be replaced(Pairs of spools and housings are matched in manufacturing).
If the spools are not damaged in any way, remove the whole actuating mechanism as described
above. Remove spring assembly(21) and grooved ring(27) and put in a new greased grooved
ring with its lips pointing downwards. Install both the spring assembly as shown in the drawing,
and the pedal. Put in spring(30), followed by spool(31), using a slight turning motion if possible.
Insert spring(32) and close the unit with screw plug(35).
Check return ports(5.1, 5.2) to see if there is a gap of approx. 2mm between the lower edged of
the hole and the control edge of spool(28). If this is not the case, take out screw plug(35) once
more and change the setting by removing or adding distance washers(19) in the upper spring
plate. Replace the screw plug and once again check the distance between the lower edge of the
hole at ports(5.1, 5.2) and the control edge of spool(28).
4-12
5. CUT OFF VALVE
1) STRUCTURE
1 35 37 36 38 30 3 2 5 6 4 34 7
31
32
23
33
21
16 15 14 20 21
VIEW A
1 Housing 15 Washer 33 Spool

2 Spool 16 Screw plug 34 Nut
3 O-ring 20 Shuttle valve 35 Ball
4 Back up ring 21 Retaining ring 36 Spring
5 Cap 23 Spring 37 Washer
6 Spring 30 Screw 38 Plug
7 Pipe 31 Ball
14 Return valve 32 Plug
4-13
2) OPERATION
E1 E2
27
F 21 22 23
5
28
27
1 28
5
21
Item Spec
Cut-in pressure 120+10kgf/cm2

22
cut off pressure 150-10kgf/cm2
Flow rate 45ℓ/min
Flow rate to the brake circuits 3+1ℓ/min
23 Max pressure at port 5 Max 200kgf/cm2
Temperature of medium -30 ~ +80°
C
Ambient temperature -30 ~ +80°
C
VIEW A Medium Mineral oil
Torque M12×1.5 2.9±0.31kg・m
M16×1.5 4.1±0.51kg・m
M18×1.5 5.1±0.51kg・m
4-14
(1) Purpose
The purpose of the cut off valve is to control the pressure level in the accumulators.
The cut off valve must keep the pressure level of the brake accumulators between 120 kgf/cm2 and
150kgf/cm2. This is obtained by a switching mechanism which pressurizes the braking system
again to approx. 150kgf/cm2, only if the pressure has dropped to less than 120kgf/cm2.
(2) Ready position
When the braking system is ready for operation(i.e. the accumulators are charged) the pump
stream is present at port 1 of the cut off valve. A connection is established between ports 1 and 5
so that the pump stream is, with a small difference in pressures, returned directly to the reservoir.
The rear of main spool(33) is pressureless. The pressure within the braking system will hold
control spool(2) in its locked position(E1) in which the rear of main spool(33) is directly connected
to return 5 via hole(G). Check valve(14) in the hole to port 27 secures the accumulator pressure
of the operating accumulator. This is available as an additional braking volume for the braking
system, preventing excessively frequent actuation of the cut off valve in the event of a leakage.
Shuttle valves(20) additionally secure each braking circuit against pressure looses in the event of
a broken pipe.
(3) Charging process
As the accumulator pressure falls to the preset value, control spool(2) will, through the force of
spring assembly(6), overcome its locked position(E1) and move to another locked position(E2).
Via orifice(F) and oil stream flows to the rear of main spool(33). The pressure building up at the
rear of main spool(33) and the pressure present below main spool(33) put main spool(33) in a
floating position, permitting a partial stream to continue to reach port 5 and the remaining stream
to flow to ports(21, 22, 23) via check valve(14) until the pressure within the braking system is
approx. 150kgf/cm2. Control spool(2) will then once again move to locked position(E1) in which a
connection is established between ports 1 and 5. The whole of the pump stream once again
flows to the reservoir via port 5. Check valve(14) again secures the accumulator pressures.
The connecting line must be installed in such a way as to permit proper bleeding. The double
check valve can be mounted in any position.
(5) Maintenance of the cut off valve
(6) Repair work
※ When doing repair wok, make sure your environment is very clean.
※ For safety reasons the whole of the cut off valve must be replaced if damaged.
4-15
6. BRAKE ACCUMULATOR
1) STRUCTURE
81L1-0004
Item
(Item15)
Diameter 136mm
Mounting height 160mm
Norminal volume 1.0m3
Priming pressure 50kgf/cm2
Operating medium Oil
B
Operating pressure Max 200kgf/cm2
Thread M18×1.5
A
Operating
C -30 ~ 80°
C
temperature range
Priming gas Nitrogen
D
A Fluid portion C Diaphragm
B Gas portion D Valve disk
2) OPERATION
(1) Purpose
Fluids are practically incompressible and are thus incapable of accumulating pressure energy. In
hydropneumatic accumulators, the compressibility of a gas is utilized to accumulate fluid. The
compressible medium used in the accumulators is nitrogen.
In braking systems, the purpose of the accumulators is to store the energy supplied by the
hydraulic pump. They are also used as an energy reserve when the pump is not working, as a
compensator for any losses through leakage, and as oscillation dampers.
(2) Operation
The accumulator consists of a fluid portion(A) and a gas portion(B) with a diaphragm(C) as a gas-
tight dividing element. The fluid portion(A) is connected to the hydraulic circuit, causing the
diaphragm accumulator to be filled and the gas volume to be compressed as the pressure rises.
When the pressure falls, the compressed gas volume will expand, thus displacing the
accumulated pressure fluid into the circuit.
The diaphragm bottom contains a valve disk(D) which, if the diaphragm accumulator is
completely empty, closes the hydraulic outlet, thus preventing damage to the diaphragm.
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.
4-16
(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.
The amount of initial gas pressure can also be checked from the vehicle. Start the vehicle's
engine. The pump will now supply oil to the accumulators. Until the initial gas pressure is
reached, the hydraulic pressure in the accumulator will rise abruptly. This is apparent from the
gauge in the cab. If the initial gas pressure is more than 30% below the prescribed value, that
initial pressure lies outside the permissible range for at least one of the accumulators fitted in the
vehicle. This accumulator can be traced only by using the method described above, i.e. all
accumulators have to be individually tested. The accumulator whose initial gas pressure is
insufficient must be replaced and scrapped following the instruction under Disposal of the
accumulator.
Accumulator M
Safety valve
A
4-17
(7) Repair work
pressure in the system. Even when the engine in switched off there will be some residual
For safety reasons the accumulators need to be replaced as a whole if damaged.
4-18
7. PRESSURE SWITCHES
1) STRUCTURE
・Normally closed
H1
・Normally open
H2
・ Technical data
H1 H2 Adjusting range Adjusting pressure Voltage
Item Type Medium G mm mm kg/cm2 kg/cm2 V
Parking NC Oil M12×1.5 55 9 20 ~ 50 21 ± 2 Max 42

Charging NC Oil M12×1.5 55 9 50 ~ 150 100 ± 10 Max 42
Brake stop NO Oil M12×1 43 9 3~6 3~6 Max 42
Clutch cut off NO Oil PF 1/4" 55 9 20 ~ 50 24 ± 2 Max 42
NC : Normally closed NO : Normally open
4-19
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.
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
※ For safety reasons the pressure switch needs to be replaced as a whole if damaged.
4-20
(7) Adjusting and testing pressure switch
The adjusting screw located between the two contact plugs can be set to the desired value within
a certain range. For adjusting range, please refer to the table Technical data on the previous
page.
After making the adjustment, the adjusting screw should be secured using wax or a similar
material.
(-)
Screw
(+)
4-21
8. PARKING BRAKE
2 5 7
11
1 4 3 8 10 6 9
1 Brake settle 5 Spring pack 9 Ring

2 Vent valve 6 Piston 10 Chamber
3 Brake lining carrier 7 Set screw 11 Counter nut
4 Brake lining carrier 8 Pressure piece
4-22
1. OPERATIONAL CHECKS
This procedure is designed so the mechanic can make a quick check of the system using a minimum
amount of diagnostic equipment. If you need additional information, read structure and function,
Group 1.
If verification is needed, you will be given next best source of information:
Chapter 2 : Troubleshooting
Group 3 : Tests and adjustments
4-23
※Hydraulic oil must be at operating temperature for these checks(Refer to page 6-48).
Parking brake capacity Start engine. OK

check 20 30 Check completed.
km/h 20 Fasten seat belt.
Seat belt must be worn 10
10
40
NOT OK
while doing this check to 0 MPH 30 Release parking brake and put
0 50 Inspect parking brake. Go
prevent possible injury VDO
transmission in 2nd gear forward.
to group 3.
when machine stops
Drive machine at 8 km/hr and
suddenly.
switch parking brake ON.
LOOK/FEEL : Machine must
come to a stop within 2 meters(6
feet) when parking brake is
engaged at 8 km/hr.
Transmission must shift to neutral.
Parking brake Turn parking brake to ON. OK

transmission lockout Check completed.
Place transmission in 2nd forward.
check
NOT OK
Engine running. Slowly increase engine speed to
Go to transmission control
high idle.
circuit in section 3.
LOOK : Machine must not move.
1
F
3
2 N
4
R
4-24
Service brake pump Stop engine. OK

flow check Check completed.
Operate brake pedal approximately 20
※ Hydraulic oil must be at
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 Install a cap on line
out in less than 4 seconds from connected to inlet of
time engine starts. pressure reducing valve
and repeat pump flow
NOTE : Indicator will not come on
check.
approximately 1 second after
starting engine. If time does not decrease,
check for worn brake
pump. Go to brake pump
flow test, in section 3.
Service brake capacity Turn clutch cut-off switch OFF. OK

check Check completed.
Apply service brakes, release park
Engine running.
brake and put transmission in 2nd NOT OK
forward. Check brake pressure in
group 3.
Increase engine speed to high
idle. IF OK
Inspect brake disk, see
LOOK : Machine may not move
group 3.
or move at a very slow speed.
Repeat check three times to
ensure accurate results.
4-25
Brake accumulator Start and run engine for 30 OK

precharge check seconds. Check completed.
※ The axles and
Stop engine and turn key switch to NOT OK
hydraulic oil must be at
ON and wait 5 seconds. Make sure brake pedal is
operating temperature
not binding and keeping
for this check. NOTE : Engine oil pressure lamp
brakes partially engaged.
will be on due to no engine oil
pressure. Bleed brakes in group 3.
Count the number of times the Check brake system
brake pedal can be fully depressed pressure in group 3.
before the low brake pressure
NOT OK
warning lamp comes ON.
If light comes on with
LOOK : Warning lamp must come engine running,
on in 1-5 applications. accumulator has lost it's
charge. Inspect and
Start engine and operate at low
recharge accumulator,
idle.
group 3.
Observe monitor 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 key switch to ON and wait 5 indicated with brakes
seconds. released, check leakage
at accumulator inlet check
LOOK : Brake oil pressure
valve and brake valve. If
warning lamp must not come on
brake leakage is indicated
within 2 minutes after stopping
with brakes applied, check
engine.
for leakage at brake valve
and brake pistons.
Check individual
component leakage.
4-26
Service brake pedal 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. Inspect
LISTEN/FEEL : A hissing noise
clutch cut off linkage.
must be heard when pedal is
depressed.
Service and parking Position machine on gradual OK

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

position. Check completed.
Release parking brake. NOT OK
Adjust clutch cut off
Run engine at half speed in 1st
switch, see group 3.
forward.
Firmly depress brake pedal.
FEEL : Transmission must
disengage when brake pedal is
depressed at 30% of pedal stroke.
NOTE : Clutch cut off pressure
switch can be adjusted to operator
preference to match your loading
needs.
4-27
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.
Wrong oil in hub. Drain and refill.
Aggressive brakes Internal restriction in circuit. Remove lines and components.

Clutch cut off switch out of Adjust switch.
adjustment.
Brake valve malfunction. Disassemble and inspect.
Low oil level. Check oil level.
Brakes drag Brake pedal not returning Inspect floor mat and pedal.
properly.
Debris holding valve partially Do brake valve pressure test.
open in brake valve.
Stuck brake piston. Repair.
Wrong oil in hub. Drain and refill.
Brakes lock up Brake valve malfunction. Clean or replace brake valve.
4-28
Brakes chatter Air in brake system. Do brake bleed procedure.

Worn brake surface material. Inspect brake surface material.
Wrong oil in differential. Drain. Refill.
Hissing noise when Leakage in brake valve, or Do brake system leakage test.
brake pedal is held with brake piston.
engine stopped
Brake pressure warning Malfunction in brake low Replace switch.

light will not go out or pressure warning switch.
stays on excessively
Brake accumulator pressure Recharge accumulator.
long after start-up
too low.
Low brake pump standby 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.
4-29
2) PARKING BRAKE MALFUNCTIONS
Brake will not hold Pads not adjusted correctly. Adjust parking brake.
Malfunctioning parking brake Inspect and replace.
solenoid.
Worn brake pads. Disassemble, inspect, repair.
Brake piston hangs up in bore. Remove and inspect. Repair.
Brake disk overheats Pads out of adjustment. Adjust parking brake.

Brake not released. Release parking brake.
Disassemble, inspect brake.
Repair if necessary.
Inspect for loosen or broken lines between brake
pressure switch and indicator on dash.
Parking brake indicator Faulty wiring or switch. Inspect for loose or broken lines between brake
in monitor does not pressure switch and indicator on dash.
come on when brake Inspect for a faulty indicator on dash. Replace if
applied necessary.
Brake will not apply Pads out of adjustment. Adjust parking brake.
Malfunctioning wiring, switch, Check electric circuit.
or solenoid.
Restriction between brake Remove hose and inspect. Replace.
valve and brake.
Brake will not release Brake pressure too low. Adjust brake pressure.
Malfunctioning parking brake Inspect and replace.
solenoid.
Pads out of adjustment. Adjust parking brake.
4-30
1. PARKING BRAKE PERFORMANCE

1) MEASUREMENT CONDITION
(1) Tire inflation pressure : Specified pressure
(2) Road surface : Flat, dry, paved surface
with 1/5(11°
20') gradient.
(3) Machine : In operating condition 20%

gradient 11°
20'
Item Standard valve
Parking brake Keep machine on 20%

performance (11°
20') gradient
2) MEASURING PROCEDURE
(1) Start the engine and drive the machine
straight up a 1/5 gradient with the bucket
unloaded.
(2) Depress the service brake, place the gear
selector lever in neutral, then stop the
engine.
(3) Turn the parking brake switch ON, then 20%
slowly release the service brake pedal 11°
20' gradient
and the machine must be kept stopped.
※ The measurement must be made with
the machine facing either up or down
the slope.
2. EXTERNAL BRAKE INSPECTION

Inspect for wear of brake lining carrier.
Adjust the gap(A) 2mm by adjust screw.
Brake disc
Screw
4-31
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. B
Search for leaks with a piece of
cardboard. Protect hands and body from
high pressure 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.
Doctors unfamiliar with this type of injury
should reference a knowledgeable
medical source.
A
Two people are required to bleed brake
system oil, one to operate brake valve and
other to open and close bleed screws.
1) Install frame locking bar. Engage parking
brake.
2) Put a clear plastic tube on bleed screw(B)
to route low to hydraulic 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.
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
Frame locking bar
air. Release brake pedal.
6) Repeat steps 1)~5) for each bleed screw.
7) Push either brake pedal and hold down.
8) Check hydraulic oil level.
4-32

1. OUTLINE
HYD TANK
HYD TANK
The steering system of this machine is a dynamic load sensing steering system.
This system offers faster response from the priority valve of flow amplifier(2) and the pump. Also if
offers advantages in connection with cold start up and improvements in system stability.
The components of the steering system are :
・Steering pump(1)
・Flow amplifier(2)
・Steering unit(3)
・Steering cylinders(4)
The flow amplifier(2) contain a directional valve, an amplification stage, a priority valve, a pilot
pressure relief valve and shock and suction valve.
The steering pump(1), draws hydraulic oil from the hydraulic oil tank.
Outlet flow from the steering pump(1) flows to the priority valve of flow amplifier(2). The priority valve
of flow amplifier preferentially supplies flow, on demand, to the steering unit(3). When the machine is
steered, the steering unit routes flow to the steering cylinders(4) to articulate the machine.
When the machine is not being steered, or if pump flow is greater than steering flow, the priority valve
supplies flow to the loader system.
That is, output flow from the steering pump enters into the main pump for the operation of the
attachment.
5-1
LH RH
6 CL CR
L R
J
P
EF
T
PP
D K 21Mpa
HP LS HT
L R
G MCV
5
RCV lever
Return line
P T LS
Brake system
2 1
Return line
24
23
25
26 27 22
Emergency steering system
1 Steering pump 9 Steering cylinder 25 Hydraulic tank

2 Main pump 22 Oil cooler 26 Return filter
5 Steering unit 23 Check valve 27 Check valve
6 Flow amplifier 24 Air breather
5-2
1) NEUTRAL
LH RH
6 CL CR
L R
J
P
EF
T
PP
D K 21Mpa
HP LS HT
L R
G MCV
5
RCV lever
Return line
P T LS
Brake system
2 1
Return line
24
23
25
26 27 22
・ The steering wheel is not being operated so control spool(G) does not move.
・ The oil from the steering pump(A) enters port HP of the priority valve of flow amplifier and the inlet
pressure oil moves the spool(D) to the right.
・ Almost all of pump flow goes to the loader system(main control valve) through the EF port and
partly flows into the hydraulic tank(25) through the control spool(D).
・ This small flow is useful to prevent the thermal shock problem of the steering unit(5).
5-3
2) LEFT TURN
LH RH
6 CL CR
L R
EF
T
PP
D K 21Mpa
HP LS HT
L R
MCV
G
RCV lever
5
Return line
P T LS
Brake system
2 1
Return line
24
23
25
26 27 22
・ When the steering wheel is turned to the left, the spool(G) within steering unit(5) connected with
steering column shaft is pushed to the right direction.
・ The oil discharged from the steering pump(1) flows into HP port of flow amplifier(6).
・ The delivered oil passes through the priority valve spool (D) of flow amplifier(6), through the main
orifice of steering unit(5). The position of priority spool(D) is determined when the pressure
difference between front and rear of main orifice is balanced with control spring(K) force.
・ The oil supplied through the directional spool(J) from the steering unit(5) is combined with the direct
oil from the priority valve spool(D) in the amplifier spool(M). The amplified oil flows into the small
chamber of the left steering cylinder and large chamber of the right steering cylinder respectively.
・ Oil returned from left and right cylinder returns to hydraulic tank through directional spool(J) of flow
amplifier(6).
・ When the above operation is completed, the machine turns to the left.
5-4
3) RIGHT TURN
LH RH
6 CL CR
L R
EF
T
PP
D K 21Mpa
HP LS HT
L R
MCV
G
RCV lever
5
Return line
P T LS
Brake system
2 1
Return line
24
23
25
26 27 22
・ When the steering wheel is turned to the right, the spool(G) within steering unit(5) connected with
steering column shaft is pushed to the left direction.
・ The oil discharged from the steering pump(1) flows into HP port of flow amplifier(6).
・ The delivered oil passes through the priority valve spool (D) of flow amplifier(6), through the main
orifice of steering unit(5). The position of priority spool(D) is determined when the pressure
difference between front and rear of main orifice is balanced with control spring(K) force.
・ The oil supplied through the directional spool(J) from the steering unit(5) is combined with the direct
oil from the priority valve spool(D) in the amplifier spool(M). The amplified oil flows into the small
chamber of the right steering cylinder and large chamber of the left steering cylinder respectively.
・ Oil returned from left and right cylinder returns to hydraulic tank through directional spool(J) of flow
amplifier(6).
・ When the above operation is completed, the machine turns to the right.
5-5
3. STEERING PUMP
1) STRUCTURE
1 4-1 4-14
2 4-3 4-5 4-7 4-6 3 4-13 4-11 5 7
11
6,8
4-2 4-4 4-8 4-9 4-10 4-12 10
1 Cap screw 4-6 Vane 4-14 Lock washer

2 End cap 4-7 Vane holdout pin 5 Internal snap ring
3 Seal 4-8 Rotor assy 6 External snap ring
4-1 Screw 4-9 Dowel pin 7 Ball bearing
4-2 Lock pin 4-10 Pressure plate 8 External snap ring
4-3 Port plate 4-11 Seal 9 Splined shaft
4-4 Dowel pin 4-12 Seal 10 Shaft seal
4-5 Cam ring 4-13 Back up ring 11 Mounting cap
5-6
2) DESCRIPION
The steering pump consist of four basic components : a end cap(1), a unitized cartridge(2)
consisting of ; rotor, vanes, vane holdout pins, cam ring, bearing, port plate and pressure plate, a
shaft(3) and bearing and a mounting cap(4).
The steering pump feature the use of a unitized pumping cartridge. The unitized cartridge
assembly is pretested at the factory and provides for ease and speed or disassembly and assembly
in the event it becomes necessary or desirable to make repairs, overhaul or revise the flow delivery.
3
1 2
3) OPERATION
Operation of steering pump is simple. The rotor, driven by the shaft, carries the vanes in radial
slots. The vanes follow the cam ring through their cycle, two cycles per revolution for each vane ;
suction-seal / discharge-seal. The rotor is loaded by the vanes only when they are on the major and
minor arcs of the cam contour. Diametrical balance of vanes, ports and pressures causes the rotor
the pumping action. The generous shaft bearings carry only the overhung and axial loads imposed
by the pump drive.
The inlet flow feeds through ports on both sides of the cartridge as well as through a large port
through the cam ring at each suction ramp. This improves inlet conditions ; permits wider, greater
displacement units for the diameters, and allows higher speed operation.
The vanes are held outward in a light but steady contact against the fluid film which separates them
from the cam ring. Their radial position changes to follow the cam and to adjust for fluid viscosity,
contaminants and component wear.
The rotor is separated from the side plates by the fluid film. The side plates are clamped axially by
an overbalance of the internal pressure forces in the pumping cartridge. They accommodate
dimensional changes due to temperature and pressure. The rotor and cam ring of tough, through-
hardened steel contribute to the long efficient service life.
5-7
4. FLOW AMPLIFIER
1) STRUCTURE
21 7 38 4 9C 21
16
T
HT
2 2
24
28
CR CL
34 34
23
L HP R
1 P 29
9A 1
27 13,14
1 1
8 41
40 35
10
11,12
37
22
P
9B HP EF 30
LS
15 PP 16
2
2
31
42 6 19 20 5 36
1 O-ring 12 Spring washer 28 Spring

2 O-ring 13 Screw 29 Spring
5 Washer 15 End cover 31 Throttle check valve
6 Washer 16 End cover 34 Orifice
7 O-ring 19 Relief valve 35 Orifice
8 O-ring 20 Plug 36 Orifice
9A Amplifier valve 21 Shock, suction valve 37 Plug
9B Priority valve 22 Spring seat 38 Plug
9C Directional valve 23 Spring seat 40 Spring
10 Check valve 24 Spring guide 41 Spring
11 Screw 27 Orifice 42 Orifice
5-8
2) OPERATION
(1) Introduction
The flow amplifier contain a directional valve, an amplification stage, a priority valve, a pilot
pressure relief valve and shock and suction valves.
The flow amplifier amplifies the oil flow from the steering unit cylinder ports L or R by an
amplification factor of 8. The amplified oil flow is directed from the flow amplifier ports CL or CR to
the steering cylinder. The amplified flow is proportional to the rate of the steering wheel rotation.
If the oil flow from the pump fails, the flow amplifier cuts off the amplification.
(2) Priority valve
The priority valve is used in load sensing systems where the same pump supplies oil to both
steering system and working hydraulics.
The steering system always has first priority.
The pressure on the LS connection is almost zero during measuring(Steering unit in neutral
position).
(3) Shock valves
The shock valves protect the flow amplifier against shock from external forces on the steering
cylinders. The shock valves in flow amplifier limit the maximum pressure drop from CL to HT and
from CR to HT.
(4) Suction valves
The suction valves ensure oil suction on the side of the steering cylinder pistons where in
unfavorable conditions cavitation might occur.
(5) HP-HT ports characteristic
The pilot pressure relief valve protects the steering unit against excess pressure. The pilot
pressure relief valve together with the priority valve limit the maximum steering pressure HP-HT.
5-9
(6) Neutral 9C
T
HT
CR CL
L HP R
P
HP EF LS
PP
42 9B 30
CL CR
L R
L R 9C
Steering unit
P
LS
9A
EF TO MCV
42 T
P T PP
9B 30
HP LS HT
5-10
In neutral position, the oil passes from the pump across the integrated priority valve(9B) in the flow
amplifier for discharge through the EF port. With the steering unit in neutral, flow through it is blocked
and all flow through the priority valve(9B) in flow amplifier is directed out the EF port to the main control
valve.
With the engine off, the priority valve spool(9B) is pushed to the left by the spring(30). The passage to
the EF port is blocked while the passage to the P port is open.
When the machine is first started, all pump flow is routed to the steering unit which blocks the flow.
With the flow blocked, the pressure increases.
Steering inlet pressure is supplied through the dynamic orifice(42) in the spool. This causes the priority
valve spool(9B) to shift to the right against the spring(30) and open the EF port.
As long as the steering unit is in neutral, just enough pressure is maintained at the steering unit to keep
the priority valve spool(9B) shifted to the right.
The operating pressure in the loader system has no effect on the operation of the priority valve(9B) of
flow amplifier. With the loader actuated in relief, the priority valve(9B) will not shift until the machine is
steered.
Flow through the priority valve spool(9B) passes from the P port through the orifice(42) and into the LS
port. It flows through the steering unit LS passage which is routed to return when the steering unit is in
neutral. This provides a warm-up circuit for the steering unit to prevent binding of the steering unit due
to oil temperature extremes.
In neutral position, also the directional valve(9C) is in its center position.
This means that knock and impacts from the cylinder are not transmitted to the steering unit. The flow
amplifier is thus of the non-reaction type.
5-11
(7) Mid-turn
9C
T
HT
CR CL
L HP R
P
S
C
N
A
M
HP EF LS
PP
9B 9A
CL CR
L R
L R 9C
Steering unit
P
LS
9A
EF
T
P T PP
9B
HP LS HT
5-12
If the steering wheel is turned to the left, a LS signal is passed to the priority valve(9B). The priority
valve(9B) is reversed so that more oil is passed across the P port to the steering unit for discharge
through the L port of the flow amplifier.
The directional valve(9C) is reversed through the pressure being transmitted across the boring in the
spool whereby the spool is moved the right.
The opening shall allow connection between the pilot flow and the pressure control/amplifier valve(9A).
The pilot pressure from the orifice in chamber C moves the valve to the left and passage for the pilot
flow therefore is possible out of hole F.
The main flow passes from the priority valve(9B) to the circular channel M. As the amplifier spool is
moved to the left, the passage will now be open across the holes N to the chamber S.
The spool goes to a position so that the pressure in chamber S equals the pressure in chamber C.
The passage is now open for the main flow through the priority valve(9B) across the holes A.
The main flow and pilot flow merge and is passed across the directional valve(9C) to the steering
cylinder through CL port.
The return oil passes across the directional valve(9C) to the hydraulic tank.
5-13
(8) Full turn
T
HT
CR CL
L HP R
P
HP EF LS
PP
9B T 30
CL CR
L R
L R 9C
Steering unit
P
LS
EF
TO MCV
T
P T PP
D
HP LS HT
5-14
When the machine is steered to a full turn, the frames bottom against the steering stops. To limit
steering system pressure, a relief system is built into the priority valve assembly(9B).
When the frames bottom is stopped, the pressure in the steering cylinders increases. This pressure is
sensed at the LS port. When the pressure in the LS port increases enough to push priority valve
spool(9B) off its seat, oil in the load sensing circuit flows to return through the T port. Load sensing
pressure is limited to the pressure setting of the relief valve.
Pressure to the steering unit(Pilot pressure), which is sensed at the left end of the priority valve
spool(9B) in flow amplifier, continues to increase until it can move the spool to the right against the load
sensing pressure plus spring(30) force. At this time, all oil flows out of the EF port to the loader control
valve.
If the loader attachment is being operated while steering, the loader function will slow until the machine
reaches the steering stops. At that time, the loader cycle speed will increase until the machine is
steered again.
5-15
5. STEERING UNIT
1) STRUCTURE
12 3 32
4 15 5 18,20
22,23
1 5 7 8 9 2 11 13 14 16 17 18,21
1 Dust seal ring 9 Cross pin 17 End cover

2 Housing, spool, sleeve 11 Shaft 18 Washer
3 Ball 12 Spring set 20 Pin screw
4 Bushing 13 O-ring 21 Screw
5 O-ring/Roto Glyd ring 14 Distributor plate 22 Name plate
7 Bearing assy 15 Gearwheel set 23 Drive screw
8 Ring 16 O-ring 32 Check valve
5-16
2) OPERATION
A Neutral
Steering
B
cylinder
C Anti-cavitation valves
D Load sense port to priority valve
E Gerotor
K System pressure oil

Spool I G Return L Work pressure oil
J H
G M Trapped oil
Steering shaft Sleeve F
Return
From priority valve N Return pressure oil
The steering unit consists of a spool(I) inside a sleeve(H) within a housing. When steering wheel is not
moving, the steering unit is in the neutral(A) position. In neutral, the spool and sleeve are aligned so that
oil flow through the steering unit is blocked. The steering cylinder(B) are held stationary by trapped oil in
the left and right workports.
When the steering unit is turned to the right, the spool rotates relative to the sleeve, and opens
passages which allow pump flow through the spool and sleeve assembly. Oil flows to the gerotor(E)
causing the gerotor gear to rotate. Oil flow from the gerotor flows back into the steering unit where it is
directed out the right workport to the respective ends of the steering cylinders.
A bypass orifice is machined into the spool and sleeve assembly. It is a variable orifice that introduces a
small leak into the pressure side of the steering unit. Its purpose is to dampen the initial pressure surge
when the steering wheel is partially turned. When the steering wheel is fully turned, the leak is closed
off.
Return oil flows back in through the left workport through the spool and sleeve assembly to return. The
load sensing orifice is located between the sleeve and the gerotor. This orifice feeds the load sensing
circuit between the steering unit and the priority valve of flow amplifier through the LS port.
When the rotation of the steering wheel stops, the gerotor gear continues to move, turning the sleeve,
until the sleeve stops the flow to the gerotor. At this point, the steering unit is back in the neutral position
and will remain there until the steering wheel is moved again.
The steering unit has a variable steering which is proportional to the speed the steering wheel is rotated.
A variable orifice bypasses oil around the gerotor. Turning the steering wheel slowly takes
approximately seven turn(Variable orifice small) lock to lock versus four turns(variable orifice large)
when turning the steering wheel quickly.
5-17
6. STEERING CYLINDER
1) STRUCTURE
8,9 3 10 5,6 7 11,12 4 24,25,26 2 14,15 16 17 13 19 18
1 23 20 21 22 27,28
1 Tube assy 11 O-ring 21 Pipe assy

2 Rod assy 12 Back up ring 22 O-ring
3 Gland 13 Piston 23 Bolt
4 Bushing 14 O-ring 24 U-bolt
5 Rod seal 15 Back up ring 25 Nut
6 Back up ring 16 Piston seal 26 Spring washer
7 Buffer ring 17 Wear ring 27 Spherical bearing
8 Dust wiper 18 Piston nut 28 Retaining ring
9 Snap ring 19 Screw
10 O-ring 20 Pipe assy
2) OPERATION
This machine use to cross connected cylinder for steering operation.
The steering cylinder use a gland(3) to remove piston and sealed seals. Dust wiper(8) located on
the in side of the gland protects cylinder inner parts from dust. The piston(13) is fastened to the
rod(2) by a piston nut(18).
The piston uses a single wear ring(17) with a piston seal(16) to seal between the piston(13) and
tube(1). The gland seals against the tube with two O-rings(10, 11). The rod(2) is sealed against
the gland(3) with a rod seal(5).
5-18
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.
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
5-19
※Hydraulic oil must be at operating temperature for these checks(Refer to page 6-48).
Steering unit check Run engine at low idle. OK

Check completed.
Turn steering wheel until frames are
at maximum right(A) and then NOT OK
A
left(B) positions. Go to next check.
LOOK : Frames must move
B smoothly in both directions.
When steering wheel is stopped,
frames must stop.
FEEL : Excessive effort must not
be required to turn steering wheel.
NOTE : It is normal for steering to
drift from stops when steering
wheel is released.
Steering system leakage Turn steering wheel rapidly until OK

check frames are against stop. Check completed.
Heat hydraulic oil to Left Right
Hold approximately 2kg on steering NOT OK
operating temperature.
wheel. Do steering system leakage
Run engine at high idle.
test in group 3 to isolate
Count steering wheel revolutions for
the leakage.
1 minute.
Repeat test in opposite direction.
LOOK : Steering wheel should
rotate less than 7rpm.
NOTE : Use good judgment;
Excessive steering wheel rpm does
not mean steering will be affected.
5-20
Priority valve(In flow Park machine on a hard surface. OK

amplifier) low pressure Check completed.
Hold brake pedal down.
check NOT OK
Do priority valve pressure
Steer machine to the right and left test in group 3.
as far as possible.
LOOK : Machine must turn at least
half way to the right and left stops.
Priority valve(In flow Steer to steering stop and release OK

amplifier) high pressure steering wheel. Check completed.
check Roll bucket back and hold over NOT OK
relief and observe engine rpm. Priority pressure is set too
Run engine at high idle. high. Do priority valve
Turn steering wheel to steering stop
pressure test in group 3.
and hold, observe engine rpm.
LOOK : Steering stall engine rpm
must be higher than hydraulic stall
rpm
5-21
2. TROUBLESHOOTING
※ Diagnose malfunction charts are arranged from most probable and simplest to verify, to least likely,
more difficult to verify. Remember the following steps when troubleshooting a problem :
Step 1. Operational check out procedure (See group 3 in section 1.)
Step 2. Operational checks (In this group.)
Step 4. Tests and adjustments (See group 3.)
No steering Low oil level. Add recommended oil.

Failed steering pump. Remove and inspect return filter for metal
pump particles.
Stuck priority valve spool. Remove and inspect priority valve spool.
Broken priority valve spring. Remove and inspect spring.
Relief valve in flow amplifier stuck open. Do relief cartridge leakage test in group 3.
Failed hydraulic lines. Check.
Slow or hard steering Too much friction in the mechanical parts Lubricate bearings and joints of steering
of the machine. column or repair if necessary.
Check steering column installation.
Cold oil. Warm the hydraulic oil.
Worn hydraulic pump. Do hydraulic pump performance check .
Sticking priority valve spool. Remove and inspect.
Broken priority valve spring. Remove and inspect.
Pinched or restricted LS line. Inspect line. Do flow amplifier LS port
flow test in group 3.
Constant steering to Air in system. Check for foamy oil.

maintain straight travel
Leakage in steering system. Do steering system leakage check.
Worn steering unit. Do steering unit neutral leakage test in
group 3.
Leaf spring without spring force or broken. Replace leaf springs.
Spring in double shock valve broken. Replace shock valve.
Gear wheel set worn. Replace gear wheel set.
Cylinder seized or piston seals worn. Replace defects parts.
Slow steering wheel Leakage in steering unit gerotor. Do steering system leakage check.
movement will not cause
any frame movement Worn steering unit gerotor. Do steering leakage check.
5-22
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 splines on Remove and inspect.
no resistance and causes steering unit.
no frame movement
Lack of oil in steering unit. Start engine and check steering operation.
Leakage in steering system. Do steering system leakage test in group
3.
Erratic steering Air in oil. Check for foamy oil.

Low oil level. Add recommended oil.
Sticking priority valve spool. Remove and inspect spool.
Loose cylinder piston. Remove rod to inspect piston.
Damaged steering unit. Remove and inspect.
Spongy or soft steering Air in oil. Check for foamy oil.

Low oil level. Add recommended oil.
Free play at steering Loose steering wheel nut. Tighten.

wheel
Worn or damaged splines on steering Inspect.
column or unit.
Steering unit binding or Binding in steering column or misalignment Inspect.

steering wheel does not of column.
immediately return to
High return pressure. Check for a pinched or damaged return
neutral when released
line.
Contamination in steering unit. Inspect hydraulic filter for contamination.
Repair cause of contamination. Flush
hydraulic system.
Steering unit locks up Large particles of contamination in steering Inspect hydraulic filter for contamination.
unit. Repair cause of contamination. Flush
hydraulic system.
★ Thermal shock Do flow amplifier LS port flow test in group
3. This oil flow provides a warm-up flow
to steering unit when not using the
steering.
Worn or damaged steering unit. Repair or replace steering unit.
★ Thermal stock is caused by a large temperature differential(Approx. 30° C, 50° F) between the steering unit
and hydraulic oil. If the steering is not operated for a long period of time and the orifice in the bottom of the
priority valve spool is plugged, the steering unit may bind up when the steering is operated if the hydraulic
oil is hot enough.
5-23
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
Worn or damaged steering unit. Repair or replace steering unit.
Vibration in steering High flow amplifier setting. Do flow amplifier pressure test in group 3.
system or hoses jump
Neutral position of Steering column and steering unit out of Align the steering column with steering
steering wheel cannot be line. unit.
obtained, i.e. there is a
Too little or no play between steering Adjust the play and, if necessary, shorten
tendency towards
column and steering unit input shaft. the splines journal.
"motoring"
Pinching between inner and outer spools. Contact the nearest service shop.
"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.
Steering wheel can be Oil is needed in the tank. Fill with clean oil and bleed the system.
turned the whole time
Steering cylinder worn. Replace or repair cylinder.
without the steered
wheels moving Gear wheel set worn. Replace gear wheel set.
Spacer across cardan shaft forgotten. Install spacer.
Backlash Cardan shaft fork worn or broken. Replace cardan shaft.

Leaf springs without spring force or broken. Replace leaf springs.
Worn splines on the steering column. Replace steering column.
Jerky steering LS port orifice missing. Inspect orifice.

Orifice in top end of priority valve spool Disassemble and inspect.
missing.
5-24
"Shimmy" effect Air in the steering cylinder. Bleed cylinder.

The steered wheels Find and remove the reason for air
vibrate collection.
(Rough tread on tires gives
Mechanical connections or wheel bearings Replace worn parts.
vibrations)
worn.
High priority valve setting pressure. Set pressure as regular value.
Steering wheel can be One or both shock valves are leaky or are Clean or replace defective of missing
turned slowly in one or missing in flow amplifier. valves.
both directions without
the steered wheels
turning
Steering is too slow and Insufficient oil supply to steering unit, pump Replace pump or increase number of
heavy when trying to turn defective or number of revolutions too low. revolutions.
quickly
Relief valve setting too low. Adjust valve to correct setting.
Relief valve sticking owing to dirt. Clean the valve.
Spool in flow amplifier sticking owing to Clean the valve, check that spool moves
dirt. 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
Heavy kick-back in Wrong setting of cardan shaft and gear- Correct setting as shown in Group 4.
steering wheel in both wheel set.
directions
Turning the steering Hydraulic hoses for the steering cylinders Connect lines to correct ports.
wheel activates the have been switched around.
steered wheels opposite
Hard point when starting Spring force in flow amplifier too weak. Replace spring by a stronger.
to turn the steering wheel
Air in LS and / or PP pipes. Bleed LS and PP pipes.
Clogged orifices in LS or PP side in flow Clean orifices in spool and in connecting
amplifier. plugs for LS and PP.
Oil is too thick(Cold). Let motor run until oil is warm.
Too little steering force Pump pressure too low. Correct pump pressure.
(Possibly to one side only)
Leakage at either input Shaft defective. Replace shaft seal.

shaft, end cover, gear-
Screws loose. Tighten screws as shown in Group 4.
wheel set, housing or top
part Washers or O-rings defective. Replace washer or O-rings.
5-25
Amplification too large Dirty, leaky or missing check valve(10). Clean or replace check valve.
Clean and check that the piston moves
Piston(9A) sticks in the open position.
easily.
Amplification too small Piston(9A) sticks in the closed position. Clean and check that the piston moves
easily.
Piston(9A) incorrectly installed. Rotate the piston 180°on its axis.
Heavy turning of steering Dirty orifices(34) in directional valve. Clean or replace orifice.
wheel and slow increase
Dirty orifices(35) in amplifier valve. Clean or replace orifice.
of amplification
Dirty orifice(27) in housing. Clean or replace orifice.
Dirty orifice(36) in LS port. Clean or replace orifice.
Dirty orifice in throttle check valve(31) in Clean or replace throttle check valve.
PP port.
Dirty orifice(42) in priority valve. Clean or replace orifice.
No end stop in one or One or both shock valves(21) set too low. Setting takes a long time without special
both directions equipment. Contact the nearest service
shop.
Missing spring seat(23) for directional Fit end stop plates.
valve.
"Hard" point when Air in LS and/or PP pipes. Bleed pipes.

starting to turn the
Spring(30) force in the built in priority valve Check or replace of necessary.
steering wheel
too weak.
Orifices in respectively LS or PP ports Take out and clean orifices.
blocked.
No pressure build-up LS pressure relief valve(19) adjusted too Remove plug(20) and set to specified
low. pressure.
Spool and sleeve in steering unit put Take out spool set and turn the inner spool
together incorrectly. 180°in the outer sleeve.(See Group 4)
Emergency control ball in steering unit Install new ball.
missing.
Pump does not run or is defective. Repair or replace pump.
5-26
1. HYDRAULIC OIL CLEAN UP PROCEDURE USING PORTABLE FILTER CADDY

※ SERVICE EQUIPMENT AND TOOL
・Portable filter caddy
・Two 3658mm(12ft) × 1" I.D. 100R1
hoses with 3/4 M NPT ends
・Quick disconnect fittings
・Discharge wand
・Various size fittings and hoses
※ Brake system uses oil from hydraulic oil
tank. Flush all lines in the brake and
pilot system.
Disassemble and clean major
components for brake and steering
system.
Brake and steering components may fail
if brake, steering system is not cleaned
after hydraulic oil tank contamination.
1) If hydraulic system is contaminated due to a
major component failure, remove and
disassemble steering cylinders to clean
debris from cylinders.
2) Install a new return filter element. Clean
filter housing before installing new element.
※ For a failure that creates a lot of debris,
remove access cover from hydraulic
tank. Drain and clean hydraulic tank of
fill the specified oil to hydraulic tank
through upper cover.
3) To minimize oil loss, pull a vacuum in
hydraulic 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.
5-27
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 tank is circulated
through filter a minimum of four times.
※ Hydraulic tank capacity 185ℓ ℓ (48.9U.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 tank ; Add oil if
necessary.
5-28
2. TEST TOOLS
1) CLAMP-ON ELECTRONIC TACHOMETER
INSTALLATION
・ Service equipment and tools
Tachometer
A : Clamp on tachometer.
Remove paint using emery cloth and B
D
connect to a straight section of
C
injection line within 100mm(4in) of
pump. Finger tighten only-do not over
tighten.
B : Black clip(-). Connect to main frame. A
C : Red clip(+). Connect to transducer.
D : Tachometer readout. Install cable.
2) DIGITAL THERMOMETER INSTALLATION

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

The display monitor tachometer is accurate
enough for test work.
20 30
10 km/h 20
10 40
0 MPH 30
0 50
VDO
5-29
3. STEERING SYSTEM RESTRICTION TEST
・ SPECIFICATION
Oil temperature 45±5° C(113±9°F)
Engine speed High idle
Maximum pressure 2.1MPa(21bar, 300psi)
at flow amplifier
・ GAUGE AND TOOL
Gauge 0~7MPa(0~70bar, 0~1000psi) 2EA
・ This test will check for restrictions in the
steering system which can cause
overheating of hydraulic oil.
HP
1) Install temperature reader.

(See temperature reader installation
procedure in this group)
2) Heat hydraulic oil to specifications.(See
hydraulic oil warm up procedure at page 6-
Fitting
48)
3) Comment fitting and install gauge to block.
Do not operate steering or loader
functions or test gauge may be
Steering pump
damaged.
4) Run engine at specification and read
pressure gauges.
If pressure is more than specification at the
flow amplifier, inspect flow amplifier for a
priority valve spool. Make sure orifice plugs
are installed in ends of priority valve spool.
Check for plugged orifice in flow amplifier
LS port.
5-30
4. STEERING UNIT LEAKAGE TEST
・ SPECIFICATION
Maximum leakage 7.5ℓ/min(2gpm)
Cap fitting
・ GAUGE AND TOOL
Temperature reader T
Measuring container(Approx. 20ℓ)

Stop watch
1) Install frame locking bar to prevent machine
from turning.
hydraulic oil warm up procedure at 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 1.2kg・m of force.
Measure oil flow from return hose for 1
minute.
Lock bar
6) Leakage is greater than specifications,
repair or replace steering unit.
5-31
5. FLOW AMPLIFIER PRESSURE TEST
・ SPECIFICATION
Oil pressure 20.1~21.1MPa
(205~215bar, 2900~3100psi)
・ GAUGE AND TOOL
Gauge 0~35MPa(0~350bar, 0~5000psi)
Relief valve
Temperature reader
1) Connect gauge to test port.
2) Install temperature reader.(See installation
3) Install frame locking bar.
hydraulic oil warm up procedure at page
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
reading.
If steering wheel continues to turn
rapidly with the frames locked, steering
system leakage is indicated.
6) Read pressure gauge. This is the flow
amplifier relief pressure.
7) If pressure in not to specification, remove
plug and turn adjusting screw in relief valve
using a hex head wrench to adjust
pressure.
Frame locking bar
If pressure cannot be adjusted to
specification, disassemble and inspect flow
amplifier.
5-32
6. FLOW AMPLIFIER LS PORT FLOW TEST
・ SPECIFICATION
Oil temperature 45±5° C(113±9° F)
Engine speed Low idle
LS port flow(Approx.) 1ℓ/min(0.3 gpm)
・ GAUGE AND TOOL
Temperature reader
Measuring container
Stop watch
Flow amplifier LS port flow test will check for
a plugged or missing orifice in the bottom of
LS
the priority valve spool. A plugged orifice EF B
HP
will block warm up flow to the steering unit
which can cause thermal shock.(See for an
explanation of thermal shock) PP
A missing orifice can cause the pump to be A

loaded to high pressure at all times causing
overheating.
6-48)
3) Disconnect line from LS port and install
plug(A).
4) Connect line(B) to flow amplifier.
5) Start engine and run at specification.
6) Measure flow from LS port for 1 minute.
If flow is low, low steering system neutral
pressure or a plugged orifice in bottom
priority valve spool is indicated.
If flow is high, remove priority valve spool
and inspect for a missing orifice.
Do hydraulic system restriction test in this
group.
5-33
7. FLOW AMPLIFIER RELIEF CARTRIDGE
LEAKAGE TEST
・ SPECIFICATION
A
Maximum leakage 1㎖/min(16 drops per min)
・ GAUGE AND TOOL
Temperature reader
Measuring container T
Stop watch B

6-48)
C
3) Install plug(A) in HT port.
4) Disconnect line from T port on flow
amplifier. Install plug(B) in line.
5) Connect line(C) to flow amplifier.
6) Start engine and run at specification.
7) Measure oil leakage from T port.
8) If leakage is more than specification,
disassemble and inspect cartridge for
damage or debris.
5-34
1. STEERING PUMP
1) STRUCTURE
11
10
9
6 7 8
5
2 4
4-11
4-9
4-8
4-4
1
4-2 4-12
4-13
4-10
4-7
4-5
4-3 4-6
4-1 4-14
1 Cap screw 4-5 Cam ring 4-13 Back up ring

2 End cap 4-6 vane 5 Internal snap ring
3 Seal 4-7 Vane holdout pin 6 External snap ring
4 Cartridge 4-8 Rotor assy 7 Ball bearing
4-1 Screw 4-9 Dowel pin 8 External snap ring
4-2 Lock pin 4-10 Pressure plate 9 Splined shaft
4-3 Port plate 4-11 Seal 10 Shaft seal
4-4 Dowel pin 4-12 Seal 11 Mounting cap
5-35
2) GENERAL INSTRUCTION
(1) Preliminary
※ Any servicing work done on main pump is to be done in a clean environment to prevent potential
contamination by foreign particles.
※ Appropriate tools and equipment are required in order to insure proper disassembly and
reassembly in suitable conditions. In case of repetitive service, a specific working bench is
recommended.
※ To prevent oil leakage and body tilting during assembly, housing bolts are to be tightened as per
the following pattern.
1 3 3 1
5 6
7 4
4 2 2
(2) Parts
※ Parts must be kept clean at all time. If cleaning is needed, solvent is to be used. It is needed to
check and oil the inner parts before assembly.
※ In case of replacement of parts with mulitiple numbers, such as vanes and holdout pins, all the
parts are to be changed.
① Vanes
The faces and edges should be free of scratch from contamination. Vanes should move
smoothly in the rotor slots, without excessive clearance. Edges may be stoned with a fine lndia
stone to remove burrs.
② Vane holdout pins :
Holdout pins should have no matting marks.
Vane
Rotor
Pin
③ Rotor :
Side surfaces and vane slots should be free of scratches. Side feeds, vane slots and holdout pin
orifices should be free of any contamination. Serration(driving splines) should not be deformed
by the shaft.
5-36
④ Camring :
No scratches or vane shock marks(waves) should be seen. Visual axial waves on new camring
are from grinding process and therefore normal.
⑤ Port plates :
Faces should not be scratched. No cavitation/aeration/fretting corrosion marks should be seen.
When there, the bronze bushing should be clean, with no abnormal wear sign.
Bi-directional cartridges use same port plates for CW and CCW rotation. Unit-directional
cartridges require different port plates.
⑥ Seals :
・ All oil seals must be cleaned, with no wear or cutting mark. When servicing a pump from field
operation, it is highly recommended to change all seals. All seals are to be greased lightly
before assembly.
・ Use seal driver tool to install shaft seal, and protective cone to install shaft assembly.
・ Backup rings(1) on pressure plates are to be replaced, anytime a cartridge is taken out of a
pump. Backup rings are to be installed as follow, behind the square seal :
Back up ring Seal
⑦ Shaft :
・ Key-way should be clean and not worn on the sides by excessive torque. No fretting corrosion
due to poor coupling should be visible. On spline shaft, splines should not be deformed.
・ No axial scratch should be on the sealing area(1). The shaft seal lip contact line may be visible,
but should not be a groove. Bronze-bushing contact area(2) should be clean and cylindrical,
without scratch marks.
5-37
2 4 1
・ Ball bearing(3) should turn freely and snap ring(4) should be in place. Some shaft assemblies
have 2 snap rings, before and after the ball bearing.
※ Never insert a snap ring from shaft seal side, to avoid scratching the sealing surface.
※ Use protective cone to install shaft assembly. If not available, make sure not to damaged the
shaft seal lips.
(3) Pre start check and priming.
① Before operating the pump again, the following points are to be checked :
・ Pump rotation is as per electric motor or engine.
・ All fittings are properly connected and tight. No oil-leak and/or air intake being allowed.
・ If any, valve on suction line is to be fully opened.
② When electric motor or engine is started up, the pump should prime immediately. However,
depending on installation and amount of air in the discharge lines, priming may take a few
seconds.
③ In case priming does not occur within 15 seconds, equipment should be switched off at once.
Then :
・ Manually fill the pump housing with fluid.
・ Bleed off air that may be trapped in the pump.
・ Check air bleed-off valves.
・ Start rotation in a jogging manner until a prime is picked up.
5-38
3) DISASSEMBLY
(1) Pump
2
① Securely hold the pump in a vise or
similar equipment, at front cap(11) level.
② Unscrew the housing bolts.
③ Note the porting then remove housing(2).
3
④ Remove seal(3).
11
⑤ Extact cartridge(4) carefully by using a

gear puller or by prying upward. Care
must be taken not to damage the parts.
4
(2) Camring replacement, cartridge

change of rotation 4-2
4-1
・ Camring change
① Unscrew the 2 bolts(4-1) holding the 4-3
cartridge together.
② Remove rear plate(4-3), save dowel 4-4
pin(4-4).
4-5
③ Take out camring(4-5) carefully, save
dowel pin(4-9). Leave rotor and vane in
place.
④ Install dowel pin(4-9) in pressure plate(4-
4-9
10) orifice.
※ Rotation should match the arrow in the a 4-10
port cutout(a) closest to the dowel pin.
4-13
⑤ Install new camring(4-5).
※ Arrow on the camring size should be as
per required rotation.
⑥ Install dowel pin(4-4) on camring.
5-39
⑦ Install back rear plate(4-3), then tighten
4-1 4-2
the bolts(4-1). Make sure dowel pin(4-2)
is in place.
4-3
⑧ Replace back up ring(4-13). Change
other seals if damaged. 4-4
・Change rotation 4-5

① Proceed as per above for disassembly.
② Save camring(4-5), remove rotor+vanes+pins.
※ Change of rotation requires exchange of
port plates. 4-9
③ Install carefully rotor+vanes+pins on new a 4-10
pressure plate(4-10).
4-13
④ Flip camring from previous position.
Then proceed re-assembly as per above,
with new rear plate(4-3).
(3) Shaft assembly replacement

① Remove circlip (5) from front cap (11).
② Gently tap the shaft end with a plastic
tipped hammer to extract the shaft
assembly.
10
※ Unless pump is new, when changing the
shaft assembly always install a new shaft 5
seal(10).
11
(4) Shaft seal

① Remove shaft seal(10) from front cap(11).
※ Removed shaft seal should not be re-
10
used.
It must be disposed of as per local 11
environmental regulation.
5-40
4) ASSEMBLY
(1) Pump
① Securely hold the pump in a vise or
similar equipment, at central housing(2)
level(light grip).
4
② Insert cartridge(4) carefully.
3
※ If not new, seals and backup ring are to
be replaced. 2
※ Make sure the dowel pin(4-2) is properly
inserted in the corresponding hole in the 4-2
housing(2).
③ Install new seal(3) in housing(2).
④ Insert front cap+shaft assembly(A)

straight and not tilted. Shaft should go
through the cartridge(4) smoothly.
※ When inserting cartridge in frontcap,
make sure the white teflon back-up ring A
(4-13) is not damaged and securely in
place.
⑤
4-13
Insert the assembly bolts front cap side,
then return the pump. Mount rear
adapter (not shown). 4
⑥
・ Tighten bolts to the indicated torque.
Tightening torque : 19.4kgf・m(140lbf・ft)
※
Shaft must rotate when turn by hand.
5-41
(3) Shaft seal
① Install very carefully the shaft seal(10) on
the seal driver (B).
※ Grease the seal driver seal lips(10)
※ damage
Make sure seal is mounted as per above. B
②
With the shaft seal securely installed on
the seal driver, insert the shaft seal(10) in 10
the front cap(1).
③ 1
Complete insertion using a constant
※ press load (1020kgf・m [7376lbf・ft] Max).
Do not use hammer.
(2) Shaft assembly

① Install the protective cone(A) on the shaft
end (9). Grease the protective cone
external surface.
② Apply small amount of grease on the
shaft seal lip(10).
5
③ Insert very carefully the shaft assembly
with protective cone in the front cap(11).
※ Do not damage the seal lips(10). 11
④ Complete insertion using a constant
press load on the bearing outer ring. 9
※ Do not use hammer. 10
⑤ Install circlip(5) in front cap(11). A
5-42
5) TROUBLESHOOTING

External leakage Seal failure. Replace seal.
Porosity in casting Replace casting.
Damaged or defective seal between Replace seal.
housing and mounting cap.
Leakage at fittings Cracked or damaged flange or fittings. Replace flange or fittings.
Damaged or defective flange threads. Replace flange.
Damaged or defective O-ring seal. Replace O-ring seal.
Burr on mating surfaces. Remove burr.
Loss in pump RPM under Power source too small for pump being Provide larger power source.
load used. See HP requirements for pump being
used.
Pump not delivering oil Pump does not prime. Bleed air from system.
Wrong direction on shaft rotation. Reverse direction of shaft.
Convert pump to reverse direction of
rotation. (Check rotation arrows on ident.
plate & cam ring).
Tank fluid level too low. Add fluid and check level to be certain
suction line is submerged (minimum
100mm : 4 inch).
Fluid inlet line or suction strainer clogged Clean strainer of all foreign material.
or undersized. Provide proper size strainer (should have
a capacity equal to 2×pump volume in
GPM).
Air leak in suction line. Tighten and seal connections.
Replace seals.
Fluid viscosity too heavy to pick up prime Use lighter viscosity fluid or increase
at low RPM. RPM.
Broken pump shaft or internal parts. Replace damaged parts per overhaul
instructions.
Pump not developing pre- Pump do not deliver oil (see above).
ssure
Relief valve setting too low. Reset relief valve.
Relief valve sticking open. Check for defective or malfunctioning
valve.
Free recirculation of fluid to tank being Check directional control valve for open
allowed. center or neutral position.
Check for open for pass valve.
5-43
Noisy or erratic operation Air leak at pump inlet or suction lines, or Check for air leaks by pouring system
at shaft seal due to misalignment. fluid around joints and listen for change in
sound level. Tighten as required.
Check for shaft misalignment.
Housing and mounting cap separation. Check bolts for poor torque.
Restricted or clogged inlet line or strainer. Provide larger inlet line or strainer.
Clean strainer.
Excessive pump RPM (cavitation). Provide power source that does not exc-
eed maximum pump RPM recommen-
dations.
Aeration in the fluid. Check for air bubbles in the tank correct
this situation with return flow.
Worn vanes, cam ring or port plates. Disassemble per overhaul instructions
and replace worn parts.
Worn bearings. Disassemble and replace.
Seal Failure Excesive inlet pressure. Decrease inlet pressure. Inlet pressure
must not exceed 0.7 bar (14 psi)*.
* Except for pump with S5 or HP seals. These must not exceed 7 bar [142 psi] inlet pressure.
5-44
2. FLOW AMPLIFIER
1) STRUCTURE
20
5
19
38
4
6
9
A
36
21
7 26
2
25 21
16
14 7 23
13 3 29
27 31 28
24
34
1 41 15
9C 11
35 2 12
12 9A
11 24
28
9A 29
34 22
8 23
13
14
30
10 1
40 9B
42
A 37

2 O-ring 13 Screw 29 Spring
4 O-ring 15 End cover 31 Throttle check valve
5 Washer 16 End cover 34 Orifice
6 Washer 19 Relief valve 35 Orifice
7 O-ring 20 Plug 36 Orifice
8 O-ring 21 Shock, suction valve 37 Plug
9 Housing 22 Spring seat 38 Plug
9A Amplifier valve 23 Spring seat 40 Spring
9B Priority valve 24 Spring seat 41 Spring
9C Directional valve 25 Drive screw 42 Orifice
10 Check valve 26 Name plate
11 Screw 27 Orifice
5-45
2) TOOLS
・ Guide screws : M8×1.0
・ Hook : Wire
・ Hexagon keys : 4, 5, 6, 8 and 10mm

・ Ratchet for socket spanners
・ Hex socket for external : 13, 17 & 19mm
・ Hex socket for internal : 8 & 10mm
・ Multigrip pliers
・ Ring spanner : 13mm
・ Screwdrivers : 3 and 10mm
・ Steel Mandrels : 3, 5 and 8mm
・ Torque wrench : 12.2kgf・m(88lbf・ft)
・ Magnetic rod
5-46
3) DISASSEMBLY
(1) Removing pressure relief valve
① Unscrew plug with washer (Hexagon
socket for 8mm internal hexagon).
② Screw pressure relief valve out(10mm

hexagon key).
③ Take out washer(Magnetic rod).
(2) Disassembly pressure relief valve

① Hold cartridge(Multigrip pliers) and screw
the adjustment screw out(5mm hexagon
key).
5-47
② Pressure relief valve shown disassembled.
(3) Removing end cover at PP-connection

① Unscrew screws with spring washer
using hexagon socket for 13mm external
hexagon and 10mm internal hexagon.
② Remove end cover.
③ Remove stop and 2 springs.
5-48
④ Remove spring.
⑤ Remove plate and 6 O-rings.
⑥ Remove spring guide.
(4) Removing end cover at LS-connection

① Unscrew screws with spring washer
using hexagon socket for 13mm external
hexagon and 10mm internal hexagon.
5-49
② Remove end cover.
③ Remove stop and 2 springs.
④ Remove stop and spring.
⑤ Remove plate and 4 O-rings.
5-50
⑥ Remove spring guide.
(5) Removing spools

① Remove directional spool.
② Remove amplifier spool.
③ Remove priority valve spool.
5-51
(6) Removing orifices and throttle check
valve
① Unscrew orifice in LS-connection with
6mm hexagon key.
② Unscrew throttle check valve in PP-

connection with 6mm hexagon key.
③ Unscrew orifice in housing with 4 mm

hexagon key.
(7) Removing shock valves

① Remove shock valve with screwdriver
and hexagon key.
5-52
(8) Overview of disassembled parts
① Housing and end cover with accessories.
② Spool with accessories.
(9) Disassembly of directional spool

① Unscrew orifice with 4mm hexagon key.
Use a mandrel.
② Directional spool shown disassembled.
5-53
(10) Disassembly of priority valve spool
① Unscrew plug or throttle check valve with
8mm hexagon key.
② Priority valve spool with plug for external

PP shown disassembled.
③ Priority valve spool with throttle check

valve for internal PP shown disassembled.
(11) Disassembly of amplifier spool

① Carefully remove the spring ring from the
recess with 3mm screwdriver.
※ Avoid damage to the spring ring.
5-54
② Carefully guide the spring ring back.
③ Carefully take the spring ring from the

recess and guide it back with 3mm
screwdriver.
※ Avoid damage to the spring ring.
④ Press pin out gently with finger.
⑤ Take out plug.
5-55
⑥ Take out spring.
⑦ Take out pin 3mm screwdriver.
⑧ Take out inner spool.
⑨ Unscrew check valve with hexagon

socket for 17mm external hexagon and
mandrel in the pin hole.
※ Avoid damaging the spool surface.
5-56
⑩ Unscrew orifice out of plug with 4mm
hexagon key. Use a mandrel.
⑪ Amplifier spool shown disassembled.
(12) Disassembly of check valve

① Unscrew plug with 4mm hexagon key and
hexagon socket for 17mm external
hexagon.
② Check valve shown disassembled.
5-57
(13) Disassembly of shock valve / suction
valve
① Unscrew locknut with hexagon socket for
13mm external hexagon. Use a mandrel.
※ When readjusting shock valve hold
locknut with 13mm ring spanner.
② Take out disc and spring.
③ Take off housing.
④ Unscrew pilot valve with hexagon socket

for 19mm external hexagon. Use a
mandrel.
5-58
⑤ Take out pilot valve and spring.
⑥ Take out spool.
⑦ Unscrew adjustment screw and take out

spring and ball.
⑧ Shock valve/suction valve shown

disassembled.
5-59
※ Cleaning
Clean all parts carefully with low aromatic
kerosene.
※ Inspection and replacement
Replace all gaskets and sealing washers.
Check all other parts carefully and
replace if necessary.
※ Lubrication
Before assembly, lubricate all parts with
hydraulic oil.
5-60
4) ASSEMBLY
(1) Assembly of shock valve / suction
valve
① Guide spring with cone into housing.
② Fit adjustment screw.
③ Fit spool.
④ Fit spring.
5-61
⑤ Fit pilot valve.
Remember O-ring.
⑥ Tighten with torque wrench for 19mm

external hexagon. Use a mandrel.
・Tightening torque : 2 ± 0.5kgf・m
(14.5 ± 3.6lbf・ft)
⑦ Fit housing.
⑧ Fit spring.
5-62
⑨ Fit disc.
⑩ Fit locknut.
・ Tightening torque : 1.5 ± 0.2kgf・m
(10.8 ± 1.4lbf・ft)
(2) Assembly of check valve

① Fit ball, spring and plug.
(3.6 ± 0.7lbf・ft)
(3) Assembly of amplifier spool

① Fit orifice in plug.
(3.6 ± 0.7lbf・ft)
5-63
② Fit check valve.
・ Tightening torque : 2 ± 0.3kgf・m
(14.5 ± 2.2lbf・ft)
※ Avoid damaging spool surface.
Remember O-ring.
③ Place inner spool in the correct position.
④ Guide inner spool in.
⑤ Fit pin.
5-64
⑥ Push spring ring into position. Place
spring ring into the recess with ends
facing away from pin holes.
⑦ Fit spring.
⑧ Fit plug.
⑨ Fit pin.
5-65
⑩ Push spring ring into position. Place
spring ring into the recess with ends
facing away from pin holes.
(4) Assembly of priority valve spool

① Fit plug or throttle check valve.
External PP : Plug.
Internal PP : Throttle check valve.
(7.2 ± 2.2lbf・ft)
(5) Assembly of directional spool

① Screw in orifice.
(3.6 ± 0.7lbf・ft)
(6) Installation of orifice and throttle check

valve
① Fit orifice in housing.
(3.6 ± 0.7lbf・ft)
5-66
② Fit orifice in LS - connection.
(7.2 ± 2.2lbf・ft)
③ Fit throttle check valve in PP -

connection.
(7.2 ± 2.2lbf・ft)
※ Comments on flow amplifiers with internal PP :

1. 1/4 BSP. F in PP - connection.
Fit washer and plug.
(29.7 ± 2.2lbf・ft)
2. 7/16 - 20 UNF in PP - connection.
Fit O-ring and plug.
・Tightening torque : 1.5 ± 0.5kgf・m
(10.8 ± 3.6lbf・ft)
(7) Installation of shock valves

① Guide shock valve in and secure it by
hand.
Remember O-ring.
5-67
(8) Assembly of pressure relief valve
① Guide adjustment screw, spring and cone
up into the cartridge.
② Screw the adjustment screw so far in that

the 10mm hexagon key fully engages.
(9) Installation of pressure relief valve

① Let the washer drop into the hole.
② Fit pressure relief valve.

(22.4 ± 2.2lbf・ft)
5-68
③ Fit plug with washer.
(44.1 ± 3.6lbf・ft)
(10)Installation of spools
① Fit directional spool.
Fit priority valve spool.
※ Spring control must be placed in correct
position against LS - connection.
② Fit spring.
※ Spring must be by the LS - connection.
③ Fit amplifier spool.

※ The orifice must be placed in correct
position against LS - connection.
5-69
(11) Installation of end cover at PP -
connection
① Fit spring with vaseline on amplifier spool.
※ The spring must be fitted at the PP -
connection.
② Fit spring guide with vaseline.
③ Fit large and small springs with vaseline.
④ Fit guide screws.
5-70
⑤ Fit 4 large and 2 small O-rings.
⑥ Guide plate in.
⑦ Fit stop(Thickness : 5mm) in end cover

with vaseline.
⑧ Guide end cover in.
5-71
⑨ Fit screw with spring washer.
⑩ Fit screws with spring washer.

(18.8 ± 3.6lbf・ft)
・ Tightening torque : 8.2 ± 1kgf・m
for large screw (59.3 ± 7.2lbf・ft)
(12) Installation of end cover at LS -

connection
① Fit guide screws.
Fit remote control with vaseline.
② Fit large and small springs with vaseline.
5-72
③ Guide in plate with 4 O-rings.
④ Fit stop for priority valve spool (Thickness

: 8mm) with vaseline.
⑤ Fit stop for directional spool (Thickness :

5mm) with vaseline.
⑥ Guide in end cover.
5-73
⑦ Fit large screw with spring washer.
⑧ Fit screws with spring washers.

(18.8 ± 3.6lbf・ft)
・ Tightening torque : 8.2 ± 1kgf・m
for large screw (59.3 ± 7.2lbf・ft)
⑨ Fit plastic plugs.
This completes assembly.
5-74
3. STEERING UNIT
1) STRUCTURE
1
2
5
7
32
3
4 8
2
11 12
13
14
15
16
18
15 21
16
17
18
20
1 Dust seal ring 9 Cross pin 17 End cover

2 Housing, Spool, Sleeve 11 Shaft 18 Washer
3 Ball 12 Spring set 20 Pin screw
4 Bushing 13 O-ring 21 Screw
5 O-ring/Roto glyd ring 14 Distributor plate 32 Check valve
7 Bearing assy 15 Gearwheel set
8 Ring 16 O-ring
5 - 75
2) TOOLS
(1) Holding tool.
(2) Assembly tool for O-ring and kin-ring.
(3) Assembly tool for lip seal.
(4) Assembly tool for cardan shaft.
5 - 76
(5) Assembly tool for dust seal.
(6) Torque wrench 0~7.1kgf・m

(0~54.4lbf・ft)
13mm socket spanner
6, 8mm and 12mm hexagon sockets
12mm screwdriver
2mm screwdriver
13mm ring spanner
6, 8 and 12mm hexagon socket spanners
Plastic hammer
Tweezers
5 - 77
3) TIGHTENING TORQUE AND HYDRAULIC CONNECTIONS
(1) Hydraulic connections
L: Left port
R: Right port
T: Tank
TLPR P: Pump
(2) Tightening torque

Max. tightening torque [ kgf・m(lbf・ft) ]
Screwed
connection With cutting With copper With aluminum
edge washer washer With O - ring
1/4 BSP.F 4.1(29.7) 2.0(14.5) 3.1(22.4) -

3/8 BSP.F 6.1(44.1) 2.0(14.5) 5.1(36.9) -
1/2 BSP.F 10.2(73.8) 3.1(22.4) 8.2(59.3) -
7/16-20 UNF - - - 2.0(14.5)
3/4-16 UNF - - - 6.1(44.1)
M 12×1.5 4.1(29.7) 2.0(14.5) 3.1(22.4) 2.0(14.5)
M 18×1.5 7.1(51.4) 2.0(14.5) 5.1(36.9) 5.1(36.9)
M 22×1.5 10.2(73.8) 3.1(22.4) 8.2(59.3) 7.1(51.4)
5 - 78
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).
(2) Remove the end cover, sideways.
(3) Lift the gearwheel set (With spacer if

fitted) off the unit.
Take out the two O-rings.
(4) Remove cardan shaft.
5 - 79
(5) Remove distributor plate.
(6) Screw out the threaded bush over the

check valve.
(7) Remove O-ring.
(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.
5 - 80
(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.
(10) Press out the cross pin. Use the special

screw from the end cover.
※ 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.
(11) Carefully press the spool out of the sleeve.
5 - 81
(12) Press the neutral position springs out of
their slots in the spool.
(13) Remove dust seal and O-ring.
(14) The steering unit is now completely

disassembled.
※ Cleaning
Clean all parts carefully in Shellsol K or
the like.
※ Inspection and replacement
Replace all seals and washers. Check all
parts carefully and make any
replacements necessary.
※ Lubrication
Before assembly, lubricate all parts with
hydraulic oil.
5 - 82
5) ASSEMBLY
(1) Assemble spool and sleeve.
※ When assembling spool and sleeve only
one of two possible ways of positioning
the spring slots is correct. There are three
slots in the spool and three holes in the
sleeve in the end of the spool / sleeve
opposite to the end with spring slots.
Place the slots and holes opposite each
other so that parts of the holes in the
sleeve are visible through the slots in the
spool.
(2) Place the two flat neutral position springs

in the slot.
Place the curved springs between the flat
ones and press them into place (See
assembly pattern).
※ Assembly pattern
・ Weak springs (Blue)
2 - off flat, blue : Part no. 150-0748
2 - off curved, blue : Part no. 150-0749
・ Blue set
Spare set : Part no. 150-4265
(3) Line up the spring set.
5 - 83
(4) Guide the spool into the sleeve. Make
sure that spool and sleeve are placed
correctly in relation to each other (See
page 5-83, No.(1)).
(5) Press the springs together and push the

neutral position springs into place in the
sleeve.
(6) Line up the springs and center them.
(7) Guide the ring down over the sleeve.

※ The ring should be able to rotate free of
the springs.
5 - 84
(8) Fit the cross pin into the spool / sleeve.
(9) Fit bearing races and needle bearing as

shown on below drawing.
※ Assembly pattern for standard bearings

1
1 Outer bearing race 2
2 Needle bearing 3
3 Inner bearing race
4 Spool
5 Sleeve 4
Installation instruction for O-ring

(10) Turn the steering unit until the bore is
horizontal. Guide the outer part of the
assembly tool into the bore for the spool /
sleeve.
5 - 85
(11) Grease O-ring with hydraulic oil and place
them on the tool.
(12) Hold the outer part of the assembly tool in

the bottom of the steering unit housing
and guide the inner part of the tool right to
the bottom.
(13) Press and turn the O-ring into position in

the housing.
5 - 86
(14) Draw the inner and outer parts of the
assembly tool out of the steering unit
bore, leaving the guide from the inner part
in the bore.
Installation instructions for lip seal

(15) Lubricate the lip seal with hydraulic oil and
place it on the assembly tool.
(16) Guide the assembly tool right to the

bottom.
5 - 87
(17) Press and turn the lip seal into place in
the housing.
(18) With a light turning movement, guide the

spool and sleeve into the bore.
※ Fit the spool set holding the cross pin
horizontal.
(19) The spool set will push out the assembly

tool guide. The O-ring are now in
position.
(20) Turn the steering unit until the bore is

vertical again. Put the check valve ball
into the hole indicated by the arrow.
5 - 88
(21) Screw the threaded bush lightly into the
check valve bore. The top of the bush
must lie just below the surface of the
housing.
(22) Grease the O-ring with mineral oil approx.

viscosity 500 cSt at 20°
C.
(23) Place the distributor plate so that the

channel holes match the holes in the
housing.
(24) Guide the cardan shaft down into the bore

so that the slot is parallel with the
connection flange.
5 - 89
(25) Place the cardan shaft as shown - so that
it is held in position by the mounting fork.
(26) Grease the two O-rings with mineral oil

approx. viscosity 500 cSt at 20° C and
place them in the two grooves in the gear
rim. Fit the gearwheel and rim on the
cardan shaft.
(27) Important
Fit the gearwheel (Rotor) and cardan
shaft so that a tooth base in the rotor is
positioned in relation to the shaft slot as
shown.
Turn the gear rim so that the seven
through holes match the holes in the
housing.
(28) Fit the spacer, if any.
5 - 90
(29) Place the end cover in position.
(30) Fit the special screw with washer and

place it in the hole shown.
(31) Fit the six screws with washers and insert

them. Cross-tighten all the screws and
the rolled pin.
(22.4 ± 4.3lbf・ft)
(32) Place the dust seal ring in the housing.
5 - 91
(33) Fit the dust seal ring in the housing.
(34) Press the plastic plugs into the connection

ports.
※ Do not use a hammer!
5 - 92
5. STEERING CYLINDER
1) STRUCTURE
8,9 3 10 5,6 7 11,12 4 24,25,26 2 14,15 16 17 13 19 18
1 23 20 21 22 27,28
1 Tube assy 11 O-ring 21 Pipe assy

2 Rod assy 12 Back up ring 22 O-ring
3 Gland 13 Piston 23 Bolt
4 Bushing 14 O-ring 24 U-bolt
5 Rod seal 15 Back up ring 25 Nut
6 Back up ring 16 Piston seal 26 Spring washer
7 Buffer ring 17 Wear ring 27 Spherical bearing
8 Dust wiper 18 Piston nut 28 Retaining ring
9 Snap ring 19 Screw
10 O-ring 20 Pipe assy
5-93
2) TOOLS AND TIGHTENING TORQUE
(1) Tools
Tool name B Remark
L-wrench 5 B
17
Spanner
70
Wrench For gland

(-) Driver Small and large sizes
Torque wrench Capable of tightening with the specified torques

Torque
Part name Item Size
kgf・m lbf・ft
Gland 3 M115×3 60±10 434±72
Piston 13 M 45×2 75±8 542±58
Piston nut 18 M 45×2 100±10 723±72
Set screw 19 M 10×1.5 5.4±0.5 39±3.6
Bolt 23 M 10×1.5 5.4±0.5 39±3.6
Nut 25 M 10×1.5 3.2×0.3 23±2.2
5-94
3) DISASSEMBLY
(1) Remove cylinder head and piston rod
① Hold the clevis section of the tube in a
vise.
※ Use mouth pieces so as not to damage
the machined surface of the cylinder
tube. Do not make use of the outside
piping as a locking means.
② Pull out piston rod(2) about 200mm

(7.8in). Because the piston rod is rather
heavy, finish extending it with air m
0m
20
pressure after the oil draining operation.
③ Loosen and remove the gland(3).

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

assembly together from cylinder tube(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(2) has
been drawn out to approximately two
thirds of its length, lift it in its center to Oil pan
Pull straight
draw it completely. sideways
5-95
Note that the plated surface of piston
rod(2) is to be lifted. For this reason, do
not use a wire sling and others that may
damage it, but use a strong cloth belt or a
rope.
⑤ Place the removed piston rod assembly

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

① Remove the set screw(19). 15 14 16 17 13 19 18
② Remove the piston nut(18).
③ Remove piston assembly(13), back up
ring(15) and O-ring(14).
③ Remove the gland(3) assembly from Lift with a crane

piston rod(2).
Plastic
※ If it is too heavy to move, move it by hammer 8,9 5,6 7 4
striking the flanged part of gland(3) with
a plastic hammer. Pull straight
※ Pull it straight with gland assembly lifted
with a crane.
Exercise care so as not to damage the lip
of rod bushing(4) and packing(5,6,7,8,9) 3 2
by the threads of piston rod(2).
5-96
(3) Disassemble the piston assembly
① Remove wear ring(17). 16 17
Remove and piston seal(16).

※ Exercise care in this operation not to
damage the grooves.
(4) Disassemble gland assembly

9,8 10 7 12,11 4
① Remove back up ring(12), and O-ring
(11).
② Remove O-ring (10).
③ Remove snap ring(9) and dust wiper(8).
④ Remove back up ring(6), rod seal(5) and
buffer ring(7).
damage the grooves.
※ Do not remove seal and ring, if does not
damaged.
5-97
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.
② Coat dust wiper(8) with grease and fit Press here

dust wiper(8) to the bottom of the hole of (Straight down)
Metal
dust wiper.
At this time, press a pad metal to the 8
metal ring of dust seal.
③ Fit snap ring(9) to the stop face.
④ Fit back up ring(6) and rod seal(5), and

buffer ring(7) to corresponding grooves,
in that order.
※ Coat each packing with hydraulic oil
Wrong Right
before fitting it.
※ Insert the backup ring until onside of it is
inserted into groove.
※ Rod seal(5) has its own fitting direction.

Therefore, confirm it before fitting them. Push bar
※ Fitting rod seal(5) up side down may
damage its lip. Therefore check the
correct direction that is shown in fig.
6
5-98
⑤ Fit back up ring(12) to gland (3).
※ Put the backup ring in the warm water of
4
30~50° C.
11
⑥ Fit O-ring(11) to gland(3).
12
3
10
(2) Assemble piston assembly

※ Check for scratches or rough surfaces.
① If found smooth with an oil stone.
13
Coat the outer face of piston(13) with
hydraulic oil.
② Fit piston seal(16) to piston

※ Put the piston seal in the warm water of 16
60~100° C for more than 5 minutes.
※ After assembling the piston seal, press
its outer diameter to fit in.
③ Fit wear ring(17) to piston(13).

15 14 17 13
④ Fit back up ring(15) and O-ring(14) to
piston(13).
5-99
(3) Install piston and gland assembly
① Fix the piston rod assembly to the work Gland assembly
bench. Piston rod
② Apply hydraulic oil to the outer surface of
piston rod(2), the inner surface of piston
and gland.
③ Insert gland assembly to piston rod(2).
④ Fit piston assembly to piston rod.

Piston assembly
Piston rod
⑤ Tighten piston nut(18) to piston rod(2).

・ Tightening torque : 100±10kgf・m 2 19 18
(723±72lbf・ft)
Tighten set screw(19) to piston nut(18).
・ Tightening torque : 5.4±0.5kgf・m
(39±3.6lbf・ft)
5-100
(4) Overall assemble
① Place a V-block on a rigid work bench. Fix with bar
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.
② Insert the piston rod assembly in to the Straight
cylinder tube assembly, while lifting and
moving the piston rod assembly with a Apply liquid packing
crane.
※ Be careful not to damage piston seal by
thread of cylinder tube.
③ Match the bolts holes in the cylinder
head flange to the tapped holes in the Tube
cylinder tube assembly and tighten
socket bolts to a specified torque. Piston rod
※ Refer to the table of tightening torque.
Wrench
Gland
5-101
6. CENTER PIVOT PIN
1) CONSTRUCTION
Figure shows the construction of the center pivot pin assembly. This assembly serves to connect
the front frame with the rear frame; two sets of assemblies are provided, one each for the upper and
lower parts.
10 13 2 3 18 10 17
9
11 13
11
7,8 4
6 7,8
19
1
19 1
5
14 5 15
3
3
20 20
12 18 16 17 18 16 12 17
UPPER LOWER
1 Bearing 8 Shim 15 Hexagon bolt

2 Collar 9 Bushing 16 Hexagon bolt
3 Collar 10 Pin 17 Collar
4 Cover 11 Dust seal 18 Collar
5 Cover 12 Plate 19 Front frame
6 Cover 13 O-ring 20 Rear frame
7 Shim 14 Hexagon bolt
5-102
2) DISASSEMBLY
After supporting the front frame and the
rear frame as horizontally as possible using
wood blocks and jacks, disassemble as
follows: In order to facilitate the
disassembly/assembly of the center pivot
pins, remove the drive shaft, hydraulic line
and steering cylinder first.
(1) Maintain the horizontal level of front
frame(19) and rear frame(20), and then 10 2
9
remove hexagon bolt(16) and plate(12).
(2) Remove collar(18) and take out pin(10) to 20
the upside using a metal punch.
(3) Remove collar(17) and keep collar(17, 18)
as a set.
19
(4) Put mating marks on collar(2, 3) fitting
3
positions and pull down collar(3) to remove. 17
18 16 12
(5) Lift the frame by passing the slinging wire

rope at four positions of front frame(19), in 9 10 13
2
order to separate it from the rear frame(20).
(6) Support the front frame safely. 11
7,8 6
1
5
14
METAL PUNCH
(7) Take out hexagon bolt(14) and then

remove covers(5, 6), shims(7, 8) and
collar(2) and keep them as a set after 11 13 2
putting marks on shim(7, 8) fitting position. 7,8
6
(8) Remove the spherical bearing(1) from the
1
front frame.
5
(9) Pull dust seal(11) out of cover(5, 6). 19
14
5-103
3) INSPECTION
(1) Check the bearing sliding surface for excessive wear, scorching or scratches; replace if
necessary.
(2) Replace all dust seals(11) and O-ring(13) with new ones.
(3) Grind any pins(10) dented with an oilstone or replace any pins abrasive excessively.
(4) Check inside cover(4, 5, 6) and collar(2, 3) for dents or scratches; if any damage is found, correct
with a grinder or replace.
(5) The serviceable limit of pins and bushings is shown in the table below.
Unit : mm
Std Serviceable limit
Item No. Name dimension Remedy
Outer dia Inner dia Clearance
10 Pin 99 -
100 1 Replace
1 Spherical bearing - 100.5
2, 3 Collar 100.2 - 100.6 1 Replace
17, 18 Dust seal
When removed Replace
13 O-ring
5-104
4) ASSEMBLY
Assemble the center pivot group by
reversing the order of disassembly while
paying close attention to the following.
(1) Put the dust seal(11) into cover(4, 5, 6).
10 13 2
※ Apply grease to the lip of the dust seal. 9
Insert the dust seal so that the dust seal
lip faces out and punch four places on the 11
outer circumference of the seal to lock it. 7,8
6
19
(2) Apply grease to the inside of spherical 1
bearing(1) and install it to front frame(19).
14 5
(3) Assemble cover(4, 5, 6). At this time,
adjust shims(7, 8) to press shoulder of the 3
bearing(1) against cover(5, 6).(Shim
thickness 0.1mm, 0.5mm) 18 16 17
(4) After setting the bearing so that its upper surface is horizontal, tighten the bolt(14).
After tightening, confirm that spherical bearing(1) moves lightly; if does not move smoothly, add
shims(7, 8).
・Tightening torque : 39±4kgf・m(282±29lbf・ft)
※ Apply locktite #242.
(5) Apply grease to upper collar(2) and insert it to the upper of spherical bearing(1). At this time,
insert pin(10) and confirm that match collar(2), spherical bearing(1) and cover (4, 5, 6) at the
center.
(6) Insert bushing(9) to the upper of the upper side rear frame and insert collar (17, 18) to the upper
of the lower side rear frame.
(7) Move the front frame and join it to the rear frame so that match the pin hole at the center.
(8) Apply grease to pin(10) and insert it into spherical bearing(1).
(9) Set plate(12) after inserting collar(3, 17, 18) through the lower side of the pin; tighten hexagon bolt
(16).
・Tightening torque : 35~38kgf・m(253~275lbf・ft)
※ Apply locktite #242.
(10) Connect the piping, pins, electrical wiring, links, etc. and remove the wooden block supporting the
frame.
(11) Check the pin function at low revolution; and apply grease if no irregularity is found.
5-105
5) TROUBLESHOOTING
Trouble Probable cause Remedy
Shock is felt when steering Capscrew for fixing steering valve is loose Retighten
Faulty center pivot pin mounting bolts Retighten
Center pivot pins have worn out Readjust or replace
Faulty hydraulic system See hydraulic system
Shock is felt when moving Fault fixing of connecting capscrews Retighten
backward or forward
Center pins have worn out Readjust or replace
Bearings of support unit have worn out Retighten
Drive shaft damaged See drive system
Faulty transmission See transmission system
5-106

1. HYDRAULIC SYSTEM OUTLINE

The loader hydraulic system is a pilot operated, open center system which is supplied with flow from
the fixed displacement main hydraulic pump.
The pilot control system is a low pressure, closed center hydraulic system which is supplied with flow
from main 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 steering pump not used by the steering system leaves the flow amplifier EF port.
It flows to the inlet port plate of a mono block type main control valve.
The main control valve is a tandem version spool type, open center valve which routes flow to the
boom, bucket or auxiliary cylinders(Not shown) when the respective spools are shifted.
Flow from the steering pump is routed to the pilot supply unit where the steering pump outlet pressure
is reduced to pilot circuit pressure. The pilot supply unit flow to the remote control valve.
The remote control valve routed flow to either end of each spool valve section in the main control
valve to control spool stroke.
A accumulator mounted on pilot supply unit supplies a secondary pressure source to operated
remote control valve so the boom can be lowered if the engine is off.
The return circuit for the main hydraulic system have return filter inside the hydraulic tank. The return
filter uses a filter element and a bypass valve. The bypass valve is located in the upside of filter.
6-1
FRONT REAR 9 10 11
19 LH RH LH RH
20 17
6 CL CR 4
8 2.4 2.1 2.5 2.2 T P
B.D/F B.U IN OUT
5.1 1.1 5.2 1.2

L R
A
5 1 3 4 2
16 P
3 T
P T
15 15 a3
B3
15 EF T
A3 Floating Ride
14
T b3
PP P
21 22 23 21MPa
7 HP LS HT
B2
25MPa
15 A2 F2
L R
Boom down Boom up
b2 13
27 a2
28
B1
23MPa
23MPa
12 P1
F1
18 A1 Dump Roll back
1 a1 b1
3MPa
U
P 21Mpa 4.5MPa
5
5 P2 T
P T LS
21
2 1
23
24
25
26 27 22
1 Steering pump 10 Bucket cylinder 19 Pressure switch

2 Main pump 11 Boom cylinder 20 Pressure switch
3 Main control valve 12 Pilot supply unit 21 Line filter
4 Remote control valve 13 Line filter 22 Oil cooler
5 Steering unit 14 Safety valve 23 Check valve
6 Flow amplifier 15 Accumulator 24 Air breather
7 Cut off valve 16 Solenoid valve 25 Hydraulic tank
8 Brake valve 17 Pressure switch 26 Return filter
9 Steering cylinder 18 Pressure switch 27 Bypass valve
6-2
3. WORK EQUIPMENT HYDRAULIC CIRCUIT
10 11
4 T P
LH RH
B.D/F B.U IN OUT
5 1 3 4 2
3 T
a3
B3
T
A3 14
Floating Ride
b3
P
B2
25MPa
A2
Boom down Boom up
a2 b2 F2
13
B1
23MPa
23MPa
A1 F1
Dump Roll back
a1 b1
P1 12
3MPa
P 21MPa
Flow amplifier EF port U
4.5MPa
P2 T
Steering system
Brake system
2 1
Return line
24
23
25
26 27 22
1 Steering pump 11 Boom cylinder 23 Check valve

2 Main pump 12 Pilot supply unit 24 Air breather
3 Main control valve 13 Line filter 25 Hydraulic tank
4 Remote control valve 14 Safety valve 26 Return filter
10 Bucket cylinder 22 Oil cooler 27 Check valve
6-3
1) WHEN THE RCV LEVER IS IN THE RAISE POSITION
10 11
4 T P
LH RH
B.D/F B.U IN OUT
5 1 3 4 2
3 T
a3
B3
T
A3 14
Floating Ride
b3
P
B2
25MPa
A2
Boom down Boom up
a2 b2 F2
13
B1
23MPa
23MPa
A1 F1
Dump Roll back
a1 b1
P1 12
3MPa
P 21MPa
4.5MPa
P2 T
Steering system
Brake system
2 1
Return line
24
23
25
26 27 22
・ When the RCV lever(4) is pulled back, the boom spool on the second block is moved to raise
position by pilot oil pressure from port 3 of RCV.
・ The oil from main pump(2) flows into main control valve(3) and then goes to the large chamber of
boom cylinder (11) by pushing the load check valve of the boom spool through center bypass circuit
of the bucket spool.
・ The oil from the small chamber of boom cylinder(11) returns to hydraulic oil tank(25) through the
boom spool at the same time.
・ When this happens, the boom goes up.
6-4
2) WHEN THE RCV LEVER IS IN THE LOWER POSITION
10 11
4 T P
LH RH
B.D/F B.U IN OUT
5 1 3 4 2
3 T
a3
B3
T
A3 14
Floating Ride
b3
P
B2
25MPa
A2
Boom down Boom up
a2 b2 F2
13
B1
23MPa
23MPa
A1 F1
Dump Roll back
a1 b1
P1 12
3MPa
P 21MPa
4.5MPa
P2 T
Steering system
Brake system
2 1
Return line
24
23
25
26 27 22
・ When the RCV lever(4) is pushed forward, the boom spool on the second block is moved to lower
position by pilot pressure from port 5 of RCV.
・ The oil from main pump(2) flows into main control valve and then goes to small chamber of boom
cylinder(11) by pushing the load check valve of the boom spool through center bypass circuit of the
bucket spool.
・ The oil returned from large chamber of boom cylinder(11) returns to hydraulic tank(25) through the
boom spool at the same time.
・ When the lowering speed of boom is faster, the return oil from the large chamber of boom cylinder
combines with the oil from the pump through the boom float spool on the third block, and flows into
the small chamber of the cylinder.
This prevents cylinder cavitation by the negative pressure when the pump flow cannot match the
boom down speed.
6-5
3) WHEN THE RCV LEVER IS IN THE FLOAT POSITION
10 11
5th control valve

4 T P
LH RH
B.D/F B.U IN OUT
5 1 3 4 2
3 T
a3
B3
T
A3 14
Floating Ride
b3
P
B2
25MPa
A2
Boom down Boom up
a2 b2 F2
13
B1
23MPa
23MPa
A1 F1
Dump Roll back
a1 b1
P1 12
3MPa
P 21MPa
4.5MPa
P2 T
Steering system
Brake system
2 1
Return line
24
23
25
26 27 22
・ When the RCV lever(4) is pushed further forward from the lower position, the boom down pilot
port(5) is connected with tank port(T) by shift of 5th control valve. Thus, the boom spool is return to
neutral position and the boom float spool is moved to float position by pilot oil pressure from port 1
of RCV.
・ The work ports(A3), (B3), (A2), (B2) 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
10 11
4 T P
LH RH
B.D/F B.U IN OUT
5 1 3 4 2
3 T
a3
B3
T
A3 14
Floating Ride
b3
P
B2
25MPa
A2
Boom down Boom up
a2 b2 F2
13
B1
23MPa
23MPa
A1 F1
Dump Roll back
a1 b1
P1 12
3MPa
P 21MPa
4.5MPa
P2 T
Steering system
Brake system
2 1
Return line
24
23
25
26 27 22
・ If the RCV lever(4) is pushed right, the bucket spool on the first block is moved to dump position by
pilot oil pressure from port 2 of RCV.
・ The oil from main pump(2) flows into main control valve(3) and then goes to the small chamber of
bucket cylinder(10) by pushing the load check valve of the bucket spool.
・ The oil at the large chamber of bucket cylinder(10) returns to hydraulic tank(25) through the bucket
spool.
・ When this happens, the bucket is dumped.
・ When the dumping speed of bucket is faster, the oil returned from the large chamber of bucket
cylinder combines with the oil from the pump, and flows into the small chamber of the cylinder.
bucket dump speed.
6-7
5) WHEN THE RCV LEVER IS IN THE ROLL BACK(Retract) POSITION
10 11
4 T P
LH RH
B.D/F B.U IN OUT
5 1 3 4 2
3 T
a3
B3
T
A3 14
Floating Ride
b3
P
B2
25MPa
A2
Boom down Boom up
a2 b2 F2
13
B1
23MPa
23MPa
A1 F1
Dump Roll back
a1 b1
P1 12
3MPa
P 21MPa
4.5MPa
P2 T
Steering system
Brake system
2 1
Return line
24
23
25
26 27 22
・ If the RCV lever(4) is pulled left, the bucket spool on the first block is moved to roll back position by
pilot oil pressure from port 4 of RCV.
・ The oil from main pump(2) flows into main control valve(3) and then goes to the large chamber of
bucket cylinder by pushing the load check valve of the bucket spool.
・ The oil at the chamber of bucket cylinder(10) returns to hydraulic tank(25) through the bucket spool.
・ When this happens, the bucket roll back.
・ When the rolling speed of bucket is faster, the return oil from the small chamber of bucket cylinder
combines with the oil from the pump, and flows into the large chamber of the cylinder.
bucket rolling speed.
6-8
6) WHEN THE RCV LEVER IS IN THE HOLD POSITION
10 11
4 T P
LH RH
B.D/F B.U IN OUT
5 1 3 4 2
3 T
a3
B3
T
A3 14
Floating Ride
b3
P
B2
25MPa
A2
Boom down Boom up
a2 b2 F2
13
B1
23MPa
23MPa
A1 F1
Dump Roll back
a1 b1
P1 12
3MPa
P 21MPa
4.5MPa
P2 T
Steering system
Brake system
2 1
Return line
24
23
25
26 27 22
・ The oil from main pump(2) flows into main control valve(3).
・ In this time, the bucket spool, the boom spool and the boom float spool are in neutral position, then
the oil supplied to main control valve(3) returns into hydraulic tank(25) through center bypass circuit
of each spool.
・ In this condition, each cylinder keeps the neutral position, so the boom and the bucket is holded.
6-9
4. MAIN PUMP OPERATION
1) STRUCTURE
4-1
15
2 4-12 4-11 4-13 3 4-8 6-1 6-2 6-4 6-6 6-7 13 6-12 6-8 6-13
12
11
8,10
14
4-10 4-6 4-9 4-5 4-7 4-4 4-2 4-3 6-3 5 6-5 6-14 6-9 6-11
1 Cap screw 4-12 Seal 6-11 Pressure pin

2 End cap 4-13 Back up ring 6-12 Seal
3 Seal 5 Center housing 6-13 Seal
4-1 Screw 6-1 Screw 6-14 Back up ring
4-2 Lock pin 6-2 Lock washer 7 Internal snap ring
4-3 Port plate 6-3 Lock pin 8 External snap ring
4-4 Dowel pin 6-4 Port plate 9 Ball bearing
4-5 Cam ring 6-5 Dowel pin 10 External snap ring
4-6 Vane 6-6 Cam ring 11 Splined shaft
4-7 Vane holdout pin 6-7 Vane 12 Shaft seal
4-8 Rotor assy 6-8 Vane holdout pin 13 Seal
4-9 Dowel pin 6-9 Rotor assy 14 Mounting cap
4-10 Pressure plate 6-10 Dowel pin 15 Cap screw
4-11 Seal
6-10
2) DESCRIPTION
The main vane pump consist of six basic components : end cap(2), B section unitlzed cartridge(4)
consisting of ; rotor, vanes, vane holdout pins, cam ring, port plate, and pressure plate, center,
housing(5), D section unitlzed cartridge(6) consisting of ; rotor, vanes, vane holdout pins, cam ring,
port plate, pressure plate, shaft(11) and bearing and mounting cap(14).
The main vane pump features the use of unitized pumping cartridge for both the D and B pump
section. The unitized cartridge assemblies are pretested and provide for ease of disassembly and
assembly in the event it becomes necessary or desirable to make repairs, overhaul or revise the
flow delivery.
C section
B section
14
11
6
5
4
2
3) OPERATION
The pumping operation of this unit(each cartridge) is obtained by providing a fixed interior cam
surface and a rotating inner member(rotor) containing vanes which held in contact with the inner
cam surface. As the rotor is rotated by the drive shaft, the vanes are urged outward against the
outward sloping cam surface, forming a cavity at the inlet ports of the port plates. Atmospheric
pressure and suction created by the expanding cavity between the rotating vanes fill the inlet cavity
with fluid.
As the rotation continues and the vanes that had previously moved outward and now have fluid
trapped between them and the port plates, follow the inward slope of the cam which decreases the
cavity containing the trapped fluid and discharges the fluid at system pressure through the pressure
port openings in the port plates.
The rotating portion of the unitized cartridges feature the use of pressure actuated vanes which are
urged against the cam ring by pins located in the bottom of each rotor vane slot. Initial force to
bring the vanes in contact with the cam ring contour during start up is provided by centrifugal force.
When pumping operation starts and pressure is established, fluid under pressure fills the pin cavity
through the feed holes.
The feed holes open to the pressure port twice every revolution. All other times they are closed off
by the port plate. This pressure under the pin provides the force necessary to keep the vanes in
contact with the cam contour.
※ When operating the pump at the maximum outlet pressure, the pump shaft rotation should not be
allowed to fall below 600rpm in order to maintain proper vane to cam ring contact.
The inlet or suction flow for both the D cartridge and B cartridge feeds through a common 3 port in
the center housing, through the large ports of each port plate for each cartridge and through the
center hole in the suction zone of each cam ring.
6-11
5. REMOTE CONTROL VALVE
1) STRUCTURE
10
60
11 12
60
33
64
4,3,1
36
4 1
63
3 2
41 43
62
2
4,3,1 61
35
65
48
4 1
66 65
49 32
42
44
45 4 1
50 3 2
69
67
51
68
10 Handle 44 Intermediary plunger 63 Regulating sub assy

11 Lever kit 45 Plunger guide assy 64 Regulating sub assy
12 Bellows 48 Joint 65 Spring set
33 Nut 49 Flange 66 Frefeel point kit
35 Shim kit 50 Electric bracket 67 Plug kit
36 Bracket 51 Bushing kit 68 5th control port kit
41 Joint kit 60 Plunger kit 69 Body
42 Solenoid complete 61 Spool
43 Plunger kit 62 Spool
6-12
2) OPERATION
5 1
5 T
3 1
4 P
14 5 2
15
T 1
5
Electromagnetic lock
SECTION
X-X X-X
9
T P 10
11
5
4
22bar 3
7
5 1 3 4 2 2
(1) Hydraulic functional principle T 8

Pilot devices with end position locks operate as x P x
direct operated pressure reducing valves. 6
They basically comprise control lever(1), four
pressure reducing valves, housing(6) and locks.
Each pressure reducing valve comprises control Port 4 Port 2
spool(2), control spring(3), return spring(4) and
push rod(5).
At rest control lever(1) is held in its neutral position
by return springs(4). Ports(1, 2, 3, 4) are
connected to tank port T via bore(8).
When control lever(1) is deflected push rod(5) is pressed against return spring(4) and control
spring(3).
Control spring(3) initially moves control spool(2) downwards and closes the connection between
the relevant port and tank port T. At the same time the relevant port is connected to port P via
bore(8). The closed loop control phase starts, as soon as control spool(2) finds its balance
between the force from control spring(3) and the force, which results from the hydraulic pressure
in the relevant port(port 1, 2, 3 or 4).
Due to the interaction between control spool(2) and control spring(3) the pressure in the relevant
port is proportional to the stroke of push rod(5) and hence to the position of control lever(1).
This closed loop pressure control dependent on the position of the control lever and the
characteristics of the control spring permits the proportional hydraulic control of the main
directional valve.
Rubber sleeve(9) 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 control lever in a deflected position
are equipped with end position locks.
Electromagnetic lock
An additional spring(7) under push rod(5) warns, due to the increase in force which is required to
keep this spring compressed, that the stroke of push rod(5) and control lever(1) is nearly at its
end.
Once this point has been exceeded ring(10) is placed in contact with solenoid armature(11).
If the solenoid is energized, control lever(1) is held in its end position by means of the
electromagnetic force.
The lock is released automatically when the solenoid is deenergized.
(3) Fifth control port
This remote control valve is equipped with a fifth control port, which is used to control the boom
floating function. This function may be operated by moving spool(14) against spring(15) under the
influence of the pressure acting in port 1.
As soon as this pressure reaches 22bar, control port 5 is connected with T.
6-14
6. MAIN CONTROL VALVE
1) STRUCTURE
300.12 300.11
300.10
54
86 300.13
14
99
85
3
is
ax
70
2
is
ax
1
is
ax
35,36
43
74,76
72,75
70.15
70.11 70 40
70.13 99
68.23
68.27 43 19
68 70.14
70.12 53
68.24
70.9
68.22 86
54
85
11 Housing 68.23 O-ring 74 Spring(Axis 1,2)

14 Short cover 68.24 Thrust ring 75 Spring(Axis 3)
19 Long cover 68.27 O-ring 76 Spring(Axis 3)
35 Spool(Axis 1,2) 70 Overload relief valve 85 Screw
36 Spool(Axis 3) 70.9 Seal 86 Seal ring
40 Ring 70.11 O-ring 99 O-ring
43 Spring retainer 70.12 Piston seal 300 Plate
53 Snap ring 70.13 O-ring 300.10 Plate
54 Bleed screw 70.14 O-ring 300.11 Locking screw
68 Main relief valve 70.15 Thrust ring 300.12 Bolt
68.22 O-ring 72 Spring(Axis 1,2) 300.13 O-ring
6-15
STRUCTURE
A3 B3
a3 b3
A2 B2
a2 b2
A1 B1
a1 b1
a3
B3
A3
Floating Ride
b3
B2
A2 25MPa
Boom down Boom up
a2 b2
B1 23MPa
A1 23MPa
Dump Roll back
a1 b1
P 21MPa
Port Port name Port size
P From main pump SAE 6000psi 1 1/2"

T To hydraulic tank SAE 6000psi 1 1/2"
A1, B1 To bucket cylinder port SAE 6000psi 1 1/4"
A3, B3, A2, B2 To boom cylinder port SAE 6000psi 1 1/4"
a1, b1 Bucket pilot port PF 1/4
a2, a3, b2, b3 Boom pilot port PF 1/4
6-16
2) BOOM SECTION OPERATION
(1) Spool in neutral
a3
LH RH B3
A3
Floating Ride
b3
B2
25MPa
A2
Boom down Boom up
a2 b2
A2 B2
a2 b2
Overload relief valve

Low pressure passage
If the remote control valve is not operated, the oil supplied from the pump port passes through the
neutral passage to the low pressure passage at the outlet section, and then returns to the tank port.
6-17
(2) Boom raise position
a3
LH RH B3
A3
Floating Ride
b3
B2
25MPa
A2
Boom up
a2 b2
A2 B2
a2 b2
When the pilot pressure from remote control valve is supplied to the pilot port(b2), the spool moves to
the left and the neutral passage is closed.
The oil supplied from the pump pushes up the load check valve(1) and flow into boom cylinder port(B2,
B3).
The pump pressure reaches proportionally the load of cylinder and fine control finished by shut off of the
neutral passage.
The return oil from cylinder port(A2, A3) flows into the tank via the low pressure passage.
6-18
(3) Boom lower position
a3
LH RH B3
A3
Floating Ride
b3
B2
25MPa
A2
Boom down
a2 b2
A2 B2
a2 b2
When the pilot pressure from remote control valve is supplied to the pilot port(a2), the spool moves to
the right and the neutral passage is closed.
The oil supplied from the pump pushes up the load check valve(2) and flow into boom cylinder port(A2,
A3).
neutral passage.
The return oil from cylinder port(B2, B3) flows into the tank via the low pressure passage.
6-19
(4) Boom float position
a3
LH RH B3
A3
Floating
b3
B2
25MPa
A2
Boom down Boom up
a2 b2
A3 B3
a3 b3
If the operator overrides the additional spring(7) in the RCV lower position, the pilot pressure from
remote control valve rises further and then the boom float spool is pushed to the end position, opening
up the neutral passage to tank and simultaneously(A2, A3), (B2, B3) T.
Parallel the boom down spool will be released to neutral, became of moving spool in the remote control
valve at 22bar(Refer to page 6-13).
In float position the boom drops quickly due to its own weight.
When the bucket touches the ground and the wheeled loader is moving, the bucket raised or lowered
following the unevenness of the ground due to the (A2, A3), (B2, B3) T connecting.
6-20
3) BUCKET SECTION OPERATION
(1) Spool in neutral
B1
23MPa
23MPa
A1
Dump Roll back
a1 b1
21MPa
A1 B1
a1 b1

Low pressure passage
If the remote control valve is not operated, the oil supplied from the pump port passage through the
neutral passage to the low pressure passage at the outlet section, and then return to the tank port.
6-21
(2) Retract (Roll back) position
B1
23MPa
23MPa
A1
Roll back
a1 b1
21MPa
A1 B1
a1 b1
When the pilot pressure from remote control valve is supplied to the pilot port(b1), the spool moves to
the left and the neutral passage is closed.
The oil supplied from the pump pushes up the load check valve(1) and flow into boom cylinder port(B1).
neutral passage.
The return oil from cylinder port(A1) flows into the tank via the low pressure passage.
6-22
(3) Dump position
B1
23MPa
23MPa
A1
Dump
a1 b1
21MPa
A1 B1
a1 b1
When the pilot pressure from remote control valve is supplied to the pilot port(a1), the spool moves to
the right and the neutral passage is closed.
The oil supplied from the pump pushes up the load check valve(1) and flow into boom cylinder port(A1).
neutral passage.
The return oil from cylinder port(B1) flows into the tank via the low pressure passage.
6-23
3) MAIN RELIEF VALVE
・ The main relief valve is installed at the inlet of Main poppet(A) Valve seat
Pilot poppet(C)
the main control valve. When the oil goes
Z
above the set pressure, the relief valve
drains the oil to the tank.
In this way, it sets the maximum pressure in
the hydraulic circuit and protects the circuit. P
T Y
・ The valve poppet(C) is connected via the
D1
throttle drillings(D1) and (D2) with the P port. D2 Pressure spring(F) Adjustment
If static pressure increases above the set screw(E)
pressure value, the valve poppet(C) opens
and allows oil to flow freely to tank(Y). This P
oil generates a pressure drop in the spring
chamber of the main poppet, the closing
force of the spring(Z) is cancelled, and the T
main poppet(A) opens to allow the pump
flow to flow to tank(T).
Damped opening and closing is obtained by
the throttled volumetric change. P
・ The set pressure can be varied by changing T Y
the tension of pressure spring(F). To change
the set pressure, remove cap nut, loosen
lock nut and turn adjustments screw(E) and
follows.
P
T Y
6-24
4) OVERLOAD RELIEF VALVE
・ The overload relief valve(Combined relief/ Annular passage
anticavition valve) is in the boom cylinder and
Valve body(1)
bucket cylinder circuit in the main control Main poppet(2)
Pilot poppet(3)
valve.
If shock causes any abnormally high
pressure in the cylinder when the main AB
valves is at neutral, the overload relief valve
releases the abnormal pressure and protects
the cylinder from damage.
T
・ During normal operation, the poppet(2) is Pressure spring(4)
positioned against the body(1) to seal the A1 A3 A2 Main poppet spring
workport(A) oil from the return(T) passage.
・ As the circuit pressure approach the relief A,B
pressure setting, the pressure forces the pilot
poppet(3) off its seat and allows oil to flow
freely via the annular passage to tank.
This oil generates a pressure drop in the
T
spring chamber of the main poppet(2), the
closing force of the spring(4) is cancelled.
The main poppet(2) opens to allow flow from
P to T.
・ If cavitation in the workport occurs, the oil
pressure in the workport drop below return
pressure. AB
Tank line return pressure oil works against
the shoulder(A3) of the poppet to force it
open against the spring and the workport
T
pressure at (A2)-(A1).
A,B
6-25
7. PILOT OIL SUPPLY UNIT
1) STRUCTURE
5
1
P
2
U
T
6
P1 2
3MPa Port Port name Port size

U
P2 From main pump 3/4-16UNF
P1 Pluging 3/4-16UNF
4.5MPa
U Supply to RCV lever 9/16-18UNF
P2 T T To hydraulic tank 9/16-18UNF

HYDRAULIC CIRCUIT
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. SAFETY VALVE UNIT
1) STRUCTURE
The safety valve locks or permits pilot oil flew to the main control valve operation.
P
12
T
13
6
2
9,10 5
7
11 4
P 14
1
T
1 Body 6 Handle 11 Spring plunger

2 Retainer 7 Spring ring 12 Knob
3 Adjust stem 8 O-ring 13 Socket set screw
4 Housing 9 O-ring 14 Spring pin
5 Clutch ring 10 Back up ring
6-27
9. BOOM AND BUCKET CYLINDER
The boom cylinders and the bucket cylinders are two 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 23 11,10 4 2 25,26,27 14,13 17 15 16 22 19 18 24 23
20 1 21 12 28,29
1 Tube assy 11 Back up ring 21 Pipe assy

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

5 Rod seal 15 Piston seal 25 Band assy
6 Back up ring 16 Wear ring 26 Bushing
7 Buffer ring 17 Dust ring 27 Dust seal
10 O-ring 20 Bolt
6-29
10. HYDRAULIC OIL TANK
1) STRUCTURE
・ The oil from the hydraulic tank is sent from the pump through 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(5) acts to allow the oil to
return directly to the hydraulic tank(1). This prevents damage to the hydraulic filter(4). The
bypass valve(5) is also actuated when negative pressure is generated in the circuit.
7
3
9
4
1
2 5
12,13
8 7
9 10,11
1 Hydraulic tank 6 Spring 11 Spring washer

2 Level gauge 7 Cover 12 Overheat switch
3 Air breather 8 Cover wa 13 O-ring
4 Element 9 O-ring
5 Bypass valve 10 Bolt
6-30
2) RETURN OIL FILTER BYPASS VALVE
(1) When the filter is clogged
Bypass valve(1) is opened and the oil
1
returns directly to the tank without passing
through the filter.
Bypass valve set pressure : 1.36kg/cm2
(19.3psi)
From MCV
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 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, 4
the difference in pressure between the
tank and the outside atmospheric 1
pressure opens the poppet in the
breather, and air from the outside is let 2
into the tank or prevent negative pressure.
3
(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. 1 Body 3 Strainer
2 Element 4 Cap
6-31
11. ACCUMULATOR
The accumulator is installed at the pilot oil 1
supply unit. When the boom is left the 2
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 3
to the control valve to actuate it and allow 4
the boom and bucket to come down under 5
their own weight.
Type of gas Nitrogen gas(N2)
Volume of gas 0.75ℓ(0.2 U.S.gal)
Charging pressure of gas 16kg/cm2(228psi)
1 Screw plug
Max actuating pressure 30kg/cm2(427psi)
2 Sealing ring
3 Diaphragm
4 Closure button
5 Steel pressure vessel
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.
If verification is needed, you will be given next best source of information:
・Chapter 2 : Troubleshooting
・Group 3 : Tests and adjustments
6-33
※ Hydraulic oil must be at operating temperature for these checks(Refer to page 6-48).
Hydraulic system warm- Hold a hydraulic function over OK

up procedure relief to heat oil.(Don't keep relief Check completed.
Run engine at high idle. condition over 5 seconds at a
Refer to page 6-49. time)
Periodically cycle all hydraulic
functions to distribute warm oil.
Repeat procedure until oil is at
FEEL : Hydraulic tank must be
uncomfortable to hold your hand
against.
(Approximately 40~50°C)
Hydraulic pump With bucket flat on ground, OK
performance check actuate boom raise. Time how Check completed.
Heat hydraulic oil to long it takes to raise boom to full
NOT OK
operating temperature. height.
Go to priority valve(In flow
LOOK : Boom must raise to full amplifier) high pressure
height in less than 7 seconds. check at page 5-32.
IF OK
Do steering system
leakage check at page 5-
31.
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 Repair lift checks in
lever(RCV lever) to boom lower loader control valve.
position.
Slowly move bucket control lever
to bucket dump position.
LOOK : Boom must not raise
before moving down.
Bucket must not rollback before
dumping.
6-34
Bucket rollback circuit Position bucket at a 45°angle OK

relief valve check against an immovable object. Check complete.
Engage transmission in 3rd speed NOT OK
forward. Do loader system and
circuit relief valve test at
LOOK : Bucket angle must not
page 6-51.
change.
Bucket dump circuit Raise front of machine which OK
relief valve low pressure bucket at 45°angle. Go to next check.
check
Backdrag with bucket while NOT OK
observing bucket angle. Do loader system and
circuit relief valve test at
LOOK : Bucket must not rollback.
page 6-51.
Pilot control valve float With the bucket partially dumped, OK
check lower boom to raise front of Check complete.
Run engine at low idle. machine.
NOT OK
Push control lever to the float
Do pilot control valve
detent position and release lever.
LOOK : Front of machine lower to
the ground and valve must remain
in float position when lever is
released.
Boom cylinder and Set the boom and bucket OK
bucket cylinder drift horizontal, then stop the engine. Check complete.
check
Stop the engine, wait for 5 NOT OK
Heat hydraulic oil to
minutes, then start measuring. Go to next check.
B
Measure the amount the lift and
dump cylinder rods retract during
15 minutes.(Unloaded bucket)
A
A : Retraction of boom cylinder
rod
B : Retraction of bucket cylinder
rod
Boom cylinder must drift less than
40mm.
Bucket cylinder must drift less
than 40mm.
6-35
Boom cylinder leakage Dump bucket until teeth or cutting OK

check edge is perpendicular to the Drift is approximately the
Heat hydraulic oil to ground. same between first and
operating temperature. Raise boom until cutting edge is second measurement.
about 1m(3ft) above ground. Repair loader control
Stop engine. Measure drift from valve or circuit relief valve.
tooth or cutting edge to ground for
NOT OK
1 minute.
If drift is considerably less
Wait 10 minutes. on second measurement,
Measure drift from tooth or cutting repair cylinder.
edge to ground for 1 minute.
LOOK : Compare the drift rate
between the first measurement
and the second measurement.
Bucket cylinder leakage Raise bucket about 1m(3ft) off OK
check ground with bucket level. Drift is approximately the
Heat hydraulic oil to Stop engine. Place a support same between first and
operating temperature. under boom. second measurement.
Measure drift from tooth or cutting Repair loader control
edge to ground for 1 minute. valve or circuit relief valve
Wait 10 minutes. at page 6-50.
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.
Pilot control valve Stop engine. Turn key switch to OK
(RCV lever) check OFF position. Check completed.
Move control lever to all positions
and then release. NOT OK
Repair pilot control valve.
LOOK : Lever must return to
neutral when released from all
positions.
6-36
Bucket leveler Position bucket fully dumped just OK

(Positioner) check above ground level. Check complete.
Move control lever to bucket NOT OK
leveler detent position and Do bucket leveler checks
release. in group 3.
LOOK : Bucket must rollback to
the level position and control lever
must return to neutral.
If bucket is in a rolled back
position when key is turned ON,
control lever must be returned to
neutral manually if placed in the
bucket leveler detent position.
After bucket is dumped once,
bucket leveler will work normally.
Boom height kickout Position bucket flat on ground. OK
check Check complete.
Move control lever to boom raise
detent position and release. NOT OK
Do boom height kickout
LOOK : Boom must raise to the
check in group 3.
set height and stop.
Control lever must return to
neutral.
Cycle time check Function Operating condition. Maximum cycle time
Heat hydraulic oil to
Boom raise Bucket flat on ground to full height. 6.3sec
Run engine at high idle. Boom lower(Float) Full height to level ground. 3.5sec
Bucket dump Boom at full height. 1.3sec
Bucket rollback Boom at full height. 1.7sec
Steering(No. of Frame stop to frame stop. 1.6sec (3.9 turns)
turns)
OK
Check complete.
NOT OK
Go to slow hydraulic
functions in group 3.
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(1 EA)
3. MEASURING PROCEDURE
1) LIFTING TIME OF BOOM Liftingtime
Lifting time of
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.
2) LOWERING TIME OF BOOM

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

Raise the boom to the maximum height and Dumping time of
Dumping time ofbucket
bucket
Rollback time
Rollback time of
of bucket
bucket
measure the time taken for the bucket to
move from the maximum tilt back position
to the maximum dump position
4) ROLL BACK TIME OF BUCKET
Raise the boom to the maximum height and
measure the time taken for the bucket to
reach the maximum tilt back position.
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)
Step 4. Tests and adjustments (See group 3)
Noisy hydraulic pump Low oil supply or wrong viscosity. Fill hydraulic tank 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.
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 hydraulic pump. Do performance check.

functions
Cold oil. Warm oil up.
Slow engine speed. Adjust engine speed control linkage.
Check high idle speed.
Suction line air leak. Check for foamy oil.
Low oil supply. Add recommended oil.
Wrong oil viscosity. Use recommended oil.
Oil leaking past cylinders or control Check cylinder drift in group 2.
valve.
Blocked or damaged line. Inspect lines.
Faulty or misadjusted pilot oil supply Do pilot oil supply unit pressure test in
unit. group 3.
Faulty pilot control valve(RCV). Do pilot control valve(RCV) pressure
test in group 3.
Binding loader control valve(MCV) Inspect valve.
spool.
Faulty flow amplifier. Check priority valve, orifice of flow
amplifier specification.
6-39
No steering or hydraulic Low oil level. Add recommended oil.
function
Failed hydraulic pump. Remove and inspect return filter for
metal pump particles.
Failed main hydraulic pump drive. Remove main hydraulic pump and
inspect drive gear.
No hydraulic functions Failed hydraulic pump. Remove and inspect return filter for
steering normal metal pump particles, or replace the
pump.
Failed pilot line filter. Remove and inspect line filter for RCV.
Faulty safety valve. Safety valve leakage test or ON, OFF
function test.
Stuck open system and port relief Replace relief valve.
valve.
Faulty or misadjusted pilot supply unit. Do pilot supply unit pressure test in
group 3.
Boom float function Low pilot control pressure. Do pilot supply unit pressure test in
does not work group 3.
Faulty pilot control valve(RCV). Do pilot control valve pressure test.
Main control valve spool binding in Inspect and repair valve.
bore.
One hydraulic function Faulty pilot control valve(RCV). Do pilot control valve pressure test.
does not work.
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.
Main control valve spool stuck in bore. Inspect and repair valve.
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
Faulty or misadjusted pilot oil supply Do pilot supply unit pressure test in
unit. group 3.
Leaking system relief valve. Remove and inspect valve.
Worn hydraulic pump. Do hydraulic pump performance check
in group 2.
Faulty pilot control valve(RCV). Do pilot control valve pressure test in
group 3.
6-40
Function drifts down Leaking cylinders. Do cylinder leakage checks in group 2.

Leaking seals in circuit relief valve(Port Inspect seals. Replace relief valve.
relief valve) or valve stuck open.
Leaking loader control valve. Repair or replace valve section.
Boom drifts up Leakage in boom down spool. Remove and inspect boom down spool.
Boom down does not Safety valve not operated. Operate valve.
work(Engine off)
Stuck pilot control valve. Inspect.
Faulty line filter. Remove and inspect filter.
Accumulator 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 Inspect for dented or kinked lines.
valve(MCV). Do hydraulic system restriction test in
group 3.
Pinched or restricted priority valve of Run engine at low idle. Steer machine
flow amplifier "LS" line. back and forth. If engine load
decreases while steering, a restricted
"LS" line or priority valve of flow
amplifier malfunction is indicated.
Do priority valve of flow amplifier "LS"
port flow test in group 3.
Malfunctioning flow amplifier. Do hydraulic system restriction test in
group 3.
Leaking system main relief valve. Remove and inspect valve and seals.
Worn hydraulic pump(Internal leakage). Do hydraulic pump performance check
in group 2.
Function drops before Stuck open lift check valve. Do control valve lift check in group 2.
raising when valve is
activated
6-41
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 1-21, Recommended lubricants.) Never mix oil of
different makes of kinds.
7) To change the hydraulic oil, use a clean vessel and funnel for pouring it into the tank. Never use
cloth because it might cause the presence of lint in the circuit.
8) When removing the hydraulic equipment, be sure to put plugs or caps on hoses, tube lines and
ports. Also, enter mating marks for later identification.
6-42
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 3658(12ft) × 1in I.D. 100R1
hoses with 1in NPT Ends
・Quick disconnect fittings.
・Discharge wand
・Various size fittings.
※ Brake system uses oil from hydraulic oil
tank. Flush all lines in the brake and
pilot system. Disassemble and clean
major component for hydraulic system.
Brake and steering components may fail
if brake, steering system is not cleaned
after hydraulic oil tank hydraulic oil tank
contamination.
1) If hydraulic system is contaminated due to a
major component failure, remove and
disassemble steering cylinders to clean
debris from cylinders.
2) Install a new return filter element. Clean
filter housing before installing new element.
※ For a failure that creates a lot of debris,
remove access cover from hydraulic oil
tank. Drain and clean hydraulic oil tank
of fill the specified oil to hydraulic oil
tank through upper cover.
3) To minimize oil loss, pull a vacuum in
hydraulic oil tank using a vacuum pump.
Connect filter caddy suction line to drain
port at bottom of hydraulic oil tank using
connector. Check to be sure debris has not
closed drain port.
4) Put filter caddy discharge line into hydraulic
oil tank 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 185ℓ ℓ (48.9 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 hydraulic oil tank ; 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
Boom Front frame
engine.
Proximity switch
Be careful lest work equipment fall
down.
Put the hydraulic safety lock lever in the
LOCK position.
With the attachment raised, proper
support must be provided for the
attachment and/or linkage.
2) Loosen the bolts. Move the plate so that

Boom Front frame
the boom is in line with the center of the
sensing surface of proximity switch. Plate
Then tighten the bolts. Bolt
3) Loosen the nuts so that a clearance Boom Front frame

between the boom and the probe of the
Plate
proximity switch are 3±1mm.
Bolt
4) Start the engine. Position the bucket on the

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

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

The display monitor tachometer is accurate
enough for test work.
20 30
10 km/h 20
10 40
0 MPH 30
0 50
VDO
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(Approximately
50°
C).
6 -48
5. MAIN HYDRAULIC PUMP FLOW TEST
・ SPECIFICATION
Oil temperature 45±5°C(113±9° F)
Engine speed 2100±25rpm
Test pressure 210±5bar(2987psi)
Maximum pump flow 193ℓ/min(51.6gpm)
・ FLOW METER GAUGE AND TOOL
Temperature reader
1) Make test connections.
(See temperature reader installation procedure
in this group.)
hydraulic oil warm up procedure in this
group.)
4) Run engine at test specifications. TO MCV
5) Close flow meter loading valve to increase Flow meter
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.
6 -49
6. LOADER SYSTEM AND PORT RELIEF
VALVE PRESSURE TEST
・ SPECIFICATION
Oil temperature (40~50°
C)
Relief valve Engine speed Relief pressure D

210±5kg/cm2
System(M) High
(2987±70psi)
Boom 250±5kg/cm2
Low
raise(U) (3556±70psi)
Bucket 230±5kg/cm2
Low
rollback(R) (3270±70psi)
U
Bucket 230±5kg/cm2 R
Low
dump(D) (3270±70psi) M
・ GAUGE AND TOOL

A : Test port
M : System(Main) relief valve
R : Bucket rollback relief
A
D : Bucket dump relief
U : Boom raise relief
1) Install pressure gauge to test port(A).
(See temperature reader installation procedure
in this group.)
3) Heat hydraulic oil to specifications. (See TO MCV
group.)
4) To check the system relief(M), run engine at
high idle. Lower boom to bottomed
position.
Slowly activate boom down function while
watching pressure gauge. If pressure is not
to specification, loosen lock nut on system
relief valve(M) and adjust to specification.
6 -50
※ Do not adjust the system relief valve
above 260kg/cm2 (3700psi). Damage to
the pump will result from excessive
pressure settings.
5) To check the bucket dump, bucket rollback,
and boom raise, adjust the system relief
valve to 260kg/cm2 (3700psi).
Run engine to maintain 800~850rpm when
hydraulic function is activated over relief.
Activate the function to be checked with the
cylinder bottomed. Read the pressure
gauge.
If pressure is not to specification cycle relief
valve over relief 10 times to flush.
Read pressure gauge again. Turn screw to
adjust valve to specification.
※ Do not work machine with system relief
adjusted above specification or
structural damage may occur.
6) Adjust system relief valve to specification.
6 -51
7. HYDRAULIC SYSTEM RESTRICTION TEST
・ SPECIFICATION
Maximum pressure 2MPa(20bar, 285psi) at
flow amplifier
Maximum pressure at main control valve
1MPa(10bar, 145psi)
・ GAUGE AND TOOL
HP
Gauge 0~7MPa(0~70bar, 0~1000psi) 2EA
This test will check for restrictions in the
hydraulic system which can cause
overheating of hydraulic oil.
(See temperature reader installation Fitting
procedure in this group.)
2) Heat hydraulic oil to specifications. (See
group.) Steering pump
3) Connect fitting and gauge to flow amplifier.
4) Connect fitting and gauge to main control
valve.
Do not operate steering or loader
functions or test gauge may be
damaged.
5) Run engine at specification and read
pressure gauges.
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 flow amplifier for a Hyd tank
stuck spool. Make sure orifice plugs are
installed in ends of priority valve spool.
Check for plugged orifice in priority valve
"LS" port and dynamic signal orifice on flow
amplifier body.
6 -52
8. LOADER CYLINDER DRIFT TEST
・ SPECIFICATION A
Oil temperature 45±5°
C(113±9°
F)
Boom horizontal
Bucket horizontal
Bucket unloaded
B
Item Standard value
Retraction of boom
40mm A : Retraction of bucket cylinder rod
cylinder rod
B : Retraction of boom cylinder rod
Retraction of bucket
40mm
cylinder rod
・ GAUGE AND TOOL

Stop watch
Temperature reader
Put the safety lock lever in the lock
position.
Do not go under the work equipment.
1) Set the boom and bucket horizontal, then
stop the engine.
2) Stop the engine, wait for 5 minutes, then
start measuring.
3) Measure the amount the boom and bucket
cylinder rods retract during 15 minutes.
6 -53
9. BOOM AND BUCKET CYLINDER LEAKAGE
TEST
・ SPECIFICATION
Maximum leakage 15 mi/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.
group.)
Never work under raised equipment
unless it is supported with a hoist or
support stands.
3) Full extend the cylinder to be tested. If
testing the boom cylinders, restrain boom in
the fully raised position using a hoist or a
stand.
※ Check cylinders for leakage in the fully
extended position only. In the retracted
position contacts the end of the cylinder
and seals off piston seal leakage.
4) Remove and plug cylinder rod end hose or
line.
5) Run engine at slow idle. Activate control
lever to extend cylinder for 1 minute over
relief while measuring leakage for open
port.
If leakage is within specification, excessive
cylinder drift is caused by leakage in the
loader control valve or circuit relief valve.
6 -54
10. PILOT CONTROL VALVE PRESSURE TEST
・ SPECIFICATION
Oil temperature 45±5° C(113±9°
F)
Begine metering 1/4" of lever travel
Pressure in detent :
Boom float detent 2.2MPa(22bar)
Pressure at feel position :
Boom power down 19~22bar
Boom raise 19~22bar
Bucket rollback 19~22bar
Bucket dump 19~22bar
・ GAUGE AND TOOL
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 test fittings and gauge to the pilot
pressure port of function to be checked.
procedure in this group.)
4) Heat hydraulic oil to specification.(See
group.)
6 -55
5) Run engine at specification. Activate
function to be checked and record pressure
reading.
※ If boom raise or bucket rollback FEEL
positions are not operation due to boom
or bucket position, plug boom float
detent wires into bucket leveler solenoid
or boom height kickout solenoid. This
will provide a feel position on the control
lever.
6 -56
11. PILOT OIL SUPPLY UNIT PRESSURE TEST
・ SPECIFICATION
Engine speed Low idle and stop
Pilot pressure setting 30~35bar(430~500psi)
Relief valve setting pressure 45bar
Accumulator precharging pressure 16bar
・ GAUGE AND TOOL
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(A).
procedure in this group.) A
3) Heat hydraulic oil to specification.(See
group.)
4) Run engine at low idle for 1 minute and
stop engine, wait for 5 minutes. Then start
measuring.
5) If pressure in not within specifications,
replace valve. The valve is staked and
should not be adjusted.
6 -57
12. CYCLE TIME TEST
・ SPECIFICATION
Oil temperature 45±5° C(113±9°
F)
Function Operating conditions Maximum cycle time(Seconds)
Boom raise Bucket flat on ground to full height 6.3

Boom lower(Float) Full height to ground level 3.5
Bucket dump Boom at full height 1.3
Bucket rollback Boom at full height 1.7
Steering(Number of turns) Frame stop to stop 1.6(3.9 turns)
Hydraulic pump performance cycle time.
Function Operating conditions Maximum cycle time(Seconds)

Bucket flat on ground to full height
Boom raise 8.0
while holding steering over relief
6 -58
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.
1
2) Remove the bolts(1) and take out the filter
case cover(2) and O-ring(3). 2
3) Remove the spring(4) and bypass valve(5). 3
4) Remove the filter element(6) from the tank. 4
5) Check the element and the filter case 5
bottom for debris. Excessive amounts of
brass and steel particles can indicate a 6
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(For
the first replacement, at 50 hours) or
more often. When the filter element is
replaced, please keep as follows.
.(1) Clean the inside of the filter case.
(2) Place new element in the proper positions
inside the filter case.
(3) Install the bypass valve and spring.
Make sure the element stand upright, and
check for complete contact of the element
bottom with the filter case bottom.
(4) Install the O-ring and filter case covers.
Tighten them with bolt. Replace the O-
ring with new one if damaged.
6 -59
1. MAIN PUMP
1) STRUCTURE(1/2)
B CARTRIDGE
5
4
3 15
2
1
D CARTRIDGE
13 14
12
11
9 10
7 8
6
1 Cap screw 9 Ball bearing

2 End cap 10 External snap ring
3 Seal 11 Splined shaft
4 Cartridge B assy 12 Shaft seal
5 Center housing 13 Seal
6 Cartridge D assy 14 Mounting cap
7 Internal snap ring 15 Cap screw
8 External snap ring
6 -60
STRUCTURE(2/2)
4-1 6-1
4-2 6-3
6-2
4-3 6-4
4-4 6-5
6-6
4-5
4-6 6-7
4-8 6-9
4-7 4-9 6-8 6-10
4-10 6-11
4-13 6-14
4-11 6-12
4-12 6-13
B CARTRIDGE D CARTRIDGE
4 Cartridge assy 4-10 Pressure plate 6-6 Cam ring

4-1 Screw 4-11 Seal 6-7 Vane
4-2 Lock pin 4-12 Seal 6-8 Vane holdout pin
4-3 Port plate 4-13 Back up ring 6-9 Rotor assy
4-4 Dowel pin 6 Cartridge assy 6-10 Dowel pin
4-5 Cam ring 6-1 Screw 6-11 Pressure plate
4-6 Vane 6-2 Lock washer 6-12 Seal
4-7 Vane holdout pin 6-3 Lock pin 6-13 Seal
4-8 Rotor assy 6-4 Port plate 6-14 Back up ring
4-9 Dowel pin 6-5 Dowel pin
6 -61
2) GENERAL INSTRUCTION
(1) Preliminary
※ Any servicing work done on main pump is to be done in a clean environment to prevent potential
contamination by foreign particles.
※ Appropriate tools and equipment are required in order to insure proper disassembly and
reassembly in suitable conditions. In case of repetitive service, a specific working bench is
recommended.
※ To prevent oil leakage and body tilting during assembly, housing bolts are to be tightened as per
the following pattern !
1 3 3 1
5 6
7 4
4 2 2
(2) Parts
※ Parts must be kept clean at all time. If cleaning is needed, solvent is to be used. It is needed to
check and oil the inner parts before assembly.
※ In case of replacement of parts with mulitiple numbers, such as vanes and holdout pins, all the
parts are to be changed.
① Vanes
The faces and edges should be free of scratch from contamination. Vanes should move
smoothly in the rotor slots, without excessive clearance. Edges may be stoned with a fine lndia
stone to remove burrs.
② Vane holdout pins :
Holdout pins should have no matting marks.
Vane
Rotor
Pin
③ Rotor :
Side surfaces and vane slots should be free of scratches. Side feeds, vane slots and holdout pin
orifices should be free of any contamination. Serration(driving splines) should not be deformed
by the shaft.
6 -62
④ Camring :
No scratches or vane shock marks(waves) should be seen. Visual axial waves on new camring
are from grinding process and therefore normal.
⑤ Port plates :
Faces should not be scratched. No cavitation/aeration/fretting corrosion marks should be seen.
When there, the bronze bushing should be clean, with no abnormal wear sign.
Bi-directional cartridges use same port plates for CW and CCW rotation. Unit-directional
cartridges require different port plates.
⑥ Seals :
・ All oil seals must be cleaned, with no wear or cutting mark. When servicing a pump from field
operation, it is highly recommended to change all seals. All seals are to be greased lightly
before assembly.
・ Use seal driver tool to install shaft seal, and protective cone to install shaft assembly.
・ Backup rings(1) on pressure plates are to be replaced, anytime a cartridge is taken out of a
pump. Backup rings are to be installed as follow, behind the square seal :
Back up ring Seal
⑦ Shaft :
・ Key-way should be clean and not worn on the sides by excessive torque. No fretting corrosion
due to poor coupling should be visible. On spline shaft, splines should not be deformed.
・ No axial scratch should be on the sealing area(1). The shaft seal lip contact line may be visible,
but should not be a groove. Bronze-bushing contact area(2) should be clean and cylindrical,
without scratch marks.
6 -63
2 4 1
・ Ball bearing(3) should turn freely and snap ring(4) should be in place. Some shaft assemblies
have 2 snap rings, before and after the ball bearing.
※ Never insert a snap ring from shaft seal side, to avoid scratching the sealing surface.
※ Use protective cone to install shaft assembly. If not available, make sure not to damaged the
shaft seal lips.
(3) Pre start check and priming.
① Before operating the pump again, the following points are to be checked :
・ Pump rotation is as per electric motor or engine.
・ All fittings are properly connected and tight. No oil-leak and/or air intake being allowed.
・ If any, valve on suction line is to be fully opened.
② When electric motor or engine is started up, the pump should prime immediately. However,
depending on installation and amount of air in the discharge lines, priming may take a few
seconds.
③ In case priming does not occur within 15 seconds, equipment should be switched off at once.
・ Then :
・ Manually fill the pump housing with fluid.
・ Bleed off air that may be trapped in the pump.
・ Check air bleed-off valves.
6 -64
3) DISASSEMBLY
(1) Pump
14
① Securely hold the pump in a vise or 15
similar equipment, at front cap(2) level. 13
② Unscrew the endcap bolts(15). D
③ Note the porting then remove end cap
(14) and cartridge D together.
④ Remove seal(13).
⑤ Extract D cartridge from end cap(14) by

using a gear puller or by prying upward.
Care must be taken not to damage the
parts.
D
14
⑥ Unscrew the 7 bolts(1).

⑦ Note the porting then remove central
housing(5).
⑧ Remove seal(3). 5
3
1
6 -65
⑨ Extract B cartridge from front cap(2) by
using a gear puller or by prying upward.
Care must be taken not to damage the
parts.
B
(2) Camring replacement, cartridge change of

rotation
Camring change
① Unscrew the 2 bolts(4-1) holding the cartridge
together. 4-1 4-2
② Remove rear plate(4-3), save dowel pin(4-4). 4-3

③ Take out camring(4-5) carefully, save dowel
pin(4-9). Leave rotor and vane in place. 4-4
④ Install dowel pin(4-9) in pressure plate(4-10)

4-5
orifice.
※ Rotation should match the arrow in the port
cutout(a) closest to the dowel pin.
⑤ Install new camring.
4-9
※ Arrow on the camring size should be as per
required rotation. a 4-10
⑥ Install dowel pin(4-4) on camring.

4-13
⑦ Install back rear plate(4-3), then tighten the
bolts(4-1). Make sure dowel pin(4-2) is in
place.
⑧ Replace back up ring(4-13). Change other
seals if damaged.
6 -66
Change rotation
① Proceed as per above for disassembly. 4-1 4-2
② Save camring(4-5), remove rotor+vanes+pins. 4-3

※ Change of rotation requires exchange of
port plates. 4-4
③ Install carefully rotor+vanes+pins on new
pressure plate(4-10). 4-5
④ Flip camring from previous position.

Then proceed reassembly as per above,
with new rear plate(4-3).
4-9
a 4-10
4-13
(3) Shaft
① Remove circlip(7) from front cap(14).
② Gently tap the shaft end with a plastic
tipped hammer to extract the shaft
assembly. 12
※ Unless pump is new, when changing the 7
shaft assembly always install a new shaft
seal(12). 14
(4) Shaft seal

① Remove shaft seal(12) from front
cap(14).
12
※ Removed shaft seal should not be
reused.
It must be disposed of as per local
14
environ-mental regulation.
6 -67
4) ASSEMBLY
(1) Shaft seal
(2) Shaft
(3) Pump
① Securely hold the pump in a vise or 3
similar equipment, at central housing(5)
level(light grip). B
② Insert B cartridge carefully.
※ If not new, seals and back up ring are to
4-2
be replaced.
5
inserted in the corresponding hole in the
central housing (5).
③ Install new seal(3) in central housing(5).
④ Insert front cap+shaft assembly(A)

carefully. Shaft should go through B
cartridge smoothly.
※ When inserting B cartridge in front cap,
make sure the white Teflon back-up ring A
1
(4-13) is not damaged and securely in
place. 4-3
⑤ Use the bolts(1) to insure the front cap
goes down straight and does not tilt. B
⑥ Tighten bolts(1) to the indicated torque.
・ Tightening torque : 19.4kgf・m(140lbf・ft)
⑦ Return the pump then securely hold it

again in the vise at front cap level. D 6-13
⑧ Insert D cartridge carefully. 6-12

※ If not new, seals and back up ring are to
be replaced. 6-3
inserted in the corresponding hole in the 5
central housing(5).
⑨ Make sure seal(6-13) is on B cartridge.
⑩ Install seal(6-12) in central housing(5).
6 -68
⑪ Insert end cap(14) carefully on D cartrid-
15 14
ge.
6-14
※ When inserting D cartridge in end cap, 13
make sure the white Teflon backup
ring(6-14) is not damaged and securely D
in place.
⑫ Use the bolts(15) to insure the end cap
goes down straight and does not tilt.
⑬ Tighten to bolts(15) to the indicated
torque.
・Tightening torque : 19.4kgf・m(140lbf・ft)
※ Final check : shaft must rotate when turn
by hand.
(2) Shaft
① Install the protective cone(A) on the shaft
end (11). Grease the protective cone
external surface.
② Apply small amount of grease on the
shaft seal lip. 12
③ Insert very carefully the shaft assembly

with protective cone in the front cap(14). 14
※ Do not damage the seal lips(12).
④ Complete insertion using a constant 11
press load on the bearing outer ring.
※ Do not use hammer. A
⑤ Install circlip(7) in front cap(14).
(3) Shaft seal

① Install very carefully the shaft seal(12) on
the seal driver(B).
※ Grease the seal driver seal lips(12)
※ damage.
Make sure seal is mounted as per above. B
②
With the shaft seal securely installed on
the seal driver, insert the shaft seal(12) in 12
the front-cap(14).
③ 14
Complete insertion using a constant
※ press load (1020kgf・m[7376lbf・ft] Max).
Do not use hammer.
6 -69
2. BOOM AND BUCKET CYLINDER
1) BOOM CYLINDER
9,8 6,5 3 7 24 23 11,10 4 2 25,26,27 14,13 17 15 16 22 19 18 24 23
20 1 21 12 28,29

5 Rod seal 15 Piston seal 25 Clamp
6 Back up ring 16 Wear ring 26 Bolt
7 Buffer ring 17 Dust ring 27 Spring washer
10 O-ring 20 Bolt
6 -70
2) BUCKET CYLINDER
9,8 6,5 7 3 4 11,10 2 25, 25-1 1 14,13 12 17 15 16 19 18 28,29
26,27 20 24 23 21 22

5 Rod seal 15 Piston seal 25 Band assy
6 Back up ring 16 Wear ring 25-1 Bolt
7 Buffer ring 17 Dust ring 26 Bushing
8 Dust wiper 18 Lock nut 27 Dust seal
9 Snap ring 19 Set screw 28 Bushing
10 O-ring 20 Bolt 29 Dust seal
6 -71
2) TOOLS AND TIGHTENING TORQUE
(1) Tools
Tool name Remark
8
10
Allen wrench B
14
17
17
Spanner
19
(-) Driver Small and large sizes
Tourque wrench Capable of tightening with the specified torques

Size
Part name Item Size
kgf・m lbf・ft
Bucket cylinder 20 M16×2.0×65 23±2 166±14
Socket head bolt
Boom cylinder 20 M20×2.5×70 46±5 333±36
Bucket cylinder 19 M10×1.5×12 5.4±0.5 39±3.6
Set screw
Boom cylinder 19 M10×1.5×12 5.4±0.5 39±3.6
Bucket cylinder 18 M64×3.0×38 150±15 1085±108
Piston nut
Boom cylinder 18 M90×3.0×45 150±15 1085±108
Bucket cylinder 12 D160×63 100±10 723±72
Piston
Boom cylinder 12 D200×77 100±10 723±72
Bucket cylinder 24 M10×1.5×55 5.4±0.5 39±3.6
Socket head bolt
Boom cylinder 24 M12×1.75×60 9.4±1 68±7.2
Bucket cylinder 25-1 M12×1.75×45 5.5±0.6 40±4.3
Hex head bolt
Boom cylinder 26 M10×1.5×15 3.2±0.5 23±3.6
6 -72
3) DISASSEMBLY
(1) Remove gland and piston rod
① Hold the clevis section of the tube in a
vise. Use mouth pieces so as not to
damage the machined surface of the
cylinder tube. Do not make use of the
outside piping as a locking means.
② Pull out piston rod(2) about 200mm

(7.8 in). Because the piston rod is rather
heavy, finish extending it with air
m
0m
20
pressure after the oil draining operation.
③ Loosen and remove socket blots(20) of

the gland(3) in sequence. 20
※ Cover the extracted piston rod(2) with
rag to prevent it from being accidentally
damaged during operation. 3
2
Cover hear
with rag Hexagon
socket wrench
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) 2
with a crane or some means and draw it
3
out. However, when piston rod(2) has
been drawn out to approximately two
thirds of its length, lift it in its center to Oil pan
Pull straight
draw it completely. sideways
6 -73
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
(2) Remove piston and gland assembly

① Loosen the screw(19) and remove the 13,14 17 15 12 16 19
piston nut(18).
② Remove piston assembly(12), back up
ring(14), O-ring(13).
③ Remove the gland assembly from piston

Lift with a crane
rod(2).
※ If is too heavy to move, move it by Plastic 3 4 2
Hammer
striking the flanged part of gland(3) with a
plastic hammer. Pull straight
※ Pull it straight with gland assembly lifted
with a crane.
Exercise care so as not to damage the lip
of rod bushing(4) and packing(5, 6, 7, 8,
9) by the threads of piston rod(2).
6 -74
(3) Disassemble the piston assembly
① Remove wear ring(16). 16 15 16
Remove and piston seal(15).
Exercise care in this operation not to
damage the grooves.
(4) Disassemble gland assembly

① Remove back up ring(11), and O-ring 9,8 6,5 7 11 10 4
(10).
② Remove snap ring(9) and dust wiper(8).
③ Remove back up ring(6), rod seal(5) and
buffer ring(7).
damage the grooves.
※ Do not remove seal and ring, if does not
damaged.
6 -75
4) ASSEMBLY
(1) Assemble gland assembly
① Coat the inner face of gland(3) with
hydraulic oil.
3
② Coat dust wiper(8) with grease and fit

Press here
dust wiper(8) to the bottom of the hole of (Straight down)
dust wiper.
Metal
③ At this time, press a pad metal to the
8
metal ring of dust seal.
Fit snap ring(9) to the stop face.
④ Fit back up ring(6), rod seal(5) and buffer

ring(7) to corresponding grooves, in that
order.
※ Coat each packing with hydraulic oil
Wrong Right
before fitting it.
※ Insert the backup ring until onside of it is
inserted into groove.
※ Rod seal(5) has its own fitting direction.

Therefore, confirm it before fitting them.
Push bar
※ Fitting rod seal(5) up side down may
damage its lip. Therefore check the
correct direction that is shown in fig.
5
6 -76
⑤ Fit back up ring(11) to gland(3).
※ Put the backup ring in the warm water of
30~50° C.
10
⑥ Fit O-ring(9) to gland(3).
11
(2) Assemble piston assembly

① Coat the outer face of piston(12) with
hydraulic oil.
② Fit piston seal(15) to piston

※ Put the piston seal in the warm water of 15
60~100° C for more than 5 minutes.
※ After assembling the piston seal, press
its outer diameter to fit in.
③ Fit wear ring(16) and dust ring(17) to

piston(12). 14,13 17 15 16 12
④ Fit back up ring(14) and O-ring(13) to
piston(12).
6 -77
(3) Install piston and gland assembly
① Fix the piston rod assembly to the work Gland assembly
bench.
Piston rod
② Apply hydraulic oil to the outer surface of
piston rod(2), the inner surface of piston
and gland.
③ Insert gland assembly to piston rod(2).
④ Fit piston assembly to piston rod.

・ Tightening torque : 100±10kgf・m Piston assembly
(723±72lbf・ft)
Piston rod
⑤ Tighten piston nut(18) and screw(19) to

piston rod(2). 2 19 18
・ Tightening torque
Item kgf・m lbf・ft
18 150 ± 15 1085 ± 108

19 5.4 ± 0.5 39 ± 3.6
6 -78
(4) Overall assemble
Fix with bar
① Place a V-block on a rigid work bench.
Mount the cylinder tube assembly(1) on it Lift 1
and fix the assembly by passing a bar
through the clevis 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
crane.
※ Be careful not to damage piston seal by
thread of cylinder tube.
③ Match the bolts holes in the cylinder
head flange to the tapped holes in the
cylinder tube assembly and tighten
socket bolts to a specified torque.
※ Refer to the table of tightening torque.
Hexagon
socket wrench
6 -79
Group 1 Component Location 7-1

Group 2 Electrical Circuit 7-3
Group 3 Monitoring System 7-23
Group 4 Electrical Component Specification 7-39
Group 5 Connectors 7-47
Group 6 Troubleshooting 7-61
GROUP 1 COMPONENT LOCATION
1. LOCATION 1
8 14
9 15
10 16
11 17
1 12 18
2 13
3
4 19
Switch panel
5 20
6 21
22
23
24
LO LE
ID
D S
IA IS
-O
G
N
LO LE
ID
DI SI
AG S
-O
7 25
26
27
1 Horn button 10 Work lamp switch 19 Hazard switch

2 Multi function switch 11 Main light switch 20 Kick down switch
3 Starting switch 12 Clutch cut off switch 21 Low idle switch
4 Cluster 13 Parking brake switch 22 Incre/decrement switch
5 Gear selector lever 14 Full automatic switch 23 Diagnostics switch
6 Kick down switch 15 Rear wiper/washer switch 24 Aircon and heater switch
7 Service meter 16 Buzzer stop switch 25 Fuse box
8 Ride coutrol switch(Option) 17 Pump motor switch 26 Check unit
9 Beacon switch(Option) 18 Aircon switch 27 Control unit
7-1
2. LOCATION 2
3
4
5
6
7
1
8
9
10
2 11
12
13
14
15 16 17 18 19
1 Proximate switch 8 Engine oil pressure switch 14 Battery

2 Horn 9 Start relay 15 Engine coolant temp switch
3 Head lamp 10 Work lamp 16 Back up buzzer
4 Front turn lamp 11 Rear turn lamp 17 Master switch
5 Gauge board assy 12 Alternator 18 Fuel sender
6 T/M oil pressure switch 13 Battery relay 19 Number plate lamp
7 T/M oil temp switch
7-2
1. ILLUMINATION CIRCUIT
1) OPERATING FLOW
Fuse box (No.2) Illumination switch [CS-39(1)] Switch ON, 1st step
[CS-39(7)] Hazard and illumination switch indicator lamp ON
[CS-39(5)] Fuse box(27) I/conn [CN-3(12)] I/conn[CN-155(4)
RH Combi clearance lamp ON [CL-16(4)]
I/conn [CN-10(1)] LH Head lamp ON [CL-3(4)]
I/conn [CN-7(14)] All cluster guage lamp ON
Fuse box(28) I/conn [CN-3(1)] No. plate lamp ON [CL-21(2)]
I/conn[CN-156(4) LH Combi clearance
lamp ON [CL-15(4)]
I/conn [CN-10(2)] RH Head lamp ON [CL-4(4)]
2) CHECK POINT
Engine Key switch Check point Voltage
① - GND (Switch input)

② - GND (Switch output)
OFF ON 20~25V
③ - GND (To light)
④ - GND (To gauge lamp)
※ GND : Ground
7-6
ILLUMINATION CIRCUIT
FUSE BOX
BEACON LAMP 20A
aAb aBb
a1b a2 b a3
ILL. LIGHT
10A
HEAD LIGHT 20A
aC
HIGH BEAM
25 b a 26 b a 27 b a 28 b
ECM IG RY
Yb
ECM IG 5A
a Z b a AA b a BB b
019 1.25 R
CLEARANCE F/L R/R 5A
015 1.25 R
ILL. DISPLAY,GAUGE
028 1.25 R
CLEARANCE F/R R/L 5A
ILL.AC,CIGAR
CN-36
LH HEAD LIGHT
5
1 Lo
6
2 Hi
7 G11 B
3 E
8 10 W
4 C
2 9
CL-3
10
ILL & HEAD LAMP SW 11 3
G19 1.25 B RH HEAD LIGHT
9 10 10 12
131A 1.25 R 1 Lo
9 CN-8
4 8 2 Hi
019A 1.25 R G22 B
2 131 1.25 R 1 3 E
7 028A 1.25 R 11 R
2 4 C
7 1 6
5 055 1.25 BR 3 CL-4
5
4
4
3
5 3
NUMBERPLATE LAMP
6
II I 0
2 1
003 1.25 OR 7
1 620A 1.25 R
8 2
CS-39 CL-21
CN-10
028B 1.25 R 620 1.25 R 3
1
1 2
6
5 RH COMBI
3 663 1.25 W
4 4 C
4
3 3 T
5 G74 1.25 B
2 2 E
6
1 1 S
7 CN-155 CL-16
8
9 6 3
10 5 LH COMBI
620B 1.25 R
11 4 4 C
019B 1.25 R 663 1.25 W
12 3 3 T
G77 1.25 B
13 2 2 E
14 1 1 S
CN-3 CN-156 CL-15
1 SPEED METER
2 E1
314B 0.85 R
B1
3
3 E
131B 1.25R
4 4 B km/h
5 8 S
6 E2
314C 0.85 R
B2
7
CN-127
CS-41
8
T/M TEMP
10 10
9
8
6 7
6
5 5
4
3
2
1
9 E
314A 0.85 R
10 B
11
G - C
12
I +
13 S S
015B 1.25 R 317 0.85 R
8
2
7
1
9
14 CN-119
HAZARD SW
CN-7 WATER TEMP
E
314D 0.85 R
B
4
G - C
I +
S S
CN-117
VOLT METER
E
314E 0.85 R
B
G - C
I +
S S
CN-104
FUEL METER
E
314F 0.85 R
B
G - C
I +
S S
CN-107
7-7
2. HEAD LIGHT CIRCUIT
1) OPERATING FLOW
Fuse box(No.3) Head light switch [CS-39(4)] Light switch ON, 2nd step [CS-39(2)]
Multi function switch [CS-11(8)]
Multi function switch MIDDLE [CS-11(7)] I/conn [CN-10(4)] LH Head light low beam
ON [CL-3(1)]
RH Head light low beam
ON [CL-4(1)]
Multi function switch DOWN [CS-11(6)] I/conn [CN-10(3)] LH Head light high beam
ON [CL-3(2)]
RH Head light high beam
ON [CL-4(2)]
I/conn [CN-7(3)] I/Conn[CN-57(1)]
Cluster high beam pilot lamp ON
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
BEACON LAMP 20A
aAb aBb
a 1 b a 2 b a 3 b 25 b a 26 b a 27 b a 28 b
ILL. LIGHT
10A
HEAD LIGHT 20A
aC
HIGH BEAM
Yb
ECM IG 5A
a Z b a AA b a BB b
ILL. DISPLAY,GAUGE
CLEARANCE F/R R/L 5A
ILL.AC,CIGAR
CN-36
5 LH HEAD LIGHT
6 13A G
1 Lo
7 12A V
2 Hi
8 G11 B
3 E
ILL & HEAD LAMP SW 9 4 C
9 10 10 10
9 1 11
B G11 CL-3
4 8 B G21
2 12 RH HEAD LIGHT
7 CN-8 13 G
1 Lo
7 1 6 7 12 V
2 Hi
5 5 1 G22 B
004 1.25G 3 E
4 2
030B 1.25V 4 C
3 3
045 1.25W 402 1.25GY CL-4
II I 0
2 4
1 5
CS-39 6
7
2 8 6
CN-10
1
HI BEAM
2
030A 1.25 V 313 1.25 V
3 1
4 2
5 3
6 4
7 5
8 6
9 7
10 8
402 1.25 GY
045 1.25 W
046 1.25 G
030 1.25 V
11 9
4 12 10
3 13 11
5 8 14 12
CN-7 13
CN-57
CS-11
5
8
4
7
3
2
1
BWG 4
W6
Hi
C
Lo
Hi
B+
C
F
R
L
O
R
L
7 Y Lo
2 BW
8 WB
3 BG
5B
MULTI FUNCTION SW
7-9
3. WORK LIGHT CIRCUIT
1) OPERATING FLOW
※ Illumination switch : ON position
① Work lamp switch ON (1st step)
ILL & head lamp switch[CS-39(7)] Work lamp switch[CS-20(1)]
(5) Front work lamp relay[CR-3(2) (4)] I/conn[CN-5(4)] LH Front work lamp ON[CL-6(2)]
RH Front work lamp ON[CL-5(2)]
(7) Work lamp switch indicator lamp ON
② Work lamp switch (2nd step)
Work lamp switch[CS-20(4) (2)] Rear work lamp relay[CR-6(2) (4)]
I/conn[CN-3(10)] I/conn[CN-155(6)] LH Rear work lamp ON[CL-22(1)]
I/conn[CN-156(6)] 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 CIRCUIT
FUSE BOX
BEACON LAMP 20A
aAb aBb
a1b a2 b a3
003 1.25 OR
ILL. LIGHT
10A
HEAD LIGHT 20A
aC
HIGH BEAM
SWITCH PARKING 10A
a Ib
a 9 b a10 b a 11 b a12 b a 13 b
SWITCH CLUTCH
FRONT WIPER 20A
aJb
REAR WIPER
081 1.25 G
WORK LAMP FRONT 30A
aKb
WORK LAMP REAR
078 1.25 GY
RIDE CONTROL 10A
aL b
E-STEERING 10A
aM b
STEERING P/P RY
CN-36
2
3
1 1
2 FRONT WORK
FR WORK LAMP RY 3 LAMP,LH
502 1.25 OR OR 4 OR 4
3 4 4 4 2
157 1.25 W 5 B G11
3 1
081 1.25 G 6
2 CL-6
G21 1.25B
7 B G11 3
1 2 1 8 FRONT WORK
LAMP,RH
CR-3 2 CN-5 OR 4A
2
B G12
RR WORK LAMP RY
1
603 1.25 BR 1 CL-5
3 4 4 2
156 1.25 L
3
078 1.25 GY
3 4
2 4 REAR WORK
G22 1.25B LAMP,LH
1 5 630A 1.25 BR
1 2 6 1
6
CR-6 5 2
7
1 8 4 CL-22
WORK LAMP SW 9 3
10 2
9 10 10
9 11 1 4
4 8 12 CN-155 REAR WORK
2 158 1.25 G 13 LAMP,RH
7 630B 1.25 BR 1
14 6
7 1 6 2
5 157 1.25 W CN-3 5
5 CL-23
131E 1.25 R 4
4
3
3 156 1.25 L 2
II I 0
2
131F 1.25 R 1
1
CN-156
CS-20
CS-39
9 10 10
9
4 8
2 131 1.25 R
7
7 1 6
5 5
4
3
II I 0
2
003 1.25 OR
1
ILL & HEAD LAMP SW : ON(1st step)
7-11
4. STARTING CIRCUIT
1) OPERATING FLOW
Battery(+) terminal Battery relay(R4 terminal) Fusible link [CN-60(1)]
I/conn [CN-1(1)] Fuse box (No.15) Start switch [CS-2(1)]
※ The gear selector lever is neutral position. It is necessary condition before the starting.
The gear selector has an output signal which is activated whenever the shift lever is in the neutral
position. This signal can be used to control a relay and prevent engine from starting whenever the
shift lever is not in the neutral position.
(1) When start key switch is in ON position
Start switch ON Start switch [CS-2(2)] I/conn [CN-3(6)] Battery relay [CR-1]
Battery relay operating(All power is supplied with the electric component)
Start switch [CS-2(3)] Fuse box [No.21] Fuse box (No.25)
ECM IG relay [CR-45(86)→(87)] Fuse box (No.26)
I/conn [CN-3(9)] I/conn [CN-4(3)] ECM[CN-20(38)]
(2) When start key switch is in START position
Start switch START [CS-2(5)] Start safety relay [CR-5(30)] Start safety relay [CR-5(87)]
I/conn [CN-2(6)] [CN-4(7)] Start relay [CR-23(2)]
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+)
④ - GND (Start key BR terminal)
⑤ - GND (I/conn CN-3(6))
Running ON 20~25V
⑥ - GND (Start key ST terminal)
⑦ - GND (Start safety relay output)
⑧ - GND (Check unit)
⑨ - GND (Start key ACC terminal)
※ GND : Ground
※ ECM : Electronic control module
7-12
STARTING CIRCUIT
CONTROL UNIT CHECK UNIT
STEERING P/P PS
STEERING P/P LP
MAIN PUMP FAIL
NEUTRAL CODE
OVER HEAT SIG
FUSE BOX
CHARGE LAMP
STEERING SIG
BUZZER STOP
NEUTRAL SIG
STEERING RY
HOUR METER
PARKING SIG
NEUTRAL RY
E/OIL FILTER
b a 13 b a14 b a15 b a16 b a17 b a18 b a19 b a 20 b a 21

PARK LAMP
ENG OIL PS
ADM1
ADM5
SDDL
AIR FILTER
VPS2
VPS1
VPE2
E-STEERING
SPEED SIG
AIP7
AIP6
AIP8
AIP4
AIP1
ALT LEVEL
HYD TEMP
BRAKE PS
WASH SIG
WIPER RY
10A
ER2
SD2
EU2
ED1
ED5
ED2
ED9
ED6
aM b
TM LAMP
EF4
BUZZER
STEERING P/P RY
INT SIG
IG 24V
TM PS
PREHEATER RY
N.C
N.C
N.C
N.C
N.C
N.C
N.C
10A
GND
aNb
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
TURN LAMP
CN-58
20A
aO b a P b
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
902A 0.85 W
1
2
3
4
5
6
7
8
9
CASSETTE 10A
ROOM LAMP
826 1.25 W
IGNITION SWITCH 20A
aQ b a R b
202A 1.25 W 8
VM OUTPUT SIGNAL K A 018A 1.25 L T/M CONTROLLER 10A
VP F B N D B
ED 1 2 3 4 1 2 3 4 1 2 3 4 C ECM + 10A
SAFETY RY ECM IG RY
aSb
AD1 B1 D 052 1.25 R
AD2 B2 X2 A 30 86 30 87a ECM +
902B 0.85 W 202B 1.25 W 202 1.25 W 87a 87 85 10A
86
aT b aU
AD3 B3 B 85
AD4 V 850 1.25 V 065 1.25 R
C 87 87 RCV 10A
AD5 R A 018 1.25 L 069 1.25 W
AD6 AS B D 85 86 PROX.SWITCH
85 87 87a
AD7 C E 87a 30 86 30 5A
a 25 b
aTb
902 0.85 W
A AD3 D
F
7 CR-5 CR-45 835 1.25 R
ECM IG RY
X3 ECM IG
B AD2 G 5A
a 26 b
aTb
C AD1
D AD7(KD)
H
X1 CN-36
J
A ED1(VP) K 601 3R
D AD6
CN-15
B AD4 MASTER SW
BATTERY
C AD5
X2 BATT RY
R4 B G
605D 1.25 L R1
G79 1.25 B R3
R2
CR-1
1
602 5 W
1
2 2
601 3 R
CN-1 1
CN-60
605C 1.25 L
2
826C 1.25 W
1
DO-3
2
STARTER
605B 1.25 L
G78 1.25 B
2 B+
1
1 DO-2
2 605A 1.25 L
2
M
3
5 605 1.25 V CN-45
1
4 DO-1 START RY
5
G11 1.25 B
6 1
850 1.25 V
085 1.25 OR
053 1.25 GY
605 1.25 V
052 1.25 R
2
9 4 7
8 CR-23
9
6 3 835A 1.25 R ECM
10 1 36 DATA LINK J1939 SHIELD
11 1 2 37 DATA LINK J1939(-)
CS-2
635 1.25 R 835 0.85 R

12 2 3 38 KEY SWITCH
5
4
1
6
2
3
13 3 4 39 ECM SUPPLY RETURN

B 14 40 ECM SUPPLY RETURN
0, I 4 5
1
G61 1.25 B G10 1.25 B 44 DIAGNOSTIC/MANUAL SNAPSHOT

CN-3 5 6
650 1.25 V 850 1.25 V 45 ALT. LOW IDLE
6 7
46 DATA LINK J1939(+)
H 0 I II 7 8 47 THROTTLE POSITION SIG.
6
5
4
2
3
H
C ST ACC BR 8 9 48 THROTTLE POSITION +5V
START SWITCH 9 10 49 THROTTLE POSITION RETURN
10 11 50 ECM SUPPLY RETURN
11 12
CN-20
12 CN-4
CN-2
7-13
CHARGING CIRCUIT
CHECK UNIT FUSE BOX

BEACON LAMP 20A
aAb aBb
a1b a2 b a3
STEERING P/P PS
STEERING P/P LP
MAIN PUMP FAIL
NEUTRAL CODE
OVER HEAT SIG
ILL. LIGHT
CHARGE LAMP
STEERING SIG
BUZZER STOP
NEUTRAL SIG
10A
STEERING RY
HOUR METER
PARKING SIG
NEUTRAL RY
E/OIL FILTER
PARK LAMP
ENG OIL PS
AIR FILTER
SPEED SIG
ALT LEVEL
HYD TEMP
BRAKE PS
WASH SIG
WIPER RY
HEAD LIGHT
TM LAMP
BUZZER
20A
aC
INT SIG
HIGH BEAM
IG 24V
TM PS
N.C
N.C
N.C
N.C
N.C
N.C
N.C
GND
6
Mb
b a14 b a15 b a16 b a17 b a18 b a19 b a 20 b a 21b a 22 b a 23 b a 24b a 25b a 26 b a 27 b a 28 b

PREHEATER RY 10A
CN-58
aNb
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
TURN LAMP
1
2
3
4
5
6
7
8
9
20A 602 5 W
2 2
aO b a P b
601 3 R
1 1
301 1.25 W
826 1.25 W
CASSETTE RADIO 10A

ROOM LAMP CN-1 CN-60
IGNITION SWITCH 20A
aQ b a R b
5
T/M CONTROLLER 10A
ECM+ 10A
aSb
ECM+ 10A
a T b aUb
RCV
10A
PROX.SWITCH
1 CHECK UNIT 5A
aVb
2 HOURMETER
3 GAUGE BOARD 10A
aWb a X b a Y b
4 WARNING BUZZER
GEAR SHIFT 10A 1
5
A/M SWITCH
7 6 CASSETTE
BATTERY MASTER SW
5A BATT RY
7 VOLT METER
G38 0.85 B ECM IG RY B G
CHARGE E
8 ECM IG 5A
a Z b a AA b a BB b
301 1.25 W
9
B
1
319A 1.25 G G45 0.85 B CLEARANCE F/L R/R
2 10 B G 5A
319G 0.85 G ILL. DISPLAY,GAUGE
3 11 E I CR-1
S CLEARANCE F/R R/L 5A
4 12
CN-104 ILL.AC,CIGAR 2
5 13
6 CN-57 CN-36
7
8 STARTER
9 M
1
10
2
11
12
3 B+ M
13
4 3 CN-45
1 5 ALTERNATOR
14
2 6 852 15 R
CN-6 B+ G
3 7
826 1.25 W 826A 1.25 W 851 1.25 W 3
4 8 I
U
5 9 GND
6 10 CN-74
7 11 4
8 12
9 CN-4
10
11
12
13
14
CN-3
7-15
ELECTRIC PARKING, DECLUTCH CIRCUIT
7-17
CS-3
G11 1.25 B
9 10 10 142B 1.25 OR
9
137 1.25 W
3 8
7 6 5 Lo M
8 142 1.25 OR 142A 1.25 OR
6 6 5 4 Hi
1 4
5
3 1B
10
4 142A 1.25 OR
0,I
134 1.25 L 2 2Pf
3 127A 1.25 Y
3E
REAR WIPER
1
2 CN-102
127B 1.25 Y
II I 0
WIIPER AND WASHER CIRCUIT
REAR WIPER & WASHER SW

1
2
CN-58
1 IG 24V
2 ALT LEVEL
3 HOUR METER
4 PARK LAMP
CHECK UNIT
5 STEERING P/P LP
6 MAIN PUMP FAIL
CN-22 7 N.C
G54 1.25 B
M 1 8 PARKING SIG
022B 1.25 R
2 9 TM PS
049 1.25 Y
FRONT WASHER
10 INT SIG
11 SPEED SIG
CN-103
G53 1.25 B 12 HYD TEMP
M 1
134 1.25 L 13 GND
2
14 STEERING RY
036 1.25 GY
15 WIPER RY
16 TM LAMP
REAR WASHER
17 BUZZER
18 CHARGE LAMP
19 N.C
20 STEERING SIG
022A 1.25 R
21 WASH SIG
22 NEUTRAL SIG
23 ENG OIL PS
24 OVER HEAT SIG
25 NEUTRAL RY
8 26 N.C
Hi 7 27 N.C
F Lo
6 28 N.C
L
O 5 29 N.C
R 4 30 N.C
5B
B+ 3 31 E/OIL FILTER
2 32 STEERING P/P PS
7-20
1 33 NEUTRAL CODE
MULTI FUNCTION SWITCH

CS-11 34 BUZZER STOP
8 WB 35 BRAKE PS
36 AIR FILTER
7 Y Lo W6
Hi
2 BW L
BWG 4
3 BG C
R
II
I
1
9
0
J 0 G 5
CS-12
II BVi 3 014B 1.25 L
6
I L 4 086 1.25 OR
5
048 1.25 G
4
J BY 1 047 1.25 OR
3
C RW 6 022 1.25 R
2
049 1.25 Y
014 1.25 L
127 1.25 Y
W Gr 2 1
HO Y
CN-36
HORN
CS-5
FUSE BOX
7
E-STEERING
STOP LAMP
REAR WIPER
RIDE CONTROL
FRONT WIPER
STEERING P/P RY
AIR CON RELAY
CIGAR LIGHTER
WORK LAMP REAR

SWITCH CLUTCH
SWITCH PARKING
WORK LAMP FRONT

AIR CON&HEATER
aM b aL b aKb aJb a Ib aH b aGb aF b aE b b
CN-21
5A
10A
10A
30A
20A
10A
20A
20A
20A
013A 1.25 W
3E 1 a 9 b a10 b a 11 b a12 b a 13 b a 8b a 7b a 6b b a 5b
086 1.25 OR
2Pf 2
G51 1.25 B
1B 3
077 1.25 G
4
4 Hi 066 1.25 R
5
FRONT WIPER
M
5 Lo 6
5
4
6
025 1.25 B
066 1.25 R
077 1.25 G
048 1.25 G
013 1.25 W
3
014A 1.25 L
036 1.25 GY
047 1.25 OR
013B 1.25 W
013C 1.25 W
85
87
86
85
87
86
30
30
87a
87a
CR-4
CR-26
30 86
30 86
87a 87 85
87a 87 85
WIPER RY LO
WIPER RY HI
MONITORING CIRCUIT
CHECK UNIT STOP

1 1 T/M TEMP
WARNING E
STEERING P/P PS
STEERING P/P LP
2 2 B
MAIN PUMP FAIL
NEUTRAL CODE
OVER HEAT SIG
CHARGE LAMP
G - °C
STEERING SIG
BUZZER STOP
3 3
NEUTRAL SIG
STEERING RY
HOUR METER
PARKING SIG
NEUTRAL RY
E/OIL FILTER
OVER HEAT I +
PARK LAMP
ENG OIL PS
4
AIR FILTER
4
SPEED SIG
S S
ALT LEVEL
HYD TEMP
BRAKE PS
WASH SIG
WIPER RY
HYD TEMP
TM LAMP
5
BUZZER
5 CN-119
INT SIG
IG 24V
TM PS
6
N.C
6
N.C
N.C
N.C
N.C
N.C
N.C
GND
7 WAIT TO START
7
BRAKE OIL 8 WATER TEMP
8
CN-58
E
9 9 B
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
1
2
3
4
5
6
7
8
9
ENGINE OIL
10 10 G - °C
MAINTENANCE I +
038 1.25 W
11
302 1.25 R
029 1.25 V
034 1.25 OR
11
408 1.25 GY
116 1.25 BR
S S
12 12 CN-117
13 13
PARKING CN-56 CN-57
FUEL METER
E
B
G -
I +
S S
CN-107
1
302 1.25 R 302 1.25 R
2
3
116A 1.25 BR 305 1.25 BR
4
034A 1.25 OR 306 1.25 OR
5
6
029B 1.25 V 308 1.25 V
7
038B 1.25 W 309 1.25 W 1
8
9 2
10 3
814 1.25 OR 384 1.25 OR
11 4
1 815 1.25 V 385 1.25 V
GY 2 12 5
2 827 1.25 W 387 1.25 W
13 T/M OIL TEMP 6
3 816 1.25 Y 386 1.25 Y
14 701 1.25 W C 7
4 CN-6 8
5 9
CD-29 371 1.25 W
6 10
7 388 1.25 BR
11
8 361 1.25 OR
12
9 13
10 1
14
11 2 CN-7
12 3
CN-8 4
5
6
7 WATER TEMP
854 0.85 G C
8
9
854 1.25 BR 654 1.25 G 854 0.85 G CD-8
1 10
116B 1.25 BR 655 1.25 BR 855 1.25 BR
2 11 ENG OIL PRESS
034B 1.25 OR 656 1.25 OR 856 1.25 OR 856 1.25 OR
3 12 1 Pa
4 CN-4 2
CN-2
CD-18
CN-20
2 ALT. TORQUE 1 OVER HEAT SW
616 1.25 Y 827 0.85 W
1 1 3 OFF IDLE SW 2 855 1.25 BR T
627 1.25 W 827 0.85 W
2 2 4 WAIT TO STOP LAMP 3
615 1.25 V 815 0.85 V
3 3 5 MAINTENANCE LAMP 4
614 1.25 OR CD-9
4 4 6 STOP LAMP 5
816 0.85 Y
5 7 ECM SUPPLY(+) 6 FUEL SENDER
5
029A 1.25 V
G72 1.25 B
G61 1.25 B
6 8 7 1
6 ECM SUPPLY(+) 661 1.25 OR 661 1.25 OR
7 9 8 2
7 PANEL GROUND
2 GY
9F B
8 9 CD-2
8 10 PANEL GROUND
9 10
9 13 ON IDLE SW
CD-26
10 11
CD-3
14 DIAGNOSTICS INCREMENT
1
2
10
2
HYD TEMP SW 11 12
11 16 WARNING LAMP
12 13
038A 1.25 W 17
Pa
ECM SUPPLY(+)
Pa
13 CN-4 14
14 CN-3
PARKING OIL PS BRAKE OIL PS CD-1 CN-14
7-21
HAZARD, TURN AND ROTARY CIRCUIT
1
135B 1.25 L 6
2 COMBI LAMP RH 1
5 ROTARY LAMP
3 161B 1.25 GY GY 2 2 GY
4 4 C 2
4 664 1.25 GY G13 B
3 3 T 3
5 G74 1.25 B
2 2 E 4 CL-7
6 1 1 S
5
7 CN-155 CL-16 FUSE BOX
6 083 1.25 G
8 BEACON LAMP 20A
aAb aBb
a1b a2 b a3
6 7
9 COMBI LAMP LH B G11
5 8 ILL. LIGHT
10 10A
136A 1.25 GY 665 1.25 L 4 4 C CN-5
11 3 3 T HEAD LIGHT
G75 1.25 B 20A
aC
12 2 2 E HIGH BEAM
13 1 1 S
b a14 b a15 b a16 b a17 b a18 b

14 CN-156 CL-15 PREHEATER RY 10A
aNb
CN-3 009 1.25 R
TURN LAMP 20A
aO b a P b
CASSETTE 5A
ROOM LAMP
FLASHER UNIT IGNITION SWITCH 5A
aQ b a R b
141C 1.25 BR
1 L
009 1.25 R G T/M CONTROLLER
2 B 20A
G62 1.25 B
3 E
ECM+
CR-11
CN-36
LH TURN
1
135C 1.25 L 311 1.25 L
1 2
136C 1.25 GY 312 1.25 GY
2 3
3 4
4 5
5 CN-57
6
1
7
2
8
3
9
4
10 RH TURN
5
11
6
12
7
13
8
14
9
CN-7
10
1 11
2 12
3 13
136B 1.25 GY
141B 1.25 BR
4
135A 1.25 L
CN-56
5
6 LH TURN,FR
14 L
7 2
G12 B
8 1
CS-11
CS-12
CS-5
6
5
4
3
2
1
8
7
6
5
4
3
2
1
9 CL-24
10 RH TURN,FR
141A 1.25 BR
161A 1.25 GY
15 GY
136 1.25 GY
141 1.25 BR
161 1.25 GY
11 2
BWG 4
G10 1.25 B
G16 1.25 B
RW 6
083 1.25 G
W6
135 1.25 L
BVi 3
L 4
G 5
BY 1
G23 B
Gr 2
12 1
Y
CN-8 CL-25
HO
W
II
I
Hi
C
J 0
J
C
1
0
II
CS-41
I
Lo
CS-23
2
10 10
10 10
9
8
7
6
5
4
3
2
1
9
8
7
6
5
4
3
2
1
3
Hi
B+
F
4
5
6
R
5
6
L
O
135D 1.25 L L 14
R
L
5
138D 1.25 GY GY 15
6
7 Y Lo
8 WB
2 BW
3 BG
5B
7
9
8
2
7
1
8
2
7
1
8
HAZARD SWITCH BEACON LAMP SWITCH MULTI FUNCTION SWITCH CN-10
7-22
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(I)] I/conn [CN-4-1(8)→CN-4(8)] I/conn [CN-3(4)]
Check unit [CN-58(2)→(18)] I/conn [CN-6(1)] I/conn [CN-57(9)]
Cluster charge warning lamp ON I/conn [CN-57(10)] Volt meter [CN-104]
(2) Charging flow
Alternator Starter [CN-45(B+)] Battery relay [CR-1]
Battery(+) terminal Charging
I/conn [CN-60(1),(2)] I/conn [CN-1(1),(2)] Fuse box
2) CHECK POINT
① - GND (Battery)
② - GND (Battery relay)
③ - GND (ALT B+)
Running ON 20~28V
④ - GND (ALT I)
⑤ - GND (Check unit)
⑥ - GND (Fuse box)
Engine Key switch Check point Resistance
Running ON ⑦ - GND (Cluster) ∞Ω

※ GND : Ground
7-14
6. ELECTRIC PARKING, DECLUTCH CIRCUIT
1) OPERATING FLOW
(1) Parking OFF
Fuse box (No.9) Parking switch OFF [CS-17(6) (8)] I/conn [CN-8(3)]
Parking solenoid ON (Activated) Parking brake released (By hydraulic pressure)
(2) Parking ON
Fuse box (No.9) Parking switch ON Parking solenoid [CN-71] OFF
Parking brake applied [By spring force]
[CS-17(6) (2)] Parking switch indicator lamp ON
[CS-17(5) (7)] I/conn [CN-15(F)]
T/M control unit [X1(21)] T/M declutch
(3) Declutch ON
Fuse box (No.9) Clutch cut-off switch ON Clutch cut-off switch [CS-42(6) (2)]
Clutch cut-off switch indicator lamp ON
Clutch cut-off switch [CS-42(5) (1)]
Service brake applied
Service brake pressure switch ON [CD-5]
I/conn [CN-15(E)] T/M control unit
[x1(66)]
Declutch
2) CHECK POINT
① - GND (Parking switch input)

② - GND (Parking switch output)
③ - GND (Parking switch input)
Running ON ④ - GND (Parking switch output) 20~25V
⑤ - GND (Parking solenoid)
⑥ - GND (Pressure switch clutch cut-off)
⑦ - GND (Decutch input signal)
※ GND : Ground
7-16
7. WIPER AND WASHER CIRCUIT
1) OPERATING FLOW
Fuse box (No.10) Wiper relay Hi [CR-4(30) (87a)] Front wiper motor [CN-21(1)]
Front relay Lo [CR-26(86), (87)]
Multi function switch [CS-12(6)]
Rear wiper & washer switch [CS-3(1)]
Rear wiper motor [CN-102(1)]
(1) Front washer switch ON
① Washer switch ON [CS-12(6) (2)] Washer tank [CN-22(2)] Washer operating
Check unit [CN-58(21) (15)] Wiper relay Lo
[CR-26(87) (30)] 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)] Check unit [CN-58(10) (15)] Wiper relay Lo[CR-26(87) (30)]
Front wiper motor [CN-21(5)] Front wiper motor intermittently operating
② Lo position
Wiper switch ON [CS-12(6) (4)] Wiper motor Lo [CR-26(87a) (30)]
Front wiper motor [CN-21(5)] Front wiper motor operating (Low)
③ Hi position
Wiper switch ON [CS-12(6) (3)] Wiper relay Hi [CR-4(30) (87)] Front wiper motor [CN-21(4)]
Front wiper motor operating(High)
(3) Auto-parking(When switch OFF)
Switch OFF Fuse box (No.10) Wiper relay Hi [CR-4(30) (87a)]
Front Wiper motor [CN-21(1) (2)] Multi function switch [CS-12(5) (4)]
Wiper relay Lo [CR-26(87a) (30)] Front wiper motor [CN-21(5)] Wiper motor stop
(4) Rear wiper and washer switch
① Wiper switch ON(1st step)
Wiper switch ON [CS-3(1) (6)] Wiper motor [CN-102(5)] Wiper motor operating
Rear wiper and washer switch indicator lamp ON
② Washer switch ON(2nd step)
Washer switch ON [CS-3(1) (3)] Rear washer tank [CN-103(2)] Washer operating
7-18
2) CHECK POINT
① - GND (Front wiper switch power input)

② - GND (Rear wiper switch power input)
③ - GND (Wiper relay power input)
④ - GND (Front wiper motor Lo power input)
⑤ - GND (Front wiper motor High power input)
Stop ON 20~25V
⑥ - GND (Wiper relay power input)
⑦ - GND (Front washer power output)
⑧ - GND (Rear washer power output)
⑨ - GND (Front wiper motor power output)
⑩ - GND (Rear wiper motor power output)
※ GND : Ground
7-19
GROUP 2 ELECTRICAL CIRCUIT
TEMP ACT MODE ACT AC RY2 RESISTOR AC RY1 MULTI FUNCTION SWITCH FRONT
WIPER CLUTCH STOP BRAKE
Lo Y 7
CIGAR
B5
WB8
BG3
BW2
M
M
065 1.25 R R/WIPER LIGHTER CUT-OFF LAMP OIL PS T/M
3
1
3
1
OIL PS
1 Lo 2
4 MH 1
3 ML 3
CHECK UNIT
2 Hi 4
M+
NC
FS
S+
M-
S-
START SWITCH
\U+f058
CD-5
CD-3
CD-4
a 1 b a 2 b a 3 b a 4 b a 5 b a 6 b a 7 b a 8 b a 9 b a10 b a11b a12 b a13 b a14 b a15 b a16 b a17 b a18 b a19 b a20b a 21b a22 b a23b a24b a25b a26b a27b a28b
Pa
Pa
Pa
4
OVER HEAT SIG
MAIN PUMP FAIL

2
HOUR METER
R
N.C
IG 24V
H BRACCSTC
STEERING RY
4
2
NEUTRAL SIG
O
NEUTRAL RY
N.C
N.C
ALT LEVEL
TM LAMP
SPEED SIG
HYD TEMP
PARKING SIG
CHARGE LAMP
ENG OIL PS
GND
STEERING P/P LP
BUZZER STOP
INT SIG
STEERING PS
PARK LAMP
WIPER RY
N.C
WASH SIG
BUZZER
TM PS
AIR FILTER
STEERING P/P PS
N.C
N.C
N.C
NEUTRAL CODE
2 BK+ BK-6
BRAKE PS
1
3 FL+ FL-7
E/OIL FILTER
1 BL+ BL-5
706 1.25 L
4
6
5
4
3
2
1
L
6
5
4
3
2
1
20A
20A
30A
20A
20A
20A
20A
20A
10A
10A
AIR-CON&HEATER 20A
10A
10A
10A
10A
10A
10A
10A
10A
10A
10A
H0I
5A
5A
5A
5A
5A
Lo Hi F
5A
5A
HYD OIL TEMP

Pa
B+
5
6
2
2
3
C
M
4
G84 1.25 B
M
1
4
2
3
1
4
2
3
a A b a B b a C b a D b a E b a F b a G b a H b a I b a J b a K b a L b aM b a N b a O b a P b a Q b a R b a S b a T b a U b a V b aWb a X b a Y b a Z b a AA b a BB b
1
2
2
CD-25
WORL LAMP REAR
WARNING BUZZER
\U+f058
CASSETTE RADIO
CL-2
CASSETTE RADIO
CLEARANCE F/L,R/R
CLEARANCE F/R,R/L
STEERING P/P RY
ILL.GAUGE,DISPLAY
2 Pf
2 Pf
TM CONTROLLER
1 B
3 E
1 B
3 E
CN-21 5 Lo
5 Lo
2
1
5 G OJ
4 Hi
3
4 Hi
I
PREHEATER RY
HO
0,I
PROXIMATE SW
CIGAR LIGHTER
WORK LAMP FR
2 Gr W
CD-1
RIDE CONTROL
C
GAUGE BOARD
6 RW C
Hi
8
BEACON LAMP
B
FRONT WIPER
1 BY J
1
HOUR METER
TURN LAMP
CN-114
4 L I
4 BWG
ILL.AC,CIGAR
IGNITION SW
SW PARKING
REAR WIPER
ROOM LAMP
CHECK UNIT
E-STEERING
029A 1.25 V
HEAD LIGHT
GEAR SHIFT
A/M SWITCH
905 1.25 OR
144 1.25 OR
SW CLUTCH
604 1.25 GY
133 1.25 GY
AIR-CON RY
3 BVi
STOP LAMP
G61 1.25 B
HIGH BEAM
ECM IG RY
CD-29
CN-102
CS-2
6 W
Y
ILL. LAMP
6 5 4 3 2 1 6 5 4 3 2 1
2
1
6
BACK UP
4
3
7
4
5
3
6
1
2
C
CN-58
ECM IG
0.85LgW
ECM +
ECM +
701 1.25 W
0.85LgB
CN-36
HORN
0.85BrR
0.85GW
0.85GY
0.85GY
0.85GR
0.85GB
0.85LG
5 1.25LW
0.85BR
0.85LG
1 1.25LR
7 1.25LG
0.85LY
4 0.85LR
1.25LB
1.25LY
6 1.25LY
RCV
0.85Br
36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 1615 14 13 12 11 10 9 8 7 6 5 4 3 2 1
0.85G
0.85B
2.0LR
CS-11
CS-5
CS-12
CN-114.
2 2.OL
1 2 3 4 5 6 T/M
2
8
1
7
6
5
142A 1.25 OR
146 1.25 OR
OIL TEMP
038A 1.25 W
085 1.25 OR
120B 1.25 R
127A 1.25 Y
137 1.25 W
053 1.25 GY
G55 1.25 B
G52 1.25 B
052 1.25 R
605 1.25 V
1
7
6
8
3
2
4
CN-13
CN-12
053 1.25 GY
055 1.25 BR
013A 1.25 W
086 1.25 OR
077 1.25 G
066 1.25 R
11
G511.25 B
12
10
209A 1.25 GY
F 1
1
2
023 1.25 BR
M R 2
3
9
8
7
6
5
4
3
2
1
012A 1.25 W
1
2
010C 1.25 R
010D 1.25 R
010E 1.25 R
010F 1.25 R
099 1.25 BR
016 1.25 BR
078 1.25 GY
146 1.25 OR
703 1.25 OR
076 1.25 OR
003 1.25 OR
085 1.25 OR
133 1.25 GY
083 1.25 G
162 1.25 W
125 1.25 W
011A 1.25 L
084 1.25 W
319 1.25 G
069 1.25 W
802 1.25 W
008 1.25 G
504 1.25 G
010 1.25 R
409 1.25 R
081 1.25 G
082 1.25 V
835 1.25 R
121 1.25 L
019 1.25 R
015 1.25 R
028 1.25 R
120 1.25 R
004 1.25 G
046 1.25 G
127 1.25 Y
150 1.25 R
009 1.25 R
205 1.25 R
801 1.25 R
901 1.25 L
124 1.25 L
014 1.25 L
151 1.25 L
501 1.25 Y
503 1.25 V
136B 1.25 GY
141B 1.25 BR
202A 1.25 W
034 1.25 OR
086 1.25 OR
602 5 W
042 1.25 GY
304 1.25 OR
116 1.25 BR
402 1.25 GY
408 1.25 GY
047 1.25 OR
016 1.25 BR
022A 1.25 R
115 1.25 GY
036 1.25 GY
601 3 R
702 1.25 BR
045 1.25 W
826 1.25 W
018A 1.25 L
014B 1.25 L
301 1.25 W
038 1.25 W
048 1.25 G
135A 1.25 L
022 1.25 R
046 1.25 G
049 1.25 Y
302 1.25 R
030 1.25 V
049 1.25 Y
310 1.25 Y
032 1.25 B
OFF IDLE
707 1.25 L
029 1.25 V
039 1.25 B
033 1.25 V
G41 1.25 B
706 1.25 L
040 1.25 L
303 1.25 L
5
119C 1.25 BR
117 2 L
209B 1.25 GY
M
012B 1.25 W
100 1.25 OR
104 1.25 GY
1051.25 BR
011B 1.25 L
107 1.25 W
010G 1.25 R
010H 1.25 R
010J 1.25 R
010K 1.25 R
106 1.25 G
109 1.25 R
103 1.25 Y
608 1.25 Y
G04 1.25 B
108 1.25 L
101 1.25 L
LINEAR THROTTLE
111 1.25 OR
110 1.25 W
114 1.25 R
853 1.25 R
BLOWER INTAKE
113 1.25 V
112 1.25 Y
3
118 1.25 L
THERMER
117B 2 L
ACT -STAT
2
841 1.25 Y 1
1
839 1.25 L 2
840 1.25 OR 3 4
AC CONTROLLER 824 1.25 L 4
ACT(+) 1 100 1.25 OR 813 1.25 G 5 6 ON IDLE
GND 2 G03 1.25 B 823F 1.25 B 6
MODE M- 3 101 1.25 L CN-144
MODE M+ 4 104 1.25 GY
TEMP M- 5 105 1.25 BR CN-5
TEMP M+ 6 106 1.25 G 504 1.25 G 1 1 CASSETTE ACC
FRE 7 107 1.25 W 161B 1.25 GY 2 2 BEACON LAMP
REC 8 108 1.25 L 501 1.25 Y 3 3 CASSETTE B+
TAIL(-) 9 G02 1.25 B 502 1.25 OR 4 4 WORK LAMP
TAIL(+) 10 120A 1.25 L 503 1.25 V 5 5 ROOM LAMP
IG 24V 11 117A 1.25 L G82 1.25 B 6 6 GND
MODE SIG 12 109 1.25 R 131D 1.25 R 7 7 ILLUMINATION
TEMP SIG 13 103 1.25 Y G80 1.25 B G81 1.25 B 8 8 GND
CN-30 TO CABIN
G42 B
G40 B
CS-58 CN-17
24 5 36
GND 1 G15 2 B 6 6
COM 2 110 1.25 W G67 1.25 B 5 5 GND
CN-92
G01 2 B
MH 3 111 1.25 OR 707 1.25 L 4 4 MAIN PUMP PS
4 112 1.25 Y 702 1.25 BR 3 3 STEER PUMP PS
G50 B
G60 B
LOW
CN-91
ML 5 113 1.25 V 703 1.25 OR 2 2 MOTOR RELAY
1 HI 6 114 1.25 R 704 1.25 Y 1 1 MOTOR RELAY
BLOWER SW GND GND TO OPTION HARNESS
018B L
GND GND
GND EARTH6 EARTH8 CN-8

EARTH4 EARTH5 403 1.25 V 1 1 HORN
408 1.25 GY 2 2 PARK PRESSURE
EARTH1 404 1.25 L 3 3 PARK SOLENIOD
405 1.25 OR 4 4 BOOM DOWN PS
CR-41 406 1.25 G 5 5 BUCKET LEVELER
86 30 87a G23 1.25 B 407 1.25 BR 6 6 BOOM KICK OUT
85 407 1.25 BR 409 1.25 R 7 7 PROXIMATE SW B+
87 410 1.25 W 8 8 BOOM DOWN PS
86 010A 1.25 R G661.25
1.25 B 9 9 RIDE CON SOL
85 87 87a30 10 10
011 1.25 L
BOOM UP 1.25 B
G631.25 11 11 GND
1.25 B
G641.25 12 12 GND
CR-40
86 30 87a CN-10
85 406 1.25 G 019A 1.25 R 1 1 ILL. LAMP LH
87 G24 1.25 B 028A 1.25 R 2 2 ILL. LAMP RH
86 010B 1.25 R 030B 1.25 V 3 3 HEAD LAMP Hi
85 8787a 4 HEAD LAMP Lo
30 012 1.25 W 402 1.25 GY 4
BUCKET 135D 1.25 L 5 5 TURN LAMP LH
136D 1.25 GY 6 6 TURN LAMP RH
CR-7 7 7
86 30 87a G65 1.25 B 8 8 GND
85 G05 1.25 B G20 1.25 B TO FRONT
87 121 1.25 L
86 119B 1.25 BR GND CN-6 NO DESTINATION
85 8787a 30 606 1.25 W 301 1.25 W 1 1 CHAGE LAMP
AIR-CON RY 302 1.25 R 2 2 PARKING LAMP
EARTH2 303 1.25 L 3 3 T/M OIL LAMP
CR-26 116A 1.25 BR 4 4 OVER HEAT LAMP
86 30 87a 048 1.25 G 034A 1.25 OR 5 5 ENG OIL LAMP
85 036 1.25 GY 115A 1.25 GY 6 6 AIR FILTER
87 013 1.25 W 029B 1.25 V 7 7 BRAKE OIL LAMP
86 013B 1.25 W 038B 1.25 W 8 8 HYD TEMP LAMP
85 8787a 30 066 1.25 R 310 1.25 Y 9 9 STRP PS
WIPER RY LO 304 1.25 OR 10 10 MAIN PUMP FAIL
814 1.25 OR 11 11 WAIT TO SRART
CR-4 815 1.25 V 12 12 MAINTENANCE LAMP
86 30 87a 013C 1.25 W 827 1.25 W 13 13 WARNING LAMP
85 G25 1.25 B 816 1.25 Y 14 14 STOP LAMP
87 077 1.25 G
86 047 1.25 OR CN-7
85 87 87a 30 014A 1.25 L 135C 1.25 L 1 1 LH TURN LAMP
136C 1.25 GY 2 2 RH TURN LAMP
WIPER RY HI
030A 1.25 V 3 3 Hi BEAM LAMP
CR-2 319 1.25 G 4 4 CLUSTER 24V
86 30 87a 314 1.25 Y 5 5 R/C AUTO LAMP
85 G261.25 B 912 1.25 BR 6 6 T/M ERROR
87 082 1.25 V 315 1.25 GY 7 7 R/C CONT ON
86 042 1.25 GY 316 1.25 L 8 8 SPEED METER TWIST
85 8787a30 403 1.25 V 917 1.25 YY 9 9 SPEED METER
701 1.25 W 10 10 T/M TEMP GAUGE
HORN RY
854 1.25 BR 11 11 WATER TAMP GAUGE
CR-10 661 1.25 OR 12 12 FUEL GAUGE
86 30 87a G56 1.25 B 13 13 CLUSTER GND
85 G27 1.25 B 015B 1.25 R 14 14 ILL LAMP
87 918 1.25 V TO GAUGE
86 015A 1.25 R
85 8787a 30 G28 1.25 B CN-15
DISPLAY ILL 901 1.25 L A A 24V
202B 1.25 W B B NEUTRAL SIG.
CR-5 903 1.25 G C C REVERSE DRIVE
86 30 87a 904 1.25 BR D D LOAD ISOLATION
85 018 1.25 L 905 1.25 OR E E SW CLUTCH CUT-OFF
87 850 1.25 V 906 1.25 V F F SW PARKING BRAKE
86 202 1.25 W 907 1.25 Y G G SW AUTO/MANUAL
8587 87a 30 052 1.25 R 209 1.25 GY H KICK DOWN
H
SAFETY RY 205A 1.25 R J J 24V(PERMANENT)
205B 1.25 R K K 24V(PERMANENT)
CR-30 CN-16
86 30 87a
85 G29 1.25 B 911 1.25 W A A ENG.DERATING
87 662 1.25 Y 912 1.25 BR B B OPTICAL WARNING
86 903 1.25 G 913 1.25 R C C RY RIDE CONTROL+
85 87 87a30 084 1.25 W D D GND
G71 1.25 B
BACK-UP RY G72 1.25 B E E GND
F F
CR-37 G G
2 1 3 079 1.25 GY 916 1.25 GY H H RY RIDE CONTROL-
6 033 1.25 V 917 1.25 Y J J SPEED METER SIG.
4 G30 1.25 B 918 1.25 V K K ILLUMINATION
2 076 1.25 OR TO TM
6 4 3 1 704 1.25 Y twist
EMERGENCY STEER CN-1
601 3 R 1 1 FUSIBLE LINK
CR-3 602 5 W 2 2 FUSIBLE LINK
3 4 4 502 1.25 OR 067 1.25 R
3 157 1.25 W CN-2
2 081 1.25 G 854 1.25 BR 1 1 WATER TEMP SEND
1 2 1 G21 1.25 B 116B 1.25 BR 2 2 OVERHEAT SW
WORK LAMP FRONT 034B 1.25 OR 3 3 ENG.OIL PS
810 1.25 LL 4 4 PREHEATER(+)
CR-6 853 1.25 R 5 5 AC COMP
3 4 4 603 1.25 BR 850 1.25 V 6 6 START RY
3 156 1.25 L 811 1.25 W 7 7 PREHEATER(-)
2 078 1.25 GY 606 1.25 W 8 8 AC COND. FAN
1 2 1 G22 1.25 B 115B 1.25 GY 9 9 AIR FILTER
WORK LAMP REAR 608 1.25 Y 10 10 R/DRYER
823 1.25 B 11 11 ENG.RETURN
CR-36 831 1.25 W 12 12 ISC SW(+)
3 4 4 831 1.25 W
3 076A 1.25 OR CN-3
2 823A 1.25 B 028B 1.25 R 1 1 LH ILLUMINATION
1 2 1 G31 1.25 B 135B 1.25 L 2 2 TURN LAMP LH
ENG DERATING 667 1.25 G 3 3 HEATER RY
826 1.25 W 4 4 ALT LEVEL
604 1.25 GY 5 5 STOP LAMP
CR-35 605 1.25 V 6 6 BATT RY
3 4 4 405 1.25 OR 662 1.25 Y 7 7 BACK BUZZER
3 913 1.25 R 661 1.25 OR 8 8 FUEL SENDOR
2 151C 1.25 L 835A 1.25 R 9 9 ECM 24V
1 2 1 916 1.25 GY 603 1.25 BR 10 10 WORK LAMP
RIDE CONTROL RY 136A 1.25 GY 11 11 TURN LAMP RH
019B 1.25 R 12 12 RH ILLUMINATION
802 1.25 W 13 13 ECM
801 1.25 R 14 14 ECM
CN-14
816 1.25 Y 1 1 STOP LAMP
G70 1.25 B 827 1.25 W 2 2 WARNING LAMP
815 1.25 V 3 3 MAINTENANCE LAMP
GND 814 1.25 OR 4 4 WAIT TO SRART
813 1.25 G 5 5 OFF IDLE
824 1.25 L 6 6 ON IDLE
G90 1.25 B
EARTH7 840 1.25 OR 7 7 POSITION 5V
839 1.25 L 8 8 POSITION SIG
841 1.25 Y 9 9 POSITION RETURN
825 1.25 Y 10 10 INCREMENT
161 1.25 GY
079 1.25 GY
162B 1.25 W
11
G17 1.25 B
083 1.25 G
11 DECREMENT
404 1.25 L
832 1.25 R
G14 1.25 B
161A 1.25 GY
142B 1.25 OR
141C 1.25 BR
141A 1.25 BR
315 1.25 GY
119A 1.25 BR
142 1.25 OR
904 1.25 BR
099 1.25 BR
003 1.25 OR
131C 1.25 R
159 1.25 OR
119 1.25 BR
125A 1.25 W
125B 1.25 W
144 1.25 OR
055 1.25 BR
136 1.25 GY
162A 1.25 W
124A 1.25 L
124B 1.25 L
127B 1.25 Y
G16 1.25 B
W
157 1.25 W
G07 1.25 B
907 1.25 Y
131A 1.25 R
137 1.25 W
12
G12 1.25 B
314 1.25 Y
G13 1.25 B
410 1.25 W
ALT. TORQUE
004 1.25 G
158 1.25 G
G54 1.25 B
G53 1.25 B
008 1.25 G
134 1.25 L
R
G06 1.25 B
12
131 1.25 R
009 1.25 R
906 1.25 V
151B 1.25 L
B
G09 1.25 B
G19 1.25 B
134 1.25 L
039 1.25 B
040 1.25 L
151A 1.25 L
091 1.25 V
156 1.25 L
118 1.25 L
G10 1.25 B
G11 1.25 B
131E 1.25 R
135 1.25 L
131B 1.25 R
032 1.25 B
G08 1.25 B
022B 1.25 R
141 1.25 BR
131F 1.25 R
13 13
825 1.25 Y
045 1.25 W
837 1.25 L ALT. LOW-DILE

G62 1.25 B
GND 837 1.25 L
832 1.25 R
G32 1.25
065 1.25
069 1.25
067 1.25
181 1.25 L
836 1.25 G 14 14 DIAGNOSTIC
823D B
823B B
823E B
EARTH3 CN-M
835B 1.25 R TO GAUGE HARNESS
CS-41
CR-11
CN-48
CS-51
CN-22
CN-103
CS-42
CS-50
CS-23
CS-34
CS-39
CS-53
CS-17
CS-54
CS-3
CS-80
CS-82
CS-20
CR-45
86 30 87a
10 10
10 10
10 10
10 10
10 9 8 7 6 5 4 3 2 1
10 10
10 10
10 10
87
10 9 8 7 6 5 4 3 2 1
10 10
10 10
85 87 87a 30
10 10
85
1 2 10 9 8 7 6 5 4 3 2 1
86
10 10
1
10 9 8 7 6 5 4 3 2 1
2
6
3
M 2
5
4
1
6 7
M 2
4
3
6
5 5
4
1
2
1
6 7
6
4 7
1
6 7
6
3 5
6 7
6 7
5 5
2
9
5 5
2
1
2
6
5 5
6
5 5
6
5 5
8
6 7
8
3
6 7
4
6 7
4 7
1
6 7
1
2
9
3
9
8
6
5 5
6
5 5
9
4
6
8
9
1
3
3
9
CS-83
PREHEATER RY
CN-26
E G
B
L
10
10
10
10
1
4
1
6
2 1
h
0,I 811 1.25 W 1

FRONT REAR 150 1.25 R 2
WARNING FLASHER WASHER WASHER HOUR 810 1.25 L 3
BUZZER METER 0I 0I 0I II O I 4
UNIT 667 1.25 G 4 3
9
9
2
9
2
7
9
8
9
7
9
8
7
1
9
7
9
8
7
1
8
8
8
2
1
2
8
2
2
ECM IG CR-42
AUTO/MANUAL SW BUZZER STOP SW CLUTCH CUT-OFF SW ILL & HEAD LAMP SW HAZARD SW REAR WIPER &WASHER SW RIDE CONTROL SW WORK LAMP SW AIR-CON SW BEACON LAMP SW PARKING SW PUMP MOTOR SW INCRE/DECREMENT SW ALT LOW-IDLE SW DIAGNOSTICS ON/OFF SW
7-3
CD-26 VM OUTPUT SIGNAL K X1
2 GY
B G32 2 Pa VP F B N D 914A 0.85 B 1 VM1
1 9F B
OR 18A 1
2 ED 1 2 3 4 1 2 3 4 1 2 3 4 915 0.85 B 2 VM2
CN-137 PARK PS AD1 B1 919A 0.85 B 3 VMG1
SOL-RIDE CONT. 920 0.85 R 4 VMG2
CL-3 AD2 B2
13A G 911 0.85 GY 5 ADM4
1 Lo AD3 B3
DO-6 12A V 6 ADM3
B G33 2 Hi AD4 V
1 B
OR 18E G11 3 E 7 ADM2
2 10 W AD5 R
4 C 913 0.85 R 8 VPS2
1 B G31 AD6 AS 921 0.85 L 9 AIP5
OR 18 HEAD LIGHT LH
2 AD7 X2 922 0.85 BR 10 AIP2
CN-136 CL-24 A AD3 A 928 0.85 R 11 ADM6
G12 B 1
G31
SOL CONT.VALVE
W 17A
B 940 0.85 L 923 0.85 G 12 VPS1
OR 17
14 L B AD2
2 C 939 0.85 G 923A 0.85 G 13 VPS1
F.COMBI LH C AD1 D 908B 0.85 Y 924 0.85 Y 14
CD-41 SD1
B
OR 18 D AD7(KD) 925 0.85 W 15 SDDK
1 CN-20 X1
Pa OR 17 G13 B 16
CN-18
2 1 EF5
A ED1(VP)
1
2
3
4
1A V A 901D 0.85 L 17 EF7
BOOM DOWN 2
HORN D AD6 B 932 0.85 BR 926 0.85 L 18 EUPR
OR
W
B
B AD4 C 903 0.85 G 927 0.85 W 19 EF1
CN-25 D 902 0.85 W 928 0.85 R 20 ED3
G21 B C AD5
9A
1
X2 ED10
8
4
1A V X3 906 0.85 G 21
2
908A 0.85 Y 22 ED7
CN-8 HORN SHIFT LEVER
V 1 909 0.85 R 23 VPE1
1
GY 2 CL-4 24 VMGA1
2 13 G
L 3 1 Lo 25 CANF_H
3 12 V
OR 4 2 Hi 26 CANF_L
4 G22 B 24V
G 5 3 E A 901 0.85 L 27 CANF_T
5 11 R RY START INTERLOCK (+)
BR 6 4 C B 902B 0.85 W 28 VGS
6 REVERSING RY (+) 903B 0.85 G 29 ED11
R 7 C 907 0.85 Y
7 HEAD LIGHT RH
W 8 SW LOAD ISOLATION(+) D 904 0.85 BR 904 0.85 BR 30 ED12
8 CL-25
B 9 G23 B SW CLUTCH CUT-OFF(+) E 905 0.85 Y 31 ED13
9 1
15 GY SW PARKING BRAKE(+) F 906 0.85 G 935 0.85 OR 32 AIP3
10 2
B G11 SWITCH A/M (+) G 907 0.85 Y 33 ADM8
11 F.COMBI RH
B G21 SW DOWN SHIFT (+) H 908 0.85 Y 34 ADM7
12 CN-71 24 V 909 0.85 R SD3
L J 35
3
2 24 V K 910 0.85 R 917 0.85 Y 36 SD4
9 B
1 CN-15 37 AU1
CN-10 3A L 38 EU1
W 10 2
1 9E B 929 0.85 Y 39 ER1
R 11 1
2 ENG.DERATING RY(GND) A 911 0.85 GY 40 EF6
V 12 PARK SOL.
3 OPTICAL WARNING B 912 0.85 BR 930 0.85 W 41 EF2
G 13
4 RY RIDE CONT.(+) C 913 0.85 R 931 0.85 W 42 EF3
L 14
5 GND D 914C 0.85 B 932 0.85 BR 43 ED4
GY 15
6 CN-100 GND E 915 0.85 B 44 ED8
7 R
7 1 B F 901C 0.85 L 45 VPI
B G1 G1 B
8 3 E G 933 0.85 B 46 VMGA2
6 BR RY RIDE CONT.(-)
4 S H 916 0.85 GY 47 CANB H
BOOM KICK OUT SIG. SPEEDOMETER J 917 0.85 Y 48 CANB_L
DISPLAY ILL.(GND) K 918 0.85 B 49 ER2
CN-127 CN-101
7A R CN-16 50 AIP7
E1 G32 0.85 B 1 B
G2 B 934 0.85 G 51 AIP6
B1 314B 0.85 R 3 E
5 G 912 0.85 BR 52 ADM1
E 3 G44 0.85 B 4 S
km/h B 4 53 VPS2
319D 0.85 G BUCKET LEVELER
54 AIP8
S 8 R/C ON
936 0.85 V 55 AIP4
E2 G33 0.85 B
937 0.85 Y 56 AIP1
B2 314C 0.85 R
916 0.85 GY 57 ADM5
SPEED METER
R/C AUTO 58 VPS1
59 SD2
CN-119
60 SDDL
E G34 0.85 B
61 EU2
B 314A 0.85 R
WARNING 938 0.85 BR 62 EF4
- 939 0.85 G 63 ED1
DC G G35 0.85 B
+ 903A 0.85 G 64 ED5
I 319E 0.85 G
S 940 0.85 L 65 ED2
S CN-56 HYD TEMP 905 0.85 Y 66 ED9
T/M TEMP 315 1.25 GY 1
902A 0.85 W 67 ED6
314 1.25 Y 2
910 0.85 R 68 VPE2
CN-117 387 1.25 W 3
E G36 0.85 B 309 1.25 W 4 BRK OIL CONTROL UNIT
B 314D 0.85 R 308 1.25 V 5
312 1.25 GY 6
DC - G G37 0.85 G41 1.25 B 7
B
+ 319F 0.85 8 RH TURN
I G 385 1.25 V
S S 392 1.25 BR 9
WATER TEMP 319C 1.25 G 10
303 1.25 L 11
CN-104 G43 1.25 B 12
B
B
933A 0.85 B
X6
E G38 0.85 B 302 1.25 R 13
935 0.85 OR
922 0.85 BR
938 0.85 BR
923B 0.85 W
901A 0.85 L
934 0.85 G
919 0.85 B
929 0.85 Y
927 0.85 W
930 0.85 W
937 0.85 Y
936 0.85 V
931 0.85 W
920 0.85 R
901E 0.85 L 4
919C 0.85
919B 0.85
921 0.85 L
949 0.85 L
VP(+)
B 314E 0.85 R MAINTENANCE
933B 0.85 B
901B 0.85 L
914B 0.85 B
925 0.85 W
926 0.85 L
914 0.85 B 3 VM(-)
- 2
DC G G45 0.85 B 355B 1.25 R 1
+ 924 0.85 Y 1 SD1
I 319G 0.85 G CN-M1
S S TM CONT ERROR
X5
VOLT METER 918 0.85 B 4 VM(-)LIGHT
GEARBOX
3
X25
CN-107
16
12
1
2
1
2
6
7
10
11
13
14
2
3
3
8
15
1
4
9
5
2
1
1
6
4
3
5
1
2
T/M OIL 2
2
1
E G39 0.85 B
X11
X12
X13
X18
1
B 314F 0.85 R DIAGNOSTIC
X17
X8
VMGA2
Y2
Y3
Y4
Y5
Y6
Y1
Pa
DISPLAY
VPS1(+)
TEMP
DC - G G40 0.85 B ENG TURBIN INTERN.GEAR
+ PICK-UP PICK-UP OUTPUT
I 319H 0.85 G PARK PICK-UP SPEED SENSOR
S S
FUEL METER
TRANSMISSION HARNESS
CN-6 Hi BEAM
1 301 1.25 W
2 302 1.25 R
3 303 1.25 L
305 1.25 BR LH TURN CN-23
4
7 W
5 306 1.25 OR
9 L
307 1.25 GY
6
7 308 1.25 V
STOP CN-5
CAB SIDE SPEAKER LH
8 309 1.25 W G 1
1 CN-24
9 310 1.25 Y GY 2 8 OR
2
10 304 1.25 OR Y 3 10 GY
3
11 384 1.25 OR CN-57 AIR CLEANER OR 4
4
12 385 1.25 V 313 1.25 V 1 FROM BATT. RY V 5 SPEAKER RH
5
13 387 1.25 W 311 1.25 L 2 B G1
6 CN-27
14 386 1.25 Y 386 1.25 Y 3 R 6 7 W
M 7 1 S.L+
307 1.25 GY 4 OVER HEAT B G11 1 G
MOTOR RY 8 2 ACC
305 1.25 BR 5 6 R
3 ILL+
CN-7 304 1.25 OR 6 8 OR
4 S.R+
1 311 1.25 L G31 1.25 B 7 G1 B
MAIN PUMP FAIL 5 ILL-
2 312 1.25 GY 384 1.25 OR 8 CD-40 9 L
5A B 6 S.L-
3 313 1.25 V 301 1.25 W 9 CN-17 2 Pa 3 Y
Y 1 3 BR 7 B+
4 319 1.25 G 319A 1.25 G 10 1 1 10 GY
OR 2 8 S.R-
5 314 1.25 Y 306 1.25 OR 11 2 G5 B
BR 3 STR PUMP PS 9 GND
6 392 1.25 BR 319B 1.25 G 12 3
L 4 G2 B
7 315 1.25 GY 310 1.25 Y 13 4 CD-39 CL-6
B 5 5 B 2 OR 4
8 G42 1.25 B WAIT TO START 5 2 Pa CASSETTE RADIO
4 L B G11
397 1.25 Y 6 1 1
9
10 371 1.25 W 355A 1.25 R 1 MAIN PUMP PS CL-5 CL-1
11 388 1.25 BR CN-M2 2 OR 4A 5 V 2
CHARGE MOTOR PUMP B G12 G3 B
12 361 1.25 OR 1 1
13 G30 1.25 B G4 B
14 317 0.85 R
ENG OIL OPTION HARNESS ROOM LAMP
CL-7
CN-M 2 GY
1 354 1.25 R G13 B M
ROTARY LAMP
STEERING PS
7-4
MASTER SW
CN-18
CR-1 B G
R1 R4
605D 1.25 L 859 1.25 R 5 COOLANT LEVEL HIGH
G79 1.25 B 810 1.25 R 10 GRID HEATER(+)
R2
R3 BATTERY 811 1.25 B 11 GRID HEATER(-)
BATT. RY CS-0
7 COOLANT LEVERL 5V SUPPLY
858 1.25 B 6 COOLANT LEVEL LOW
TO STARTER 19 COOLANT LEVEL RETURN
CN-60
2 602 5 W TO PREHEATER RY
CN-20
1 601 3 R
2 ALT. TORQUE
813 0.85 G 3 OFF IDLE SW
814 0.85 L 4 WAIT TO STOP LAMP
815 0.85 V 5 MAINTENANCE LAMP
816 0.85 Y 6 STOP LAMP
817 0.85 R 7 ECM SUPPLY(+)
818 0.85 R 8 ECM SUPPLY(+)
821 0.85 B 9 PANEL GROUND
822 0.85 B 10 PANEL GROUND
824 0.85 L 13 ON IDLE SW
GND 825 0.85 Y 14 DIAGNOSTICS INCREMENT
827 0.85 W 16 WARNING LAMP
819 0.85 R 17 ECM SUPPLY(+)
EARTH4 828 0.85 R 18 ECM SUPPLY(+)
831 0.85 G 23 ISC SWITCH
832 0.85 R 24 DIAGNOSTICS DECREMENT
26 DATA LINK J1587(+)
27 DATA LINK J1587(-)
829 0.85 R 28 ECM SUPPLY(+)
DO-3 G01 0.85 B 29 ECM SUPPLY RETURN
1 826C 1.25 W G02 0.85 B 30 ECM SUPPLY RETURN
2 605C 1.25 L CN-12 CN-12-1 833 shield 36 DATA LINK J1939 SHIELD
616 1.25 Y 1 1 816 0.85 Y 834 0.85 L 37 DATA LINK J1939(-)
627 1.25 W 2 2 827 0.85 W 835 0.85 R 38 KEY SWITCH
DO-2 615 1.25 V 3 3 815 0.85 V G04 0.85 B 39 ECM SUPPLY RETURN
1 G78 1.25 B 614 1.25 OR 4 4 814 0.85 L G05 0.85 B 40 ECM SUPPLY RETURN
2 605B 1.25 L 613 1.25 G 5 5 813 0.85 G 836 0.85 G 44 DIAGNOSTIC/MANUAL SNAPSHOT
624 1.25 L 6 6 824 0.85 L 837 0.85 L 45 ALT. LOW IDLE
DO-1 640 1.25 OR 7 7 840 0.85 BR 838 0.85 Y 46 DATA LINK J1939(+)
1 605 1.25 V 639 1.25 R 8 8 839 0.85 R 839 0.85 R 47 THROTTLE POSITION SIG.
2 605A 1.25 L 641 1.25 V 9 9 841 0.85 G 840 0.85 BR 48 THROTTLE POSITION +5V
625 1.25 Y 10 10 825 0.85 Y 841 0.85 G 49 THROTTLE POSITION RETURN
632 1.25 R 11 11 832 0.85 R G06 0.85 B 50 ECM SUPPLY RETURN
12 12 ECM
637 1.25 L 13 13 837 0.85 L
CN-1 636 1.25 G 14 14 836 0.85 G
1 601 3 R CN-19 STARTER
2 602 5 W CN-4 CN-4-1 G20 1.25 B A CR-23 M
M
623 1.25 B 1 1 823 0.85 B 861 1.25 R B 1
G11 1.25 B
CN-2 631 1.25 W 2 2 831 0.85 G 838 0.85 Y C 2
850 1.25 V
1 654 1.25 G 635 1.25 R 3 3 835 0.85 R D B+ M
B
2 655 1.25 BR 610 1.25 L 4 4 810 1.25 R 834 0.85 L E START RY. CN-45
3 656 1.25 OR 611 1.25 B 5 5 811 1.25 B 862 0.85 L F
4 610 1.25 L G61 1.25 B 6 6 G10 1.25 B 863 0.85 BR G
5 653 1.25 R 650 1.25 V 7 7 850 1.25 V H
6 650 1.25 V 826A 1.25 W 8 8 851 1.25 W J
7 611 1.25 B 653 1.25 R 9 9 853 1.25 R
8 606 1.25 W 654 1.25 G 10 10 854 0.85 G
9 608 1.25 GY 655 1.25 BR 11 11 855 1.25 BR
10 607 1.25 Y 656 1.25 OR 12 12 856 1.25 OR
11 623 1.25 B
631 1.25 W 852 15 R
12
CN-17 CN-17-1
1 1
617 1.25 R 2 2 830 2 R
618 1.25 R 3 3 820 2 R
RESTRICTION SENSOR
FUEL INLET
31P OEM
4 4
19
11
10
5
6
7
CN-3 667 1.25 G 5 5 867 1.25 G
6
SIG
1 620 1.25 R 6
5V
(-)
2 665 1.25 L 7 7
CYLINDER #1
CYLINDER #4
CYLINDER #3
CYLINDER #2
CYLINDER #6
CYLINDER #5
3 667 1.25 G 8 8
B
C
A
4 826 1.25 W 34 GRID HEATER ACT SIG
CN-74
5 604 1.25 G 43 GRID&SWITCH RETURN
B+ G 29 FUEL RESTRIC 5V+
6 605 1.25 V
3 28 FUEL RESTRIC SIG
2
1
662 1.25 Y
2
1
2
2
2
1
1
7
2
1
851 1.25 W I
8 661 1.25 OR U 27 FUEL RESTRIC RETURN
G16 5 B GND 24 WASTEGATE ACTUATOR1
9 635 1.25 R
ALT 23 WASTEGATE ACTUATOR2
10 603 1.25 BR
ACTUATOR CONNECTOR 50P

11 664 1.25 GY 20 REAL TIME BACKUP+
12 663 1.25 W 47 REAL TIME BACKUP RTN
13 617 1.25 R 33 FUEL SHUT-OFF ACT
14 618 1.25 R 1 10 CYL. NO.1 SUPPLY+
GND 2 9 CYL. NO.1 RETURN-
3 8 CYL. NO.2 SUPPLY+
4 7 CYL. NO.2 RETURN-
CN-14 EARTH3
1 616 1.25 Y CL-21 5 6 CYL. NO.3 SUPPLY+
2 627 1.25 W 620A 1.25 R 2 6 16 CYL. NO.3 RETURN-
3 615 1.25 V G71 1.25 B 1 7 26 CYL. NO.4 SUPPLY+
4 614 1.25 OR NUMBER PLATE LAMP 8 36 CYL. NO.4 RETURN-
5 613 1.25 G 9 4 CYL. NO.5 SUPPLY+
6 624 1.25 L CD-2 10 3 CYL. NO.5 RETURN-
7 640 1.25 OR G72 1.25 B 11 2 CYL. NO.6 SUPPLY+
1
8 639 1.25 R 661 1.25 OR 2 CN-28 12 1 CYL. NO.6 RETURN-
641 1.25 V FUEL SENDER G12 1.25 B 1 13 44 SPARE +
9
10 625 1.25 Y 853 1.25 R 14 15 SPARE +
2
11 632 1.25 R CN-65 15 31 SPARE -
AIR COMP.
12 G73 1.25 B A
637 1.25 L 662 1.25 Y 23 COOLANT LEVEL RTN
13 B
CD-4 25 COOLANT LEVEL +5V
14 636 1.25 G BACK BUZZER 0 DC 22 COOLANT LEVEL Lo SW
854 0.85 G
24 COOLANT LEVEL Hi SW
WATER TEMP 9 WIF SIG.
G08 1.25 B
CN-155 10 WIF SIG. RETURN

603A 1.25 BR 6 38 INTAKE TEMP
SENSOR CONNECTOR 50P

CD-9
G76 1.25 B 40 INTAKE TEMP&PS RTN
5 CL-16
S 39 INTAKE PRESS SIG
663 1.25 W 4 4 C 855 1.25 BR
37
G63 1.25 B
664 1.25 GY 3 INTAKE PRESS +5V

GND 3 T
G74 1.25 B 2 OVERHEAT SW 2 COOLANT TEMP INPUT
2 E
604A 1.25 G 1 3 COOLANT TEMP RTN
1 S
EARTH2 43 OIL PS&TEMP RTN
CL-23 CD-18 42 OIL TEMP SIG.
1 44 OIL PRESS SIG.
CN-83 856 1.25 OR 1 Pa
2 45 OIL PS&TEMP +5V
606 1.25 W 1 M 2
G17 1.25 B 2 31 AIR PRESS RTN
ENG. OIL PS 6 AIR PRESS SIG.
AIR-CON FAN CN-156
603B 1.25 BR 6 TO BATT. RELAY 17 AIR PRESS +5V
G77 1.25 B 5 49 ENG POS SENSOR2-
CL-15
WASTEGATE
CN-29 50 ENG POS SENSOR2+
FUEL SHUTOFF
GND 620B 1.25 R 4 4 C
CR-24 48 ENG POS SENSOR1-
607 1.25 Y 2 PA 665 1.25 L 3 3 T
1
2
G75 1.25 B 2 47 ENG POS SENSOR1+
J18 1.25 B 1 2 E 867 1.25 G
INTAKE MANIFOLD TEMP

EARTH1 604B 1.25 G 1 1 S
R/DRY
INTAKE MANIFOLD PRESS
OIL PRESS/TEMP SENSOR
AMBIENT AIR PRESS

CL-22
COOLANT TEMP
ENG POSITION
HEATER RELAY PREHEATER
WIF SENSOR
1
A
D
C
B
C
A
B ÅiÅ|Åj
2
4
3
1
CD-10
B
A DC
C
2
1
A
B
B
A DC
2
SIG
608 1.25 GY
5V
Pa
ÅiÅ|Åj
SIG
5V
G62 1.25 B
AIR FILTER
7-5
3. MONITORING SYSTEM
1. CLUSTER
The gauges panel consists of gauges and monitors as shown below, to warn the operator in case
of abnormal machine operation or conditions for the appropriate operation and inspection.
・ Gauges : Indicate operating status of the machine.
・ Warning lamp : Indicate abnormality of the machine.
・ Pilot lamp : Indicate operating status of the machine.
※ The monitor installed on this machine does not entirely guarantee the condition of the
machine. Daily inspection should be performed according to chapter 6, MAINTENANCE
in operator's manuel.
※ When the monitor provides a warning immediately check the problem, and perform the
required action.
High beam pilot lamp Parking brake pilot lamp
Steering warning lamp(Emergency) Ride control pilot lamp(ON)
Steering warning lamp(Primary) Ride control pilot lamp(AUTO)
Overheat warning lamp Engine warning lamp
Air cleaner warning lamp Hyd oil temp warning lamp
Engine stop warning lamp Brake fail warning lamp
Left turning pilot lamp Right turning pilot lamp
20 30
10 km/h 20
10 40
0 MPH 30
0 50
VDO
Speedometer
Battery volt meter T/M oil temperature gauge
Engine coolant temperature gauge Fuel gauge
Engine warming up lamp T/M oil pressure warning lamp
Battery charging warning lamp T/M error warning lamp
Engine oil pressure warning lamp Engine maintenance warning lamp
7803ACD02
1) SPEEDOMETER
(1) The speedometer displays the speed of machine in mph and
20 30
km/h.
10 km/h 20
10 40
0 MPH 30
0 50
VDO
7-23
2) FUEL GAUGE
(1) This gauge indicates the amount of fuel in the fuel tank.
(2) Fill the fuel when the indicator moves 0 point, refuel as soon as
possible to avoid running out of fuel.
※ If the gauge indicates below 0 point even though the
VDO
machine is on the normal condition, check the electric
703CD03A device as that can be caused by the poor connection of
electricity or sensor.
3) ENGINE COOLANT TEMPERATURE GAUGE

(1) This indicates the temperature of coolant.
Green Red ・Green range : 40-105°C (104-221°F )
・Red range : 105°C (221°F ) Above
(2) The green range illuminates when operating.
(3) Keep idling engine at low speed until the green range
7303CCD09 illuminates, before operation of machine.
(4) When the red range illuminates, turn OFF the engine, check
the radiator and engine.
4) TRANSMISSION OIL TEMPERATURE GAUGE

(1) This range indicates the temperature of transmission oil.
Green Red ・Green range : 50-120° C(99-248°F)
・Red range : 120° C(248°F) Above
(2) The green range indicates when operating.
(3) Keep idling engine at low speed until the green range indicates,
7303CCD12
before operation of machine.
(4) If the indicator is in the red range, it means the transmission is
overheated. Be careful that the indicator does not move into
the red range.
5) BATTERY VOLT METER
Red Green Red

(1) This gauge indicates the voltage in the charging system when
the engine is running.
(2) If the indicator is below 20V(Red range), it means that the
electricity is being discharged. If the indicator is above
28V(Red range), an unusually high voltage may damage the
alternator. Check the charging system in both cases.
7303CCD13
7-24
6) DIRECTION PILOT LAMP
(1) This lamp flashes when the signal indicator lever is moved.
(2) When the lamp lights up, the alarm(50dB) sounds.
7803ACD03
7) 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.
7803ACD04
8) PARKING BRAKE PILOT LAMP

(1) When the parking brake is actuated, the lamp lights ON.
※ Check the lamp is OFF before driving.
7803ACD05
9) 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.
7803CD06
10) TRANSMISSION OIL PRESSURE WARNING LAMP

(1) The lamp lights ON when the oil pressure of the
transmission drops.
(2) When the lamp is ON, stop the engine and check the
transmission system.
7803ACD07
7-25
11) AIR CLEANER WARNING LAMP
(1) This lamp operates by the vacuum caused inside when the
filter of air cleaner is clogged.
(2) Check the filter and clean or replace it when the lamp is
ON.
7803ACD08
12) 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.
7803A3CD09
13) ENGINE OIL PRESSURE WARNING LAMP

(1) If lamp comes ON during engine operation, shut OFF
engine immediately. Check oil level.
7803A3CD10
14) OVERHEAT WARNING LAMP

(1) This lamp is turned ON when the temperature of cooling water
is over the normal temperature (110°C , 230°F ).
(2) Check the cooling system when the lamp is ON.
7803A3CD11
15) HYDRAULIC OIL TEMP 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.
7803A3CD12
7-26
16) TRANSMISSION ERROR WARNING LAMP
(1) This lamp lights ON and the transmission error display show
the wrench with the error codes when a error occurs in the
transmission.
(2) Immediately pull the machine to a convenient stop. Stop the
engine. Investigate the cause.
7803ACD13 ※ Consult a HYUNDAI dealer to investigate the cause.
※ Do not operate until the cause has been corrected.
17) STEERING WARNING LAMP(Option)

(1) Primary
This lamp indicates that the primary steering has failed. when
the indicators come on and the action alarm sounds, steer the
machine immediately to a convenient location and stop the
machine. stop the engine and investigate the cause.
※ Do not operate the machine until the cause has been
7803ACD14
corrected.
(2) Emergency
This lamp indicates the 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.
7803ACD15
Refer to page 7-36.
18) RIDE CONTROL PILOT LAMP(Option)

(1) Auto ride control
This lamp lights ON when push in the top of the ride control
switch in order to turn on the automatic ride control.
7803ACD16
(2) Ride control

This lamp lights ON when push in the bottom of the ride control
switch in order to turn on the system for ride control.
7803ACD17
7-27
19) ENGINE WARMING UP LAMP
(1) This lamp lights ON when key ON, it will be ON to indicate the
air grid heater is being heated.
(2) When the lamp goes out the operator should start cranking the
engine.
7803ACD19
20) ENGINE WARNING LAMP

(1) This lamp lights ON during a nonfatal system error. The
engine can still be run, but the fault should be corrected as
soon as possible.
In the diagnostic mode, the lamp will flash after the engine
stop warning lamp complete the three-digit fault code.
7803ACD20
Refer to diagnostic fault codes, page 7-29.
21) ENGINE STOP WARNING LAMP

(1) This lamp indicates that the engine needs to be shut down
before permanent damage occurs to the engine.
The engine should be shut off as soon as it can be shut
off safely.
This lamp is also used to flash out the fault code number
7803ACD18
in the diagnostic mode.
Refer to diagnostic fault codes, page 7-29.
22) ENGINE MAINTENANCE WARNING LAMP

(1) This lamp lights ON when it is time to change oil and perform
any other simultaneous maintenance tasks.
(2) This lamp will alert the operator of the need to change oil by
flashing this lamp for approximately 12 seconds after start
switch ON. The flashing sequence will be three quick flashes,
7803ACD21 followed by a pause. This flash sequence will go through five
cycles in the 12 seconds period. This sequence will occur at
every start switch ON until the lamp has been reset.
The diagnostics switch must be in the OFF position for
the flashing sequence to occur.
7-28
Resetting the engine maintenance lamp with the
diagnostic switch
The engine maintenance lamp can be reset using by following
steps 1 through 6 below.
Steps through must be done within a maximum of 30
seconds.
The diagnostics switch must be in the OFF position.
① Turn ON the starting switch (engine must not be operating)
② Diagnostics switch ON within 3 secods, then the switch OFF
③ Diagnostics switch ON twice more briefly within 3 seconds
each
④ Diagnostics switch ON within 3 seconds, then the switch OFF
⑤ The lamp will flash three times
⑥ Turn OFF the starting switch
If the engine maintenance lamp does not flash three times,
the reset sequence must be performed again.
23) CHECK DIAGNOSTIC FAULT CODES

(1) The system can show and record operation
irregularities that present themselves as fault
codes. These codes will make troubleshooting
easier. The fault codes are recorded in the
ECM. They can be read using the two fault
ECM
lamps.
7803A4OP20
(2) Engine electronic fuel system codes
① The engine electronic fuel system fault codes

can be seen on the engine warning lamp and
engine stop warning lamp in the cab.
7803A4OP21
7-29
② The engine stop warning lamp is red. The
engine warning lamp is yellow. When the
machine starting switch is turned ON and the
diagnostic switch is OFF, all three lamps will About
2 seconds
illuminate to check their operation. The lamps
will go OFF in sequence after about 2 seconds.
7803A4OP22
③ The lamps will remain OFF until a fault code is

recorded. If a lamp remains ON, an active fault
1 2
exists. If the engine stop warning lamp(1) is
illuminated while operating, the fault can be
engine disabling. The machine must be shut off
as soon as it can be done in a safe manner. 10
20
10
30
km/h 20
40
The machine must remain parked as long as

0 MPH 30
0 50
VDO
this fault exists. If the engine warning lamp(2) is

illuminated, the machine can be safely
7803A4OP23
operated, but the fault must be corrected as
soon as possible.
(3) Engine protection system codes
① The engine protection system logs separate

fault codes for out-of-range conditions
associated with any of the following sensors:
Coolant temperature
Oil pressure
Intake manifold temperature.
7803A4OP24
② This system will activate an incab warning

device when an out-of-range condition occurs.
The warning device is a engine stop warning Stop warning lamp Maintenance lamp
lamp.
This system will also activate the engine
maintenance lamp(blue).
7803A4OP25
7-30
③ If the engine stop warning lamp comes ON
while driving, it means a fault code has been
recorded. The lamp will remain ON as long as
the fault exists, and engine power and speed Fault code
will gradually be reduced after 30 seconds
warning.
※ The fault must be corrected as soon as
possible.
7803A4OP26
(4) Turn off the engine. To check for engine

electronic fuel system and engine protection
system fault codes, move the diagnostic switch
to the ON position.
D S
IA IS
-O
G
N
7803A4OP27
(5) Turn the starting switch to the ON position.

If no active fault codes are recorded, both lights
will come ON and stay on.
If active fault codes are recorded, both lights will
come ON momentarily, then begin to flash the
code of the recorded faults.
7803A4OP28
(6) The fault code will flash in the following sequence:

Example fault code sequences
First, a engine warning lamp(yellow) light will P Pause
Fault code 242:
flash. Then there will be a short 1-or 2-second
pause after which the number of the recorded
fault code will flash in engine stop lamp(red). P P P P
1 Blink 2 Blinks 4 Blinks 2 Blinks 1 Blink
There will be a 1- or 2-second pause between
Fault code 112:
each number. When the number has finished
flashing in red, a yellow light will appear again.
The three-digit code will repeat in the same P P P P
sequence. 1 Blink 1 Blink 1 Blink 2 Blinks 1 Blink
7803AOP29
7-31
3. SWITCHES
Ride control switch(option) Full automatic switch

Beacon switch(option) Rear wiper/washer switch
Work lamp switch Buzzer stop switch
Main light switch Pump motor switch(option)
Clutch cut off switch Aircon switch
Parking brake switch
Switch panel Hazard switch

Kick down switch
Low idle switch
Horn button Incre/decrement switch
Multi function switch Diagnostics switch
Starting switch
Kick down switch
LO LE
ID
D S
IA IS
-O
G
N
LO LE
ID
D SI
IA S
-O
G
N
7803A3CD22
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.
※ Key must be in the ON position with engine running maintain
electrical and hydraulic function and prevent serious machine
7803A3CD23 damage.
7-32
2) HAZARD SWITCH
(1) Use for parking, or roading machine.
※ If the switch is left ON for a long time, the battery may be
discharged.
(2) The below indicator lamp is turned ON when operating this switch.
73033CD16
3) CLUTCH CUT OFF SWITCH

(1) This switch is pressed, it will cut off the clutch when brake operates.
※ Be careful not to use this switch when driving on a slope.
73033CD17
4) PARKING BRAKE SWITCH

(1) This switch is pressed, the parking brake will start to operate and the
gauge panel warning lamp will comes ON.
※ When operating the gear selector lever, be sure to release the
P parking brake. If the machine is operated with the parking
brake engaged, the brake will overheat and may cause the
brake system to go out of order.
73033CD18
5) MAIN LIGHT SWITCH

(1) This switch use to operates the clearance lamp and head light by two step.
ㆍFirst step : Clearance lamp and cluster illumination lamp comes
ON. Also, the below indicator lamp comes ON.
ㆍSecond step : Head light comes ON.
73033CD19
7-33
6) WORK LAMP SWITCH
(1) This switch use to operates the front and rear work lamps by two
step.
First step : Front work lamp located on the cab comes ON.
Second step : Rear work lamp located on the cowl comes ON.
7803A3CD24
7) AIR CONDITIONER SWITCH

(1) This switch use to operates the air conditioner.
(2) Refer to the air conditioner and heater for detail operation.
73033CD21
8) REAR WIPER AND WASHER SWITCH

(1) The switch use to operates the rear wiper and washer by two step.
・First step : The rear wiper operates.
・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.
73033CD22
9) BUZZER STOP SWITCH

(1) The red lamp on the cluster lights ON and the buzzer sounds when
the machine has a problem.
In this case, if the switch is pressed, the buzzer will be stopped. Be
sure to check machine for problems.
(2) Wait until the lamp is turned OFF, if the red lamp lights ON after the
73033CD23 buzzer stopped.
If not, stop engine and check the system which the lamp is ON.
7-34
10) FULL AUTOMATIC SWITCH
(1) Manual mode(①)
①
Press the top of the switch for the manual mode of the autoshift function.
② The operator selects the desired speed and the desired direction in the
A manual mode with the gear selector lever.
(2) Automatic mode(②)
73033CD60
Press the bottom of the switch for the autoshift function in the automatic
mode. Press the bottom of the switch prior to shifting the transmission into
forward or reverse in order to activate the autoshift function.
11) BEACON SWITCH (Option)

(1) This switch turns ON the rotary light on the cab.
73033CD32
12) RIDE CONTROL SWITCH (Option)

AUTO (1) AUTO position
Push in the top of the ride control switch in order to turn on the
automatic ride control. The automatic ride control automatically turns
on when the travel speed exceeds a preset speed of approximately
9.5km/h. The automatic ride control automatically shuts off during low
speed travel mode.
72033CD10
(2) ON position
ON
Push in the bottom of the ride control switch in order to turn on the
system for ride control. The ride control will smooth the ride of the
machine during travel.
72033CD11
MIDDLE (3) MIDDLE position

Push the ride control switch to the middle position in order to turn off
the system for the ride control.
72033CD12
7-35
13) PUMP MOTORSWITCH (option)
(1) The emergency steering system can be manually tested.
Push the pump motor switch in order to determine if the emergency
steering and the emergency steering lamp are functional.
(2) When the switch is pushed, the emergency steering pump motor will
run.
7803A3CD26 The emergency steering lamp will light. If the emergency steering
lamp does not light, do not operate the machine.
14) LOW IDLE SWITCH

(1) This switch allows the operator to switch the low idle speed between
2 value, "Normal idle and Alternate idle(1200RPM)" depending on
low idle switch position.
W There is no adjusting the alternate idle speed through the use of
LOIDLE
Incre/decrement switch. This feature can be configured to require a
normal idle to alternate idle switch transition to go to alternate idle at
7803A3CD27
start up and to warm the cab quickly up.
15) INCRE/DECREMENT SWITCH

(1) Use this switch to adjust the engine low idle speed increments of
25rpm. Each time the switch is briefly pushed down, the idle speed is
decreased by 25rpm. When the switch is briefly pushed up, the idle
speed is increased by 25rpm.
7803A3CD28
16) DIAGNOSTICS SWITCH

(1) Use this switch to check for engine electronic fuel system and engine
protection system fault codes.
Refer to dignostic fault codes, page 7-29.
GN
DI-AOSIS
7803A3CD29
7-36
17) HORN BUTTON
(1) If you press the button on the top of the multifunction switch, the horn
Horn button will sound.
73033CD28A
18) CAB LAMP SWITCH

(1) This switch turns ON the cab room lamp.
73033CD24
19) KICK DOWN SWITCH
Kick down switch (1) The kick-down switch into first gear is not allowed. Press the switch
and release the switch. The transmission downshift one gear speed,
provided that an engine overspeed would not occur.
76043CD08
20) MULTI FUNCTION SWITCH

(1) Front wiper and washer switch
O J Ⅰ Ⅱ
When the switch is in J position, the wiper moves intermittently.
When placed in or position, the wiper moves continuously.
If you press a button at the end 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.
7-37
(2) Dimmer switch
Up
① This switch is used to turn the head lights direction.
M ② Switch positions
Up : To flash for passing
Down
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.
Right turning
73033CD31
7-38
GROUP 4 ELECTRICAL COMPONENT SPECIFICATION
Part name Symbol Specifications Check
※ Check specific gravity

12V × 200Ah 1.280 over : Over charged
Battery
(2EA) 1.280 ~ 1.250 : Normal
1.250 below : Recharging
Rated load : ※ Check coil resistance

24V Normal : About 50Ω
Battery relay
100A(Continuity) ※ Check contact
CR-1 1000A(30seconds) Normal : ∞Ω
※ Check disconnection
2 Normal : 0Ω
Fusible link 1 24V 60A (Connect ring terminal and
CN-35 check resistance between
terminal 1 and 2)
H BR ACC ST C ※ Check contact

23 56
H 0 I II 4
OFF : ∞Ω(For each
terminal)
0, I 1
Start key B - ON : 0Ω(For terminal 1-3)
1 2 3 4 5 6 ∞Ω(For terminal 1-5)
START : 0Ω(For terminal 1-3
CS-2
and 1-5)
1
Pa
2 ※ Check contact
Pressure switch N.C TYPE
CD-3 CD-26 Normal : 0Ω(CLOSE)
CD-25 CD-25 CD-41
1
※ Check contact
Pressure switch 2 Pa N.O TYPE
Normal : ∞Ω(OPEN)
CD-4 CD-40
CD-5
7-39
1
Pressure switch
Pa 0.5kg/cm2 ※ Check contact
(For engine oil) 2 (N.C TYPE) Normal : 0Ω(CLOSE)
CD-18
T ※ Check resistance
Coolant temp - Normal : ∞Ω
sensor
CD-9 225°
F Over : 0Ω
C
Coolant ※ Check resistance
-
temp sensor 192±13.5Ω at 73.9°
C
CD-8
Air cleaner Pa Pressure :

※ Check contact
635mmH2O
pressure switch Normal : ∞Ω
(N.O TYPE)
CD-10
2 ※ Check LED lamp

Parking
1 24V 1.2A ※ Check Resistance
solenoid
About 24Ω
CN-71
1
※ Check resistance
Reed switch :
Fuel sender 2 Full : About 30Ω
Magnetic type
CD-2 Low level : About 300Ω
7-40
C
T/M oil ※ Check resistance
temperature 1/2 P.T.F 137.2±14.5Ω
sender CD-29 at 87.8°
C
1 2 1
2 ※ Check resistance
3 Normal : About 200Ω
Relay
4 4 3 24V 20A (For terminal 1-3)
(4pin)
AC RY1CR-26ACAC
CR-2 RY2
RY1 : ∞Ω
CR-35
CR-5 CR-36
CR-30 CR-42
AC RY2 (For terminal 2-4)
CR-3 CR-6
30
86
87a 87 85 Normal : About 160Ω
87 (For terminal 2-6)
Relay 85
24V 20A : 0Ω
(5pin) 87a 30 86
CR-2 CR-4 CR-5 (For terminal 1-3)

CR-7 CR-10 CR-26 : ∞Ω
CR-30 CR-40 CR-41 CR-45 (For terminal 1-3)
1 B
Proximate 3 E
switch 4 24V 400mA -
S
CN-100 CN-101
T ※ Check resistance
Hydraulic
- Normal : ∞Ω
temperature
105°
C over : 0Ω
CD-1
※ Check contact
4 MH 1 Normal : 1.12Ω
(For terminal 2-4)
3 ML 3
Aircon resistor - : 2.07Ω
2 Hi 4
(For terminal 3-4)
1 Lo 2
: 3.17Ω
(For terminal 4-1)
7-41
Speaker 4Ω 20W
Normal : 50Ω
CN-23(LH)
CN-24(RH)
10 9 8 7 6 5 4 3 2 1
10 6 5 ※ Check contact
OFF : ∞Ω
Switch 24V 8A (For terminal 1-5, 2-6)
(Locking type)
9 8 2 7 1 : 0Ω
CS-17 CS-23 CS-42 CS-41 (For terminal 5-7, 6-8)
CS-51 CS-54 CS-82 CS-83
10 9 8 7 6 5 4 3 2 1
10 4 1
Switch ※ Check contact
(Non-locking 24V 8A OFF : ∞Ω
type) 0I (For terminal 2-4, 1-7)
9 2 75
CS-3 CS-20 CS-39
1 Work lamp
Work lamp, 24V 70W
Room lamp, 2 Number plate lamp
※ Check disconnection
Number plate Normal : A fewΩ
CL-1 CL-6 CL-22 Room lamp
lamp
CL-5 CL-21 CL-2 3 24V 10W
M 24V 70W ※ Check disconnection

Beacon lamp
(H1 TYPE) Normal : A fewΩ
CL-7
1 ※ Check operation
h -
Supply power(24V) to
Hour meter 2
terminal No.2 and contact
CN-48
terminal No.1 and ground
7-42
1 ※ Check operation
22-28V 2A Supply power(24V) to each
Horn 2
110dB terminal and connect ground
CN-20 CN-25
Pa
※ Check contact
Receiver dryer 24V 2.5A
Normal : ∞Ω
CN-29
1 S.L+
2 ACC
3 ILL+
4 S.R+
5 ILL- ※ Check resistance
6 S.L-
Cassette radio 7 B+
24V 20W+20W Power ON : 4Ω+4Ω
8 S.R- (For terminal 1-6, 4-8)
9 GND
CN-27
A
24V 0.5A
Back up buzzer B -
110dB
CN-65
1
※ Check contact
Washer pump 24V 2.5A Normal : 26.4 Ω
2
(For terminal 1-2)
CN-103 CN-22
24V 1.5A
M
Wiper motor 2-speed -

2 Pf
1 B
3 E
5 Lo
4 Hi
Auto parking
CN-21
6 5 4 3 2 1
CN-102
7-43
3
2
Cigar lighter 24V 5A -
1
CL-2
B+ G
3
I ※ Check voltage
Alternator U 20V 60A
GND Normal : 24-28V
CN-74
Delco Remy
Starter ※ Operating or not
B+ M 28MT 24V
CN-45
1
Aircon ※ Check contact
2 24V 79W
compressor Normal : 13.4Ω
CN-28
2 ※ Check contact
Start relay 1 24V 200A
Normal : 11.3Ω
CR-23
Blower
M 1 24V 9A
-
2900±150rpm
2
7-44
24 536
GND 1
COM 2
MH 3 ※ Check resistance
Blower switch
LOW 4 Normal : 0Ω(For terminal 1-2,
-
ML 5
1 HI 6 3, 4, 5, 6)
CS-58
Mode actuator M
DC Servo motor
NC
and M+
-
S+
FS
M-
S-
temp actuator 9-16V 300mA Max

6 5 4 3 2 1
R 2 ※ Check resistance
Intake actuator M 12V
F 1 Normal : 2.0Ω
Working
temperature of
1
Thermostat contact point -
2 A/C ON : 4.5° C
A/C OFF : 1.5°C
3 E
G 24V
2 B
Flasher unit 85 ~ 190 C/M -
1 L
50dB
CR-11
1 Lo
Hi 24V 75W/70W
2
(H4 TYPE) ※ Check disconnection
Head lamp 3 E
24V 4W Normal : A few Ω
4 C (T4W)
CL-3 CL-4
7-45
4 C
24V 5W
3 T
(R5W)
Combi lamp 2 E -
1 S
2×24V 21W
(P21W)
CL-15 CL-16
1
24V 21W
Turn lamp 2 -
(P21W)
CL-24 CL-25
Continuous
capacity :
Master switch 180Amp -
Push in capacity :
1000Amp
2
24V 200mA
Warning buzzer 1 -
90±5dB(ℓm)
CN-26
1
2
3
Buzzer stop 4 ※ Check contact
switch 5 5 1
6 24V 28A OFF : ∞Ω
(Rocker switch 7 6
push button) 8
2
(For terminal 1-5, 2-6)
9
10 10 9 CS-34
1 ※ Check contact
5 BL- BL+ 1
2
6 BK- BK+ 2 Normal : 80~90Ω
3
7 FL- FL+ 3
4 (For terminal 1-5, 2-6
Joy stick lever -
5 3-7, )
6
4 8
7 : ∞Ω
8 CN-114 (For terminal 4-8)
7-46
Connector No. of Connector part No.
Type Destination
number pin Female Male
CN-83 MWP 2 Aircon fan PH805-02028 -
CN-98 SWP 4 (Frame harness-Main harness) S814-004000 S814-104000
CN-100 J 3 Boom kick out S816-003001 -
CN-101 J 3 Bucket leveler S816-003001 -
HW090
CN-102 sealed 6 Rear wiper motor 6189-01330 -
CN-103 SWP 2 Rear washer tank S814-002000 -
CN-104 Ring term 1 Volt meter - S824-025213
CN-107 Ring term 1 Fuel gauge - S824-025213
CN-114 250 8 Joy stick S810-008202 -
CN-117 Ring term 1 Water temp - S824-025213
CN-119 Ring term 1 Transmission temp - S824-025213
CN-127 - 8 Speed meter 1630070 -
CN-135 Mate-N-Lok 3 Diagnostic - 6029-199-030
CN-136 - 2 Ride control valve 827551-2 -
CN-137 J 2 Ride control solenoid S816-002001 -
CN-144 J 6 Pedal S816-006002 -
CN-155 SWP 6 Work/combi lamp, RH S814-006000 -
CN-156 SWP 6 Work/combi lamp, LH S814-006000 -
Relay
CR-1 Ring term - Battery relay S820-104000 -
CR-2 250 4 Horn relay S810-004202 -
CR-3 250 4 Front work lamp relay S810-004202 -
CR-4 250 6 Wiper relay S810-006202 -
CR-5 250 2 Safety relay S810-006202 -
CR-6 250 4 Rear work lamp relay S810-004202 -
CR-11 250 3 Flasher unit S810-003702 -
CR-23 J 2 Start relay S816-002003 -
CR-24 Ring term - Preheater relay S820-306001 -
CR-30 250 4 Ride control relay S810-004202
CR-35 250 6 Ride control relay S810-006202 -
CR-42 250 4 Preheater relay S810-004202 -
CR-46 250 4 Fuel warmer relay S810-004202 -
Switch -
CS-2 SWP 6 Start key switch S814-006000 -
CS-3 SWF 10 Rear wiper switch 593757 -
CS-5 Shur 1 Horn switch S822-014000 -
CS-11 SWP 8 Multi function switch S814-008000 -
7-48
Connector No. of Connector part No.
Type Destination
number pin Female Male
Sensor, sender
CD-1 - 1 Hyduaulic oil temp sendor 1-150656 -
CD-2 SWP 2 Fuel sendor S814-002000 -
CD-3 Rubber cap - Brake fail pressure switch 21EA-00310 -
CD-4 Rubber cap - Stop lamp pressure switch 21EA-00300 -
CD-5 Rubber cap - Clutch cut off pressure switch 21EA-00310 -
CD-8 Ring term - Water temp sendor - S820-105000
CD-9 PLC(MARK II) 1 Over heat switch S819-010122 -
CD-10 Ring term 2 Air cleaner switch S820-105000 -
CD-18 Ring term - Engine oil pressure switch - S820-105000
CD-25 PLC(MARK II) - Transmission oil pressure switch S819-010122 -
CD-26 Rubber cap - Parking pressure switch 21EA-00310 -
CD-29 Ring term - Transmission temp sendor - S820-106000
CD-39 PLC(MARK II) 2 Steering pressure switch S819-010122 -
CD-40 PLC(MARK II) 2 Steering pump pressure switch S819-010122 -
CD-41 Rubber cap - Boom down pressure switch 21EA-00310 -
7-50
2. CONNECTION TABLE FOR CONNECTORS
1) 58-L TYPE CONNECTOR
No. of
pin Receptacle connector(Female) Plug connector(Male)
1 1
S813-030100 S813-130100
1 2 1 2
S813-030200 S813-130200
7-51
2) PA TYPE CONNECTOR
No. of
1 3
2 5
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
7-52
No. of
6 13 1 7
13
1 7 6 13
S811-013002 S811-113002
8 17 1 9
17
1 9 8 17
S811-017002 S811-117002
10 21 1 11
21
1 11 10 21
S811-021002 S811-121002
7-53
3) J TYPE CONNECTOR
No. of
Receptacle connector(Female) Plug connector(Male)
pin
1 1
2 2
S816-002001 S816-102001
2 3 1
3 1 2
S816-003001 S816-103001
7-54
4) SWP TYPE CONNECTOR
No. of
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
7-55
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
1 9 4 12
S814-012000 S814-112000
3 14 1 11
14
1 11 3 14
S814-014000 S814-114000
7-56
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 4
1 3 2 3
S810-004202 S810-104202
7-57
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
7-58
6) ITT SWF CONNECTOR
No. of
pin
2
10
1 10
SWF593757
7) HW090 SEALED CONNECTOR

No. of
pin
6 3
4
6
6189-0133
8) MWP02F-B CONNECTOR
No. of
pin
2 1
2
PH805-02028
7-59
9) AMP ECONOSEAL CONNECTOR
No. of
pin
1
12
1 13
24
36
36
13 25 12
24
25
36
344111-1 344108-1
7-60
GROUP 6 TROUBLESHOOTING
1. WHEN STARTING SWITCH IS TURNED ON, CLUSTER LAMP DOES NOT LIGHT UP
・Before carrying out below procedure, check all the related connectors are properly inserted and the
fuse No.23 is not blown out and ON/OFF of bulb.
・After checking, connect the disconnected connectors again immediately unless otherwise specified.
Cause Remedy
Defective cluster Replace
YES
Check voltage
between CN-56
(10) and chassis Disconnection in
wiring harness or
YES Check voltage poor contact
between CN-57
(10) and chassis between
CN-56(10) and
CN-7(4)
Check voltage Repair or replace
between CN-7(4) Disconnection in (After clean)
NO
and chassis wiring harness or
poor contact
between
CN-57(10) and
CN-7(4)
Repair or replace
Disconnection in (After clean)
NO
wiring harness or
poor contact
between CN-7(4)
and fuse No.23
CLUSTER
FUSE
10 4
NO.23
CN-57 CN-7
CLUSTER
10
CN-56
Check voltage
YES 20 ~ 30V
NO 0V
7-61
2. WHEN COOLANT OVERHEAT LAMP LIGHTS UP(Engine is started)
・Before carrying out below procedure, check all the related connectors are properly inserted.
Cause Remedy
YES Coolant overheat Check engine
(105°
C±2° C) system
YES
ⓐ
Check resistance
YES
between CN-2(2)
Does display go and chassis
off when Disconnection in Repair or replace
Starting switch : OFF NO
disconnect CD-9 wiring harness or (After clean)
Check resistance
and connector? YES poor contact
between CN-6(4)
Starting switch : ON between CN-6(4)
Engine : start
and chassis
and CN-2(2)
Starting switch : OFF
Check resistance Disconnection in Repair or replace

NO
between CN-57(5) wiring harness or (After clean)
NO
and chassis poor contact
between CN-57
Before checking, (5) and CN-6(4)
disconnect CD-9
NO
Defective PCB Replace
pannel
YES
Defective Replace
Check resistance overheat switch
ⓐ between CN-4(11)
and chassis
Disconnection in Repair or replace
wiring hamess or (After clean)
poor contact
between CD-9
and CN-4(11)
CLUSTER OVER HEAT SWITCH
5 4 2 11
CN-57 CN-6 CN-2 CN-4 CD-9
CHECK UNIT
24
Check resistance
CN-58
YES MAX 1Ω
NO MIN 1MΩ
7-62
3. WHEN AIR CLEANER LAMP LIGHTS UP(Engine is started)
Cause Remedy
YES
Defective air Repair air cleaner
cleaner or air or replace air
cleaner switch cleaner switch
Does display go YES
off when Disconnection in Repair or replace
disconnect CD-10 wiring harness or (After clean)
and connector? poor contact
Starting switch : ON between CN-2(9)
Engine : start
Check resistance and CD-10
between CN-2
NO YES
(9) and chassis Disconnection in Repair or replace
wiring harness or (After clean)
Before checking, poor contact
disconnect CD-10
between CN-2(9)
Check resistance
between CN-6(6) and CN-6(6)
and chassis
YES
Check resistance
poor contact CN-6
between CN-57(4)
NO and chassis (6) and CN-57(4)

NO
CLUSTER
AIR FILTER
4 6 9 Pa
CN-57 CN-6 CN-2
CD-10
CHECK UNIT
36
CN-58
Check resistance
YES MAX 1Ω
NO MIN 1MΩ
7-63
4. WHEN ENGINE OIL PRESSURE LAMP LIGHTS UP(Engine is started)
Cause Remedy
YES
Engine oil leakage, Check engine oil
or defective switch level or replace
switch
YES
Does display go YES Check resistance poor contact
off when between CN-4
between CN-4(12)
disconnect CD-18 (12) and chassis
-CD-18
and connector? Check resistance
Starting switch : ON YES between CN-6 (5) Disconnection in Repair or replace
NO
Engine : start and chassis wiring harness or (After clean)
poor contact
between CN-6(5) -
CN-2(3)-CN-4(12)
Check resistance
between CN-57 NO
NO wiring harness or (After clean)
(11) and chassis
poor contact
Starting switch : OFF between CN-
Before checking, 57(11) - CN-6(5)
disconnect CD-18
NO
CLUSTER ENGINE OIL PRESSURE SWITCH
11 5 3 12 Pa
CN-57 CN-6 CN-2 CN-4 CD-18
CHECK UNIT
23
CN-58
Check resistance
YES MAX 1Ω
NO MIN 1MΩ
7-64
5. WHEN HYDRAULIC OIL TEMPERATURE LAMP LIGHTS UP(Engine is started)
Cause Remedy
YES
High temperature Check hydraulic
of hydraulic oil or oil temperature
defective switch (105° C±2° C),
hydraulic cooling
Does display go or replace switch
off when
YES
disconnect CD-1 Disconnection in Repair or replace
and connector? wiring harness or (After clean)
Starting switch : ON Check resistance
YES poor contact
Engine : start between CN-6
(8) and chassis between CN-56
(4) and CN-6(8)
Check resistance Starting switch : OFF
between CN-56
NO
(4) and chassis NO
Starting switch : OFF poor contact
Before checking,
disconnect CD-1 between CN-6(8)
and CD-1
NO Defective PCB Replace

pannel
HYDRAULIC OIL
CLUSTER TEMPERATURE SWITCH
4 8
CN-56 CN-6 CD-1
CHECK UNIT
12
CN-58
Check resistance
YES MAX 1Ω
NO MIN 1MΩ
7-65
6. WHEN TORQUE CONVERTER OIL TEMPERATURE GAUGE DOES NOT OPERATE
(Check torque converter oil temperature lamp ON/OFF)
Cause Remedy
YES
Check resistance
between CN-7
(10) and chassis
Starting switch : ON YES
Engine : start
See : TABLE wiring harness or (After clean)
Check resistance poor contact
between CD-29 between CN-7(10)
NO
and chassis and CD-29
See : TABLE Defective sender Replace
NO
TRANSMISSION OIL
GAUGE TEMPERATURE SENDER
S 10 C
CN-119 CN-7 CD-29
Check resistance
YES MAX 1Ω
NO MIN 1MΩ
Check table
Temperature
50°
C 92°
C 120°
C 130°
C
Item
Unit resistance(Ω) 168.7 (34) 19.5 12.4
Tolerance 0°~ -10° (-) ±3° +10°~ 0°
Angle -30° -8° +27° +30°
7-66
7. WHEN COOLANT TEMPERATURE GAUGE DOES NOT OPERATE
(Check coolant temperature lamp ON/OFF)
Cause Remedy
YES
YES
Check resistance wiring harness or (After clean)
between CN-7 poor contact
(11) and chassis
between CN-7
Starting switch : ON (11) and CN-2(1)
Engine : start Check resistance
See : TABLE between CN-2(1) YES
NO Disconnection in Repair or replace
and chassis
Before checking, poor contact
disconnect connector between CN-2(1)
See : TABLE
Check resistance and CN-4(10)
between CN-4
NO
(10) and chassis YES
Starting switch : OFF wiring harness or (After clean)
See : TABLE
Check resistance poor contact
between CD-8 between CN-4
NO
and chassis (10) and CD-8
See : TABLE Coolant overheat Check coolant
NO
or defective temperature or
sender replace
WATER TEMPERATURE
GAUGE SENDER
S 11 C
1 10
CN-117 CN-7 CN-2 CN-4 CD-8
Check resistance
YES MAX 1Ω
NO MIN 1MΩ
Check table
Temperature
(40°
C) 91°
C 105°
C 120°
C
Item
Unit resistance(Ω) 222 (41.3) 28 19.2
Tolerance ±5° (-) ±4.5 (-)
Angle -30° 0° +13° +30°
7-67
8. WHEN FUEL GAUGE DOES NOT OPERATE(Check warning lamp ON/OFF)
Cause Remedy
YES
YES
Check resistance Disconnection in Repair or replace
between CN-7 wiring harness or (After clean)
(12) and chassis poor contact
Starting switch : OFF between CN-7
See : TABLE (12) and CN-3(8)
Check resistance
between CN-3(8)
NO YES
and chassis Disconnection in Repair or replace
See : TABLE wiring harness or (After clean)
poor contact
Check resistance between CD-2(1)
between CD-2(2) and CN-3(8)
NO
and chassis
YES
See : TABLE Check circuit Repair or replace
Check resistance
between CD-2(2) (After clean)
between CD-3(8)
and chassis
NO and CD-2(1) with
chassis
See : TABLE Defective sensor Replace
NO
GAUGE
FUEL SENDER
S 12 8 1
2
CN-107 CN-7 CN-3 CD-2
Check resistance
YES MAX 1Ω
NO MIN 1MΩ
Check table
Temperature
Empty (1/2) Full
Item
Unit resistance(Ω) 95 (32.5) 7
Tolerance ±2.5° ±5° ±2.5°
Angle -30° 0° +30°
7-68
9. WHEN GAUGES OF FUEL, HYDRAULIC OIL AND COOLANT INDICATE HIGH OR FULL
Cause Remedy
YES Defective gauge Replace
Check resistance
between CN-7
(13) and chassis
Starting switch : ON NO
Voltage : 20~30v
poor contact
between CN-7
(13) and chassis
CLUSTER
13
CN-7
Check resistance
YES MAX 1Ω
NO MIN 1MΩ
7-69
10. WHEN BATTERY LAMP LIGHTS UP(Engine is started)
Cause Remedy
YES
Check voltage Defective cluster Replace
YES
between CN-6(1)
and chassis Disconnection in Repair or replace
NO
poor contact
between CN-6(1)
and CN-58(18)
YES
Defective check Replace
Check voltage
YES unit
between CN-58
(2) and chassis
Voltage : 27.5~30V
NO
poor contact
Check voltage Check voltage between CN-58(2)
YES
between between CN-3(4) and CN-3(4)
alternator terminal and chassis
YES
"I" and chassis Voltage : 26~30V Disconnection in Repair or replace
Voltage : 26~30V wiring harness or (After clean)
Starting switch : ON
Check voltage poor contact
between CN-4(8) between CN-4(8)
NO
and chassis and CN-3(4)

NO
poor contact
between CN-4(8)
and alternator
terminal " I "
Defective alternator Replace

NO
CLUSTER CHECK UNIT
9 1 18
CN-57 CN-6
2
CN-58
ALTERNATOR
4 8 " I " TERMINAL
Check valtage CN-3 CN-4
YES 20 ~ 30V
NO 0V
7-70
11. WHEN PARKING SOLENOID DOES NOT WORK
fuse No.9 is not blown out.
Cause Remedy
YES
Defective parking Replace
brake solenoid
Check voltage YES

between CN-71 Disconnection in Repair or replace
(2) and chassis wiring harnessor (After clean)
poor contact
Parking switch : ON-OFF
Check voltage between CN-8(3)
Voltage : 20~30V NO between CN-8(3) and CN-71(2)
and chassis
YES
Voltage : 20~30V Disconnection in Replace
wiring harness or
poor contact
between CS-17(8) Repair or replace
and CN-71(2) (After clean)
YES
Defective parking
Check voltage Check voltage switch
between CS-17 between CS-17
NO NO
(8) and chassis (6) and chassis
Disconnection in
NO
Parking switch : OFF Voltage : 20~30V wiring harness or
Voltage : 20~30V
poor contact
between CS-17(6)
and Fuse No.9
PARKING SWITCH
8 3
CN-8 FUSE
6
No.9
CS-17
PARKING SOLENOID
2
1
2
1
CN-71
7-71
12. TRANSMISSION IS NOT RETURNED TO NEUTRAL WHEN PARKING BRAKE IS APPLIED
fuse No.18(T/M controller) and No.9 are not blown out.
Cause Remedy
YES
Defective T/M Replace
controller
Check voltage YES

between CN-15
(F) and chassis
poor contact
Starting switch : ON Check voltage between CN-15
Parking switch : ON between CS-17
Voltage : 20~30V NO (F) and CS-17(7)
(7) and chassis
YES
Voltage : 20~30V Defective switch Replace
Parking switch : ON Check voltage
between CS-17
NO
(5) and chassis
NO
Voltage : 20~30V wiring harness or (After clean)
poor contact
between CS-17(5)
and fuse No.9
F
CN-15
PARKING SWITCH FUSE

6
9
No.10
5
71
CS-17
Check resistance
YES MAX 1Ω
NO MIN 1MΩ
7-72
13. MACHINE DOES NOT TRAVEL
fuse No.18(Transmission controller) is not blown out.
・Wiring diagram : See page 7-17.
Cause Remedy
YES
Defective clutch Replace
cut-off switch
Check resistance
YES
between CD-5
and chassis
NO Is there continuity Defective T/M Replace

between CN-15(E) NO
and chassis? controller
NO
Defective T/M Replace
Is voltage between
controller
CN-15(F) and
chassis 20-28V? YES
Defective parking Replace
Parking switch : OFF
switch
Clutch cut-off Is there continuity
switch : ON between CS-17(1)
YES
and chassis?
Disconnection Repair or replace

NO
poor contact
between CN-15(F)
and CS-17(1)
Check resistance
YES MAX 1Ω
NO MIN 1MΩ
7-73
14. WHEN STARTING SWITCH IS TURNED ON, HEAD LAMP DOES NOT LIGHTS UP
fuse No.3 is not blown out and ON/OFF of bulb.
FUSE BOX
BEACON LAMP 20A
aAb aBb
a 1 b a 2 b a 3 b 25 b a 26 b a 27 b a 28 b
Cause Remedy
ILL. LIGHT
10A
YES
Defective bulb Replace HEAD LIGHT 20A
aC
HIGH BEAM
Check voltage
YES ECM IG RY
Yb
between CL-3(1) - ECM IG 5A
a Z b a AA b a BB b
(3) and CL-4(1) -(3)
Voltage : 20~30V Disconnection in Repair or replace ILL. DISPLAY,GAUGE
NO CLEARANCE F/R R/L 5A
Starting switch : ON wiring harness or (After clean) ILL.AC,CIGAR
Check voltage Head lamp switch : ON
YES between CN-10(4) poor contact CN-36
and CN-8(11), (12) between CN-10(4)- 5 LH HEAD LIGHT

6 13A G 1 Lo
CL-3(1), 4(1) and 7 12A V
2 Hi
Voltage : 20~30V 8 G11 B
Starting switch : ON CL-3(3)-CN-8(11), ILL & HEAD LAMP SW 9
3 E
4 C
Head lamp switch : ON CL-4(3)-CL-8(12) 9 10 10 10 CL-3
9 11 B G11
4 8 B G21
Repair or replace 2
7
12
13 G
RH HEAD LIGHT
CN-8 1 Lo
NO
Disconnection in (After clean) 7
5
1 6 12 V
2 Hi
5 1 G22 B
Check voltage wiring harness or 4
004 1.25G
2
3 E
030B 1.25V 4 C
between CS-11 poor contact
3
045 1.25W 402 1.25GY
3
CL-4
II I 0
2 4
(7) and chassis between CN-10(4)
1 5
CS-39 6
7
Starting switch : ON and CS-11(7) 8
Head lamp switch :
ON-OFF Replace CN-10
YES
Defective
multifunction switch
1
HI BEAM
2
Check voltage Repair or replace 030A 1.25 V
3
313 1.25 V
1
YES
between CS-11 Disconnection in (After clean) 4 2
NO 5 3
(8) and chassis wiring harness or 6 4
7 5
Voltage : 20~30V poor contact 8 6
Starting switch : ON Check voltage between CS-11(8) 9 7
10 8
between CS-39 and CS-39(2) 11 9
NO
(2) and chassis 10
402 1.25 GY
12
Replace switch
045 1.25 W
046 1.25 G
030 1.25 V
13 11
YES
Defective head 14 12
CN-7 13
Check voltage lamp switch CN-57
CS-11
between CS-39
3
2
7
6
5
4
1
8
NO
(4) and chassis Repair or replace
BWG 4
W6
NO Disconnection in (After clean)
Hi
C
wiring harness or
Lo
Hi
B+
C
poor contact
R
L
O
R
L
7 Y Lo
between CS-39(4)
2 BW
8 WB
3 BG
5B
and fuse No.3 MULTI FUNCTION SW
7-74
15. WHEN STARTING SWITCH IS TURNED ON, WIPER MOTOR DOES NOT OPERATE
・After checking, connect the disconnected connectors again immediately unless otherwise specified. CHECK UNIT
STEERING P/P PS
STEERING P/P LP
MAIN PUMP FAIL
NEUTRAL CODE
OVER HEAT SIG
CHARGE LAMP
STEERING SIG
BUZZER STOP
NEUTRAL SIG
STEERING RY
HOUR METER
PARKING SIG
NEUTRAL RY
E/OIL FILTER
PARK LAMP
ENG OIL PS
AIR FILTER
SPEED SIG
ALT LEVEL
HYD TEMP
BRAKE PS
WASH SIG
WIPER RY
FUSE BOX
TM LAMP
BUZZER
INT SIG
b a 5b
IG 24V
TM PS
STOP LAMP
N.C
N.C
N.C
N.C
N.C
N.C
N.C
GND
Cause Remedy 5A
aE b
YES HORN
CN-58
20A
aF b
a 6b
Check voltage Defective front Replace
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
1
2
3
4
5
6
7
8
9
AIR CON&HEATER
YES between front wiper motor 20A
aGb
a 7b
AIR CON RELAY
036 1.25 GY
022A 1.25 R
049 1.25 Y
CIGAR LIGHTER
wiper motor and 20A
aH b
a 8b
chassis Poor connection of Replace SWITCH PARKING 10A
NO
a Ib
a 9 b a10 b a 11 b a12 b a 13 b
Check voltage Voltage : 20~30V chassis 014 1.25 L
SWITCH CLUTCH
YES Starting switch : ON FRONT WIPER 20A
between CN-21(5)
aJb
REAR WIPER
Wiper switch : 1st
and chassis WORK LAMP FRONT 30A
aKb
WORK LAMP REAR
RIDE CONTROL
Voltage : 20~30V 10A
aL b
Starting switch : ON Disconnection in Repair or replace E-STEERING
Check voltage Wiper switch : 1st NO 10A
aM b
STEERING P/P RY
YES wiring harness or (After clean)
between CS-12
(4) and chassis poor contact CN-36
between CS-12(4) WIPER RY LO

Voltage : 20~30V 066 1.25 R 30
and CN-21(5) 013B 1.25 W 86
87a 87 85
Check voltage 013 1.25 W
Wiper switch : OFF 87
036 1.25 GY
CS-12(6) Defective wiper Replace 85
048 1.25 G 30 86
NO 87a
switch CR-26
Voltage : 20~30V
Wiper switch : 1st Disconnection in Repair or replace
NO WIPER RY HI
wiring harness or (After clean) 014A 1.25 L
30
047 1.25 OR 87a 87 85
poor contact 077 1.25 G
86
87
between CS-12(6) 025 1.25 B
85
013C 1.25 W 30 86
and fuse No.10 87a
CR-4
086 1.25 OR
047 1.25 OR
014B 1.25 L
048 1.25 G
022 1.25 R
049 1.25 Y
013A 1.25 W
086 1.25 OR
G51 1.25 B
077 1.25 G
066 1.25 R
CS-11
CS-12
CS-5
6
5
4
3
2
1
8
7
6
5
4
3
2
1
CN-21
1
2
3
5
4
6
BWG 4
RW 6
W6
BVi 3
L 4
5 Lo
G 5
4 Hi
3E
2Pf
BY 1
1B
Gr 2
M
HO
W
II
I
Hi
C
J 0
J
C
0
II
I
Lo
Hi
B+
FRONT WIPER
F
R
L
O
R
L
7 Y Lo
8 WB
2 BW
3 BG
5B
MULTI FUNCTION SWITCH
7-75
16. 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.17 is not blown out.
FUSE BOX

Cause Remedy E-STEERING
10A
aM b
STEERING P/P RY
YES PREHEATER RY
Defective cable Repair or replace 10A
aNb
Check voltage (After clean) TURN LAMP
YES assembly 20A
aO b a P b
between CN-60(2) CASSETTE 10A
and chassis ROOM LAMP
Short circuit or Replace IGNITION SWITCH 20A
aQ b a R b
Voltage : 20~30V NO
Check voltage defect of fusible T/M CONTROLLER 10A
YES
between CR-1 link or defective ECM + 10A
aSb
(M4) and chassis
battery relay ECM + 10A
aT b aU
Voltage : 20~30V
RCV 10A
PROX.SWITCH
Disconnection in Replace 5A
a 25 b
aTb
NO ECM IG RY
Check voltage wiring harness or ECM IG
YES between CS-2 5A
a 26 b
aTb
(1)[and CS-2(2)] poor contact
CN-36
and chassis between CS-2(2) -
Voltage : 20~30V 601 3R
CN-3(6)-CR-1 MASTER SW
BATTERY
(M4) BATT RY
R4 B G
R1
605D 1.25 L
G79 1.25 B R3
R2
Disconnection in Replace CR-1
Check voltage NO 1
602 5 W
wiring harness or 2 2
and specific CN-1
601 3 R
1
gravity of battery poor contact CN-60
TO STARTER
between fuse No.
Specific gravity : MIN 1.28
Voltage : MIN 24V 17 and CS-2(1) or
defect of start
switch 1
2 605A 1.25 L
2
3 605 1.25 V
1
4 DO-1
Battery capacity Repair or replace
NO 5
too low (After clean) 6
7
085 1.25 OR
605 1.25 V
8
9
10
11
CS-2
12
5
4
1
6
2
3
13
B 14
0, I
1
CN-3
H 0 I II
6
5
4
2
3
H
C ST ACC BR
START SWITCH
7-76
17. WHEN STARTING SWITCH IS TURNED ON, WORK LAMP DOES NOT LIGHTS UP
・Before carrying out below procedure, check all the related connectors are properly inserted, and the
FUSE BOX
b a 5b
STOP LAMP 5A
aE b
HORN
Cause Remedy 20A
aF b
a 6b
YES AIR CON&HEATER 20A
aGb
a 7b
Defective lamp Replace AIR CON RELAY
Check voltage CIGAR LIGHTER
YES between each 20A
aH b
a 8b
SWITCH PARKING
lamp and chassis 10A
a Ib
a 9 b a10 b a 11 b a12 b a 13 b
SWITCH CLUTCH
NO FRONT WIPER 20A
aJb
Voltage : 20~30V REAR WIPER
Check voltage Starting switch : ON poor contact 081 1.25 G WORK LAMP FRONT 30A
aKb
078 1.25 GY WORK LAMP REAR
YES between CN-5(4), between CL-6(2), RIDE CONTROL 10A
CN-3(10) and
aL b
CL-5(2), CL-22(1),
E-STEERING
chassis CL-23(1) and CN- 10A
aM b
STEERING P/P RY
Voltage : 20~30V 5(4), CN-3(10). CN-36
Check voltage Disconnection in Repair or replace
YES between CR-3(4), NO
CR-6(4) and poor contact
chassis between CN-5(4) -
Voltage : 20~30V
CR-3(4) and CN-
3(10) - CR-6(4)
Check voltage
between CR- Defective work Replace relay
3(2), CR-6(2) and NO
lamp relay
chassis
Voltage : 20~30V YES
wiring harness or (After clean) 1
2 FRONT WORK
Check voltage poor contact FR WORK LAMP RY
502 1.25 OR
3
OR 4 OR 4
LIGHT,LH
3 4 4 4 2
between CR-3(2), 157 1.25 W 5 B G11
between fuse No. 3
6
1
NO CR-6(2) and fuse 2
081 1.25 G
7
CL-6
17 and chassis G21 1.25B B G11
No.11 1 2 1 8 FRONT WORK
LIGHT,RH
CR-3 CN-5 OR 4A
Voltage : 20~30V 2
B G12
Starting switch : ON Short circuit of fuse Replace RR WORK LAMP RY 1
1 CL-5
NO 3 4 4
603 1.25 BR
2
156 1.25 L
3 3
078 1.25 GY REAR WORK
2 4
G22 1.25B 5 LIGHT,LH
1 2 1 630A 1.25 BR
6 6 1
CR-6 2
7 5
8 4 CL-22
WORK LAMP SW 9 3
10 2
9 10 10 11
9 1
4 8 12
CN-155 REAR WORK
2 158 1.25 G 13 LIGHT,RH
7 14 630B 1.25 BR
6 1
7 1 6
5 157 1.25 W CN-3 5 2
5
4 CL-23
4
3 3
156 1.25 L
II I 0
2 2
1 1
CS-20 CN-156
7-77
18. WHEN ENGINE DOES NOT START
・Check supply of the power at engine stop solenoid while starting switch is ON.
・Before carrying out below procedure, check all the related connectors are properly inserted. CONTROL UNIT
・After checking, connect the disconnected connectors again immediately unless other wise specified.
・Check forward reverse switch at neutral position. FUSE BOX

ADM1
ADM5
SDDL
VPS2
VPS1
VPE2
E-STEERING
AIP7
AIP6
AIP8
AIP4
AIP1
10A
ER2
SD2
EU2
ED1
ED5
ED2
ED9
ED6
aM b
EF4
STEERING P/P RY
PREHEATER RY
10A
aNb
Cause Remedy
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
TURN LAMP 20A
aO b a P b
YES
902A 0.85 W
Defective battery Check engine CASSETTE 10A
ROOM LAMP
system charge or IGNITION SWITCH 20A
aQ b a R b
replace (after
VM OUTPUT SIGNAL K A T/M CONTROLLER
checking specific VP F B N D B
10A
gravity of battery) ED 1 2 3 4 1 2 3 4 1 2 3 4 C ECM + 10A

SAFETY RY
aSb
YES AD1 B1 D
052 1.25 R
Check voltage Defective magnet Replace AD2 B2 X2 A 30 ECM +
902B 0.85 W 202 1.25 W 87a 87 85 10A
Check operation 86
aT b aU
AD3 B3 B
YES between starter of start motor AD4 V 850 1.25 V
C 87 RCV
of start motor magnet coil and AD5 R A 018 1.25 L
85 PROX.SWITCH
10A
AD6 AS B D
chassis Defective start Replace AD7 C E 87a 30 86 5A
a 25 b
aTb
902 0.85 W ECM IG RY
Starting switch : start NO A AD3 D
F CR-5
Starting switch : start relay X3 ECM IG
B AD2 G 5A
a 26 b
aTb
C AD1
H
YES D AD7(KD)
CN-36
ⓐ X1
J
A ED1(VP)
Check operation Check voltage
K
D AD6
CN-15
NO of starter relay YES
between CR-5 B AD4
C AD5
X2
(87) and chassis
Starting switch : start
Disconnection in Replace
wiring harness or
Check operation poor contact
of start safety between CN-2(6)
NO
relay and CR-5(87)
Check switch : neutral YES
Defective relay Replace
Check voltage
between CR-5
NO
(86) and chassis
ⓑ
YES
Defective start Replace
Check voltage relay STARTER
053 1.25 GY
085 1.25 OR
605 1.25 V
052 1.25 R
TO BATT
ⓐ between CR-23 B+
(2) and chassis 1

Disconnection in Repair or replace 1 2 M
Voltage : 20~30V NO CS-2 2 3 CN-45
5
4
1
6
2
3
Starting switch : ON wiring harness or 3 4
B START RY
poor contact 0, I 4 5
1
G61 1.25 B G10 1.25 B
between CN-2(6)- 5 6 1
650 1.25 V 850 1.25 V
6 7 2
CN-4(7)-CR-23(2) H 0 I II 7 8 CR-23
6
5
4
2
3
H
C ST ACC BR 8 9
YES START SWITCH 9 10
10 11
wiring harness or 11 12
Check voltage poor contact 12 CN-4
CN-2
ⓑ between CN-15 between CN-15(B)
(B) and chassis and CR-5(86)
Defective DW-3 Replace
NO
7-78

Hyundai HL780-3A

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WHEEL LOADER HYUNDAI HL780-3A

HL780-3A Service Manual Open index screen

SECTION 3 POWER TRAIN SYSTEM

SECTION 4 BRAKE SYSTEM

SECTION 5 STEERING SYSTEM

SECTION 6 WORK EQUIPMENT

SECTION 7 ELECTRICAL SYSTEM

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

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

-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

SECTION 3 POWER TRAIN SYSTEM

SECTION 4 BRAKE SYSTEM

SECTION 5 STEERING SYSTEM

SECTION 6 WORK EQUIPMENT

Group 1 Safety Hints 1-1

FOLLOW SAFE PROCEDURE

WEAR PROTECTIVE CLOTHING

WARN OTHERS OF SERVICE WORK

right side controller lever. NOT

USE HANDHOLDS AND STEPS

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 FLUID

PREVENT BATTERY EXPLOSIONS

USE TOOLS PROPERLY

USE PROPER LIFTING EQUIPMENT

DISPOSE OF FLUIDS PROPERLY

LIVE WITH SAFETY

KEEP ROPS INSTALLED PROPERLY

Boom Bucket cylinder Main control valve Step Battery Counterweight

1) WITHOUT TOOTH AND CUTTING EDGE TYPE BUCKET

Description Unit Specification

Operating weight kg(lb) 28880(63670)

Description Unit Specification

Description Unit Specification

Front frame assembly 2825 6228

Model Cummins QSM 11-C

Type Fixed displacement single vane pump

4) MAIN CONTROL VALVE

5) REMOTE CONTROL VALVE

Type Pressure reducing type