HL780 7a PDF

SECTION 1 GENERAL
Group 1 Safety Hints - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1

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

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

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

Unexpected machine movement can cause
serious injury.
Before performing any work on the wheel
WARN
loader, attach a「Do Not Operate」tag on the
DO
right side controller lever. NOT
OPERATE
7707GE01
USE HANDHOLDS AND STEPS

Falling is one of the major causes of personal injury.
When you get on and off the machine, always
maintain a three point contact with the steps and
handrails and face the machine. Do not use any
controls as handholds.
Never jump on or off the machine. Never mount or
dismount a moving machine.
Be careful of slippery conditions on platforms, 73032E01
steps, and handrails when leaving the machine.
1-1
PREPARE FOR EMERGENCIES
Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors,
ambulance service, hospital, and fire
department near your telephone.
73031GE03
WORK IN CLEAN AREA

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Make certain all parts are reinstalled correctly if
the roll-over protective structure(ROPS) is
loosened or removed for any reason. Tighten
mounting bolts to proper torque.
The protection offered by ROPS will be impaired
if ROPS is subjected to structural damage, is
involved in an overturn incident, or is in any way
altered by welding, bending, drilling, or cutting.
A damaged ROPS should be replaced, not 73031GE22
reused.
1-9
GROUP 2 SPECIFICATION
1. MAJOR COMPONENT
Bucket Tire Head light Hydraulic tank Air cleaner Battery
Boom Bucket cylinder Main control valve Step Radiator Counterweight
Bucket link Bell crank Steering cylinder Cab Precleaner Muffler Engine
Front axle Boom cylinder Main pump Transmission Rear axle Fuel tank
7807ASE01
1-10
2. SPECIFICATIONS
1) WITHOUT TOOTH AND CUTTING EDGE TYPE BUCKET
B
F
I
J
6160
H
4510
3620
K
40
C
G
64
755 30
D
0
E 2680
A
7807ASE02
Description Unit Specification

Operating weight kg(lb) 29300(64600)
Struck 4.1(5.4)
Bucket capacity m3(yd3)
Heaped 4.8(6.3)
Overall length A 9325(30' 7")
Overall width B 3450(11' 4")
Overall height C 3805(12' 6")
Ground clearance D 475( 1' 7")
Wheelbase E mm(ft-in) 3700(12' 2")
Tread F 2440( 8' 0")
Dump clearance at 45。 G 3385(11' 1")
Dump reach at 45。 H 1330( 4' 4")
Width over tires I 3220(10' 7")
Dump angle J 47
Degree (。)
Roll back angle(Carry position) K 48
Lift(With load) 6.4
Cycle time Dump(With load) sec 1.4
Lower(Empty) 3
Maximum travel speed km/hr(mph) 33.9(21.1)
Braking distance 12(39' 4")
m(ft-in)
Minimum turning radius(Center of outside tire) 6.43(21' 1")
Gradeability Degree (。) 30
First gear 6.2(3.9)
Second gear 11.4(7.1)
Forward
Third gear 17.5(10.9)
Fourth gear km/hr(mph) 33.9(21.1)
Travel speed
First gear 6.2(3.9)
Reverse Second gear 11.4(7.1)
1-11
2) WITH BOLT-ON CUTTING EDGE TYPE BUCKET
B
F
I
J
6160
H
4510
3620
K
40
C
G
64
758 30
D
5
E 2680
A
7807ASE03

Struck 4.3(5.6)
Heaped 5.1(6.7)
Tread F 2440( 8' 0")
Dump reach at 45。 H 1365( 4' 6")
Dump angle J 47
Degree (。)
Lift(With load) 6.4
Lower(Empty) 3
m(ft-in)
First gear 6.2(3.9)
Forward
Travel speed Fourth gear km/hr(mph) 33.9(21.1)
First gear 6.2(3.9)
1-12
3) WITH TOOTH TYPE BUCKET
B
F
I
J
6160
H
4510
40
3620
K
C
G
64
767 30
0
D
E 2680
A
7807ASE04

Struck 4.1(5.4)
Heaped 4.8(6.3)
Tread F 2440( 8' 0")
Dump reach at 45。 H 1485( 4' 10")
Dump angle J 47
Degree (。)
Lift(With load) 6.4
Lower(Empty) 3
m(ft-in)
First gear 6.2(3.9)
Forward
Fourth gear 33.9(21.1)
Travel speed km/hr(mph)
First gear 6.2(3.9)
1-13
3. WEIGHT
Item kg lb
Front frame assembly 2714 5983

Rear frame assembly 3531 7785
Front fender(LH & RH) 74 163
Counterweight 1300 2866
Cab assembly 1030 2271
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 509 1122
Main pump assembly 37 82
Steering pump assembly 24 53
Main control valve 95 209
Flow amplifier 29 64
Boom 2095 4619
Bell crank 263 580
Bucket link 55 121
5.1m bucket, with bolt on cutting edge
3
2590 5710
4.8m3 bucket, with tooth 2460 5423
4.7m bucket, without tooth and cutting edge
3
2250 4960
Boom cylinder assembly(2EA) 290 639
Bucket cylinder assembly(2EA) 130 287
Steering cylinder assembly(2EA) 60 132
Seat 40 88
Battery 55 121
1-14
4. SPECIFICATION FOR MAJOR COMPONENTS
1) ENGINE
Item Specification
Model Cummins QSM 11

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 2000rpm
Maximum gross torque at 1400rpm 171kgf·m(1235lbf·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 162g/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 113.5cc/rev 15.9cc/rev
Maximum operating pressure 210kgf/cm (2987psi)
2
150kgf/cm2(2130psi)
Rated oil quantity 212ℓ/min(56U.S.gpm) 30ℓ/min(7.9U.S.gpm)
Rated speed 2000rpm
3) STEERING PUMP(+FAN PUMP)

Specification
Item
Steering pump Fan pump
Type Fixed displacement single vane pump
Capacity 137.5cc/rev 24.9cc/rev
Maximum operating pressure 210kgf/cm2(2987psi) 140kgf/cm2(1990psi)
Rated oil quantity 270ℓ/min(71.3U.S.gpm) 49ℓ/min(12.9U.S.gpm)
Rated speed 2000rpm
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) 240kgf/cm2(3414psi)
Overload relief valve pressure(Bucket) 240kgf/cm2(3414psi)
5) REMOTE CONTROL VALVE
Item Specification
Type Pressure reducing type
Minimum 5.8kgf/cm2(82.5psi)
Operating
Maximum 24kgf/cm2(341psi)
Single operation stroke Lever 75mm(3.0in)
1-16
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
7) DYNAMIC POWER TRAIN DEVICES
Item Specification
Model ZF 4WG310
Converter Single-stage, single-phase
Type
Transmission 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
FNR Switch on joystick lever(option)
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(FLARE TYPE)
Thread size Width across flat(mm) kgf·m lbf·ft
1/4" 19 4 28.9
3/8" 22 5 36.2
1/2" 27 6 43.4
3/4" 36 12 86.8
1" 41 14 101
3) PIPE AND HOSE(ORFS TYPE)
13/16-16" 24 4.4 32.5

1-3/16-12" 36 9.3 67.3
1-7/16-12" 41 13.2 95.5
1-11/16-12" 50 18.3 132
2-12" 55 22.6 164
4) FITTING
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
5) 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 M20×2.5 57.9 ± 8.7 419± 62.9
5 Fuel tank mounting bolt, nut M16×2.0 29.7 ± 4.5 215± 32.5
6 Main pump housing mounting bolt M16×2.0 29.7 ± 4.5 215± 32.5
7 Steering pump housing mounting bolt M10×1.5 6.9 ± 1.4 49.9± 10.1
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 M12×1.75 12.3 ± 2.0 89.0± 14
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 Transmission bolt, nut(Rubber, 4EA) M24×3.0 100 ± 15.0 723 ± 108
18 Transmission 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 48.5 ± 2.5 351± 18
22 Drive shaft joint mounting bolt, nut M20×2.5 57.9± 8.7 419± 62.9
23 Counterweight mounting bolt M30×2.0 199 ± 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) M27×2.0 124 900
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
ℓ(U.S. gal) 30 40
(-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-90LS/API GL-5
Rear : 60(15.9)
Tank: ISO VG 32
210(55.5)
Hydraulic tank Hydraulic oil ISO VG 46
System:
340(90) 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 Ethylene glycol base permanent type
Radiator 65(17.2)
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. 7807AOP02
OK NOT
Item OK Comments
1. Monitor indicator and gauge checks(Engine OFF)
· Hourmeter and gauge check

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

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

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

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

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

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

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

·Steering system leakage check
·Priority valve
Low check pressure
High check pressure
8. Accessory checks
·Operating lights check

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

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

Group 2 Engine speed & stall rpm - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-14
Group 3 Fan drive circuit for cooling system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-15
SECTION 2 ENGINE
GROUP 1 STRUCTURE AND FUNCTION
1. STRUCTURE
Engine coolant vent

Air intake manifold
Exhaust manifold
Corrosion resistor
Dipstick
Coolant inlet
Filler cap
Oil filter
Oil pan sump heater
Oil drain
Air intake connection

Lifting bracket Blowby measurement
Compressor
mounting location
Electronic control
module(ECM)
Flywheel
Fuel inlet to pump
Fuel filter
Engine support
Oil pan
Side oil drain
7807AEN01
Â 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.
Â Lower Overhead Force and Cam Stress
Â Improved Injection Train Component Life
Â Shorter Heat Release during Combustion
Â Lower Emissions
Â 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 SPEED & STALL RPM
1. TEST CONDITION
1) Normal temperature of the whole system
- Coolant : Approx 80 äC (176 ä
F)
- Hydraulic oil : 45 Ü 5 ä
C (113 Ü 10 ä F)
- Transmission oil : 75 Ü 5 ä
C (167 Ü 10 ä F)
2) Normal operating pressure : See page 6-53.
2. SPECIFICATION
Engine speed, rpm
Remark
Low idle High idle Pump stall Converter stall Full stall
800Ü25 2130Ü70 2040Ü70 2020Ü70 1620Ü100
3. ENGINE RPM CHECK

Remark : If the checked data is not normal, it indicates that the related system is not working properly.
Therefore, it is required to check the related system pressure : See page 6-53.
1) Pump stall rpm
- Start the engine and raise the bucket
approx 45cm (1.5ft) as the figure.
- Press the accelerator pedal fully and
operate the bucket control lever to the
retract position fully.
- Check the engine rpm at the above
condition.
7807Awe61
2) Convertor stall rpm

- Start the engine and lower the bucket on
the ground as the figure.
- Set the clutch cut off switch at the released
position.
- Press the brake pedal and accelerator
pedal fully.
- Shift the transmission lever to the 4th
forward position.
- Check the engine rpm at the above 7807Awe62
condition.
3) Full stall rpm
- Start the engine and raise the bucket
approx 45 cm (1.5 ft) as the figure.
- Set the clutch cut off switch at the
released position.
- Press the brake pedal and accelerator
pedal fully .
- Shift the transmission lever to the 4th
forward position and operate the bucket
lever to the retract position fully. 7807Awe63
- Check the engine rpm at the above

condition.
2-14
GROUP 3 FAN DRIVE CIRCUIT FOR COOLING SYSTEM
1. REQUIRED TOOL
Item Spec
Pressure gauge 250~300kgf/cm2(3550~4270psi)
rpm gauge 200~2000rpm
Wrench 13mm
Tool
Hex. wrench 3mm
2. PRESSURE CHECK AND ADJUSTMENT

1) Specification
Cooling fan speed(rpm) Pressure[kgf/cm2(psi)]
1050±20 130~140(1850~1990)
2) Check point Harness connector

(CN-154) Relief valve
Relief valve Harness connector

(CN-154)
Uni-dictional Bi-dictional
WTHCS01
3) Pressure check
(1) Install the pressure gauge to fan drive motor. ( )
(2) Disconnect CN-154.
(3) Check the fan drive motor pressure at high engine rpm.
(4) Check the cooling fan speed using rpm gauge at high engine rpm.
4) Adjustment
(1) Turn the adjusting screw clockwise to
increase the cooling fan rpm and relief
pressure.
(2) Turn the adjusting screw counter
clockwise to decrease the cooling fan rpm
and relief pressure.
Adjusting screw
WTHCS02
2-15
SECTION 3 POWER TRAIN SYSTEM
Group 1 Structure and Function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1

Group 2 Operational Checks and Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-66
Group 3 Tests and Adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-77
Group 4 Disassembly and Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-80
SECTION 3 POWER TRAIN SYSTEM
1. POWER TRAIN COMPONENT OVERVIEW
Transmission Upper drive shaft Engine
Front axle Front drive shaft Center drive shaft Rear drive shaft Rear axle
7807APT01
The power train consists of the following components:

ÂTransmission
ÂFront, center, rear and upper drive shafts
ÂFront 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
7803APT02
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 X X KR F 60
Y2 X K4 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
7803APT03
1 Turbine 3 Pump 5 Input shaft

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

TT = Torque of the turbine wheel
TR = Torque of the reaction member(Stator)
Pump wheel TR
Turbine wheel
From the engine
TT
TP
To the gearbox
Starting
condition 1 Reaction member nT = 0
1.5 2.5 Machine stopped
(Stator)
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
7807APT03
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
7807APT05
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 lineS2clutch K4/K3
9 Lifting lug 22 Lubricating oil lineS1clutch 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
Η 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
7807APT07
3-7
Θ 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
7807APT08
3-8
Ι 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
7807APT09
3-9
Κ 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
7807APT10
3-10
(2) Reverse
Η 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
7807APT11
3-11
Θ 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
7807APT12
3-12
Ι 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
7807APT13
3-13
4) ELECTRO-HYDRAULIC SHIFT CONTROL WITH PROPORTIONAL VALVE
2 1 3
A A
Y6 Y1
Y5 Y2
B
Y4 Y3
3 6
2 6 1 4 11 9 10
Y5
SECTION A-A SECTION B-B

8 7
73033CV01
1 Pressure reducing valve(9bar) 7 Intermediate 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 3-78.
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
1
(Speeds) 1 to 4 are selected by tilting the 2
3
N
4
R
lever, the driving direction Forward(F)-
Neutral(N)-Reverse(R).
The gear selector is also available with
integrated kickdown push button.
For the protection from unintended start off,
a neutral interlock is installed :
Position N - Gear selector lever blocked in N D
this position.
Position D - Driving. 73033TM17
3-15
6) LCD
Cluster 1( ) LCD
1 2( ) MENU
- Display main menu
2
MENU
- Return to the normal display
BACK
3 3( ) BACK
NEXT 4 Return to the previous menu
SELECT
5 4( ) NEXT, BUZZER STOP
Move to the next selection
5( ) SELECT
7807A3CD72
Activate the currently chosen item
(1) Normal display

TYPE 1 TYPE 2
1
c
a e 3
2 d
b
6 4
5
7807A3CD93
No Symbol Meaning Remark
Forward, reverse, neutral LCD type 1 Display symbol during AEB mode
F, R, N Forward, reverse, neutral LCD type 2 Display symbol during AEB mode
1
1, 2, 3, 4 Actual gear -
P Parking brake mode active -
a Wiper motor intermittently operating -
2 When operating intermittently, it
b -
shows an operating time interval.
c, d Up and down shifting c : Forward, d : Reverse
3 Automatic mode
e Pre-selected gear -
HOUR
4 Hour meter Display the total operation hours of the machine

COOLANT
5 C Engine coolant temperature Display in accordance with selected items
AUT Ride control mode active Ride control switch AUTO position, see page 7-36
ON Ride control mode active Ride control switch ON position, see page 7-36
6 OFF Ride control mode turn off Ride control switch MIDDLE position, see page 7-36
(Option)
Reversible fan active -
Buzzer stop -
Mirror defrost active -
ö Both type1 and type2 are LCD modes and they can be changed each other by operator’s selection.
3-16
(2) Display map
Normal Main menu Sub menu Activate item
Press MENU Press ACCESSORY Press ACCESSORY
ACCESSORY JOB TIMER JOB TIMER

CLOCK STOP WATCH ON
USER ODOMETER OFF
ADJUSTMENT LIGHT CONT
DIAGNOSTICS RESET
Previous Press Previous Press Previous Press

menu menu menu
7807A3CD60
Main group Sub group Meaning Display on LCD

JOB HOUR
Accessory ÂMeasure the various job time.
Job timer
ÂPress : Display ON, OFF or RESET
ÂMeasures time in seconds.
Stop watch -
ÂPress : Start. Press again : Stop.
LATEST-DIS
Latest ÂDistance until recent times. Km
Odometer TOTAL-DIS
Total ÂTotal distance. Km
ÂControl of LCD display luminosity.

Light control -
ÂBrightness control : , .
Clock ÂWhen 12H or 24H is selected, the current
Time set hour appears.
Â , : input, : setting.
PM
Clock ON/OFF Â : Clock display ON or OFF.
1
ÂAlarm setting. It is possible to set 3 alarms.
Alarm 2
ÂStop alarming :
3
User
ÂRaise the idle rpm to 1200rpm automatically
Alternate idle -
to warm up the engine.
Mode 1 ÂAutomatic travelling speed is applied from 1st
(1st-4th) to 4th gear. -
Auto 1/2
Mode 2 ÂAutomatic travelling speed is applied from
(2nd-4th) 2nd to 4th gear. -
Mode 1 ÂPress button once : Shift down, press button
(Down/Up) again ; shift up. -
Quick
shift Mode 2 ÂPress button every time : Shift to lower gear
(Down) respectively. -
Auto ÂON : Transmission auto condition.
Select ÂOFF : Transmission semi-auto condition.
Aux-sw
Clutch ÂON : Clutch cut-off is activated. -
Cut-off ÂOFF : Clutch cut-off is cancelled.
Cooling fan Forward ÂForward active -
Control Reverse ÂReverse activeø
øReverse mode cleans out quickly dirt and dust on radiator and cooler by reverse rotation of cooling fan.
3-17
Main group Sub group Meaning Display on LCD display
Adjustment Unit ÂChoose between metric and inch unit display.
TOTAL-DIS TOTAL-DIS
Km Mile
Wiper ÂWhen using the intermittent function of wiper

Intermittence motor, it regulates operation time.
ÂRegulate idle rpm.
Alternate RPM ÂPress , : Adjust idle rpm increments -
(or decrement) by 25rpm.
Pulse ÂPress : Modification. -

ÂIt controls the disk interval of the transmission,
AEB -
automatically.
ÂEnglish : Display in English.
ENG/KOR -
ÂKorean : Display in Korean.
ÂType 1 : Indicate with the symbol.
Display 1/2 ÂType 2 : Indicate with a letter. ,
Diagnostics Fault ÂError code display.
-
Code ÂRefer to page 3-19.
Machine ÂHydraulic temperature and battery voltage HYD BATT-VOLT
Monitor display. C V
ÂPress : Display ON or OFF.
Fault ÂError code display.
-
Code ÂConsult a Hyundai dealer to error code.
Engine
ÂEngine coolant temperature display. COOLANT
Monitor C
ÂPress : Display ON or OFF.
Fault ÂError code display.

ÂConsult a Hyundai dealer to error code. -
Transmis- Code
sion Transmission oil temperature display. OIL TEMP
Monitor ÂPress : Display ON or OFF. F
Version ÂDisplay the controller(MCU) and cluster version. -
3-18
(3) Machine fault code
When selecting the fault code menu, it shows all of the fault codes which mean abnormal
conditions of present time.
Press ö To go out from fault explanation window,

press button.
030 Er : 030 (Press , to go out to first menu.)
050 ö No error will be indicated in case that
025 there’s no fault.
046
Fuel level sensor open
or short to power
77073CD60
Description Code Meaning Remark
010 Power input voltage low Below 18V

011 Power input voltage high Above 38V
Electrical 012 Alternator voltage low Below 5V
system 013 Alternator voltage high Above 36V
014 Buzzer circuit open or short to ground
015 Buzzer circuit short to power
Hydraulic 020 Hydraulic oil temperature sensor open or short to power
system 021 Hydraulic oil temperature sensor short to ground
030 Fuel level sensor open or short to power
Engine 031 Fuel level sensor short to ground
system 034 Cooling fan driving valve open or short to ground
035 Cooling fan driving valve short to power
050 Auto select switch supply power open or short to power
051 Auto select switch supply power short to ground
T/M system
052 Clutch cutoff supply power open or short to power
053 Clutch cutoff supply power short to ground
Steering 060 Emergency steering relay open or short to ground Option
system 061 Emergency steering relay short to power Option
070 MCU communication error
Communication 071 TCU communication error
072 ECM communication error
MCU : Machine control unit TCU : Transmission control unit ECM : Engine control module
3-19
(4) Display during AEB mode
Symbol Meaning Remarks
K1~K4, KV, KR Calibrating clutch K1~K4, KV

or KR respectively
- And Kx Wait for start, initialization of
clutch Kx, x : 1, 2, 3, 4, V, R
And Kx Fast fill time determination of
clutch Kx
= And Kx Compensating pressure
determination of clutch Kx
OK Calibration for all clutches Transmission stays in neutral, you have to restart the
finished TCU(Ignition off/on) after removing AEB-Starter
STOP AEB cancled(Activation Transmission stays in neutral, you have to restart the
stopped) TCU(Ignition off/on)
STOP and Kx AEB stopped, clutch Kx can't Transmission stays in neutral, you have to restart the
be calibrated TCU(Ignition off/on)
Spanner and Kx Kx couldn't be calibrated, AEB Transmission stays in neutral, you have to restart the
finished TCU(Ignition off/on)
ĀE Engine speed too low,
- Raise engine speed
ĂE Engine speed too high,
- Lower engine speed
ĀT Transmission oil temperature
too low,
- Heat up transmission
ĂT 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)
ö AEB mode : It controls the disk internal of the transmission, automatically.
3-20
(5) Engine fault code(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 104ÁC(220Á 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 87.8ÁC(190Á 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.
3-21
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 123.9ÁC(225ÁF). 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.
3-22
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).
3-23
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.
3-24
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.
3-25
(6) DEFINITION OF OPERATING MODES
Η Normal
There's no failure detected in the transmission system or the failure has no or slight effects on
transmission control. TCU will work without or in special cases with little limitations.(See
following table)
Θ 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)
Ι 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.
Κ 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.
Λ 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.
ö Abbreviations
OC : Open circuit
SC : Short circuit
OP mode : Operating mode
TCU : Transmission control unit
EEC : Electronic engine controller
PTO : Power take off
3-26
(7) Transmission fault codes
Fault code Meaning of the fault code
(Hex) possible reason for fault detection Reaction of the TCU Possible steps to repair Remarks
11 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 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 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 Logical error at direction select signal 2 TCU shifts transmission to Check the cables from TCU to Fault is taken back if TCU
shift 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 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
3-27
21 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 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
3-28
25 S.C. to battery voltage or O.C. at No reaction, TCU use default Check the cable from TCU to
transmission 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 S.C. to battery voltage or O.C. at No reaction, TCU uses default Check the cable from TCU to
transmission sump temperature sensor input temperature the sensor
The measured voltage is too low: OP mode : Normal Check the connectors
vehicle ground
ground
27 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 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
3-29
27 S.C. to battery voltage or O.C. at No reaction, TCU uses default Check the cable from TCU to
converter output temperature sensor input temperature the sensor
battery voltage
28 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 S.C. to battery voltage or O.C. at engine OP mode : Substitute clutch control Check the cable from TCU to
speed input the sensor
TCU measures a voltage higher than 7.00V Check the connectors
at speed input pin Check the speed sensor
battery voltage
Speed sensor has an internal defect
voltage or has no contact
32 S.C. to ground at engine speed input OP mode : Substitute clutch 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
3-30
33 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 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 S.C. to ground at turbine speed input OP mode : Substitute clutch control Check the cable from TCU to This fault is reset after power
TCU measures a voltage less than 0.45V at If a failure is existing at output the sensor up of TCU
speed input pin speed, Check the connectors
Cable/connector is defective and is TCU shifts to neutral Check the speed sensor
contacted to vehicle ground OP mode : Limp home
36 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
3-31
37 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 S.C. to ground at turbine speed input OP mode : Substitute clutch control Check the cable from TCU to
TCU measures a voltage less than 0.45V at the sensor
speed input pin Check the connectors
Cable/connector is defective and is Check the speed sensor
39 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 S.C. to battery voltage or O.C. at output Special mode for gear selection Check the cable from TCU to
speed input OP mode : Substitute clutch control the sensor
TCU measures a voltage higher than 12.5V If a failure is existing at turbine Check the connectors
at speed input pin speed, Check the speed sensor
Cable is defective and is contacted to TCU shifts to neutral
battery voltage OP mode : lamp home
3-32
3B 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 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 Turbine speed zero doesn't fit to other - - Not used

speed signals
3E Output speed zero doesn't fit to other Special mode for gear 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.
3-33
71 S.C. to battery voltage at clutch K1 TCU shifts to neutral Check the cable from TCU to
The measured resistance value of the valve is OP mode : Limp home the gearbox
out of limit, the voltage at K1 valve is too high If failure at another clutch is Check the connectors from
Cable/connector is defective and has pending TCU to the gearbox
contact to battery voltage TCU shifts to neutral Check the regulator resistance* * See Chapter (8)
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 S.C. to ground at clutch K1 TCU shifts to neutral Check the cable from TCU to
out of limit, the voltage at K1 valve is too low If failure at another clutch is Check the connectors from
Cable/connector is defective and has pending gearbox to TCU
contact to vehicle ground TCU shifts to neutral Check the regulator resistance* * See Chapter (8)
Regulator has an internal defect OP mode : TCU shutdown Check internal wire harness of
the gearbox
73 O.C. at clutch K1 TCU shifts to neutral Check the cable from TCU to
The measured resistance value of the valve OP mode : Limp home the gearbox
is out of limit If failure at another clutch is Check the connectors from
Cable/connector is defective and has no pending gearbox to TCU
contact to TCU TCU shifts to neutral Check the regulator resistance* * See Chapter (8)
the gearbox
is out of limit, the voltage at K2 valve is too If failure at another clutch is Check the connectors from
high pending gearbox to TCU
Cable/connector is defective and has TCU shifts to neutral Check the regulator resistance* * See Chapter (8)
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
3-34
the gearbox
the gearbox
TCU
the gearbox
3-35
the gearbox
7A S.C. to battery voltage at converter clutch - -
7B S.C. to ground at converter clutch - -
7C O.C. at converter clutch - - Not used
7D S.C. ground at engine derating device Engine derating will be on until Check the cable from TCU to Not used
Cable is defective and is contacted to TCU power down even if fault the engine derating device
vehicle ground vanishes(Loose connection) Check the connectors from Not used
Engine derating device has an internal defect OP mode : Normal engine derating device to TCU
Connector pin is contacted to vehicle ground Check the resistance* of engine * See Chapter (8)
derating device
7E S.C. battery voltage at engine derating No reaction Check the cable from TCU to
device OP mode : Normal the engine derating device
Cable/connector is defective and is Check the connectors from
contacted to battery voltage backup alarm device to TCU
Engine derating device has an internal Check the resistance* of * See Chapter (8)
defect backup alarm device
7F O.C. at engine derating device No reaction Check the cable from TCU to
TCU detected a wrong voltage at the output OP mode : Normal the engine derating device
pin, that looks like a O.C. for this output pin Check the connectors from
Cable is defective and has no connection engine derating device to TCU
to TCU Check the resistance* of * See Chapter (8)
Engine derating device has an internal engine derating device
defect
Connector has no connection to TCU
3-36
TCU
The measured resistance value of the valve is OP mode : Limp home the engine derating device
the gearbox
the gearbox
TCU
3-37
85 S.C. to ground at clutch KV TCU shifts to neutral Check the cable from TCU to
the gearbox
86 O.C. at clutch KV TCU shifts to neutral Check the cable from TCU to
the gearbox
87 S.C. to battery voltage at clutch KR TCU shifts to neutral Check the cable from TCU to
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* * See Chapter (8)
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 S.C. to ground at clutch KR TCU shifts to neutral Check the cable from TCU to
out of limit, the voltage at KR valve is too low If failure at another clutch is Check the connectors from
the gearbox
89 O.C. at clutch KR TCU shifts to neutral Check the cable from TCU to
the gearbox
3-38
91 S.C. to ground at relay reverse warning Backup alarm will be on until Check the cable from TCU to
alarm TCU power down even if fault the backup alarm device
TCU detected a wrong voltage at the output vanishes(Loose connection) Check the connectors from
pin, that looks like a S.C. to vehicle ground OP mode : Normal backup alarm device to TCU
Cable is defective and is contact to vehicle Check the resistance* of * See Chapter (8)
ground backup alarm device
Backup alarm device has an internal defect
92 S.C. to battery voltage at relay reverse No reaction Check the cable from TCU to
warning alarm OP mode : Normal the backup alarm device
TCU detected a wrong voltage at the output Check the connectors from
pin, that looks like a S.C. to battery voltage backup alarm device to TCU
Cable is defective and is contacted to Check the resistance* of * See Chapter (8)
battery voltage backup alarm device
Backup alarm device has an internal
defect
voltage
93 O.C. at relay reverse warning alarm No reaction Check the cable from TCU to
TCU detected a wrong voltage at the output OP mode : Normal the backup alarm device
Cable is defective and has no connection backup alarm device to TCU
Backup alarm device has an internal defect backup alarm device
94 S.C. to ground at relay starter interlock No reaction Check the cable from TCU to
TCU detected a wrong voltage at the output OP mode : Normal the stater interlock relay
pin, that looks like a S.C. to vehicle ground Check the connectors from
Cable is defective and is connection to starter interlock relay to TCU
vehicle ground Check the resistance* of * See Chapter (8)
Starter interlock relay has an internal defect starter interlock relay
ground
3-39
95 S.C. to battery voltage at relay starter No reaction Check the cable from TCU to
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 * See Chapter (8)
to battery voltage starter interlock relay
Starter interlock relay has an internal defect
96 O.C. at relay starter interlock No reaction Check the cable from TCU to
TCU detected a wrong voltage at the output OP mode : Normal the starter interlock relay
Cable is defective and has no connection starter interlock relay to TCU
Starter interlock relay has an internal defect starter interlock relay
97 S.C. to ground at park brake solenoid No reaction Check the cable from TCU to
TCU detected a wrong voltage at the output OP mode : Normal the park brake solenoid
Cable is defective and is connection to park brake solenoid to TCU
vehicle ground Check the resistance* of park * See Chapter (8)
Park brake solenoid has an internal defect brake solenoid
ground
98 S.C. to battery voltage at park brake No reaction Check the cable from TCU to
solenoid Optional : (Some customers) the park brake solenoid
TCU detected a wrong voltage at the output TCU shifts to neutral caused by Check the connectors from
pin, that looks like a S.C. to battery voltage park brake feed back park brake solenoid to TCU
Cable is defective and is connection to OP mode : Normal Check the resistance* of park * See Chapter (8)
battery voltage brake solenoid
Park brake solenoid has an internal defect
voltage
3-40
99 O.C. at park brake solenoid No reaction Check the cable from TCU to
TCU detected a wrong voltage at the output Optional : Some customers the park brake solenoid
pin, that looks like a O.C. for this output pin TCU shifts to neutral caused by Check the connectors from
Cable is defective and has no connection park brake feed back park brake solenoid to TCU
to TCU OP mode : Normal Check the resistance* of park * See Chapter (8)
Park brake solenoid has an internal defect brake solenoid
9A S.C. to ground at converter lock up clutch No reaction Check the cable from TCU to
solenoid OP mode : Normal the converter clutch solenoid
pin, that looks like a S.C. to vehicle ground converter clutch solenoid to
Cable is defective and is contacted to TCU
vehicle ground Check the resistance* of park * See Chapter (8)
Converter clutch solenoid has an internal brake solenoid
defect
9B O.C. at converter lock up clutch solenoid Converter clutch always open, Check the cable from TCU to
TCU detected a wrong voltage at the output retarder not available the converter clutch solenoid
pin, that looks like a O.C. for this output pin OP mode : Normal Check the connectors from
Cable is defective and has no connection converter clutch solenoid to
to TCU TCU
Converter clutch solenoid has an internal Check the resistance* of park * See Chapter (8)
defect brake solenoid
9C S.C. to battery voltage at converter lock No reaction Check the cable from TCU to
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 * See Chapter (8)
Converter clutch solenoid has an internal converter clutch solenoid
defect
3-41
9D S.C. to ground at retarder solenoid No reaction Check the cable from TCU to
TCU detected a wrong voltage at the output OP mode : Normal the retarder solenoid
Cable is defective and is contacted to retarder solenoid to TCU
Retarder solenoid has an internal defect retarder solenoid
ground
9E O.C. at retarder solenoid No reaction Check the cable from TCU to

Cable is defective and has no connection retarder solenoid to TCU
9F S.C. to battery voltage at retarder solenoid No reaction Check the cable from TCU to
pin, that looks like a S.C. to battery voltage Check the connectors from
Cable is defective and has no connection retarder solenoid to TCU
to battery voltage Check the resistance* of * See Chapter (8)
3-42
A1 S.C. to ground at difflock or axle No reaction Check the cable from TCU to
connection solenoid OP mode : Normal the difflock solenoid
pin, that looks like a S.C. to vehicle ground difflock solenoid to TCU
Cable is defective and is contacted to Check the resistance* of * See Chapter (8)
vehicle ground difflock solenoid
Difflock solenoid has an internal defect
A2 S.C. to battery voltage at difflock or axle No reaction Check the cable from TCU to
connection solenoid OP mode : Normal the difflock solenoid
pin, that looks like a S.C. to battery voltage difflock solenoid to TCU
Cable is defective and has no connection Check the resistance* of * See Chapter (8)
to battery voltage difflock solenoid
Difflock solenoid has an internal defect
A3 O.C. at difflock or axle connection solenoid No reaction Check the cable from TCU to
TCU detected a wrong voltage at the output OP mode : Normal the difflock solenoid
Cable is defective and has no connection difflock solenoid to TCU
Difflock solenoid has an internal defect difflock solenoid
A4 S.C. to ground at warning signal output No reaction Check the cable from TCU to
TCU detected a wrong voltage at the output OP mode : Normal the warning device
Cable is defective and is contacted to warning device to TCU
Warning device has an internal defect warning device
3-43
A5 O.C. voltage at warning signal output No reaction Check the cable from TCU to
TCU detected a wrong voltage at the output OP mode : Normal the warning device
Cable is defective and has no connection warning device to TCU
Warning device has an internal defect warning device
A6 S.C. to battery voltage at warning signal No reaction Check the cable from TCU to
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 * See Chapter (8)
battery voltage warning device
Warning device has an internal defect
voltage
3-44
B1 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
3-45

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 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 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
3-46
B7 Overtemp sump No reaction Cool down machine

TCU measured a temperature in the oil OP mode : Normal Check oil level
sump that is over the allowed threshold. Check temperature sensor
B8 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 Overspend engine Retarder applies -

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

TCU measured a voltage at differential OP mode : Normal Check wiring from TCU to
pressure switch out of the allowed range differential pressure switch
Oil filter is polluted 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 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
3-47
BD S.C. to ground at engine brake solenoid No reaction Check the cable from TCU to
TCU detected a wrong voltage at the output OP mode : Normal engine brake solenoid
Cable is defective and is contacted to engine brake solenoid to TCU
vehicle ground Check the resistance* of engine * See Chapter (8)
Engine brake solenoid has an internal brake solenoid
defect
BE S.C. to battery voltage at engine brake No reaction Check the cable from TCU to
TCU detected a wrong voltage at the output OP mode : Normal the engine brake solenoid
pin, that looks like a S.C. to battery voltage Check the connectors from
Cable is defective and is contacted to engine brake solenoid to TCU
battery voltage Check the resistance* of engine * See Chapter (8)
Engine brake solenoid has an internal defect brake solenoid
BF O.C. at engine brake No reaction Check the cable from TCU to

TCU detected a wrong voltage at the output OP mode : Normal the engine brake solenoid
Cable is defective and has no connection engine brake solenoid to TCU
to TCU Check the resistance* of engine * See Chapter (8)
Engine brake solenoid has an internal brake solenoid
defect
3-48
C3 Overtemp converter output No reaction Cool down machine

TCU measured a oil temperature at the OP mode : Normal Check oil level
converter output that is the allowed threshold Check temperature sensor
C4 S.C. to ground at joystick status indicator No reaction Check the cable from TCU to
TCU detected a wrong voltage at the output OP mode : Normal joystick status indicator
Cable is defective and is contacted to joystick status indicator to TCU
vehicle ground Check the resistance* of *See chapter (8)
Joystick status indicator has an internal joystick status indicator
defect
C5 S.C. to battery voltage at joystick status No reaction Check the cable from TCU to
indicator OP mode : Normal joystick status indicator
pin, that looks like a S.C. to battery voltage joystick status indicator to TCU
Cable is defective and is contacted to Check the resistance* of *See chapter (8)
battery voltage joystick status indicator
Joystick status indicator has an internal
defect
C6 O.C. at joystick status indicator No reaction Check the cable from TCU to
TCU detected a wrong voltage at the output OP mode : Normal joystick status indicator
Cable is defective and has no connection joystick status indicator to TCU
to TCU Check the resistance* of *See chapter (8)
Joystick status indicator has an internal joystick status indicator
defect
Connector pin has no connection to TCU
3-49
D1 S.C. to battery voltage at power supply for See fault codes No.21 to 2C Check cables and connectors Fault codes No.21 to No.2C
sensors to sensors, which are supplied may be reaction of this fault
TCU measures more than 6V at the pin AU1 from AU1
(5V sensor supply) Check the power supply at the
pin AU1(Should be appx. 5V)
D2 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 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 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 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
3-50
D6 Error at valve power supply VPS2 Shift to neutral Check fuse

TCU switched on VPS2 and measured OP mode : TCU shutdown Check cables from gearbox to
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
3-51
E1 S.C. battery voltage at speedometer - - Not used

output
E2 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 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 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
3-52
F1 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 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 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 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 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
3-53
(8) Measuring of resistance at actuator/sensor and cable
Η Actuator
2 G
76043PT19
Open circuit R12 = R1G = R2G = â

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)
Θ Cable
UBat
P(Power supply)
TCU
1 2 Actuator/
Sensor
C(Chassis)
Ground
76043PT20
Open circuit R12 = R1P = R1C = R2P = R2C= â

Short cut to ground R12 = 0; R1C = R2C = 0, R1P = R2P = â
Short cut to battery R12 = 0; R1C = R2C = 0, R1P = R2P = 0
3-54
7) ELECTRIC CONTROL UNIT
(1) Complete system
8
5 10
9
4
3 11
A
2
6 12
13
14
16
8 15
1
7
17
7807APT03
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
17 Brake pressure sensor / Load sensor
(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.
3-55
ÂGear determination depending on controller position, driving speed and load condition.
ÂProtection from operating error as far as necessary, is possible via electronic protection.
ÂProtection from overspends(On the basis of engine and turbine speed).
ÂAutomatic reversing(Driving speed-dependent).
ÂPressure cut off possible.
ÂChange-over possibility for Auto/manual mode.
ÂDownshifting functions possible.
(3) Gearshifts
The control unit(EST-37) is shifts the required speeds fully-automatically under consideration of
the following criteria.
ÂGear selector position
ÂDriving speed
ÂLoad level
At the same time, the following speeds are picked up by the control unit(EST-37).
Ân Engine
Ân Turbine
Ân Central gear train
Ân 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
1F1R and 2F2R(As a rule, this is the maximum driving speed of the 2nd speed).
3-56
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).
3-57
5. AXLE
1) OPERATION
Â The power from the engine passes through torque converter, transmission and drive shafts, and is
then sent to the front and rear axles.
Â Inside the axles, the power passes from the bevel pinion to the bevel gear and is sent at right
angles. At the same time, the speed is reduced and passes through the both differentials to the
axle shafts. The power of the axle shafts is further reduced by planetary-gear-type final drives and
is sent to the wheels.
(1) Front axle
3
2
7803APT20
1 Final drive 2 Differential 3 Axle
(2) Rear axle
7803APT20
1 Final drive 2 Differential 3 Axle
3-58
2) LIMITED SLIP DEFFERENTIAL(FRONT AND REAR)
(1) Structure
7803APT21
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
3-59
(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.
Η 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.
Θ 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.
3-60
3) DIFFERENTIAL
(1) Description
3
When the machine makes a turn, the
2 4
outside wheel must rotate faster than the
inside wheel. A differential is a device
which continuously transmits power to the
right and left wheels while allowing them
to turn a different speeds, during a turn.
The power from the drive shaft passes
through bevel pinion(1) and is transmitted
to the bevel gear(2). The bevel gear
changes the direction of the motive force
by 90 degree, and at the same time
reduces the speed. 1
It then transmits the motive force through
the differential(3) to the axle gear shaft(4). 3-26(1)
(2) When driving straight forward

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

When turning, the rotating speed of the Pinion gear
left and right wheels is different, so the Side gear Side gear
pinion gear and side gear inside the
differential assembly rotate in accordance
with the difference between the rotating
speed of the left and right wheels.
The power of the carrier is then
Carrier
transmitted to the axle gear shafts.
Pinion gear Ring gear
3-26(3)
3-61
4) TORQUE PROPORTIONING DIFFERENTIAL
(1) Function
Η Because of the nature of their work, 4-
wheel-drive loaders have to work in
places where the road surface is bad.
In such places, if the tires slip, the ability
to work as a loader is reduced, and also
the life of the tire is reduced.
The torque proportioning differential is
installed to overcome this problem.
In structure it resembles the differential of
an automobile, but the differential pinion
gear has an odd number of teeth.
Because of the difference in the
resistance from the road surface, the
position of meshing of the pinion gear
and side gear changes, and this changes
the traction of the left and right tires.
(2) Operation Spider rotating

Η When traveling straight(Equal resistance direction
from road surface to left and right tires)
Under this condition, the distances
involving the engaging points between
right and left side gears and pinion-a and FL FR
b-are equal and the pinion is balanced as Engaging a b
Engaging
FLÝa=FRÝb. Thus, FL=FR, and the point point
right and left side gears are driven with
the same force.
Left side gear Right side gear
Pinion
3-27
3-62
Θ 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
Ýa=FRÝb, where FL>FR. The right Engaging Engaging
side gear is driven with a greater force point point
than the left side gear. The torque can
Left side gear Right side gear
be increased by up to about 30% for Pinion
either side gear.
The pinion therefore does not run idle
and driving power is transmitted to both
side gears until the difference between
road resistance to the right and left
3-27
wheels reaches about 30%.
3-63
5) FINAL DRIVE(Front & rear)
7803APT22
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.
3-64
6. TIRE AND WHEEL
1
3-30
1 Wheel rim 3 O-ring 5 Side ring

2 Tire 4 Lock ring 6 Valve assembly
1) The tire acts to absorb the shock from the ground surface to the machine, and at the same time
they must rotate in contact with the ground to gain the power which drives the machine.
2) Various types of tires are available to suit the purpose. Therefore it is very important to select the
correct tires for the type of work and bucket capacity.
3-65
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
3-66
※ Transmission oil must be at operating temperature for these checks.
Item Description Service action
Transmission oil warm- Start engine. Apply service OK

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

neutral "N" position and run for 15
seconds.
1
4
2
3
F
N
R
Repeat procedure until
transmission temperature gauge
arrow points to bar above dial.
Gear selector lever and Move gear selector lever to each OK

neutral lock latch 1
4
2
3
position. Check completed.
checks
NOTE : Gear selector lever
Engine OFF. NOT OK
position changes slightly as
Repair lock or replace
steering column is tilted.
switch.
FEEL : Lever must move freely
through all positions.
Engage neutral lock.
Apply slight effort to move lever
into forward(F) and reverse(R).
LOOK : Neutral lock must stay
engaged.
Automatic shifting Start engine. OK

check Check completed.
Move gear selector lever to 4th
speed.
1
4
2
3
F
N
R
NOT OK
Go to transmission error
Turn full automatic switch ON.
code group at page 3-27~
LOOK : Automatic sign on
Automatic sign 3-53.
display.
Repair or replace the
Move gear selector lever to display or harness.
forward or reverse position.
Increase engine rpm.
LOOK : Speed(2nd~4th) on
display must vary with machine
speed.
3-67
Transmission noise Run engine at approximately OK

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

shift" check full automatic switch to manual Check completed.
Engine running. mode①.
NOT OK
Shift to 2nd forward. Check connector at base
of control valve.
Drive machine at approximately
5km/h and press gear selector IF OK
lever kick down switch or RCV Go to transmission
lever switch once. controller circuit in group
1.
LOOK/FEEL : Transmission must
shift to and remain in 1st gear.
Press gear selector lever kick
down switch once.
1
2
3
4

shift back to 2nd gear.
Shift to (3rd or 4th) gear and press
gear selector lever kick down
switch once.
not shift down.
Select full automatic switch to
automatic mode②.
Drive machine at approximately
90% speed of max speed in each
gear(2nd or 3rd or 4th).
Shift to(2nd or 3rd or 4th) gear in
each forward and reverse speed
and press gear selector kick down
lever switch or RCV lever switch
once.
shift to lower(1st or 2nd or 3rd)
gear respectively.
Press gear selector lever kick
down switch or RCV lever switch
once again.
3-68
LOOK/FEEL : Transmission
must shift to former(2nd or 3rd or
4th) gear.
NOTE : If gear selector lever kick
down switch or RCV lever switch
is pressed twice, transmission will
shift down the immediately back
to former gear.
Forward, reverse and Park unit on level surface. OK
4th speed clutch pack 1
2
3
Check completed.
Apply service brakes.
4
drag check
NOT OK
※ Transmission must Move gear selector lever to
If unit moves, repair
be warmed up for neutral.
transmission.
this check.
Move gear selector lever to 1st.
Engine running.
Release parking brake and
service brakes.
Run engine at low idle.
LOOK : Unit must not move in
either direction.
NOTE : If unit moves forward,
either the forward pack or the 4th
speed pack is dragging.
Transmission shift Run engine at approximately OK

modulation check 1
2
1300rpm. Check completed.
3
Engine running.
4
Put transmission in 1st forward, NOT OK

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

1
4
2
3
brakes and release parking brake. Check completed.
Move gear selector lever to 3rd NOT OK
speed. If stall rpm are too low or
too high, problem may be
Move gear selector control lever
engine power or torque
to forward "F" position.
converter.
Increase engine speed to high
IF OK
idle.
Replace transmission
LOOK : Torque converter stall torque converter.
rpm must be within the following
range.
Stall rpm : 2020±70rpm
Move gear selector control lever
to neutral "N" position and run for
15 seconds.
3-69
2. TROUBLESHOOTING
1) TRANSMISSION
Diagnose malfunction charts are arranged from most probable and simplest to verify, to least
likely, more difficult to verify. Remember the following steps when troubleshooting a problem :
Step 1. Operational check out procedure(See group 3 in section 1.)
Step 2. Operational checks(In this group.)
Step 3. Troubleshooting
Step 4. Tests and/or adjustments(See group 3.)
Problem Cause Remedy
Transmission slippage Low oil level. Add oil.

Wrong oil grade. Change oil.
Restricted transmission pump Remove and clean screen.
suction screen.
Leak in transmission control valve Remove valve and inspect gaskets.
or gasket.
Low transmission pump flow due Do transmission pump flow test.
to worn pump.
Weak or broken pressure regulat- Do transmission system pressure test.
ing valve spring.
Error code on display Something wrong in transmission. Go to transmission error code group at page
3-27~3-53.
3-70
Machine will not move Low oil level. Add oil.

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

engage in low gear control solenoid valve.
Stuck spool in transmission Remove and inspect transmission control valve
control valve. spools.
Stuck PPC valve. Remove end cover to inspect PPC valve.
Replace if necessary.
Malfunctioning transmission Check speed sensor.
speed sensor.
3-71
Transmission pressure is Low oil level. Check transmission oil level and refill if
low(All gears) necessary.
Failed transmission pressure Verify transmission system pressure. Do
switch. transmission system pressure test.
Plugged suction strainer. Transmission pump may be noisy if transmission
suction screen is clogged. Drain transmission.
Remove and clean suction screen.
Also, check condition of transmission filter.
Stuck transmission pressure Remove transmission pressure regulating valve.
regulating valve or broken spring. Inspect for damage(See transmission control
valve).
Failed control valve gasket. Inspect transmission control valve for external
leakage. Remove control valve.
Inspect or replace gasket.
Stuck PPC valve. Remove end cover to inspect modulation spool
and check torque on cap screws retaining
control valve to transmission.
Transmission system Failed transmission pump. Do pump flow test.

pressure is low (One or
Failed transmission control valve Inspect transmission control valve for external
two gears)
gasket. leakage. Remove control valve.
Inspect or replace gasket.
Leakage in clutch piston or seal Disassemble and repair.
ring.
Transmission shifts too Low oil level(Aeration of oil). Add oil.

low
Low transmission pressure. Do transmission system pressure test.
Restricted transmission pump Remove and clean screen.
suction screen.
Low transmission pump flow. Do transmission pump flow test.
Excessive transmission Do transmission element leakage test using
element leakage. system pressure.
Stuck PPC valve. Remove end cover to inspect modulation spool.
Restricted PPC valve orifice. Remove orifice and inspect for contamination
and /or plugging.
Restricted oil passages between Remove control valve and inspect oil passage.
control valve and transmission
elements.
Incorrect transmission oil. Change oil(SAE 10W-30/15W-40)
3-72
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-30/15W-40)
Machine "creeps" Warped disks and plates in Check transmission.

in neutral transmission.
Transmission hydraulic High oil level. Transmission overfilled or hydraulic pump seal
system overheats leaking.
Low oil level. Add oil.
Wrong oil grade. Change oil.
Park brake dragging. Check for heat in park brake area.
Pinched, restricted or leaking lube Check cooler lines.
lines.
Machine operated in too high gear Operate machine in correct gear range.
range.
Malfunction in temperature gauge Install temperature sensor the verify temperature.
or sensor. Do tachometer/temperature reader installation
procedure.
Restricted air flow through oil Do radiator air flow test.
cooler or radiator.
Failed oil cooler bypass valve(In Disassemble and inspect.
thermal bypass valve).
Failed thermal bypass valve. Remove thermal bypass valve and check to see
if machine still overheats. Do transmission oil
cooler thermal bypass valve test.
Internally restricted oil cooler. Do oil cooler restriction test.
Leakage in transmission hydraulic Do transmission system pressure, element
system. leakage test.
Malfunction in converter relief Do converter out pressure test.
valve.
Low transmission pump output. Do transmission pump flow test.
3-73
Excessive transmission Too low engine low idle. Check engine low idle speed.
noise(Under load or no
Worn parts or damaged in Remove transmission suction screen. Inspect
load)
transmission. for metal particles.
Repair as necessary.
Warped drive line between engine Inspect drive line.
and torque converter.
Low or no lube. Do converter-out and lube pressure test. Do
transmission pump flow test.
Foaming oil Incorrect type of oil. Change oil.

High oil level. Transmission overfilled or hydraulic pump seal
leaking.
Low oil level. Add oil.
Air leak on suction side of pump. Check oil pickup tube on side of transmission.
Oil ejected from dipstick Plugged breather. Inspect breather on top of transmission.
Replace.
Machine vibrates Aerated oil. Add oil.

Low engine speed. Check engine speed.
Failed universal joints on Check universal joints.
transmission drive shaft or
differential drive shafts.
Machine lacks power Engine high idle speed set too Check high idle adjustment.
and acceleration low.
Incorrect transmission oil. Change oil.
Aerated oil. Add oil.
Low transmission pressure. Do transmission system pressure test.
Warped transmission clutch. Do transmission clutch drag checks.
Torn transmission control valve Inspect gasket.
gasket.
Brake drag. Do brake drag check.
Failed torque converter. Do torque converter stall speed test.
Low engine power. Do engine power test.
Torque converter stall Aerated oil. Put clear hose on thermal bypass outlet port.
RPM too high Run machine to check for bubbles in oil.
Stuck open converter relief valve. Do converter-out pressure test.
Leakage in torque converter seal. Do converter-out pressure test.
Torque converter not Replace torque converter.
transferring power(Bent fins,
broken starter).
3-74
Torque converter stall Low engine power. Do engine power test.

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

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

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

circuit.
Failed transmission pump. Do transmission pump flow test.
Clogged filter. Inspect filter. Replace.
3-75
2) DIFFERENTIAL / AXLE
Differential low on oil External leakage. Inspect axle and differential for leaks.
Excessive differential Low oil level in differential. Check oil. Remove drain plug and inspect for
and/or axle noise metal particles in differential case.
Disassemble and determine cause.
Incorrect type of oil. Change oil
Dragging brakes. Do brake check.
Failed pinion bearing. Remove and inspect pinion.
Check to ensure pinion housing was indexed.
Incorrect gear mesh pattern Remove pinion gear housing and inspect ring
between ring and pinion gear. and pinion gear.
Failed differential pinion gears Remove differential housing drain plug and
and/or cross shafts. inspect for metal particles. Disassemble and
inspect.
Failed axle bearing. Do axle bearing adjustment check.
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 shafts. Inspect. Align drive shaft yokes.
vibration or noise
Worn front drive line support Inspect, repair.
bearing.
Bent drive shaft. Inspect all drive shafts. Replace.
Loose yoke retaining nuts(Drive Inspect. Replace.
shafts wobble at high speed).
Rear axle oscillating support. Inspect, repair.
Lack of lubrication. Lubricate with proper grade of grease.
3-76
GROUP 3 TESTS AND ADJUSTMENTS
1. CLUTCH CUT-OFF PRESSURE SWITCH TEST

The setting pressure of the clutch cut-off
pressure switch should be suited with the
specification. The rated pressure is 25kgf/cm2.
For the detailed method for pressure
adjusting, refer to page 4-19.
BL1
Clutch cut off

pressure switch
Brake valve
7707PT12
3-77
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
7803APT19
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
3-78
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
3-79
GROUP 4 DISASSEMBLY AND ASSEMBLY
1. ELECTRO-HYDRAULIC CONTROL UNIT

1) DISASSEMBLY
(1) Loosen socket head screws and remove
selector housing.
ö 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.
ö Special tool
Figure 2
(3) Mark installation position of the cable

harness to the valve block.
Figure 3
3-80
(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
3-81
(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.
ö Special tool
Adjusting screws 5870 204 036
Figure 9
(10) Separate housing from valve body by

uniform loosening of the adjusting screws.
ö Special tool
Figure 10
(11) Remove components.
Figure 11
3-82
(12) Remove opposite pressure regulators,
housing as well as components accordingly.
Figure 12
2) ASSEMBLY
ö 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.
ö 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.

ö 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
3-83
(4) Install two adjusting screws.
ö Line up flat gasket(Arrow) and housing
cover(see Figure16).
Now, bring housing cover by means of
adjusting screws uniformly against
shoulder (Figure 17).
ö 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.
Â Torque limit : 0.56kgfÂm (4.06lbfÂft)
Figure 19
3-84
(7) Introduce pressure regulators and fix them
by means of retaining plates and socket
head screws.
ö 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
ö Now, fasten housing cover by means of

socket head screws.
Remove cylindrical pins (assembly aid)
again.
ö Special tool
3-85
(10) Introduce pressure regulators and fix them
by means of retaining plates and socket
head screws.
ö Install retaining plates, with the claw
showing downward. Pay attention to the
radial installation position of the pressure
regulators, see Figure.
ÂTorque limit : 0.56kgfÂm(4.06lbfÂft)
Figure 23
(11) Introduce cable harness and connect

pressure regulators(6EA).
ö 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.
ÂTorque limit : 0.56kgfÂm (4.06lbfÂft)
Figure 25
(13) Locate the femal connector by means of

retaining clip.
Install opposite cover.
Figure 26
3-86
(14) Install two adjusting screws and mount
gasket I.
ö Pay attention to the different gaskets, see

Figure 27 and 30.
ö 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.
ö 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
3-87
(18) Mount duct plate(Arrow) and fasten it
uniformly by means of socket head
screws.
ö 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.
ÂTorque limit Screw plugs (M10x1): 6
0.61kgfÂm (4.43lbfÂft) 7
ö Install always new O-rings.
1 2 3 4 5
Figure 34
3-88
(22) Install two adjusting screws(M8) and
mount housing gasket.
ö At the following steps(Figure 35~39), pay
attention to the installation positions of the
different gaskets.
ö 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.
ÂTorque limit(M8/10.9) :
2.35kgfÂm (17.0lbfÂft)
ö Special tool
Figure 38
3-89
(26) Install 2 adjusting screws(M6).
Mount gasket(Arrow).
ö Special tool
Figure 39
(27) Fasten complete valve block uniformly

with socket head screws(2 pieces M6Ý
105 and 21 pieces M6Ý80mm).
ö Pay attention to the position of the two
socket head screws (M6Ý105), see
Arrows.
ö Special tool
Box spanner TX-27 5873 042 002 Figure 40
3-90
2. RETARDER
1) DISASSEMBLY
(1) Fasten the complete transmission on the
assembly car.
ö Special tool
Assembly car 5870 350 000
Clamping bracket 5870 350 071
(2) Tilt gearbox housing 90Á

.
Remove lock plate.
Loosen hexagon head screws and pull off
input flange.
ö 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
3-91
(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.

ö 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.
ö Special tool
Set of eye bolts 5870 204 002
Figure 57
(7) Loosen socket head screws, separate

spacer ring from stator housing.
Figure 58
3-92
(8) Loosen socket head screws and separate
cover from stator housing.
Figure 59
(9) Drive flange shaft out.

ö Pay attention to the released components.
ö 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
3-93
(12) Loosen hexagon head screws and
remove thrust ring.
Figure 63
(13) Remove stator ring.

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

ö Special tool
Pry bar 5870 345 036
Figure 65
(15) Drive ball bearing out.
Figure 66
3-94
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.
Â Torque limit (M8/8.8): 2.35kgfÂm
(17.0lbfÂft
ö 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(3pieces) according

to Figure 75 and Figure 76.
ö 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
3-95
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.
ö Install rectangular ring with the marking
"Top" see Arrow, showing upward (to the
prime mover).
Figure 77
Figure 78
3-96
(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.

ö 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.

ö Install rectangular ring with the marking
"Top" see Arrow, showing upward (to the
prime mover).
Figure 82
3-97
(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.
ö Pay attention to the radial installation
position.
ö Special tool
Adjusting screws M8 5870 204 011 Figure 83
(12) Fasten cover finally by means of socket

head screws (install flat washers).
ö Secure socket head screws with Loctite
(Type No. 243).
Â Torque limit(M8/10.9): 2.35kgfÂm
(17.0lbfÂft)
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.
ÂDimension I e.g. 13.10mm
ö Special tool
Digital depth gauge 5870 200 072
Figure 86
3-98
(15) Determine Dimension II from the
mounting face(flange shaft) to the plane
face/stator (contact face - axial bearing).
ÂDimension 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.
ö The ball bearing must be resting on the
whole plane face(bearing inner and outer
race).
ö Special tool Figure 90
Plug gauge 5870 200 106
3-99
(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
ö 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.

ö Special tool
Hot-air blower 230V 5870 221 500
Figure 94
3-100
(23) Introduce flange shaft until contact is
obtained.
Figure 95
(24) Install shaft seal(Arrow), using driver.

ö 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.
ö Special tool
driver 5870 048 193
Figure 96
(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.
Â Torque limit(M10/8.8): 3.26kgfÂ m
(23.6lbfÂft)
Figure 98
3-101
(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.
position of the retarder.
(58.3lbfÂft)
ö Special tool
Figure 100
(29) Fasten rotor and flange shaft on the

converter, using hexagon head screws.
ö Tighten hexagon head screws uniformly
(180Ádisplaced) as well as secure them
with Loctite(Type No. 243).
(33.9lbfÂft)
Figure 101
(30) Equip screw plug with new O-ring and

install it.
Â Torque limit (M30Ý1.5): 9.18kgfÂm
(66.4lbfÂft)
Figure 102
3-102
(31) Line up shim(s = 1.5 mm).
Figure 103
(32) Install dust plate(Arrow).

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

means of disk and hexagon head screws.
ö Wet contact face of the disk with Loctite
(Type No. 574).
Â Torque limit (M10/8.8): 4.69kgfÂm
(33.9lbfÂft)
Figure 105
(34) Fix hexagon head screws with lock plate.

ö Special tool
Driver 5870 057 009
Handle 5870 260 002
Figure 106
3-103
3. TRANSMISSION
1) DISASSEMBLY
(1) Fasten the complete transmission on the
assembly car.
ö 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.
ö Special tool
Lifting chain 5870 281 047
Figure 121
(3) Pull oil feed flange by means of special

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

(ball+spring, see Arrow).
Figure 124
3-104
(5) Loosen screw connection(M8 and M12).
Separate converter bell from the
transmission, using lifting device.
ö 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
3-105
(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
3-106
(13) Separate spur gear from the shaft and
squeeze circlip out (Arrow).
ö Special tool
Set of pliers 5870 900 016
Figure 133
(14) Pull bearing inner race from spur gear.

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

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

shaft.
ö Support puller on the end face-input shaft.
Pay attention to the released shims.
ö Special tool
3-Leg puller 5870 971 002
Figure 136
3-107
(17) Separate bearing inner race from driver.
ö Pay attention to released washers.
If necessary, squeeze circlips(3EA) out.
Figure 137
Transmission pump
(1) Tilt gearbox housing 180Á.

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

remove spacer.
ö Special tool
Internal puller 5870 300 017
Counter support 5870 300 009
Figure 140
3-108
(4) Loosen socket head screws, demount
pump cover and remove rotor set.
ö 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
Â Torque limit(M8/8.8): 2.35kgfÂm (17.0lbfÂft)

Â Torque limit(M6/8.8): 0.97kgfÂm (7.0lbfÂft)
Emergency steering pump

(1) Loosen hexagon head screws and pry the
emergency steering pump out of the
housing.
ö 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
3-109
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.
ö Separate axle disconnection device from
the housing, using pry bars.
During the separating procedure, drive the
output shaft by tapping downward.
ö 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
3-110
(5) Remove cover as well as circlip and drive
pin out of the bore, using striker.
Remove the released components.
ö 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
3-111
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.
ö Special tool
Striker 5870 650 014
Figure 152
D isassemble 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.
ö Mark installation position of the bearing
covers.
Figure 154
ö Special tool
Threaded insert 5870 204 042
3-112
(2) Loosen screw connection and separate
housing cover by means of back-off
screws (Arrows) and lifting device from the
gearbox housing.
ö During the separating procedure, drive the
output shaft by tapping continuously
downward.
ö 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.
ö Special tool
Figure 157
(2) Remove plate and disassemble bearing

inner race.
Figure 158
3-113
(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
3-114
(7) Pull bearing inner race from the internal
gear.
ö 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.
ö Figure 167 shows the released
component.
Figure 166
Figure 167
3-115
(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
3-116
(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.
ö At the disassembly of the clutch K4/K3, lift
clutch KR/K2 slightly and displace it in
arrow direction, see Figure on the right.
ö Special tool
Figure 175
(2) The Figure on the right shows the clutches

in disassembled condition.
K3 K2 K1
K4 KR KV
Figure 176
3-117
(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.
ö Special tool
Pry bar 5870 345 036
Figure 179
(3) Take output shaft out of the housing.
Figure 180
3-118
(4) Pull bearing outer race out of the housing
bore.
ö 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.
ö The separation of shaft and gear is not
possible(shrink fit).
ö 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.
ö Special tool
Clamping ring 5870 654 022
Figure 185
(2) Pull roller bearing from plate carrier.

ö Special tool
3-Leg puller 5870 971 002
Figure 186
3-119
(3) Separate spur gear K3 from plate carrier.
Figure 187
(4) Pull bearing inner race from plate carrier.

ö 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 90Á.

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

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

ö Special tool
3-Leg puller 5870 971 002
Figure 194
3-121
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.
ö 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.
ö Special tool
Figure 198
3-122
Loosen slotted nut.
the slotted nut prior to loosen it (about
120Á C).
ö Special tool
Figure 199
(3) Pull tapered roller bearing from plate

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

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

Remove shim.
ö Special tool
Figure 202
3-123
carrier.
ö Special tool
Basic tool 5873 002 001
Figure 203

Figure 204
(8) Tilt plate carrier 90Á

Loosen slotted nut.
To prevent a damage of the thread, heat the
slotted nut prior to loosen it (about 120ÁC).
ö Special tool
Hot-air blower 115V 5870 221 501 Figure 205

carrier.
ö Spcial tool
Basic tool 5873 002 001
Figure 206
3-124
carrier.
ö 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.
ö Special tool
Basic tool 5873 002 001
Disassemble both pistons, as described at
Figure 196 and 197.
Figure 210
3-125
Dismantle Multi-disk clutch KV/K1
Fasten clutch by means of clamping ring
on the assembly car. Loosen slotted nut
(Figure 211).
ö Slotted nut is secured with Loctite.
To prevent a damage of the thread, heat the
slotted nut prior to loosen it (about 120Á
C ).
ö Special tool
Figure 211

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

ö Special tool
3-Leg puller 5870 971 003
Figure 214
3-126
(4) The Figure on the right shows the spur
gear bearing K1. 1
The bearing(1) is only as sub-assembly
available.
ö 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).
ö Pay attention to the released balls.
ö Special tool
Pry bar 5870 345 036
Figure 217
Figure 218
3-127
Figure 219

Loosen slotted nut.
ö Slotted nut is secured with Loctite.
the slotted nut prior to loosen it(about
120ÁC).
ö Special tool
Figure 220

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

ö Special tool
3-Leg puller 5870 971 003
Figure 222
3-128
(11) Remove shim and ring.
Figure 223

carrier (Figure 224).
Squeeze snap ring out.
Disassemble end shim and plate pack KV.
Disassemble both pistons (as described at
Figure 196 and 197).
ö Special tool
Basic tool 5873 001 000
Figure 224
3-129
2) ASSEMBLY
(1) Install studs (Arrows).
ö 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 -80Á C), heat
gear (+120Á 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
3-130
(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

Insert sealing disk(Arrow), with the
concave side showing downward, into the
housing bore until contact is obtained.
ö Wet contact face with Loctite(Type No.
262).
ö Do not damage the centric orifice hole ͚
0.8mm during the installation of the
sealing disk.
Figure 237
3-131
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 180Á.
Insert both roll pins (6Ý24 and 3.5Ý24)
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.
ö 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
3-132
(5) Oil O-rings and piston bearing surfaces.
Insert piston K3 uniformly until contact is
obtained.

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).
ö 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.
Figure 246
Now, lift plate carrier, with the K4-side
showing downward, into the clamping ring
and fix it. Tilt plate carrier 180Á.
3-133
Multi-disk clutch-K4
ö 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
ö 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)
3-134
Check Plate clearance - K4 =2.2 ~
2.4mm(Figure 249 ~ 251) :
ö 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.
ö 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.
ö Special tool
Magnetic stand 5870 200 055
Dial indicator 5870 200 057
3-135
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.
ö 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
3-136
(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.
ö Use protective gloves.
Figure 257

Figure 258
3-137
components.
1 Plate carrier 1
2 Piston 1
5 Inner plate 3 2.5
6 Inner plate 5 3.0
9 End shim 1
ö Install outer plates item 3, with the uncoated side facing the piston, respective the end shim.
K3 = Dimension Y (long plate-carrier side)
3-138
Check plate clearance K3 = 2.6 ~ 2.8mm
(Figure 260 ~ 262) :

install the plates for the present without oil.
Draft, respective the chart.
Figure 260

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.
ö Special tool
3-139
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.
ö Support on the lower as well as on the
upper bearing inner race.
Use pressure pieces.
ö Special tool
Pressure pieces 5870 506 096 Figure 264
(6) Lift plate carrier, with the K4-side showing

Tilt plate carrier 90Á.
Wet thread of slotted nut with Loctite (Type
No. 262) and install slotted nut(Figure 265).
ö Install slotted nut, with the collar(͚ 60mm)
facing the bearing inner race.
ö 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
3-140
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.
ö At correctly installed components, the
closing, respective opening of the clutches
is clearly audible.
Figure 270
3-141
(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

Insert both roll pins (6Ý24 and 3.5Ý24)
flush-mounted into the spur gear-side bore
(Arrow) of the plate carrier.
ö Special tool
Figure 275

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

with the chamfer showing downward.
ö Special tool
Figure 277
3-142
(4) Lay both O-rings scrollfree into the ring
Figure 278

Insert K2 piston uniformly until contact is
obtained.
Figure 279
(6) Introduce intermediate plate and

compression spring
Figure 280

Figure 281
3-143
(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.
ö Special tool
3-144
Multi-disk clutch-KR
components.
1 Plate carrier 1
2 Piston 1
5 Inner plate 11 2.5
8 End shim 1
ö Install outer plates Item 3, with the uncoated side facing the piston, respective the end shim.
KR = Dimension Y (long plate-carrier side)
3-145
(1) Check Plate clearance KR = 2.8~3.0mm
(Figure 285~287):
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

ö Special tool
3-146
Preassemble and install Spur gear KR
(Figure 288~296) :
components of spur gear KR.
2 Shims s = 3.0 and s = 3.10mm
(ɨ = 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
3-147
(5) Preload the tapered roller bearing with
about 5 ton and determine the axial play
with dial indicator.
axial play, correct with corresponding
shims (Item 2/figure 288).
ö 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
3-148
Figure 296

Figure 297
3-149
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)
3-150
Check plate clearance K2 = 2.6 ~
2.8mm(Figure300 ~ 302) :
ö 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
In case of deviations from the required
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.
ö Special tool
3-151
Preassemble and install spur gear K2
(Figure 303 ~ 312) :
1
(1) Supercool gear wheel 1 (about 80Á C) and 2
heat gear wheel 2 (about 120Á 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
3-152
(5) Determine Dimension I (bearing dimension)
Dimension I e.g. 76.27mm
ö 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
3-153
are 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) aHeat bearing inner race(clutch bearing)

and position it against shoulder.
Figure 313
3-154
components, preload bearing with 10 ton.
upper bearing race. Use pressure pieces.
ö Special tool
Pressure pieces 5870 506 096
Figure 314
Lift plate carrier into the clamping ring and

fix it.
(13) Tilt clutch 90Á
Â K2-Side:
No. 262) and install it (Figure 315).
ö Install slotted nut with the chamfer facing
Â Torque limit : 81.6kgfÂm(590lbfÂft) Figure 315
ö Special tool
Â KR-Side:
No. 262) and install it.
ö Install slotted nut, with the collar(͚76mm)
facing the bearing inner race.
Â Torque limit : 81.6kgfÂm(590lbfÂft)
ö 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
3-155
Reassemble Multi-disk clutch KV/K1
(1) Lift plate carrier, with the KV-side showing
Insert both roll pins(6Ý24 and 3.5Ý24)
flush-mounted into the end face-side bore
of the plate carrier (Arrow).
ö Special tool
Figure 320

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

in, with the chamfer showing downward.
ö Special tool
Figure 322
(4) Lay both O-rings scrollfree into the ring

Figure 323
3-156
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 180Á
ö Special tool
3-157
Multi-disk clutch-KV
ö 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 ͚)
3-158
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

ö Special tool
3-159
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
3-160
(5) Preload the tapered roller bearing with
about 5ton.
axial play, correct with corresponding shim
(Item 4 / Figure 335).
ö 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

are accommodated.
Figure 342
3-161
(9) Heat bear ing inner r ace(spur gear
bearing) and position it against
shoulder.
ö
es.
Use protective gloves.
Figure 343
(10) Heat bearing inner race(clutch bearing)

and position it against shoulder.
Figure 344
3-162
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 ͚)
3-163
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

ö Special tool
3-164
Pre-assemble and install Spur gear K1
(Figure 353~360):
1
components of spur gear K1.
1 Ball bearing (complete)
2 Snap ring
3 Spur gear
3
ö Prior to assemble the components, align 2
plate pack by means of the spur gear
Figure 353
radially 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
3-165
(4) Press ball bearing in until contact is
obtained.
ö 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

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

it until all inner plates are accommodated.
Figure 360
3-166
(8) Line up shim = 1.2mm.
Figure 361

Figure 362

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

and tilt it 90Á.
Wet thread of slotted nut with Loctite,
(Type No. 262) and install slotted nut.
ö Install slotted nut, with the collar facing the
bearing inner race.
Â Torque limit : 56.1kgfÂm(40.6lbfÂm)
Install opposite slotted nut(KV-side)
accordingly. Figure 364
ö Special tool
3-167
(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
3-168
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).
ö 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
3-169
ö 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.

ö Special tool
Figure 372
(7) Position clutch KR/K2.
Figure 373
3-170
(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.
ö The spur gear fixing prevents the slipping
out of the plates during the lifting into
position of the clutch.
ö 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
3-171
Interaxle differential
(1) Close bores (6EA/Arrows) by means of
set screws.
ö 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.
ö 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
3-172
(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
ö 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.
ö Drive the roll pins each time in up to the
shaft center, see Arrow.
Figure 387
3-173
(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
3-174
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
3-175
(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.
ö Special tool
Figure 399
3-176
(21) Position upper oil baffle and fasten both oil
baffles by means of hexagon head screws
(5EA) and hexagon nut (1EA).
ö Mount flat washers.
Secure hexagon head screws with Loctite
(Type No. 243).
Â Torque limit (M8/8.8):2.35kgfÂm(17.0lbfÂft)
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
ö According to the transmission version,
differences concerning components and
their installation positions are possible.
Figure 401
(2) Drive the roll pin(2Ý8mm) 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
3-177
(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
ö Special tool
Clamping Pliers 5870 900 026
Figure 404
(5) Insert gear wheel until contact is obtained.

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

ö 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
3-178
(8) Mount bearing outer race.
Press bearing outer race uniformly on and
determine Dimension II from bearing outer
race to the mounting face.
ö Apply several measuring points and
determine the average value.
ö Special tool
Straightedge 5870 200 022 Figure 408
EXAMPLE E :
Dimensio I e.g. 66.36mm
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.
ö Special tool
Figure 411
3-179
(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
Â Torque limit(M10/8.8):4.70kgfÂm(33.9lbfÂft)
Figure 412

obtained.
Figure 413
(14) Introduce shim s = 4.0mm.
Figure 414
(15) Fix ball bearing playfree, using shim and

circlip.
ö Special tool
Clamping pliers 5870 900 021
Figure 415
3-180
(16) Install shaft seal, with the sealing lip facing
the oil chamber.
Grease sealing lip.
ö 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).
ö Special tool
Driver 5870 048 228
(17) Press screening plate against shoulder.

ö 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.
ö Special tool
Driver 5870 057 009
Handle 5870 260 002
Figure 419
3-181
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
ö
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
3-182
(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.
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
3-183
Housing dimension :
Determine Dimension I from bearing outer
race to mounting face.
Figure 428
Cover dimension :
contact/bearing outer race to the mounting
face.
ö 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
3-184
(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 :
mounting face to the ring.
ö Special tool
Figure 435
3-185
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).
ö Special tool
Figure 439
3-186
Install Countershaft axle
Align countershaft gear centrically.
Install adjusting screw (Figure 440).
ö 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.
ö Wet thread of hexagon head screw with
Loctite (Type No. 243).
Figure 443
3-187
(5) Drive the sealing covers(Arrows) in, with
the concave side showing downward,
flush-mounted to the housing face.
ö 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.
ö 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.
ö Special tool
Pressing-in tool 5870 058 041
Figure 447
3-188
(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 - 80Á C.

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

flange.
Figure 451
3-189
(6) Fasten pump flange, respective the pump
by means of hexagon head screws.
ö Wet thread of the two hexagon head
screws, (Position, see Arrows) with Loctite
(Type No. 243) (through holes).
Figure 452

groove and grease it. Fasten pump flange
(Power take-off) with hexagon head
screws.
Figure 453
3-190
Axle disconnection
obtained.
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.
ö 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
3-191
(5) Insert disk, with the chamfer(Arrow)
showing upward.
Figure 464
(6) Preload compression spring, install sliding

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

Measuring device (Figure 466~470):
(7) Insert stop screw into the measuring
device.
ö 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.
ö Special tool
Measuring device 5870 200 107
Figure 467
3-192
(9) Determine Dimension I, see Figure on the
right.
Dimension I.g. 32.90mm
ö 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
ö Adjusting dimension = 1.0mm, gives the
required shifting travel.
(11) Line up shim(s) s = 2.6mm(Arrow) and

install socket head screw.
ö Wet thread of socket head screw with
Figure 470
3-193
(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.
ö 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
3-194
(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.
ö 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
ö Special tool
Driver 5870 048 228
3-195
(18) Press screening plate(Arrow) against
shoulder.
ö 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.
ö Special tool
Drive 5870 057 009
Handle 5870 260 002
Figure 480
Filter
(6) Introduce filter into the housing bore.
ö Oil sealing ring (Arrow).
Figure 481
3-196
(2) Fasten cover by means of hexagon head
screws (mount flat washers).
ö 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.
Â Torque limit(screw plugs):14.3kgfÂm
3
(103lbfÂft) 1
Figure 483
Input shaft (Power take-off-Pump)

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

(Driver/Input shaft) (Figure 485~489) :
1 Driver
2 Input shaft
Figure 485
3-197
(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
3-198
(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
3-199
(9) Squeeze circlip in(Arrow) and engage it.
Figure 493
(10) Introduce preassembled input shaft until

ö 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.
ö Apply several measuring points and Figure 495
(12) Measure Dimension II from the mounting

face/converter bell to the locating
face/bearing outer race.
ö Special tool
Gauge blocks 5870 200 080
Figure 496
3-200
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
3-201
(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.
ö Special tool
Figure 504
3-202
(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

ö Assembly of the shim, see Figure 508.
ö Special tool
Gauge blocks 5870 200 067
(9) Insert needle sleeve(Arrow), with the

reinforced shell facing the pressing-in tool
ö 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
ö Special tool
3-203
(11) Supercool oil feed flange, (about -80Á
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
Â Torque limit(10Ý1):2.55kgfÂm(18.4lbfÂft)
Â Torque limit(M14Ý1.5):3.57kgfÂm(25.8lbfÂft) 2
1 3
Figure 511
3-204
Converter pressure back-up valve
(Figure 512 and 513):
(15) Drive roll pin (6Ý50mm) into the bore until
Figure 512
(16) Introduce spool and compression spring.

Equip screw plug with new O-ring and
install it.
Â Torque limit : 13.3kgfÂm(95.9lbfÂft)
Figure 513
(17) Remove input shaft and heat housing

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

it centrically. Introduce input shaft until
ö Pay attention to the overlapping of the
fitting key with the fitting key groove.
Figure 515
3-205
(19) Install two adjusting screws and mount flat
gasket (Arrow 1).
Lay O-ring(Arrow 2) into the annular
groove. 1
ö Special tool
2
Figure 516
(20) Introduce converter bell by means of lifting

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

head screws.
Figure 518

groove of the converter bell.
Figure 519
3-206
(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.
ö Special tool
Figure 521
(25) Tilt transmission 90Á.

Insert pot flush-mounted to the housing
face.
ö Wet sealing surface with Loctite (Type No.
262).
Figure 522
(26) Install breather (Arrow).
Figure 523
3-207
(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.
ö The line routing is different according to
the design. In this connection, pay
attention to the Perspective Illustrations of
the corresponding Spare Parts List.
I nductive 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
3-208
ö 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.
ö 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 = 0.3Ü0.1 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).
ö Special tool
Plug gauge 5870 200 104 Figure 532
3-209
ö 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 mm) e.g. - 0.60mm
+3
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
Loctite(Type No. 574).
Figure 535
3-210
(6) Install inductive transmitter n-Engine(14),
see Arrow.
ö 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):
ö 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
3-211
(9) Measure Dimension II from the contact
face to the mounting face.
ö 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.
Â Torque limit(M8/8.8) : 2.35kgfÂm(17.0lbfÂft)
ö Installation position of the speed sensor.
ö Prior to the commissioning of the Transm-
ission, carry out the oil filling according to
the Operating Instructions.
Figure 545
3-212
3. AXLE
1) FINAL DRIVE
(1) DISASSEMBLY
Η Loosen oil drain plug and drain oil.
AX002
Θ Loosen hexagon head screws and lift off

the planetary carrier.
AX003
Ι Squeeze out circlip and pull off the

planetary gears.
Remove thrust washer.
AX004
Κ Pull sun gear along with inner plate

carrier from the stub shaft, respectively
out of the plate pack.
AX005
3-213
Λ Loosen locking screws and remove ring
from the inner plate carrier.
AX006
Μ Squeeze out circlip.
AX007
Ν Remove backing plate and plate pack.
AX008
Ξ Remove thrust washer.
AX009
3-214
Ο Remove lock plate.
AX010
Π Loosen and remove slotted nut.
AX011
Ρ Pull stub shaft out of the axle housing.
AX012
΢ Separate complete hub from hub carrier.
AX013
3-215
Σ Lift internal gear and internal gear carrier
out of the hub.
Remove released spacer.
AX014
Τ Unhook return springs.
AX015
Υ Take out the piston and remove sealing

components.
AX016
͂ Pull off tapered roller bearing from the

internal gear carrier.
AX017
3-216
̓ 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
3-217
(2) ASSEMBLY
Hub carrier
Η Fasten hub carrier on the axle housing by
means of hexagon head screws.
ö Pay attention to the installation position.
Cover flange-mounted surface with
sealing compound.
AX022
Θ Pull the wheel studs into the hub bores,

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

against shoulder.
AX024
Κ Guide the bearing inner race over the

end of the hub carrier until contact is
obtained.
AX025
3-218
Λ Guide hub over the end of the hub
carrier.
AX026
Μ Heat bearing inner race and place it

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

value).
ö 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 Π, page 3-220.
AX028
Ξ Screw installer over the threads of the

hub carrier.
Guide complete internal gear over the
hub carrier splines and fix the hub.
AX029
3-219
Ο Tighten slotted nut by continuous turning
of the hub.
ÂTorque limit : 204~224kgfÂm
(1475~162 3lbfÂft).
AX030
Rolling resistance of the wheel bearing

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

Â1.4~2.0kgfÂm(10.3~14.8 lbfÂft)
ö 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 Ν).
After adjustment of the wheel bearing
remove hub again.
Hub
Η Insert bearing inner race into the hub.
AX032
3-220
Θ Cover outside of shaft seal with Loctite
and drive it in.
ö 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
Ι Guide hub over the hub carrier end

carefully against shoulder.
AX034
Complete internal gear carrier

Pre-assemble piston
Κ 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
Λ Clean the piston with spirit.

Stick on support ribbons at two points by
means of Loctite. The support ribbons
must adhere exactly around the whole
circumference. Remove any sticking
residues.
3-221
Μ Install packing rings(2) and U-section
rings(3).
ö Pay attention to the installation position,
see draft Κ page 3-221.
AX037
Ν Insert piston into the installer(S).

ö Lubricate sealing and back-up elements,
(Use W-10 oil).
AX038
Ξ 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
Ο Press piston carefully against shoulder,

using clamping plate and two-leg puller.
AX040
3-222
Π 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
Ρ 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

Η Screw installer over the threads of the
hub carrier. Assemble the spacer
determined in Figure Ν, page 3-222.
AX044
3-223
Θ 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
Ι 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).
ö 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.
Κ Tighten slotted nut by continuous turning

of the hub finally.
Â Torque limit : 204~224kgfÂm
(1475~ 1623lbfÂft)
AX047
Λ Install lock plate and secure slotted nut.
AX048
3-224
Μ Assemble stub shaft until contact is
obtained.
AX049
Ν Screw oil seal with inner plate carrier.

AX050
Ξ Install thrust washer.
AX051
Ο Guide the inner plate carrier(Along with

the sun gear) upon the stub shaft splines.
AX052
3-225
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
Π 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
ö Pay attention to the correct location of the
piston against the internal gear carrier. AX053
Ρ 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 : 4Ý4.5mm

Dimension C e.g. 18.00mm
AX055
3-226
Σ Inner plate : 3Ý4.5mm
Dimension D e.g. 13.50mm
AX056
Τ Dimension E = Backing plate

Dimension E e.g. 18.00mm
AX057
Υ 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
ö If the required plate clearance according
to the Table, page 3-226, is not obtained,
correct with corresponding outer plate.
If necessary, mount thinner outer plates
on the piston side, respectively backing
plate side.
3-227
͂ Install alternating outer and inner
plates(Starting with one outer plate).
AX058
̓ 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
3-228
͆ Heat planetary gear and place it upon the
planetary carrier.
ö Pay attention to the installation position,
large radius of the bearing inner race
showing to the planetary carrier
(Downwards).
AX062
͇ 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.
ö For the measurement, lay thrust washer
into the planetary carrier.
AX065
3-229
͊ Example
Dimension A 6.00mm
Dimension B -5.50mm
Required end play =0.50mm
of the sun-gear shaft
ö Remove thrust washer again and make it
adhere with Loctite.
͋ Insert new O-ring into the ring groove of

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

is obtained.
AX067
͍ Tighten hexagon head screws.
AX068
3-230
Check tightness of the brake hydraulic
system
ö 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.

ö Before the axle is put into Service, pay
attention to the Lubrication Instructions,
page3-201.
AX070
3-231
2) DIFFERENTIAL CARRIER
(1) DISASSEMBLY
Remove the two stub shafts prior to
separate the differential carrier from the
axle housing, see figure Η~Ι.
Η 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
Θ Pull inner plate carrier(Along with sun

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

Squeeze out circlip and remove the plate
pack.
ö This step is necessary to make the later
installation of the inner plate carrier
possible.
AX073
3-232
Κ Loosen hexagon head screws and
separate the differential carrier from the
axle housing.
AX074
Λ Fasten the differential carrier in the

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

remove the two bearing caps.
ö Mark bearing caps with housing, see
arrow.
AX077
3-233
Ξ Remove adjusting nuts.
Remove differential assembly from the
axle carrier.
AX078
Differential
Η Pull the two bearing inner races of the
tapered roller bearing from the differential
case halves.
AX079
Θ Mark housing cover with differential.

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

ö Pay attention to the released thrust
washer.
AX081
3-234
Κ Take all components of the multi-disk
self-locking differential out of the
differential case.
AX082
Λ Press crown wheel from the differential

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

nut(According to the version) and remove
it along with washer.
AX085
3-235
Ι Pull off the drive flange.
AX086
Κ Pry out the shaft seal.
AX087
Λ Press drive pinion out of the axle carrier.

ö Pay attention to the released tapered
roller bearing.
AX088
Μ Remove spacer from the drive pinion

end.
AX089
3-236
Ν Press tapered roller bearing from the
drive pinion, using grab sleeve(See
arrow.).
AX090
Ξ If necessary, drive the two bearing outer

races out of the axle carrier bores.
AX091
(2) Assembly
ö If crown wheel or drive pinion are
damaged, the two parts must be
renewed as a set. 4
If a new complete crown wheel set is 3
c
installed, pay attention that crown wheel

and drive pinion have the same mating
3
b
numbers.
When replacing a complete crown wheel
x
1
set or axle carrier, pay attention to the 2
Draft.
Determine thickness of shim-to obtain a

correct contact pattern
ö 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, page3-202.
3-237
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
Η Determine gap(Dimension b) between

measuring pin and measuring shaft with
feeler gauge.
Dimension b e.g. 0.70mm
EXAMPLE Ɇ
Dimension a(=measuring piston)
166.80mm
Dimension b +0.70mm
Dimension c (1/2θmeasuring shaft)
+15.00mm AX092
gives Dimension X 182.50mm
Θ Measure bearing width.

Bearing width e.g. 33.50mm
AX093
Ι Read pinion dimension.

Pinion dimension e.g. 148.0-0.2
147.80mm
EXAMPLE ɇ
Bearing width 33.50mm
Pinion dimension +147.80mm
gives dimension X1 181.30mm
AX094
3-238
EXAMPLE Ɉ
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.
Κ Lay shim(s = 1.20mm) into the housing

bore.
AX095
Λ Undercool bearing outer race and press

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

drive pinion end until contact is obtained.
ö Pay attention to a correct contact, reset
after the cooling.
3-239
Adjust rolling resistance of the drive
pinion bearing
Η Nominal value : DK/CK 0.11~0.23kgfÂm
HK 0.15~0.31kgfÂm
LK/RK 0.31~0.46kgfÂm
Lay measuring ring over the drive pinion
collar.
ö Configuration and description of the
measuring ring, see below draft.
AX098
Draft for the determination of the spacer :

1 = Measuring ring 30Á 3Ý
12
2 = Roll pin(Set of 3, each spaced for 0Á
120Á)
ö Dimension X = Thickness of spacer.
2 1
X
Θ 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
Ι Insert the drive pinion into the axle carrier

and assemble the heated bearing inner
race until contact is obtained.
AX100
3-240
Κ Guide drive flange over the drive pinion
splines.
Apply washer and tighten slotted nut until
the required rolling resistance is obtained.
ö When tightening, make several full
revolutions of the drive pinion in both
senses, and check the rolling resistance
continuously.
AX101
Λ Loosen slotted nut, pull off drive flange

and remove the pinion again.
Take off measuring ring and determine
dimension X (See draft, page 3-240).
Dimension X e.g. s=8.55mm
ö 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.
Μ Replace drive flange, apply washer and

tighten slotted nut.
ÂTorque limit : RK 112kgfÂm
LK 122kgfÂm
CK 71kgfÂm
ö When tightening, make several full
revolutions of the drive pinion in both
senses.
AX103
Ν Check rolling resistance.

ö If the required rolling resistance is not
obtained correct again with one
corresponding spacer.
AX104
3-241
Ξ Remove the drive flange and install the
shaft seal.
ö 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
Ο Replace drive flange, assemble washer

and tighten slotted nut, respectively
hexagon nut(According to the version)
finally.
ÂTorque limit : RK 112kgfÂm
LK 122kgfÂm
CK 71kgfÂm
ö The securing of the slotted nut,
respectively hexagon nut(According to
the version) is carried out after the AX106
contact pattern is taken.
Differential
Η Heat the crown wheel, center and fasten
it provisionally.
AX107
Θ Insert the two thrust washers into the

differential case half.
ö Mount the brass washer on top with the
lubricating groove facing the side gear.
AX108
3-242
Ι Insert circlip and install drive pin.
AX109
Κ Assemble alternating outer and inner

plates, starting with one outer plate.
ö 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
Λ Mount pressure ring.
AX111
Μ Insert side gear and assemble inner

plates at the same time.
AX112
3-243
Ν Insert the complete differential spider.
AX113
Ξ Replace the second side gear.
AX114
Ο Install the second pressure ring and

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

plates, starting with one inner plate.
ö Number and installation position of the
inner and outer plates, see
corresponding lost of spare
parts(According to the version).
AX116
3-244
Determine plate clearance
Ρ 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
Σ EXAMPLE
Dimension A 3.40mm
Dimension B -3.10mm
Difference = Plate clearance 0.30mm
ö 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.
Τ Make the two thrust washers adhere with

grease in the housing cover.
ö Mount the brass washer on top with the
lubricating groove facing the side gear.
AX119
3-245
Υ Fasten the housing cover by means of
locking screw.
ö 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
̓ 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.
ö Pay attention to the marking(Arrow).
AX123
3-246
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
0.3~0.4kgfÂm.
Check backlash again and correct if
necessary.
ö At this step make several full revolutions AX125
of the differential.
Determine yoke width ;
e.g. CK 258+0.1mm
͇ 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-
202.
AX127
3-247
͉ 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
͊ Secure hexagon head screws of the

bearing cap fastening against getting
loose by means of lock wire(θ1.6mm).
AX129
͋ Tilt differential carrier.

Insert lock plate firmly against shoulder
and caulk it on the drive flange, using a
suitable tool.
AX130
͌ Cover 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
3-248
͍ Fasten differential carrier on the axle
housing by means of hexagon head
screws.
ö Cover hexagon head screws with sealing
compound Loctite.
AX132
ö 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 3-250.
3-249
3) 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 5Áis 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.
(1) Oil level
..
1. Wheel end : Turn wheel hubs until the word "Olstand" can be read in a horizontal position. Fill
up oil to the overflow on the level plug.
2. Axle housing : Fill up oil, to the overflow on the level plug or the oil filler opening respectively,
installed in the center(SAE 80W-90LSD/API GL-5).
3. Differential carrier, not installed in a axle : Fill up oil 20mm below the middle of the crown wheel.
(2) Check
After a few minutes, if oil level has dropped fill up to the correct level until level remains constant.
Oil level check monthly. Especially before you start a vehicle with new or repaired axles or their
components respectively.
(3) Oil change
1st oil change after 200 operating hours. Further oil changes must be made every 1000
operating hours, or at least once a year.
(4) Brake
For the pneumatic-hydraulic or memory controlled brake actuation are admitted :
1. Motor oils SAE 10W according to specifications MIL-L-2104C, MIL-L-46152, API-CC, CD, SC,
SD, SE, SF
2. ATF-oils(Type A/Suffix A, Dexron IID)
ö Other brake fluids may be not used.
(5) Points of grease lubrication
At greasing points, use a multi-purpose grease with following properties : Lithium soap, drop point
170C, NLGI class 2. The grease must abe anti-corrosive, water-resistant and walk stable.
Regrease all pressure grease fittings monthly.
(6) Important notes
Check correct torque limit of all screwed joints within regular intervals.(First check after 50
operating hours.)
Axles with multi-disk self-locking differentials : A slight noise could be noted, when oil without
limited slip additives have been filled in. This noise can be regarded as harmless. In case of a
heavy noise or when the tire is jerking, use EP-gear lubricants with Limited-Slip additives.
3-250
6) EXAMPLES OF CONTACT PATTERNS FOR THE GLEASON GEAR-TOOTH SYSTEM
(1) Coast side(Concave)
(2) Drive side(Convex)
3-251
SECTION 4 BRAKE SYSTEM
Group 1 Structure and Function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1

Group 2 Operational Checks and Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-21
Group 3 Tests and Adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-29
SECTION 4 BRAKE SYSTEM
1. OUTLINE
ö 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 in cut-off valve.
The brake system contains the following components:
ÂBrake pump
ÂParking brake solenoid valve in cut-off valve
ÂCut-off valve
ÂBrake valve
ÂAccumulators
ÂPressure 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(lbÂin)
air/hydraulic and full power hydraulic brake
actuation system. 600
Brake pressure
Full power systems can supply significantly 500 (Air/hydraulic)
higher brake pressures with relatively low Brake torque
400
reactive pedal forces. The reactive pedal (Air/hydraulic)
force felt by the operator will be proportional 300
Brake torque
to the brake line pressure being generated. 200 (Full power)
This is referred to as brake pressure
modulation. 100
Another key design feature of full power
0 1 2 3 4
systems is the ability to control maximum
brake line pressure. In addition, because Time(seconds)
these systems operate with hydraulic oil,
filtration can be utilized to provide long
component life and low maintenance
operation.
Because these systems are closed center,
by using a properly sized accumulator,
emergency power-off braking that is
identical to power-on braking can be
achieved. These systems can be either
dedicated, where the brake system pump
supplies only the demands of the brake
system or non-dedicated, where the pump
supplies the demands of the brake system
as well as some secondary down stream
hydraulic device.
Another important note is that all seals
within these system must be compatible
with the fluid medium being used.
4-2
2. HYDRAULIC CIRCUIT
FRONT
28 REAR
Parking brake
17
19
BL1 BR1 BL2 BR2
8
T1 P1 T2 P2
15 15
16 7 B1 A1 B2 A2
A3
18 PS T1
B
Steering system
PS1
18
P T
Parking brake MCV RCV lever
solenoid Return line
20
Fan drive
1 2 motor
23
Return line
24 25
27 Return line
26
22
7807ABS01
1 Main pump(+Brake pump) 17 Pressure switch 24 Strainer

2 Steering pump(+Fan pump) 18 Pressure switch 25 Hydraulic tank
7 Cut off valve 19 Pressure switch 26 Return filter
8 Brake valve 20 Line filter 27 Bypass valve
15 Accumulator 22 Oil cooler 28 Axle
16 Accumulator 23 Air breather
4-3
1) SERVICE BRAKE RELEASED
FRONT
28 REAR
Parking brake
17
19
BL1 BR1 BL2 BR2
8
T1 P1 T2 P2
15 15
16 7 B1 A1 B2 A2
A3
18 PS T1
B
Steering system
PS1
18
P T
20
Fan drive
motor
1 2
23
Return line
24 25
27 Return line
26
22
7807ABS02
When the pedal of brake valve(8) is released, the operating force is eliminated by the force of the
spring, and the spool is returned.
When the spool removes up, the drain port is opened and the hydraulic oil in the piston of axles
return to the tank(25).
Therefore, the service brake is kept released.
4-4
2) SERVICE BRAKE OPERATED
FRONT
28 REAR
Parking brake
17
19
BL1 BR1 BL2 BR2
8
T1 P1 T2 P2
15 15
16 7 B1 A1 B2 A2
A3
18 PS T1
B
Steering system
PS1
18
P T
20
Fan drive
motor
1 2
23
Return line
24 25
27 Return line
26
22
7807ABS03
When the pedal of brake valve(8) is depressed, the operating force overcomes the force of the
spring, and is transmitted to the spool. When the spool moves down, the inlet port is opened, and
at the same time the hydraulic oil controlled the pressure level by the cut-off valve(7) enters the
piston in the front and rear axles. Therefore, the service brake is applied.
4-5
3) PARKING BRAKE RELEASED
FRONT
28 REAR
Parking brake
17
19
BL1 BR1 BL2 BR2
8 B
A
T1 P1 T2 P2
Parking brake switch

15 15
16 7 B1 A1 B2 A2
A3
18 PS T1
B
Steering system
PS1
18
P T
20
Fan drive
1 motor
2
23
Return line
24 25
27 Return line
26
22
7807ABS04
When the parking brake switch is pressed B position, the solenoid valve is energized and the
hydraulic oil controlled the pressure level by the cut-off valve(7) enters the parking brake on the front
axle. It overcomes the force of the spring and pushes the piston rod. This releases the brake.
Therefore, the hydraulic oil pressure is applied to the parking brake piston through the solenoid
valve and the parking brake is kept released.
4-6
4) PARKING BRAKE OPERATED
FRONT
28 REAR
Parking brake
17
19
BL1 BR1 BL2 BR2
8 B
A
T1 P1 T2 P2
Parking brake switch

15 15
16 7 B1 A1 B2 A2
A3
18 PS T1
B
Steering system
PS1
18
P T
20
Fan drive
motor
1 2
23
Return line
24 25
27 Return line
26
22
7807ABS05
When the parking brake switch is pressed A position, the solenoid valve is deenergized and the
valve open the exhaust port.
At the same time, the hydraulic oil in the parking brake return to the tank through the solonoid valve.
When the piston rod is returned by the force of the spring, the parking brake is applied.
4-7
3. BRAKE PUMP
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 6-58.
4-8
4. BRAKE VALVE
1) STRUCTURE
18
17
19
23 22
24
21
2
20 8
9
25
30
25
16 14
15 7
5 13
31
12 6
1 10
26
4
11
3
7807ABS21
1 Lower body 11 O-ring 21 Torsion spring

2 Upper body 12 Oil seal 22 Stop ring
3 Spool 13 Spring guide 23 Hexagon bolt
4 Plug 14 Stop ring 24 Hexagon nut
5 Holder 15 Bushing 25 Bolt
6 Lower spring 16 Pedal plate 26 Spring washer
7 Upper spring 17 Pedal assy 30 Plain washer
8 Main spring 18 Rubber(Pedal) 31 Stop ring
9 Spring retainer 1 19 Cover
10 O-ring 20 Lock pin 1
4-9
2) OPERATION
BL1 BR1 BL2 BR2
T1 P1 T2 P2
Hydraulic circuit
T1 Porte Port name Port size

BL1
P1, P2 Port PF3/8
P1
T1, T2 Drain port PF3/8
BR1
BR1, BR2 Brake cylinder port PF3/8
T2 BL1 Pressure switch port PF1/4
BL2
BL2 Pressure switch port M12Ý1.5
P2
BR2
7807ABS22
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
(P1, P2) of the brake valve. A connection is established between ports(BR1, BR2) and ports(T1,
T2) so that the wheel brakes ports(BR1, BR2) are pressureless via the returns ports(T1, T2).
(3) Partial braking
When the brake valve is actuated, an amount of hydraulic pressure is output as a ratio of the foot
force applied.
The spring assembly(8) beneath base plate(16) is designed in such a way that the braking
pressure changes depending on the angle. In the lower braking pressure range, the machine
can be slowed sensitively.
When the braking process is commenced, the upper spool is mechanically actuated via spring
assembly(8), and the lower spool is actuated hydraulically by spool. As spools(3) move
downward, they will first close returns(T1, T2) via the control edges, thus establishing a
connection between accumulator ports(P1, P2) and ports(BR1, BR2) for the wheel brake
cylinders. The foot force applied now determines the output braking pressure. The control
spools(3) are held in the control position by the force applied(Spring assembly above the spools
and the hydraulic pressure below the spool(Balance of forces).
After output of the braking pressure, spools(3) are in a partial braking position, causing ports(P1,
P2) and ports(T1, T2) to close and holding the pressure in ports(BR1, BR2).
(4) Full braking position
When pedal is fully actuated, end position of the brakes is reached and a connection established
between accumulator ports(P1, P2) and brake cylinder ports(BR1, BR2). Returns(T1, T2) are
closed at this point.
When the braking process is ended, a connection is once again established between brake
cylinder ports(BR1, BR2) and return ports(T1, T2), closing accumulator ports(P1, P2).
The arrangement of spools in the valve ensures that even if one braking circuit fails the other
remains fully operational. This is achieved by means of the mechanical actuation of both spools
and requires slightly more pedal travel.
(5) Limiting the braking pressure
Pedal restriction bolt(23) on base plate below pedal is used to limit the braking pressure.
(6) Failure of a circuit
In the event of the lower circuit failing, the upper circuit will remain operational. Spring assembly
(8) will mechanically actuate spool. 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.
(7) Installation requirements
Return lines(T1, T2) must be connected directly to the tank.
The connecting lines must be installed is such a way as to permit proper bleeding.
4-11
(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.
ö When doing repair work, make sure your environment is very clean.
Immediately close all open ports on the components and on pipes using plugs.
(10) Replacing the pedal cover
Pedal cover(18) is simply pulled of by hand. The new pedal cover is pushed over pedal(17) and
tightened manually. Fasten the bellows with the strap retainers.
(11) Replacing the complete actuating mechanism
Carefully clamp the unit vertically in a fixture. The actuating mechanism can be removed by
taking out the four bolts. Make sure that spring assembly(8) does not fall out. When installing the
new actuating mechanism, make sure that spring assembly(8) is fitted in the right order. Tighten
the four bolts(25).
(12) Replacing the bellows
To change bellows(19) it is advisable to remove pedal(17). For this purpose, loosen retaining ring
(22) and knock out pin(20) using a mandrill. When knocking out the bolt, make sure that the
mandrill is applied to the side of the bolt without a knurl. Remove pedal(17) and bellows(19).
Now fit the new bellows and proceed in reverse order as described above. The upper portion of
bellows is fastened to piston, its lower portion to base plate(16) secure the bellows using clamps.
4-12
5. CUT-OFF VALVE
1) STRUCTURE
3 4
5 C B
D D
P PS1
A A
C B
SECTION A - A SECTION B - B
1 2
HYDRAULIC SYMBOL
B1 A1 A2 B2
A1 A2
A3
PS
PS T1 T1
B1 B2 B
PS1
A3
B
P T
SECTION C - C SECTION D - D
7707BS06
1 Cut-off valve 4 Coil

2 Relief valve 5 Solenoid valve
3 Check valve
2) OPERATION
When the pump works, the oil under the pressure flows into P port.
The oil in P port is stored in the accumulator on A3 port.
As the pressure on P line rises to 150bar, the cut off valve(1) starts cut-offing and the oil in the P
port is unloaded. The pressure on P line goes down 120bar by the minute leakage from valve and
other factors.
At this pressure, the cut-off valve starts cut-ining.
This process is repeated in the regular period of 30~40 seconds.
4-13
6. BRAKE ACCUMULATOR
1) STRUCTURE
81L1-0004 81L1-0003
Item
(Item16) (Item15)
Diameter 121mm 136mm
Mounting height 146mm 160mm
Norminal volume 0.75m 3
1.0m3
Priming pressure 50kgf/cm2 50kgf/cm2
Operating medium Oil Oil
B
Operating pressure Max 210kgf/cm 2
Max 200kgf/cm2
Thread M18Ý1.5 M18Ý1.5
A
C Priming gas Nitrogen Nitrogen
A Fluid portion C Diaphragm

D B Gas portion D Valve disk
(770-3ATM) 4-22
2) OPERATION
(1) Purpose
Fluids are practically incompressible and are thus incapable of accumulating pressure energy. In
hydropneumatic accumulators, the compressibility of a gas is utilized to accumulate fluid. The
compressible medium used in the accumulators is nitrogen.
In braking systems, the purpose of the accumulators is to store the energy supplied by the
hydraulic pump. They are also used as an energy reserve when the pump is not working, as a
compensator for any losses through leakage, and as oscillation dampers.
(2) Operation
The accumulator consists of a fluid portion (A) and a gas portion (B) with a diaphragm (C) as a
gas-tight dividing element. The fluid portion (A) is connected to the hydraulic circuit, causing the
diaphragm accumulator to be filled and the gas volume to be compressed as the pressure rises.
When the pressure falls, the compressed gas volume will expand, thus displacing the
accumulated pressure fluid into the circuit.
The diaphragm bottom contains a valve disk (D) which, if the diaphragm accumulator is
completely empty, closes the hydraulic outlet, thus preventing damage to the diaphragm.
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.
4-14
(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.
ö 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
A Safety valve
(770-3ATM) 4-23
4-15
(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.
4-16
7. PRESSURE SWITCHES
1) STRUCTURE
H1 ÂNormally closed
H2
ÂNormally open
(770-3ATM) 4-25
ÂTechnical data
H1 H2 Adjusting range Adjusting pressure Voltage
Item Type Medium G
mm mm kgf/cm2 kgf/cm2 V
Charging/Parking NC Oil M12Ý1.5 55 9 50 ~ 150 100 Ü10 Max 42

Brake stop NO Oil M12Ý1.5 55 9 1 ~ 10 5Ü1 Max 42
Clutch cut-off NO Oil PF 1/4" 55 9 20 ~ 50 24 Ü 2 Max 42
NC : Normally closed NO : Normally open
4-17
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
pressure in the system. Even when the engine is switched off there will be some residual
ö For safety reasons the pressure switch needs to be replaced as a whole if damaged.
4-18
(7) Adjusting and testing pressure switch
The adjusting screw located between the two contact plugs can be set to the desired value within
a certain range. For adjusting range, please refer to the table Technical data on the previous
page.
After making the adjustment, the adjusting screw should be secured using wax or a similar
material.
()
(+) Screw
(770-3ATM) 4-25
4-19
8. PARKING BRAKE
2 21 22 1 6 19 5 17 9 18 16
20 4 3 13 14 8 10 15 7 11 12
7807APB01
1 Housing 9 Pressure ring 17 Seals

2 Guide bolt 10 U-ring 18 Circlip
3 Brake pads 11 Lock nut 19 Bleeding valve
4 Brake pads 12 Screw cap 20 Clearance ring
5 Cup springs 13 Dust protection cap 21 Locking splint
6 Piston 14 Seal rings 22 Castellated nut
7 Adjusting screw 15 Seal rings
8 Pressure bolt 16 O-ring
4-20
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
4-21
öH
Hydraulic oil must be at operating temperature for these checks(Refer to page 6-51).
Parking brake capacity Start engine. OK

Fasten seat belt.
Seat belt must be worn
NOT OK
while doing this check to Release parking brake and put
Inspect parking brake. Go
prevent possible injury transmission in 2nd gear forward.
to group 3.
when machine stops
Drive machine at 8 km/hr and
suddenly.
switch parking brake ON.
mph
LOOK/FEEL : Machine must

come to a stop within 2 meters(6
feet) when parking brake is
engaged at 8 km/hr.
Transmission must shift to neutral.
Parking brake Turn parking brake to ON. OK

transmission lockout Check completed.
Place transmission in 1st forward.
check
NOT OK
Engine running. Slowly increase engine speed to
Go to transmission control
high idle.
circuit in section 3.
LOOK : Machine must not move.
4-22
Service brake pump flow Stop engine. OK

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

Service brake capacity Check completed.
Apply service brakes, release park
check
brake and put transmission in 2nd NOT OK
Engine running. Check brake pressure in
forward.
group 3.
Increase engine speed to high idle.
IF OK
LOOK : Machine may not move or Inspect brake disk, see
move at a very slow speed. group 3.
Repeat check three times to ensure
accurate results.
4-23
Brake accumulator Start and run engine for 30 OK
precharge check seconds. Check completed.
ö The axles and
Stop engine and turn start 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, accumulator
on in 1-5 applications. has lost it's charge.
Inspect and recharge
Start engine and operate at low
accumulator, group 3.
idle.
Observe cluster while applying
brake pedal with maximum force.
LOOK/LISTEN : Brake pressure
indicator must not come ON.
Brake system leakage ON Start engine and wait 30 seconds. OK

Stop engine.
NOT OK
Wait 2 minutes.
If brake leakage is
Turn start switch to ON and wait 5 indicated with brakes
seconds. released, check leakage at
accumulator inlet check
LOOK : Brake oil pressure warning
valve and brake valve. If
lamp must not come on within 2
brake leakage is indicated
minutes after stopping engine.
with brakes applied, check
for leakage at brake valve
and brake pistons.
Check individual
component leakage.
4-24
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 slope. OK

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

position. Check completed.
Release parking brake. NOT OK
Adjust clutch cut-off switch,
Run engine at half speed in 1st
see group 3.
forward.
Firmly depress brake pedal.
FEEL : Transmission must
disengage when brake pedal is
depressed at 30% of pedal stroke.
NOTE : Clutch cut-off pressure
switch can be adjusted to operator
preference to match your loading
needs.
4-25
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.
öIIt is normal for the oil level to be slightly
above the check plug.
Aggressive brakes Internal restriction in circuit Remove lines and components.

Clutch cut-off switch out of Adjust switch.
adjustment
Brake valve malfunction Disassemble and inspect.
Low oil level Check oil level.
Brakes drag Brake pedal not returning Inspect floor mat and pedal.
properly
Debris holding valve partially Do brake valve pressure test.
open in brake valve
Warped brake disk Inspect brake disk.
Stuck brake piston Repair.
Brakes lock up Brake valve malfunction Clean or replace brake valve.
4-26
Brakes chatter Air in brake system Do brake bleed procedure.

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

light will not go out or pressure warning switch
stays on excessively long
Brake accumulator pressure too Recharge accumulator.
after start-up
low
Low brake pump standby Do brake pump standby pressure test.
pressure setting.
Leakage in pressure reducing Do pressure reducing valve manifold leakage test.
manifold block
Leakage in brake system Do brake system components leakage tests.
Worn brake pump Do brake pump flow test.
Leakage in parking brake Do parking brake pressure test.
solenoid
4-27
2) PARKING BRAKE MALFUNCTIONS
Brake will not hold Pads not adjusted correctly Adjust parking brake.
Malfunctioning parking brake Inspect and replace.
solenoid
Worn brake disk and / or brake Disassemble, inspect, repair.
pads
Brake piston hangs up in bore Remove and inspect. Repair.
Brake disk overheats Pads out of adjustment Adjust parking brake.

Brake not released Release parking brake.
Disassemble, inspect brake.
Repair if necessary.
Inspect for loosen or broken lines between brake
pressure switch and indicator on dash.
Parking brake indicator Faulty wiring or switch Inspect for loose or broken lines between brake
in monitor does not pressure switch and indicator on dash.
come on when brake Inspect for a faulty indicator on dash. Replace if
applied necessary.
Brake will not apply Pads out of adjustment Adjust parking brake.
Malfunctioning wiring, switch, or Check electric circuit.
solenoid
Restriction between brake valve Remove hose and inspect. Replace.
and brake
4-28
1. PARKING BRAKE PERFORMANCE

1) MEASUREMENT CONDITION
(1) Tire inflation pressure : Specified
pressure
(2) Road surface : Flat, dry, paved surface
with 1/5(11ä
20') gradient.
20%
(3) Machine : In operating condition gradient 11ä
20'
Item Standard valve
Parking brake Keep machine on 20% 7807ABS16
performance (11ä
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 11ä
20' gradient
and the machine must be kept stopped.
ö The measurement must be made with
the machine facing either up or down
the slope. 7807ABS17
2. EXTERNAL BRAKE INSPECTION

Inspect for wear of brake lining carrier.
Adjust the gap(A) 2mm by adjust screw.
Brake disc Screw

7807APB02
4-29
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.
ö 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.
ö 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 Lock bar
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. 7807ABS18
4-30
SECTION 5 STEERING SYSTEM

Group 3 Tests and Adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-28
Group 4 Disassembly and Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-36
SECTION 5 STEERING SYSTEM
1. OUTLINE
The steering system of this machine is a dynamic load sensing steering system.
This system offers faster response from the priority valve of flow amplifier and the pump. Also if
offers advantages in connection with cold start up and improvements in system stability.
The components of the steering system are :
·Steering pump
·Flow amplifier
·Steering unit
·Steering cylinders
The flow amplifier contain a directional valve, an amplification stage, a priority valve, a pilot pressure
relief valve and shock and suction valve.
The steering pump, the first pump of hydraulic pump, draws hydraulic oil from the reservoir.
Outlet flow from the pump flows to the priority valve of flow amplifier. The priority valve of flow
amplifier preferentially supplies flow, on demand, to the steering unit. When the machine is steered,
the steering unit routes flow to the steering cylinders to articulate the machine.
When the machine is not being steered, or if pump flow is greater than steering flow, the priority valve
supplies flow to the loader system.
That is, output flow from the steering pump enters into the main pump for the operation of the
attachment.
5-1
LH RH
6 CL CR
L R
EF
T
PP
21MPa
HP LS HT
L 5 R
MCV
RCV lever
P T LS
Brake system Fan drive

motor
1 2
Return line
23
Return line
24 25
27 Return line
26
22
7807ASE01
1 Main pump(+Brake pump) 23 Air breather

2 Steering pump(+Fan pump) 24 Strainer
5 Steering unit 25 Hydraulic tank
6 Flow amplifier 26 Return filter
9 Steering cylinder 27 Bypass valve
22 Oil cooler
5-2
1) NEUTRAL
LH RH
6 CL CR
L R
EF
T
PP
D 21MPa
HP LS HT
L 5 R
MCV
RCV lever
P T LS

motor
1 2 A
Return line
23
Return line
24 25
27 Return line
26
22
7807ASE02
· The steering wheel is not being operated so control spool(G) does not move.
· The oil from the steering pump(A) enters port HP of the priority valve of flow amplifier and the inlet
pressure oil moves the spool(D) to the right.
· Almost all of pump flow goes to the loader system(Main control valve) through the EF port and
partly flows into the hydraulic tank(25) through the control spool(D).
· This small flow is useful to prevent the thermal shock problem of the steering unit(5).
5-3
2) LEFT TURN
LH RH
6 CL CR
L R
J
EF
T
PP
D K 21MPa
HP LS HT
L 5 R
MCV
RCV lever
P T LS

motor
1 2 A
Return line
23
Return line
24 25
27 Return line
26
22
7807ASE03
· When the steering wheel is turned to the left, the spool(G) within steering unit(5) connected with
steering column shaft is pushed to the right direction.
· The oil discharged from the pump(A) flows into HP port of flow amplifier(6).
· The delivered oil passes through the main orifice of steering unit(5), through the priority valve spool
(D) of flow amplifier(6). The position of priority spool(D) is determined when the pressure
difference between front and rear of main orifice is balanced with control spring(K) force.
· The oil supplied through the directional spool(J) from the steering unit(5) is combined with the direct
oil from the priority valve spool(D) in the amplifier spool(M). The amplified oil flows into the small
chamber of the left steering cylinder and large chamber of the right steering cylinder respectively.
· Oil returned from left and right cylinder returns to hydraulic tank through directional spool(J) of flow
amplifier(6).
· When the above operation is completed, the machine turns to the left.
5-4
3) RIGHT TURN
LH RH
6 CL CR
L R
J
EF
T
PP
D K 21MPa
HP LS HT
L 5 R
MCV
RCV lever
P T LS

motor
1 2 A
Return line
23
Return line
24 25
27 Return line
26
22
7807SE04
· When the steering wheel is turned to the right, the spool(G) within steering unit(5) connected with
steering column shaft is pushed to the right direction.
· The oil discharged from the pump(A) flows into HP port of flow amplifier(6).
· The delivered oil passes through the main orifice of steering unit(5), through the priority valve spool
(D) of flow amplifier(6). The position of priority spool(D) is determined when the pressure
difference between front and rear of main orifice is balanced with control spring(K) force.
· The oil supplied through the directional spool(J) from the steering unit(5) is combined with the direct
oil from the priority valve spool(D) in the amplifier spool(M). The amplified oil flows into the small
chamber of the right steering cylinder and large chamber of the left steering cylinder respectively.
· Oil returned from left and right cylinder returns to hydraulic tank through directional spool(J) of flow
amplifier(6).
· When the above operation is completed, the machine turns to the right.
5-5
3. STEERING PUMP(+FAN PUMP)
1) STRUCTURE
35 36 37 39
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 19
33 34 32 31 30 29 28 25 24 27 26 23 22 21 20
7807AWE09
1 End cap 14 Section seal 28 Dowel pin

2 Section seal 15 Section seal 29 Dowel pin
3 Section seal 16 Retaining ring 30 Rotor assembly
4 Back up ring 17 Ball bearing 31 Vane holdout pin
5 Pressure port plate 19 Shaft 32 Vane
6 Camring 20 Shaft seal 33 Dowel pin
7 Rear port plate 21 Round section ring 34 Section seal
8 Bushing 22 Mounting cap 35 Screw
9 Rear port plate 23 Pressure port plate 36 Screw
10 Camring 24 Rotor assembly 37 Screw
11 Dowel pin 25 Vane 39 Screw
12 Vane holdout pin 26 Section seal
13 Back up ring 27 Housing
5-6
2) DESCRIPTION
The main vane pump consist of six basic components : end cap(2), P2 section unitlzed cartridge(4)
consisting of ; rotor, vanes, vane holdout pins, cam ring, port plate, and pressure plate, center,
housing(5), P1 section unitlzed cartridge(6) consisting of ; rotor, vanes, vane holdout pins, cam ring,
port plate, pressure plate, shaft(11) and bearing and mounting cap(14).
The main vane pump features the use of unitized pumping cartridge for both the P1 and P2 pump
section.
The unitized cartridge assemblies are pretested and provide for ease of disassembly and assembly
in the event it becomes necessary or desirable to make repairs, overhaul or revise the flow delivery.
P1 section
P2 section
14
11
6
5
4
2
7707WE10
3) OPERATION
with fluid.
contact with the cam contour.
※ When operating the pump at the maximum outlet pressure, the pump shaft rotation should not be
allowed to fall below 600rpm in order to maintain proper vane to cam ring contact. The inlet or
suction flow for both the P1 cartridge and P2 cartridge feeds through a common 3 port in the center
housing, through the large ports of each port plate for each cartridge and through the center hole in
the suction zone of each cam ring.
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
(5) Neutral
9C
T
HT
CR CL
L HP R
P
HP EF LS
PP
42 9B 30
CL CR
L R
L R 9C
Steering unit
P
LS
9A
EF TO MCV
42 T
P T PP
9B 30
HP LS HT
(770-3ATM) 5-8
5-10
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 loader control
valve.
With the engine off, the priority valve spool(9B) is pushed to the left by the spring(30). The passage to
the EF port is blocked while the passage to the P port is open.
When the machine is first started, all pump flow is routed to the steering unit which blocks the flow.
With the flow blocked, the pressure increases.
Steering inlet pressure is supplied through the dynamic orifice(42) in the spool. This causes the priority
valve spool(9B) to shift to the right against the spring(30) and open the EF port.
As long as the steering unit is in neutral, just enough pressure is maintained at the steering unit to keep
the priority valve spool(9B) shifted to the right.
The operating pressure in the loader system has no effect on the operation of the priority valve(9B) of
flow amplifier. With the loader actuated in relief, the priority valve(9B) will not shift until the machine is
steered.
Flow through the priority valve spool(9B) passes from the P port through the orifice(42) and into the LS
port. It flows through the steering unit LS passage which is routed to return when the steering unit is in
neutral. This provides a warm-up circuit for the steering unit to prevent binding of the steering unit due
to oil temperature extremes.
In neutral position, also the directional valve(9C) is in its center position.
This means that knock and impacts from the cylinder are not transmitted to the steering unit. The flow
amplifier is thus of the non-reaction type.
5-11
(6) Mid-turn
9C
T
HT
CR CL
L HP R
P
S
C
N
A
M
HP EF LS
PP
9B 9A
CL CR
L R
L R 9C
Steering unit
P
LS
9A
EF
T
P T PP
9B
HP LS HT
(770-3ATM) 5-10
5-12
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
(7) Full turn
T
HT
CR CL
L HP R
P
HP EF LS
PP
9B T 30
CL CR
L R
L R 9C
Steering unit
P
LS
EF
TO MCV
T
P T PP
D
HP LS HT
(770-3ATM) 5-12
5-14
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
4. STEERING UNIT
1) STRUCTURE
12 3 32
4 15 5 18,20
22,23
1 5 7 8 9 2 11 13 14 16 17 18,21
(770-3ATM) 5-14
1 Dust seal ring 9 Cross pin 17 End cover

2 Housing, spool, sleeve 11 Shaft 18 Washer
3 Ball 12 Spring set 20 Pin screw
4 Bushing 13 O-ring 21 Screw
5 Lip seal 14 Distributor plate 22 Name plate
7 Bearing assy 15 Gearwheel set 23 Drive screw
8 Ring 16 O-ring 32 Check valve
5-16
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
(770-3ATM) 5-15
The steering unit consists of a spool(I) inside a sleeve(H) within a housing. When steering wheel is not
moving, the steering unit is in the neutral(A) position. In neutral, the spool and sleeve are aligned so
that oil flow through the steering unit is blocked. The steering cylinder(B) are held stationary by trapped
oil in the left and right workports.
When the steering unit is turned to the right, the spool rotates relative to the sleeve, and opens
passages which allow pump flow through the spool and sleeve assembly. Oil flows to the gerotor(E)
causing the gerotor gear to rotate. Oil flow from the gerotor flows back into the steering unit where it is
directed out the right workport to the respective ends of the steering cylinders.
A bypass orifice is machined into the spool and sleeve assembly. It is a variable orifice that introduces a
small leak into the pressure side of the steering unit. Its purpose is to dampen the initial pressure surge
when the steering wheel is partially turned. When the steering wheel is fully turned, the leak is closed
off.
Return oil flows back in through the left workport through the spool and sleeve assembly to return. The
load sensing orifice is located between the sleeve and the gerotor. This orifice feeds the load sensing
circuit between the steering unit and the priority valve of flow amplifier through the LS port.
When the rotation of the steering wheel stops, the gerotor gear continues to move, turning the sleeve,
until the sleeve stops the flow to the gerotor. At this point, the steering unit is back in the neutral position
and will remain there until the steering wheel is moved again.
The steering unit has a variable steering which is proportional to the speed the steering wheel is rotated.
A variable orifice bypasses oil around the gerotor. Turning the steering wheel slowly takes
approximately seven turn(Variable orifice small) lock to lock versus four turns(Variable orifice large)
when turning the steering wheel quickly.
5-17
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
78035CY01
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 nut(18).
The piston uses a single wear ring(17) with a piston seal(16) to seal between the piston and tube.
The gland seals against the tube with two O-rings(10, 11). The rod is sealed against the gland 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 6-51).
Steering unit check Run engine at low idle. OK

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

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

amplifier) low pressure Check completed.
Hold brake pedal down.
check NOT OK
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
Run engine at high idle. too 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.
5-20
2. TROUBLESHOOTING
※ Diagnose malfunction charts are arranged from most probable and simplest to verify, to least
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.
Failed main pump drive Do main pump flow test.
Remove and inspect priority valve spool.
Stuck priority valve spool
Remove and inspect spring.
Broken priority valve spring
Do priority valve relief cartridge leakage
Relief valve in priority valve stuck open. test in group 3.
No hydraulic functions Shorted boom lower solenoid valve Disconnect wires from solenoid valve and
steering normal ground wire or wrong ground wire check operation of hydraulics.
connected to solenoid.
Boom lower solenoid valve stuck in Remove and inspect solenoid valve.
actuated position
Faulty or misadjusted pilot supply unit Do pilot supply unit test in group 3.
valve
Stuck open system relief valve Replace relief valve.
Locked safety valve Unlock safety valve.
Plugged pilot line filter Inspect and replace.
Failed hydraulic pump Remove and inspect the pump.
Low secodary pressure of RCV Check the pressure and replace if
necessary.
5-21
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.
Low priority valve pressure setting Do priority valve pressure test in group 3.
Clean or replace cartridge in bottom of
priority valve.
Worn hydraulic pump Do hydraulic pump performance check .
Sticking priority valve spool Remove and inspect.
Broken priority valve spring Remove and inspect.
Pinched or restricted LS line Inspect line. Do priority valve LS port
flow test in group 5.
Constant steering to Air in system Check for foamy oil.
maintain straight travel
Leakage in steering system Do steering system leakage check.
Worn steering unit Do steering system leakage check.
Do steering unit neutral leakage test in
group 3.
Leaf spring without spring force or broken Replace leaf springs.
Spring in double shock valve broken Replace shock valve.
Gear wheel set worn Replace gear wheel set.
Cylinder seized or piston seals worn Replace defects parts.
Slow steering wheel Leakage in steering unit gerotor Do steering system leakage check.
movement will not cause
any frame movement Worn steering unit gerotor Do steering leakage check.
Steering wheel can be Leakage in steering system Do steering system leakage check.
turned with frames
against steering stop
Steering wheel turns with Broken steering column or splined Remove and inspect.
no resistance and causes coupling
no frame movement Start engine and check steering operation.
Lack of oil in steering unit
Do steering system leakage test in group
Leakage in steering system 3.
5-22
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 Inspect.

steering wheel does not misalignment of column
immediately return to
High return pressure Check for a pinched or damaged return
neutral when released
line.
Contamination in steering unit Inspect hydraulic filter for contamination.
Repair cause of contamination. Flush
hydraulic system.
Large particles of contamination in Inspect hydraulic filter for contamination.
steering unit Repair cause of contamination. Flush
hydraulic system.
Steering unit locks up ★ Thermal shock Do priority valve LS port flow test in group
5. This oil flow provides a warm -up flow
to steering unit when not using the
steering.
Worn or damaged steering unit Repair or replace steering unit.
Abrupt steering wheel Improperly timed gerotor gear in steering Time gerotor gear.
oscillation unit
Steering wheel turns by Lines connected to wrong port Reconnect lines.

itself
Vibration in steering High priority valve setting Do priority valve pressure test in group 3.
system or hoses jump
★ Thermal stock is caused by a large temperature differential(Approx. 30。 C, 50。

F) between the steering
valve and hydraulic oil. If the steering is not operated for a long period of time and the orifice in the
bottom of the priority valve spool is plugged, the steering valve may bind up when the steering is operated
if the hydraulic oil is hot enough.
5-23
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 Replace leaf springs.
The steering wheel can have therefore reduced spring force
turn on its own.
Inner and outer spools pinch, possibly Clean steering unit or contact the nearest
due to dirt service shop.
Return pressure in connection with the Reduce return pressure.
reaction between differential cylinder and
steering unit too high
Oil is needed in the tank Fill with clean oil and bleed the system.
Steering cylinder worn Replace or repair cylinder.
Gear wheel set worn Replace gear wheel set.
Spacer across cardan shaft forgotten Install spacer.
5-24
Backlash Cardan shaft fork worn or broken Replace cardan shaft.

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

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

steered wheels vibrate. Find and remove the reason for air
(Rough tread on tires collection.
gives vibrations)
Mechanical connections or wheel Replace worn parts.
bearings worn
High priority valve setting pressure Set pressure as regular value.
Steering wheel can be One or both shock valves are leaky or Clean or replace defective of missing
turned slowly in one or are missing in flow amplifier valves.
both directions without
the steered wheels
turning.
Steering is too slow and Insufficient oil supply to steering unit, Replace pump or increase number of
heavy when trying to turn pump defective or number of revolutions revolutions.
quickly. too low
Relief valve setting too low Adjust valve to correct setting.
Relief valve sticking owing to dirt Clean the valve.
Spool in priority valve sticking owing to 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.
5-25
Heavy kick-back in Wrong setting of cardan shaft and gear- Correct setting as shown in service
steering wheel in both wheel set manual.
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 priority valve too weak Replace spring by a stronger.
to turn the steering wheel
Air in LS and / or PP pipes Bleed LS and PP pipes.
Clogged orifices in LS or PP side in Clean orifices in spool and in connecting
priority valve plugs for LS and PP.
Oil is too thick(Cold) Let motor run until oil is warm.
Too little steering force Pump pressure too low Correct pump pressure.
(Possibly to one side
Too little steering cylinder Fit a larger cylinder.
only).
Piston rod area of the differential cylinder Fit cylinder with thinner piston rod or 2
too large compared with piston diameter differential cylinders.
Leakage at either input Shaft defective Replace shaft seal.

shaft, end cover, gear-
Screws loose Tighten screws.
wheel set, housing or top
part. Washers or O-rings defective Replace.
5-26
Amplification too large Dirty, leaky or missing check valve(10). Clean or replace check valve.
Clean and check that the piston moves
Piston(9A) sticks in the open position.
easily.
Amplification too small Piston(9A) sticks in the closed position. Clean and check that the piston moves
easily.
Piston(9A) incorrectly installed Rotate the piston 180°on its axis.
Heavy turning of steering Dirty orifices(34) in directional valve. Clean or replace orifice.
wheel and slow increase
Dirty orifices(35) in the combivalve spool. Clean or replace orifice.
of amplification
Dirty orifice(27) in housing. Clean or replace orifice.
Dirty orifice(36) in LS port. Clean or replace orifice.
Dirty orifice in throttle / check valve(31) in Clean or replace throttle/check valve.
PP port.
Dirty orifice(42) in priority valve. Clean or replace orifice.
No end stop in one or One or both shock valves(21) set too low. Setting takes a long time without special
both directions equipment. Contact the nearest service
shop.
Missing end stop plate(23) for directional Fit end stop plates.
valve.
"Hard" point when Air in LS and/or PP pipes. Bleed pipes.

starting to turn the
Spring(30) force in the built in priority Check or replace of necessary.
steering wheel.
valve too weak.
Orifices in respectively LS or PP ports Take out and clean orifices.
blocked.
LS pressure limitation valve(19) adjusted Remove plug and set to specified

No pressure build-up too low pressure.
Spool and sleeve in steering unit put
together incorrectly Take out spool set and turn the inner spool
180°in the outer sleeve.(See Group 4)
Emergency control ball in steering unit
missing Install new ball.
Pump does not run or is defective Repair or replace pump.
5-27
1. HYDRAULIC OIL CLEAN UP PROCEDURE USING PORTABLE FILTER CADDY

※ Service equipment and tool.
·Portable filter caddy
·Two 3658mm(12ft) × 1" I.D. 100R1
hoses with 3/4 M NPT ends
·Quick disconnect fittings
·Discharge wand
·Various size fittings and hoses
※ Brake system uses oil from hydraulic oil
tank. Flush all lines in the steering
system.
Disassemble and clean major components
for steering system.
Steering components may fail if steering
system is not cleaned after hydraulic oil
tank contamination.
1) If hydraulic system is contaminated due to a
major component failure, remove and
disassemble steering cylinders to clean
debris from cylinders.
2) Install a new return filter element. Clean
filter housing before installing new element.
※ For a failure that creates a lot of debris,
remove access cover from hydraulic oil
tank. Drain and clean hydraulic oil tank
of fill the specified oil to hydraulic oil tank
through upper cover.
3) To minimize oil loss, pull a vacuum in
hydraulic oil tank using a vacuum pump.
Connect filter caddy suction line to drain
port at bottom of hydraulic oil tank using
connector. Check to be sure debris has not
closed drain port.
4) Put filter caddy discharge line into hydraulic
oil tank filter hole so end is as far away from
drain port as possible to obtain a through
cleaning of oil.
5-28
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 210 ℓ
(55.5U.S. gal).
Leave filter caddy operating for the next
steps.
6) Start the engine and run it at high idle.
※ For the most effective results, cleaning
procedure must start with the smallest
capacity circuit then proceed to the next
largest capacity circuit.
7) Operate all functions, one at a time, through
a complete cycle in the following order:
clam, steering, bucket, and boom. Also
include all auxiliary hydraulic functions.
Repeat procedure until the total system
capacity has circulated through filter caddy
seven times, approximately 30 minutes.
Each function must go through a minimum
of three complete cycles for a through
cleaning for oil.
※ Filtering time for machines with auxiliary
hydraulic functions must be increased
because system capacity is larger.
8) Stop the engine. Remove the filter caddy.
9) Install a new return filter element.
10) Check oil level in hydraulic oil tank ; Add oil
if necessary.
5-29
2. TEST TOOLS
1) CLAMP-ON ELECTRONIC TACHOMETER
INSTALLATION
· Service equipment and tools
Tachometer
A : Clamp on tachometer.
Remove paint using emery cloth and B
connect to a straight section of D
injection line within 100mm(4in) of C
pump. Finger tighten only-do not over
tighten.
B : Black clip(-). Connect to main frame. A
C : Red clip(+). Connect to transducer.
D : Tachometer readout. Install cable.
(770-3ATM) 6-49
2) DIGITALTHER MOMETER 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 : Cable. B C
C : Digital thermometer.
(770-3ATM) 6-49
3) DISPLAY MONITOR TACHOMETER

The display monitor tachometer is accurate
enough for test work.
mph
7807A3CD03
5-30
3. STEERING SYSTEM RESTRICTION TEST
· SPECIFICATION
Oil temperature 45±5。 C(113±9。F)
Engine speed High idle
Maximum pressure 2.1MPa(21bar,300psi)
at flow amplifier
· GAUGE AND TOOL
Gauge 0~7MPa(0~70bar, 0~1000psi) 2EA HP
· This test will check for restrictions in the

steering system which can cause
overheating of hydraulic oil.
1) Install temperature reader.
(See temperature reader installation Fitting
procedure in this group).
2) Heat hydraulic oil to specifications.
(See hydraulic oil warm up procedure at
page 6-46). Steering pump
3) Connect fitting and install gauge.
Do not operate steering or loader funct-
ions or test gauge may be damaged.
4) Run engine at specification and read
pressure gauges.
If pressure is more than specification at the
flow amplifier, inspect flow amplifier for a
priority valve spool. Make sure orifice
plugs installed in ends of priority valve spool.
Check for plugged orifice in flow amplifier 7707SE18
LS port.
5-31
4. STEERING UNIT LEAKAGE TEST
· SPECIFICATION
Oil temperature 45±5。 C(113±9。
F)
Maximum leakage 7.5ℓ/min(2gpm)
· GAUGE AND TOOL
Cap fitting
Temperature reader
Measuring container(Approx. 20ℓ)
T
Stop watch L
R
1) Install frame locking bar to prevent machine

from turning.
(See temperature reader installation
(See hydraulic oil warm up procedure at
page 6-46).
4) Disconnect return hose from fitting.
Install cap fitting.
5) Run engine at specifications. Rotate
steering wheel against locking bar using
approximately 1.2kgf·m of force.
Measure oil flow from return hose for 1
minute.
6) Leakage is greater than specifications,
Lock bar
repair or replace steering unit.
7807ASE23
5-32
5. FLOW AMPLIFIER PRESSURE TEST
· SPECIFICATION
Oil temperature 45±5。 C(113±9。 F)
Engine speed High idle Relief valve
Oil pressure 20.1~21.1MPa
(205~215bar, 2900~3100psi)
· GAUGE AND TOOL
Gauge 0~35MPa(0~350bar, 0~5000psi)
Temperature reader
1) Connect gauge to test port.
2) Install temperature reader(See installation
3) Install frame locking bar.
4) Heat hydraulic oil to specifications(See
hydraulic oil warm up procedure at page
6-46).
5) Run engine at specifications and turn
steering wheel rapidly hold approximately
22N(5lb force) pressure on wheel with
frames locked.
※ If steering wheel is turned slowly, it will
continue to with the frames locked.
This will give an incorrect pressure
reading.
If steering wheel continues to turn rapidly
with the frames locked, steering system
leakage is indicated.
6) Read pressure gauge. This is the flow
amplifier relief pressure.
7) If pressure in not to specification, turn
adjusting screw in relief cartridge using a
hex head wrench to adjust pressure.
If pressure cannot be adjusted to Safety lock bar
specification, disassemble and inspect flow 77807ASE07
amplifier.
5-33
6. FLOW AMPLIFIER LS PORT FLOW TEST
· SPECIFICATION
Oil temperature 45±5。 C (113±9。 F)
Engine speed Low idle
LS port flow(Approx.) 1ℓ/min(0.3 gpm)
· GAUGE AND TOOL
Temperature reader
Measuring container EF LS B
Stop watch HP
Flow amplifier LS port flow test will check

PP
for a plugged or missing orifice in the
bottom of the priority valve spool. A plugg- A
ed orifice will block warm up flow to the
steering unit which can cause thermal
shock(See for an explanation of thermal
shock page 5-23).
A missing orifice can cause the pump to be
loaded to high pressure at all times causing
overheating.
1) Install temperature reader(See temperature
reader installation procedure in this group.)
hydraulic oil warm up procedure at page
6-46).
3) Disconnect line from LS port and install
plug(A).
4) Connect line(B) to flow amplifier.
5) Start engine and run at specification.
6) Measure flow from LS port for 1 minute.
If flow is low, low steering system neutral
pressure or a plugged orifice in bottom
priority valve spool is indicated.
If flow is high, remove priority valve spool
and inspect for a missing orifice.
Do hydraulic system restriction test in this
group. 7707SE19
5-34
7.FLOW AMPLIFIER RELIEF CARTRIDGE
LEAKAGE TEST
· SPECIFICATION
Oil temperature 45±5。 C (113±9。 F) A
Maximum leakage 1mℓ/min(16 drops per min)
· GAUGE AND TOOL T
Temperature reader
B
Measuring container
Stop watch
(See hydraulic oil warm up procedure at C
page 6-46).
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, 7707SE20
disassemble and inspect cartridge for

damage or debris.
5-35
1. STEERING(+Fan pump)
1) STRUCTURE(1/2)
P2 CARTRIDGE
27
34 39
35 1
20 26
17 21 22
16 21
P1 CARTRIDGE 19
7807WE28
1 End cap 22 Mounting cap

2 Bushing 26 Section seal
16 Internal snap ring 27 Center housing
17 Ball bearing 34 Section seal
19 Splined shaft 35 Cap screw
20 Shaft seal 39 Cap screw
21 Internal snap ring
5-36
STRUCTURE(2/2)
37
8
36 28
29
7
9
11
6
10
32
25
30
24
31
12
33
5 11
23
4
3
13
2
14
15
P2 CARTRIDGE P1 CARTRIDGE
7807AWE29
2 Section seal 11 Dowel pin

3 Section seal 12 Vane holdout pin 29 Lock pin
4 Back up ring 13 Back up ring 30 Rotor assembly
5 Pressure port plate 14 Section seal 31 Vane holdout pin
6 Camring 15 Section seal 32 Vane
7 Rear port plate 23 Pressure port plate 33 Dowel pin
8 Bush bearing 24 Rotor assembly 36 Screw
9 Rear port plate 25 Vane 37 Screw
10 Camring 28 Lock pin
öDisassembly and assembly : See page 6-58.
5-37
2) 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 2Ýpump 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.
5-38
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.
5-39
2. FLOW AMPLIFIER
1) STRUCTURE
20
5
19
38
6
9 4
A
21 36
21 23
7 2 25
26 7 2829
24
16 34
14 15 12 11
13 27 9C
41 31 2
9A 34
3 24
12 1 35 28
11 29
23
9A 22
13
8 14
30 1
10 9B
40
A 42
37
(770-3ATM) 5-36

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 guide 41 Spring
9C Directional valve 26 Name plate 42 Orifice
10 Check valve 27 Orifice
11 Screw
5-40
2) TOOLS
Â Guide screws : M8Ý1.0
Â Hook : Wire
(770-3ATM) FA001
Â Hexagon keys : 4, 5, 6, 8 and 10mm

Â Ratchet for socket spanners
Â Hex socket for external : 13, 17 & 19mm
Â Hex socket for internal : 8 & 10mm
Â Multigrip pliers
Â Ring spanner : 13mm
Â Screwdrivers : 3 and 10mm
Â Steel Mandrels : 3, 5 and 8mm
Â Torque wrench : 12.2kgfÂm(88lbfÂft)
(770-3ATM) FA002
Â Magnetic rod
3) DISASSEMBLY
(1) Disassembly counter pressure valve
Η Unscrew plug with O-ring(Hexagon
socket for 8mm internal hexagon).
(770-3ATM) FA003
Θ Take out small spring(hook).
(770-3ATM) FA004
5-41
Ι Take out ball(magnetic rod).
(770-3ATM) FA005
Κ Take out piston.
(770-3ATM) FA006
Λ Take out spring.
(770-3ATM) FA007
Μ Counter pressure valve shown disassem-

bled.
(770-3ATM) FA008
5-42
Ν Counter pressure valve with orifice
shown disassembled.
(770-3ATM) FA009
(2) Removing pressure relief valve

Η Unscrew plug with washer(Hexagon
socket for 8mm internal hexagon).
(770-3ATM) FA010
Θ Screw pressure relief valve out(10mm

hexagon key).
(770-3ATM) FA011
Ι Take out washer(Magnetic rod).
(770-3ATM) FA012
5-43
(3) Disassembly pressure relief valve
Η Hold cartridge(Multigrip pliers) and screw
the adjustment screw out(5mm hexagon
key).
(770-3ATM) FA013
Θ Pressure relief valve shown disassembled.
(770-3ATM) FA014
(4) Removing end cover at PP-connection

Η Unscrew screws with spring washer
using hexagon socket for 13mm external
hexagon and 10mm internal hexagon.
(770-3ATM) FA015
Θ Remove end cover.
(770-3ATM) FA016
5-44
Ι Remove stop and 2 springs.
(770-3ATM) FA017
Κ Remove spring.
(770-3ATM) FA018
Ι Remove plate and 6 O-rings.
(770-3ATM) FA019
Κ Remove spring guide.
(770-3ATM) FA020
5-45
(5) Removing end cover at LS-connection
Η Unscrew screws with spring washer
using hexagon socket for 13mm external
hexagon and 10mm internal hexagon.
(770-3ATM) FA021
Θ Remove end cover.
(770-3ATM) FA022
Ι Remove stop and 2 springs.
(770-3ATM) FA023
Κ Remove stop and spring.
(770-3ATM) FA024
5-46
Λ Remove plate and 4 O-rings.
(770-3ATM) FA025
Μ Remove spring guide.
(770-3ATM) FA026
(6) Removing spools

Η Remove directional spool.
(770-3ATM) FA027
Θ Remove amplifier spool.
(770-3ATM) FA028
5-47
Ι Remove priority valve spool.
(770-3ATM) FA029
(7) Removing orifices and throttle check

valve
Η Unscrew orifice in LS-connection with
6mm hexagon key.
(770-3ATM) FA030
Θ Unscrew throttle check valve in PP-

connection with 6mm hexagon key.
(770-3ATM) FA031
Ι Unscrew orifice in housing with 4 mm

hexagon key.
(770-3ATM) FA032
5-48
(8) Removing shock valves
Η Remove shock valve with screwdriver
and hexagon key.
(770-3ATM) FA033
(9) Overview of disassembled parts

Η Housing and end cover with accessories.
(770-3ATM) FA034
Θ Spool with accessories.
(770-3ATM) FA035
(10) Disassembly of directional spool

Η Unscrew orifice with 4mm hexagon key.
Use a mandrel.
(770-3ATM) FA036
5-49
Θ Directional spool shown disassembled.
(770-3ATM) FA037
(11) Disassembly of priority valve spool

Η Unscrew plug or throttle check valve with
8mm hexagon key.
(770-3ATM) FA038
Θ Priority valve spool with plug for external

PP shown disassembled.
(770-3ATM) FA039
Ι Priority valve spool with throttle check

valve for internal PP shown disassembled.
(770-3ATM) FA040
5-50
(12) Disassembly of amplifier spool
Η Carefully remove the spring ring from the
recess with 3mm screwdriver.
ö Avoid damage to the spring ring.
(770-3ATM) FA041
Θ Carefully guide the spring ring back.
(770-3ATM) FA042
Ι Carefully take the spring ring from the

recess and guide it back with 3mm
screwdriver.
ö Avoid damage to the spring ring.
(770-3ATM) FA043
Κ Press pin out gently with finger.
(770-3ATM) FA044
5-51
Λ Take out plug.
(770-3ATM) FA045
Μ Take out spring.
(770-3ATM) FA046
Ν Take out pin 3mm screwdriver.
(770-3ATM) FA047
Ξ Take out inner spool.
(770-3ATM) FA048
5-52
Ο Unscrew check valve with hexagon
socket for 17mm external hexagon and
mandrel in the pin hole.
ö Avoid damaging the spool surface.
(770-3ATM) FA049
Π Unscrew orifice out of plug with 4mm

hexagon key. Use a mandrel.
(770-3ATM) FA050
Ρ Amplifier spool shown disassembled.
(770-3ATM) FA051
(13) Disassembly of check valve

Η Unscrew plug with 4mm hexagon key and
hexagon socket for 17mm external
hexagon.
(770-3ATM) FA052
5-53
Θ Check valve shown disassembled.
(770-3ATM) FA053
(14) Disassembly of shock valve / suction

valve
Η Unscrew locknut with hexagon socket for
13mm external hexagon. Use a mandrel.
ö When readjusting shock valve hold
locknut with 13mm ring spanner.
(770-3ATM) FA054
Θ Take out disc and spring.
(770-3ATM) FA055
Ι Take off housing.
(770-3ATM) FA056
5-54
Κ Unscrew pilot valve with hexagon socket
for 19mm external hexagon. Use a
mandrel.
(770-3ATM) FA057
Λ Take out pilot valve and spring.
(770-3ATM) FA058
Μ Take out spool.
(770-3ATM) FA059
Ν Unscrew adjustment screw and take out

spring and ball.
(770-3ATM) FA060
5-55
Ξ Shock valve / suction valve shown
disassembled.
(770-3ATM) FA061
ö Cleaning
Clean all parts carefully with low aromatic
kerosene.
ö Inspection and replacement
Replace all gaskets and sealing washers.
Check all other parts carefully and
replace if necessary.
ö Lubrication
Before assembly, lubricate all parts with
hydraulic oil.
5-56
4) ASSEMBLY
(1) Assembly of shock valve / suction
valve
Η Guide spring with cone into housing.
(770-3ATM) FA062
Θ Fit adjustment screw.
(770-3ATM) FA063
Ι Fit spool.
(770-3ATM) FA064
Κ Fit spring.
(770-3ATM) FA065
5-57
Λ Fit pilot valve.
Remember O-ring.
(770-3ATM) FA066
Μ Tighten with torque wrench for 19mm

external hexagon. Use a mandrel.
ÂTightening torque : 2 Ü 0.5kgfÂm
(14.5 Ü 3.6lbfÂft)
(770-3ATM) FA067
Ν Fit housing.
(770-3ATM) FA068
Ξ Fit spring.
(770-3ATM) FA069
5-58
Ο Fit disc.
(770-3ATM) FA070
Π Fit locknut.
ÂTightening torque : 1.5 Ü 0.2kgfÂm
(10.8 Ü 1.4lbfÂft)
(770-3ATM) FA071
(2) Assembly of check valve

Η Fit ball, spring and plug.
(3.6 Ü 0.7lbfÂft)
(770-3ATM) FA072
(3) Assembly of amplifier spool

Η Fit orifice in plug.
(3.6 Ü 0.7lbfÂft)
(770-3ATM) FA073
5-59
Θ Fit check valve.
(14.5 Ü 2.2lbfÂft)
ö Avoid damaging spool surface.
Remember O-ring.
(770-3ATM) FA074
Ι Place inner spool in the correct position.
(770-3ATM) FA075
Κ Guide inner spool in.
(770-3ATM) FA076
Λ Fit pin.
(770-3ATM) FA077
5-60
Μ Push spring ring into position. Place
spring ring into the recess with ends
facing away from pin holes.
(770-3ATM) FA078
Ν Fit spring.
(770-3ATM) FA079
Ξ Fit plug.
(770-3ATM) FA080
Ο Fit pin.
(770-3ATM) FA081
5-61
Π Push spring ring into position. Place
spring ring into the recess with ends
facing away from pin holes.
(770-3ATM) FA082
(4) Assembly of priority valve spool

Η Fit plug or throttle check valve.
External PP : Plug.
Internal PP : Throttle check valve.
(7.2 Ü 2.2lbfÂft)
(770-3ATM) FA083
(5) Assembly of directional spool

Η Screw in orifice.
(3.6 Ü 0.7lbfÂft)
(770-3ATM) FA084
(6) Installation of orifice and throttle check

valve
Η Fit orifice in housing.
(3.6 Ü 0.7lbfÂft)
(770-3ATM) FA085
5-62
Θ Fit orifice in LS - connection.
(7.2 Ü 2.2lbfÂft)
(770-3ATM) FA086
Ι Fit throttle check valve in PP -

connection.
(7.2 Ü 2.2lbfÂft)
(770-3ATM) FA087
ö Comments on flow amplifiers with internal PP :

1. 1/4 BSP. F in PP - connection.
Fit washer and plug.
(29.7 Ü 2.2lbfÂft)
2. 7/16 - 20 UNF in PP - connection.
Fit O-ring and plug.
(10.8 Ü 3.6lbfÂft)
(7) Installation of shock valves

Η Guide shock valve in and secure it by
hand.
Remember O-ring.
(770-3ATM) FA088
5-63
(8) Assembly of pressure relief valve
Η Guide adjustment screw, spring and cone
up into the cartridge.
(770-3ATM) FA089
Θ Screw the adjustment screw so far in that

the 10mm hexagon key fully engages.
(770-3ATM) FA090
(9) Installation of pressure relief valve

Η Let the washer drop into the hole.
(770-3ATM) FA091
Θ Fit pressure relief valve.

(22.4 Ü 2.2lbfÂft)
(770-3ATM) FA092
5-64
Ι Fit plug with washer.
(44.1 Ü 3.6lbfÂft)
(770-3ATM) FA093
(10) Installation of back pressure valve

Η First fit spring in piston with vaseline.
Fit assembled piston and spring.
(770-3ATM) FA094
Θ Let the ball drop down.
(770-3ATM) FA095
Ι Fit spring in plug with vaseline.

Fit assembled plug and spring.
Remember O-ring.
(18.8 Ü 2.2lbfÂft)
(770-3ATM) FA096
5-65
(11) Installation of spools
Η Fit directional spool.
Fit priority valve spool.
ö Spring control must be placed in correct
position against LS - connection.
(770-3ATM) FA097
Θ Fit spring.
ö Spring must be by the LS - connection.
(770-3ATM) FA098
Ι Fit amplifier spool.

ö The orifice must be placed in correct
position against LS - connection.
(770-3ATM) FA099
(12) Installation of end cover at PP -

connection
Η Fit spring with vaseline on amplifier spool.
ö The spring must be fitted at the PP -
connection.
(770-3ATM) FA100
5-66
Θ Fit spring guide with vaseline.
(770-3ATM) FA101
Ι Fit large and small springs with vaseline.
(770-3ATM) FA102
Κ Fit guide screws.
(770-3ATM) FA103
Λ Fit 4 large and 2 small O-rings.
(770-3ATM) FA104
5-67
Μ Guide plate in.
(770-3ATM) FA105
Ν Fit stop(Thickness : 5mm) in end cover

with vaseline.
(770-3ATM) FA106
Ξ Guide end cover in.
(770-3ATM) FA107
Ο Fit screw with spring washer.
(770-3ATM) FA108
5-68
Π Fit screws with spring washer.
(18.8 Ü 3.6lbfÂft)
ÂTightening torque : 8.2 Ü 1kgfÂm
for large screw (59.3 Ü 7.2lbfÂft)
(770-3ATM) FA109
(13) Installation of end cover at LS -

connection
Η Fit guide screws.
Fit remote control with vaseline.
(770-3ATM) FA110
Θ Fit large and small springs with vaseline.
(770-3ATM) FA111
Ι Guide in plate with 4 O-rings.
(770-3ATM) FA112
5-69
Κ Fit stop for priority valve spool (thickness :
8mm) with vaseline.
(770-3ATM) FA113
Λ Fit stop for directional spool(Thickness :

5mm) with vaseline.
(770-3ATM) FA114
Μ Guide in end cover.
(770-3ATM) FA115
Ν Fit large screw with spring washer.
(770-3ATM) FA116
5-70
Ξ Fit screws with spring washers.
(18.8 Ü 3.6lbfÂft)
ÂTightening torque : 8.2 Ü 1kgfÂm
for large screw (59.3 Ü 7.2lbfÂft)
(770-3ATM) FA117
Ο Fit plastic plugs.
(770-3ATM) FA118
This completes assembly.
5-71
3. STEERING VALVE
1) STRUCTURE
7707SE21
1 Dust seal ring 9 Cross pin 16 O-ring

2 Housing, Spool, sleeve 11 Shaft 17 End cover
3 Ball 12 Spring set 18 Washer
4 Bushing 13 O-ring 20 Pin screw
5 Lip seal 14 Distributor plate 21 Screw
7 Bearing assy 15 Gearwheel set 32 Check valve
8 Ring
5-72
2) TOOLS
(1) Holding tool.
(770-3ATM) 5-69(1)
(2) Assembly tool for O-ring and kin-ring.
(770-3ATM) 5-69(2)
(3) Assembly tool for lip seal.
(770-3ATM) 5-69(3)
(4) Assembly tool for cardan shaft.
(770-3ATM) 5-69(4)
5-73
(5) Assembly tool for dust seal.
(770-3ATM) 5-70(1)
(6) Torque wrench 0~7.1kgfÂm

(0~54.4lbfÂft)
13mm socket spanner
6, 8mm and 12mm hexagon sockets
12mm screwdriver
2mm screwdriver
13mm ring spanner
6, 8 and 12mm hexagon socket spanners
Plastic hammer
(770-3ATM) 5-70(2)
Tweezers
5-74
3) TIGHTENING TORQUE AND HYDRAULIC CONNECTIONS
(1) Hydraulic connections
L: Left port
R: Right port
T: Tank
TLPR P: Pump
(770-3ATM) 5-71
(2) Tightening torque

Max. tightening torque [ kgfÂm(lbfÂft) ]
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 12Ý1.5 4.1(29.7) 2.0(14.5) 3.1(22.4) 2.0(14.5)
M 18Ý1.5 7.1(51.4) 2.0(14.5) 5.1(36.9) 5.1(36.9)
M 22Ý1.5 10.2(73.8) 3.1(22.4) 8.2(59.3) 7.1(51.4)
5-75
4) DISASSEMBLY
(1) Disassemble steering column from
steering unit and place the steering unit in
the holding tool.
Screw out the screws in the end cover(6-
off plus one special screw).
(770-3ATM) 5-72(1)
(2) Remove the end cover, sideways.
(770-3ATM) 5-72(2)
(3) Lift the gearwheel set(With spacer if fitted)

off the unit.
Take out the two O-rings.
(770-3ATM) 5-72(3)
(4) Remove cardan shaft.
(770-3ATM) 5-72(4)
5-76
(5) Remove distributor plate.
(770-3ATM) 5-73(1)
(6) Screw out the threaded bush over the

check valve.
(770-3ATM) 5-73(2)
(7) Remove O-ring.
(770-3ATM) 5-73(3)
(8) Take care to keep the cross pin in the

sleeve and spool horizontal. The pin can
be seen through the open end of the
spool. Press the spool inwards and the
sleeve, ring, bearing races and needle
bearing will be pushed out of the housing
together.
(770-3ATM) 5-73(4)
5-77
(9) Take ring, bearing races and needle
bearing from sleeve and spool. The outer
(Thin) bearing race can sometimes "stick"
in the housing, therefore check that it has
come out.
(770-3ATM) 5-74(1)
(10) Press out the cross pin. Use the special

screw from the end cover.
(770-3ATM) 5-74(2)
ö A small mark has been made with a

pumice stone on both spool and sleeve
close to one of the slots for the neutral
position springs(See drawing).
If the mark is not visible, remember to
leave a mark of your own on sleeve and
spool before the neutral position springs
are disassembled.
(770-3ATM) 5-74(3)
(11) Carefully press the spool out of the sleeve.
(770-3ATM) 5-74(4)
5-78
(12) Press the neutral position springs out of
their slots in the spool.
(770-3ATM) 5-75(1)
(13) Remove dust seal and O-ring.
(770-3ATM) 5-75(2)
(14) The steering unit is now completely

disassembled.
(770-3ATM) 5-75(3)
ö Cleaning
Clean all parts carefully in Shellsol K or
the like.
ö Inspection and replacement
Replace all seals and washers. Check all
parts carefully and make any
replacements necessary.
ö Lubrication
Before assembly, lubricate all parts with
hydraulic oil.
5-79
5) ASSEMBLY
(1) Assemble spool and sleeve.
ö When assembling spool and sleeve only
one of two possible ways of positioning
the spring slots is correct. There are
three slots in the spool and three holes in
the sleeve in the end of the spool / sleeve
opposite to the end with spring slots.
Place the slots and holes opposite each (770-3ATM) 5-76(1)
other so that parts of the holes in the
sleeve are visible through the slots in the
spool.
(2) Place the two flat neutral position springs

in the slot.
Place the curved springs between the flat
ones and press them into place (see
assembly pattern).
(770-3ATM) 5-76(2)
ö Assembly pattern.
Â Weak springs (Blue)
2 - off flat, blue : Part no. 150-0748
2 - off curved, blue : Part no. 150-0749
Â Blue set
Spare set : Part no. 150-4265
(770-3ATM) 5-76(3)
(3) Line up the spring set.
(770-3ATM) 5-76(4)
5-80
(4) Guide the spool into the sleeve. Make
sure that spool and sleeve are placed
correctly in relation to each other(See page
3-76, No.(1)).
(770-3ATM) 5-77(1)
(5) Press the springs together and push the

neutral position springs into place in the
sleeve.
(770-3ATM) 5-77(2)
(6) Line up the springs and center them.
(770-3ATM) 5-77(3)
(7) Guide the ring down over the sleeve.

ö The ring should be able to rotate free of
the springs.
(770-3ATM) 5-77(4)
5-81
(8) Fit the cross pin into the spool / sleeve.
(770-3ATM) 5-78(1)
(9) Fit bearing races and needle bearing as

shown on below drawing.
(770-3ATM) 5-78(2)
ö Assembly pattern for standard bearings

1
1 Outer bearing race 2
2 Needle bearing 3
3 Inner bearing race
4 Spool
5 Sleeve 4
5
(770-3ATM) 5-78(3)
Installation instruction for O-ring

(10) Turn the steering unit until the bore is
horizontal. Guide the outer part of the
assembly tool into the bore for the spool /
sleeve.
(770-3ATM) 5-78(4)
5-82
(11) Grease O-ring with hydraulic oil and place
them on the tool.
(770-3ATM) 5-79(1)
(770-3ATM) 5-79(2)
(12) Hold the outer part of the assembly tool in

the bottom of the steering unit housing
and guide the inner part of the tool right to
the bottom.
(770-3ATM) 5-79(3)
(13) Press and turn the O-ring into position in

the housing.
(770-3ATM) 5-79(4)
5-83
(14) Draw the inner and outer parts of the
assembly tool out of the steering unit bore,
leaving the guide from the inner part in the
bore.
(770-3ATM) 5-80(1)
Installation instructions for lip seal

(15) Lubricate the lip seal with hydraulic oil and
place it on the assembly tool.
(770-3ATM) 5-80(2)
(770-3ATM) 5-80(3)
(16) Guide the assembly tool right to the

bottom.
(770-3ATM) 5-80(4)
5-84
(17) Press and turn the lip seal into place in the
housing.
(770-3ATM) 5-81(1)
(18) With a light turning movement, guide the

spool and sleeve into the bore.
ö Fit the spool set holding the cross pin
horizontal.
(770-3ATM) 5-81(2)
(19) The spool set will push out the assembly

tool guide. The O-ring are now in
position.
(770-3ATM) 5-81(3)
(20) Turn the steering unit until the bore is

vertical again. Put the check valve ball
into the hole indicated by the arrow.
(770-3ATM) 5-81(4)
5-85
(21) Screw the threaded bush lightly into the
check valve bore. The top of the bush
must lie just below the surface of the
housing.
(770-3ATM) 5-82(1)
(22) Grease the O-ring with mineral oil approx.

viscosity 500 cSt at 20Á
C.
(770-3ATM) 5-82(2)
(23) Place the distributor plate so that the

channel holes match the holes in the
housing.
(770-3ATM) 5-82(3)
(24) Guide the cardan shaft down into the bore

so that the slot is parallel with the
connection flange.
(770-3ATM) 5-82(4)
5-86
(25) Place the cardan shaft as shown - so that
it is held in position by the mounting fork.
(770-3ATM) 5-83(1)
(26) Grease the two O-rings with mineral oil

approx. viscosity 500 cSt at 20ä C and
place them in the two grooves in the gear
rim. Fit the gearwheel and rim on the
cardan shaft.
(770-3ATM) 5-83(2)
(27) Important
Fit the gearwheel(Rotor) and cardan shaft
so that a tooth base in the rotor is
positioned in relation to the shaft slot as
shown.
Turn the gear rim so that the seven
through holes match the holes in the
housing.
(770-3ATM) 5-83(3)
(28) Fit the spacer, if any.
(770-3ATM) 5-83(4)
5-87
(29) Place the end cover in position.
(770-3ATM) 5-84(1)
(30) Fit the special screw with washer and

place it in the hole shown.
(770-3ATM) 5-84(2)
(31) Fit the six screws with washers and insert

them. Cross-tighten all the screws and
the rolled pin.
(22.4 Ü 4.3lbfÂft)
(770-3ATM) 5-84(3)
(32) Place the dust seal ring in the housing.
(770-3ATM) 5-84(4)
5-88
(33) Fit the dust seal ring in the housing.
(770-3ATM) 5-85(1)
(34) Press the plastic plugs into the connection

ports.
ö Do not use a hammer!
(770-3ATM) 5-85(2)
5-89
4. 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
78035CY01
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
5-90
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
(2) Tightening torque

Torque
Part name Item Size
kgfÂm lbfÂft
Gland 3 M115Ý3 60Ü10 434Ü72
Piston 13 M 45Ý2 75Ü8 542Ü58
Piston nut 18 M 45Ý2 100Ü10 723Ü72
Set screw 19 M 10Ý1.5 5.4Ü0.5 39Ü3.6
Bolt 23 M 10Ý1.5 5.4Ü0.5 39Ü3.6
Nut 25 M 10Ý1.5 3.2Ü0.3 23Ü2.2
5-91
3) DISASSEMBLY
(1) Remove cylinder head and piston rod
Η Hold the clevis section of the tube in a
vise.
ö 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.
Θ Pull out piston rod(2) about 200mm

(7.8in). Because the piston rod is rather
heavy, finish extending it with air pressure m
0m
20
after the oil draining operation.
5-88(1)
Ι Loosen and remove the gland(3).

ö Cover the extracted piston rod(2) with rag Wrench
to prevent it from being accidentally
damaged during operation.
3
2
5-88(2)
Κ Draw out gland(3) and piston rod (2)

assembly together from cylinder tube(1).
ö Since the piston rod assembly is heavy in Lift
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
5-88(3)
5-92
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.
Λ Place the removed piston rod assembly

on a wooden V-block that is set level.
ö Cover a V-block with soft rag. Piston rod assy
Wooden block
5-89(1)
(2) Remove piston and gland assembly

Η Remove the set screw(19). 15 14 16 17 13 19 18
Θ Remove the piston nut(18).
Ι Remove piston assembly(13), back up
ring(15) and O-ring(14).
5-89(2)
Ι Remove the gland(3) assembly from Lift with a crane

piston rod(2).
Plastic
ö 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
ö 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 5-89(3)
by the threads of piston rod(2).
5-93
(3) Disassemble the piston assembly
Η Remove wear ring(17). 16 17
Remove and piston seal(16).

ö Exercise care in this operation not to
damage the grooves.
5-90(1)
(4) Disassemble gland assembly

9,8 10 7 12,11 4
Η Remove back up ring(12), and O-ring
(11).
Θ Remove O-ring (10).
Ι Remove snap ring(9) and dust wiper(8).
Κ Remove back up ring(6), rod seal(5) and
buffer ring(7).
ö Exercise care in this operation not to
damage the grooves.
5-90(2)
ö Do not remove seal and ring, if does not
damaged.
5-94
4) ASSEMBLY
(1) Assemble gland assembly
ö Check for scratches or rough surfaces if
found smooth with an oil stone.
Η Coat the inner face of gland(3) with
hydraulic oil.
5-91(1)
Θ 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.
Ι Fit snap ring(9) to the stop face.
5-91(2)
Κ Fit back up ring(6) and rod seal(5), and

buffer ring(7) to corresponding grooves,
in that order.
ö Coat each packing with hydraulic oil
Wrong Right
before fitting it.
ö Insert the backup ring until onside of it is
inserted into groove.
5-91(3)
ö Rod seal(5) has its own fitting direction.

Therefore, confirm it before fitting them. Push bar
ö Fitting rod seal(5) up side down may
damage its lip. Therefore check the
correct direction that is shown in fig.
6
5-91(4)
5-95
Λ Fit back up ring(12) to gland (3).
ö Put the backup ring in the warm water of
4
30~50ä C.
11
Μ Fit O-ring(11) to gland(3).
12
3
10
5-92(1)
(2) Assemble piston assembly

ö Check for scratches or rough surfaces.
Η If found smooth with an oil stone.
13
Coat the outer face of piston(13) with
hydraulic oil.
5-92(2)
Θ Fit piston seal(16) to piston

ö Put the piston seal in the warm water of 16
60~100ä C for more than 5 minutes.
ö After assembling the piston seal, press
its outer diameter to fit in.
5-92(3)
Ι Fit wear ring(17) to piston(13).

Κ Fit back up ring(15) and O-ring(14) to 15 14 17 13
piston(13).
5-92(4)
5-96
(3) Install piston and gland assembly
Η Fix the piston rod assembly to the work Gland assembly
bench. Piston rod
Θ Apply hydraulic oil to the outer surface of
piston rod(2), the inner surface of piston
and gland.
Ι Insert gland assembly to piston rod(2).
5-93(1)
Κ Fit piston assembly to piston rod.

Piston assembly
Piston rod
5-93(2)
Λ Tighten piston nut(18) to piston rod(2).

Â Tightening torque : 100Ü10kgfÂm 2 19 18
(723Ü72lbfÂft)
Tighten set screw(19) to piston nut(18).
Â Tightening torque : 5.4Ü0.5kgfÂm
(39Ü3.6lbfÂft)
5-93(3)
5-97
(4) Overall assemble
Η 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.
Θ 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
5-94(1)
crane.
ö Be careful not to damage piston seal by
thread of cylinder tube.
Ι 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
ö Refer to the table of tightening torque.
Wrench
Gland
5-94(2)
5-98
5. 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
12 18 16 17 18 16 12 17
UPPER LOWER
7704ST07
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
5-99
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
7704ST08
(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
7704ST09
(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
7704ST10
5-100
3) INSPECTION
(1) Check the bearing sliding surface for excessive wear, scorching or scratches; replace if necessary.
Replace all dust seals(11) and O-ring(13) with new ones.
(2)
Grind any pins(10) dented with an oilstone or replace any pins abrasive excessively.
(3)
Check inside cover(4, 5, 6) and collar(2, 3) for dents or scratches; if any damage is found, correct
(4) with a grinder or replace.
The serviceable limit of pins and bushings is shown in the table below.
(5)
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
5-101
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).
ö Apply grease to the lip of the dust seal. 10 13 2
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
7704ST11
(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).
ÂTightening torque : 39Ü4kgfÂm(282Ü29lbfÂft)
ö 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).
ÂTightening torque : 35~38kgfÂm(253~275lbfÂft)
ö 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.
5-102
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
5-103
SECTION 6 WORK EQUIPMENT

Group 3 Tests and Adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-42
Group 4 Disassembly and Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-58
SECTION 6 WORK EQUIPMENT
1. HYDRAULIC SYSTEM OUTLINE

The loader hydraulic system is a pilot operated, open center system which is supplied with flow from
the fixed displacement main hydraulic pump.
The pilot control system is a low pressure, closed center hydraulic system which is supplied with flow
from the first(Steering) pump.
The loader system components are :
ÂMain pump
ÂMain control valve
ÂBucket cylinder
ÂBoom cylinders
ÂPilot supply unit
ÂRemote control valve(Pilot control valve)
ÂSafety valve
The pilot unit supply consists of the pressure reducing valve, relief valve and accumulator.
Flow from the main hydraulic pump not used by the steering system leaves the flow amplifier EF port.
It flows to the inlet port plate of a mono block type main control valve.
The main control valve is a tandem version spool type, open center valve which routes flow to the
boom, bucket or auxiliary cylinders(Not shown) when the respective spools are shifted.
Flow from the steering pump is routed to the pilot supply unit where the steering pump outlet pressure
is reduced to pilot circuit pressure. The pilot supply unit flow to the remote control valve.
The remote control valve routed flow to either end of each spool valve section in the main control
valve to control spool stroke.
A accumulator mounted on pilot supply unit supplies a secondary pressure source to operated
remote control valve so the boom can be lowered if the engine is off.
The return circuit for the main hydraulic system have return filter inside the hydraulic tank. The return
filter uses a filter element and a bypass valve. The bypass valve is located in the upside of filter.
6-1
9 10 11 4 T P
FRONT REAR
B.D/F B.U IN OUT
LH RH LH RH LH RH
17 1 3 4 2 1.1 2.1
19
BL1 BR1 BL2 BR2
6 CL CR
8
T1 P1 T2 P2
L R 3 L1 L2 T
15 15
EF
3B 14 B
3A
T
7 PP P3A
Boom up Boom down
P3B
A
16 B1 A1 B2 A2 21MPa
HP LS HT 2B 24MPa
2A
A3 L 5 R
P2A P2B F2
18 PS T1
Dump Roll back
13
1B 24MPa 24MPa
B 1A
F1
PS1 P1A P1B
12 U
18 24MPa 24MPa
P T 21MPa 4.5MPa
P
T
P T LS
20 3MPa P2
P1
1 2
23
24 25
26 27 T P
22
21
C
7807AWE01
1 Main pump(+Brake pump) 10 Bucket cylinder 19 Pressure switch

2 Steering pump(+Fan pump) 11 Boom cylinder 20 Line filter
3 Main control valve 12 Pilot supply unit 21 Fan drive motor
4 Remote control valve 13 Line filter 22 Oil cooler
5 Steering unit 14 Safety valve 23 Air breather
6 Flow amplifier 15 Accumulator 24 Strainer
7 Cut off valve 16 Accumulator 25 Hydraulic tank
8 Brake valve 17 Pressure switch 26 Return filter
9 Steering cylinder 18 Pressure switch 27 Bypass valve
6-2
3. WORK EQUIPMENT HYDRAULIC CIRCUIT
10 11 4 T P
B.D/F B.U IN OUT
LH RH
1 3 4 2 1.1 2.1
3 L1 L2 T
3B 14 B
3A
P3A P3B
Boom up Boom down A
2B 24MPa
2A
P2A P2B F2
Dump Roll back
13
1B 24MPa 24MPa
1A
F1
P1A P1B
12 U
24MPa 24MPa
21MPa 4.5MPa
P
T
Flow amplifier EF port P1

3MPa P2
Steering system
Brake system
1 2
Return line
23
24 25 T P
26 27
22
C
7807AWE02
1 Main pump(+Brake pump) 11 Boom cylinder 23 Air breather

2 Steering pump(+Fan pump) 12 Pilot supply unit 24 Strainer
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 Bypass valve
6-3
1) WHEN THE RCV LEVER IS IN THE RAISE POSITION
10 11 4 T P
B.D/F B.U IN OUT
LH RH
1 3 4 2 1.1 2.1
3 L1 L2 T
3B 14 B
3A
P3A P3B
Boom Boom down A
up
2B 24MPa
2A
P2A P2B F2
Dump Roll back
13
1B 24MPa 24MPa
1A
F1
P1A P1B
12 U
24MPa 24MPa
21MPa 4.5MPa
P
T
Flow amplifier EF port 3MPa P2

P1
Steering system
Brake system
1 2
Return line
23
24 25 T P
26 27
22
C
7807AWE03
Â When the RCV lever(4) is pulled back, the boom spool is moved to raise position by pilot oil
pressure from port 3 of RCV.
Â The oil from main pump(1) flows into main control valve(3) and then goes to the large chamber of
boom cylinder(11) by pushing the load check valve of the boom spool through center bypass circuit
of the bucket spool.
Â The oil from the small chamber of boom cylinder(11) returns to hydraulic oil tank(25) through the
boom spool at the same time.
Â When this happens, the boom goes up.
6-4
2) WHEN THE RCV LEVER IS IN THE LOWER POSITION
10 11 4 T P
B.D/F B.U IN OUT
LH RH
1 3 4 2 1.1 2.1
3 L1 L2 T
3B 14 B
3A
P3A P3B
Boom up Boom down A
2B 24MPa
2A
P2A P2B F2
Dump Roll back
13
1B 24MPa 24MPa
1A
F1
P1A P1B
12 U
24MPa 24MPa
21MPa 4.5MPa
P
T

3MPa P2
Steering system
Brake system
1 2
Return line
23
24 25 T P
26 27
22
C
7807AWE04
Â When the RCV lever(4) is pushed forward, the boom spool is moved to lower position by pilot
pressure from port 1 of RCV.
Â The oil from main pump(1) flows into main control valve and then goes to small chamber of boom
cylinder(11) by pushing the load check valve of the boom spool through center bypass circuit of the
bucket spool.
Â The oil returned from large chamber of boom cylinder(11) returns to hydraulic tank(25) through the
boom spool at the same time.
Â When the lowering speed of boom is faster, the return oil from the large chamber of boom cylinder
combines with the oil from the pump, and flows into the small chamber of the cylinder.
This prevents cylinder cavitation by the negative pressure when the pump flow cannot match the
boom down speed.
6-5
3) WHEN THE RCV LEVER IS IN THE FLOAT POSITION
10 11 4 T P
B.D/F B.U IN OUT
LH RH
1 3 4 2 1.1 2.1
3 L1 L2 T
A A
3B 14 B
3A
P3A P3B
Boom up Boom down A
2B 24MPa
2A
P2A P2B F2
Dump Roll back
13
1B 24MPa 24MPa
1A
F1
P1A P1B
12 U
24MPa 24MPa
21MPa 4.5MPa
P
T

3MPa P2
Steering system
Brake system
1 2
Return line
23
24 25 T P
26 27
22
C
7807AWE05
Float is achieved by opening 2 large capacity check valves(A) fitted into the bolt on float check
block. These check valves connect each of the boom service ports(3A, 3B) to the tank gallery.
Opening of these valves is controlled by pilot pressure from the hydraulic pilot control valve(4).
As the hydraulic control lever is selected in the power down direction the pressure at the spool pilot
end can on the main valve increases and at some point the spool starts to move progressively
through its stroke. This pilot pressure is also connected, internally within the valve, onto a separate
pilot spool which controls the opening and closing of the pilot check valves(A). As the pilot pressure
operates the main spool up to its maximum stroke the pilot spool then selects at some pressure
beyond that and the check valves open, operating a separate connection between the large
chamber and small chamber ports and tank.
6-6
Subsequent deselection of the control lever allows the pilot spool to deselect, the check valves
close, followed by the main spool returning to neutral, all with minimal hysteresis.
On a four position spool, when selecting the spool in one direction, it has to control both power
down and float. This means that the spool stroke for the power down part of the stroke is limited
and so the metering length is shortened, giving limited control on the service.
Because float is achieved by separate check valves, the whole of the spool selection in that
direction can be used for power down and so the metering performance can be maximized.
Because the float is achieved by opening two large capacity check valves, the ability of the valve to
‘make up’ any cavitation during power down is greatly improved over that of a standard 4 position
spool. The original benchmark of no dead time(cavitation in the boom cylinder small chamber)
while floating down from full lift height at mid engine speed, has been surpassed. The achievement
that has been measured with this product is that there is less than 1 second dead time when
floating down from full height at low idle.
6-7
4) WHEN THE RCV LEVER IS IN THE DUMP POSITION
10 11 4 T P
B.D/F B.U IN OUT
LH RH
1 3 4 2 1.1 2.1
3 L1 L2 T
3B 14 B
3A
P3A P3B
Boom up Boom down A
2B 24MPa
2A
P2A P2B F2
Dump Roll back
13
1B 24MPa 24MPa
1A
F1
P1A P1B
12 U
24MPa 24MPa
21MPa 4.5MPa
P
T

3MPa P2
Steering system
Brake system
1 2
Return line
23
24 25 T P
26 27
22
C
7807AWE06
Â If the RCV lever(4) is pushed right, the bucket spool is moved to dump position by pilot oil pressure
from port 2 of RCV.
Â The oil from main pump(1) flows into main control valve(3) and then goes to the small chamber of
bucket cylinder(10) by pushing the load check valve of the bucket spool.
Â The oil at the large chamber of bucket cylinder(10) returns to hydraulic tank(25) through the bucket
spool.
Â When this happens, the bucket is dumped.
Â 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.
6-8
5) WHEN THE RCV LEVER IS IN THE ROLL BACK(RETRACT) POSITION
10 11 4 T P
B.D/F B.U IN OUT
LH RH
1 3 4 2 1.1 2.1
3 L1 L2 T
3B 14 B
3A
P3A P3B
Boom up Boom down A
2B 24MPa
2A
P2A P2B F2
Dump Roll back
13
1B 24MPa 24MPa
1A
F1
P1A P1B
12 U
24MPa 24MPa
21MPa 4.5MPa
P
T

3MPa P2
Steering system
Brake system
1 2
Return line
23
24 25 T P
26 27
22
C
7807AWE07
Â If the RCV lever(4) is pulled left, the bucket spool is moved to roll back position by pilot oil pressure
from port 4 of RCV.
Â The oil from main pump(1) flows into main control valve(3) and then goes to the large chamber of
bucket cylinder by pushing the load check valve of the bucket spool.
Â The oil at the chamber of bucket cylinder(10) returns to hydraulic tank(25) through the bucket spool.
Â When this happens, the bucket roll back.
Â 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.
6-9
6) WHEN THE RCV LEVER IS IN THE HOLD POSITION
10 11 4 T P
B.D/F B.U IN OUT
LH RH
1 3 4 2 1.1 2.1
3 L1 L2 T
3B 14 B
3A
P3A P3B
Boom up Boom down A
2B 24MPa
2A
P2A P2B F2
Dump Roll back
13
1B 24MPa 24MPa
1A
F1
P1A P1B
12 U
24MPa 24MPa
21MPa 4.5MPa
P
T
Flow amplifier EF port 3MPa P2

P1
Steering system
Brake system
1 2
Return line
23
24 25 T P
26 27
22
C
7807AWE08
Â The oil from main pump(1) flows into main control valve(3).
Â 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.
Â In this condition, each cylinder keeps the neutral position, so the boom and the bucket is holded.
6-10
3. MAIN PUMP OPERATION
1) STRUCTURE
35 36 37 39
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 19
33 34 32 31 30 29 28 25 24 27 26 23 22 21 20
7807AWE09
1 End cap 14 Section seal 28 Dowel pin

2 Section seal 15 Section seal 29 Dowel pin
3 Section seal 16 Retaining ring 30 Rotor assembly
4 Back up ring 17 Ball bearing 31 Vane holdout pin
5 Pressure port plate 19 Shaft 32 Vane
6 Camring 20 Shaft seal 33 Dowel pin
7 Rear port plate 21 Round section ring 34 Section seal
8 Bushing 22 Mounting cap 35 Screw
9 Rear port plate 23 Pressure port plate 36 Screw
10 Camring 24 Rotor assembly 37 Screw
11 Dowel pin 25 Vane 39 Screw
12 Vane holdout pin 26 Section seal
13 Back up ring 27 Housing
6-11
2) DESCRIPTION
The main vane pump consist of six basic components : end cap(2), P2 section unitlzed cartridge(4)
consisting of ; rotor, vanes, vane holdout pins, cam ring, port plate, and pressure plate, center,
housing(5), P1 section unitlzed cartridge(6) consisting of ; rotor, vanes, vane holdout pins, cam ring,
port plate, pressure plate, shaft(11) and bearing and mounting cap(14).
The main vane pump features the use of unitized pumping cartridge for both the P1 and P2 pump
section.
The unitized cartridge assemblies are pretested and provide for ease of disassembly and assembly
in the event it becomes necessary or desirable to make repairs, overhaul or revise the flow delivery.
P1 section
P2 section
14
11
6
5
4
2
7707WE10
3) OPERATION
with fluid.
contact with the cam contour.
ö When operating the pump at the maximum outlet pressure, the pump shaft rotation should not be
allowed to fall below 600rpm in order to maintain proper vane to cam ring contact. The inlet or
suction flow for both the P1 cartridge and P2 cartridge feeds through a common 3 port in the center
housing, through the large ports of each port plate for each cartridge and through the center hole in
the suction zone of each cam ring.
6-12
4. REMOTE CONTROL VALVE
1) STRUCTURE
4,3,1
4 1
10 3 2 12
30
11
2
33 30
4,3,1 14 32
40
15
40
4 1 42
20 3 2
22
21
23 4 1
3 2
25
26
45
7707WE11
1 Handle 14 Shim set 26 Bushing kit

3 Lever kit 15 Joint 30 Plunger kit
4 Bellows 20 Flange 32 Regulating unit
5 Nut 21 Solenoid complete 33 Regulating unit
10 Bracket 22 Plunger kit 40 Spring set
11 Detent kit 23 Plunger guide 42 Prefeel point kit
12 Plunger kit 25 Electric bracket 45 Plug set
6-13
2) OPERATION
T P
B.D/F B.U IN OUT
1 34 2
HYDRAULIC CIRCUIT
(3 Electromagnetic locks)
Electromagnetic lock 9
10
11 5
4
12
(1) Hydraulic functional principle 3
Pilot devices with end position locks operate as 2
7
direct operated pressure reducing valves.
They basically comprise of control lever(1), four T 8
x
pressure reducing valves, housing(6) and locks. P
Each pressure reducing valve comprises of a

control spool(2), a control spring(3), a return 6
spring(4) a plunger(5).
At rest, control lever(1) is held in its neutral position Port 4 Port 2
by return springs(4). Ports(1, 2, 3, 4) are connected 7707WE12
to tank port T via drilling(8).

When control lever(1) is deflected, plunger(5) is pressed against return spring(4) and control
spring(3).
Control spring(3) initially moves control spool(2) downwards and closes the connection between
the relevant port and tank port T. At the same time the relevant port is connected to port P via
drilling(8). The control phase starts as soon as control spool(2) finds its balance between the
force from control spring(3) and the force, which results from the hydraulic pressure in the relevant
port(ports 1, 2, 3 or 4).
Due to the interaction between control spool(2) and control spring(3) the pressure in the relevant
port is proportional to the stroke of plunger(5) and hence to the position of control lever(1).
This pressure control which is dependent on the position of the control lever and the
characteristics of the control spring permits the proportional hydraulic control of the main
directional valves and high response valves for hydraulic pumps.
A rubber bellows(9) protects the mechanical components in the housing from contamination.
6-14
(2) End position lock
Only those control ports, for which it is necessary to hold the control lever in a deflected position
are equipped with end position locks.
Electromagnetic lock
An additional spring(7), which is fitted below an additional plate(12) warns, by means of an
increased force, which is required for compressing this spring, that the plunger(5) and the control
lever(1) have almost reached their end position.
When this threshold is overcome, a ring(10) contacts the solenoid armature(11); if the solenoid is
energized, then control lever(1) is held in its end position by magnetic force.
This lock is released automatically when the solenoid is deenergized.
6-15
5. MAIN CONTROL VALVE
1) STRUCTURE
10 17
7 9
7
11
12
16
13
10
6
14
17
5
7
8
2 15
1 4
6
2
5 12
7707WE30
1 Housing group 10 Pilot valve assembly

2 Main relief valve assembly 11 Pilot operated float check block assembly
3 Double acting spool(Bucket) 12 Adaptor & check valve
4 Double acting spool(Boom) 13 Shuttle valve assembly
5 Bucket spool centering 14 Anti-cavitation check valve assembly
6 Boom spool centering 15 1/4ĥ BSPP plug
7 Combined overload & anti-cavitation assembly 16 Check valve assembly
8 Back pressure valve 17 Pilot valve assembly
9 Check valve assembly
6-16
STRUCTURE
P3A 3A 3B P3B
P2A 2A 2B P2B
L1 L2 T
3B
3A
P3A P3B
Boom up Boom down
2B 24MPa
2A
P2A P2B
Dump Roll back
1B 24MPa 24MPa
1A
P1A P1B
24MPa 24MPa
21MPa
P
7707WE71
Port Port name Port size
P From main pump 1-1/4æSAE split flange

T To hydraulic tank 2æSAE split flange
2A, 2B To bucket cylinder port 1-1/2æsplit flange
3A, 3B To boom cylinder port 1-1/2æsplit flange
P3A, P3B Boom pilot port PF 3/8æfitting
P2A, P2B Bucket pilot port 9/16æ-18 UNF
6-17
2) BOOM SECTION OPERATION
(1) Spool in neutral
L1 L2 T
LH RH
3B
3A
P3B
P3A
Boom up Boom down
2B 24MPa
2A
P2B
P2A
Dump Roll back
24MPa 24MPa
3A 3B Boom spool
P3A P3B
Main relief valve
7707WE72
If the remote control valve is not operated, the oil supplied from the pump port passes through the
neutral passage to the low pressure passage at the outlet section, and then returns to the tank port.
6-18
(2) Boom raise position
L1 L2 T
LH RH
3B
3A
P3A P3B
Boom up
2B 24MPa
2A
P2B
P2A
Dump Roll back
24MPa 24MPa
3A 3B
P3A P3B
7707WE73
When the pilot pressure from remote control valve is supplied to the pilot port(P3A), the spool moves to
the right and the neutral passage is closed.
The oil supplied from the pump flow into boom cylinder port(3A).
The pump pressure reaches proportionally the load of cylinder and fine control finished by shut off of the
neutral passage.
The return oil from cylinder port(3B) flows into the tank via the low pressure passage.
6-19
(3) Boom lower position
L1 L2 T
LH RH
3B
3A
P3B
P3A
Boom down
2B 24MPa
2A
P2B
P2A
Dump Roll back
24MPa 24MPa
3A 3B
P3A P3B
7707WE74
When the pilot pressure from remote control valve is supplied to the pilot port(P3B), the spool moves to
the left and the neutral passage is closed.
The oil supplied from the pump flow into boom cylinder port(3B).
neutral passage.
The return oil from cylinder port(3A) flows into the tank via the low pressure passage.
öB
Boom float position : Refer to page 6-6.
6-20
3) BUCKET SECTION OPERATION
(1) Spool in neutral
L1 L2 T
3B
3A
P3B
P3A
Boom up Boom down
2B 24MPa
2A
P2B
P2A
Dump Roll back
24MPa 24MPa
P2A P2B
Bucket spool
Main relief valve

2A 2B
7707WE75
If the remote control valve is not operated, the oil supplied from the pump port passage through the
neutral passage to the low pressure passage at the outlet section, and then return to the tank port.
6-21
(2) Retract (Roll back) position
L1 L2 T
3B
3A
P3B
P3A
Boom up Boom down
2B 24MPa
2A
P2B
P2A
Roll back
24MPa 24MPa
P2A P2B
2A 2B
7707WE77
When the pilot pressure from remote control valve is supplied to the pilot port(P2B), the spool moves to
the left and the neutral passage is closed.
The oil supplied from the pump flow into bucket cylinder port(2B).
neutral passage.
The return oil from cylinder port(2A) flows into the tank via the low pressure passage.
6-22
(3) Dump position
L1 L2 T
3B
3A
P3A P3B
Boom up Boom down
2B 24MPa
2A
P2A
P2B
Dump
24MPa 24MPa
P2A P2B
2A 2B
7707WE76
When the pilot pressure from remote control valve is supplied to the pilot port(P2A), the spool moves to
the right and the neutral passage is closed.
The oil supplied from the flow into boom cylinder port(2A).
neutral passage.
The return oil from cylinder port(2B) flows into the tank via the low pressure passage.
6-23
6. PILOT OIL SUPPLY UNIT
1) STRUCTURE
5
1
P
2
U
T
6
P2 2
PILOT SUPPLY UNIT
3MPa Port Port name Port size

U
P1 From steering pump 3/4-16UNF
P2 Pluging 3/4-16UNF
4.5MPa
U Supply to RCV lever 9/16-18UNF
T T To hydraulic tank 9/16-18UNF
P1
HYDRAULIC CIRCUIT 7807AWE49
1 Manifold complete 4 Accumulator

2 Reducing valve 5 Gasket
3 Seal kit 6 Relife valve
(2) OPERATION
The pilot supply manifold reduces the pressure from the high pressure circuit to a low pressure
circuit in order to supply the remote control valve.
The accumulator satisfies short term peak power demands and is a source of emergency power
in case of main circuit pressure failures.
The unit consists of the housing, the accumulator(4), the relief valve(6), the check valve and the
reducing valve(2).
The flow path is from the high pressure circuit through port P2 to the pressure reducing valve(2).
The pressure is reduced in the reducing valve(2) and oil passes the check valve into the
accumulator(4) and to the port U, which is connected with the remote control valve.
The pressure relief valve(6) protects the pilot circuit in case of the reducing valve(2) failures or
external increase of pressure.
6-24
7. 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 78036CY02
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
6-25
2) BUCKET CYLINDER
30,32 31,33
20
8,9 5,6 7 3 4 10,11 2 1 21 22 13,14 12 17 15 16 19 18 23 24
7807AWE13
1 Tube assy 12 Piston 23 O-ring

2 Rod assy 13 O-ring 24 Bolt
3 Gland 14 Back up ring 25 Bracket
4 Du bush 15 Piston seal 26 Bolt
5 Rod seal 16 Wear ring 27 Spring washer
6 Back up ring 17 Dust ring 28 U-bolt
7 Buffer ring 18 Lock nut 29 Nut
8 Dust wiper 19 Screw 30 Pin bush
9 Snap ring 20 Bolt 31 Pin bush
10 O-ring 21 Pipe assy 32 Dust seal
11 Back up ring 22 Pipe assy 33 Dust seal
6-26
8. HYDRAULIC OIL TANK
1) STRUCTURE
Â The oil from the hydraulic tank is sent from the pump through main control valve to the cylinders.
In the return circuit, the oil from various parts merges.
Â A part of oil is cooled in the oil cooler, passes through the hydraulic filter and returns to the
hydraulic tank(1).
Â If the hydraulic return oil filter becomes clogged, return filter bypass valve(6) acts to allow the oil to
return directly to the hydraulic tank(1). This prevents damage to the hydraulic filter(5). The
bypass valve(6) is also actuated when negative pressure is generated in the circuit.
4,10,11 13 7 5
14 15 12 1 9 2 8
7807AWE19
1 Hydraulic tank wa 9 Bolt

2 Pipe wa 10 Retaining ring
3 Sight gauge 11 Strainer
4 Air breather 12 Cover
5 Element assembly 13 Cover
6 By pass valve 14 O-ring
7 Spring 15 Bolt
8 O-ring
6-27
2) RETURN OIL FILTER BYPASS VALVE
(1) When the filter is clogged
Bypass valve(1) is opened and the oil
returns directly to the tank without passing 1
through the filter.
ÂBypass valve set pressure : 1.36kg/cm2
(19.3psi)
From MCV
770-3ATM (6-33)
6-28
3) AIR BREATHER
The air breather is equipped with the
capacity to perform three functions Air breather
simultaneously-as an air filter, breathing Element
valve, and as a lubrication opening. Retaining ring
Strainer
(1) Preventing negative pressure inside the
tank
The tank is a pressurized sealed type, so
negative pressure is formed inside the
hydraulic tank when the oil level drops
during operations. When this happens,
the difference in pressure between the
tank and the outside atmospheric
pressure opens the poppet in the
breather, and air from the outside is let
into the tank or prevent negative pressure.
(2) Preventing excessive pressure inside
the tank
When the hydraulic cylinder is being used,
the oil level in the hydraulic system
increases and as temperature rises. If
the hydraulic pressure rises above the set
pressure, breather is actuated to release
the hydraulic pressure inside the tank. 7807AWE66
6-29
9. ACCUMULATOR
The accumulator is installed at the pilot oil
supply unit. When the boom is left the raised
position, and the control levers are operated
with the engine stopped the pressure of the
compressed nitrogen gas inside the
accumulator sends pilot pressure to the
1
control valve to actuate it and allow the boom
2
and bucket to come down under their own
3
weight.
Type of gas Nitrogen gas(N2)
Volume of gas 0.75˶(0.2 U.S.gal)
Charging pressure of gas 16kg/cm2(228psi)
Max actuating pressure 128kg/cm2(1820psi)
1 Diaphragm
2 Closure button
3 Steel pressure vessel
7803AWE56
6-30
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:
ÂChapter 2 : Troubleshooting
ÂGroup 3 : Tests and adjustments
6-31
ö Hydraulic oil must be at operating temperature for these checks(Refer to page 6-46).
Hydraulic system warm- Hold a hydraulic function over OK
up procedure relief to heat oil.(Don't keep relief Check completed.
condition over 5 seconds at a
time)
Refer to page 6-46.
Periodically cycle all hydraulic
functions to distribute warm oil.
Repeat procedure until oil is at
FEEL : Hydraulic reservoir must
be uncomfortable to hold your
hand against.
(approximately 45 ~55ÁC)
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 5-33.
IF OK
Do steering system
leakage check at page
5-30.
IF OK
Do main hydraulic pump
flow test at page 6-47.
Control valve lift check With bucket partially dumped, OK
Run machine at low idle. lower boom to raise front of Check complete.
machine.
NOT OK
Slowly move boom control Repair lift checks in
lever(RCV lever) to boom lower loader control valve.
position.
Slowly move bucket control lever
to bucket dump position.
LOOK : Boom must not raise
before moving down.
Bucket must not rollback before
dumping.
6-32
Bucket rollback circuit Position bucket at a 45Áangle OK
relief valve check against an immovable object. Check complete.
Engage transmission in 3rd speed NOT OK
forward. Replace boom lower
check valve.
LOOK : Bucket angle must not
change.
Bucket dump circuit Raise front of machine which OK
relief valve low pressure bucket at 45Áangle. Go to next check.
check
Backdrag with bucket while NOT OK
observing bucket angle. Do loader system and
circuit relief valve test at
LOOK : Bucket must not rollback
page 6-48.
Pilot control valve float With the bucket partially dumped, OK
check lower boom to raise front of Check complete.
machine.
Run engine at low idle. NOT OK
Push control lever to the float
Do pilot control valve
detent position and release lever.
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
6-33
Boom cylinder leakage Dump bucket until teeth or cutting OK
check edge is perpendicular to the Drift is approximately the
ground. same between first and
Heat hydraulic oil to
second measurement.
operating temperature. Raise boom until cutting edge is
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
1 minute. NOT OK
If drift is considerably less
Wait 10 minutes.
on second measurement,
Measure drift from tooth or cutting repair cylinder.
edge to ground for 1 minute.
LOOK : Compare the drift rate
between the first measurement
and the second measurement.
Bucket cylinder leakage Raise bucket about 1m(3ft) off OK
check ground with bucket level. Drift is approximately the
same between first and
Heat hydraulic oil to Stop engine. Place a support
second measurement.
operating temperature. under boom.
Measure drift from tooth or cutting Repair loader control
edge to ground for 1 minute. valve or circuit relief valve
at page 6-48.
Wait 10 minutes.
Measure drift from tooth or cutting NOT OK
edge to ground for 1 minute. Drift is considerably less
on second measurement.
LOOK : Compare the drift rates
between the first measurement
Repair cylinder.
and the second measurement.
Check valve of safety Put bucket level and position
valve leakage check about 1.2m(4ft) above ground. OK
Check complete.
Heat hydraulic oil to Place a piece of tape on cylinder
operating temperature. rod at least 51mm(2in) from rod
NOT OK
guide.
Check or replace safety
Run engine at low idle in safety-
valve.
release position.
LOOK : Bucket must not drift up.
Pilot control valve Stop engine. Turn key switch to
OFF position.
(RCV lever) check OK
Move control lever to all positions Check completed.
and then release.
NOT OK
LOOK : Lever must return to
Repair pilot control valve.
neutral when released from all
positions.
6-34
Bucket leveler Position bucket fully dumped just OK
(Positioner) check above ground level. Check complete.
Run engine at low idle. Move control lever to bucket NOT OK
leveler detent position and Do bucket leveler checks
release. in group 3.
LOOK : Bucket must rollback to
the level position and control lever
must return to neutral.
If bucket is in a rolled back
position when key is turned ON,
control lever must be returned to
neutral manually if placed in the
bucket leveler detent position.
After bucket is dumped once,
bucket leveler will work normally.
Boom height kickout Position bucket flat on ground. OK
check Check complete.
Move control lever to boom raise
Run engine at low idle. detent position and release. NOT OK
Do boom height kickout
LOOK : Boom must raise to the
check in group 3.
set height and stop.
Control lever must return to
neutral.
Cycle time check Function Operating condition. Maximum cycle time
Heat hydraulic oil to Boom raise Bucket flat on ground to full height. 7.0sec
Boom lower(Foat) Full height to level ground. 3.5sec
Bucket dump Boom at full height. 1.6sec
Bucket rollback Boom at full height. 2.0sec
Steering(No. of Frame stop to frame stop. 3.0sec(4.5 turns)
turns)
OK
Check complete.
NOT OK
Go to slow hydraulic
functions in group 3.
6-35
ö MEASURING BOOM AND BUCKET CYCLE TIME
1. MEASUREMENT CONDITION
ÂCoolant temperature : Inside operating range
ÂSteering position : Neutral
ÂHydraulic temperature : 40~50Á C
ÂBucket : Unloaded
ÂEngine speed : High idling
2. MEASURING TOOL
Â Stop watch(1EA)
3. MEASURING PROCEDURE
1) LIFTING TIME OF BOOM Lifting time of boom
Set the bucket near the maximum tilt back
position and at the lowest position on the
ground. Raise the bucket and measure the
time taken for bucket to reach the maximum
height of the boom.
7807AWE16
2) LOWERING TIME OF BOOM

Set the bucket horizontal with the boom at
Lowering time of boom
the maximum height, lower the bucket and
measure the taken for the bucket to reach
the lowest position on the ground.
7807AWE17
3) DUMPING TIME OF BUCKET

Raise the boom to the maximum height and Dumping time of bucket
measure the time taken for the bucket to Rollback time of bucket
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. 7807AWE18
6-36
2. TROUBLESHOOTING
ö Diagnose malfunction charts are arranged from most probable and simplest to verify, to least
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 reservoir with recommended oil.
Plugged or pinched suction line Clean or replace line.
Air in oil Check for foamy oil. Tighten
connections.
Replace O-rings and or lines.
Plugged suction strainer nspect and clean strainer in reservoir.

Loose or missing hydraulic line clamps Tighten or replace clamps.
Hydraulic lines in contract with frame Inspect and repair.
Worn or damaged pump Do hydraulic pump performance check
in group 2. Do hydraulic pump flow test
in group 3.
No or Slow hydraulic Failed or worn hydrualic pump Do performance check.

functions
Cold oil Warm oil up.
Slow engine speed Adjust engine speed control linkage.
Check high idle speed.
Suction line air leak Check for foamy oil.

Low oil supply Add recommended oil.
Wrong oil viscosity Use recommended oil.
Oil leaking past cylinders or control Check cylinder drift in group 2.
valve
Blocked or damaged line Inspect lines.
Faulty or misadjusted pilot oil supply Do pilot oil supply unit pressure test in
unit group 3.
Faulty pilot control valve(RCV) Do pilot control valve(RCV) pressure
test in group 3.
Binding loader control valve(MCV) Inspect valve.
spool
Faulty flow amplifier Check priority valve, orifice of flow
amplifier specification
6-37
Item Cause Remedy
No steering or hydraulic Low oil level Add recommended oil.

function
Failed hydraulic pump Remove and inspect return filter for
metal pump particles.
Failed main hydraulic pump drive Remove main hydraulic pump and
inspect drive gear.
No hydraulic functions Failed hydraulic pump Remove and inspect return filter for
steering normal metal pump particles, or replace the
pump.
Failed line filter Remove and inspect line filter for RCV.
Faulty safety valve Safety valve leakage test or ON, OFF
function test.
Stuck open port relief valve Replace relief valve.
Boom float function Low pilot control pressure Do pressure reducing valve pressure
does not work test in group 3.
Faulty pilot control valve(RCV) Replace relief valve.
Loader control valve(MCV) spool Do pressure reducing valve pressure
binding in bore test in group 3.
One hydraulic function Faulty pilot control valve(RCV) Do pilot control valve pressure test.
does not work. Inspect and repair valve.
Replace relief valve.
Stuck open port relief valve
Oil leaking past cylinder packings Do boom and bucket cylinder leakage
test in group 3.
Blockage in oil lines or valve Inspect lines for damage.
Disconnect and inspect lines for internal
blockage.
Loader control valve(MCV) spool stuck Inspect and repair valve.

in bore
Low hydraulic power Leakage within work circuit Do cylinder drift check in group 2.
Low system relief valve(main relief Do loader system and port relief valve
valve) setting pressure test in group 3.
Low port relief valve setting Do loader system and port relief valve
Faulty or misadjusted pilot oil supply Do pilot oil supply unit pressure test in
unit group 3.
Leaking system relief valve Remove and inspect valve.
Worn hydraulic pump Do hydraulic pump performance check
in group 2.
Faulty pilot control valve Do pilot control valve pressure test in
group 3.
6-38
Item Cause Remedy
Function drifts down Leaking cylinders Do cylinder leakage checks in group 2.

Leaking seals in circuit relief valve(port Inspect seals. Replace relief valve.
relief valve) or valve stuck open
Leaking loader control valve Repair or replace valve section.
Boom drifts up Leakage in boom down spool Remove and inspect boom down spool.
Boom down does not Safety valve not operated Operate valve.
work(Engine off)
Stuck pilot control valve Inspect.
Faulty line filter Remove and inspect filter.
Accumulation not operated. Inspect.
MCV spool stuck Inspect and repair valve.
Oil overheats Low oil viscosity in hot weather Use recommended oil.
Excessive load Reduce load.
Holding hydraulic system over relief Reduce load.
Leakage in work circuit Do boom and bucket cylinder leakage
test in group 3.
Plugged fins in oil cooler Inspect and clean oil cooler.
Internally plugged oil cooler Do hydraulic oil cooler restriction test in
group 3.
Incorrect system or circuit relief valve Do loader system and circuit relief valve
setting pressure test in group 3.
Restriction in oil lines or loader Inspect for dented or kinked lines.
valve(MCV)
Do hydraulic system restriction test in
group 3.
Pinched or restricted priority valve of Run engine at low idle. Steer machine
flow amplifier "LS" line back and forth. If engine load
decreases while steering, a restricted
"LS" line or priority valve of flow
amplifier malfunction is indicated.
Do priority valve of flow amplifier
"LS" port flow test in group 3.
Malfunctioning flow amplifier Do hydraulic system restriction test in
group 3.
Leaking system main relief valve Remove and inspect valve and seals.
Worn hydraulic pump(internal leakage) Do hydraulic pump performance check
in group 2.
Function drops before Stuck open lift check valve Do control valve lift check in group 2.
raising when valve is
activated
6-39
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.
ö Followings are general precautions for the hydraulic system and equipment.
1) Every structure has its limit of strength and durability. The relief valve is installed to limit the
pressure on the hydraulic equipment and protect various parts of the wheel loader from possible
damage. Therefore, never change the preset pressure of the relief valve unless absolutely
necessary.
2) Since the hydraulic equipment is built with precision, the presence of only the slightest amount of
dust and / or other particles in the hydraulic circuit might cause wear and/or damage, resulting in
unstable functions and/or damage, resulting in unstable functions and/or unexpected accidents.
Therefore, always keep hydraulic oil clean. Periodically, check the filter in the return circuit and
replace the element as necessary.
3) Extract about 200cc of hydraulic oil from the tank as a sample every 6 months. If possible, have it
analyzed by a specialist to confirm that the oil can still be used. Never extract the oil for sampling
until the oil temperature has become the normal operating temperature. Since the replacement
period varies depending on operating conditions, refer to Operator's Manual and change oil.
4) Should the equipment get damaged due to the presence of metal particles and/or foreign matter in
the circuit drain out the hydraulic oil and carry out flushing. Also, replace the filter element and
clean the hydraulic tank. Change the hydraulic oil entirely.
5) When checking the filter, if found metal particles in the element, drain out the hydraulic oil entirely,
flush the whole circuit, and then fill with new oil. The presence of metal particles may indicate
internal damage to the equipment. In such a case, check carefully before flushing, and repair or
replace as required.
6) To add and/or change the hydraulic oil, always use recommended oil.(Refer to the list of
recommended oils and lubricants at page 1-21, Recommended lubricants.) Never mix oil of
different makes of kinds.
7) To change the hydraulic oil, use a clean vessel and funnel for pouring it into the tank. Never use
cloth because it might cause the presence of lint in the circuit.
8) When removing the hydraulic equipment, be sure to put plugs or caps on hoses, tube lines and
ports. Also, enter mating marks for later identification.
6-40
9) Disassemble and/or assemble the hydraulic equipment only in a clean place free of dust. When
disassembling, be careful about the interchangeability of parts, and clean the disassembled parts
with pure and clean mineral cleansing oil. Clean the internal passages as well. After the parts
have dried, wipe them off with a clean lint-free cloth.
10) When overhauling the hydraulic equipment replace all O-rings, backup rings, etc. with new ones.
Assemble O-rings with grease or vaseline applied.
11) After installing the equipment, add more hydraulic oil to make up for that lost during disassembly.
12) Tighten joints correctly. Loose joints will cause the hydraulic oil to leak. If the oil leaks, the tank oil
level drops and air gets sucked in, so the pump will break down. Also loose joints in suction lines
will take air in and might cause abnormal noise, malfunction or damage to pumps.
6-41
1. HYDRAULIC OIL CLEAN UP PROCEDURE USING PORTABLE FILTER CADDY

ö Service equipment and tool
ÂPortable filter caddy
ÂTwo 4000mm Ý 1in 100R1 Hoses
ÂQuick disconnect fittings.
ÂDischarge wand
ÂVarious size fittings.
ö Brake system uses oil from hydraulic oil
tank. Flush all lines in the brake, pilot,
steering system and cut off system.
Disassemble and clean major
components for brake and steering
system. Remove and clean pilot caps
from main control valve.
Brake and steering components may fail
if brake and steering system is not
cleaned after hydraulic oil tank
contamination.
1) If hydraulic system is contaminated due to a
major component failure, remove and
disassemble steering cylinders to clean
debris from cylinders.
2) Install a new return filter element. Inspect
filter housing before installing new element.
ö For a failure that creates a lot of debris,
remove access cover from hydraulic oil
tank. Drain and clean hydraulic oil tank
of fill the specified oil to hydraulic oil tank
through upper cover.
3) To minimize oil loss, pull a vacuum in
hydraulic oil tank using a vacuum pump.
Connect filter caddy suction line to drain
port at bottom of hydraulic oil tank using
connector. Check to be sure debris has not
closed drain port.
4) Put filter caddy discharge line into hydraulic
oil tank filler hole so end is as far away from
drain port as possible to obtain a thorough
cleaning of oil.
6-42
5) Start the filter caddy. Check to be sure oil is
flowing through the filters.
Operate filter caddy approximately 10
minutes so oil in hydraulic oil tank is
circulated through filter a minimum of four
times.
ö Hydraulic oil tank capacity : 210˶(55.5U.S.
gal)
Leave filter caddy operation for the next
steps.
6) Start the engine and run it at high idle.
ö 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.
ö Filtering time for machines with auxiliary
hydraulic functions must be increased
because system capacity is larger.
8) Stop the engine. Remove the filter caddy.
9) Install a new return filter element.
10) Check oil level in reservoir; Add oil if
necessary.
6-43
2. BOOM HEIGHT KICKOUT ADJUSTMENT
1) Lift the boom up to a desired height, set the
boom control lever at hold, then stop the
engine.
Be careful lest work equipment fall down.
Put the hydraulic safety lock lever in the Boom
LOCK position.
Proximate switch
7707WE20
2) Loosen nuts and bolts then tighten them

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

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

Neutral
the ground. Then lift the bucket to a
desired height by using the control lever
and release the hand. Detent position
Confirm the lever automatically returns to
the neutral position and the boom(the
bucket) stop at the adjusted position.
7707WE23
6-44
3. TEST TOOLS
1) CLAMP-ON ELECTRONIC TACHOMETER
INSTALLATION
ÂService equipment and tools
Tachometer
A : Clamp on tachometer.
Remove paint using emery cloth and B
connect to a straight section of injection D
line within 100mm(4in) of pump. Finger C
Tighten only-do not over tighten.
B : Black clip(-). Connect to main frame.
C : Red clip(+). Connect to transducer. A
D : Tachometer readout. Install cable.
(770-3ATM) 6-49
2) DIGITAL THERMOMETER INSTALLATION

ÂService equipment and tools
Digital thermometer
A : Temperature probe.
Fasten to a bare metal line using a tie A
band. Wrap with shop towel.
B : Cable. B C
C : Digital thermometer.
(770-3ATM) 6-49
3) DISPLAY MONITOR TACHOMETER

The display monitor tachometer is accurate
enough for test work.
mph
7807A3CD03
6-45
4. HYDRAULIC OIL WARM UP PROCEDURE
reader installation procedure in this group).
2) Run engine at high idle.
3) Hold a hydraulic function over relief to heat
the oil.
4) Periodically cycle all hydraulic functions to
distribute warm oil.
5) Heat oil to test specification(Approx. 45°
C).
※ Ride control system(Option)

Attention Ride control valve
1) Before carrying out any maintenance work
the accumulators must be unloaded(Zero
pressure). AB
2) For this, unscrew the plug(A) then rotate the
drain screw(B), located under the plug(A), 2
turns anti-clockwise with 3mm L-wrench.
3) The lifting system must firstly be secured
against lowering. 7707AWE21
4) After carrying out maintenance work, screw

the plug(A) and drain screw(B).
·Tightening torque
A : 0.71kgf·m(5.16lbf·ft)
B : 0.36kgf·m(2.58lbf·ft)
6-46
5. MAIN HYDRAULIC PUMP FLOW TEST
Â SPECIFICATION
Oil temperature 45Ü5äC(113Ü9ä F)
Engine speed 2000Ü25rpm
Test pressure 200Ü10bar(2845psi)
Maximum pump flow 482˶/min(127gpm)
Â FLOW METER GAUGE AND TOOL
Temperature reader
To MCV
1) Make test connections. Flow meter

procedure in this group)
(See hydraulic oil warm up procedure in this
group) Hyd tank
4) Run engine at test specifications.
5) Close flow meter loading valve to increase
pressure to test specifications.
6) Read flow meter.
7) If flow is below specifications, check suction
line and suction pressure for abnormality
before removing pump. 7807AWE24
6-47
6. LOADER SYSTEM AND PORT RELIEF
VALVE PRESSURE TEST
Â SPECIFICATION
Oil temperature (40~50ä
C)
Relief valve Engine speed Relief pressure U D

R
210Ü5kgf/cm2
System(M) High
(2987Ü70psi)
Boom 240Ü5kgf/cm2
Low
raise(U) (3414Ü70psi)
Bucket 240Ü5kgf/cm2
Low M
rollback(R) (3414Ü70psi)
Bucket 240Ü5kgf/cm2
Low
dump(D) (3414Ü70psi)
Â Gauge and tool

M : System(Main) relief valve
R : Bucket rollback relief
D : Bucket dump relief
U : Boom raise relief
1) Install fitting and pressure gauge to test port
in pump delivery line. Main pump
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.
7807AWE69
6-48
ö Do not adjust the system relief valve
above 250kg/cm 2 (3560psi). Damage to
the pump will result from excessive
pressure settings.
5) To check the bucket dump, bucket rollback,
and boom raise, adjust the system relief
valve to 250kg/cm2 (3560psi).
Run engine to maintain 800 ~ 850rpm when
hydraulic function is activated over relief.
Activate the function to be checked with the
cylinder bottomed. Read the pressure
gauge.
If pressure is not to specification cycle relief
valve over relief 10 times to flush.
Read pressure gauge again. Turn screw
to adjust valve to specification.
ö Do not work machine with system relief
adjusted above specification or structural
damage may occur.
6) Adjust system relief valve to specification.
6-49
7. HYDRAULIC SYSTEM RESTRICTION TEST
Â SPECIFICATION
Oil temperature 45Ü5ä C(113Ü9äF)
Maximum pressure 2MPa(20bar, 285psi) at EF port
flow amplifier
Maximum pressure at main control valve
1MPa(10bar, 145psi)
Â GAUGE AND TOOL
Gauge 0~7MPa(0~70bar, 0~1000psi) 2EA
This test will check for restrictions in the
hydraulic system which can cause Flow amplifier
overheating of hydraulic oil.
group)
3) Connect fitting and gauge to flow amplifier.
4) Connect fitting and gauge to main control
valve.
Do not operate steering or loader
Hyd tank
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
stuck spool. Make sure orifice plugs are
installed in ends of priority valve spool.
Check for plugged orifice in priority valve
7807AWE68
"LS" port and dynamic signal orifice on flow
amplifier body.
6-50
8. LOADER CYLINDER DRIFT TEST
Â SPECIFICATION A
Oil temperature 45Ü5ä
C(113Ü9ä
F)
Boom horizontal
Bucket horizontal
Bucket unloaded
Item Standard value B
Retraction of boom
40mm A : Retraction of bucket cylinder rod
cylinder rod
B : Retraction of boom cylinder rod
Retraction of bucket
40mm
cylinder rod
Â GAUGE AND TOOL

Stop watch
Temperature reader
Put the safety lock lever in the lock
position.
Do not go under the work equipment.
1) Set the boom and bucket horizontal, then
stop the engine.
2) Stop the engine, wait for 5 minutes, then
start measuring.
3) Measure the amount the boom and bucket
(770-3ATM) 6-55(1)
cylinder rods retract during 15 minutes.
6-51
9. BOOM AND BUCKET CYLINDER LEAKAGE
TEST
Â SPECIFICATION
Oil temperature 45Ü5ä C(113Ü9ä
F)
Maximum leakage 15 m˶/min(1/2 oz/min)
Â 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.
hydraulic oil warm up procedure in this
group).
Never work under raised equipment
unless it is supported with a hoist or
support stands.
3) Full extend the cylinder to be tested. If
testing the boom cylinders, restrain boom in
the fully raised position using a hoist or a
stand.
ö Check cylinders for leakage in the fully
extended position only. In the retracted
position contacts the end of the cylinder
and seals off piston seal leakage.
4) Remove and plug cylinder rod end hose or
line.
5) Run engine at slow idle. Activate control
lever to extend cylinder for 1 minute over
relief while measuring leakage for open
port.
If leakage is within specification, excessive
cylinder drift is caused by leakage in the
loader control valve or circuit relief valve. (770-3ATM) 6-56
6-52
10. PILOT CONTROL VALVE PRESSURE TEST
Â SPECIFICATION
Oil temperature 45Ü5ä C(113Ü9ä F)
Begin metering 1/4" of lever travel
Pressure in detent :
Boom float detent 1.9MPa(19bar)
Pressure at feel position :
Boom power down 19~22bar
Boom raise 19~22bar
Bucket rollback 19~22bar
Bucket dump 19~22bar
Â 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.
ö The FEEL position is when lever is
moved to feel the ramp of the detent
before lever passes into detent position.
1) Lower boom to ground.
2) Connect gauge to the pilot pressure port(A)
of function to be checked.
4) Heat hydraulic oil to specification(See
group). 7707WE67
6-53
5) Run engine at specification. Activate
function to be checked and record pressure
reading.
ö If boom raise or bucket rollback FEEL
positions are not operation due to boom
or bucket position, plug boom float
detent wires into bucket leveler solenoid
or boom height kickout solenoid. This
will provide a feel position on the control
lever.
6-54
11. PILOT OIL SUPPLY UNIT PRESSURE TEST
Â SPECIFICATION
Oil temperature 45Ü5ä C(113Ü9ä F)
Engine speed Low idle and stop
Pilot pressure setting
30~35bar(430~500psi)
Relief valve setting pressure 45bar
Â 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.
U
1) Connect gauge to test port on the screw T P2
coupling.
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.
7707WE26
6-55
12. CYCLE TIME TEST
Â SPECIFICATION
Oil temperature 45Ü5ä C(113Ü9ä
F)
Function Operating conditions Maximum cycle time(seconds)
Boom raise Bucket flat on ground to full height 7.0

Boom lower(float) Full height to ground level 3.5
Bucket dump Boom at full height 1.6
Bucket rollback Boom at full height 2.0
Steering(Number of turns) Frame stop to stop 3.0(4.5 turns)
Hydraulic pump performance cycle time.
Function Operating conditions Maximum cycle time(seconds)

Bucket flat on ground to full height
Boom raise 10.0
while holding steering over relief
6-56
13. HYDRAULIC OIL FILTER INSPECTION
PROCEDURE
1) Lower the bucket to the ground, stop the
engine, move the control lever back and
1
forth several times, and clean all over the
upper surface of the hydraulic oil tank. 2
3
2) Remove the bolts(1) and take out the filter
4
case cover(2) and O-ring(3).
5
3) Remove the spring(4) and bypass valve(5).
6
4) Remove the filter element(6) from the tank.
5) Check the element and the filter case
bottom for debris. Excessive amounts of
brass and steel particles can indicate a
failed hydraulic pump or a pump failure in
process. A rubber type of material can
indicated cylinder packing or other packing
failure.
ö The hydraulic oil filter in the filter case of
the hydraulic oil tank should be replaced
every 250 operating hours or more often.
When the filter element is replaced,
please keep as follows.
(1) Clean the inside of the filter case.
(2) Place new element in the proper positions
inside the filter case.
(3) Install the bypass valve and spring. Make
sure the element stand upright, and check
for complete contact of the element
bottom with the filter case bottom.
(4) Install the O-ring and filter case covers.
Tighten them with bolt. Replace the O-
ring with new one if damaged.sa
7807AWE27
6-57
1. MAIN PUMP
1) STRUCTURE(1/2)
P2 CARTRIDGE
27
34 39
35 1
20 26
17 21 22
16 21
P1 CARTRIDGE 19
7807WE28
1 End cap 22 Mounting cap

2 Bushing 26 Section seal
16 Internal snap ring 27 Center housing
17 Ball bearing 34 Section seal
19 Splined shaft 35 Cap screw
20 Shaft seal 39 Cap screw
21 Internal snap ring
6-58
STRUCTURE(2/2)
37
8
36 28
29
7
9
11
6
10
32
25
30
24
31
12
33
5 11
23
4
3
13
2
14
15
P2 CARTRIDGE P1 CARTRIDGE
7807AWE29
2 Section seal 11 Dowel pin

3 Section seal 12 Vane holdout pin 29 Lock pin
4 Back up ring 13 Back up ring 30 Rotor assembly
5 Pressure port plate 14 Section seal 31 Vane holdout pin
6 Camring 15 Section seal 32 Vane
7 Rear port plate 23 Pressure port plate 33 Dowel pin
8 Bush bearing 24 Rotor assembly 36 Screw
9 Rear port plate 25 Vane 37 Screw
10 Camring 28 Lock pin
6-59
2) GENERAL INSTRUCTION
(1) Preliminary
ö Any servicing work done on main pump is to be done in a clean environment to prevent potential
contamination by foreign particles.
ö 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.
ö To prevent oil leakage and body tilting during assembly, housing bolts are to be tightened as per
the following pattern !
1 3 3 1
5 6
7 4
4 2 2
7803AWE05
(2) Parts
ö 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.
ö In case of replacement of parts with mulitiple numbers, such as vanes and holdout pins, all the
parts are to be changed.
Η 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.
Θ Vane holdout pins :
Holdout pins should have no matting marks.
Vane
Rotor
Pin
7803AWE50
Ι Rotor :
Side surfaces and vane slots should be free of scratches. Side feeds, vane slots and holdout pin
orifices should be free of any contamination. Serration(driving splines) should not be deformed
by the shaft.
7803AWE51
6-60
Κ Camring :
No scratches or vane shock marks(waves) should be seen. Visual axial waves on new camring
are from grinding process and therefore normal.
7803ASE06
Λ 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.
ö Bi-directional cartridges use same port plates for CW and CCW rotation. Unit-directional
cartridges require different port plates.
7803ASE08
Μ Seals :
Â 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.
Â Use seal driver tool to install shaft seal, and protective cone to install shaft assembly.
Â Backup rings(1) on pressure plates are to be replaced, anytime a cartridge is taken out of a
pump. Backup rings are to be installed as follow, behind the square seal :
Back up ring Seal
7803ASE07
Ν Shaft :
Â 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.
Â No axial scratch should be on the sealing area(1). The shaft seal lip contact line may be visible,
but should not be a groove. Bronze-bushing contact area(2) should be clean and cylindrical,
without scratch marks.
6-61
2 4 1
7803ASE10
Â 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.
ö Never insert a snap ring from shaft seal side, to avoid scratching the sealing surface.
ö 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.
Η Before operating the pump again, the following points are to be checked :
Â Pump rotation is as per electric motor or engine.
Â All fittings are properly connected and tight. No oil-leak and/or air intake being allowed.
Â If any, valve on suction line is to be fully opened.
Θ 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.
Ι In case priming does not occur within 15 seconds, equipment should be switched off at once.
Â Then :
Â Manually fill the pump housing with fluid.
Â Bleed off air that may be trapped in the pump.
Â Check air bleed-off valves.
Â Start rotation in a jogging manner until a prime is picked up.
6-62
3) DISASSEMBLY
(1) Install the pump on the table.
ö Two bolts will help to unscrew the 4 pump
bolts.
(2) Unscrew the bolts.
7707WE31
(3) Remove the end cap (P2 cartridge will

come with it).
ö Cartridge : Be careful as some items
could fall if the retaining cartridge bolts are
totally loose or broken.
ö The seal(34) usually stays in the rear cap.
34
7707WE32
6-63
(4) Disassemble the P2 cartridge/end cap
with an extractor.
ö If you want to continue the pump disasse-
mbly(P1 & shaft), go to page 6-65.
ö If you want to reassemble the P2 cartrid-
ge, go to page 6-66.
7707WE33
(5) Put two screws in the housing and flip the

pump (housing + P1 assy).
7707WE34
(6) Remove the bolts.
7707WE35
6-64
(7) Remove the front cap.
ö P1 cartridge will come with the front cap /
shaft assembly.
7707WE36
(8) Disassemble the P1 cartridge / front cap

with an extractor.
7707WE37
A : Remove the retaining ring

B : Extract the shaft / bearing assembly. A
ö Take a protection cone to prevent seal
damage.
If you don’t, change the shaft seal.
ö If not new, the shaft seal should be
replaced.
ö If the shaft ͚ is bigger than the shaft seal B
͚, please contact HYUNDAI.
7707WE38
6-65
(9) The pump is now disassembled.
Housing End cap Cartridge P2 Cartridge P1
Retaining ring Shaft assy Front cap Shaft seal

7707WE39
4) ASSEMBLY
(1) Fit the cartridge P1 into the housing.
7707WE40
(2) Check if the dowel pin is in its position in

the housing by trying to rotate the
cartridge.
ö If the cartridge does rotate, the dowel pin
is not in the hole.
Take the cartridge out and try again.
7707WE41
6-66
A : Protective cone on the shaft assembly.
B : Shaft assembly + protective cone into the
front cap. Slightly rotate the shaft to avoid C
the shaft seal lip(s) to be deteriorated.
C Retaining ring into the front cap.
:
To avoid damaging the shaft seal do not
ö forget to put a protective cone on the B
shaft.
Push on the external bearing cage.
ö
If the shaft ͚ is bigger than the shaft seal
ö ͚, please contact HYUNDAI.
7707WE42
(3) Assemble the front cap assy on the

housing & cartridge assy.
ö Position the shaft / front cap assy only if
the cartridge is well positioned, dowel pin
in the housing dowel pin hole.
ö Put some grease on the seals to prevent
them from moving.
7707WE43
6-67
Η Always check if the shaft rotates freely.
If not, disassemble and go back to the 19.1kgf .m(138lbf .ft)
previous step.
Θ Check the porting configuration.
Ι Tighten the 4 bolts.
1 4
Step by step to
avoid damaging
the seals.
3 2
Κ Always check if the shaft rotates freely.

If not, disassemble and go back to the
previous step.
6.9kgf.m(50lbf .ft)
7707WE44
(4) Fit the cartridge(P2) into the housing.

(5) Check if the dowel pin is in its position in
the housing by trying to rotate the
cartridge.
ö If the cartridge does rotate, the dowel pin
is not in the hole. Take the cartridge out
and try again.
7707WE45
6-68
(6) Assemble the end cap on the housing
assy.
ö
Position the shaft / front cap assy only if
the cartridge is well positioned, dowel pin
in the housing dowel pin hole.
ö
Put some grease on the seals to prevent
them from moving.
ö
Always check if the shaft rotates freely.
7707WE46
(7) Final assembly

Η Always check if the shaft rotates freely.
previous step.
Θ Check the porting configuration.
Ι Tighten the 4 or 7 bolts.
1 4 1 4
6 7
3 2
3 2 5
Κ Step by step to avoid damaging the

seals.
ÂTightening torque
Mounting cap : 19.1kgfÂm(138lbfÂft)
End cap : 6.9kgfÂm(50lbfÂft)
Λ Always check if the shaft rotates freely.
previous step.
7707WE47
6-69
2. MAIN CONTROL VALVE
1) STRUCTURE
10 17
7 9
7
11
12
16
13
10
6
14
17
5
7
8
2 15
4.2kgf.m(30.4lbf.ft)
Spool to be assembled with

identification groove at the
1 B port end
6
2
Spool to be assembled with

identification groove at the
B port end
5 12
7707WE50
1 Housing group 10 Pilot valve assembly

2 Main relief valve assembly 11 Pilot operated float check block assembly
3 Double acting spool(Bucket) 12 Adaptor & check valve
4 Double acting spool(Boom) 13 Shuttle valve assembly
5 Bucket spool centering 14 Anti-cavitation check valve assembly
6 Boom spool centering 15 1/4ĥ BSPP plug
7 Combined overload & anti-cavitation assembly 16 Check valve assembly
8 Back pressure valve 17 Pilot valve assembly
9 Check valve assembly
6-70
2) DISASSEMBLY AND ASSEMBLY
ö Ensure that the machine is in a safe condition with no suspended loads or trapped pressure within
the system before removing any pipework or component.
Servicing must only be carried out by trained personel.
(1) MAIN RELIFE VALVE(Item 2)
Η Removal
Unscrew both the pilot assembly and the plug from both ends of the relief valve. The main stage
assembly must be driven or pressed out in the direction of the pilot assembly using a soft drift.
Θ Refitting
Lubricate sleeve and assemble by pressing into housing until detent ring(12) locates on housing.
Fit the pilot assembly and end cap.
Ι Adjusting
The main relief valve must be adjusted to the required setting when the machine is
recommissioned.
Adjustment is made by first unscrewing the adjuster(1) until there is no load on the pilot
spring(10).
Select a machine service to its end stop.
Screw in the adjuster until the correct pressure setting is measured at the valve inlet, account
must be taken for the effect of back pressure on the measured setting.
8
1
16
3 15.5kgf.m(112lbf.ft)
14
10
5
Pil
ot 7
as
sy
9
12
17
4
6
Ma 15
in 13
sta 11
ge 14
as
sy 2
15.5kgf.m(112lbf.ft) 7707WE51
1 Adjusting screw 7 Sleeve 13 O-ring

2 Plug cap 8 Lock nut 14 O-ring
3 Cap 9 Spring 15 O-ring
4 Seat 10 Spring 16 O-ring
5 Poppet 11 Detent ring 17 Orifice wire
6 Plunger 12 Detent ring
6-71
(2) DOUBLE ACTING SPOOL(Item 3, 4) 4
Control spools are not replaceable as they 3
2
are individually sized to suit the housing.
Bucket spool
When removing and refitting spools
ensure that they are refitted into the 1
correct bore and correctly orientated as
shown by the identification groove location 2
3
on the valve assembly drawing. 4
1 Spool 3 Spring
2 Plunger 4 O-ring
Boom spool
7707WE52
(3) BUCKET SPOOL CENTERING(Item 5)

Remove 4 retaining screws(8) from the spring centring end. Remove the cover(1) and withdraw the
spring pack and spool from the valve.
Hold the spool in a suitable soft clamp being careful not to damage the spool surface or bend the
spool. Remove the spool caps from the spool. The replacement assembly is supplied with the spring
set to the correct load. Refit the spool caps to the specified torque using Loctite 542 or similar
medium strength oil tolerant thread locking product.
8
3.1kgf.m(22.4lb.ft)
2
3
6
10
1 5
3.1kgf.m(22.4lb.ft)
6
9
7
16
4
12
9 15
9.7kgf.m(70.2lb.ft)
17
9.7kgf.m(70.2lb.ft)
7707WE53
1 Cover 6 Spring retainer 12 Spool cap

2 Cap screw 7 Seal retainer 15 Cover
3 Washer 8 Cap screw 16 O-ring
4 Spool cap 9 O-ring 17 Cap screw
5 Spring 10 Shim(0.020, 0.010, 0.005, 0.002inch)
6-72
(4) BOOM SPOOL CENTERING(Item 6)
Remove 4 retaining screws(8) from the spring centering end. Remove the cover(1) and withdraw the
spring pack and spool from the valve.
Hold the spool in a suitable soft clamp being careful not to damage the spool surface or bend the
spool. Remove the spool caps from the spool. The replacement assembly is supplied with the spring
set to the correct load. Refit the spool caps to the specified torque using loctite 542 or similar medium
strength oil tolerant thread locking product.
16
15
17
2
6
8
10,11,13
1
3
6
3.1kgf.m(22.4lbf. ft) 9
7
18
5 4
12
17
15
9.7kgf.m(70.2lbf. ft) 16
9.7kgf.m(70.2lbf. ft)
9
19
14
7707WE54
1 Cover 8 Cap screw 14 Cover

2 Cap screw 9 O-ring 15 O-ring
3 Washer 10 Shim(0.020inch, 2EA) 16 Plug
4 Spool cap 11 Shim(0.005inch, 2EA) 17 Back up ring
5 Spring 12 Spool cap 18 O-ring
6 Spring retainer 13 Shim(0.005inch, 1EA) 19 Cap screw
7 Seal retainer
6-73
(5) COMBINED OVERLOAD AND ANTI-CAVITATION(Item 7)
This is a non servicable item and a replacement unit factory set to the correct setting should be fitted.
Inspect seat in valve housing for damage before refitting.
10
5 3
12
6
9
15 14
13
10
2
4
8
11
1
7
7707WE55
1 Adjusting screw 6 Pilot pin 11 O-ring

2 Pilot housing 7 Thin nut 12 Composite piston seal
3 A/C housing 8 Pilot spring 13 Composite piston seal
4 Pilot poppet 9 Spring 14 A/C check and main housing
5 Main plunger 10 O-ring 15 Return spring
(6) BACK PRESSURE VALVE(Item 8)

This assembly is retained by screws(5)
when replacing the check valve(2) ensure
that it is free to slide in the housing before 1
refitting the blanking plate.
2
4
3 5
1 Blanking plate 4 O-ring

2 Check valve 5 Socket screw
3 Spring
7707WE56
6-74
(7) CHECK VALVE ASSEMBLY(Item 9, 16)
This is a non servicable item and a
7
replacement unit should be fitted. 1
Ensure that orifice in check valve(1) is
6
clear when refitting. Inspect seat in float
5
check block for damage before refitting. 4
8
1 Float check valve 6 Spring
2
2 Housing 7 Composite piston seal
4 O-ring 8 O-ring
5 Back up ring
7.6kgf.m(55lbf.ft)
7707WE57
(8) PILOT VALVE ASSEMBLY(Item 10)

The replacement of this item requires that the float check block is first removed from the valve.
This is a non servicable item and a replacement unit should be fitted.
The logic spool is individually sized to the housing bore in item 12.
Replacement assemblies are supplied factory set.
15
12
11
10
7
9
6
8
5
3
4
17 2
16
1
7707WE58
1 Socket set screw 6 Back up ring 11 O-ring

2 Lock nut 7 Back up ring 12 Logic seat and spool
3 Spring body 8 O-ring 15 Plug
4 Spring 9 O-ring 16 O-ring
5 Spring retainer 10 O-ring 17 Spring guide
6-75
(9) PILOT OPERATED FLOAT CHECK BLOCK ASSEMBLY(Item 11)
Remove the three retaining screws(2) and
lift the block from the main housing. 2 3
Do not slide the block accross the face as
this may damage the sealing face and 1 3
seals. 78
8 7
6
3 3
4 5
1 Float check block 5 O-ring
2 Cap head screw 6 Plug
3 Plug 7 O-ring
4 O-ring 8 Plug
7707WE59
(10) ADAPTER+ORIFICE SCREW+CHECK VALVE(Item 12)
3
4
2
1
1 Adapter
2 Socket set screw
3 Check valve
4 O-ring
7707WE60
(11) SHUTTLE VALVE ASSEMBLY(Item 13)

This is non servicable item and a 0.51kgf.m(3.7lbf.ft)
replacement unit should be fitted.

Inspect seat in float check block for
damage before refitting. 2
3
1 Seat
2 Metric ball
3 O-ring
7707WE61
6-76
(12) A/C CHECK VALVE ASSEMBLY(Item 14)
This is a non servicable item and a
replacement unit should be fitted. Inspect
seat in float check block for damage 4
before refitting. 2
3
1 Body 4 Piston seal 5
2 Check valve 5 O-ring
3 Spring 1
7707WE62
(13) PILOT VALVE ASSEMBLY(Item 17)

The replacement of this item requires that the float check block is first removed from the valve.
This is a non servicable item and a replacement unit should be fitted. The logic spool is individually
sized to the housing bore in item 12.
Replacement assemblies are supplied factory set.
13
12
11
10 4.6kgf.m(33.2lbf.ft)
7
9
68 16
5
4
15
14
16
3
1
2
7707WE63
1 Socket set screw 7 Back up ring 12 Logic seat and spool

2 Hexagon nut 8 O-ring 13 Plug
3 Spring body 9 O-ring 14 O-ring
4 Spring 10 O-ring 15 Spring guide
5 Spring retainer 11 O-ring 16 Plug
6 Back up ring
6-77
3. REMOTE CONTROL VALVE
1) STRUCTURE
2
1
3-1
3-2
Locite 262
3-3
5
11-1
11-2 12-1
4,3,1 12-2
4 1
10 3 2
30
11-3 12-3
11-4 12-4
2
33 30
11-5
11-6
4,3,1 14 32
40
15
40
4 1
20-1 42
20 3 2
22
21
23 4 1
3 2
25
26
7707WE64
1 Handle 11-4 Cardan 21 Solenoid

2 Push button 11-5 Armature 22 Intermediary plunger kit
3-1 Locking pin 11-6 Spring ring 23 Intermediary plunger
3-2 Bent lever 12-1 Counter nut guide
3-3 Nut 12-2 Spring ring 25 Electric bracket
4 Rubber boot 12-3 Switch plate screw 26 Bushing
5 Locking nut 12-4 Press screw 30 Plunger kit
10 Cardan bracket 14 Shims(0.1, 0.2, 0.5mm) 32 Regulation unit
11-1 Self-locking nut 15 Cardan 33 Regulation unit
11-2 Washer 20 Flange 40 Return spring
11-3 Washer 42 Prefeeling point kit
6-78
2) DISASSEMBLY AND ASSEMBLY
(1) PUSH BUTTEN
ö The remote control valve does not need to be removed from the machine to perfom this operation.
Remove worn pushbutton using a small screwdriver.
The installation of new elements is performed without any special tools; the parts are simply
pressed into place.
(2) RUBBER BOOT
Η Remove the remote control valve from the machine or free the valve by unscrewing the 4 screws
fixing the plate in order to release the electrical cable.
ÂAssembly
Torque : 1.02kgfÂm(7.4lbfÂft)
Hold the remote control valve using a vice or a vice-grip wrench(clamp onto the body).
ö The pilot unit does not need to be removed from the machine to release the cable. However, it is
recommended to lift the control unit by undoing the 4 fixing screws on the arm rest.
ö It is unnecessary to remove the units with no electrical functions.
Θ Lift and turn the boot inside out.
Ι Remove the grommet(7) from its emplacement to free the cable.
Κ Loosen the handle mounting nut(3-3) using a 19mm open-end wrench.
ÂAssembly : torque 4.08kgfÂm(29.5lbfÂft)
Λ Unscrew and remove the handle(1).
ÂAssembly
- Add loctite 262 onto the lever thread
- Torque : 4.08kgfÂm(29.5lbfÂft)
Μ Replace the faulty rubber boot(4) with a new one.
Ν Replace the handle(1) following the disassembly instructions in reverse order.
(3) HANDLE
Η Clamp the threaded section of the lever(3-2) in a vice fitted with V-shaped vice clamp.
Θ Remove the pin(3-1) using a 5mm pin driver.
Ι Replace the lever(3-2) onto the new handle(1) and secure it with the pin(3-1) using a 5mm pin
driver.
ö Respect the position of the curved lever to ensure that the handle is correctly oriented as
indicated by the machine’s technical specifications.
Κ Replace the nut(3-3) on the threaded section and replace the boot(4).
6-79
(4) DETENT CARDAN BRACKET KIT
ö Remove the 2 grommets(20-1) from the W
flange (20).
V
ö Place centering sleeves V & W to avoid
damaging the cardan knuckles while
loosening the nuts.
ö Unscrew the locking nut(5) using a
23mm open-end wrench.
ÂAssembly : Torque 4.08Ü0.4kgfÂm
(29.5Ü2.9lbfÂft)
Η Unscrew the self-locking nut(11-1) using Before loosening the nuts
a 13mm open-end wrench.

ÂAssembly W
- Torque 1.02kgfÂm(7.4lbfÂft)
- Place centering sleeves(V-W) to
avoid damaging the cardan knuckles
while screwing the nuts.
Θ Remove : - Friction washer(11-2) V
- Friction washer(11-3)
- Cardan/armature assembly
7707WE65
(11-4 ~ 11-6)
(5) NON-DETENT PLUNGER KIT

Η Unscrew the self-locking nut(12-1) using a 13mm open-end wrench.
ÂReassembly : - Torque 1.02kgfÂm(7.4lbfÂft)
- Place centering sleeves(V-W) to avoid damaging the cardan knuckles while
screwing the nuts.
Θ Undo the snap ring(12-2) using a flat-end screwdriver.
Ι Remove the screw assembly(12-3, 12-4)
(6) CARDAN
Η Remove the centering sleeves V & W.
Θ Remove the cardan bracket(10) and the shims(14).
Ι Unscrew the cardan(15) using a 17mm open-end wrench.
ÂReassembly : - Ungrease the cardan threads
- Add loctite 262 onto the cardan threads(both end)
- Torque 4.08kgfÂm(29.5lbfÂft)
(7) SOLENOID AND CONNECTOR
ö It is advised to mount the connector onto the solenoid cable once the remote control valve is
assembled.
Η Remove the flange(20) and the electrical bracket(25),
Θ Remove the protecting bushes(26) from the electrical bracket(25).
Ι Undo the solenoid(21) from the electric bracket(25).
Κ Replace the solenoid.
ö Clean the polar face using a piece of cloth and pay attention not to hit them.
Λ Assembly : Place the solenoid cable in its emplacement on the electric bracket before fitting the
protection bushes.
6-80
(8) INTERMEDIARY PLUNGER KIT
Η Undo the intermediary plunger guide(23).
Θ Remove and replace the intermediary plunger kit assembly(22).
(9) GUIDE / PLUNGER AND REGULATION UNIT
ö Beware of the plungers that might jump out due to the spring return.
Η Remove : - Guide/plunger assembly(30).
- Regulation unit(32/33).
- Return spring(40).
- Pre-feeling point kit(42).
Θ The remote control valve is now totally disassembled.
Assemble in reverse order following the torque specification.
6-81
SECTION 7 ELECTRICAL SYSTEM
Group 1 Component Location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-1

Group 2 Electrical Circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
Group 3 Monitoring System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-22
Group 4 Electrical Component Specification - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-38
Group 5 Connectors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-45
Group 6 Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-62
SECTION 7 ELECTRICAL SYSTEM
GROUP 1 COMPONENT LOCATION
1. LOCATION 1
1
2
Cab roof
LH Side
Front
3 11 14
4 15
12
Cab roof 5 16
13
17
6 18
7
8 19
A
9
10
20
21
22
23
ECM
24
O R
NS
SE T
OR POR
AT
TU
AC T
R
M PO
OE T
R
PO
7807AEL02
1 Radio & cassette(STD) 9 Hazard switch 18 Clutch cut off switch

Radio & CD player(OPT) 10 Kick down switch 19 Transmission control unit(TCU)
2 Aircon & heater switch 11 Starting switch 20 Fuse box
3 Rear wiper/washer switch 12 Ride control switch(Option) 21 Relay board
4 Mirror defrost switch(Option) 13 Pump motor switch(Option) 22 Cigar lighter
5 Beacon switch(Option) 14 Parking brake switch 23 12V socket
6 Kick down switch 15 Main light switch 24 Engine control module(ECM)
7 Horn button 16 Work lamp switch
8 Multi function switch 17 Auto select switch
7-1
2. LOCATION 2
3 2 1
6 7
4
8
15 14 13 12 11 10
7807AEL23
1 Proximity switch 6 Work lamp 11 Number plate lamp

2 Head lamp 7 Switch panel 12 Back up buzzer
3 Front turn lamp 8 Alternator 13 Rear combi lamp
4 Proximity switch 9 Work lamp 14 Battery
5 Horn 10 Master switch 15 Fuel sender
7-2
1. ILLUMINATION CIRCUIT
1) OPERATING FLOW
Fuse box (No.2) Illumination switch [CS-21(1)] Switch ON, 1st step
[CS-21(7)] All switch indicator lamp ON
[CS-21(5)] Fuse box(27) I/conn [CN-4(12)] LH Combi clearance lamp ON [CL-15(4)]
I/conn [CN-10(6)] RH Head lamp ON [CL-4(3)]
I/conn [CN-15(10)] Cluster [CN-56(17)] All cluster gauge and
LCD lamp ON
Hazard switch indicator lamp ON
Fuse box(28) I/conn [CN-4(10) Number plate lamp ON [CL-21(2)]
RH Combi clearance lamp ON [CL-14(4)]
I/conn [CN-10(7)] LH Head lamp ON [CL-3(3)]
2) CHECK POINT
Engine Key switch Check point Voltage
① - GND (Switch input)

② - GND (Switch output)
OFF ON 20~25V
③ - GND (To light)
④ - GND (To cluster)
※ GND : Ground
7-5
ILLUMINATION CIRCUIT
FUSE BOX
BEACON/RR WORKLAMP 20A
1
10 OrW ILL.LAMP 20A
2
11 YW HEAD LAMP 20A
3
BACK/STOP LAMP 10A
4
24
CLUSTER 10A
25
CASSETTE 10A
26
7 ROr ILLUMINATION LAMP 5A
27
6 RW ILLUMINATION LAMP 5A
28
CN-36
R 35
LH HEAD LIGHT
3 1 Lo
1 2 Hi
14 G
2 3 C
G32 B
3 4 E
2 4 CL-3
5
ILL & HEAD LAMP SW 7A ROr ROr 13
6
B G35 6A RW RW 14
9 10 10 R 1H
7 RH HEAD LIGHT
9 8 3 1 Lo
4 8 9 2 Hi
2 R 1 13 ROr
7 10 3 C
7 G31 B
1 6 11 4 E
5 R 35
5 12 CL-4
4
YW 11
13
3
B G31 NUMBERPLATE LAMP
3 14 36A RW
II I 0
2 2
15 G1 B
OrW 10 1
1 CN-10
CS-21 CL-21
3
1
1 2 RH COMBI REAR
3 36 RW
4 C
4
3 T
5 G4 B
2 E
6
ALL SWITCH INDICATOR LAMP ON 1 S
7
CL-16
8
6 RW
9
RW 36 3 LH COMBI REAR
10
38 ROr
11 4 C
7 ROr ROr 38
12 3 T
G6 B
13 2 E
14 1 S
CN-4 CL-15
CLUSTER
20 RS232 RX
12 19 GND
11 18 NC
7E BOr 7A BOr
10 17 ILLUMINATION
9 16 F/R SIGNAL
8 15 SERIAL-L
14 SERIAL-H
7
4 6
13 NC
12 GND
5 11 GND
4 10 RS232 TX
9 PROGRAM DUMP
3
8 NC
2 7 MIRROR HEATED
1 6 HIGH BEAM
CN-15 5 RH TURN
10 10 7 BOr
4 LH.TURN
3 BATT 24V
2 IG 24V
CS-41
1 IG 24V
9
8
6 7
6
5 5
4
3
2
1
CN-56
8
2
7
1
9
HAZARD SW
7807AEL03
7-6
2. HEAD LIGHT CIRCUIT
1) OPERATING FLOW
Fuse box(No.3) Head light switch [CS-21(4)] Light switch ON, 2nd step [CS-21(2)]
I/conn [CN-16(7)] Multi function switch [CS-11(8)]
Multi function switch MIDDLE [CS-11(7)] I/conn [CN-16(6)] I/conn [CN-10(8)]
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-16(5)] I/conn [CN-10(2)]
LH Head light high beam ON [CL-3(2)]
RH Head light high beam ON [CL-4(2)]
I/conn [CN-15(7)]
Cluster high beam pilot lamp ON [CN-56(6)]
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
7-7
HEAD LIGHT CIRCUIT
FUSE BOX
BEACON/RR WORK LAMP 20A
1
ILL.LAMP 20A
2
11 YW HEAD LAMP 20A
3
BACK/STOP LAMP 10A
4
24
TCU 10A
25
CLUSTER 10A
26
ILLUMINATION LAMP 5A
27
ILLUMINATION LAMP 5A
28
CN-36
LH HEAD LIGHT
15A GW
1 Lo
7 12A V
2 Hi
3 C
ILL & HEAD LAMP SW 1 G32 B
58 V V 12 4 E
2
9 10 10 1
9 3 CL-3
4 8 4
2 RH HEAD LIGHT
7 5 6 15 GW
1 Lo
7 1 6 6 12 V
5 2 Hi
5 7 G31 B
11 YW GW 15 3 C
4 8
134 GW 4 E
3 9
161 W
II I 0
2 13 CL-4
B G31
1 14
CS-21 15
CN-10
2
CLUSTER
20 RS232 RX
19 GND
CN-16
18 NC
10
11
12
13
14
1
2
3
4
5
6
7
8
9
17 ILLUMINATION
16 F/R SIGNAL
15 SERIAL-L
14 SERIAL-H
13 NC
12 12 GND
11 11 GND
10 10 RS232 TX
9 PROGRAM DUMP
9 8 NC
68A V 8 10 V 7 MIRROR HEATED
7 6 HIGH BEAM
6 5 RH TURN
5 4 LH.TURN
3 BATT 24V
4 2 IG 24V
4 3 1 IG 24V
4 2
GW
YW
CN-56
W
3 1
5
25
22
23
24
CN-15
8
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
7807AEL04
7-8
3. WORK LIGHT SWITCH
1) OPERATING FLOW
※ Illumination switch : ON position
(1) Work lamp switch ON (1st step)
ILL & head lamp switch [CS-21(7)] Work lamp switch indicate lamp ON
Work lamp switch [CS-36(1)→(7)]
Front work lamp relay[CR-3(30)→(87)] I/conn [CN-7(2)]
RH Front work lamp ON [CL-5(2)]
LH Front work lamp ON [CL-6(2)]
(2) Work lamp switch (2nd step)
Work lamp switch [CS-36(4)→(2)] Rear work lamp relay [CR-55(30)→(87)]
I/conn [CN-4(14)] LH Rear work lamp ON [CL-22(2)]
RH Rear work lamp ON [CN-23(2)]
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
7-9
WORK LIGHT SWITCH
FUSE BOX
5 G BEACON/RR WORK LAMP 20A
1
10 OrW ILL.LAMP 20A
2
HEAD LAMP 20A
3
BACK/STOP LAMP 10A
4
HORN/CONVERTER 30A
5
AIR-CON/HEATER 30A
6
CIGAR LIGHTER/MIRROR 30A
7
SWITCH 30A
8
WIPER 20A
9
15 Gr FR WORK LAMP 30A
10
EMER STEER/RIDE CON 20A
11
CN-36
OPT
FRONT WORK LAMP
RW 2F
2
B G24
1
CL-36
FRONT WORK LAMP
RW 2E
2
B G23
1
2 CL-35
FR WORK LAMP RY 1 RW 2 FRONT WORK
86 30 87a 2 LAMP,LH
B G16 3 RW 2A
85 2
RW 171 4 B G22
87 1
G 170 5 CL-6
85 87 87a
86
Gr 15 6 3
30 7 FRONT WORK
B G21
CR-3 8 LAMP,RH
RW 2
2
1 9
10
B G21
1
11 CL-5
12 OPT
13 REAR WORK LAMP
R 10 R 10
14 2
B G25
15 1
2 CN-7 CL-32
RR WORK LAMP RY REAR WORK LAMP
86 30 87a R 10A 2
B G17 1 B G26
85 2 1
R 63
87 3 CL-33
L 180
86 4
85 87 87a Gr 5 REAR WORK
30 5
LAMP,LH
CR-55 6 40A R
7 2
G3 B
1 8 1
WORK LAMP SW 9 CL-22
B G36 10
9 10 10
9 R 1G 11 4
4 8 12 REAR WORK
2 G 170 13 LAMP,RH
7 R 40 40 R
14 2
7 1 6 G2 B
15 1
5 5
R 1F CN-4 CL-23
4
G1
3
L 180
II I 0
2
1 R 1E
CS-36 EARTH 1
CS-21
9 10 10
9
4 8
2 R 1
7
7 1 6
5 5
4
3
II I 0
2
OrW 10
1
ILL & HEAD LAMP SW : ON(1st step)
7807AEL5
7-10
4. STARTING CIRCUIT
1) OPERATING FLOW
Battery(+) terminal Fusible link [CN-60(1)→(2)] Master switch [CS-74]
I/conn [CN-1(1)] Fuse box (No.15) Start switch [CS-2(1)]
ECM power relay [CR-25(30)]
Power relay [CR-35(30)]
※ The gear selector lever is neutral position. It is necessary condition before the starting.
The gear selector has an output signal which is activated whenever the shift lever is in the neutral
position. This signal can be used to control a relay and prevent engine from starting whenever the shift
lever is not in the neutral position.
(1) When start key switch is in ON position
Start switch ON Start switch [CS-2(2)] I/conn [CN-3(9)] Battery relay [CR-1]
Battery relay operating(All power is supplied with the electric component)
Start switch [CS-2(3)] ECM power relay [CR-25(30)→(87)] Fuse box[No.21]
I/conn [CN-2(6)] I/conn [CN-12(10)]
OEM port 50P[CN-93(38)]
Power relay[CR-35(30)→(87)] Fuse box[No.23]
MCU[CN-58(12)]
(2) When start key switch is in START position
Start switch START [CS-2(5)] Start safety relay [CR-5(30)→(87)] I/conn [CN-3(4)]
[CN-13(8)] Start relay [CR-23] Starter(Terminal B and M connector of start motor)
+
2) CHECK POINT
① - GND (Battery B+)

② - GND (Fusible link)
③ - GND (Start key B terminal)
④ - GND (Start key BR terminal)
Running ON ⑤ - GND (I/conn CN-3(9)) 20~25V
⑥ - GND (Start key ST terminal)

⑦ - GND (Start safety relay output)
⑧ - GND (MCU)
⑨ - GND (Start key ACC terminal)
※ GND : Ground
※ ECM : Electronic control module
7-11
STARTING CIRCUIT
T/M CONTROL UNIT MCU
HYD TEMP SENDER
FAN CLUTCH +
CLUTCH CUT-OFF PS
SAFETY RY
COOLANT TEMP
WIPER RY
STEERING RY
ALT LEVEL
FUEL SENSOR
PREHEATER
SERIAL-H
NEUTRAL SIG
FAN CLUTCH -
ADM2-JOYSTICK SELECT LAMP(-)
ELEC STEERING
ADM5-JOYSTICK SELLECTER(+)
CLUTCH CUT-OFF SW
SERIAL-L
GND
AUTO SEL.SW
ADM1-START INTERLOCK RY(-)
AIR FILTER
IG 24V
ED9-CLUTCH CUT-OFF SW(+)
ADM4-REVERSE DRIVE RY(-)

ED6-SHIFT LEVER X2D-NEU
ED2-SHIFT LEVER X1B-B2
VPE2-CONTINUANCE 24V
FUSE BOX
ED14-NEU-JOYSTICK
ED13-REV-JOYSTICK
ED8-FWD-JOYSTICK
10
11
17 G NEUTRAL RY/JOYSTICK F/R 10A
12
PREHEATER 30A
22
23
35
34
24
36
31
26
25
32
33
27
30
29
28
11
12
10
13
14
SAFETY RY 13
X-1 G 17 TURN LAMP
30 14
65
85 W 66
67
68
44
31
35
52
59
VM A CN-58
112 YW
OUTPUT SIGNAL
5
7
27 RW
K
73 BOr
G 17A 85 3R 34
86 87a 87
CASSETTE/ROOM LAMP 5A
VP F B N D B CN-157 15
BOr 73 21 3Or START KEY
ED 1 2 3 4 1 2 3 4 1 2 3 4 C 8 87
30A
16
AD1 B1 D BOr 88 TCU 10A
AD2 B2
85 17
CN-158 ECM 10A
AD3 B3 87a 30 86 18
AD4 V X-2 CR-5 CLUSTER/MCU 10A
19
AD5 R A 1 AC & HEATER 20A
SAFETY RY 20
AD6 AS B 2 GrW 157
30 26 WOr ECM 10A
AD7 C 3 21
85
86 87a 87
W 33 BOr 73A RCV
A AD3 D 4 10A
BW 151 22
B AD2 CN-159 5 87 27 RW MCU 10A
Or 104 23
C AD1 6 85 10A
TCU
D AD7(KD) 7 24
X1 87a 30 86 CLUSTER 10A
8 25
A ED1(VP) 9 7 CR-5 CASSETTE 10A
26
D AD6 10 ILLUMINATION LAMP 5A
B AD4 27
11 5A
ILLUMINATION LAMP
C AD5 12 28
X2
13
14 CN-36
CN-17 MASTER SW
34 3R 1 5R
1 2
2 1
CS-74 FUSIBLE LINK
CN-1 2 5W CN-60
2
69 5W
1
2
BATTERY
BATT RY CN-95
66 G
G12 B
CR-1
1 G 66E
2
1
2 L 22 STARTER
1
3 B+
BW 18 DO-3
4 G 66A
YW 19 2
5 B G13
6 1 M
7 DO-2 CN-45
G 66
8 2
L 22 L 22 START RY
9 1
21E Or
153 L
157 GrW
65 G
DO-1 20 BW
9 4 10
11
5
12 5
6 3 6 CR-23
CN-3
7
21 3Or
G14 B
31 3Br
65A G
G15 B
32 3Y
65 G
21A Or
CS-2
8
5
4
1
6
2
3
9 ECM OEM PORT 50P

1 48 ACCEL POSITION SUPPLY 5V
CR-35
CR-25
87a 85 87 86 30 87a 85 87 86 30 B 10
0, I 2 09
1
11 SWITCH RETURN
87a 87a 3 46 J1939 (+)
12
30 87 30 87 4 37 J1939 (-)
86 86 H 0 I II CN-13
85 85 5 9 36 J1939 SHIELD
4
6
5
3
2
8 WOr LW 10 8 G
C ST ACC BR
H
6 10 38 KEY SW "ON"SIGNAL
POWER RY ECM POWER RY START SWITCH 7 11 18 BATTERY 24V
8 12 CN-93
9 13
10 14
11 15
12 CN-12
CN-2
7807AEL06
7-12
5. CHARGING CIRCUIT
When the starter is activated and the engine is started, the operator releases the key switch to the ON
position.
Charging current generated by operating alternator flows into the battery through the battery
relay(CR-1).
The current also flows from alternator to each electrical component and controller through the fuse
box.
1) OPERATING FLOW
(1) Warning flow
Altermator [CN-74(2)] I/conn [CN-13(9)] I/conn [CN-3(5)] MCU[CN-58(25)]
Cluster charge warning lamp ON
(2) Charging flow
Alternator Starter [CN-45(B+)] Battery relay [CR-1]
Battery(+) terminal Charging
Fusible link [CN-95(1)→(2)] I/conn [CN-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 2)
⑤ - GND (MCU)
⑥ - GND (Fuse box)
※ GND : Ground
7-13
CHARGING CIRCUIT
MCU FUSE BOX

HYD TEMP SENDER

CLUTCH CUT-OFF PS
SPEEDMETER SIG.
RIDE CONT. AUTO

SAFETY RY
COOLANT TEMP
BUZZER STOP
ELEC STEERING
WIPER RY
STEERING RY
ALT LEVEL
FUEL SENSOR
TACHO SENSOR+
PREHEATER
SERIAL-H
MAIN PUMP PS
WASH SIG
NEUTRAL SIG
CAN-H
AUTO SEL.TCU
CAN-L
CLUTCH CUT-OFF SW
STEERING P/P PS
RIDE CONT. ON
WIPER INT SIG
PARKING SIG
SERIAL-L
GND
BUZZER
AUTO SEL.SW
FAN CLUTCH +
BRAKE PS
TAHCO SENSOR -
AIR FILTER
IG 24V
FAN CLUTCH -
1
ILL.LAMP 20A
2
HEAD LAMP 20A
3
BACK/STOP LAMP 10A
4
HORN/CONVERTER 30A
5
AIR-CON/HEATER 30A
6
CIGAR/MIRROR 30A
23
35
34
24
36
31
26
25
32
33
27
21
20
30
29
28
22
17
19
11
18
16
12
10
13
15
14
MASTER SW
1
2
3
6
8
4
5
7
9
7
SWITCH 30A
CN-58 8 1 3R
112 YW
WIPER 20A 34 3R 2
9
1
33 5W
FR WORK LAMP 30A 2 1
10
5 EMER STEER/RIDE CON 20A CN-1 CS-74
2 5W
FUSIBLE LINK
CN-60
11 2
NEUTRAL RY/JOYSTICK F/R 10A 69 5W
12 1
PREHEATER 30A
13
6 CN-95
BATTERY
TURN LAMP 20A
BATT RY
14
CASSETTE/ROOM LAMP 5A
15
START KEY 30A
16
TCU 10A
17 CR-1 1
ECM 10A
18
2
CLUSTER/MCU 10A
19 STARTER
AC & HEATER 20A
20 M
ECM 10A
21
RCV 10A
22
MCU 10A B+
23
TCU 10A
CN-45
24
CLUSTER 10A
1
25 2
CASSETTE 10A
26 3
ILLUMINATION 5A
27 4
ILLUMINATION 5A
28 1 5
2 6
CN-36
3 7
8 28 R
4 2
112 YW 19 YW YW 21 21A YW 3W/300
5 9 1
6 10 RS-1
15 R CN-74
7 11
28 R
8 12 B+
G
9 CN-13
21 YW
3 1 P
3~
10 2 L
3 FI U
11
4 NC
12 4
ALTERNATOR
13
14
15
CN-3
7807AEL07
7-14
6. ELECTRIC PARKING, DECLUTCH CIRCUIT
1) OPERATING FLOW
(1) Parking OFF
Fuse box (No.8) Parking switch OFF [CS-17(6)→(8)] Parking solenoid ON (Activated)
Parking brake released (By hydraulic pressure)
(2) Parking ON
Fuse box (No.8) Parking switch ON Parking solenoid [CN-71] OFF
Parking brake applied [By spring force]
[CS-17(5)→(7)] T/M control unit [CN-157(21)]
T/M declutch
(3) Declutch ON
Fuse box (No.8) Clutch cut-off switch ON Clutch cut-off switch [CS-42(5)→(1)]
MCU [CN-58(10)→(29)] Service brake applied Service brake pressure switch
ON [CD-5] T/M control unit [CN-157(66)] Declutch
2) CHECK POINT
① - GND (Parking switch input)

② - GND (Parking switch output)
③ - GND (Parking switch input)
Running ON 20~25V
④ - GND (Parking switch output)
⑤ - GND (Parking solenoid)
⑥ - GND (Pressure switch clutch cut-off)
※ GND : Ground
7-15
5
7
2
9
9
9
8
8
7
2
7
2
1
1
II I 0
6
6
PARKING SW
5
5
4
1
2
3
4
5
1 6
7
4 8
9
10 10
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
10 10
10 10
CS-17
CS-42
CLUTCH CUT-OFF SW
R 1
ELECTRIC PARKING, DECLUTCH CIRCUIT
R 1N
3
OrW 10
R 1R
2
B G38
Y 127
B G34
YW 50
WOr 3A
FUSE BOX[CN-36(2)]
WOr 3F
WOr 3E
OrW 119
ILL & HEAD LAMP SW : ON(1st step)
1
19 EF1-SPEED PICK-UP ENG
20 ED3-SHIFT LEVER-X1A-B3
50 YW
21 ED10-PARKING BRAKE SW(+)
22 ED7-SHIFT LEVER-X1D-KD
23 VPE1-CONTINUANCE 24V
25 CANF_H
T/M CONTROL UNIT
26 CANF_L
27 CANF_T
28 VGS-CAN SHIELD
63 ED1-SHIFT LEVER X1C-B1

CN-71 64 ED5-SHIFT LEVER X2C-REV
65 ED2-SHIFT LEVER X1B-B2
B G25 84 Gr
66 ED9-CLUTCH CUT-OFF SW(+)
1 2
PARK
Y 127
67 ED6-SHIFT LEVER X2D-NEU
SOLENOID
CN-157
68 VPE2-CONTINUANCE 24V
7-16
CD-26
2
Pa 70E B
1
125 V
PARK PS
CD-5
Pa 2
G 109
1
Gr B4
CLUTCH
CUT-OFF
6
NEUTRAL SIG
MCU
SAFETY RY
CN-58
PREHEATER
WIPER RY
STEERING RY
SERIAL-H
3 WOr
109 G SERIAL-L
CLUTCH CUT-OFF PS
36 35 34 33 32 31 30 29 28
FUEL SENSOR
119 OrW AUTO SEL.SW

CLUTCH CUT-OFF SW
CN-36
WIPER
TACHO +
SWITCH
ILL.LAMP
11 10 9 8
FUSE BOX
WIPER INT SIG

HEAD LAMP
RIDE CONT. ON
RIDE CONT. AUTO
CIGAR/MIRROR
AIR-CON/HEATER
BACK/STOP LAMP
WASH SIG
HORN/CONVERTER
7 6 5 4
BUZZER STOP
3
125 V STEERING P/P PS

10A
10A
10A
30A
20A
20A
20A
20A
PARKING SIG
2
1
2 1
7
3
9
8
4
6
5
BRAKE PS
7807AEL08
7. WIPER AND WASHER CIRCUIT
1) OPERATING FLOW
Fuse box (No.9) Wiper relay [CR-4(30)→(87a)] I/conn [CN-17(9)]
Front wiper motor [CN-21(1)]
Wiper relay Lo [CR-26(86), (87)]
I/conn [CN-15(8)] Multi function switch [CS-12(6)]
I/conn [CN-8(1)] Rear wiper & washer switch [CS-35(1)]
Rear wiper motor [CN-102(1)]
(1) Front washer switch ON
① Washer switch ON [CS-12(6)→(2)] Washer tank [CN-15(12)] Washer operating
MCU [CN-58(5)→(33)] Front wiper relay Lo
[CR-26(87)→(30)] I/conn [CN-17(13)]
Front wiper motor [CN-21(5)] Wiper motor operating(Low)
(2) Front wiper switch ON
① INT position
Wiper switch ON [CS-12(6)→(1)] I/conn [CN-15(13)] MCU [CN-58(8)→(33)]
Wiper relay Lo [CR-26(87)→(30)] I/conn [CN-17(13)] Front wiper motor [CN-21(5)]
Front wiper motor intermittently operating
② Lo position
Wiper switch ON [CS-12(6)→(4)] I/conn [CN-15(10)] Wiper relay Lo [CR-26(87a)→(30)]
I/conn [CN-17(13)] Front wiper motor [CN-21(5)] Front wiper motor operating (Low)
③ Hi position
Wiper switch ON [CS-12(6)→(3)] I/conn [CN-15(11)] Wiper relay Hi [CR-4(30)→(87)]
I/conn [CN-17(12)] Front wiper motor [CN-21(4)] Front wiper motor operating(High)
(3) Auto-parking(When switch OFF)
Switch OFF Fuse box (No.9) Wiper relay Hi [CR-4(30)→(87a)] I/conn [CN-17(9)]
Front wiper motor [CN-21(1)→(2)] Multi function switch [CS-12(5)→(4)] I/conn [CN-15(10)]
Wiper relay Lo [CR-26(87a)→(30)] I/conn [CN-17(13)] Front wiper motor [CN-21(5)]
Wiper motor stop
(4) Rear wiper and washer switch
① Wiper switch ON(1st step)
Wiper switch ON [CS-35(1)→(6)] I/conn [CN-8(4)] Rear wiper motor [CN-102(5)]
Rear wiper motor operating
② Washer switch ON(2nd step)
Washer switch ON [CS-35(1)→(3)] I/conn [CN-8(2)] Rear washer tank [CN-103(2)]
Washer operating
7-17
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
7-18
CS-35
B G8
9 10 10 1
9 2
W 15
3 8 3
7 4 6 5 Lo M
8 Or 16 5 Or 164
6 6 5 4 Hi
1 6 4
5 7 B G4
3 1B
10
4 8 W 165
0,I
V 14 2 2Pf
3 L 14E
REAR WIPER
CN-8 1 3E
2 CN-102
WIPER AND WASHER CIRCUIT
L 13
II I 0
REAR WIPER & WASHER SW

1
8
2
36 NEUTRAL SIG
MCU
35 SAFETY RY
34 PREHEATER
105 GOr
33 WIPER RY
32 STEERING RY
CN-22 31 SERIAL-H
B G2
M 1 30 SERIAL-L
Gr 69
2 29 CLUTCH CUT-OFF PS
28 FUEL SENSOR
FRONT WASHER
27 HYD TEMP SENDER
CN-103 26 COOLANT TEMP
B G3
M 1 25 ALT LEVEL
V 166
2 24 FAN CLUTCH -
23 FAN CLUTCH +
22 GND
21
REAR WASHER
BUZZER
20 SPEEDMETER SIG.
19 CAN-L
18 CAN-H
17 AUTO SEL.TCU
16 TAHCO SENSOR -
15 MAIN PUMP PS
14 ELEC STEERING
13 AIR FILTER
12 IG 24V
11 AUTO SEL.SW
10 CLUTCH CUT-OFF SW
8 9 TACHO SENSOR+
120 LW
Hi 7 8 WIPER INT SIG
F Lo
6 7 RIDE CONT. ON
L 6 RIDE CONT. AUTO
O 5 69A G
R 5 WASH SIG
4
5B 4 BUZZER STOP
B+ 3
3 STEERING P/P PS
2 2 PARKING SIG
7-19
1 1 BRAKE PS
CN-58
MULTI FUNCTION SWITCH

CS-11
8 WB
7 Y Lo W6
Hi
2 BW L
BWG 4
3 BG C
R
II
1
9
I
0
6
J 0 G 5
CS-12 7
II BVi 3 14F L
6 8
I L 4
5 9
162 G
4 10
J BY 1 163 Br
3 11
C RW 6 59 Gr
2 12
W Gr 2 120 LW
1 13
14
HO Y CN-15
CS-5
7
14 L
1
2
3
4
WIPER
SWITCH
ILL.LAMP
5
FUSE BOX
6
HEAD LAMP
7
CIGAR/MIRROR
38 VOr
CN-21
FR WORK LAMP
8 8 W
AIR-CON/HEATER
BACK/STOP LAMP
3E 1 9
HORN/CONVERTER
2Pf 2 10 G61 B
1B 3 11
30A
10A
20A
30A
20A
30A
30A
20A
30A
172 G
4 12
173 R
2
1
7
3
9
8
4
6
5
10
4 Hi 5 13
CN-36
FRONT WIPER
M
5 Lo 6 14
CN-17
5
8 W
8A W
173 R
162 G
6
105 GOr
14A L
BE W
172 G
G13 B
163 Br
4
3
85
87
86
30
85
87
86
30
87a
CR-4
87a
CR-26
30 86
30 86
87a 87 85
87a 87 85
WIPER RY LO
WIPER RY HI
7807AEL09
HAZARD, TURN AND ROTARY CIRCUIT
1
2
3 1
4 REAR COMBI RH 2
5 3
4 C
6 37 Or 4 BEACON LAMP
3 T 22 GY
7 G33 B 5
2 E G1 B FUSE BOX
8 1 S 6 5 G BEACON/RR WORK LAMP 20A
ILL & HEAD LAMP SW 1
9 CL-16 7 CL-7 ILL. LAMP 20A
10 8 2
66A Or HEAD LAMP 20A
11 REAR COMBI LH 9 3
BACK/STOP LAMP 10A
12 4 C 10 4
67A Y 39 Y HORN/CONVERTER 30A
13 3 T 11 5
G31 B
14 2 E 12 AIR-CON/HEATER 30A
6
CN-4 1 S
13 CIGAR/MIRROR 30A
CL-15 7
14 SWITCH 30A
8
15 WIPER 20A
CN-7 9
FR WORK LAMP 30A
10
11
NEUTRAL RY/JOYSTICK F/R 5A
12
PREHEATER 30A
13
TURN LAMP 20A
14
RADIO/ROOM LAMP 5A
15
START KEY 30A
FLASHER UNIT 16
BrW 158 TCU 10A
1 L 17
R 19
2 B G CN-36
B G51
3 E
CN-16
CLUSTER
7
6
5
4
3
2
1
CR-11
20 RS232 RX
19 GND
18 NC
17 ILLUMINATION
16 F/R SIGNAL
15 SERIAL-L
14 SERIAL-H
13 NC
12 GND
11 GND
10 RS232 TX
9 PROGRAM DUMP
8 NC
7 MIRROR HEATED
2E Or 6 HIGH BEAM
5 RH TURN
4 LH.TURN
1E Y 3 BATT 24V
2 IG 24V
1 IG 24V
CN-56
1
2 COMBI LH
G2 B
11 ROr
3 1
12 W
16 Y
20 G
4 2
5 CL-24
CS-12
CS-11
CS-5
6
6
5
4
3
2
1
8
7
6
5
4
3
2
1
7
8 COMBI RH
67 Y G3 B
BWG 4
RW 6
W6
BVi 3
L 4
G 5
BY 1
Gr 2
66 Or 17 Or
3E BrW
3A BrW
10 2
Y
22 GY
2A Or
G2 B
G7 B
7H R
1A Y
11 CL-25
9 G
HO
12
W
II
I
Hi
C
J 0
J
C
CN-10
0
II
CS-41
I
CS-23
Lo
10 10
10
9
8
7
6
5
4
3
2
1
9
8
7
6
5
4
3
2
1
Hi
B+
F
10
5
6
R
L
O
R
L
7 Y Lo
8 WB
2 BW
3 BG
5B
9
8
2
7
1
8
2
7
1
HAZARD SWITCH BEACON LAMP SWITCH MULTI FUNCTION SWITCH
7807AEL10
7-20
GROUP 2 ELECTRICAL CIRCUIT
5W 33 MCU
BRAKE PS PARKING
3R 34 EM'CY PUMP MOTOR SW PS WARNING
MECHANICAL ENG(GND)
STEERING RY RESISTER
3Br 31 BUZZER
2
R 35
HYD TEMP SENDER
CLUTCH CUT-OFF SW
TACHO SENSOR+
CLUTCH CUT-OFF PS
TACHO SENSOR-
SPEEDMETER SIG.
AIR COND."ON"SIG
B
Pa
RIDE CONT. AUTO
Pa
A
REVERSE FAN SOL
STEERING P/P PS
REVERSE FAN SIG
3Y 32
ELEC.STEERING
PROGRAM DUMP
COOLANT TEMP
FAN CLUTCH+
RIDE CONT. ON
FAN CLUTCH-
AUTO SEL.TCU
MAIN PUMP PS
WIPER INT SIG

FUEL SENDOR
85
86
AUTO SEL.SW
STEERING RY
STOP LAMP PS
NEUTRAL SIG
POWER IG(NC)
POWER IG(NC)
PARKING SIG
MULTI SW- LIGHT COM
FUEL HEATER
PREHEATER
HOUR METER
CLUSTER SERIAL GND
CD-26
OPTION PS 2
OPTION PS 1
CLUSTER HIGH BEAM
SAFETY RY
87a 87
MULTI SW- WIPER Lo
AIR FILTER
30
CD-3
MULTI SW- WIPER Hi
ALT LEVEL
MULTI SW- WASHER
WIPER RY
BRAKE PS
WASH SIG
CLUSTER SERIAL-Lo
CN-26
CLUSTER SERIAL Hi
SERIAL-H
2
SERIAL-L
2
1
CN-98
1
RS232 RX
RS232 TX
BUZZER
6
MULTI SW- HORN
TURN LAMP COM
10
WIPER MOTOR Lo
1
10
ATT. UNLOCK SW
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
WIPER MOTOR Hi
MIRROR HEATED
OPTION
OPTION
OPTION
OPTION
MULTI SW- COM
WIPER MOTOR B
CAN-H
IG 24V
2
MULTI SW- Hi IG
1
CAN-L
OTMP1
C
B
TURN LAMP RH
A
LIGHT Lo BEAM
Bat24V
CR-37
TURN LAMP LH
LIGHT Hi BEAM
CS-75
SPARE
MULTI SW- INT
GND
CLUSTER GND
ODP2
ODP1
87a
ATT. LOCK SW
ILLUMINATION
CN-170
X2B-FWD-ED4
GND
ATT. SW COM
X2D-NEU-ED6
30
10A
20A
20A
20A
10A
30A
30A
20A
30A
20A
30A
20A
30A
20A
30A
10A
10A
10A
10A
10A
10A
10A
CLUSTER F/R
10A
86
X2C-REV-ED5
85
87
X1C-AD1-ED1
10A
20A
X1B-AD2-ED2
X1A-AD3-ED3
5A
5A
5A
10
1
2
3
8
9
B
7
6
NC
X1D-KD-ED7
70E B
V
L
RW
2
1
BATT. 24V
W
CN-58
G
V
CN-59
70A
125
126
EM'CY STEERING/RIDE CON.
BEACON/REAR WORK LAMP
CIGARLIGHTER/MIRROR
CASSETTE/ROOM LAMP
X2A-VP
IG 24V
27
26
24
23
21
28
25
20
36
35
34
33
32
31
30
29
22
19
11
17
14
GrW
18
16
15
13
12
10
6
7
5
4
3
2
1
23
22
21
20
8
OrW
9
OrW
19
18
17
16
15
14
13
12
11
10
53G
B
9
8
7
52F
5
27A
6
3
B
4
GND
115
G
ILLUMINATION LAMP
ILLUMINATION LAMP
NC
NC
FRONT WORK LAMP
HORN/CONVERTER
NC
NC
NC
NC
NC
NC
NC
NC
G
G19 B
64E Or
G23
AIR-CON/HEATER
BACK.STOP LAMP
AIR-CON/HEATER
G11 B
G41
G40
PRE-HEATER 1
OrW
GrW
GrW
WOr
GOr
GOr
GOr
PRE-HEATER 2
16A
BOr
BOr
106
174
CLUSTER/MCU
24A ROr
177
BOr
174
RW
GW
BW
YW
128
15
14
13
12
11
10
LW
SEAT
11
12
W
10
15
14
13
12
11
10
Or
Or
Or
7
1L
9
8
Or
B
9
8
7
6
5
4
Br
4
3
2
1
3
2
1
W
72A Br
L
CN-156
7
9
8
G
4
3
2
1
5
6
4
3
2
1
6
Y
B
V
L
L
TURN LAMP
HEAD LAMP
START KEY
CASSETTE
G21
B
A
CLUSTER
ILL.LAMP
100
101
102
103
160
123
143
69A
198
104
105
106
107
108
109
110
111
112
113
114
175
115
116
117
118
191
120
121
122
123
124
125
126
CN-16
CN-163
SWITCH
73
57
53
52
55
70
27
WIPER
CN-17
CN-15
CR-35
CN-36
15
14
13
12
11
10
ECM
7
9
8
5
4
3
2
1
11
6
MCU
12
ECM
10
15
14
13
12
11
10
RCV
TCU
TCU
9
8
7
6
5
4
3
2
1
7
9
8
5
4
3
2
1
5
6
4
3
2
1
6
86 30 87a
12F LW
B G14
G5 B
85
BrW
3Br 31
ROr
ROr
GW
OrW
WOr
GrW
WOr
GrW
GrW
YW
VW
LW
ROr
ROr
LW
GY
TO: FRONT HARNESS
GW
SH
VOr
3Or
RW
RW
YW
VW
RW
LW
3W
Gr
Or
87
LW
Br
W
W
CN-9
2L
Or
Gr
Gr
Gr
V
V
B
Y
Y
L
W
W
Br
W
CS-59
W
G
G
R
R
Y
L
G61 B
L
L
G
CN-126
65A G37 GOr
86 B 116
10 1 1 MAIN PUMP PS
11E
14F
85
159
120
163
162
161
134
158
87 87a 3Or 21
181
68A
92A
9 10
16K
108
182
107
28A
12
4B
154
155
10
13
14
15
19
21
23
173
172
G
11
16
22
24
25
26
69
68
66
67
64
20
27
28
29
30
4
3
1
2
R 1K 124
7E
30
90
24
29
2
51
81
83
49
85
82
74
5
6
9 2 2 STEERING PUMP PS
8
16F GrW
POWER RY 8 3 3 STEERING MOTOR RY
8 TO:PC 128 OrW
CR-25 6 7 4 4 STEERING MOTOR RY
2 129 V
86 30 87a 6 5 5 HORN
B G15 7 WOr 3 130 LW
85 5 5 6 6 BOOM DOWN PS
3Y 32 1 131 G
87 4 7 7 BUCKET LEVELER
G 65 SH 182 Br
132
86 3 8 8 BOOM KICK OUT
85 87 87a Or 21A SH 187 133 Or
30 2 9 9 BOOM DOWN PS
GrW 118 155 W
ECM POWER RY 1 10 10 ATT. UNLOCK SOL
70 B
AUTO/MANUAL SW 11 11 STEERING PS(GND)
154 GW
12 12 ATT. LOCK SOL
ST C
6
5 CS-2
17 G
6 CN-10
GrW 157 2H R
BR ACC
3 5 1 1 PROXIMITY SW 24V
68 V
2 2 2 HEAD LIGHT Hi
B
1 4
G 65 G23 B
3 3 3 GND
H
4
153 B
0, I
L G24
2 4 4 GND
Or 21E 177 B
H0 I
1 5 5 PROXIMITY SW(GND)
7A ROr
6 6 ILLUMINATION RH
6A RW
CR-33 7 7 ILLUMINATION LH
START SWITCH 134 GW
86 30 87a 8 8 HEAD LIGHT Lo
BW 197 67 Y
85 9 9 TURN LAMP LH
BrW 176 66 Or
87 10 10 TURN LAMP RH
L 9G 152 BW
86 11 11 GND TM
85 87 87a L 9F 144 BOr
30 12 12 GND STD
AC CONDENSOR FAN RY 13 13
G21 2B
14 14 HEAD LIGHT GND
15 15
CN-92A
CN-11 36 CN-134
1 AC CONTROLLER GND
B 96A 6
1
DIAGNOSTIC
2 BLOWER MOTOR GND
B 96 5
2 BW
2L 9 47
3 AC 24V 3 4
Or 160 36E B
4 REVERSE FAN SIGNAL 4 3
R 25 44 Gr
5 AC CONTROLLER B+ 5 2
Y 145 28E L
6 AC COMP 6 1
BW 186
7 AC CONDENSOR FAN 7
R 1A CN-157
8 ILLUMINATION 8
BW 198 36 B
CR-7 1 VM1-GND
36A B
86 30 87a CN-92 CN-92B B
2 VM2-GND
V 146 37
85 3 VMG1-SPEED PICK-UP COM
VW 147 38 BOr
87 4 VMG2-SPEED SENSOR OUTPUT
L 39 ROr
9E 8 VPS2-RIDE CONT. RY(+)
86 40 LW
85 87 87a L 9A 9 AIP5-GEAR BOX Y5
30 41 YW
AIR-CON RY 10 AIP2-GEAR BOX Y1
6 ADM3-TM ERROR
CR-26 43 W
G 162 12 VPS1-GEAR BOX VPS1(+)
86 30 87a 43A W
GOr 105 CN-148 13 VPS1-GEAR BOX VPS1(+)
85 54E B 44 Gr
W 8 C 15 SDDK-DIAGNOSTIC
87 53F G 45 WOr
W 8A B 17 ER3-SW FILTER RESTRICTION
86 52E V 46 BOr
85 87 87a R 173 A 49 ER2-SENSOR TEMP CONVERTER
30 47 BW
DATA LINK 18 EUPR-DIAGNOSTIC
WIPER RY LO 48 W
19 EF1-SPEED PICK-UP ENG
49 RW
CR-4 20 ED3-SHIFT LEVER-X1A-B3
W 8E 50 YW
86 30 87a 21 ED10-PARKING BRAKE SW(+)
B G13 51 VOr
85 22 ED7-SHIFT LEVER-X1D-KD
G 172 22A R
87 23 VPE1-CONTINUANCE 24V
Br 163 52A V
86 25 CANF_H
85 87 87a L 14A 53A G
30 26 CANF_L
WIPER RY HI 27 CANF_T
54A SH
28 VGS-CAN SHIELD
55 Or
TO: CABIN HARNESS CN-7 29 ED11-SW AUTO/MANU SIG(+)
G 56 OrW
30 32 AIP3-GEAR BOX Y3
CASSETTE IG24V 1 1
RW 57 Y
WORK LAMP FRONT 2 171 36 SD4-SPEED METER CLUSTER
2
Y 58 BW
20 39 ER1-GEAR BOX TEMP
CASSETT B+/ROOM LAMP 3 3
LW 169 59 W
MIRROR HEATER SW 4 4 41 EF2-SPEED PICK-UP TURBIN
Or 189 60 W
ECONO SW 5 5 42 EF3-SPEED PICK-UP GEAR
B 74 Br
178 43 ED4-SHIFT LEVER X2B-FWD
GND (CASSETTE) 6 6
R 28 L
ILLUMINATION 7 1 45 VPI-POWER IG
7 BOr
B 179 75
GND 8 8 46 VMGA2-GEAR BOX TEMP(COM)
BOr 190 76 G
ECONO SW 9 9 51 AIP6-GEAR BOX Y6
B 77 V
GND 10 G7 55 AIP4-GEAR BOX Y4
10 78 Gr
G 5A 56 AIP1-GEAR BOX Y2
BEACON SW 11 11
Or 79 GOr
SEAT HEATER SW 12 64F 57 ADM5-RY RIDE CONT.(-)
12 80 Br
L 93 62 EF4-SPEED SENSOR(SIG)
SEAT HEATER SW 13 13
R 81 LW
63 63 ED1-SHIFT LEVER X1C-B1
WORK LAMP REAR 14 14
82 GrW
15 15 64 ED5-SHIFT LEVER X2C-REV
83 L
65 ED2-SHIFT LEVER X1B-B2
84 Gr
CN-8 66 ED9-CLUTCH CUT-OFF SW(+)
L 14 85 W
REAR WIPER 24V 1 1
V 67 ED6-SHIFT LEVER X2D-NEU
WIPER SW-WASHER 2 166 22 R
2 68 VPE2-CONTINUANCE 24V
W 165 86 BOr
WIPER SW-PF 3 3
Or 44 ED8-FWD-JOYSTICK
WIPER SW-ON 4 4 164 87 Or
31 ED13-REV-JOYSTICK
5 5 168 BW
30 ED14-NEU-JOYSTICK
VW 92 88 BOr
MIRROR HEATER 6 6 52 ADM1-START INTERLOCK RY(-)
STEERING SW 7 7 89 WOr
5 ADM4-REVERSE DRIVE RY(-)
GrW 16H 90 LW
STEERING SW 8 8 7 ADM2-JOYSTICK SELECT LAMP(-)
91 OrW
CR-3 59 ADM5-JOYSTICK SELLECTER(+)
86 30 87a
G16
B TM CONTROLER
85
RW 171 CN-6
87
G 170 1 1 NC
86 75 BOr
85 87 87a Gr 15 2 2 GEAR BOX -TEMP(COM)
30 48 W
3 3 ENG.PICK-UP SENSOR
WORK LAMP FRONT 37 B 4 4 ENG.PICK-UP SENSOR
CR-55 45 WOr 5 5 FILTER RESTRICTION
86 30 87a 46 BOr
B G17 6 6 TEMP CONVERTER
85
R 63 7 7 NC
87 58 BW
L 180 8 8 GEAR BOX -TEMP
86 76 G
85 87 87a Gr 5 9 9 GEAR BOX -Y6
30 40 LW
10 10 GEAR BOX -Y5
WORK LAMP REAR 77 V
11 11 GEAR BOX -Y4
56 OrW
CS-36 12 12 GEAR BOX -Y3
B G36 78 Gr
9 10 10 13 13 GEAR BOX -Y2
R 1G 43 W
9 14 14 GEAR BOX -VPS1+
4 41 YW
8 15 15 GEAR BOX -Y1
2 G 170
7
CN-5
7 1 6
5 1 1 NC
5 70F B
R 1F 2 2 GND-MCU
4 111 Br
3 3 HYD TEMP SENSOR
3 117 BOr
180 4 AIR CLEANER SW
I 0
L 4
2 110 V
R 1E 5 5 FUEL SENDOR
1 59 W
6 6 TURBIN PICK-UP SENSOR
WORK LAMP 37A B
7 7 TURBIN PICK-UP SENSOR
CS-21 8 8 NC
B G35
38 BOr
9 10 10 9 9 SPEED SENSOR-VMG2
R 1H 80 Br
9 10 10 SPEED SENSOR-EF4(2)
4 28F L
8 11 11 SPEED SENSOR-24V
2 R 1 37E B
7 12 12 INTER GEAR PICK-UP SENSOR
60 W
7 1 6 13 13 INTER GEAR PICK-UP SENSOR
5 R 35
5 14 14 NC
YW 11
4 15 15 NC
3
161 CN-4
I 0
W
2
OrW 10 1 1
1 176 BrW
2 2 AC CONDENSOR FAN
ILL.HEAD LAMP
3 3
16G GrW
CR-56 4 4 FAN REVERSE SOL
SW2 B
3 G52 123 GW
5
IG 1 5 FAN REVERSE SOL
LW 169 145 Y
2 6 6 AC R/DRYER
Or 64 146 V
3 7 7 AC R/DRYER
VW 92 147 VW
4 4 8 8 AC COMP
GND 1 148 L
OUT 9 9 BACK BUZZER
6 RW
MIRROR HEAT 10 10 ILLUMINATION
66A Or
11 11 RH TURN LAMP
7 ROr
CN-138 12 12 ILLUMINATION
VW 13A 67A Y
24V 24V A 13 13 LH TURN LAMP
B G53 63A R
GND B 14 14 WORK LAMP
Or 167 72 Br
12V 12V C 15 15 STOP LAMP
DC/DC CONVERTER CN-3
189 Or
CN-139 1 1 ECM ECONO
149 LW
Or 167 2 2 FUEL HEATER
2 190 BOr
B G32 3 3 ECM ECONO
1 151 BW
4 4 START RY
112 YW
12V SOCKET 5 5 ALT I
187 SH
6 6 SHIELD
CL-2 150 G
7 7 PRE-HEAT RY
Or 64A
8 8 NC
R 1T 153 L
9 9 BATT.RY (DO-1)
B G31 114 Y
10 10 FAN PROPORTIONAL V/V
113 L
CIGAR B 11 11 FAN PROPORTIONAL V/V
12 12 NC
13 13 NC
23 3.0W
14 14 ECM Bat 24V
15 15 NC
CN-1
34 3R
1 1 MASTER SW
33 5W
2 2 FUSIBLE LINK
CN-2
52 V
Gr 196A 1 1 ECM-J1939+
2 53 G
Or 195 2 2 ECM-J1939-
1 54 SH
3 3 SHIELD
DO-17 135 LW
G38
G39
G34
14E
4
164
165
G18
G51
G4
GrW 16E
Gr 196B 4
BOr 73A
ECM-AIR HEATER OUT

G1
104
GrW 157
156
WOr 122
130
127
OrW 119
BW 151
GOr 121
17A
193
93
192
1N
1R
1S
WOr 3A
WOr 3E
LW 12A
GY 159
WOr 3F
158
129
YW 50
148
GrW 16
G3
G2
2 136
17
166
BW
BOr 88
BOr 73
69
19
13
WOr 89
LW 12
Or 194 5 5 ECM-AIR HEATER RETURN
G12
1 26
168
144
193
192
109
191
WOr
119
Or
152
131
132
W
LW
Br
3H
LW
CN-162
B
L
Or
84
6
2A
B
Y
B
R
86
87
B
VW
62
61
BrW
G62
6 POWER IG
Or 133
156
LW 149
B
BOr 143
17E
G
G
VOr 51A
B
2
B
V
B
V
L
BOr
Gr
DO-16
4A
4E
GOr 79
ROr 39
OrW 91
BOr 137 137 BOr
1V
2E
R
61
62
B
Or
BW136
LW 135
G 150
6 7 ECM-SW RETURN
62A
61A
G73
G74
G72
2G
LW 12H
LW 12G
GrW
OrW
WOr
195
194
CN-170
LW 12E
Gr 196
BOr
GOr 138 138 GOr
2F
6
BOr
BW
Gr 4
BOr
BW
CS-55
G25
72
Br
Gr
Gr
8
127
CN-102
CR-5
Or
CS-17
CS-42
5
CR-58
8 ECM-OFF IDLE
W
CR-38
Br
W
Or
Gr
R
G
R
B
G
B
2
CR-2
1
L
CR-11
L
ON IDLE
G
CN-103
4
3
6
5
R
CN-22
1
7
OrW 139 139

10
OrW
9
87
30
85
86
CD-5
5
6
4
87
2
87a
87
30
3
10
85
1
86
30
7
85
10
86
8
6
5
7
4
6
5
87a
9
87a
3
9
1
4 9
87
9
30
ECM-ON IDLE
85
W
Br
86
Or
Or
3
1
87a
1
1
2
R
R
2
B
L
4
B
1
2
CN-246
Gr 140 140 Gr
Y
B
LINEAR THROTTLE
CR-46
CR-59
10
3 10
4
10 ECM-ACCEL POS SUPPLY

87 87a
10
B
E
10
87 87a
6
87 87a
L
CN-114
CR-40
CR-41
CR-36
87
30
85
86
8 7 6 2 141 141
87a
87 87a
4 1
87
5 3
30
85
86
W W
87a
Lo 5
M
1
3
2
Hi 4
2
CD-4
CD-4A
11
CN-71
JOYSTICK SELECT 10
12
11
1
87
87
11
CR-63
ECM-ACCEL POS SIG
30
85
87
30
6
5
4
3
2
1
86
85
86
30
85
8
86
9
87a
87a
87a
30
30
30
DO-4
DO-5
Pa
G
1
142 142
2
30
SEAT HEATER C B A C B A B B
E
87
B
30
85
86
1
1
Pf
2
2
87 87a
87a
1
87 87a
12 12 ECM-ACCEL POS RETURN

85
86
85
R/WASHER
85
86
86
FRONT
87 87a
85
87 87a
87 87a
86
2
30
30
ILLUMINATION
WASHER
87 87a
FLASHER
M
Pa Pa CLUTCH
24V(DETEND)
24V(HANDLE)
30
30
30
85
9
86
7
KICK DOWN
8
2
85
86
UNIT
9
9
8
7
2
CUT-OFFF
2
BACK-UP RY
30
SAFETY RY
BUCKET(-)
HORN RY NEUTRAL
85
85
86
86
85
3
86
NEUTRAL
PARKING PARKING RIDE CONTROL
BOOM(-)
CLUTCH CUT-OFF
85
86
- -
FWD
+ +
GND
S S FUEL WARMER
REV
RIDE CONTROL 5
NC
REAR WIPER STOP STOP BOOM UP BUCKET PREHEAT RY OFF IDLE
STOP LAMP RY
LAMP LAMP
THROTTLE ASSEMBLY
7807AEL00
7-3
ELEC. STEERING CN-23
SEAT HEATER MIRROR HEATER BEACON LAMP 17 W
1
ACTUATOR
2
8
7
18
9
1 2 L
2
8
SENSOR
9
OEM
2
8
7
9
2
PORT PORT PORT ACTUATOR CONNECTOR 50P SENSOR CONNECTOR 50P
BEACON
LAMP SPEAKER LH
WASTEGATE ACTUATOR1
WASTEGATE ACTUATOR2
M
10
FUEL RESTRIC RETURN
REAL TIME BACKUP RTN

GRID&SWITCH RETURN
COOLANT LEVEL Lo SW
10
COOLANT LEVEL Hi SW
10
COOLANT TEMP INPUT
5 6
GRID HEATER ACT SIG
6
CN-24
INTAKE TEMP&PS RTN
CS-80
COOLANT LEVEL RTN
CS-23
CS-82
COOLANT LEVEL +5V
REAL TIME BACKUP+
CS-76
COOLANT TEMP RTN
ENG POS SENSOR2+
ENG POS SENSOR1+

FUEL SHUT-OFF ACT
ENG POS SENSOR2-
ENG POS SENSOR1-

19
CYL. NO.1 SUPPLY+
CYL. NO.2 SUPPLY+
CYL. NO.3 SUPPLY+
CYL. NO.4 SUPPLY+
CYL. NO.5 SUPPLY+
CYL. NO.6 SUPPLY+

CYL. NO.1 RETURN-
CYL. NO.2 RETURN-
CYL. NO.3 RETURN-
CYL. NO.4 RETURN-
CYL. NO.5 RETURN-
CYL. NO.6 RETURN-
CL-7
OR
10
INTAKE PRESS +5V
FUEL RESTRIC 5V+
INTAKE PRESS SIG
1
FUEL RESTRIC SIG
9
2
4
5
6
8
7
10
10
OIL PS&TEMP RTN
10
1
3
3
1
9
2
4
5
6
5
6
8
OIL PS&TEMP +5V
7
3
9
2
4
5
6
8
7
WIF SIG. RETURN
20 GY
AIR PRESS RTN

AIR PRESS SIG.
OIL PRESS SIG.
AIR PRESS +5V

2
OIL TEMP SIG.

FUEL HEATER
INTAKE TEMP
BW
GY
LW
GY
B
Or
Or
SPEAKER RH
W
SPARE +
SPARE +
G
WIF SIG.
R
B
B
R
R
B
B
SPARE -
G7 B
R
B
L
G4
G5
G1
7H
7E
6E
7F
36
22
22
37
11
37
36
7L
G11
9
CN-27
17 W
1 S.L+
1 G
9
8
7
6
4
3
2
1
2
3
6
45
34
43
29
28
27
24
23
20
47
33
10
16
26
36
44
15
31
23
25
22
24
10
38
40
39
37
43
42
44
45
31
17
49
50
48
47
2 ACC
7 R
3 ILL+
19 OR
4 S.R+
CN-94 6A B
5 ILL-
8 18 L
18 LW 6 S.L-
CN-99 10 B 3 Y
7A V 19 BW 7 B+
A A 11 C 20 GY
8A G 25 Y 8 S.R-
B 19 D 6 B
24 L 9 GND
C 7 A
B
25 Y CASSETTE RADIO
6
24 L ENG POSITION
5
CN-12 CN-93
10 GOr GOr 1 1 GOr A 5V
1 03 OFF IDLE SW 31P OEM CN-7
2 OrW C SIG
2 13 ON IDLE SW G 1
14 3 3 B B 1 FUSE-CASSETTE 1
B B RW 2
3 49 ACCEL POSITION RTN- 5V A 2 CL-1
13 W W 4 4 W AMBIENT AIR PRESS 2 WORK LAMP RY FRONT
Y 3 3A Y
4 47 ACCEL POSITION SIG. SIG C 3 2
12 Gr Gr 5 5 Gr 3 FUSE-CASSETTE/ROOM LAMP
5 48 ACCEL POSITION SUPPLY 5V (-) 1 LW 4 21 Or
B 4 1
9 BOr BOr 6 6 BOr 4 MIRROR HEATER CONT.
6 09 SWITCH RETURN 3 Or 36
7 V FUEL INLET 5 ECM 5 G2 B
7 46 J1939 (+) 4 B 6
G21 B 8 G RESTRICTION SENSOR 6 GND 6
B G1 R
8 37 J1939 (-) 2 7 ROOM LAMP
5 9 9 SH 7 ILLUMINATION 7
SH SH B G21 CL-30
9 36 J1939 SHIELD 2 Y
8 WOr LW 10 10 LW 1 OIL PRESS/TEMP SENSOR 8 GND 8 3E
10 38 KEY SW "ON"SIGNAL BW 37 2
1 2 9 9 21A Or
3 V V 7 11A W A C ECM
B G1 1
11 18 BATTERY 24V 3
4 8 11E W CYLINDER #1 10 GND 10
G G B G 9 G3 B
12 28 BATTERY 24V 4 11
11F W 11 FUSE BOX
13 07 BATTERY 24V 2 COOLANT TEMP Or 36
5 12 12
17 3W 3W 11 11G W FUSE BOX
L 37
14 08 BATTERY 24V 1 6 A 5V CS-55
11 OrW OrW 2 11H W 13 SEAT HEATER 13
15 17 BATTERY 24V R 10 21 Or
CYLINDER #2 7 C SIG 14 14
27 B WORK LAMP REAR
29 BATTERY RETURN
DOOR SW
8 B 15 15
26 B 2
CN-13 30 BATTERY RETURN 9
15 B 1 INTAKE MANIFOLD PRESS
1 39 BATTERY RETURN 10
CN-8 CS-1
16 B A C L 13 21E
2 40 BATTERY RETURN CYLINDER #3 11 1 FUSE BOX 1 Or
17 B B V 14
3 50 BATTERY RETURN 2 12 2 REAR WASHER 2
15A LW LW 14A W 15
4 01 1 13 INTAKE MANIFOLD TEMP 3 WIPER PF 3
15 LW LW 14 Or 16
5 OEM PORT 50P 14 1 4 WIPER ON SIG 4
6 LW LW 18 CYLINDER #4
6 2 5 CN-27A
15 5 NC 513 RW
7 BW BW 19 VW 12
2
USB CONNECTOR
7 6 MIRROR HEAT TIMER 6 1 USB 5V
18 BW BW 20 WIF SENSOR W 8 514 Or
8 1 7 2 USB D-
7 NC 515 GOr
19 YW YW 21 GrW 11
9 CN-28 CYLINDER #5 8 NC 8 3 USB D+
34 VW VW 22 22 VW 516 OrW
10 1 FUEL SHUTOFF 4 USB GND
G2 B 2
11 5 NC
20 G G 23 1 1 517 W
12 6 AUX_L
27
26
15
16
17
AC COMP CYLINDER #6 2 518 R
7 AUX_R
519 LW
WASTEGATE 8 AUX_GND
G8
7A
15
14
13
16
514 Or
USB PORT
1 USD D-
515 GOr
G25
G21
G22
G24
G23
G26
10A
Or
2 USD D+
RW 2F
RW 2A
RW 2E
10
R
V
B
L
516 OrW
RW 2
G10
12A
3 USB GND
G9
12
CR-23 CN-45 INLET M/ACT TEMP M/ACT MODE(D/FOOT) MODE(VENT) RESISTOR RELAY(HI) RELAY(M2) 517 W
CS-35
R
B
R
B
B
4 AUX S1
B
EARTH
10
5
4
1
518 R
2
9
VW
VW
20 BW M
M 2 2 5 AUX S2
B
7 7
M 1 M 4 M 1 M 4 BLOWER 513 RW
CL-5
CL-6
CL-35
CL-36
CL-32
CL-33
3 3
3
7
1
7
10
6
6 USB +(5V)
3
Lo 1
4
ML 2
MH 3
1
2
2
0,
5 5 I 519 LW
CN-149
CN-150
M
10 AUX GND
Hi
4
2
1
2
1
2
B+
5
6
7
5
6
7
5
6
7
1
2
3
4
5
6
7
1
2
3
4
1
2
3
4
1
2
3
4
START RY. FROM CN-27B
1
2
3
4
BATTERY STARTER
1
2
1
1
4
4
2
3
2
3
0 I
GW
WR
BW
WB
BG
BG
GB
GB
GL
YB
RELAY
LR
1
8
LB
Y
Y
WORK LAMP F WORK LAMP FRONT WORK LAMP REAR
YBr
YW
LG
REAR WIPER
YW
BG
RY
RY
2B
YB
L
L
20A
L
9A
9B
OPTION
21
22
17
20
18
19
23
24
25
16
15
28 R MIRROR HEATER
2
36A
26
35
27
33A
32
36
6B
6A
29
33
36
28
35
21A YW 3W/300
1
CN-96 AC-11 AC-1
RS-1
14 LW 18 18
B 15 R Y 23 23 Y
G1 B CN-74 17 17 CONDENSER FAN
A 28 R LW 24 24 LW
B+ 16 16 COMPRESSOR(DPS)
YW 25 25 YW
FUEL HEATER G 15 15 BLOWER RELAY(HI)
1 P BOr 26 26 BOr
21 YW
2 L
3 ~ 14
YW 27 27 YW
14 BLOWER RELAY(M2)
U 13 13 BLOWER RELAY(M1)
CR-24 3 FI LW 28 28 LW
8W 12 12 BLOWER RELAY(LO)
23 G 4 NC Y 29 29 Y
11 11 MODE M/ACT(PBR)
8W ALT LW 30 30 LW
CN-80 CN-11 NO. DESTINATION 10 10 MODE M/ACT(M-)
1,2 BR WOr 31 31 WOr
1 1 GND(CONTROLLER) 9 9 MODE M/ACT(M+)
32 2B BW 32 32 BW
GLOW PLUG RY 2 2 GND(BLOWER) 8 8 MODE M/ACT(FOOT)
GLOW PLUG 6 RY
7
GY 33 33 GY
3 3 FUSE(IG) 7 MODE M/ACT(DEF)
10 RW Y 34 34 Y
G 66A CS-74 4 4 MCU 6
G 35 35 G
6 MOTOR ACT(REF)
2 33 2R
5 5 TEMP M/ACT(PBR)
B G13 5 5 FUSE(Battery) BOr 36 36 BOr
1 CN-60 30 LW 4 4 TEMP MOTOR ACT(-)
1 5R 6 6 DPS(COMPRESSOR) L 37 37 L
DO-2 2 31 LY 3 3 TEMP MOTOR ACT(+)
7 7 CONDENSOR FAN 38 38
G 66 5 G BW BW
1 8 2 2 INLET MOTOR(FRE)
2 8 ILLUMINATION 39 39
L 22 WOr WOr
1 1 1 INLET MOTOR(REC)
MASTER SW AIR CON
DO-1
CN-95 AC-22 AC-2
2 5W
WB 15
BW 16
17
BG 18
GL 19
20
GW 21
BG 22
WR 23
24
25
26
27
28
29
30
31
GB 10
1
2
RW 3
RW 4
5
RY 6
8
GB 9
2 14 14 NC
GrW
ROr
69 5W
BrR
YBr
LW
BG
9
BR
BR
8
13
YB
LG
YB
CABIN HARNESS
LR
1
LB
LY
13 NC
G
Y
L
FUSIBLE LINK 12 12 NC
1.25LgB
1.25G
CR-1
0.85
0.85
0.85
11 11 NC
10
11
12
13
14
15
16
17
18
10
11
12
13
14
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
66 G 10 10 REVERSABLE FAN SIG
GW 40 40 GW
G12 B 9 9 DUCT SENSOR(GND)
2
3
CN-1 BW 41 41 BW
TEMP MOTOR ACT(+)
DUCT SENSOR(GND)
TEMP MOTOR ACT(-)
BLOWER RELAY(M1)
BLOWER RELAY(M2)
COMPRESSOR(DPS)
8 8
BLOWER RELAY(LO)
1
2
DUCT SENSOR(+)
MODE M/ACT(FOOT)
5R 1
INLET MOTOR(REC)
BLOWER RELAY(HI)
INLET MOTOR(FRE)
BATTERY
MODE M/ACT(PBR)
MODE M/ACT(DEF)
REVERSE FAN SIG

1 FUSE BOX 1
TEMP M/ACT(PBR)
1 2 3 4 5 6 7 8
MOTOR ACT(REF)
CONDENSER FAN
DUCT SENSOR(+)
MODE M/ACT(M+)
BATT. RY 7
MODE M/ACT(M-)
5W 2 7 NC
2 FUSE BOX 2 R 42 42 R
ILLUMINATION
6 6 POWER IG
BATTERY(+)
BATTERY(+)
G 43 43 G
CN-246A 5
POWER IG
TO STARTER 5 ILLUMINATION
CN-2 4
RW 44 44 RW
3 DUCT 4 BATTERY(+)
V RW 45 45 RW
GND
GND
1 J1939+ 1 SENSOR 3 3 BATTERY(+)
NC
NC
NC
NC
NC
G 4 BrW 46 46 BrW
2 J1939- 2 2
5 2 GND
SH BrW 47 47 BrW
3 SHIELD 3 AC&HEATER CONTROLLER 1 1
6 GND
LW
4 AIR-HEATER RY+ 4
BW 7
5 AIR-HEATER RY RETURN 5
WOr 8
6 FUSE-IG 6
BOr 9
7 THROTTLE RETURN 7
GOr 10
8 THROTTLE OFF-IDLE 8
CN-114
CN-114
OrW 11
CN-114
CN-114
JOYSTICK SELECT 10
12
11
6
5
4
3
2
1
8
9
9 THROTTLE ON-IDLE
JOYSTICK SELECT 10
12
11
6
5
4
3
2
1
9
8
9
JOYSTICK SELECT 10
JOYSTICK SELECT 10
12
11
12
11
12
6
5
4
3
2
1
6
5
4
3
2
1
8
8
9
9
7
7
Gr
10 ACCEL-SUPPLY 10
W 13
11 ACCEL SIG 11
ILLUMINATION
ILLUMINATION
B 14
ILLUMINATION
ILLUMINATION
KICK DOWN
KICK DOWN
12 ACCEL RETURN 12
BUCKET(-)
BUCKET(-)
KICK DOWN
KICK DOWN
NEUTRAL
NEUTRAL
BOOM(-)
BUCKET(-)
BUCKET(-)
F/R COM
BOOM(-)
NEUTRAL
NEUTRAL
BOOM(-)
BOOM(-)
CN-3
COM
FWD
GND
REV
FWD
GND
REV
24V
24V
NC
COM
COM
FWD
FWD
GND
GND
NC
REV
REV
24V
24V
1 NC 1
NC
NC
LW 15
2 FUEL HEATER RY OUT 2 OrW
VOr
BOr
BW
10 Or
3 NC 3
W
G
R
B
L
BW 18 CN-110
4 ANTI-RESTART RY 4 FROM BATT. RY
5
7
6
4
3
2
8
9
1
YW 19 1
5 MCU-ALT 5
SH 24 2
6
7
SHIELD
PRE-HEAT RY OUT
6
7
G 20 M
CN-114A CN-114A
8 NC 8
8 5
MOTOR RY
L 22
9 START KEY SW-br 9 5 4
Y 25 7 7
10 MCU-FAN CLUTCH+ 10 7 FL- FL+ 3
L 26 6 8
11 MCU-FAN CLUTCH+ 11 FL+ 2
CD-40
5 7 FL- 6 5A B
12 NC 12 6 BO- BO+ 2 CN-19 2 Pa
7A
10
4 4 4 OrW OrW 1 3 G
BOr 9
BW 8
7
VOr 6
OrW 5
8 BO- BO+ 1
1E
1A
13 NC 13 CN-154 1 1
CN-114A
W 3
2
4
5 BK- BK+ 1
CN-110
3W 17 25 Y 3 2 3 GrW GrW 2
Or
4
SOL
6
2
1
2
G
G
14 ECM FUSE 24V 14
1
2
R
R
R
B
6 BK- BK+ 3
L
26 L 2 1
CONT.VALVE BOOM DOWN 2 G G 3 STR PUMP PS
15 NC 15 1

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SECTION 1 GENERAL

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

FOLLOW SAFE PROCEDURE

WEAR PROTECTIVE CLOTHING

WARN OTHERS OF SERVICE WORK

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

PREVENT BATTERY EXPLOSIONS

USE TOOLS PROPERLY

USE PROPER LIFTING EQUIPMENT

DISPOSE OF FLUIDS PROPERLY

LIVE WITH SAFETY

KEEP ROPS INSTALLED PROPERLY

Bucket Tire Head light Hydraulic tank Air cleaner Battery

Boom Bucket cylinder Main control valve Step Radiator Counterweight

Description Unit Specification

Description Unit Specification

Description Unit Specification

Front frame assembly 2714 5983

Model Cummins QSM 11

3) STEERING PUMP(+FAN PUMP)

4) MAIN CONTROL VALVE

5) REMOTE CONTROL VALVE

Boom cylinder Bore dia×Rod dia×Stroke Ø200×Ø110×863mm

7) DYNAMIC POWER TRAIN DEVICES

Electrical single lever type, kick-down system,

Drive devices 4-wheel drive

1) BOLT AND NUT

(1) Coarse thread

(2) Fine thread

Thread size Width across flat(mm) kgf·m lbf·ft

3) PIPE AND HOSE(ORFS TYPE)

Thread size Width across flat(mm) kgf·m lbf·ft

13/16-16" 24 4.4 32.5

Thread size Width across flat(mm) kgf·m lbf·ft

No. Items Size kgf·m lbf·ft

ASTM D975 NO. 1

※ Use this sheet to record operational

1. Monitor indicator and gauge checks(Engine OFF)

· Hourmeter and gauge check

2. Transmission, axle and engine linkages, neutral start

· Transmission control lever and neutral

3. Monitor indicator and gauge checks(Engine running)

· Monitor display and alternator output checks

· Park brake capacity check

·Transmission oil warm up procedure

6. Hydraulic system checks

·Hydraulic system warm up procedure

·Steering valve check

·Operating lights check

9. Cab components and vandal protection checks

·Cab door latch check