HL730 3

WHEEL LOADER HYUNDAI HL730-3
HL730-3 Service Manual Open index screen
CONTENTS
Foreword
SECTION 1 GENERAL
Group 1 Safety hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Group 2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Group 3 Operational checkout record sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
SECTION 2 ENGINE
Group 1 Structure and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
SECTION 3 POWER TRAIN SYSTEM

Group 1 Structure and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Group 2 Operational checks and troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
Group 3 Tests and adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
Group 4 Disassembly and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
SECTION 4 BRAKE SYSTEM

SECTION 5 STEERING SYSTEM

SECTION 6 WORK EQUIPMENT

SECTION 7 ELECTRICAL SYSTEM

Group 1 Component location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Group 2 Electrical circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Group 3 Monitoring system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
Group 4 Electrical component specification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33
Group 5 Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41
Group 6 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-58
FOREWORD
1. STRUCTURE
This service manual has been prepared as an aid to improve the quality of repairs by giving the
serviceman an accurate understanding of the product and by showing him the correct way to perform
repairs and make judgements. Make sure you understand the contents of this manual and use it to
full effect at every opportunity.
This service manual mainly contains the necessary technical information for operations performed in
a service workshop.
For ease of understanding, the manual is divided into the following sections.
Structure and function

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

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

1mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

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

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

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

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

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

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

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

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

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

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

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

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

-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 172 347.0
0-8
REPLACE SAFETY SIGNS
Replace missing or damaged safety signs. See
the machine operator's manual for correct safety
sign placement.
LIVE WITH SAFETY

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

Make certain all parts are reinstalled correctly if the
roll-over protective structure(ROPS) is loosened or
removed for any reason. Tighten mounting bolts
to proper torque.
The protection offered by ROPS will be impaired if
ROPS is subjected to structural damage, is
involved in an overturn incident, or is in any way
altered by welding, bending, drilling, or cutting. A
damaged ROPS should be replaced, not reused.
1-9
GROUP 2 SPECIFICATION
1. MAJOR COMPONENT
Tooth Bucket Tire Bucket cylinder Hydraulic tank Engine Radiator
Boom cylinder Main control valve Main pump Air cleaner Battery
Bucket link Bell crank Head light Cab Rain cap Muffler Counterweight
Boom Front axle Steering cylinder Step Transmission Rear axle Fuel tank
1-10
2. SPECIFICATIONS
1) WITHOUT TOOTH AND CUTTING EDGE TYPE BUCKET
F
J
B
I
4700
H
3580
K
3033
40Ş
C
G
46
5280 34
D
E 1636
A
Description Unit Specification

Operating weight kg(lb) 8930(19690)
Struck 1.2(1.6)
Bucket capacity m3(yd3)
Heaped 1.5(2.0)
Overall length A 6556(21' 6")
Overall width B 2400( 7' 10")
Overall height C 3180(10' 5")
Ground clearance D 373( 1' 3")
Wheelbase E mm(ft-in) 2700( 8' 10")
Tread F 1850( 6' 1")
Dump clearance at 45Ş G 2792( 9' 2")
Dump reach H 935( 3' 1")
Width over tires I 2295( 7' 6")
Dump angle J 45
Degree (Ş)
Roll back angle(Carry position) K 48
Lift(With load) 5.4
Cycle time Dump(With load) sec 1.0
Lower(Empty) 2.5
Maximum travel speed km/hr(mph) 38.1(23.7)
Braking distance 13.9(45' 7")
m(ft-in)
Minimum turning radius(Center of outside tire) 4.66(15' 3")
Gradability Degree (Ş) 30
First gear 7.1(4.4)
Second gear 12.3(7.6)
Forward
Third gear 22.6(14.0)
Travel speed Fourth gear km/hr(mph) 38.1(23.6)
First gear 7.4(4.6)
Reverse Second gear 13.0(8.1)
1-11
2) BOLT-ON CUTTING EDGE TYPE BUCKET
B
F
I
4700
H
3580
K
3033
4 0Ş
C
G
46
3
5350 4
D
E 1636
A

Struck 1.4(1.8)
Heaped 1.6(2.1)
Tread F 1850( 6' 1")
Dump angle J 45
Degree (Ş)
Lift(With load) 5.4
Lower(Empty) 2.5
m(ft-in)
First gear 7.1(4.4)
Forward
First gear 7.4(4.6)
1-12
3) WITH TOOTH TYPE BUCKET
B
4700
H
3580
K
3033
C
40Ş
G
46
3
5460 4
D
E 1636
A

Struck 1.2(1.6)
Heaped 1.5(2.0)
Tread F 1850( 6' 1")
Dump angle J 45
Degree (Ş)
Lift(With load) 5.4
Lower(Empty) 2.5
m(ft-in)
First gear 7.1(4.4)
Forward
First gear 7.4(4.6)
1-13
3. WEIGHT
Item kg lb
Front frame assembly 808 1781

Rear frame assembly 801 1766
Front fender(2EA) 28 62
Rear fender(2EA) 38 84
Counterweight 295 650
Cab assembly 1000 2205
Engine assembly 380 838
Transmission 360 794
Drive shaft(Engine to transmission) 7 15
Drive shaft(Front) 16 35
Drive shaft(Center) 17 37
Drive shaft(Rear) 10 22
Front axle(Include differential) 475 1047
Rear axle(Include differential) 485 1069
Tire(4EA) 816 1799
Hydraulic tank 92 203
Fuel tank 158 348
Main pump assembly 25 55
Main control valve 55 121
Boom 546 1204
Bell crank 133 293
Bucket link 25 55
1.6m bucket, with bolt on cutting edge
3
688 1517
1.5m3 bucket, with tooth 625 1378
1.5m bucket, without tooth and cutting edge
3
553 1219
Boom cylinder assembly(2EA) 160 353
Bucket cylinder assembly 75 165
Steering cylinder assembly(2EA) 36 79
Seat 40 88
Battery 44 97
1-14
4. SPECIFICATION FOR MAJOR COMPONENTS
1) ENGINE
Item Specification
Model Deutz BF4M1012EC

Type 4-cycle turbocharged diesel engine
Cooling method Water cooling
Number of cylinders and arrangement 4 cylinders, in-line
Firing order 1-3-4-2
Combustion chamber type Direct injection type
Cylinder bore ź stroke 94ź115mm(3.7"ź4.52")
Piston displacement 3190cc(238cu in)
Compression ratio 17.5 : 1
Rated gross horse power 107ps at 2300rpm
Maximum gross torque at 1500rpm 38.5kgfşm(279lbfşft)
Engine oil quantity 12.6ֻ (3.3 U.S. gal)
Dry weight 382kg(842lb)
High idling speed 2450 Ź 50rpm
Low idling speed 800 Ź 50rpm
Rated fuel consumption 160.3g/ps.h
Starting motor Delco Remy 37MT(24V)
Alternator DAC HC60(24V-55AMP)
Battery 2ź12Vź100Ah
2) MAIN PUMP
Item Specification
Type Fixed displacement tandem gear pump

Capacity 33*29cc/rev
Maximum operating pressure 215kgf/cm2(3058psi)
Rated oil quantity 139ֻ.min(35.7U.S.gpm)
Rated speed 2300rpm
1-15
3) BRAKE PUMP
Item Specification
Type Fixed displacement tandem gear pump

Capacity 5cc/rev
Maximum operating pressure 150kgf/cm2(2130psi)
Rated oil quantity 11ֻ/ min(2.9U.S.gpm)
4) MAIN CONTROL VALVE
Item Specification
Type 2 spool
Operating method Hydraulic pilot assist
Main relief valve pressure 215kgf/cm2(3058psi)
Overload relief valve pressure 240kgf/cm2(3414psi)
5) REMOTE CONTROL VALVE
Item Specification
Type Pressure reducing type

Minimum 5.8kgf/cm2(82.5psi)
Operating
Maximum 30kgf/cm2(427psi)
Single operation stroke Lever 77mm(3.0in)
6) CYLINDER
Item Specification
Boom cylinder Bore diaźRod diaźStroke ‫ٻ‬105ź‫ٻ‬65ź710mm

Bucket cylinder Bore diaźRod diaźStroke ‫ٻ‬120ź‫ٻ‬70ź525mm
Steering cylinder Bore diaźRod diaźStroke ‫ ٻ‬60ź‫ٻ‬35ź390mm
1-16
7) DYNAMIC POWER TRANSMISSION DEVICES
Item Specification
Model ZF 4WG130
Torque converter
Type Single-stage, single-phase
Type Full-automatic power shift
Transmission Gear shift Forward fourth gear, reverse third gear
Adjustment Electrical single lever type, kick-down system
Drive devices 4-wheel drive
Axle Front Front fixed location
Rear Oscillation 13Şof center pin-loaded
Wheels Tires 17.5-25, 12PR(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 40Şto both right and left angle, respectively
1-17
5. TIGHTENING TORQUE OF MAJOR COMPONENT
No. Items Size kgfşm lbfşft
1 Engine mounting bolt, nut M12ź1.75 12.4 Ź 2.5 89.7Ź 18.1

Engine
2 Radiator mounting bolt, nut M12ź1.75 12.3 Ź 2.5 89.0Ź 18.1
3 Main pump housing mounting bolt M14ź2.0 19.6 Ź 2.9 142Ź 20.9
4 Main control valve mounting bolt M12ź1.75 12.8Ź 3.0 92.6Ź 21.7
5 Steering unit mounting bolt M 8ź1.25 2.5 Ź 0.5 18.1Ź 3.6
Hydraulic
6 system Priority valve mounting bolt M 8ź1.25 2.5 Ź 0.5 18.1Ź 3.6
7 Brake valve mounting bolt M 8ź1.25 3.0 Ź 0.3 21.7Ź 2.2
8 Fuel tank mounting bolt M16ź2.0 29.7 Ź 4.5 215Ź 32.5
9 Hydraulic oil tank mounting bolt M12ź1.75 12.3 Ź 2.5 89.0Ź 18
10 Transmission mounting bolt M16ź2.0 29 Ź 5.0 210Ź 36.2
11 Front axle mounting bolt M24ź2.0 100Ź15 723Ź108
Power train
12 Rear axle support mounting bolt, nut M24ź2.0 94.5Ź10.5 683Ź75.9
system
13 Tire mounting nut M22ź1.5 76Ź 8.5 550Ź61.5
14 Drive shaft joint mounting bolt, nut M20ź2.5 57.9Ź 8.7 419Ź62.9
15 Counterweight mounting bolt M24ź2.0 107 Ź 16.1 774Ź116
16 Others Operator's seat mounting bolt M 8ź1.25 3.4 Ź 0.8 24.6 Ź 5.8
17 ROPS Cab mounting bolt(4EA) M24ź3.0 28Ź 2.6 203 Ź18.8
1-18
6. TORQUE CHART
Use following table for unspecified torque.
1) BOLT AND NUT
(1) Coarse thread
8T 10T
Bolt size
kgfşm lbfşft kgfşm lbfşft
M 6 ź 1.0 0.85 ~ 1.25 6.15 ~ 9.04 1.14 ~ 1.74 8.2 ~ 12.6
M 8 ź 1.25 2.0 ~ 3.0 14.5 ~ 21.7 2.73 ~ 4.12 19.7 ~ 29.8
M10 ź 1.5 4.0 ~ 6.0 28.9 ~ 43.4 5.5 ~ 8.3 39.8 ~ 60
M12 ź 1.75 7.4 ~ 11.2 53.5 ~ 79.5 9.8 ~ 15.8 71 ~ 114
M14 ź 2.0 12.2 ~ 16.6 88.2 ~ 120 16.7 ~ 22.5 121 ~ 167
M16 ź 2.0 18.6 ~ 25.2 135 ~ 182 25.2 ~ 34.2 182 ~ 247
M18 ź 2.5 25.8 ~ 35.0 187 ~ 253 35.1 ~ 47.5 254 ~ 343
M20 ź 2.5 36.2 ~ 49.0 262 ~ 354 49.2 ~ 66.6 356 ~ 482
M22 ź 2.5 48.3 ~ 63.3 350 ~ 457 65.8 ~ 98.0 476 ~ 709
M24 ź 3.0 62.5 ~ 84.5 452 ~ 611 85.0 ~ 115 615 ~ 832
M30 ź 3.5 124 ~ 168 898 ~ 1214 169 ~ 229 1223 ~ 1655
M36 ź 4.0 174 ~ 236 1261 ~ 1703 250 ~ 310 1808 ~ 2242
(2) Fine thread

8T 10T
Bolt size
kgfşm lbfşft kgfşm lbfşft
M 8 ź 1.0 2.17 ~ 3.37 15.7 ~ 24.3 3.04 ~ 4.44 22.0 ~ 32.0
M10 ź 1.25 4.46 ~ 6.66 32.3 ~ 48.2 5.93 ~ 8.93 42.9 ~ 64.6
M12 ź 1.25 7.78 ~ 11.58 76.3 ~ 83.7 10.6 ~ 16.0 76.6 ~ 115
M14 ź 1.5 13.3 ~ 18.1 96.2 ~ 130 17.9 ~ 24.1 130 ~ 174
M16 ź 1.5 19.9 ~ 26.9 144 ~ 194 26.6 ~ 36.0 193 ~ 260
M18 ź 1.5 28.6 ~ 43.6 207 ~ 315 38.4 ~ 52.0 278 ~ 376
M20 ź 1.5 40.0 ~ 54.0 289 ~ 390 53.4 ~ 72.2 386 ~ 522
M22 ź 1.5 52.7 ~ 71.3 381 ~ 515 70.7 ~ 95.7 512 ~ 692
M24 ź 2.0 67.9 ~ 91.9 491 ~ 664 90.9 ~ 123 658 ~ 890
M30 ź 2.0 137 ~ 185 990 ~ 1338 182 ~ 248 1314 ~ 1795
M36 ź 3.0 192 ~ 260 1389 ~ 1879 262 ~ 354 1893 ~ 2561
1-19
2) PIPE AND HOSE
Thread size Width across flat'mm( kgfşm lbfşft

1/4" 19 3 21.7
3/8" 22 4 28.9
1/2" 27 5 36.2
3/4" 36 12 86.8
1" 41 14 101
3) FITTING
Thread size Width across flat'mm( kgfşm lbfşft

1/4" 19 4 28.9
3/8" 22 5 36.2
1/2" 27 6 43.4
3/4" 36 13 94.0
1" 41 15 109
1-20
7. RECOMMENDED LUBRICANTS
Use only oils listed below or equivalent.
Do not mix different brand oil.
Ambient temperature Ş
C( Ş
F)
Capacity
Service point Kind of fluid
ֻ(U.S. gal) -20 -10 0 10 20 30 40
(-4) (14) (32) (50) (68) (86) (104)
SAE 30
SAE 10W
Engine oil pan Engine oil 12.6(3.3)
SAE 10W-30
SAE 15W-40
Torque converter
Oil 20(5.3) DEXRONє
Transmission
Front :
18.4(4.9)
Axle Gear oil SAE 80W-90LSD/API GL-5
Rear :
18.4(4.9)
Tank: ISO VG 32
60(15.9)
Hydraulic tank Hydraulic oil ISO VG 46
System:
87(23) ISO VG 68
ASTM D975 NO.1

Fuel tank Diesel fuel 160(42.3)
ASTM D975 NO.2
NLGI NO.1
Fitting
Grease As required
(Grease nipple)
NLGI NO.2
Mixture of
antifreeze
Radiator 30(7.9) Ethylene glycol base permanent type
and water
50 : 50
1-21
GROUP 3 OPERATIONAL CHECKOUT RECORD SHEET
şOwner 9
şDate 9
şHours 9
şSerial No. 9
şTechnician 9
Ɠ Use this sheet to record operational

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

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

switch and reverse warning alarm switch checks
ş Transmission control lever and neutral Ә Ә

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

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

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

şTransmission noise check Ә Ә
şSpeedometer check Ә Ә
şTransmission kick down system check Ә Ә
ş1st, 2nd, 3rd and 4th speed clutch pack drag check Ә Ә
şTransmission pressure, pump flow and leakage check Ә Ә
şTransmission shift modulation check Ә Ә
şTorque converter check Ә Ә
şEngine power check Ә Ә
6. Hydraulic system checks
şHydraulic system warm up procedure Ә Ә

şHydraulic pump performance check Ә Ә
şPilot control valve boom float check Ә Ә
şBoom down solenoid valve check Ә Ә
şControl valve lift check Ә Ә
şBucket rollback circuit relief valve check Ә Ә
şBucket dump circuit relief
Low pressure check Ә Ә
High pressure check Ә Ә
şBoom and bucket cylinder drift check Ә Ә
şBoom down solenoid valve leakage check Ә Ә
şPilot controller check Ә Ә
şReturn to dig check Ә Ә
şBoom height kickout check-if equipped Ә Ә
1-23
7. Steering system checks
şSteering valve check Ә Ә

şSteering system leakage check Ә Ә
şPriority valve
Low check pressure Ә Ә
High check pressure Ә Ә
8. Accessory checks
şOperating lights check Ә Ә

şWork light check Ә Ә
şBrake light check Ә Ә
şCab light check Ә Ә
şHorn circuit check Ә Ә
şWindshield washer and wiper check Ә Ә
şDefroster blower check Ә Ә
şHeater/Air conditioner blower check Ә Ә
şHeater functional check Ә Ә
şAir conditioner functional check Ә Ә
şStart aid system check Ә Ә
9. Cab components and vandal protection checks
şCab door latch check Ә Ә

şCab door hold open latch check Ә Ә
şCab door release button check Ә Ә
şCab door lock check Ә Ә
şCab door window check Ә Ә
şCab window latch check Ә Ә
şSteering column adjustment check Ә Ә
şSeat and seat belt check Ә Ә
şAir intake filter door check Ә Ә
şEngine side panels check Ә Ә
şRadiator cap access door check Ә Ә
şFrame locking bar check Ә Ә
şBoom lock check Ә Ә
şService decal check Ә Ә
1-24
SECTION 3 POWER TRAIN SYSTEM
GROUP 1 STRUCTURE AND FUNCTION
1. POWER TRAIN COMPONENT OVERVIEW
Transmission Upper drive shaft Engine
Front axle Front drive shaft Center drive shaft Rear drive shaft Rear axle
The power train consists of the following components :

şTransmission
şFront, upper, center and rear drive shafts
şFront 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 disk type parking brake is located in 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 front
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
K4 KR K1 K3 KV K2
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
System
pressure
Valve block control circuit valve
Converter
Relief Filter
valve
Oil cooler Back

pressure
valve
Bypass Pump
valve
Oil sump
Lubrication
Main oil circuit
NFS Follow-on slide P3 Proportional valve clutch K1

D Oscillation damper P4 Proportional valve clutch K3
B Orifice P5 Proportional valve clutch KV
P1 Proportional valve clutch K4 P6 Proportional valve clutch K2
P2 Proportional valve clutch KR Y1~Y6 Pressure regulator
Forward Reverse
Speed Neutral
1 2 3 4 1 2 3
Y1 X
Y2 X X X
Y3 X X
Y4 X X X
Y5 X X X
Y6 X X
X : Pressure regulator under voltage
3-2
2. TORQUE CONVERTER
5 1 2 3 4
1 Pump 3 Turbine 5 Input flange

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

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

about the same speed as
pump wheel.
3-4
3. TRANSMISSION
1) LAYOUT
12
1
11
10
3
9 4
5
15
14
13 6
1 Reverse clutch(KR) 6 Rear output flange 11 Converter

2 Engine-dependent 7 Converter side output 12 Inductive transmitter
power take-off flange for engine speed
3 Forward clutch(KV) 8 Output shaft 13 4th clutch(K4)
4 2nd clutch(K2) 9 Transmission pump 14 Converter relief valve
5 3rd clutch(K3) 10 Input flange 15 1st clutch(K1)
3-5
2) INSTALLATION VIEW
1 2 9 10 11 12 14
15
20
3
19
8 16
3 13
18
4 17
7 6 5
1 Lifting lugs 11 Breather

2 Input flange-input through universal shaft 12 Transmission-case cover
3 Transmission suspension threads M20 13 Transmission case
4 Output flange-converter side 14 Power take-off; Coaxial;
5 Oil drain plug with magnetic insert M38ź1.5 Engine-dependent
6 Model identification plate 15 Electro-hydraulic control
7 Attachment possibility for oil level tube 16 Oil level tube with oil dipstick
with oil dipstick(Converter side) 17 Transmission suspension threads M20
8 Attachment possibility for emergency 18 Output flange-rear
steering pump 19 Exchange filter(Fine filter)
9 Cover 20 Filter head with connection for filter
10 Converter bell housing restriction switch
3-6
3) OPERATION OF TRANSMISSION
(1) Forward
‫ ڸ‬Forward 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.
KR KR
KV IN
K4
K2
INPUT
K3 K1
KV
OU
GEAR PATTERN
K2
K1 K3
K4
OUTPUT OUTPUT
3-7
‫ ڹ‬Forward 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.
KR KR
KV IN
K4
K2
INPUT
K3 K1
KV
OU
GEAR PATTERN
K2
K1 K3
K4
OUTPUT OUTPUT
3-8
‫ ں‬Forward 3rd
In 3rd forward, forward clutch and 3rd clutch are engaged.
Forward clutch and 3rd clutch are actuated by the hydraulic pressure applied to the clutch piston.
KR KR
KV IN
K4
K2
INPUT
K3 K1
KV
OU
GEAR PATTERN
K2
K1 K3
K4
OUTPUT OUTPUT
3-9
‫ ڻ‬Forward 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.
KR KR
KV IN
K4
K2
INPUT
K3 K1
KV
OU
GEAR PATTERN
K2
K1 K3
K4
OUTPUT OUTPUT
3-10
(2) Reverse
‫ ڸ‬Reverse 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.
KR KR
KV IN
K4
K2
INPUT
K3 K1
KV
OU
GEAR PATTERN
K2
K1 K3
K4
OUTPUT OUTPUT
3-11
‫ ڹ‬Reverse 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.
KR KR
KV IN
K4
K2
INPUT
K3 K1
KV
OU
GEAR PATTERN
K2
K1 K3
K4
OUTPUT OUTPUT
3-12
‫ ں‬Reverse 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.
KR KR
KV IN
K4
K2
INPUT
K3 K1
KV
OU
GEAR PATTERN
K2
K1 K3
K4
OUTPUT OUTPUT
3-13
4) ELECTRO-HYDRAULIC SHIFT CONTROL WITH PROPORTIONAL VALVE
2 1 3
A A
Y6 Y1
Y5 Y2
B
Y4 Y3
3 6
2 6 1 4 11 9 10
Y5
SECTION A-A SECTION B-B

8 7
1 Pressure reducing valve(9 bar) 7 Intermediate sheet

2 System pressure valve(16+2 bar) 8 Duct plate
3 Housing 9 Oscillation damper
4 Cable harness 10 Follow-on slide
5 Cover 11 Pressure regulator
6 Valve block
Transmission control see schedule of measuring points, hydraulic schematic and electro-hydraulic
control unit at page 3-2, 3-14 and 3-44.
The six clutches of the transmission are selected through the 6 proportional valves P1 to P6. The
proportional valve(Pressure regulator-unit) consists of pressure regulator(e.g. Y1), booster valve
oscillation damper.
The pilot pressure of 9 bar for the control of the follow-on slides is created by the reducing valve.
The pressure oil (16+2 bar) is directed through the follow-on slide to the corresponding clutch.
3 - 14
By the direct proportional selection with separate pressure modulation for each clutch, the
pressures to the clutches, taking part in the gear change, are controlled. In this way, a hydraulic
overlab of the clutches to be engaged and disengaged is achieved.
This is leading to fast shiftings without traction force interruption.
At the shifting, the following criteria are considered:
- Speed of engine, turbine, central gear train and output.
- Transmission temperature.
- Shifting mode(Up-, down-, reverse shifting and gear engaging from neutral).
- Load level(Full- and partial load, traction, coasting inclusive consideration of load cycles during the
shifting).
The system pressure valve is limiting the maximum control pressure to 16+2 bar and releases the
main stream to the converter and lubricating circuit.
A converter relief valve is installed in the converter inlet, which protects the converter against high
internal pressures(Opening pressure 9bar).
Within the converter, the oil transfers the power transmission according to the well-known
hydrodynamic principle(See torque converter, page 3-3).
In order to avoid cavitation, the converter must be always completely filled with oil.
This is achieved by a converter back pressure valve, following the converter, with an opening
pressure of about 3.5bar.
The oil, escaping from the converter, is directed to a oil cooler.
The oil is directed from the oil cooler to the transmission and from there to the lubricating-oil circuit
so that all lubricating points are supplied with cooled oil.
In the electro-hydraulic control unit there are 6 pressure regulators installed.
5) GEAR SELECTOR(DW-3)
The gear selector is designed for the

mounting on the left side of the steering
column. The positions(Speeds) 1 to 4 are F
1
selected by a rotary motion, the driving 2
3
N
4
R
direction Forward(F)-Neutral(N)-Reverse(R)
by tilting the gear selector lever.
The gear selector is also available with
integrated kickdown control knob.
A neutral lock is installed as protection
against inadvertent drive off.
N D
Position N - Gear selector lever blocked in
this position.
Position D - Driving.
3 - 15
6) DISPLAY
(1) Function
The display can be used with the gear selector(DW-3). It indicates speed and driving direction as
well as the activated kickdown.
When driving in the automatic mode, a bar indicator gives additionally also information about the
selected driving range; The automatic range is symbolized by arrows above and below the bar
indicator. In case of possible errors in the system, a wrench appears on the display, combined
with indication of the error number. Also sporadically occurring errors can be indicated.
d f e First position g
h S
T
O
P
b a c Second position
a Preselection reverse driving direction

b, c, d, e Monitoring different gear-ranges
1 Bars
f Preselection forward driving direction
Flashing Kick-down modus is activated
Shows the actual driving direction
2 First position F : Forward, R : Reverse
First segment of the error code
Shows the current gear
3 Second position
Second segment of the error code
4 Spanner g Electronic control unit recognized an error
5 Letters STOP h Immediate stop is required(At the moment not activated)
3 - 16
(2) Definition of the error codes
Introduction
The error codes consists of two hexadecimal numbers.
The first number shows the type of signal, the second number shows signal and the type of the
error.
Description of error codes
First No. Meaning of number

1 hex Digital input signals
2 hex Analog input signals
3 hex Speed signals
4 hex Speed signals
7 hex Analog current output signals
8 hex Analog current output signals
9 hex Digital output signals
A hex Digital output signals
B hex Clutch errors
D hex Power supply
E hex High speed signals
F hex General errors
List of error codes
Number Meaning of error code

11 hex Logical error at gear range signal
12 hex Logical error at direction select signal
21 hex Short circuit to battery voltage at clutch cutoff input

22 hex Short circuit to ground or open circuit at clutch cutoff input
23 hex Short circuit to battery voltage at load sensor input not used
24 hex Short circuit to ground or open circuit at load sensor input not used
25 hex Short circuit to battery voltage or open circuit at temperature sensor input
26 hex Short circuit to ground at temperature sensor input
31 hex Short circuit to battery voltage at engine speed input

32 hex Short circuit to ground or open circuit at engine speed input
33 hex Logical error at engine speed input
34 hex Short circuit to battery voltage at turbine speed input
35 hex Short circuit to ground or open circuit at turbine speed input
36 hex Logical error at turbine speed input
37 hex Short circuit to battery voltage at internal speed input
38 hex Short circuit to ground or open circuit at internal speed input
39 hex Logical error at internal speed input
3 - 17
3A hex Short circuit to battery voltage at output speed input
3B hex Short circuit to ground or open circuit at output speed input
3C hex Logical error at output speed input
71 hex Short circuit to battery voltage at clutch K1

72 hex Short circuit to ground at clutch K1
73 hex Open circuit at clutch K1
7A hex Short circuit to battery voltage at converter clutch not used
7B hex Short circuit to ground at converter clutch not used
7C hex Open circuit at converter clutch not used

84 hex Short circuit to battery voltage at clutch KV
85 hex Short circuit to ground at clutch KV
86 hex Open circuit at clutch KV
87 hex Short circuit to battery voltage at clutch KR
88 hex Short circuit to ground at clutch KR
89 hex Open circuit at clutch KR
91 hex Short circuit battery voltage at relay reverse warning alarm

92 hex Short circuit to ground at relay reverse warning alarm
93 hex Open circuit at relay reverse warning alarm
94 hex Short circuit to battery voltage at relay starter interlock
95 hex Short circuit to ground at relay starter interlock
96 hex Open circuit at relay starter interlock
97 hex Short circuit to battery voltage at park brake solenoid
98 hex Short circuit ground at park brake solenoid
99 hex Open circuit at park brake solenoid
3 - 18
B1 hex Slippage at clutch K1
B5 hex Slippage at clutch KV
B6 hex Slippage at clutch KR
D1 hex Short circuit to battery voltage at power supply for sensors

D2 hex Short circuit to ground at power supply for sensors
D3 hex Low power at battery
D4 hex High power at battery
D5 hex Error at switch 1 for valve power supply
D6 hex Error at switch 2 for valve power supply
E1 hex Short circuit to battery voltage at speedometer output not used

E2 hex Short circuit to ground or open circuit at speedometer output not used
E3 hex Short circuit to battery voltage at display output not used
E4 hex Short circuit to ground or open circuit at display output not used
E5 hex Error at communication on CAN
F1 hex General EEPROM fault

F2 hex Configuration lost
F3 hex Application error
Summary
This is only a proposal for error codes. If necessary, we will change the error codes or we will add
new error codes.
3 - 19
7) ELECTRIC CONTROL UNIT
(1) Complete system
2
1
5
12
4 10
3 9
2
6 7 13
11 8
14
1 Control unit(EST-37)
2 Kickdown switch
3 Clutch cut off switch
4 Full automatic switch
5 Display
6 Gear selector(DW-3) with integrated kickdown switch
7 Supply-system connection
8 Transmission
9 Cable to inductive transmitter - speed central gear train
10 Cable to inductive transmitter - speed turbine
11 Cable to inductive transmitter - speed engine
12 Cable to speed sensor output and speedometer
13 Cable to plug connection on the electro - hydraulic control unit
14 Brake pressure sensor/load sensor
(2) Description of the basic functions
The powershift-reversing transmissions will be equipped with the electronic transmission control
unit(EST-37), developed for them.
The system is processing the wishes of the driver according to the following criteria.
şSpeed definition as a function of gear selector position, driving speed and load level.
3 - 20
şProtection against operating errors, as far as possible and practical.
şProtection against overspeeds(On the basis of engine and turbine speed).
şReversing-automatic system(Driving speed-dependent).
şPressure cut off(Disconnecting of the drive train for maximum power on the power take-off).
şSwitch for manual or automatic operation.
şReversing function button, respectively kickdown function.
(3) Gearshifts
The control unit(EST-37) is shifts the required speeds fully-automatically under consideration of
the following criteria.
şGear selector position
şDriving speed
şLoad level
At the same time, the following speeds are picked up by the control unit(EST-37).
şn Engine
şn Turbine
şn Central gear train
şn 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
1F‫ء‬1R and 2F‫ء‬2R(As a rule, this is the maximum driving speed of the 2nd speed).
3 - 21
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 - 22
5. AXLE
1) OPERATION
ş The power from the engine passes through torque converter, transmission and drive shafts, and is
then sent to the front and rear axles.
ş 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
1 Final drive 2 Differential 3 Axle
(2) Rear axle
1 Final drive 2 Differential 3 Axle
3 - 23
2) SECTION OF FRONT AXLE DIFFERENTIAL
A A
1
5
SECTION A-A
1 Bevel pinion 3 Sun gears 5 Side gear(Differential)

2 Bevel gear 4 Shaft
3 - 24
3) SECTION OF REAR AXLE DIFFERENTIAL
A A
1
5
SECTION A-A
1 Bevel pinion 3 Sun gears 5 Side gear(Differential)

2 Bevel gear 4 Shaft
3 - 25
4) DIFFERENTIAL
(1) Description 3
When the machine makes a turn, the 2 4
outside wheel must rotate faster than the
inside wheel. A differential is a device
which continuously transmits power to the
right and left wheels while allowing them
to turn a different speeds, during a turn.
The power from the drive shaft passes
through bevel pinion(1) and is transmitted
to the bevel gear(2). The bevel gear
changes the direction of the motive force
by 90 degree, and at the same time
1
reduces the speed.
It then transmits the motive force through
the differential(3) to the axle gear shaft(4).
(2) When driving straight forward

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

When turning, the rotating speed of the Pinion gear
left and right wheels is different, so the Side gear Side gear
pinion gear and side gear inside the
differential assembly rotate in accordance
with the difference between the rotating
speed of the left and right wheels.
The power of the carrier is then
transmitted to the axle gear shafts. Carrier
Pinion gear Ring gear
3 - 26
5) TORQUE PROPORTIONING DIFFERENTIAL
(1) Function
‫ ڸ‬Because 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
‫ ڸ‬When traveling straight(Equal Spider rotating
direction
resistance 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
a b
b-are equal and the pinion is balanced as Engaging Engaging
point point
FLźa=FRźb. Thus, FL=FR, and the
right and left side gears are driven with
the same force. Left side gear Pinion Right side gear
3 - 27
‫ ڹ‬When 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
źa=FRźb, 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
wheels reaches about 30%.
3 - 28
6) FINAL DRIVE(Front & rear)
1 Axle shaft 3 Ring gear 4 Sun gear

2 Planetary gear
(1) To gain a large drive force, the final drive uses a planetary gear system to reduce the speed and
send drive force to the tires.
(2) The power transmitted from the differential through axle shaft(1) to sun gear(4) is transmitted to
planetary gear(2). The planetary gear rotates around the inside of a fixed ring gear(3) and in this
way transmits rotation at a reduced speed to the planetary carrier.
This power is then sent to the wheels which are installed to the planetary carriers.
3 - 29
6. TIRE AND WHEEL
1 Wheel rim 3 O-ring 5 Side ring

2 Tire 4 Lock ring 6 Valve assembly
1) The tire acts to absorb the shock from the ground surface to the machine, and at the same time
they must rotate in contact with the ground to gain the power which drives the machine.
2) Various types of tires are available to suit the purpose. Therefore it is very important to select the
correct tires for the type of work and bucket capacity.
3 - 30
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
3-31
Ɠ 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.
TRANS Select full automatic switch to
manual mode.
Move gear selector lever to 3rd
speed.
Move gear selector lever to
forward "F" position.
Increase engine speed to high idle
for 30 seconds.
Move gear selector lever to
neutral "N" position and run for 15
seconds.
Repeat procedure until
transmission temperature gauge
arrow points to bar above dial.
Gear selector lever and Move gear selector lever to each OK

neutral lock latch 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.
ND 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.
NOT OK
Turn full automatic switch ON.
Go to transmission error
code group at page 3-17~
LOOK : Automatic sign on
3-19.
display.
Repair or replace the
S
T
Move gear selector lever to display or harness.

O
P
forward or reverse position.

Increase engine rpm.
LOOK : Speed(2nd~4th) on
display must vary with machine
speed.
3-32
Transmission noise Run engine at approximately OK

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

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

switch once.
not shift down.
Select full automatic switch to
automatic mode.
Drive machine at approximately
90$ speed of max speed in each
gear(2nd or 3rd or 4th).
Shift to(2nd or 3rd or 4th) gear in
each forward and reverse speed
and press gear selector kick down
lever switch or RCV lever switch
once.
shift to lower(1st or 2nd or 3rd)
gear respectively.
Press gear selector lever kick
down switch or RCV lever switch
once again.
3-33
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 Check completed.
Apply service brakes.
drag check
NOT OK
Ɠ Transmission must Move gear selector lever to
If unit moves, repair
be warmed up for neutral.
transmission.
this check.
Move gear selector lever to 1st.
Engine running.
Release parking brake and
service brakes.
Run engine at low idle.
LOOK : Unit must not move in
either direction.
NOTE : If unit moves forward,
either the forward pack or the 4th
speed pack is dragging.
Transmission pressure, Run engine at low idle. OK

pump flow, and leakage Check completed.
Release parking brake.
check
NOT OK
Engine running. Shift transmission to reverse, then
Do transmission leakage
forward, and then to 1st, 2nd, and
test, system pressure test,
3rd speeds.
or pump flow test in group
Wait 5 seconds after each shift 3.
and observe transmission
pressure indicator light.
LOOK : Indicator light must not
come on.
NOTE : If light comes on in one
gear only, leakage is indicated on
that gear.
If light comes on in all gears, low
pump flow or pressure is
indicated.
3-34
Transmission shift Run engine at approximately OK

modulation check 1600rpm. Check completed.
Engine running.
Put transmission in 1st forward, NOT OK
shift several times from forward to Go to unit shifts too fast,
reverse and reverse to forward. chapter 2 in this group.
Repeat check in 2nd gear.
LOOK : Unit must slow down and
change direction smoothly.
Torque converter check Start engine. Apply service OK

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 : 2250 ~ 2390rpm
Move gear selector control lever
to neutral "N" position and run for
15 seconds.
3-35
2. TROUBLESHOOTING
1) TRANSMISSION
Ɠ Diagnose malfunction charts are arranged from most probable and simplest to verify, to least
likely, more difficult to verify. Remember the following steps when troubleshooting a problem :
Step 1. Operational check out procedure(See group 3 in section 1.)
Step 2. Operational checks(In this group.)
Step 3. Troubleshooting
Step 4. Tests and/or adjustments(See group 3.)
Problem Cause Remedy
Transmission slippage Low oil level. Add oil.

Wrong oil grade. Change oil.
Restricted transmission pump Remove and clean screen.
suction screen.
Leak in transmission control Remove valve and inspect gaskets.
valve or gasket.
Low transmission pump flow Do transmission pump flow test.
due to worn pump.
Weak or broken pressure Do transmission system pressure test.
regulating valve spring.
Something wrong in Go to transmission error code group at page

Error code on display
transmission. 3-17~3-19.
3-36
Machine will not move Low oil level. Add oil.

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

engage in low gear control solenoid valve.
Stuck spool in transmission Remove and inspect transmission control valve
control valve. spools.
Stuck PPC valve. Remove end cover to inspect PPC valve.
Replace if necessary.
Malfunctioning transmission Check speed sensor.
speed sensor.
3-37
Transmission pressure Low oil level. Check transmission oil level and refill if
is low(All gears) necessary.
Failed transmission pressure Verify transmission system pressure. Do
switch. transmission system pressure test.
Plugged suction strainer. Transmission pump may be noisy if transmission
suction screen is clogged. Drain transmission.
Remove and clean suction screen.
Also, check condition of transmission filter.
Stuck transmission pressure Remove transmission pressure regulating valve.
regulating valve or broken Inspect for damage(See transmission control
spring. valve).
Failed control valve gasket. Inspect transmission control valve for external
leakage. Remove control valve.
Inspect or replace gasket.
Stuck PPC valve. Remove end cover to inspect modulation spool
and check torque on cap screws retaining control
valve to transmission.
Transmission system Failed transmission pump. Do pump flow test.

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

low
Low transmission pressure. Do transmission system pressure test.
Restricted transmission pump Remove and clean screen.
suction screen.
Low transmission pump flow. Do transmission pump flow test.
Excessive transmission Do transmission element leakage test using
element leakage. system pressure.
Stuck PPC valve. Remove end cover to inspect modulation spool.
Restricted PPC valve orifice. Remove orifice and inspect for contamination and
/or plugging.
Restricted oil passages Remove control valve and inspect oil passage.
between control valve and
transmission elements.
Incorrect transmission oil. Change oil(DEXRON є or DEXRON ѕ)
3-38
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(DEXRON є or DEXRON ѕ)
Machine "creeps" Warped disks and plates in Check transmission.

in neutral transmission.
Transmission hydraulic High oil level. Transmission overfilled or hydraulic pump seal
system overheats leaking.
Low oil level. Add oil.
Wrong oil grade. Change oil.
Park brake dragging. Check for heat in park brake area.
Pinched, restricted or leaking Check cooler lines.
lube lines.
Machine operated in too high Operate machine in correct gear range.
gear range.
Malfunction in temperature Install temperature sensor the verify temperature.
gauge or sensor. Do tachometer/temperature reader installation
procedure.
Restricted air flow through oil Do radiator air flow test.
cooler or radiator.
Failed oil cooler bypass Disassemble and inspect.
valve(In thermal bypass valve).
Failed thermal bypass valve. Remove thermal bypass valve and check to see if
machine still overheats. Do transmission oil
cooler thermal bypass valve test.
Internally restricted oil cooler. Do oil cooler restriction test.
Leakage in transmission Do transmission system pressure, element
hydraulic system. leakage test.
Malfunction in converter relief Do converter out pressure test.
valve.
Low transmission pump output. Do transmission pump flow test.
3-39
Excessive transmission Too low engine low idle. Check engine low idle speed.
noise(Under load or no
Worn parts or damaged in Remove transmission suction screen. Inspect
load)
transmission. for metal particles.
Repair as necessary.
Warped drive line between Inspect drive line.
engine and torque converter.
Low or no lube. Do converter-out and lube pressure test. Do
transmission pump flow test.
Foaming oil Incorrect type of oil. Change oil.

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

Low engine speed. Check engine speed.
Failed universal joints on Check universal joints.
transmission drive shaft or
differential drive shafts.
Machine lacks power Engine high idle speed set too Check high idle adjustment.
and acceleration low.
Incorrect transmission oil. Change oil.
Aerated oil. Add oil.
Low transmission pressure. Do transmission system pressure test.
Warped transmission clutch. Do transmission clutch drag checks.
Torn transmission control valve Inspect gasket.
gasket.
Brake drag. Do brake drag check.
Failed torque converter. Do torque converter stall speed test.
Low engine power. Do engine power test.
Torque converter stall Aerated oil. Put clear hose on thermal bypass outlet port.
RPM too high Run machine to check for bubbles in oil.
Stuck open converter relief Do converter-out pressure test.
valve.
Leakage in torque converter Do converter-out pressure test.
seal.
Torque converter not Replace torque converter.
transferring power(Bent fins,
broken starter).
3-40
Torque converter stall Low engine power. Do engine power test.

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

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

light comes ON for each
No time delay in monitor. Do monitor check.
shift
Restriction in modulation orifice. Remove orifice and inspect for restriction and/or
plugging.
Stuck PPC valve. Remove and inspect.
Low transmission pressure Do transmission system pressure test.
circuit.
Leak in transmission pressure Do converter out pressure test.
circuit.
Failed transmission pump. Do transmission pump flow test.
Clogged filter. Inspect filter. Replace.
3-41
2) DIFFERENTIAL / AXLE
Differential low on oil External leakage. Inspect axle and differential for leaks.
Excessive differential Low oil level in differential. Check oil. Remove drain plug and inspect for
and/or axle noise metal particles in differential case.
Disassemble and determine cause.
Incorrect type of oil. Change oil
Dragging brakes. Do brake check.
Failed pinion bearing. Remove and inspect pinion.
Check to ensure pinion housing was indexed.
Incorrect gear mesh pattern Remove pinion gear housing and inspect ring and
between ring and pinion gear. pinion gear.
Failed differential pinion gears Remove differential housing drain plug and
and/or cross shafts. inspect for metal particles. Disassemble and
inspect.
Failed axle bearing. Do axle bearing adjustment check.
Mechanical failure in axle Remove differential. Inspect, repair.
planetary.
Oil seeping from outer Excessive end play in axle. Do axle bearing adjustment check.
axle seal
Worn outer bearing and/or cup. Disassemble and inspect outer axle bearing, cup,
spacer, and seal. Replace, if necessary.
Overfilled differential. Check differential oil return system for excessive
internal restriction.
Axle overheats Low differential oil. Add oil.

Overfilled differential. See differential overfills with oil in this group.
Brake drag. See brakes drag in this group.
3) DRIVE LINE
Excessive drive line Yokes not in line on drive Inspect. Align drive shaft yokes.
vibration or noise shafts.
Worn front drive line support Inspect, repair.
bearing.
Bent drive shaft. Inspect all drive shafts. Replace.
Loose yoke retaining nuts(Drive Inspect. Replace.
shafts wobble at high speed).
Rear axle oscillating support. Inspect, repair.
Lack of lubrication. Lubricate with proper grade of grease.
3-42
GROUP 3 TESTS AND ADJUSTMENTS
1. CLUTCH CUT-OFF PRESSURE SWITCH TEST

The setting pressure of the clutch cut-off Clutch cut off
pressure switch should be suited with the pressure switch
specification. The rated pressure is 25 kgf/cm2.
For the detailed method for pressure adjusting,
refer to page 4-22.
Brake valve
3-43
2. TRANSMISSION MEASURING POINTS AND CONNECTIONS
The measurements have to be carried outat hot transmission(About 80~95Ş
C).
48 47 21
34
65 51 68
69 49
H J
K
G
57 60
A F
B E 16
53 55 15
C D
58 56 52,63
VIEW X VIEW Y
1) OIL PRESSURE AND TEMPERATURE
Port Description Size

51 Converter inlet-opening pressure(9 bar) H M10ź1
52 Converter outlet-opening pressure(3.5 bar) M14ź1.5
53 Forward clutch(16+2 bar) B M10ź1
55 Reverse clutch(16+2 bar) E M10ź1
56 1st clutch(16+2 bar) D M10ź1
57 2nd clutch(16+2 bar) A M10ź1
58 3rd clutch(16+2 bar) C M10ź1
60 4th clutch(16+2 bar) F M10ź1
63 Converter outlet temperature 100ŞC, short-time 120ŞC M14ź1.5
65 System pressure(16+2 bar) K M10ź1
3 - 44
2) DELIVERY RATES

15 Connection to oil cooler 1 5/16"-12UNF-2B
16 Connection from the oil cooler 1 5/16"-12UNF-2B
3) INDUCTIVE TRANSMITTER AND SPEED SENSOR

21 Inductive transmitter n turbine M18ź1.5
34 Speed sensor n output and speedometer -
47 Inductive transmitter n central gear train M18ź1.5
48 Inductive transmitter n engine M18ź1.5
4) CONNECTIONS

49 Plug connection on the hydraulic control unit -
68 Pilot pressure(Option) J M16ź1.5
69 System pressure(Option) G M16ź1.5
3-45
SECTION 4 BRAKE SYSTEM
1. OUTLINE
Ɠ 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 service brake circuit and park brake circuits. It
flows to four accumulator. The accumulator has a gas precharge and an inlet check valve to
maintain a pressurized volume of oil for reserve brake applications.
Oil through the accumulator flows to the brake valves. The brake valve is a closed center design,
dual circuit operated by a pedal.
The front and rear brakes will operate simultaneously with only one brake pedal depressed.
The differential contains annular brake piston and double sided disk.
Brake pump flow also goes to the parking brake solenoid valve.
The brake system contains the following components:
şBrake pump
şParking brake solenoid valve
şBrake valve
şAccumulators
şPressure 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(lbşin)
air/hydraulic and full power hydraulic brake
actuation system. 600
Brake pressure
Full power systems can supply significantly 500 (Air/hydraulic)
higher brake pressures with relatively low Brake torque
400
reactive pedal forces. The reactive pedal (Air/hydraulic)
force felt by the operator will be proportional 300
Brake torque
to the brake line pressure being generated. 200 (Full power)
This is referred to as brake pressure
modulation. 100
Another key design feature of full power
0 1 2 3 4
systems is the ability to control maximum
brake line pressure. In addition, because Time(Seconds)
these systems operate with hydraulic oil,
filtration can be utilized to provide long
component life and low maintenance
operation.
Because these systems are closed center,
by using a properly sized accumulator,
emergency power-off braking that is
identical to power-on braking can be
achieved. These systems can be either
dedicated, where the brake system pump
supplies only the demands of the brake
system or non-dedicated, where the pump
supplies the demands of the brake system
as well as some secondary down stream
hydraulic devise.
Another important note is that all seals
within these system must be compatible
with the fluid medium being used.
4-2
2. HYDRAULIC CIRCUIT
FRONT 29 REAR
20
17 A B
P T
16
15
8
15 21 18
7 BR1 BR2 M2
DS1
A 1st pump
S1 B 2nd pump
DS2 S2 Return line C Brake pump
S3
19 T
N
Steering system MCV P1 RCV lever
12 3Mpa
U
22 P2 T
C B A 1
23 Return line
24 25 26
1 Main pump 17 Solenoid valve 23 Air breather

7 Brake valve 18 Pressure switch 24 Hydraulic tank
8 Check valve 19 Pressure switch 25 Return filter
12 Pilot supply unit 20 Pressure switch 26 Bypass valve
15 Accumulator 21 Pressure switch 29 Axle
16 Accumulator 22 Line filter
4-3
1) SERVICE BRAKE RELEASED
FRONT 29 REAR
20
17 A B
P T
16
15
8
15 21 18
7 BR1 BR2 M2
DS1
A 1st pump
S1
B 2nd pump
S3
19 T
N
12 3Mpa
U
22 P2 T
C B A 1
23 Return line
24 25 26
When the pedal of brake valve(7) is released, the operating force is eliminated by the force of the
spring, and the spool is returned.
When the spool removes up, the exhaust port is opened and the hydraulic oil in the piston of axles
(29) return to the tank(24).
Therefore, the service brake is kept released.
4-4
2) SERVICE BRAKE OPERATED
FRONT 29 REAR
20
17 A B
P T
16
15
8
15 21 18
7 BR1 BR2 M2
DS1
A 1st pump
S1
B 2nd pump
S3
19 T
N
12 3Mpa
U
22 P2 T
C B A 1
23 Return line
24 25 26
When the pedal of brake valve(7) 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 other spool in the brake valve
enters the piston in the front and rear axles. Therefore, the service brake is applied.
4-5
3) PARKING BRAKE RELEASED
FRONT 29 REAR
20
A B
17
P T
16 ‫ڸ‬
15 ‫ڹ‬
8 P
15 21 18
7 BR1 BR2 M2 Parking brake switch
DS1
A 1st pump
S1 B 2nd pump
DS2 S2 Return line
S3
C Brake pump
19 T
N
12 3Mpa
U
22 P2 T
C B A 1
23 Return line
24 25 26
When the parking brake switch is pushed(‫)ڹ‬, the solenoid valve(17) is energized and the hydraulic
oil enters the front axle. It overcomes the force of the spring and pushes the piston. This releases
the brake.
Therefore, the hydraulic oil pressure is applied to the parking brake piston in front axle through the
solenoid valve(17) and the parking brake is kept released.
4-6
4) PARKING BRAKE OPERATED
FRONT 29 REAR
20
17 A B
P T
16
‫ڸ‬
15 ‫ڹ‬
8
P
15 21 18
7 BR1 BR2 M2
Parking brake switch
DS1
A 1st pump
S1
DS2 S2 Return line B 2nd pump
S3 C Brake pump
19 T
N
12 3Mpa
U
22 P2 T
C B A 1
23 Return line
24 25 26
When the parking brake switch is pushed(‫ )ڸ‬once more, the solenoid valve(17) is deenergized
and the valve open the exhaust port.
At the same time, the hydraulic oil return to the tank through the solenoid valve(17). When the
piston is returned by the force of the spring, the parking brake is applied.
4-7
3. BRAKE PUMP
1) STRUCTURE
22 23 26 28 27 31 32,33
24
21 27 29 30 26
25
21 Splined coupling 26 Bushing 31 Cover

22 Spacer plate 27 Bushing 32 Spring washer
23 O-ring 28 Driven gear 33 Bolt
24 Seal 29 Drive gear
25 Seal 30 Body
Hydraulic pumps used for the work equipment hydraulic units on construction machinery are pressure
loaded type gear pumps. This gear pump have a maximum delivery pressure of 150kgf/cm2(2130psi).
The pressure loaded type gear pump is designed so that the clearance between the gear and the side
plate can be automatically adjusted according to the delivery pressure. Therefore, the oil leakage from
the side plate is less than that in the case of the fixed side plate type under a high discharge pressure.
Consequently, no significant reduction of the pump delivery occurs, even when the pump is operated
under pressure.
4-8
2) PRINCIPLE OF OPERATION
(1) Mechanism for delivering oil

The drawing at right shows the
operational principle of an external gear
pump in which two gears are rotating in
mesh.
The oil entering through the suction port is
trapped in the space between two gear Suction Discharge
teeth, and is delivered to the discharge
port as the gear rotates.
Except for the oil at the bottom of the gear
teeth, the oil trapped between the gear
teeth, is prevented from returning to the
suction side with the gears in mesh.
Since the gears are constantly delivering
oil, the oil delivered to the discharge port
is forced out of the port.
The amount of discharge increases with
the speed of rotation of the gear.
If there is no resistance in the oil passage
into which the discharged oil flows, the oil
merely flows through the passage,
producing no increase in pressure.
If however, the oil passage is blocked with
something like a hydraulic cylinder, there
will be no other place for the oil to flow, so
the oil pressure will rise. But the pressure
which rises in this way will never go
higher, once the hydraulic cylinder piston
starts moving because of the oil pressure.
As described earlier, the pump produces
the oil flow, but not the oil pressure. We
can therefore conclude that pressure is a
consequence of load.
In other words, the pressure depends on
a counterpart.
4-10
(2) Internal oil leakage
Oil leaks from a place under higher
pressure to a place under lower pressure,
provided that a gap or a clearance exists
in between.
In the gear pump, small clearances are
provided between the gear and the case
and between the gear and the side plate
to allow the oil to leak out and to serve as
a lubricant so that the pump will be
e
protected from seizure and binding. charg
Dis
The drawing at right shows how the
leaked oil flows in the pump. As such,
there is always oil leakage in the pump
from the discharge side(Under higher
pressure) to the suction side. The
n
delivery of the pump is reduced by an ctio
Su
amount equal to the pump discharge.
In addition, the delivery of the pump will
also decrease as the amount of oil
leakage increases because of expanded
radial clearance resulting from the wear of
pump parts, the lower oil viscosity
resulting from increases in the oil
temperature, and the initial use of low
viscosity oil.
4-11
(3) Forces acting on the gear
The gear, whose outer surface is
subjected to oil pressure, receives forces
jointing towards its center.
Due to the action of the delivery pressure,
the oil pressure in higher on the delivery
side of the pump, and due to suction
pressure, is lower on the suction side. In
the intermediate section, the pressure will
gradually lower as the position moves
from the delivery side to the suction side. Drive gear
This phenomenon is shown in the
drawing at right.
In addition, the gears in mesh will receive
Suction Discharge
interacting forces. side side
These forces pushing the gears toward
the suction side are received by the
bearings. Since the gears are pressed
Driven gear
toward the suction side by these forces,
the radial clearance becomes smaller on
the suction side in the case. In some
pumps, the clearance may become zero,
thus allowing the gear teeth and the case Pressure distribution
to come into light contact.
For this reason, an excessive increase in
the delivery pressure must be avoided,
since it will produce a large force which
will act on the gears, placing an overload
on the bearings, and resulting in a
shortened service life of the bearing or
interference of the gear with the case.
4-11
(4) "Trapping" phenomenon of the oil
When a gear pump is rotating with the
gears in mesh as shown in the drawing at
right, in some instances two sets of gear
Delivery Suction side
teeth are in mesh while in other instances side
only one set of the gear teeth is in mesh.
When two sets of the teeth are in mesh
simultaneously, the oil in the space Trapping starts
between the meshed gear teeth will be
trapped inside-the front and rear exits will The space
reaches the
be completely shut. minimum
This is called the "trapping" phenomenon
of oil.
The space in which the oil is trapped Trapping ends
moves from the suction side to the
delivery side as the gears rotate. The
volume of the space gradually decreases
from the start of trapping until the space
reaches the center section, and then
gradually increases after leaving the
center section until the end of trapping. Fixed side plate type
Since the oil itself is non-shrinkable, a
reduction of the volume of space will
greatly increase the oil pressure, unless
Side plate
some plosion in made to relieve oil
pressure. The high pressure oil will
cause the pump to make noise and
vibrate.
To prevent this, relief notches are Relief notch
provided on the side plates to release the
oil to the delivery side.
As shown in the drawing at right, the relief
notches are provided in such a way that Pressure loaded type Bushing
the oil can be relieved from the tapping
space to the delivery side when the
volume of the space is reduced.
Relief notches are also provided on the
suction side to prevent the formation of a
vacuum in the space by allowing the oil to
enter the space from the suction side
when the space is reduced.
4-12
4. BRAKE VALVE
1) STRUCTURE
72
42 80
41
26
86
14
27 1.25
4
82
28
5 32
36
55 21
64 37
9 65 41
1
18
43
1.47
1.22
12
30
29
12 1.23
87 31
59
24
115
1 Housing 24 Reducer 43 Locking screw
1.22 Spool 26 Spring 55 O-ring
1.23 Spool 27 Spring 59 O-ring
1.25 Spool 28 Spring 64 Thrust ring
1.47 Spool 29 Spring 65 Shaft seal
4 Sleeve 30 Spring 72 Pedal unit
5 Sleeve 31 Spring 80 O-ring
9 Sleeve 32 Spring 82 Spring
12 Spring retainer 36 Circlip 86 Unit RV
14 Spring retainer 37 Circlip 87 Sleeve
18 Unit WVI 41 Locking screw 115 Locking screw
21 Spring retainer 42 Locking screw
4-13
2) OPERATION
A
M1
T S1
M2
BR1 BR2 M2
DS1
BR1
S1
DS2 S3
S2
DS2
S3
BR2 S2
T
N
VIEW A
Port Port name Size
P From main pump M18ź1.5

N To hydraulic tank M18ź1.5
BR1 To service brake in front axle M16ź1.5
BR2 To service brake in rear axle M16ź1.5
DS1 Pressure switch stop light M12ź1.5
DS2 Pressure switch accumulator pressure M12ź1.5
S1 Accumulator service brake M18ź1.5
S2 Accumulator service brake M18ź1.5
S3 Accumulator parking brake M16ź1.5
M2 Accumulator parking brake M12ź1.5
T To hydraulic tank M16ź1.5
4-14
(1) Accumulator charging valve
The accumulator loading valve or
pressure switch-off valve has the purpose
S2
to keep a pressure level within certain limit
values(Switch-off pressure, switch-on
pressure) in an accumulator circuit. The 1
switching pressure difference is approx S1
18% of the switch-off pressure. 3 T
Ɠ If actuators(N) downstream from the

N
pump produce a higher pressure than the
switch-off pressure of the accumulator
loading valve the accumulator circuit is
raised to this pressure level.
X P 2
The valve consists mainly of pilot control
with pressure setting element(1), pressure
compensator(2) and check valve(3).
Switching over of pump flow from accumulator load into neutral circulation
The pump delivers into the accumulator circuit via the check valve(3) during the loading
procedure. For this the pressure is passed to the load signal side of the pressure compensator(2)
via the control line and pilot control. This throttles the pump flow until the pressure, which builds
up in the accumulator circuit, overcomes the spring force of the pressure setting element(1).
The pilot control element switches the load signal line of the pressure compensator(2) from S1 to
T. The pressure compensator(2) then switches the pump flow from P to N and the check valve(3)
closes. The loading pressure is complete and the pump flow flows with low ՠp through the
loading valve.
Switching over of pump flow from neutral circulation into accumulator load
If the pressure in the accumulator circuit decreases to the lower switching point(Adding pressure)
P is connected to the load signal chamber of the pressure compensator(2) and the pump delivers
again into the accumulator circuit.
4-15
(2) 2 circuit brake valve
The 2-circuit remotely powered braking
valve is direct controlled pressure relief
valve in 3-way design with infinite
4 2 7 2 1
mechanical operation.
BR1 BR2 M2
It has a maximum pressure relief of
secondary circuits and infinite adjustability
DS1
of pressure in the secondary circuits
(Braking circuits) proportional to the
direction of the operating element(4).
With failure of one braking circuit the
SP1 T SP2
second braking circuit remains fully
functional because of the mechanical 3 5 2 1
contact of both spools(2).
The operating force at the pedal remains
unchanged.
The 2-circuit remotely powered brake valve consists mainly of housing(1) and control spool(2),
main compression spring(3), operating element(4) and the return springs(5) and (6).
The valve is operated via the operating element(4). It pushes the main control spring(3) against
both control spools(2). First the control edges close at channel T, afterwards the flow from SP and
BR is released in both braking circuits.
The pressure building up in the brake lines pushes simultaneously via the pilot oil drillings(7)
behind the control spool against the main compression spring(3) so that the braking
pressure(Secondary pressure) rises proportional to the operating element kept constant the
control spools(2) moves into control position and holds the controlled pressure in channels BR1
and BR2 constant. The operating force of the operating element is proportional to its deflection.
When the main compression spring(3) is unloaded the pressure springs and the control spools
move in such a way that they close SP towards BR and open BR towards T and thus close the
secondary circuits(Braking circuits).
4-16
5. BRAKE ACCUMULATOR
1) STRUCTURE
31EC-0219 81L1-0004
Item
(Item16) (Item15)
Diameter 121mm 121mm
Mounting height 145mm 151mm
Norminal volume 0.75m 3
0.75m3
Priming pressure 7kgf/cm2 50kgf/cm2
Operating medium Oil Oil
B
Operating pressure Max 56kgf/cm 2
Max 180kgf/cm2
Thread M18ź1.5 M18ź1.5
A
Operating
C -30 ~ 80Ş
C -30 ~ 80Ş
C
temperature range
Priming gas Nitrogen Nitrogen
D
A Fluid portion C Diaphragm
B Gas portion D Valve disk
2) OPERATION
(1) Purpose
Fluids are practically incompressible and are thus incapable of accumulating pressure energy. In
hydropneumatic accumulators, the compressibility of a gas is utilized to accumulate fluid. The
compressible medium used in the accumulators is nitrogen.
In braking systems, the purpose of the accumulators is to store the energy supplied by the
hydraulic pump. They are also used as an energy reserve when the pump is not working, as a
compensator for any losses through leakage, and as oscillation dampers.
(2) Operation
The accumulator consists of a fluid portion(A) and a gas portion(B) with a diaphragm(C) as a gas-
tight dividing element. The fluid portion(A) is connected to the hydraulic circuit, causing the
diaphragm accumulator to be filled and the gas volume to be compressed as the pressure rises.
When the pressure falls, the compressed gas volume will expand, thus displacing the
accumulated pressure fluid into the circuit.
The diaphragm bottom contains a valve disk(D) which, if the diaphragm accumulator is
completely empty, closes the hydraulic outlet, thus preventing damage to the diaphragm.
(3) Installation requirements
The accumulators can be fitted in the hydraulic circuit, directly on a component or in blocks on
suitable consoles.
They should be fitted in as cool a location as possible.
Installation can be in any position.
4-17
(4) Maintenance of the accumulator
No special maintenance beyond the legal requirements is necessary.
The accumulator should be checked annually. It should be replaced if the initial gas
pressure has fallen by more than 30%(Please refer to Performance testing and
checking of the accumulator).
(5) Disposal of the accumulator
Before the accumulator is scrapped, its gas filling pressure must be reduced. For this
purpose, drill a hole through gas chamber(B) using a drill approx. 3mm in diameter. The
gas chamber is located on the side opposite the threaded port above the welding seam
around the center of the accumulator.
Ɠ 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
4-18
(7) Repair work
When working on the braking system, always make sure that there is absolutely no
pressure in the system. Even when the engine in switched off there will be some residual
pressure in the system.
Ɠ When doing repair work, make sure your environment is very clean.
Immediately close all open ports on the components and on pipes using plugs.
For safety reasons the accumulators need to be replaced as a whole if damaged.
4-19
6. PRESSURE SWITCHES
1) STRUCTURE
şNormally closed
H1
şNormally open
H2
ş Technical data
H1 H2 Adjusting range Adjusting pressure Voltage
Item Type Medium G
mm mm kg/cm2 kg/cm2 V
Parking NC Oil M12ź1.5 55 9 10 ~ 20 13 Ź 1 Max 42

Charging NC Oil M12ź1.5 55 9 20 ~ 50 45 Ź 2 Max 42
Brake stop NO Oil M12ź1.5 55 9 1 ~ 10 5Ź1 Max 42
Clutch cut off NO Oil 55 9 20 ~ 50 25 Ź 1 Max 42
NC : Normally closed NO : Normally open
4-20
2) OPERATION
(1) Purpose
The pressure switches are used to visually or audibly warn the driver of the pressure within the
system.
(2) Make contact / circuit closer
The pressure switch can be fitted in the braking system or directly on one of its components.
The system pressure acts on an absorption area within the switch, making an electrical contact as
the pressure on that area is increased. The resulting current is used to activate a warning facility,
for instance.
(3) Break contact / circuit breaker
The pressure switch can be fitted in the braking system or directly on one of its components.
The system pressure acts on a absorption area within the switch, breaking an electrical contact
as the pressure on that area is increased. The current is now broken, e.g. to deactivate a
warning facility.
(4) Installation requirements
No special measures need to be taken.
(5) Maintenance of the pressure switch
No special maintenance beyond the legal requirements is necessary.
When using high-pressure cleaners on the vehicle, please make sure that the water jet is not
directed at the pressure switch(Corrosion of contacts).
(6) Repair work
When working on the braking system, always make sure that there is absolutely no
pressure in the system. Even when the engine is switched off there will be some residual
pressure in the system.
Ɠ When doing repair work, make sure your environment is very clean.
Immediately close all open ports on the components and on pipes using plugs.
Ɠ For safety reasons the pressure switch needs to be replaced as a whole if damaged.
4-21
(7) Adjusting and testing pressure switch
The adjusting screw located between the two contact plugs can be set to the desired value within
a certain range. For adjusting range, please refer to the table Technical data on the previous
page.
After making the adjustment, the adjusting screw should be secured using wax or a similar
material.
(,)
Screw
(+)
4-22
1. OPERATIONAL CHECKS
This procedure is designed so the mechanic can make a quick check of the system using a minimum
amount of diagnostic equipment. If you need additional information, read structure and function,
Group 1.
If verification is needed, you will be given next best source of information:
4-23
ƓHydraulic oil must be at operating temperature for these checks(Refer to page 6-54).
Parking brake capacity Start engine. OK

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

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

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

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

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

ON STAR
T
Stop engine.
F
OF
NOT OK
Wait 2 minutes.
If brake leakage is
Turn key switch to ON and wait 5 indicated with brakes
seconds. released, check leakage
at accumulator inlet check
LOOK : Brake oil pressure
valve and brake valve. If
warning lamp must not come on
brake leakage is indicated
within 2 minutes after stopping
with brakes applied, check
engine.
for leakage at brake valve
and brake pistons.
Check individual
component leakage.
4-26
Service brake pedal Slowly depress brake pedal. OK

Listen for a hissing noise that
indicates oil is flowing to brake NOT OK
pistons. Inspect for debris under
brake pedal. Inspect
LISTEN/FEEL : A hissing noise
clutch cut off linkage.
must be heard when pedal is
depressed.
Service and parking Position machine on gradual OK

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

position. Check completed.
Release parking brake. NOT OK
Adjust clutch cut off
Run engine at half speed in 1st
switch.
forward.
Firmly depress brake pedal.
FEEL : Transmission must
disengage when brake pedal is
depressed at 30% of pedal stroke.
NOTE : Clutch cut off pressure
switch can be adjusted to operator
preference to match your loading
needs.
4-27
2. TROUBLESHOOTING
1) SERVICE BRAKE
Diagnose malfunction charts are arranged from most probable and simplest to verify, to least likely,
more difficult to verify. Remember the following steps when troubleshooting a problem :
Step 1. Operational check out procedure(See section 1)
Step 2. Operational checks(In this group)
Step 4. Tests and adjustments(See group 3)
Poor or no brakes Brake accumulator charge low. Do brake accumulator check.

Brake pump standby pressure Do brake pump standby pressure test.
low.
Brake pressure low. Do brake valve pressure test.
Air in system. Bleed brakes.
Worn brake surface material. Inspect brake surface material.
Leakage in brake valve. Do brake valve leakage test.
Leakage in brake piston seal. Check for an over filled differential.
Apply brakes and check for leakage from check
plug.
ƓIt is normal for the oil level to be slightly
above the check plug.
Incorrect oil. Change oil.
Aggressive brakes Internal restriction in circuit. Remove lines and components.

Brake valve malfunction. Disassemble and inspect.
Low oil level. Check oil level.
Brakes drag Brake pedal not 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.
4-28
Brakes chatter Air in brake system. Do brake bleed procedure.

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

light will not go out or pressure warning switch.
stays on excessively
Brake accumulator pressure Recharge accumulator.
long after start-up
too low.
Low brake pump standby Do brake pump standby pressure test.
pressure setting.
Leakage in pressure reducing Do pressure reducing valve manifold leakage
manifold block. test.
Leakage in brake system. Do brake system components leakage tests.
Worn brake pump. Do brake pump flow test.
Leakage in parking brake Do parking brake pressure test.
solenoid.
4-29
2) PARKING BRAKE MALFUNCTIONS
Brake will not hold Pads not adjusted correctly. Adjust parking brake.
Malfunctioning parking brake Inspect and replace.
solenoid.
Worn brake 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, Check electric circuit.
or solenoid.
Restriction between brake Remove hose and inspect. Replace.
valve and brake.
4-30
1. PARKING BRAKE PERFORMANCE

1) MEASUREMENT CONDITION
(1) Tire inflation pressure: Specified pressure
(2) Road surface : Flat, dry, paved surface
20') gradient.
with 1/5(11Ɓ
(3) Machine : In operating condition
20%
gradient 11Ɓ
20'
Item Standard valve
Parking brake Keep machine on 20%

performance (11Ɓ
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 11Ɓ
20' gradient
and the machine must be kept stopped.
Ɠ The measurement must be made with
the machine facing either up or down
the slope.
2. EXTERNAL BRAKE INSPECTION

Remove axle housing and inspect for wear of
brake disks.
Replace brake disks if oil grooves of facing
material are no longer visible.
4-31
3. HYDRAULIC BRAKE BLEEDING PROCEDURE
Escaping fluid under pressure can
penetrate the skin causing serious injury.
Avoid the hazard by relieving pressure
before disconnecting hydraulic or other
lines. Tighten all connections before B
applying pressure.
Search for leaks with a piece of
cardboard. Protect hands and body from
high pressure fluids.
Ɠ 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.
Two people are required to bleed brake
system oil, one to operate brake valve and
other to open and close bleed screws. A
1) Install frame locking bar. Engage parking

brake.
2) Put a clear plastic tube on bleed screw(B)
to route low to hydraulic reservoir filler tube
or container(A).
3) Start engine and run at low idle.
4) Push and hold brake pedal down until
brake bleeding procedure is complete.
Ɠ If bubbles continue for more than 2
minutes, stop bleeding procedure.
Check for and correct problem, then
continue.
5) Open on bleed screw on differential and
axle assembly until hydraulic oil starts to
flow. Close bleed screw when oil is free of Frame
locking bar
air. Release brake pedal.
6) Repeat steps 1) ~ 5) for each bleed screw.
7) Push either brake pedal and hold down.
8) Check hydraulic oil level.
4-32
GROUP 4 DISASSEMBLY AND ASSEMBLY
1. BRAKE PUMP
1) STRUCTURE
33
32
31
23
24
25
27
30
26 28
26
25
24
23 22
29
27
12
21
17
12 O-ring 24 Seal 29 Drive gear

17 O-ring 25 Seal 30 Body
21 Splined coupling 26 Bushing 31 Cover
22 Spacer plate 27 Bushing 32 Spring washer
23 O-ring 28 Driven gear 33 Bolt
4-33
2) GENERAL
(1) Introduction
Each unit comprises an end cover, body housing, the bush/gear assembly and a mounting flange
bolted together. The gear/bush assembly consists of a pair of meshing gears supported by plain
bearings in the bushes. The drive gear journal extends through the mounting flange to form the
drive shaft. A lip type shaft seal and O-rings provide external sealing whilst special lobe seals and
backing rings are used internally.
(2) Routine maintenance
No maintenance is necessary other than periodic checks for tightness of the mounting bolts and
visual examination for oil leakage. The unit should be kept externally clean, especially in the area
of the shaft seals as dirt can accelerate seal wear and cause leakage.
The unit must be operated only with clean oil and the system manufacturer's directions for
periodic renewal of system oil filter elements must be strictly observed.
(3) Field servicing
Seal kits and spare parts are available to enable units to be serviced.
4-34
3) DISASSEMBLY
33
32
31
23
24
25
27
30
26 28
26
25
24
23 22
29
27
12
21
17
Ɠ Before disassembling ensure that the unit itself, bench and tools are thoroughly clean.
(1) Lightly mark the end cover(31), body(30) and spacer plate(22) to ensure reassembly in the
correct position.
(2) Remove the bolts(33) and separate the brake pump unit from the main pump using a soft faced
hammer.
(3) Remove splined coupling(21) and O-rings(12, 17) sealing the internal passages between the
pump sections.
(4) Remove the spacer plate(22) from the body(30), free from spacer plate using a soft faced
hammer.
(5) Remove the backup seal(24), the seal element(25) and the body O-ring(23).
(6) Remove the end cover(31) from the body(30).
(7) Remove the backup seal(24), the seal element(25) and the body O-ring(23).
Ɠ Before removing the internal components each bushing(26, 27) must be marked to denote its
location within the body. On the plain area of the bush away from the seal location, lightly mark.
(8) With the unit laying on its side grasp hold of the drive shaft(29) and pull it squarely out of the body
(30) bringing the bushing(26, 27) with it.
(9) Remove the driven gear(28) and the two remaining bushing(26, 27).
4-35
4) INSPECTION AND REPAIR
(1) Assessment
Each components should be thoroughly cleaned, carefully examined and assessed for suitability
re-use. Below is a guide for inspecting the various components.
(2) Body
‫ ڸ‬Inspect the body bore cut-in where both gears wipe into the body.
‫ ڹ‬The body can only be re-used if the cut-in is bright and polished in appearance and the depth
does not exceed 0.15mm(0.006").
‫ ں‬The body should be replaced if the surface is scored, has a matt appearance or shows signs that
the tip of the gears have dug in and torn away the surface material.
‫ ڻ‬The body should be inspected to ensure that there is no superficial damage which may
adversely effect performance or sealing. Pay particular attention to the port threads and body O-
ring seal recesses.
(3) Spacer plate and end cover
‫ ڸ‬The inner surfaces should be inspected to ensure that there is no unusual wear or scoring in the
regions where the body O-rings and backing rings contact, which result in external leakage.
‫ ڹ‬Check the shaft seal recess for scoring or damage that could result in oil leakage around the
outer diameter of the shaft seal. Replacement shaft seals can be refitted with Loctite hydraulic
sealant to overcome slight damage in this area.
(4) Bushing
‫ ڸ‬The side faces which abut the gears should be perfectly flat showing no sign of scoring.
Characteristically there are bright polished areas on this surface caused by loading against the
gear side faces, which is often more pronounced on the low pressure side. The bush should be
replaced if there is any general scoring or fine scoring with a matt appearance or tearing of the
surface material. Often there is a witness where the tips of the opposing gears have wiped an
overlap reassembling a half moon shape. There must be no noticeable wear step as it is critical
that the bush side face is completely flat to the gear side face.
‫ ڹ‬The bearing liners are acceptable providing that they are not scored or show other damage.
The general outside area of the bush should not show any prominent signs of wear.
(5) Gears
‫ ڸ‬The gear side faces should be examined for bruising or scoring. Often operation on
contaminated fluid shows scoring between the root of the gear and the journal undercut, which
leaves a wear step. If a wear step can be felt, coincidental with the root diameter, by drawing a
sharp pointed tool across the surface from the undercut outwards towards the tip of the gear,
then the gear is unserviceable.
‫ ڹ‬The gear teeth should then be carefully examined to ensure that there are no signs of bruising or
pitting.
‫ ں‬The journal bearing surfaces should be completely free from scoring or bruising. The surface
should appear highly polished and smooth to touch.
‫ ڻ‬Examine the area where the shaft seal lips run on the drive shaft, this shows up as a polished
ring or rings. If a noticeable groove can be felt or there is scoring the shaft should be replaced.
‫ ڼ‬Provided the drive shaft is not damaged from the drive-coupling and the gears have not been
harmed as described above, then the gears can be re-used. If, however, the gears are
damaged they must be replaced as a matched pair.
‫ ڽ‬As a matter of good practice, when pumps have been disassembled, all the seals should be
replaced. It is most important that only the genuine seals are used.
4-36
5) ASSEMBLY
33
32
31
23
24
25
27
30
26 28
26
25
24
23 22
29
27
12
21
17
Ɠ Ensure that all parts are perfectly clean and lightly lubricate the bushes and gears with hydraulic
oil(Ensure body O-ring recess and end faces remain free from oil). This will assist with their
assembly when they are later fitted into the body.
(1) Refit the cover drive shaft bushing(26) and cover driven bushing(27) into the undowelled end of
the body(30) from where they were removed.
(2) Place the end cover(31) against the body(30) and then stand the assembly on the cover so that
the hollow dowels are uppermost, i.e. the bushing should be at the bottom with the bushings
against the cover.
(3) Fit the drive shaft(29) and driven gear(28) back into their original positions in the body(30).
(4) Refit the separate plate drive shaft bushing(27) and the separate plate driven bushing(26) into
their original bores.
(5) Fit the new body O-ring(23).
(6) Fit the new seal element(25) and backup seal(24) to the bushing.
(7) Carefully refit the spacer plate(22) to the body(30). If the spacer plate(22) is not fitted squarely
the backup seal(24) may become misplaced and trapped, resulting in internal damage if the unit
is run in this condition.
4-37
ASSEMBLY
33
32
31
23
24
25
27
30
26 28
26
25
24
23 22
29
27
12
21
17
(8) Fit O-rings(12, 17) and coupling(21) to the spacer plate(22).

(9) Holding the whole unit together carefully turn it over, making sure it is supported on the spacer
plate(22) not the shaft.
(10) Slide off the end over and fit seals as in (5) and (6) above.
(11) Fit the end cover(31), taking care not to dislodge the backup seal(24) and bolt(33) the unit
together. Tighten the bolts to the torque figures stated below.
şTightening torque : 4.8Ź0.4kgfşm(35Ź3lbfşft)
Ɠ Pour a small amount of oil into a port and check that the shaft can be rotated without undue force
using a smooth jawed hand wrench hooked around the shaft or a suitable half coupling locked
against the key.
4-38
6) RUNNING-IN
Pressure gauge
Test unit Variable

Microbic restrictor
filter
Flow
meter
Relief valve
Strainer
Tank
(1) A unit which has been re-assembled with either new gears, bushes or body, must be carefully
run-in before it is subjected to full working conditions.
(2) Ideally this should be done on a test rig(See figure) where pressure can be gradually applied and
any wipings from the body cut-in arrested by filters.
(3) It is recommended that the unit is run-in at 1500rpm, initially, at zero pressure for one minute then
in stages with the pressure increased by 500psi every minute, until maximum rated pressure has
been attained. Frequently check the system temperature, ensuring that it does not exceed the
maximum permissible figure of 80Ɓ C. If the temperature exceeds the system or unit specification
the test must be delayed and operated off-load until acceptable temperatures are obtained.
4-39
SECTION 5 STEERING SYSTEM
1. OUTLINE
The steering system of this machine consists of a fixed-displacement pump supplying a load sensing
steering system and an open center loader system.
The components of the steering system are :
şSteering pump(1st pump)
şSteering unit
şOverload valve block
şPriority valve
şSteering cylinders
The steering pump, the first pump of main pump, draws hydraulic oil from the hydraulic tank.
Outlet flow from the pump flows to the priority valve. The priority valve preferentially supplies flow, on
demand, to the steering unit. When the machine is steered, the steering unit routes flow to the
steering cylinders to articulate the machine.
When the machine is not being steered, or if pump flow is greater than steering flow, the priority valve
supplies flow to the loader system.
That is, output flow from the steering pump enters into the first pump of main pump for the operation
of the attachment.
5-1
2. HYDRAULIC CIRCUIT
LH RH
6 5
L
T 21Mpa
MCV RCV lever
P
LS
4 CF EF
LS
P
Brake system A 1st pump

C B A 1 B 2nd pump
Return line
C Brake pump
23 Return line
24
25 26
1 Main pump 6 Overload valve block 24 Hydraulic tank

4 Priority valve 9 Steering cylinder 25 Return filter
5 Steering unit 23 Air breather 26 Bypass valve
5-2
1) NEUTRAL
LH RH
6 5
L G
T 21Mpa
MCV RCV lever
P
LS
4 CF EF
LS
P
Brake system
A 1st pump
B A 1 B 2nd pump
Return line
23 Return line
24
25 26
ş The steering wheel is not being operated so control spool(G) does not move.
ş The oil from the steering pump(B) enters port P of the priority valve and the inlet pressure oil moves
the spool(D) to the right.
ş Oil flow into LS port to the hydraulic tank(24) through orifice and return filter.
ş So, the pump flow is routed to the loader system(Main control valve) through the EF port.
5-3
2) LEFT TURN
LH RH
6 5
L G
E
R
T 21Mpa
MCV RCV lever
P
LS
4 CF EF
LS
P
Brake system A 1st pump

B A 1 B 2nd pump
Return line
23 Return line
24
25 26
ş When the steering wheel(E) is turned to the left, the spool(G) within the steering unit(5) connected
with steering column turns in left hand direction.
ş At this time, the oil discharged from the steering pump flows into the spool(G) of the steering unit(5)
through the spool(D) of priority valve and flows into the gerotor(H).
ş Oil flow from the gerotor flows back into the spool(G) where it is directed out the left work port(L) to
the respective chamber of the steering cylinders(9).
ş Oil returned from left and right cylinder returns to hydraulic tank through the spool of the steering unit.
ş When the above operation is completed, the machine turns to the left.
5-4
3) RIGHT TURN
LH RH
6 5
L G
E
R
H
T 21Mpa
MCV RCV lever
P
LS
4 CF EF
LS
P
Brake system
B A 1 A 1st pump
Return line B 2nd pump
23 Return line
24
25 26
ş When the steering wheel(E) is turned to the right, the spool(G) within the steering unit(5) connected
with steering column turns in right hand direction.
ş At this time, the oil discharged from the steering pump flows into the spool(G) of the steering unit(5)
through the spool(D) of priority valve and flows into the gerotor(H).
ş Oil flow from the gerotor flows back into the spool(G) where it is directed out the right workport to the
respective chamber of the steering cylinders(9).
ş Oil returned from left and right cylinder returns to hydraulic tank through the spool of the steering unit.
ş When the above operation is completed, the machine turns to the right.
5-5
3. PRIORITY VALVE
1) STRUCTURE
1 2 3 4 9 6 5
LS
EF CF
1 Plug 4 Spool 9 Housing

2 Seal ring 5 Spring
3 Orifice 6 Plug
5-6
2) OPERATION
(1) Neutral
4 P A 5 A
CF EF
LS
LS
EF CF LOADER ACTUATED(D)
The priority valve is a pressure control valve that maintains priority pressure to the closed center
steering unit. With the steering unit in neutral, flow through is blocked and all flow through the priority
valve is directed out the EF port to the main control valve.
With the engine off, the spool(4) is pushed to the left(Viewed from sectional drawing at previous page)
by the spring(5). The passage to the EF port is blocked while the passage to the CF 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 pilot orifice to the left end of the spool. This causes the
priority valve spool(4) to shift to the right against the spring 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 shifted to the right.
The operating pressure in the loader system has no effect on the operation of the priority valve. With
the loader actuated in relief(D), the priority valve will not shift until the machine is steered.
Flow through the priority valve spool passes from the CF port through the orifice(A) 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.
5-7
(2) Midturn
4 P A 5 A
CF EF
LS
LS
FULL STEER RATE(D)

EF CF
When the machine is steered, load sensing pressure from the steering unit flows through the orifices LS
port in the priority valve. Load sensing pressure plus spring(5) force move the spool(4) to the against
the pilot pressure on the left end of the spool. This restricts flow to the loader through the EF port while
the CF port is opened to the steering unit.
The load sensing circuit is control circuit that routes steering workport pressure to the spring side of the
priority valve spool. It allows the priority valve spool to sense the pressure that is required to steer the
unit under varying conditions.
During normal steering conditions, oil is entered into the load sensing circuit through an orifice in the
steering unit. When steering at the full steer rate(D), the orifice opens to an unrestricted passage. At
low engine speed, the spool will shift to the full left position, directing all flow to the steering unit. At high
idle, the steering system can use about one-half of the pump flow. Therefore, the excess oil flows to
the main control valve.
The load-sensing circuit receives the majority of its flow from the load sensing orifice in the steering unit.
Some flow is also supplied from the CF port through orifice(A) in the priority valve spool.
5-8
(3) Full turn
4 P 5
CF EF
LS
LS
EF CF
When the machine is steered to a full turn, the frames bottom against the steering stops.
Pressure to the steering unit(Pilot pressure), which is sensed at the left end of the priority valve spool(4),
continues to increase until it can move the spool to the right against the load sensing pressure plus
spring force. At this time, all oil flows out of the EF port to the main 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.
5-9
4. STEERING UNIT
1) STRUCTURE
1 2
24
2 5
6
7
3
4
2
A
2
8
14 9 10
13
14 A
14
15
14
17
16 18
21
18
20
1 Dust seal ring 8 Cross pin 16 Gearwheel set

2 Housing assy 9 Spring set 17 End cover
3 Ball 10 Cardan shaft 18 Washer
4 Bushing 12 O-ring 20 Pin screw
5 Roto Glyd ring 13 Intermediate plate 21 Screw
6 Bearing assy 14 O-ring 24 Pilot relief valve
7 Ring 15 Distributor plate
5-10
2) OPERATION
A NEUTRAL
B
C Anti-cavitation valves
D Load sense port to priority valve
E Gerotor
System pressure oil

Spool I G Return
Work pressure oil
J H
G Trapped oil
Steering shaft Sleeve F
Return
From priority valve Return pressure oil
The steering unit consists of a spool(I) inside a sleeve(H) within a housing. When steering wheel is not
moving, the valve is in the neutral(A) position. In neutral, the spool and sleeve are aligned so that oil
flow through the valve 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 valve 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 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 valve is back in the neutral position and
will remain there until the steering wheel is moved again.
The valve 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.
5-11
5. OVERLOAD VALVE
2
9
3 8
7
6
9
P R 5
T L
5
6 4
7
8 4
R
P, T, L, R port 3/4-16 UNF
T
Shock valves 270-290 bar
P
Screw M10ź1ź46
HYDRAULIC CIRCUIT
1 O-rings set 4 Screw 7 O-ring

2 O-rings set 5 Shock valve 8 Plug
3 Rolled pin 6 Spring 9 Housing assy
5-12
6. STEERING CYLINDER
1) STRUCTURE
22,23 9,8 10 6,5 7 11,12 4 3 2 1 13 14 15 16 17
19,20,21 18
1 Tube assy 9 Snap ring 17 Nylon nut

2 Rod assy 10 O-ring 18 Pipe assy
3 Gland 11 O-ring 19 U-bolt
4 Du bushing 12 Back up ring 20 Hexagon nut
5 Rod seal 13 Piston 21 Spring washer
6 Back up ring 14 O-ring 22 Bushing
7 Step seal 15 Piston seal 23 Dust seal
8 Dust wiper 16 Wear ring
2) OPERATION
This machine use to cross connected cylinder for steering operation.
The steering cylinder use a gland(3) to remove piston and sealed seals. Dust wiper(8) located on
the in side of the gland protects cylinder inner parts from dust. The piston(13) is fastened to the
rod(2) by a nut(17).
The piston uses a single wear ring(16) with a piston seal(15) to seal between the piston and tube.
The gland seals against the tube with two O-rings. The rod is sealed against the gland with a rod
seal(5).
5-13
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.
If verification is needed, you will be given next best source of information :
5-14
ƓHydraulic oil must be at operating temperature for these checks(Refer to page 6-54).
Steering unit check Run engine at low idle. OK

Check completed.
A
Turn steering wheel until frames
are at maximum right(A) and then NOT OK
left(B) positions. Go to next check.
B
LOOK : Frames must move
smoothly in both directions.
When steering wheel is stopped,
frames must stop.
FEEL : Excessive effort must not
be required to turn steering
wheel.
NOTE : It is normal for steering to
drift from stops when steering
wheel is released.
Steering system leakage Turn steering wheel rapidly until OK
check Left Right frames are against stops. Check completed.
Heat hydraulic oil to
operating temperature. Hold approximately 2kg on NOT OK
Run engine at high idle. steering wheel. Do steering system
leakage test in group 3 to
Count steering wheel revolutions isolate the leakage.
for 1 minute.
Repeat test in opposite direction.
LOOK : Steering wheel should
rotate less than 5rpm.
NOTE : Use good judgment;
Excessive steering wheel rpm
does not mean steering will be
affected.
Priority valve low Park machine on a hard surface. OK
pressure check Check completed.
Hold brake pedal down.
NOT OK
Run engine at high idle. Do priority valve pressure
Steer machine to the right and left test in group 3.
as far as possible.
LOOK : Machine must turn at
least half way to the right and left
stops.
5-15
Priority valve high Steer to steering stop and release OK

pressure check wheel. Check completed.
Run engine at high idle.
Roll bucket back and hold over NOT OK
relief and observe engine rpm. Priority pressure is set too
high. Do priority valve
Turn wheel to steering stop and pressure test in group 3.
hold, observe engine rpm.
LOOK : Steering stall engine rpm
must be higher than hydraulic stall
rpm.
5-16
2. TROUBLESHOOTING
Ɠ 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)
No steering Low oil level. Add recommended oil.

Restricted suction line. Check.
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.
Stuck priority valve spool. Remove and inspect priority valve spool.
Broken priority valve spring. Remove and inspect spring.
Relief valve in priority valve stuck open. Do priority valve relief cartridge leakage
test in group 3.
Failed hydraulic lines. Check.
Slow or hard steering Too much friction in the mechanical parts Lubricate bearings and joints of frame or
of the machine. cylinders 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.
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 3.
Low system relief valve setting. Test and adjust if necessary.
Low overload relief valves setting. Test and adjust if necessary.
5-17
Constant steering to Air in system. Check for foamy oil.

maintain straight travel
Leakage in steering system. Do steering system leakage check.
Worn steering unit. Do steering unit neutral leakage test in
group 3.
Leaf spring without spring force or Replace leaf springs.
broken.
Spring in overload relief valve broken. Replace overload relief valve.
Gear wheel set worn. Replace gear wheel set.
Cylinder seized or piston seals worn. Replace defects parts.
Slow steering wheel Leakage in steering system. Do steering system leakage check.
movement will not cause
Worn steering unit gerotor. Do steering unit leakage check.
any frame movement
Steering wheel can be Leakage in steering system. Do steering system leakage check.
turned with frames
against steering stop
Steering wheel turns Broken steering column or splined of Remove and inspect.
with no resistance and steering unit.
causes no frame
Lack of oil in steering unit. Start engine and check steering
movement
operation.
Leakage in steering system. Do steering system leakage test in
group 3.
Erratic steering Air in oil. Check for foamy oil.
Low oil level. Add recommended oil.
Sticking priority valve spool. Remove and inspect spool.
Loose cylinder piston. Remove rod to inspect piston.
Damaged steering unit. Remove and inspect.
Spongy or soft steering Air in oil. Check for foamy oil.
Low oil level. Add recommended oil.
Free play at steering Loose steering wheel nut. Tighten.
wheel
Worn or damaged splines on steering Inspect.
column or valve.
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.
5-18
Steering unit locks up Large particles of contamination in Inspect hydraulic filter for contamination.
steering unit. Repair cause of contamination. Flush
hydraulic system.
ƕ 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
Worn or damaged steering unit. Repair or replace steering unit.
Vibration in steering High priority valve setting. Do priority valve pressure test in group 3.
system or hoses jump
Neutral position of Steering column and steering unit out of Align the steering column with steering
steering wheel cannot line. unit.
be obtained, i.e. there is
Too little or no play between steering Adjust the play and, if necessary, shorten
a tendency towards
column and steering unit input shaft. the splines journal.
"motoring"
Pinching between inner and outer Contact the nearest service shop.
spools.
"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
due to dirt. nearest service shop.
Return pressure in connection with the Reduce return pressure.
reaction between differential cylinder and
steering unit too high.
Backlash Cardan shaft fork worn or broken. Replace cardan shaft.
Leaf springs without spring force or Replace leaf springs.
broken.
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.
ƕ Thermal shock is caused by a large temperature differential(Approx 30Ş C, 50ŞF) between the steering unit and
hydraulic oil. If the steering is not operated for a long period of time and the orifice in the bottom of the priority
valve spool is plugged, the steering unit may bind up when the steering is operated if the hydraulic oil is hot
enough.
5-19
"Shimmy" effect Air in the steering cylinder. Bleed cylinder.

The steered wheels Find and remove the reason for air
vibrate collection.
(Rough tread on tires
Mechanical connections or wheel Replace worn parts.
gives vibrations.)
bearings worn.
High priority valve setting pressure. Set pressure as regular value.
Steering wheel can be Oil is needed in the tank. Fill with clean oil and bleed the system.
turned the whole time
Steering cylinder worn. Replace or repair cylinder.
without the steered
wheels moving Gear wheel set worn. Replace gear wheel set.
Spacer across cardan shaft forgotten. Install spacer.
Steering wheel can be One or both anticavitation valves are Clean or replace defect or missing
turned slowly in one or leaky or are missing in overload relief valves.
both directions without valves.
the steered wheels
One or both overload relief valves are Clean or replace.
turning
leaky.
Steering is too slow and Insufficient oil supply to steering unit, Replace pump or increase number of
heavy when trying to pump defective or number of revolutions revolutions.
turn 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
Heavy kick-back in Wrong setting of cardan shaft and Correct setting as shown in group 4.
steering wheel in both gear-wheel set.
directions
Turning the steering Hydraulic hoses for the steering Connect lines to correct ports.
wheel activates the cylinders have been switched around.
steered wheels opposite
Hard point when Spring force in priority valve too weak. Replace spring by a stronger.
starting to turn the
Air in LS and / or PP line. Bleed LS and PP line.
steering wheel
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 machine run until oil is warm.
Too little steering force Pump pressure too low. Correct pump pressure.
5-20
1. HYDRAULIC OIL CLEAN UP PROCEDURE USING PORTABLE FILTER CADDY

Ɠ Service equipment and tool
şPortable filter caddy
şTwo 4000mm ź 1" 100R1 Hoses
şQuick disconnect fittings
şDischarge wand
şConnectors
Ɠ Brake system and steering system use
oil from hydraulic oil tank. Flush all
lines in the brake and steering system.
Disassemble and clean major
components for brake and steering
system.
Brake and steering components may fail
if brake, steering system is not cleaned
after hydraulic oil tank contamination.
1) If hydraulic system is contaminated due to a

major component failure, remove and
disassemble steering cylinders to clean
debris from cylinders.
2) Install a new return filter element. Inspect
filter before installing new element.
Ɠ 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.
5-21
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.
Ɠ Hydraulic tank capacity : 60ֻ(15.9U.S.
gal)
Leave filter caddy operating for the next
steps.
6) Start the engine and run it at high idle.
Ɠ 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.
Ɠ 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.
5-22
2. TEST TOOLS
1) CLAMP-ON ELECTRONIC TACHOMETER

INSTALLATION
ş Service equipment and tools
Tachometer
A : Clamp on tachometer
B
Remove paint using emery cloth and
connect to a straight section of injection D
C
line within 100mm(4in) of pump. Finger
tighten only-do not over tighten.
B : Black clip(-). Connect to main frame.
C : Red clip(+). Connect to transducer. A
D : Tachometer readout. Install cable.
2) DIGITAL THERMOMETER INSTALLATION

ş Service 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
3) DISPLAY MONITOR TACHOMETER

The display monitor tachometer is accurate
enough for test work.
20 30
10 km/h 20
10 40
0 MPH 30
0 50
VDO
5-23
3. STEERING SYSTEM RESTRICTION TEST
ş SPECIFICATION
Oil temperature 65Ź6Ş C(150Ź10Ş F)
Engine speed High idle
Maximum pressure 2.0Mpa(20bar, 285psi)
at steering unit
ş GAUGE AND TOOL
Gauge 0~7.0Mpa(0~70bar, 0~1000psi) 1EA
şThis test will check for restrictions in the

steering system which can cause overheating
of hydraulic oil.
1) Install temperature reader.(See

temperature reader installation procedure in
this group.)
2) Heat hydraulic oil to specifications.(See
hydraulic oil warm up procedure at page
6-54.)
3) Connect fitting(A) and gauge to steering
unit.
Do not operate steering or loader
functions or test gauge may be
damaged. T A
4) Run engine at specification and read

pressure gauges.
If pressure is more than specification at the
steering unit, inspect priority valve for a
stuck spool. Make sure orifice plugs are
installed in ends of priority valve spool.
Check for plugged orifice in priority valve LS
port.
5-24
4. STEERING UNIT LEAKAGE TEST
ş SPECIFICATION
Oil temperature 40Ź6Ş C(100Ź10Ş
F)
Maximum leakage 5.7cc/ 10min
ş GAUGE AND TOOL
Temperature reader T
Measuring container(Approx 20ֻ)

Stop watch
1) Install frame locking bar to prevent machine

from turning.
this group.)
6-54.)
4) Disconnect return hose from fitting.
Install cap on fitting.
5) Run engine at specifications. Rotate
steering wheel against locking bar using
approximately 1.2kgşm of force.
Measure oil flow from return hose for 1
minute.
Frame locking bar
6) Leakage is greater than specifications,
repair or replace steering unit.
5-25
5. STEERING UNIT PRESSURE TEST
ş SPECIFICATION
Relief pressure 20.5~21.5Mpa
(205~215bar, 3200~3300psi)
ş GAUGE AND TOOL
Gauge 0~35.0Mpa(0~350bar, 0~5000psi)
CF
Temperature reader
1) Connect test fitting and gauge to P port on P
steering unit.
2) Install temperature reader.(See temperature
installation procedure in this group.)
3) Install frame locking bar.
6-54.)
5) Run engine at specifications and turn
steering wheel rapidly hold approximately
22N(5lb force) pressure on wheel with
frames locked.
Ɠ If steering wheel is turned slowly, it will
Frame locking bar
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 Relief valve
system leakage is indicated.
6) Read pressure gauge. This is the steering
unit relief pressure. A
7) If pressure in not to specification, remove
the plug(A) from steering unit. Turn
adjusting screw in relief cartridge using a
hex head wrench to adjust pressure.
If pressure cannot be adjusted to
specification, disassemble and inspect
steering unit.
5-26
6. PRIORITY VALVE "LS" PORT FLOW TEST
ş SPECIFICATION
Engine speed Low idle
LS port flow(Approx) 0.5ֻ/min(0.13gpm)
ş GAUGE AND TOOL
Temperature reader
Measuring container LS
Stop watch
Priority valve LS port flow test will check for a
plugged or missing orifice in the priority valve
spool. A plugged orifice will block warm up
flow to the steering unit which can cause
thermal shock.(See for an explanation of A
thermal shock, page 5-19). B
A missing orifice can cause the pump to be

loaded to high pressure at all times causing
overheating.

this group.)
6-54.)
3) Disconnect line from LS port and install
plug(A).
4) Connect line(B) to priority valve.
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 priority
valve spool is indicated.
If flow is high, remove priority valve spool
and inspect for a missing orifice.
Do hydraulic system restriction test in this
group.
5-27
1. PRIORITY VALVE
1) STRUCTURE
1
2
3
7 6
1 Plug 4 Spool 7 Name plate

2 Seal ring 5 Spring 8 Drive screw
3 Orifice 6 Plug 9 Housing
5-28
2) TOOLS
şOpen-end spanner 22mm.
şNylon pin.
şHexagon socket spanner 8mm.
şTorque wrench.
şSocket spanner 22mm.
şHexagon socket spanner insert 8mm.
3) DISASSEMBLY
Ɠ Cleanliness is the primary means of
assuring satisfactory the priority valve life.
Select clean place.
Before removing the piping, clean the
surrounding area of valve ports.
(1) Screw out the PP plug using the 8mm

hexagon socket spanner.
Remove the seal ring.
PP
(2) Loosen the LS plug using the 22mm open-

end spanner.
LS
5-29
(3) Pull out the plug with seal ring and spring.
LS
(4) Press out the spool using the nylon pin.
PP
LS
(5) Disassembled priority valve.
5-30
4) MODIFICATION
(1) The control spring pressure can be altered by replacing the spring(See table below). Replace
name plate so that code no. and control spring pressure match each other again.
Control spring
d(mm) Di(mm) L(mm)
pressure(bar)
4 1.8 6.9 54
7 Di
2.0 6.5 55
d
L
(2) Cleaning
Clean all parts carefully in low aromatic kerosene.
(3) Inspection and replacement
Check all parts carefully and make any replacements necessary. All seal rings must be replaced.
(4) Lubrication
Before assembly, lubricate all parts with hydraulic oil.
5) ASSEMBLY
(1) Guide the spool into the bore. Use the
nylon pin to center the spool in the bore.
PP
LS
(2) Put in the PP plug.

Remember seal ring.
PP
LS
5-31
(3) Guide the spring and LS plug into the
bore.
Remember seal ring.
LS
(4) Tighten the LS plug with torque wrench

using a 22 socket spanner insert.
şTighten torque : 5.1Ź1kgfşm
(36.9Ź7.2lbfşft)
LS
(5) Tighten the PP plug with a torque wrench

using a 8mm hexagon socket spanner
insert.
şTighten torque : 5.1Ź1kgfşm
(36.9Ź7.2lbfşft) PP
(6) The priority valve is now assembled.
PP
LS
5-32
6) TROUBLESHOOTING
Steering wheel 1. Relief valve of steering unit is clogged Disassembly, clean and reassembly.
is heavy with dirt.
2. Spool is stuck. Disassembly, clean and reassembly or
replace.
3. Orifice of plug and spool is clogged. Disassembly, clean and reassembly.
(Steering wheel a. Pump is faulty. Check pump.
is heavy at
engine low idle)
(Steering speed b. Control pressure is low. Reset control pressure.

is not high at
c. Piping is faulty. Replace piping.
engine high idle)
d. Pump is faulty. Check pump.
Abnormal noise 1. Relief valve of steering unit is clogged Disassembly, clean and reassembly.
with dirt.
2. Spool is stuck. Disassembly, clean and reassembly or
replace.
Leakage 1. Loosen the plug. Retighten the specified torque.

2. O-ring is damaged. Replace.
5-33
2. STEERING UNIT
1) STRUCTURE
1 2
24
2 5
6
7
3
4
2
A
2
8
14 9 10
13
14 A
14
15
14
17
16 18
21
18
20
1 Dust seal ring 8 Cross pin 16 Gearwheel set

2 Housing assy 9 Spring set 17 End cover
3 Ball 10 Cardan shaft 18 Washer
4 Bushing 12 O-ring 20 Pin screw
5 Roto Glyd ring 13 Intermediate plate 21 Screw
6 Bearing assy 14 O-ring 24 Pilot relief valve
7 Ring 15 Distributor plate
5-34
2) TOOLS
(1) Holding tool.
(2) Assembly tool for O-ring and kin-ring.
(3) Assembly tool for dust seal.
(4) Torque wrench 0~7.1kgfňm(0~51.6lbfňft).

13mm socket spanner
12mm screwdriver
6mm screwdriver
2mm screwdriver
Plastic hammer
Ratchet spanner
5-35
3) 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(7-off-one rolled pin).
(2) Remove the end cover, sideways.
(3) Lift the gearwheel set with spacer

bushing(And spacer if fitted) off the unit.
Take out the two O-rings.
(4) Remove spacer bushing and spacer(If

fitted) from the gearwheel.
5-36
(5) Remove cardan shaft.
(6) Remove distributor plate.
(7) Remove O-ring.
(8) Lift off intermediate plate.
5-37
(9) Remove O-ring.
(10) Screw out the threaded bushing.
(11) Remove cross pin.
(12) Shake out the ball(‫ٻ‬8.5mm).
5-38
(13) Pull sleeve and spool out of the housing.
(14) 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.
(15) Carefully pull the spool out of the sleeve.
(16) Press the neutral position springs out of

their slots in the spool.
5-39
(17) Remove dust seal and O-ring.
(18) The steering unit is now completely

disassembled.
Cleaning
Clamp all parts carefully in Shellsol K or the
like.
Inspection an replacement
Replace all seals and washer. Check all
parts carefully and make any replacements
necessary.
Lubrication
Before assembly, lubricate all parts with
hydraulic oil.
5-40
4) ASSEMBLY
(1) Assemble spool and sleeve.
Ɠ The sleeve and spool are correctly B A
assembled when
‫ ڸ‬The slots-in sleeve and spool-for the
neutral position springs are opposite
each other and
‫ ڹ‬One of the 3 T-shaped grooves(A) in the
spool is opposite one of the sets(B) of
small holes in the sleeve.
(2) Place the two flat neutral position springs

in the slot.
(3) Place the curved springs between the flat

ones and press them into place.
(4) Line up the spring set.
5-41
(5) Guide the spool into the sleeve.
(6) Press the springs together and push the

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

Ɠ The ring should be able to rotate-free of
the springs.
5-42
(9) Fit the cross pin into the spool/sleeve.
(10) Fit bearing races and needle bearing as

shown on below drawing.
1 Outer bearing race

1
2 Needle bearing
2
3 Inner bearing race
3
4 Spool
5 Sleeve *
) Inside chamfer on inner bearing race 4
must face inner spool.
5
(11) Grease O-ring and kin-ring with hydraulic

oil and place them on the tool. See next
page.
5-43
(12) Put the steering unit in the holding tool
keeping the bore vertical. Guide the outer
part of the assembly tool into the bore.
Guide the inner part of the tool right to the
bottom.
(13) Press and turn the O-ring into position in

the housing. Draw the inner and outer
parts of the assembly tool out of the
steering unit bore, leaving the guide in the
bore.
(14) Take the steering unit out of the holding

tool and place it horizontally. With a light
turning movement, guide the spool and
sleeve into the bore.
5-44
(15) The spool set will push out the assembly
tool guide. The O-ring is now in position.
(16) Put the steering unit back into the holding

tool keeping the bore vertical. Place the
cross pin in the spool/sleeve so that it is
parallel to the port flange.
(17) Put the ball into the hole indicated by the

arrow.
(18) Screw the threaded bushing lightly into the

bore. The top of the bushing must lie just
below the surface of the housing.
5-45
(19) Grease the O-ring with mineral oil
approximate viscosity 500cSt at 20Ş
C and
place it in the groove.
(20) Place the intermediate plate so that the

channel holes match the holes in the
housing.
(21) Grease the O-ring with mineral oil

approximate viscosity 500cSt at 20Ş
C and
place it in the groove.
(22) Place the distributor plate so that the

channel holes match the holes in the
intermediate plate and the housing.
5-46
(23) Guide the cardan shaft down into the bore
so that the slot is parallel with the
connection flange.
(24) Place the gear wheel(Rotor) so that the

cross pin from item 33 is positioned in
relation to two tooth bases - as the screw
driver indicates.
(25) Grease the two O-rings with mineral oil

approximate viscosity 500cSt at 20ŞC and
place them in the two grooves in the gear
rim. Fit the gear rim so that the seven
through holes match the holes in the
distributor plate.
Ɠ Turn the gear rim so that the smaller
diameter of the holes face the distributor
plate.
(26) Orientate the holes with a single screw.
5-47
(27) Place the end cover in position.
(28) Place the washers over the holes and the

rolled pin in the hole shown.
(29) Fit the other six screws. Cross - tighten all

the screws and the rolled pin with a torque
of 3Ź0.6kgfňm(22Ź4.4lbfňft). Steering unit
can now be function tested.
(30) Turn the steering unit 180Şand place the

dust seal ring in the housing.
5-48
(31) Fit the dust seal ring in the housing using
special tool and a plastic hammer.
(32) Press the plastic plugs into the connection

ports. Do not use a hammer.
5-49
3. OVERLOAD VALVE
1) STRUCTURE
2
9
3 8
7
6
9
P R 5
T L
5
6 4
7
8 4
1 O-rings set 4 Screw 7 O-ring

2 O-rings set 5 Shock valve 8 Plug
3 Rolled pin 6 Spring 9 Housing assy
5-50
2) TOOLS
(1) Hexagon socket spanner, 8mm.
(2) Torque wrench, 0~7.1kgfňm(0~51lbfňft)

with 8mm hexagon socket spanner.
(3) Adjustable wrench.
5-51
3) DISASSEMBLY
(1) Remove the rolled pin.
(2) Remove the plug(8) and O-ring(7).
8
7
(3) Remove the spring(6) and shock valve(5).

6
(4) Remove the O-ring set(1, 2).
1,2
5-52
(5) Remove the check valve(9).
9
(6) The overload valve is now disassembled.
5-53
4) ASSEMBLY
Cleaning
Clean all parts carefully in Shellsol K or the
like.
Inspection an replacement
Replace all seals and washers. Check all
parts carefully and make any replacements
necessary.
Lubrication
Before assembly, lubricate all parts with
hydraulic oil.
(1) Fit check valve(9).
(2) Fit the shock valve(5) and spring(6).

6
(3) Fit the O-ring(7) and screw the plug(8).
8
7
5-54
(4) Fit the rolled pin.
(5) The overload valve is now assembled. It

can be checked for leakage separately or
when mounted on a steering unit.
(6) Locate the four O-rings between overload

valve and steering unit and fit these
components together.
(7) Tighten the hexagon socket screws with a

torque of 6.6+0.5
0 kgfňm(47.7 0 lbfňft).
+3.6
5-55
(8) Press the plastic plugs into the connection
ports. The overload valve is now
assembled.
5) TROUBLESHOOTING
Steering wheel 1. Over tighten mounting torque. Retighten as specified torque.

is heavy
2. Over load valve seat side is clogged Disassembly, clean, reassembly.
with dirt.
Steering cylinder 1. Overload valve seat side is clogged Disassembly, clean, reassembly.
reaction is bad with dirt.
2. Anti cavitation check valve seat is Disassembly, clean, reassembly.
clogged with dirt.
3. Damage of O-ring for adjusting. Replace.
Abnormal noise 1. Overload valve seat side clogged Disassembly, clean, reassembly.
with dirt.
Leakage 1. Loosen 2 mounting bolt. Retighten as specified torque.

2. Damage of O-ring. Replace.
3. Leakage through plug. Apply seal tape to thread and retighten
as specified torque.
5-56
4. STEERING CYLINDER
1) STRUCTURE
22,23 9,8 10 6,5 7 11,12 4 3 2 1 13 14 15 16 17
19,20,21 18
1 Tube assy 9 Snap ring 17 Nylon nut

2 Rod assy 10 O-ring 18 Pipe assy
3 Gland 11 O-ring 19 U-bolt
4 Du bushing 12 Back up ring 20 Hexagon nut
5 Rod seal 13 Piston 21 Washer spring
6 Back up ring 14 O-ring 22 Bushing
7 Step seal 15 Piston seal 23 Dust seal
8 Dust wiper 16 Wear ring
5-57
2) TOOLS AND TIGHTENING TORQUE
(1) Tools
Tool name Remark
17 B
Spanner 32
36
Steel bar For gland
(-) Driver Small and large sizes
Torque wrench Capable of tightening with the specified torques
(2) Tightening torque

Torque
Part name Item Size
kgfşm lbfşft
Gland 3 M64 ź 1.5 65 Ź 7 470 Ź 51
Nylon nut 17 M24 ź 2 40 Ź 4 289 Ź 28.9
Nut(Pipe assy) 18 M22 ź 1.5 30 Ź 3 217 Ź 21.7
Nut 20 M10 ź 1.5 3.2 Ź 0.3 23.1Ź 2.2
5-58
3) DISASSEMBLY
(1) Remove cylinder head and piston rod
‫ ڸ‬Hold the clevis section of the tube in a
vise.
Ɠ 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.
‫ ڹ‬Pull out piston rod(2) about 200mm

'7.1in(-Because the piston rod is rather
heavy, finish extending it with air pressure
m
0
m
after the oil draining operation. 20
‫ ں‬Loosen and remove the gland(3).

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

assembly together from cylinder tube(1).
Ɠ 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 Full straight Oil pan
draw it completely. sideways
5-59
Ɠ 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.
‫ ڼ‬Place the removed piston rod assembly

on a wooden V-block that is set level.
Ɠ Cover a V-block with soft rag. Piston assy
Wooden block
(2) Remove piston and cylinder head

‫ ڸ‬Remove the nylon nut(17). 14 15 16 13 17
‫ ڹ‬Remove piston assembly(13), and O-
ring(14).
‫ ڻ‬Remove the gland(3) assembly from

Lift with a crane
piston rod(2).
Ɠ If it is too heavy to move, move it by Plastic 8,9 5,6
hammer
striking the flanged part of gland(3) with 7 4
a plastic hammer. Full straight
Ɠ Pull it straight with cylinder head
assembly lifted with a crane.
Exercise care so as not to damage the
lip of rod bushing(4) and packing
3 2
(5,6,7,8,9) by the threads of piston
rod(2).
5-60
(3) Disassemble the piston assembly
‫ ڸ‬Remove wear ring(16) and piston seal 15 16
(15).
Ɠ Exercise care in this operation not to
damage the grooves.
(4) Disassemble gland assembly

‫ ڸ‬Remove back up ring(11), and O-ring 8,9 12 5,6 7 10,11 4
(10).
‫ ڹ‬Remove O-ring(12).
‫ ں‬Remove snap ring(9) and dust wiper(8).
‫ ڻ‬Remove back up ring(6), rod seal(5).
‫ ڼ‬Remove buffer ring(7).
damage the grooves.
Ɠ Do not remove seal and ring, if does not
damaged.
5-61
4) ASSEMBLY
(1) Assemble gland assembly
Ɠ Check for scratches or rough surfaces if
found smooth with an oil stone.
‫ ڸ‬Coat the inner face of gland(3) with
hydraulic oil.
‫ ڹ‬Coat dust wiper(8) with grease and fit

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

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

Therefore, confirm it before fitting them. Push bar
Ɠ Fitting rod seal(5) and buffer ring(7) up
side down may damage its lip. Therefore
check the correct direction that is shown
in fig. 7
5,6
5-62
‫ ڽ‬Fit back up ring(11) to gland (3).
Ɠ Put the backup ring in the warm water of
30~50Ş C- 4
‫ ھ‬Fit O-ring(10) to gland(3). 10
‫ ڿ‬Fit O-ring(12) to gland(3). 11
3
12
(2) Assemble piston assembly

Ɠ Check for scratches or rough surfaces.
If found smooth with an oil stone.
‫ ڸ‬Coat the outer face of piston(13) with
hydraulic oil.
‫ ڹ‬Fit piston seal(15) to piston

Ɠ Put the piston seal in the warm water of
60~100Ş C for more than 5 minutes. 15
Ɠ After assembling the piston seal, press its
outer diameter to fit in.
‫ ں‬Fit wear ring(16) to piston(13).

‫ ڻ‬Fit O-ring(14) to piston(13). 14 15 16 13
5-63
(3) Install piston and gland
‫ ڸ‬Fix the piston rod assembly to the work
Gland assembly Piston rod
bench.
‫ ڹ‬Apply hydraulic oil to the outer surface of
piston rod(2), the inner surface of piston
and gland.
‫ ں‬Insert gland assembly to piston rod(2).
‫ ڻ‬Fit piston assembly to piston rod.

şTightening torque : 50Ź5kgfşm Piston assembly
(362Ź36lbfşft) Piston rod
‫ ڼ‬Tighten nylon nut(17) to piston rod(2).

şTightening torque : 75Ź8kgfşm 2 17
(542Ź58lbfşft)
5-64
(4) Overall assemble
Fix with a bar
‫ ڸ‬Place a V-block on a rigid work bench.
Mount the cylinder tube assembly(1) on it Lift
and fix the assembly by passing a bar
through the clevis pin hole to lock the
assembly.
Straight
‫ ڹ‬Insert the piston rod assembly in to the
cylinder tube assembly, while lifting and
moving the piston rod assembly with a
Apply liquid packing
crane.
Ɠ Be careful not to damage piston seal by
thread of cylinder tube.
‫ ں‬Match the bolts holes in the cylinder head
flange to the tapped holes in the cylinder Tube
tube assembly and tighten socket bolts to
a specified torque. Piston rod
Ɠ Refer to the table of tightening torque.
Wrench
Gland
5-65
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:
6-39
Ɠ Hydraulic oil must be at operating temperature for these checks(Refer to page 6-54).
Hydraulic system warm- Hold a hydraulic function over OK

up procedure relief to heat oil.(Don't keep relief Check completed.
Run engine at high idle. condition over 5 seconds at a
Refer to page 6-54. time)
Periodically cycle all hydraulic
functions to distribute warm oil.
Repeat procedure until oil is at
operating temperature.
FEEL : Hydraulic tank must be
uncomfortable to hold your hand
against.
(Approximately 45~55ŞC)
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 steering unit high
Run engine at high idle.
LOOK : Boom must raise to full pressure check at page
height in less than 7 seconds. 5-26.
IF OK
Do steering unit leakage
check at page 5-25.
IF OK
Do main hydraulic pump
flow test at page 6-55.
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 main
lever(RCV lever) to boom lower 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.
6-40
Bucket rollback circuit Position bucket at a 45Şangle 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 45Şangle. 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 6-56.
Pilot control valve float With the bucket partially dumped, OK
check lower boom to raise front of Check complete.
Run engine at low idle. machine.
NOT OK
Push control lever to the float
Do pilot control valve
detent position and release lever.
pressure test in group 3.
LOOK : Front of machine lower to
the ground and valve must remain
in float position when lever is
released.
Boom cylinder and Set the boom and bucket OK
bucket cylinder drift horizontal, then stop the engine. Check complete.
check
Stop the engine, wait for 5 NOT OK
minutes, then start measuring. Go to next check.
Measure the amount the lift and
dump cylinder rods retract during
15 minutes.(Unloaded bucket)
B
A : Retraction of boom cylinder

rod
A
B : Retraction of bucket cylinder
rod
Boom cylinder must drift less than
20mm.
Bucket cylinder must drift less
than 30mm.
6-41
Boom cylinder leakage Dump bucket until teeth or cutting OK

check edge is perpendicular to the Drift is approximately the
Heat hydraulic oil to ground. same between first and
operating temperature. second measurement.
Raise boom until cutting edge is
about 1m(3ft) above ground. Repair main control valve
or circuit relief valve.
Stop engine. Measure drift from
tooth or cutting edge to ground for NOT OK
1 minute. If drift is considerably less
on second measurement,
Wait 10 minutes.
repair cylinder.
Measure drift from tooth or cutting
edge to ground for 1 minute.
LOOK : Compare the drift rate
between the first measurement
and the second measurement.
Bucket cylinder leakage Raise bucket about 1m(3ft) off OK
check ground with bucket level. Drift is approximately the
Heat hydraulic oil to same between first and
Stop engine. Place a support
operating temperature. second measurement.
under boom.
Repair main control valve
Measure drift from tooth or cutting
or circuit relief valve at
edge to ground for 1 minute.
page 6-56.
Wait 10 minutes.
NOT OK
Measure drift from tooth or cutting Drift is considerably less
edge to ground for 1 minute. on second measurement.
LOOK : Compare the drift rates Repair cylinder.
between the first measurement
and the second measurement.
Check valve of safety Put bucket level and position OK
valve leakage check about 1.2m(4ft) above ground. Check complete.
Place a piece of tape on cylinder NOT OK
rod at least 51mm(2in) from rod Check or replace safety
guide. valve.
Run engine at low idle in safety-
release position.
LOOK : Bucket must not drift up.
Pilot control valve Stop engine. Turn key switch to OK
(RCV lever) check OFF position. Check completed.
Move control lever to all positions
NOT OK
and then release.
Repair pilot control valve.
LOOK : Lever must return to
neutral when released from all
positions.
6-42
Bucket leveler Position bucket fully dumped just OK

(Positioner) check above ground level. Check complete.
Move control lever to bucket NOT OK
leveler detent position and Do bucket leveler checks
release. in group 3.
LOOK : Bucket must rollback to
the level position and control lever
must return to neutral.
If bucket is in a rolled back
position when key is turned ON,
control lever must be returned to
neutral manually if placed in the
bucket leveler detent position.
After bucket is dumped once,
bucket leveler will work normally.
Boom height kickout Position bucket flat on ground. OK
check Check complete.
Move control lever to boom raise
detent position and release. NOT OK
Do boom height kickout
LOOK : Boom must raise to the
check in group 3.
set height and stop.
Control lever must return to
neutral.
Cycle time check Function Operating condition. Cycle time
Boom raise Bucket flat on ground to full height. 5.4sec
Run engine at high idle. Boom lower Full height to level ground. 2.5sec
(Float)
Bucket dump Boom at full height. 1.0sec
Bucket rollback Boom at full height. 1.4sec
Steering(No. of Frame stop to frame stop. 1.5sec(3.5 turns)
turns)
OK
Check complete.
NOT OK
Go to slow hydraulic
functions in group 3.
6-43
Ɠ MEASURING BOOM AND BUCKET CYCLE TIME
1. MEASUREMENT CONDITION
şCoolant temperature : Inside operating range
şSteering position : Neutral
şHydraulic temperature : 45~55Ş C
şBucket : Unloaded
şEngine speed : High idling
2. MEASURING TOOL
şStop watch(1 EA)
3. MEASURING PROCEDURE
Lifting time of boom
1) 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.
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 time taken for the bucket to
reach the lowest position on the ground.
3) DUMPING TIME OF BUCKET

Raise the boom to the maximum height and Dumping time of 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.
6-44
2. TROUBLESHOOTING
Ɠ 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)

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.
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 main control valve spool. Inspect valve.
Faulty priority valve. Check priority valve specification.
6-45
No steering or hydraulic Low oil level. Add recommended oil.
function
Failed hydraulic pump. Remove and inspect return filter for
metal pump particles.
Failed main hydraulic pump drive. Remove main hydraulic pump and
inspect drive gear.
No hydraulic functions Failed hydraulic pump. Remove and inspect return filter for
steering normal metal pump particles, or replace the
pump.
Failed pilot line filter. Remove and inspect line filter for RCV.
Faulty safety valve. Safety valve leakage test or ON, OFF
function test.
Stuck open system and port relief Replace relief valve.
valve.
Faulty or misadjusted pilot supply unit. Do pilot supply unit pressure test in
group 3.
Boom float function Low pilot control pressure. Do pilot supply unit pressure test in
does not work group 3.
Faulty pilot control valve(RCV). Do pilot control valve pressure test.
Main control valve spool binding in Do pressure reducing valve pressure
bore. test in group 3.
One hydraulic function Faulty pilot control valve(RCV). Do pilot control valve pressure test.
does not work
Stuck open port relief valve. Replace relief valve.
Oil leaking past cylinder packings. Do boom and bucket cylinder leakage
test in group 3.
Blockage in oil lines or valve. Inspect lines for damage.
Disconnect and inspect lines for internal
blockage.
Main control valve spool stuck in bore. Inspect and repair valve.
Low hydraulic power Leakage within work circuit. Do cylinder drift check in group 2.
Low system relief valve(Main relief Do loader system and port relief valve
valve) setting. pressure test in group 3.
Low port relief valve setting. Do loader system and port relief valve
pressure test in group 3.
Faulty or misadjusted pilot oil supply Do pilot oil supply unit pressure test in
unit . group 3.
Leaking system relief valve. Remove and inspect valve.
Worn hydraulic pump. Do hydraulic pump performance check
in group 2.
Faulty pilot control valve(RCV). Do pilot control valve(RCV) pressure
test in group 3.
6-46
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
Stuck pilot control valve. Inspect.
Engine off.
Faulty line filter. Remove and inspect filter.
Accumulation not operated. Inspect.
Main control valve spool stuck. Inspect and repair valve.
Oil overheats Low oil viscosity in hot weather. Use recommended oil.
Excessive load. Reduce load.
Holding hydraulic system over relief. Reduce load.
Leakage in work circuit. Do boom and bucket cylinder leakage
test in group 3.
Plugged fins in oil cooler. Inspect and clean oil cooler.
Internally plugged oil cooler. Do hydraulic oil cooler restriction test.
Incorrect system or circuit relief valve Do loader system and circuit relief valve
setting. pressure test in group 3.
Restriction in oil lines or main control Inspect for dented or kinked lines.
valve. Do hydraulic system restriction test in
group 3.
Pinched or restricted priority valve LS Run engine at low idle. Steer machine
line. back and forth. If engine load
decreases while steering, a restricted
LS line or priority valve malfunction is
indicated.
Do priority valve LS port flow test in
group 3.
Malfunctioning priority valve. 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
6-47
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.
6-48
Ɠ 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.
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.
6-49
1. HYDRAULIC OIL CLEAN UP PROCEDURE USING PORTABLE FILTER CADDY

Ɠ Service equipment and tool
şPortable filter caddy
şTwo 4000mm ź 1in 100R1 Hoses
şQuick disconnect fittings.
şDischarge wand
şVarious size fittings.
Ɠ Brake system uses oil from hydraulic oil
tank. Flush all lines in the brake, pilot.
Disassemble and clean major
components for hydraulic system.
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. Clean
filter housing before installing new element.
Ɠ 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 -50
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.
Ɠ Hydraulic tank capacity : 60ֻ(15.9U.S.
gal)
Leave filter caddy operation for the next
steps.
6) Start the engine and run it at high idle.
Ɠ 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.
Ɠ Filtering time for machines with auxiliary
hydraulic functions must be increased
because system capacity is larger.
8) Stop the engine. Remove the filter caddy.
9) Install a new return filter element.
10) Check oil level in hydraulic oil tank ; Add oil
if necessary.
6 -51
2. BOOM HEIGHT KICKOUT ADJUSTMENT
1) Lift the boom up to a desired height, set the
boom control lever at hold, then stop the Proximity switch
Front frame
engine.
Plate
Be careful lest work equipment fall
down.
Put the hydraulic safety lock lever in the
LOCK position.
Boom
2) Loosen bolts then tighten them after

adjusting the plate(A) so that it comes in Proximity switch
Plate(A)
contact with the center of the probe of the
proximate switch. Plate Bolt
Boom
3) Loosen the nuts so that a clearance

between the plate(B) and the probe of the Proximity switch
Plate(B) Nut
proximate switch are 3Ź1mm.
3Ź1mm
4) Start the engine. Position the bucket on

the ground. Then lift the bucket to a Detent position
desired height by using the control lever
and release the hand.
Confirm the lever automatically returns to
the neutral position and the boom(The
bucket) stop at the adjusted position.
6 -52
3. TEST TOOLS
1) CLAMP-ON ELECTRONIC TACHOMETER
INSTALLATION
şService equipment and tools
Tachometer
A : Clamp on tachometer.
Remove paint using emery cloth and B
connect to a straight section of injection D
C
line within 100mm(4in) of pump. Finger
tighten only-do not over tighten.
B : Black clip(-). Connect to main frame.
C : Red clip(+). Connect to transducer. A
D : Tachometer readout. Install cable.
2) DIGITAL THERMOMETER INSTALLATION

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

The display monitor tachometer is accurate
enough for test work.
20 30
10 km/h 20
10 40
0 MPH 30
0 50
VDO
6 -53
4. HYDRAULIC OIL WARM UP PROCEDURE
1) Install temperature reader(See temperature
reader installation procedure in this group).
2) Run engine at high idle.
3) Hold a hydraulic function over relief to heat
the oil.
4) Periodically cycle all hydraulic functions to
distribute warm oil.
5) Heat oil to test specification(Approx 50Ɓ
C).
6 -54
5. MAIN HYDRAULIC PUMP FLOW TEST
ş SPECIFICATION
Oil temperature 65Ź6ƁC(150Ź10Ɓ F)
Engine speed 2300Ź25rpm
Test pressure 220Ź10bar(3190psi)
Maximum pump flow 65ֻ/min(17.2gpm)
ş FLOW METER GAUGE AND TOOL
Gauge 0~35MPa(0~350bar, 0~5000psi)
Temperature reader
1) Make test connections.
2) Install temperature reader.
(See temperature reader installation
procedure in this group.)
3) Heat hydraulic oil to specifications.
(See hydraulic oil warm up procedure in this
group.)
4) Run engine at test specifications.
5) Close flow meter loading valve to increase
pressure to test specifications.
To MCV
6) Read flow meter.
7) If flow is below specifications, check suction
line and suction pressure for abnormality
before removing pump.
6 -55
6. LOADER SYSTEM AND PORT RELIEF
VALVE PRESSURE TEST
ş SPECIFICATION
Oil temperature(45~55Ɓ
C)
Relief valve Engine speed Relief pressure
215*5kgf/cm2
System(M) High
(3130*70psi)
U
Boom 240Ź5kgf/cm2
Low
raise(U) (3410Ź70psi) D
Bucket 240Ź5kgf/cm 2
M
Low
rollback(R) (3410Ź70psi)
Bucket 240Ź5kgf/cm2
Low
dump(D) (3410Ź70psi)
R
ş Gauge and tool

D : Bucket dump relief valve
M : System(Main) relief valve
R : Bucket rollback relief valve
U : Boom raise relief valve
1) Install pressure gauge to block(A) in pump
delivery line.
A
3) Heat hydraulic oil to specifications.
(See hydraulic oil warm up procedure in this
Block(Rear frame mounting)
group.)
4) To check the system relief valve(M), run
engine at high idle. Lower boom to
bottomed position.
Slowly activate boom down function while
watching pressure gauge. If pressure is not
to specification, loosen lock nut on system
relief valve(M) and adjust to specification.
6 -56
Ɠ Do not adjust the system relief valve
above 250kgf/cm2 (3560psi). Damage to
the pump will result from excessive
pressure settings.
5) To check the bucket dump, bucket rollback,
and boom raise, adjust the system relief
valve to 250kgf/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.
Ɠ Do not work machine with system relief
adjusted above specification or
structural damage may occur.
6) Adjust system relief valve to specification.
6 -57
7. HYDRAULIC SYSTEM RESTRICTION TEST
ş SPECIFICATION
Oil temperature 65Ź6Ɓ C(150Ź10Ɓ F)
Maximum pressure at steering(Orbitrol)
valve 2MPa(20bar, 285psi)
Maximum pressure at main control valve
1MPa(10bar, 145psi)
ş GAUGE AND TOOL
Gauge 0~7MPa(0~70bar, 0~1000psi) 2EA
This test will check for restrictions in the
hydraulic system which can cause
overheating of hydraulic oil.
1) Install temperature reader.(See temperature T
reader installation procedure in this group.)

hydraulic oil warm up procedure in this
group.)
3) Connect gauge to steering unit.
4) Connect fitting and gauge to main control
valve.
Do not operate steering or loader
functions or test gauge may be
damaged.
5) Run engine at specification and read
pressure gauges.
T
main control valve, check for a kinked,
dented or obstructed hydraulic line. Check
main control valve for a binding spool.
block, inspect neutral condition of the
steering valve and priority valve for a stuck
spool. Make sure orifice plugs are installed
in ends of priority valve spool.
Check for plugged orifice in priority valve LS
port and dynamic signal orifice on the spool
of priority valve.
6 -58
8. LOADER CYLINDER DRIFT TEST
A
ş SPECIFICATION
Oil temperature 40Ź6Ɓ
C(100Ź10Ɓ
F)
Boom horizontal
Bucket horizontal
Bucket unloaded
B
Item Standard value
Retraction of boom
20mm A : Retraction of bucket cylinder rod
cylinder rod
B : Retraction of boom cylinder rod
Retraction of bucket
30mm
cylinder rod
ş GAUGE AND TOOL

Stop watch
Temperature reader
Put the safety lock lever in the lock
position.
Do not go under the work equipment.
1) Set the boom and bucket horizontal, then
stop the engine.
2) Stop the engine, wait for 5 minutes, then
start measuring.
3) Measure the amount the boom and bucket
cylinder rods retract during 15 minutes.
6 -59
9. BOOM AND BUCKET CYLINDER LEAKAGE
TEST
ş SPECIFICATION
Oil temperature 40Ź6Ɓ C(100Ź10Ɓ
F)
Maximum leakage 12cc/10min
ş GAUGE AND TOOL
Temperature reader
Stop watch
Measuring container
1) Fasten temperature sensor to head end
port of cylinder to be tested. Cover sensor
with a shop towel.
group.)
Never work under raised equipment
unless it is supported with a hoist or
support stands.
3) Full extend the cylinder to be tested. If
testing the boom cylinders, restrain boom in
the fully raised position using a hoist or a
stand.
Ɠ 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 low 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
main control valve or circuit relief valve.
6 -60
10. PILOT CONTROL VALVE PRESSURE TEST
ş SPECIFICATION
Begin metering 1/4" of lever travel
Pressure at feel positionƕ:
Boom power down 18.1~19.0bar
Boom raise 19.0~30.0bar
Bucket rollback 19.0~30.0bar
Bucket dump 19.0~30.0bar
ş GAUGE AND TOOL
ƕ As the control lever is moved from neutral,
the pilot pressure will suddenly jump up to T
P
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
19.0bar as the lever is moved into detent.
This test will determine if adequate pilot
pressure is available to move the loader
control valve spools.
Ɠ The FEEL position is when lever is
moved to feel the ramp of the detent
before lever passes into detent position.
A
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.)
6 -61
5) Run engine at specification. Activate
function to be checked and record pressure
reading.
Ɠ 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 -62
11. PILOT OIL SUPPLY UNIT PRESSURE TEST
ş SPECIFICATION
Engine speed Low idle and stop
Pilot pressure setting 30~35bar(430~500psi)
Relief valve setting pressure
45bar
Accumulator precharging pressure
16bar
ş GAUGE AND TOOL
The pilot supply unit consist of the pressure
reducing valve, the relief valve and an
accumulator. This regulates pressure to
the pilot control circuit.
1) Connect gauge to test port(A) on the block.
A
3) Heat hydraulic oil to specification.(See
group.)
4) Run engine at low idle for 1 minute and
stop engine, wait for 5 minutes. Then start
measuring.
5) If pressure in not within specifications,
replace valve. The valve is staked and
should not be adjusted.
6 -63
12. CYCLE TIME TEST
ş SPECIFICATION
Oil temperature 65Ź6Ɓ C(150Ź10Ɓ
F)
Function Operating conditions Maximum cycle time(Seconds)
Boom raise Bucket flat on ground to full height 5.4

Boom lower(Float) Full height to ground level 2.5
Bucket dump Boom at full height 1.0
Bucket rollback Boom at full height 1.4
Steering(Number of turns) Frame stop to stop 1.5(3.5 turns)
Hydraulic pump performance cycle time.
Function Operating conditions Maximum cycle time(Seconds)

Bucket flat on ground to full height
Boom raise 7.0
while holding steering over relief
6 -64
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 2
upper surface of the hydraulic oil tank.
2) Remove the bolts(1) and take out the filter 3
case cover(3) and O-ring(4). 4
3) Remove the spring(5) and bypass valve(6). 5

4) Remove the filter element(7) from the tank.
6
5) Check the element and the filter case
bottom for debris. Excessive amounts of
brass and steel particles can indicate a 7
failed hydraulic pump or a pump failure in
process. A rubber type of material can
indicated cylinder packing or other packing
failure.
Ɠ The hydraulic oil filter in the filter case of
the hydraulic oil tank should be
replaced every 250 operating hours(For
the first replacement, at 50 hours) or
more often. When the filter element is
replaced, please keep as follows.
(1) Clean the inside of the filter case.
(2) Place new element in the proper positions
inside the filter case.
(3) Install the bypass valve and spring.
Make sure the element stand upright, and
check for complete contact of the element
bottom with the filter case bottom.
(4) Install the O-ring and filter case covers.
Tighten them with bolt. Replace the O-
ring with new one if damaged.
6 -65
1. MAIN PUMP
1) STRUCTURE
10
5
6
7
7
6
5
16
9 4
3
19
20
4
5
6
7 1
14
2
7
18 6
5
15 13
12
11
1 Shaft seal 8 Driven gear 14 Driven gear

2 Circlip 9 Drive gear 15 Drive shaft
3 Flange 10 Front body 16 Cover
4 O-ring 11 Splined coupling 18 Stud assy
5 Seal 12 O-ring 19 Serrated washer
6 Seal 13 Center body 20 Nut
7 Balance plate
6 -66
2) GENERAL INSTRUCTION
(1) Cleanliness
‫ ڸ‬Cleanliness is the primary means of assuring satisfactory hydraulic pump life. Components
such as flanges and covers are best cleaned in soap and hot water, then air dried. Gears
should be washed in solvent, air dried, and oiled immediately.
Certain cleaning solvents are flammable. Do not allow sources of ignition in the area
when using cleaning solvents.
‫ ڹ‬Protect all exposed surfaces and open cavities from damage and foreign material.
Ɠ Gear journals and gear faces are super finished. Take care not to touch these surfaces
after oil and solvent have been removed.
(2) Lubrication of moving parts
During assembly, all running surfaces(Bushing and spacer plate) must be lightly lubricated with a
clean oil or aerosol lubricant.
(3) Tools required for assembly
‫ ڸ‬Torque wrench(0~20kgfşm, 0~150lbfşft)
‫ ڹ‬Open end wrenches
‫ ں‬Seal installation tools(Inner and outer)
‫ ڻ‬Shaft bullet(Seal protector)
‫ ڼ‬Installation plate
6 -67
3) DISASSEMBLY
10
5
6
7
7
6
5
16
9 4
3
19
20
4
5
6
7 1
14
2
7
18 6
5
15 13
12
11
Ɠ Prior to starting work ensure that the pump and the working area are thoroughly clean and free
from sources of contamination.
(1) Mark end cover(16), center body(13), front body(10) and mounting flange(3) to ensure correct
assembly.
(2) Remove the 4 bolts(18), serrated washers(19), nut(20) clamping the units together, separate the
pumps by removing the rear unit from the location dowels in the center body - use a soft faced
hammer.
(3) Remove splined coupling(11) and discard O-ring(12) sealing the internal passages between the
pump sections.
(4) Disassemble rear pump by removing the end cover(16) from the body(13), free cover front
location spigot using a soft faced hammer.
(5) Remove drive shaft(15) from its bore by pushing it out from the connection hole in the rear face,
this will also remove balance plate(7).
Ɠ Note position of gear and balance plate for correct reassembly.
6 -68
DISASSEMBLY
10
5
6
7
7
6
5
16
9 4
3
19
20
4
5
6
7 1
14
2
7
18 6
5
15 13
12
11
(6) Remove driven gear(14) and lower balance plate(7).

(7) Discard O-ring(4) from end cover, seal element(5) and seal energizer(6) from balance plates.
(8) Disassemble front pump by separating flange(3) from its location spigot in body(10) - use soft
faced hammer.
(9) Remove shaft seal(1) from flange(3). Flanges have two shaft seals fitted back to back and the
outer shaft seal must be removed first to gain access to retaining circlip(2).
(10) Remove circlip(2) and inner shaft seal(1) take care to ensure that the seal recess is not damaged
as this could result in leakage.
(11) Grasp drive shaft(9) and remove it with balance plate(7), finally remove driven gear(8) and lower
balance plate(7).
Ɠ Note their positions for correct assembly.
(12) Remove and discard O-ring(4) in flange recess and seal element(5) and seal energizer(6) from
balance plates.
(13) Clean off all loctite sealant from flange/ body and end cover/body interfaces.
6 -69
4) INSPECTION AND REPAIR
(1) Assessment
Each components should be thoroughly cleaned, carefully examined and assessed for suitability
re-use. Below is a guide for inspecting the various components.
(2) Body
‫ ڸ‬Inspect the body bore cut-in where both gears wipe into the body.
‫ ڹ‬The body can only be re-used if the cut-in is bright and polished in appearance and the depth
does not exceed 0.15mm(0.006").
‫ ں‬The body should be replaced if the surface is scored, has a matt appearance or shows signs that
the tip of the gears have dug in and torn away the surface material.
‫ ڻ‬The body should be inspected to ensure that there is no superficial damage which may adversely
effect performance or sealing. Pay particular attention to the port threads and body O-ring seal
recesses.
(3) Mounting flange and end cover
‫ ڸ‬The inner surfaces should be inspected to ensure that there is no unusual wear or scoring in the
regions where the body O-rings and backing rings contact, which result in external leakage.
‫ ڹ‬Check the shaft seal recess for scoring or damage that could result in oil leakage around the
outer diameter of the shaft seal. Replacement shaft seals can be refitted with Loctite hydraulic
sealant to overcome slight damage in this area.
(4) Balance plate
‫ ڸ‬The side faces which abut the gears should be perfectly flat showing no sign of scoring.
Characteristically there are bright polished areas on this surface caused by loading against the
gear side faces, which is often more pronounced on the low pressure side. The balance plate
should be replaced if there is any general scoring or fine scoring with a matt appearance or
tearing of the surface material. Often there is a witness where the tips of the opposing gears
have wiped an overlap reassembling a half moon shape. There must be no noticeable wear
step as it is critical that the balance plate side face is completely flat to the gear side face.
‫ ڹ‬The bearing liners are acceptable providing that they are not scored or show other damage. The
general outside area of the balance plate should not show any prominent signs of wear.
(5) Gears
‫ ڸ‬The gear side faces should be examined for bruising or scoring. Often operation on
contaminated fluid shows scoring between the root of the gear and the journal undercut, which
leaves a wear step. If a wear step can be felt, coincidental with the root diameter, by drawing a
sharp pointed tool across the surface from the undercut outwards towards the tip of the gear,
then the gear is unserviceable.
‫ ڹ‬The gear teeth should then be carefully examined to ensure that there are no signs of bruising or pitting.
‫ ں‬The journal bearing surfaces should be completely free from scoring or bruising. The surface
should appear highly polished and smooth to touch.
‫ ڻ‬Examine the area where the shaft seal lips run on the drive shaft, this shows up as a polished
ring or rings. If a noticeable groove can be felt or there is scoring the shaft should be replaced.
‫ ڼ‬Provided the drive shaft is not damaged from the drive-coupling and the gears have not been
harmed as described above, then the gears can be re-used. If, however, the gears are
damaged they must be replaced as a matched pair.
‫ ڽ‬As a matter of good practice, when pumps have been disassembled, all the seals should be
replaced. It is most important that only the genuine seals are used.
6 -70
5) ASSEMBLY
10
5
6
7
7
6
5
16
9 4
3
19
20
4
5
6
7 1
14
2
7
18 6
5
15 13
12
11
Ɠ Prior to assembly all parts must be perfectly clean and lubricated with clean hydraulic oil.
Ɠ Renew all seals using clean hydraulic oil as a lubricant.
(1) Front pump
‫ ڸ‬Fit inner shaft seal(1) into the recess in the mounting flange, with the garter spring facing into the
pump, refit circlip(2) into its groove.
Fit outer shaft seal with garter spring facing uppermost. Coat lips of seals with a high melting
point grease.
Ɠ If the seal recess has been scored, then seal outside diameter can be coated with loctite
hydraulic sealant to prevent leakage.
‫ ڹ‬Stand pump body on its rear face, fit seal element(5) and seal energizer(6) to the groove in the
balance plate. Carefully feed the balance plate into the body bores. Ensure that the seals
remain in position and that the two small holes through the balance plate are to the low pressure
side of the unit, i.e. side with large 4 bolt port pattern.
6 -71
ASSEMBLY
10
5
6
7
7
6
5
16
9 4
3
19
20
4
5
6
7 1
14
2
7
18 6
5
15 13
12
11
‫ ں‬Insert drive shaft(9) and driven gear(8) into their original bores.
‫ ڻ‬Replace top balance plate with small holes to low pressure side of the unit, fit seal element(5)
and seal energizer(6) to grooves in balance plate.
‫ ڼ‬Fit O-ring(4) to groove in mounting flange and apply a small amount of loctite sealant to the body
lower face, i.e. outboard of oval spigot. This sealant is to prevent moisture entering this area
preventing corrosion.
‫ ڽ‬Carefully feed mounting flange over the drive shaft, ensure flange is in its original position-4mm
hole in rear face of flange must be to the low pressure side of the unit. Tap flange on to its
location spigot with a soft faced hammer.
(2) Rear pump

‫ ڸ‬Support front pump on the mounting flange-not the drive shaft-fit O-rings(12) into the grooves
around connection passages in the rear face, replace splined coupling(11).
‫ ڹ‬Fit rear pump body to front pump ensuring that it locates on the dowels and the through holes
line up.
6 -72
10
5
6
7
7
6
5
16
9 4
3
19
20
4
5
6
7 1
14
2
7
18 6
5
15 13
12
11
‫ ں‬Fit seal element(5) and seal energizer(6) to grooves in balance plate(7) and carefully feed into
body bores. Ensure seals remain in position and that the two small holes through the balance
plate are to the low pressure side, i.e. the side without a port.
‫ ڻ‬Fit drive gear(15) ensuring that it locates in the splined coupling(11), fit driven gear(14).
‫ ڼ‬Replace upper balance plate in its original position, i.e. with 2 small holes to low pressure side, fit
seal element(5) and seal energizer(6) to groove in plate.
‫ ڽ‬Fit O-ring(4) to groove in end cover, apply a small amount of loctite sealant to lower face of body,
i.e. outboard of oval spigot.
‫ ھ‬Studs(18) to be screwed into cover(16). Prior to fitting flange(3) washers(19) and nuts(20).
şTightening torque : 9.5Ź0.7kgfşm(68.7Ź5.1lbfşft)
‫ ڿ‬Pour a small amount of clean hydraulic oil into ports and check that the unit rotates without undue
force. If excessive force it required then seals in balance plates are possibly trapped and the unit
should be disassembled and reassembled correctly.
6 -73
6) RUNNING-IN
Pressure gauge
Test unit Variable

Micronic restrictor
filter
Flow
meter
Relief valve
Strainer
Tank
(1) A unit which has been reassembled with either new gears, balance plate or body, must be
carefully run-in before it is subjected to full working conditions.
(2) Ideally this should be done on a test rig(See figure) where pressure can be gradually applied and
any wipings from the body cut-in arrested by filters.
(3) It is recommended that the unit is run-in at 1500rpm, initially, at zero pressure for one minute then
in stages with the pressure increased by 500psi every minute, until maximum rated pressure has
been attained. Frequently check the system temperature, ensuring that it does not exceed the
maximum permissible figure of 80Ɓ C. If the temperature exceeds the system or unit specification
the test must be delayed and operated off-load until acceptable temperatures are obtained.
6 -74
2. RCV LEVER
1) STRUCTURE
B
17
12
4 1
29 24 2 13
3
28 5 6
23
26 4 7
21 2 2
1
3
27
15
16 A
10 9 4 1
8
3 2
18 14
25
15 19
11 30
22
20
A
B
1 Spring pack 11 Detent 21 Rubber boot

2 Spring pack 12 Prefeel cage assy 22 Coil
3 Spring 13 Spindle retainer 23 O-ring
4 Plunger assy 14 Spindle 24 Wiper seal
5 Plunger assy 15 Nut 25 Plug
6 Plunger assy 16 Lever assy 26 Boot retainer collar
7 Plunger assy 17 Handle assy 27 Handle adapter
8 Body 18 Universal joint 28 Nut
9 Prefeel 19 Socket screw 29 Nut
10 Prefeel 20 Connector assy 30 Tube
6 -75
2) DISASSEMBLY AND ASSEMBLY
(1) Detach the rubber boot(21) from the
retainer collar and lift the boot clear from 21
the selector assembly.
The capscrew(19) can now be easily
accessed.
Selector assy
(2) Loosen and remove all four M6

capscrews(19).
şTightening torque : 1.0kgfşm(7.2lbfşft) 19
(3) The upper portion of the valve, from the

mounting plate upwards, can now be
detached and placed to one side. Upper portion
Ɠ The magnets will still be connected to the of valve
connector.
(4) Remove the ball carriers off of the spindle

guide - carefully detach the spindle
guides, being careful to ensure that no
contamination enters the valve. Spindle
Ɠ The spindle guide are retained by guide
interference between the body and the

guide O-ring.
6 -76
(5) The spindle guides can now be replaced.
The O-rings on the spindle guide must be
replaced before the valve is reassembled. O-ring
Reassembly is the opposite of

disasembly.
6 -77
3. BOOM AND BUCKET CYLINDER
1) BOOM CYLINDER
3 1 20 24 25,26 21 27,28
19 5,6 7 10,11 23 22 4 2 13,14 17 15 16 12 18
8,9
INTERNAL DETAIL
1 Tube assy 11 Back up ring 21 Pipe assy

2 Rod assy 12 Piston 22 O-ring
3 Gland 13 O-ring 23 Socket bolt
4 Bushing 14 Back up ring 24 Pipe clamp
5 Rod seal 15 Glyd ring 25 Hexagon bolt
6 Back up ring 16 Wear ring 26 Spring washer
7 Buffer ring 17 Dust ring 27 Bushing
8 Dust wiper 18 Nylon nut 28 Dust seal
9 Snap ring 19 Socket bolt
10 O-ring 20 Pipe assy
6 -78
2) BUCKET CYLINDER
1 23-1,23-2 23-4,23-5,23-6 20 22 24,25
23-3,23-5,23-6
19 5,6 3 7 10,11 4 2 13,14 17 15 16 12 18 21
8,9
INTERNAL DETAIL
1 Tube assy 12 Piston 23 Band assy

2 Rod assy 13 O-ring 23-1 Band sub assy
3 Gland 14 Back up ring 23-2 Band
4 Bushing 15 Piston seal 23-3 U-bolt
5 Rod seal 16 Wear ring 23-4 Hexagon bolt
6 Back up ring 17 Dust ring 23-5 Hexagon nut
7 Buffer ring 18 Nylon nut 23-6 Spring washer
8 Dust wiper 19 Socket bolt 24 Bushing
9 Snap ring 20 Pipe assy 25 Dust seal
10 O-ring 21 O-ring
11 Back up ring 22 Socket bolt
6 -79
3) TOOLS AND TIGHTENING TORQUE
(1) Tools
Tool name Remark
8 B
Allen wrench
12
17
Spanner
19
(-) Driver Small and large sizes
Torque wrench Capable of tightening with the specified torques
(2) Tightening torque

Torque
Part name Item Size
kgfşm lbfşft
Bucket cylinder
19 M14ź2.0ź55 15Ź2 108Ź14.5
Boom cylinder
Socket head bolt
Bucket cylinder 22
M10ź1.5ź45 5.4Ź0.5 39.1Ź3.6
Boom cylinder 23
Bucket cylinder M48ź2.0ź48 250Ź25 1808Ź181
Nylon nut 18
Boom cylinder M45ź2.0ź45 250Ź20 1808Ź145
Boom cylinder 25 M12ź1.75ź40 5.5Ź0.6 39.8Ź4.3
Hex head bolt
Bucket cylinder 23-4 M10ź1.5ź35 3.2Ź0.3 23.1Ź2.2
U-bolt nut Bucket cylinder 23-5 M10ź1.5 3.2Ź0.3 23.1Ź2.2
6 -80
4) DISASSEMBLY
(1) Remove gland and piston rod
‫ ڸ‬Hold the clevis section of the tube in a
vise. Use mouth pieces so as not to
damage the machined surface of the
cylinder tube. Do not make use of the
outside piping as a locking means.
‫ ڹ‬Pull out piston rod(2) about 200mm

(7.8 in). Because the piston rod is rather
200mm
heavy, finish extending it with air
pressure after the oil draining operation.
‫ ں‬Loosen and remove socket bolts(19) of

Hexagon
the gland(3) in sequence. socket wrench
Ɠ Cover the extracted piston rod(2) with
rag to prevent it from being accidentally
damaged during operation.
3
19
2
Cover here
with rag
‫ ڻ‬Draw out gland(3) and piston rod (2)

assembly together from cylinder tube(1).
Lift 1
Ɠ Since the piston rod assembly is heavy
in this case, lift the tip of the piston rod(2)
with a crane or some means and draw it
out. However, when piston rod(2) has 3 2
been drawn out to approximately two
Oil pan
thirds of its length, lift it in its center to Pull straight
sideways
draw it completely.
6 -81
Ɠ 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.
‫ ڼ‬Place the removed piston rod assembly

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

‫ ڸ‬Remove the nylon nut(18). 13,14 17 15 12 16 18
‫ ڹ‬Remove piston assembly(12) and O-ring
(13), back up ring(14).
‫ ں‬Remove the gland assembly from piston

Lift with a crane
rod(2).
Ɠ If is too heavy to move, move it by Plastic 3 4 2
Hammer
striking the flanged part of gland(3) with a
plastic hammer. Pull straight
Ɠ Pull it straight with gland assembly lifted
with a crane.
Exercise care so as not to damage the lip
of rod bushing(4) and packing(5, 6, 7, 8,
9) by the threads of piston rod(2).
6 -82
(3) Disassemble the piston assembly
‫ ڸ‬Remove wear ring(16), dusting(17), and 17 15 16
piston seal (15).
damage the grooves.
(4) Disassemble gland assembly

‫ ڸ‬Remove back up ring(11) and O-ring 8,9 5,6 7 11 10 4
(10).
‫ ڹ‬Remove snap ring(9) and dust wiper(8).
‫ ں‬Remove back up ring(6), rod seal(5) and
buffer ring(7).
damage the grooves.
Ɠ Do not remove seal and ring, if does not
damaged.
6 -83
5) ASSEMBLY
(1) Assemble gland assembly
‫ ڸ‬Coat the inner face of gland(3) with
hydraulic oil.
3
‫ ڹ‬Coat dust wiper(8) with grease and fit

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

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

Therefore, confirm it before fitting them.
Push bar
Ɠ Fitting rod seal(5) up side down may
damage its lip. Therefore check the
correct direction that is shown in fig.
5
6 -84
‫ ڼ‬Fit back up ring(11) to gland(3).
Ɠ Put the backup ring in the warm water of
30~50Ş C.
11
‫ ڽ‬Fit O-ring(9) to gland(3).
10
(2) Assemble piston assembly

12
‫ ڸ‬Coat the outer face of piston(12) with
hydraulic oil.
‫ ڹ‬Fit piston seal(15) to piston

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

piston(12). 17 15 16 12
‫ ڻ‬Fit O-ring(13) and backup ring(14) to
piston(12).
6 -85
(3) Install piston and gland assembly
‫ ڸ‬Fix the piston rod assembly to the work Gland assembly
bench.
Piston rod
‫ ڹ‬Apply hydraulic oil to the outer surface of
piston rod(2), the inner surface of piston
and gland.
‫ ں‬Insert gland assembly to piston rod(2).
‫ ڻ‬Fit piston assembly to piston rod.

Piston assembly
Piston rod
‫ ڼ‬Tighten nylon nut(18) to piston rod(2)

şTightening torque : 250Ź20kgfşm 2 18
(1808Ź145lbfşft)
6 -86
(4) Overall assemble Fix with a bar
‫ ڸ‬Place a V-block on a rigid work bench.
Mount the cylinder tube assembly(1) on it
Lift
and fix the assembly by passing a bar
through the clevis hole to lock the
assembly.
‫ ڹ‬Insert the piston rod assembly in to the Straight
cylinder tube assembly, while lifting and

moving the piston rod assembly with a
Apply liquid packing
crane.
Ɠ Be careful not to damage piston seal by
thread of cylinder tube.
‫ ں‬Match the bolts holes in the cylinder Tube
head flange to the tapped holes in the
cylinder tube assembly and tighten
socket bolts to a specified torque. Piston rod
Ɠ Refer to the table of tightening torque. Hexagon
socket bolt
Gland
6 -87
SECTION 7 ELECTRICAL SYSTEM
GROUP 1 COMPONENT LOCATION
1. LOCATION 1
9 15
10 16
11
12 17
1 13
2 14
3
4 18
5 Switch panel 19
20
6 21
7
22
8 23
24
1 Horn button 10 Work lamp switch 18 Rear wiper/washer switch

2 Multi function switch 11 Work lamp switch 19 Air conditioner switch
3 Starting switch 12 Main light switch 20 Hazard switch
4 Cluster 13 Clutch cut off switch 21 Aircon & heater switch
5 Gear selector lever 14 Parking brake switch 22 Check unit
6 Kick down switch 15 Full automatic switch 23 Relay board
7 Ride control switch(Option) 16 Emergency steering pilot 24 Fuse box
8 Service meter lamp (Option)
9 Beacon switch(Option) 17 Buzzer stop switch
7-1
2. LOCATION 2
8
7
6
1
5
14
16
10
11
12
4
13
15
3
2
1 Alternator 7 T/M oil pressure switch 13 Temp sendor

2 Rear combination lamp 8 Relay board 14 Back up buzzer
3 Battery 9 Proximate switch 15 Glow timer
4 Overheat switch 10 Front combination lamp 16 Terminal
5 Water temp switch 11 Light
6 T/M temp sendor 12 Air horn
7-2
1. ILLUMINATION CIRCUIT
1) OPERATING FLOW
Fuse box (No.20) Illumination switch [CS-39(1)] Switch ON, 1st step
[CS-39(7)] Hazard and illumination switch indicator lamp ON
[CS-39(5)] Fuse box(11) I/conn [CN-2(6)] RH Combi clearance lamp ON [CL-16(4)]
I/conn [CN-4(1)] LH Head lamp ON [CL-3(4)]
Fuse box(12) I/conn [CN-2(5)] No. plate lamp ON [CL-21(2)]
LH Combi clearance lamp ON [CL-15(4)]
I/conn [CN-4(2)] RH Head lamp ON [CL-4(4)]
I/conn [CN-7(14)] All cluster guage lamp ON
2) CHECK POINT
Engine Key switch Check point Voltage
① - GND (Switch input)

② - GND (Switch output)
OFF ON 20~25V
③ - GND (To light)
④ - GND (To gauge lamp)
※ GND : Ground
7-5
ILLUMINATION CIRCUIT
CN-36
126 GL
046 RL
143 RG
FUSE BOX
CN-4 CL-3
2
LH HEAD LIGHT
CS-39
CL-4
3
CN-8
RH HEAD LIGHT
3
CL-21
ILL & HEAD LAMP SW

1
NUMBERPLATE LAMP
CL-16
CN-2
3 RH COMBI
CL-15
LH COMBI
1.25R CN-127
3 E
B km/h
4
306 1.25R 8 S
G3
SPEED METER
CS-41
CN-7 CN-119
T/M TEMP
HAZARD SW
CN-117
WATER TEMP
JT-29
CN-104
VOLT METER
4
CN-107
FUEL METER
7-6
2. HEAD LIGHT CIRCUIT
1) OPERATING FLOW
Fuse box(No.19) Head light switch [CS-39(4)] Light switch ON, 2nd step [CS-39(2)]
Multi function switch [CS-11(8)]
Multi function switch MIDDLE [CS-11(7)] I/conn [CN-4(3)] 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-4(4)] LH Head light high beam
ON [CL-3(2)]
RH Head light high beam
ON [CL-4(2)]
I/conn [CN-7(3)] Cluster high beam pilot
lamp ON [CL-41(2)]
2) CHECK POINT

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
CN-36
FUSE BOX
CL-3
CS-39
CN-8
1
LH HEAD LIGHT
CL-4
ILL & HEAD LAMP SW

RH HEAD LIGHT
2
CN-4
6
CL-41
7
HI BEAM PILOT LAMP
4
CN-7 JT-28
3
5 8
CS-11
MULTI FUNCTION SW EARTH
7-8
3. WORK LIGHT SWITCH
1) OPERATING FLOW
Fuse box(No.17) Front work light switch [CS-21(6)] Work light switch ON [CS-21(2)]
I/conn [CN-5(4)] LH Front work lamp ON [CL-6(2)]
RH Front work lamp ON [CL-5(2)]
Front work lamp switch indicator lamp ON
Rear work light switch [CS-20(6)] Work light switch ON [CS-20(2)]
I/conn [CN-5(3)] LH Rear work lamp ON [CL-22(2)]
RH Rear work lamp ON [CL-23(2)]
Rear work lamp switch indicator lamp ON
2)

OFF ON 20~25V
③ - GND (Front work light)
④ - GND (Rear work light)
※ GND : Ground
7-9
WORK LIGHT SWITCH
CN-36
FUSE BOX
CN-5
3
1
CL-6
CS-21
FRONT WORK
LIGHT,LH
CL-5
FRONT WORK
LIGHT,RH
1 3
FRONT WORK LAMP
2 4
CS-20
CL-22
REAR WORK
LIGHT,LH
CL-23
REAR WORK LAMP REAR WORK

LIGHT,RH
2 4
7-10
4. STARTING CIRCUIT
1) OPERATING FLOW
Battery(+) terminal Battery relay(M8, B+ terminal) Fusible link [CN-60(1)]
I/conn [CN-1(1)] Fuse box (No.13) Start switch [CS-2(1)]
※ The gear selector lever is neutral position. It is necessary condition before the starting.
The gear selector lever 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-2(2)] Battery relay [CR-1]
Battery relay operating(All power is supplied with the electric component)
Start switch [CS-2(3)] Fuse box [No.4] I/conn [CN-3(3)]
I/conn [CN-13(5)] Fuel shut off solenoid [CN-79]
(2) When start key switch is in START position
Start switch START [CS-2(5)] Start safety relay [CR-5(2)] Start safety relay [CR-5(4)]
I/conn [CN-3(2)] I/conn [CN-13(4)] Start relay [CR-23(1)]
Starter(Terminal B+ and M connector of start motor)
2) CHECK POINT
① - GND (Battery B+)

② - GND (Fusible link)
③ - GND (Start key B+)
④ - GND (Start key BR terminal)
⑤ - GND (I/conn CN-2(2))
Running ON 20~28V
⑥ - GND (Start key R2 terminal)
⑦ - GND (Start safety relay output)
⑧ - GND (Check unit)
⑨ - GND (Start key IG terminal)
⑩ - GND (Fuel shut off solenoid)
※ GND : Ground
7-11
5. FUEL SHUT OFF CIRCUIT
1) OPERATING FLOW
Start key OFF [CS-2(3)] Fuse box (No.4) I/conn [CN-2(3)] I/conn [CN-13(5)]
Fuel shut off solenoid [CN-79(1)]
2) CHECK POINT
⑨ - GND (Start key IG terminal)

OFF OFF 0V
⑩ - GND (Fuel shut off solenoid)
※ GND : Ground
3) WIRING DIAGRAM - See page 7-12.
7-13
6. CHARGING CIRCUIT
When the starter is activated and the engine is started, the operator releases the key switch to the
ON position.
Charging current generated by operating alternator flows into the battery through the battery
relay(CR-1).
The current also flows from alternator to each electrical component and controller through the fuse
box.
1) OPERATING FLOW
(1) Warning flow
Altermator [CN-74(D+)] I/conn [CN-13(3)] I/conn [CN-3(1)]
Check unit [CN-58(2)]
I/conn [CN-6(1)] Cluster charge warning lamp ON [CL-46(1), Below 24V]
JT-27(4)→(10) Volt meter [CN-104(B)]
(2) Charging flow
Alternator [CN-74(B+)] Starter [CN-45(B+)] Battery relay [CR-1]
Battery(+) terminal Charging
I/conn [CN-60(1),(2)] I/conn [CN-1(1),(2)] Fuse box
2) CHECK POINT
① - GND (Battery)
② - GND (Battery relay)
③ - GND (ALT B+)
Running ON 20~28V
④ - GND (ALT D+)
⑤ - GND (Check unit)
⑥ - GND (Fuse box)
Engine Key switch Check point Resistance
Running ON ⑦ - GND (Cluster) ∞Ω

※ GND : Ground
7-14
7. ELECTRIC PARKING, DECLUTCH CIRCUIT
1) OPERATING FLOW
(1) Parking OFF
Fuse box (No.6) Parking switch OFF [CS-17(6) (8)] I/conn [CN-8(10)]
Parking solenoid ON(Activated) Parking brake released(By hydraulic pressure)
(2) Parking ON
Fuse box (No.6) Parking switch ON Parking solenoid [CN-71] OFF
Parking brake applied [By spring force]
[CS-17(6) (2)] Parking switch indicator lamp ON
[CS-17(5) (1)] I/conn [CN-15(F)]
Control unit [X1(21)] T/M declutch
(3) Declutch ON
Fuse box (No.20) Clutch cut-off switch ON Clutch cut-off switch [CS-42(6) (2)]
Clutch cut-off switch indicator lamp ON
Clutch cut-off switch [CS-42(5) (1)]
Service brake applied
Service brake pressure switch ON [CD-5]
I/conn [CN-15(E)] Control
unit [X1(66)] Declutch
Clutch oil pressure switch
2) CHECK POINT
① - GND (Parking switch input)

② - GND (Parking switch output)
③ - GND (Parking switch input)
Running ON ④ - GND (Parking switch output) 20~28V
⑤ - GND (Parking solenoid)
⑥ - GND (Clutch cut-off press switch)
⑦ - GND (Declutch input signal)
※ GND : Ground
7-16
8. WIPER AND WASHER CIRCUIT
1) OPERATING FLOW
Fuse box (No.7) Wiper relay Hi [CR-4(1) (3)] Front wiper motor [CN-21(1)]
Wiper relay Lo [CR-26(2), (4)]
Multi function switch [CS-12(6)]
Rear wiper & washer switch [CS-3(1)]
Rear wiper motor [CN-102(1)]
(1) Front washer switch ON
① Washer switch ON [CS-12(6) (2)] Washer tank [CN-22(2)] Washer operating
Check unit [CN-58(21) (15)] Wiper relay Lo
[CR-26(4) (1)] Wiper motor [CN-21(5)]
Wiper motor operating(Low)
(2) Front wiper switch ON
① INT position
Wiper switch ON [CS-12(6) (1)] Check unit [CN-58(10) (15)] intermittent signal Wiper
relay Lo [CR-26(4) (1)] Wiper motor [CN-21(5)] Wiper motor intermittently operating
② Lo position
Wiper switch ON [CS-12(6) (4)] Wiper relay Lo [CR-26(3) (1)] Wiper motor [CN-21(5)]
Wiper motor operating (Low)
③ Hi position
Wiper switch ON [CS-12(6) (3)] Wiper relay Hi [CR-4(1) (4)] Wiper motor [CN-21(4)]
Wiper motor operating(High)
(3) Auto-parking(When switch OFF)
Switch OFF Fuse box (No.7) Wiper relay Hi [CR-4(1) (3)] Wiper motor
[CN-21(1) (2)] Multi function switch [CS-12(5) (4)] Wiper relay Lo [CR-26(3) (1)]
Front wiper motor [CN-21(5)] Wiper motor stop
(4) Rear wiper and washer switch
① Wiper switch ON(1st step)
Wiper switch ON [CS-3(1) (6)] Wiper motor [CN-102(5)] Wiper motor operating
Rear wiper and washer switch indicator lamp ON
② Washer switch ON(2nd step)
Washer switch ON [CS-3(1) (3)] Rear washer tank [CN-103(2)] Washer operating
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
3. MONITORING SYSTEM
1. CLUSTER
The gauges panel consists of gauges and monitors as shown below, to warn the operator in case of
abnormal machine operation or conditions for the appropriate operation and inspection.
ş Gauges : Indicate operating status of the machine.
ş Warning lamp : Indicate abnormality of the machine.
ş Pilot lamp : Indicate operating status of the machine.
Ɠ The monitor installed on this machine does not entirely guarantee the condition of the
machine.
Daily inspection should be performed according to chapter 6, MAINTENANCE.
T/M error warning lamp Glow pilot lamp

Battery charging warning lamp Hyd oil temp warning lamp
Overheat warning lamp Brake fail warning lamp
Left turning pilot lamp Right turning pilot lamp
High beam pilot lamp Parking brake pilot lamp
20 30
10 km/h 20 P
10 40
0 MPH 30
0 50
VDO
E F
WATER FUEL
TRANS BATT
Speedometer
T/M oil temperature gauge Battery volt meter
Engine coolant temperature gauge Fuel gauge
Engine oil pressure warning lamp T/M oil pressure warning lamp
1) SPEEDOMETER
(1) The speedometer displays the speed of machine in mph and
20 30
km/h.
10 km/h 20
10 40
0 MPH 30
0 50
VDO
7-22
2) FUEL GAUGE
(1) This gauge indicates the amount of fuel in the fuel tank.
Red
Red White
White
(2) Fill the fuel when the red range illuminates.
E F
(3) The gauge indicates continuously the current fuel amount
FUEL
even after turn OFF the starting switch. This does not mean
that the gauge is out of order.
Ɠ If the gauge illuminates the red range even though the
machine is on the normal condition, check the electric
device as that can be caused by the poor connection of
electricity or sensor.
3) ENGINE COOLANT TEMPERATURE GAUGE

(1) This indicates the temperature of coolant.
Green
Green Red
Red şGreen range : 37~105Ş C(99~221Ş F)
şRed range : 105Ş C(221ŞF) Above
(2) The green range illuminates when operating.
WATER
(3) Keep idling engine at low speed until the green range
illuminates, before operation of machine.
(4) When the red range illuminates, turn OFF the engine, check
the radiator and engine.
4) TRANSMISSION OIL TEMPERATURE GAUGE

(1) This range indicates the temperature of transmission oil.
Green
Green Red
Red şGreen range : 37~120Ş C(99~248ŞF)
şRed range : 120Ş C(248ŞF) Above
(2) The green range indicates when operating.
TRANS
(3) Keep idling engine at low speed until the green range
indicates, before operation of machine.
(4) If the indicator is in the red range, it means the transmission is
overheated. Be careful that the indicator does not move into
the red range.
7-23
5) BATTERY VOLT METER
(1) This gauge indicates the voltage in the charging system when
White
White Green
Green Red
Red the engine is running.
(2) If the indicator is below 24V(White range), it means that the
electricity is being discharged. If the indicator is above
BATT
30V(Red range), an unusually high voltage may damage the

alternator. Check the charging system in both cases.
6) DIRECTION PILOT LAMP

(1) This lamp flashes when the signal indicator lever is moved.
(2) When the lamp lights up, the alarm(50dB) sounds.
7) HIGH BEAM PILOT LAMP

(1) This lamp works when the illuminating direction is upward.
(2) This lamp comes ON when the dimmer switch is operated,
e.g., when passing another vehicle.
8) PARKING BRAKE PILOT LAMP

(1) When the parking brake is actuated, the lamp lights ON.
Ɠ Check the lamp is OFF before driving.
P
9) BRAKE FAIL WARNING LAMP
(1) The lamp lights ON when the oil pressure of service brake
drops below the normal range.
(2) When the lamp is ON, stop the engine and check for its
cause.
Ɠ Do not operate until any problems are corrected.
7-24
10) TRANSMISSION OIL PRESSURE WARNING LAMP
(1) The lamp lights ON when the oil pressure of the
transmission drops.
(2) When the lamp is ON, stop the engine and check the
transmission system.
11) GLOW PILOT LAMP

(1) This lamp lights ON when key ON, it will be ON to indicate the
glow plugs are being heated.
(2) When the lamp goes out the operator should start cranking the
engine.
12) BATTERY CHARGING WARNING LAMP

(1) This lamp is ON when key ON, it is turned OFF after starting
the engine.
(2) Check the battery charging circuit when this lamp comes ON,
during engine operation.
13) ENGINE OIL PRESSURE WARNING LAMP

(1) If lamp comes ON during engine operation, shut OFF
engine immediately. Check oil level.
14) OVERHEAT WARNING LAMP

(1) This lamp is turned ON when the temperature of cooling water
is over the normal temperature (110Ş
C, 230Ş
F).
(2) Check the cooling system when the lamp is ON.
7-25
15) HYDRAULIC OIL TEMP WARNING LAMP
(1) This warning lamp operates and the buzzer sounds when the
temperature of hydraulic oil is over 105Ş
C(221Ş
F).
(2) Check the hydraulic oil level when the lamp is turned ON.
(3) Check for debris between oil cooler and radiator.
16) TRANSMISSION ERROR WARNING LAMP

(1) This lamp lights ON and the transmission error display show
the wrench with the error codes when a error occurs in the
transmission.
(2) Immediately pull the machine to a convenient stop. Stop the
engine. Investigate the cause.
Ɠ Consult a HYUNDAI dealer to investigate the cause.
Ɠ Do not operate until the cause has been corrected.
7-26
3. SWITCHES
Beacon switch(Option) Full automatic switch

Work lamp switch Emergency steering
Work lamp switch pilot lamp(Option)
Main light switch Buzzer stop switch
Clutch cut off switch
Parking brake switch
Switch panel Rear wiper/washer switch

Aircon switch
Horn button Hazard switch
Multi function switch
Starting switch
Kick down switch
Ride control switch
(Option)
1) STARTING SWITCH
(1) There are three positions, OFF, ON and START.
ON STAR
T
(2) OFF : None of electrical circuits activate.
F
OF
(3) ON : All the systems of machine operate.

(4) START : Use when operating the engine.
Release key immediately after starting.
7-27
2) FULL AUTOMATIC SWITCH
‫ڹ‬ (1) Manual mode(‫)ڸ‬

Press the bottom of the switch for the manual mode of the autoshift
‫ڸ‬
function. The operator selects the desired speed and the desired
direction in the manual mode with the gear selector lever.
A
(2) Automatic mode(‫)ڹ‬

Press the top of the switch for the autoshift function in the automatic
mode. Press the top of the switch prior to shifting the transmission
into forward or reverse in order to activate the autoshift function.
3) HAZARD SWITCH
(1) Use for parking, or roading machine.
Ɠ If the switch is left ON for a long time, the battery may be
discharged.
(2) The below indicator lamp is turned ON when operating this switch.
4) CLUTCH CUT OFF SWITCH

(1) This switch is pressed, it will cut off the clutch when brake operates.
Ɠ Be careful not to use this switch when driving on a slope.
5) PARKING BRAKE SWITCH

(1) This switch is pressed, the parking brake will start to operate and the
gauge panel warning lamp will comes ON.
Ɠ When operating the gear selector lever, be sure to release the
P parking brake. If the machine is operated with the parking
brake engaged, the brake will overheat and may cause the
brake system to go out of order.
7-28
6) MAIN LIGHT SWITCH
(1) This switch use to operates the clearance lamp and head light by two
step.
ϦFirst step : Clearance lamp and cluster illumination lamp
comes ON. Also, the below indicator lamp comes
ON.
ϦSecond step : Head light comes ON.
7) WORK LAMP SWITCH

(1) This switch turns ON the working lamps located on the front of the
cab.
8) WORK LAMP SWITCH

(1) This switch turns ON the working lamps located on the rear of the
cab.
9) AIR CONDITIONER SWITCH

(1) This switch use to operates the air conditioner.
(2) Refer to the air conditioner and heater for detail operation.
7-29
10) REAR WIPER AND WASHER SWITCH
(1) The switch use to operates the rear wiper and washer by two step.
şFirst step : The rear wiper operates.
şSecond step : The washer liquid is sprayed and the rear wiper is
operated only while pressing. If release the switch,
return to the first step position.
11) BUZZER STOP SWITCH

(1) The red lamp on the cluster lights ON and the buzzer sounds when
the machine has a problem.
In this case, if the switch is pressed, the buzzer will be stopped. Be
sure to check machine for problems.
(2) Wait until the lamp is turned OFF, if the red lamp lights ON after the
buzzer stopped.
If not, stop engine and check the system which the lamp is ON.
12) CAB LAMP SWITCH

(1) This switch turns ON the cab room lamp.
13) KICK DOWN SWITCH

(1) The kick-down switch into first gear is not allowed. Press the switch
and release the switch. The transmission downshifts one gear
Kick down switch
speed, provided that an engine overspeed would not occur.
7-30
14) EMERGENCY STEERING PILOT LAMP(Option)
Primary
Primary (1) Primary
Emergency
Emergency If the oil pressure in the steering pump drops, the lamp will light up. If
this lamp flashes during operation, the action alarm should sound.
Ɠ If the lamp lights up, immediately pull the machine to a safe
place and stop the machine.
(2) Emergency
This lamp will flash if the oil pressure in the emergency steering
pump drops. The lamp notifies the operator that if the steering
system also failed at this time, there is no emergency steering
system for backup.
Ɠ Immediately pull the machine to a convenient stop and stop the
engine.
Ɠ This machine is equipped with ground driven emergency
steering pump. It is normal for the lamp to flash after 5
seconds when the machine is stopped.
15) MULTI FUNCTION SWITCH

(1) Front wiper and washer switch
‫ ڸ‬When the switch is in J position, the wiper moves intermittently.
O J ѓє ‫ ڹ‬When placed in ѓ or є position, the wiper moves continuously.
‫ ں‬If you press a button at the end of the lever, washer liquid will be
sprayed and the wiper will be activated 2-3 times.
Ɠ Check the quantity of washer liquid in the tank. If the level of
the washer liquid is LOW, add the washer liquid (In cold, winter
days) or water. The capacity of the tank is 1 liter.
(2) Dimmer switch

‫ ڸ‬This switch is used to turn the head lights direction.
Up ‫ ڹ‬Switch positions
şUp : To flash for passing
M
şMiddle : Head lights low beam ON
Down şDown : Head lights high beam ON
‫ ں‬If you release the switch when it's in up position, the switch will return
to middle.
(3) Turning switch
Left turning ‫ ڸ‬This switch is used to warn or signal the turning direction of the
machine to other vehicles or equipment.
‫ ڹ‬Push the lever up for turning left, pull the lever down for turning right.
Right turning
7-31
16) HORN BUTTON
(1) If you press the button on the top of the multifunction switch, the horn
Horn button will sound.
17) BEACON SWITCH(Option)

(1) This switch turns ON the rotary light on the cab.
18) RIDE CONTROL SWITCH(Option)

(1) This switch is pressed, the ride control system will start to operate.
The ride control system significantly reduces pitching and loping
without slowing down the travel speed.
7-32
GROUP 4 ELECTRICAL COMPONENT SPECIFICATION
Part name Symbol Specifications Check
Ɠ Check specific gravity

12V ź 100Ah 1.280 Over : Over charged
Battery
(2EA) 1.280 ~ 1.250 : Normal
1.250 Below : Recharging
Ɠ Check coil resistance

Rated load : 24V Normal : About 50‫װ‬
Battery relay 100A(Continuity) Ɠ Check contact
1000A(30sec) Normal : ſ‫װ‬
CR-1
Ɠ Check disconnection
2 Normal : 0‫װ‬
Fusible link 24V 60A (Connect ring terminal and
1 check resistance between
CN-60 terminal 1 and 2)
105 BW
036 GY
001 LW
603 LR
Ɠ Check contact
OFF : ſ‫(װ‬For each terminal)
6 5 4 3 2 1
ON : 0‫(װ‬For terminal 1-3)
Start key -
ST
ſ‫(װ‬For terminal 1-5)
ACC START : 0‫(װ‬For terminal 1-3
OFF
HT and 1-5)
C R2 R1 IG BR B OFF CS-2
Pa Ɠ Check contact
Pressure switch N.C TYPE
Normal : 0‫(װ‬Close)
CD-3 CD-26
CD-25 CD-39
Pa
Ɠ Check contact
Pressure switch N.O TYPE
Normal : ſ‫(װ‬Open)
CD-4 CD-5
CD-40
7-33
1 Pa
Pressure switch 0.5kg/cm2 Ɠ Check contact
(For engine oil) 2 (N.C TYPE) Normal : 0‫(װ‬Close)
CD-18
T Ɠ Check resistance
Coolant temp
- Normal : ſ‫װ‬
sensor
225Ş
F Over : 0‫װ‬
CD-9
Ş
Coolant - Ɠ Check resistance
temp sensor 192Ź13.5‫ װ‬at 73.9Ş
C
CD-8
1 Ɠ Check LED lamp

Parking
24V 1.2A Ɠ Check Resistance
solenoid
2 About 24‫װ‬
CN-71
1 Ɠ Check resistance
Reed switch : Full : About 30‫װ‬
Fuel sender
2 Magnetic type Low level : About 300‫װ‬
CD-2
Transmission °C
1/2 P.T.F Ɠ Check resistance
oil temperatur
137.2Ź14.5‫ װ‬at 87.8Ş
C
sender
CD-29
7-34
1 2 1
Ɠ Check resistance
2
Normal : About 200‫װ‬
Relay 3 24V 20A (For terminal 1-3)
(4pin) 4 4 3 : ſ‫װ‬
CR-2 CR-7 AC RY1 (For terminal 2-4)
CR-5 CR-10 CR-30 AC RY2
Ɠ Check resistance
1
3 4 6 Normal : About 160‫װ‬
2
(For terminal 2-6)
4
Relay 24V 20A : 0‫װ‬
6
(5pin) (For terminal 1-3)
3 1 2
: ſ‫װ‬
CR-4 CR-26 CR-35 (For terminal 1-3)
1 B
Proximate -
2 S 24V 400mA
switch
3 E
CN-100 CN-101
Ɠ Check resistance
Hydraulic - Normal : ſ‫װ‬
temperature
105Ş
C Over : 0‫װ‬
CD-1
Ɠ Check contact
2 Lo 1 Normal : 1.12‫װ‬
4
(For terminal 2-4)
Hi 2
Air conditioner - : 2.07‫װ‬
3 ML 3
resistor (For terminal 3-4)
1 MH 4 : 3.17‫װ‬
(For terminal 4-1)
Ɠ Check resistance
Speaker 4‫ װ‬20W
Normal : 50‫װ‬
CN-23(LH)
CN-24(RH)
7-35
10 9 8 7 6 5 4 3 2 1
10 6 5
Ɠ Check contact
OFF : ſ‫װ‬
Switch 24V 8A (For terminal 1-5, 2-6)
(Locking type) 9 8 2 7 1 : 0‫װ‬
CS-17 CS-21 CS-41 CS-50 (For terminal 5-7, 6-8)
CS-20 CS-23 CS-42 CS-54
10 9 8 7 6 5 4 3 2 1
Switch 10 4 1 Ɠ Check contact

(Non-locking 24V 8A OFF : ſ‫װ‬
type) (For terminal 2-4, 1-7)
9 2 7 5
CS-3 CS-39
Work lamp
Work lamp, 2 24V 70W
Room lamp, Number plate Ɠ Check disconnection
Number plate 1 lamp Normal : A few‫װ‬
lamp Room lamp
CL-1 CL-6 CL-22
CL-5 CL-21 CL-23 24V 10W
Beacon lamp M 24V 70W Ɠ Check disconnection

(H1 TYPE) Normal : A few‫װ‬
CL-7
Ɠ Check operation
Supply power(24V) to
Hour meter
h -
terminal No.2 and contact
terminal No.1 and ground
CN-48
Ɠ Check operation
22-28V 2A Supply power(24V) to each
Horn
110dB terminal and connect ground
CN-20 CN-25
7-36
PA 1 Ɠ Check contact
Receiver dryer 24V 2.5A
2 Normal : ſ‫װ‬
CN-29
1 SL+
2 ACC
3 NC
4 SR+ Ɠ Check resistance
Cassette radio 5 NC 24V 20W+20W Power ON : 4‫װ‬+4‫װ‬
6 SL-
7 B+
(For terminal 1-6, 4-8)
8 SR-
9 NC CN-27
Back up buzzer 24V 0.5A 110dB -
CN-65
M 1 Ɠ Check contact
Washer pump 24V 2.5A Normal : 26.4 ‫װ‬
2 (For terminal 1-2)
CN-103 CN-22
24V 1.5A
Wiper motor
Hi
2-speed -
E
Lo M
Auto parking
CN-103 CN-22
Cigar lighter 2 24V 5A -
CL-2
7-37
B+
G
3~ Ɠ Check voltage
Alternator I 20V 60A
Normal : 24-28V
GND
CN-74
B+
M Delco Remy
Starter Ɠ Operating or not
28MT 24V
M
CN-45
1
Air conditioner Ɠ Check contact
24V 79W
compressor 2 Normal : 13.4‫װ‬
CN-28
1 Ɠ Check contact
Start relay 24V 200A
2 Normal : 11.3‫װ‬
CR-23
M 1
-
Blower 24V 9A
2 2900Ź150rpm
1 GND
2 COM 2 4 5 3 6
Ɠ Check resistance
3 MH
Blower switch 4
- Normal : 0‫(װ‬For terminal 1-2,
LOW
5 ML
3, 4, 5, 6)
1
6 HI CS-58
7-38
M+ 1
Mode actuator S+ 2
M DC Servo motor
3
and M-
-
4
9-16V 300mA
FS
temperature
5
Max
S-
actuator
NC 6
R 2
12V Ɠ Check resistance
Intake actuator M Normal : 2.0‫װ‬
F 1
Working
1 temperature of
Thermostat contact point -
2 A/C ON : 4.5Ş C
A/C OFF : 1.5ŞC
3 E
G 24V
Flasher unit 2 B 85 ~ 190 C/M -
1 L 50dB
CR-11
1 Lo
2 Hi 24V 75W/70W
Head lamp Ɠ Check disconnection
3 E (H4 TYPE) Normal : A few‫װ‬
24V 4W(T4W)
4 C
CL-3 CL-4
4 C
3 T 24V 5W(R5W)
Combi lamp 2 E 2ź24V 21W -
1 S (P21W)
CL-15 CL-16
7-39
1
Turn lamp 24V 21W -
2 (P21W)
CL-24 CL-25
Continuous
Capacity :
Master switch 180Amp -
Push in capacity:
1000Amp
2
Warning buzzer 24V 200mA -
1 90Ź5dB(ֻm)
CN-26
M 1
Air conditioner 24V -
fan 2
CN-83
1
2
Buzzer stop 3
4 Ɠ Check contact
switch 5 5 1
6 24V 8A OFF : ſ‫װ‬
(Rocker switch 7 6 2 (For terminal 1-5, 2-6)
push button) 8
9
10 10 9 CS-34
1 Ɠ Check contact
5 BL- BL+ 1
2
6 BK- BK+ 2 Normal : 80~90‫װ‬
3
Joy stick lever

7 FL- FL+ 3
4 (For terminal 1-5, 2-6
5
-
3-7, )
6
4 8
7 : ſ‫װ‬
8 CN-144 (For terminal 4-8)
7-40
GROUP 5 CONNECTORS
1. CONNECTOR DESTINATION
Connector No. of Connector part No.
Type Destination
number pin Female Male
CN-1 58 2 I/conn(Frame harness-Main harness) S813-030200 S813-130200
CN-2 SWP 12 I/conn(Frame harness-Main harness) S814-012000 S814-112000
CN-3 SWP 12 I/conn(Frame harness-Main harness) S814-012000 S814-112000
CN-4 SWP 8 I/conn(Front harness-Main harness) S814-008000 S814-108000
CN-5 SWP 8 I/conn(Cab harness-Main harness) S814-008000 S814-108000
CN-6 SWP 12 I/conn(Gauge harness-Main harness) S814-012000 S814-112000
CN-8 SWP 12 I/conn(Front harness-Main harness) S814-012000 S814-112000
CN-9 SWP 6 I/conn(T/M check harness-Main harness) S814-006000 S814-106000
CN-13 SWP 12 I/conn(Frame-Engine harness) S814-012000 S814-112000
CN-15 - 10 I/conn(Main harness-T/M harness) 6029199086 6029199085
CN-16 - 10 I/conn(Main harness-T/M harness) 6029199086 6029199085
CN-20 - 2 Horn 35215-0200
CN-21 - 6 Front wiper motor 6189-0133
CN-22 - 2 Front washer tank S814-002000
CN-23 Shur 1 Speaker(LH) S822-014000 S822-114004
CN-24 Shur 1 Speaker(RH) S822-014000 S822-114004
CN-25 - 2 Horn 35215-0200
CN-26 Fasten 2 Warning buzzer S810-002202
CN-27 PA 9 Cassette and radio S811-009003
CN-28 - 2 Compressor(Air conditioner) 0297-3407
CN-29 Grommet - Receiver drier 21L7-12000
CN-30 PA 13 Air conditioner controller S811-013002
CN-36 - 20 Fuse box S812-002001
CN-45 Ring term - Starter S820-410000 S820-310000
CN-48 - 1 Hour meter S819-010112
CN-58 - 36 Check unit 344111-1
CN-60 58 2 Fusible link S813-130200
CN-62 - 5 Glow controller 963013-1
CN-65 Shur 1 Back up buzzer S822-014000
CN-71 J 2 Parking solenoid S816-002001
CN-74 Ring term - Alternator S820-408000 S820-104000
CN-79 - 2 Fuel cut off solenoid 827551-2
CN-83 - 2 Air conditioner fan PH805-02028
CN-100 J 3 Boom kick out S816-003001
CN-101 J 3 Bucket leveler S816-003001
7-41
Type Destination
CN-102 - 6 Rear wiper motor 6189-0133
CN-103 - 2 Rear washer tank S814-002000
CN-104 Ring term - Volt meter S821-105000
CN-107 Ring term - Fuel gauge S821-105000
CN-114 - 8 Joy stick S816-008002
CN-117 Ring term - Water temp S821-105000
CN-119 Ring term - Transmission temp S821-105000
CN-125 Ring term - Glow terminal S820-308000
CN-127 - 8 Speed meter 1630070
CN-130 - 3 Excess fuel solenoid APV-P3AC
Relay
CR-1 Ring term - Battery relay S820-104000
CR-2 Fasten 4 Horn relay S810-004202
CR-4 Fasten 6 Wiper relay Hi S810-006202
CR-5 Fasten 4 Safety relay S810-004202
CR-7 Fasten 4 Air-con relay S810-004202
CR-11 Fasten 3 Flasher unit S810-003702
CR-23 J 2 Start relay S816-002003
CR-26 Fasten 4 Wiper relay Lo S810-004202
CR-30 Fasten 4 Back up relay S810-004202
CR-35 Fasten 6 Ride control relay S810-006202
Switch
CS-2 SWP 6 Start key switch S814-006000
CS-3 SWF 10 Rear wiper switch 593757
CS-5 Shur 1 Horn switch S822-014000
CS-11 SWP 8 Multi function switch S814-008000
CS-12 SWP 6 Multi function switch S814-006000
CS-17 SWF 10 Parking switch 593757
CS-20 SWF 10 Rear work lamp switch 593757
CS-21 SWF 10 Front work lamp switch 593757
CS-23 SWF 10 Beacon switch 593757
CS-34 SWF 10 Buzzer stop switch 593757
CS-39 SWF 10 Illumination and head lamp switch 593757
CS-41 SWF 10 Hazard switch 593757
CS-42 SWF 10 Clutch cut off switch 593757
CS-50 SWF 10 Ride control 593757
CS-51 SWF 10 Full automatic switch 593757
CS-54 SWF 10 Air conditioner switch 593757
CS-58 Fasten 6 Blower switch S810-006202
7-42
Type Destination
Light
CL-1 - 2 Room lamp MG610392
CL-2 Fasten 3 Cigar lighter S810-003202
CL-3 SWP 4 Head light(LH) S814-004000
CL-4 SWP 4 Head light(RH) S814-004000
CL-5 SWP 2 Work light(LH) S814-002000
CL-6 SWP 2 Work light(RH) S814-002000
CL-7 Fasten 1 Beacon lamp S810-001202
CL-15 SWP 4 Combi lamp(RR, LH) S814-004000
CL-16 SWP 4 Combi lamp(RR, RH) S814-004000
CL-21 SWP 2 Numberplate lamp S814-002000
CL-22 SWP 2 Work light(LH) S814-002000
CL-23 SWP 2 Work light(RH) S814-002000
CL-24 SWP 2 Turn lamp(LH) S814-002000
CL-25 SWP 2 Turn lamp(RH) S814-002000
CL-41 SWF 2 Hi beam lamp(Dash board) 913328
CL-42 SWF 2 Turn lamp(LH, Dash board) 913328
CL-43 SWF 2 Turn lamp(RH, Dash board) 913328
CL-44 SWF 2 Parking lamp(Dash board) 913328
CL-45 SWF 2 Brake fail lamp(Dash board) 913328
CL-46 SWF 2 Charge lamp(Dash board) 913328
CL-47 SWF 2 Hydraulic oil lamp(Dash board) 913328
CL-48 SWF 2 Over heat lamp(Dash board) 913328
CL-49 SWF 2 Engine oil lamp(Dash board) 913328
CL-50 SWF 2 Transmission error 913328
CL-51 SWF 2 Transmission oil lamp(Dash board) 913328
CL-52 SWF 2 Glow lamp(Dash board) 913328
CL-53 SWF 2 Steering pressure lamp 913328
CL-54 SWF 2 Steering pump pressure lamp 913328
Sensor, sender
CD-1 - 1 Hyduaulic oil temp switch S819-010122
CD-2 SWP 2 Fuel sendor S814-002000
CD-3 - 1 Brake fail pressure switch S819-010112
CD-4 - 1 Stop lamp pressure switch S819-010112 S820-105000
CD-5 - 1 Clutch cut off pressure switch S819-010112
CD-8 Ring term - Water temp sendor S820-105000
CD-9 - 1 Over heat switch 1-150656
CD-18 - 2 Engine oil pressure switch 827551-2
CD-25 - 1 Transmission oil pressure switch S819-010122
7-43
Type Destination
CD-29 Ring term - Transmission temp sendor S820-105000
CD-39 - 2 Steering pressure switch S819-010122
CD-40 - 2 Steering pump pressure switch S819-010122
7-44
2. CONNECTION TABLE FOR CONNECTORS
1) 58-L TYPE CONNECTOR
No. of
Receptacle connector(Female) Plug connector(Male)
pin
1 1
S813-030100 S813-130100
1 2 1 2
S813-030200 S813-130200
7-45
2) PA TYPE CONNECTOR
No. of
pin
2 5 1 3
1 3 2 5
S811-005002 S811-105002
3 7 1 4
1 4 3 7
S811-007002 S811-107002
4 9 1 5
1 5 4 9
S811-009002 S811-109002
5 11 1 6
11
1 6 5 11
S811-011002 S811-111002
7-46
No. of
pin
6 13 1 7
13
1 7 6 13
S811-013002 S811-113002
8 17 1 9
17
1 9 8 17
S811-017002 S811-117002
10 21 1 11
21
1 11 10 21
S811-021002 S811-121002
7-47
3) 58-X TYPE CONNECTOR
No. of
pin
1 1
S813-060100 S813-160100
2 1
1 2
S813-060200 S813-160200
7-48
4) J TYPE CONNECTOR
No. of
pin
1 1
2 2
S816-002001 S816-102001
2 3 1
3 1 2
S816-003001 S816-103001
7-49
5) SWP TYPE CONNECTOR
No. of
pin
1 1
S814-001000 S814-101000
2 1
1 2
S814-002000 S814-102000
3 1
2 1 23
S814-003000 S814-103000
2 4 1 3
1 3 2 4
S814-004000 S814-104000
7-50
No. of
pin
3 6
1 4
1 4 3 6
S814-006000 S814-106000
4 8
1 5
1 5 4 8
S814-008000 S814-108000
4 12 1 9
12
4 12
1 9
S814-012000 S814-112000
3 14 1 11
14
1 11 3 14
S814-014000 S814-114000
7-51
6) CN TYPE CONNECTOR
No. of
pin
1 1
S810-001202 S810-101202
2 2
1 1
S810-002202 S810-102202
3 2
1 2 1 3
S810-003202 S810-103202
2 4 1 4
1 3 2 3
S810-004202 S810-104202
7-52
No. of
pin
3 6 1 4
1 4 3 6
S810-006202 S810-106202
4 8 1 5
1 5 4 8
S810-008202 S810-108202
7-53
7) BS TYPE CONNECTOR
No. of
pin
2 1
1 2
S812-002001 S812-102001
1 3 1 2
2 3
S812-003001 S812-103001
2 4 1 3
1 3 2 4
S812-004001 S812-104001
3 6 1 4
1 4 3 6
S812-006001 S812-106001
7-54
8) LC TYPE CONNECTOR
No. of
pin
5 10
10
1 6
S815-010000
6 12
12
1 7
S815-012000
8 16
16
1 9
S815-016000
9 18
18
1 10
S815-018000
7-55
No. of
pin
12 24
24
1 13
S815-024000
7-56
9) 375 FASTEN TYPE CONNECTOR
No. of
pin
1 2 1 2
S810-002402 S810-102402
7-57
GROUP 6 TROUBLESHOOTING
1. WHEN STARTING SWITCH IS TURNED ON, CLUSTER LAMP DOES NOT LIGHT UP
şBefore carrying out below procedure, check all the related connectors are properly inserted and the
fuse No.2 is not blown out and ON/OFF of bulb.
şAfter checking, connect the disconnected connectors again immediately unless otherwise specified.
Cause Remedy
YES
Defective cluster Replace
YES Check voltage
between CN-58
(1) and chassis
Disconnection in Repair or replace
NO
wiring harness or (After clean)
Check voltage poor contact
between CN-7(4) between
and chassis
CN-58(1) and
fuse No.2

NO
poor contact
between CN-7(4)
and fuse No.2
CLUSTER
FUSE
4
No.2
CN-7
CN-58
Check voltage
YES 20 ~ 28V
NO 0V
7-58
2. WHEN COOLANT OVERHEAT LAMP LIGHTS UP(Engine is started)
şBefore carrying out below procedure, check all the related connectors are properly inserted.
Cause Remedy
YES
Coolant overheat Check engine
(105Ş
CŹ2Ş C) system
YES
Defective Replace
Check resistance
YES overheat switch
between CN-13
Does display go (10) and chassis
off when Disconnection in Repair or replace
Starting switch : OFF NO
disconnect CD-9 wiring harness or (After clean)
Check resistance
and connector? YES poor contact
between CN-3(9)
Starting switch : ON between CD-9
Engine : start
and chassis
and CN-3(9)
Starting switch : OFF
Check resistance Disconnection in Repair or replace

NO
between CN-6(4) wiring harness or (After clean)
NO
and chassis poor contact
between CN-6(4)
Before checking, and CN-3(9)
disconnect CD-9

NO
CLUSTER OVERHEAT SWITCH

T
4 9 10
CN-6 CN-3 CN-13 CD-9
CHECK UNIT
24
CN-58
Check resistance
YES MAX 1‫װ‬
NO MIN 1M‫װ‬
7-59
3. WHEN ENGINE OIL PRESSURE LAMP LIGHTS UP(Engine is started)
Cause Remedy
YES
Engine oil leakage, Check engine oil
or defective switch level or replace
switch
YES
Does display go
off when wiring harness or (After clean)
disconnect CD-18 Check resistance poor contact
YES
and connector? between CN-13 between CN-13(7)
Starting switch : ON (7) and chassis -CD-18
Engine : start
Disconnection in Replace
Check resistance NO
wiring harness or
between CN-6(5)
NO
between CN-6(5) -
Starting switch : OFF CN-3(5)- CN-13(7)
Before checking,
disconnect CD-18
NO
CLUSTER ENGINE OIL PRESSURE SWITCH

5 5 7 1
Pa
CN-6 2
CN-3 CN-13
CD-18
CHECK UNIT
23
CN-58
Check resistance
YES MAX 1‫װ‬
NO MIN 1M‫װ‬
7-60
4. WHEN HYDRAULIC OIL TEMPERATURE LAMP LIGHTS UP(Engine is started)
Cause Remedy
YES
High temperature Check hydraulic
of hydraulic oil or oil temperature
defective switch (105Ş CŹ2Ş C),
hydraulic cooling
or replace switch
Does display go YES

off when Disconnection in
disconnect CD-1 wiring harness or
and connector? Check resistance poor contact
YES
Starting switch : ON between CN-2(10) between CN-6(8)
Engine : start and chassis and CN-2(10)
Before checking, Disconnection in Repair or replace
Check resistance disconnect CD-1 NO
between CN-6(8)
NO
between CN-
Before checking,
2(10) and CD-1
disconnect CD-1
NO
HYDRAULIC OIL
CLUSTER TEMPERATURE SWITCH
T
8 10
CN-6 CN-2 CD-1
CHECK UNIT
12
CN-58
Check resistance
YES MAX 1‫װ‬
NO MIN 1M‫װ‬
7-61
5. WHEN TORQUE CONVERTER OIL TEMPERATURE GAUGE DOES NOT OPERATE
(Check torque converter oil temperature lamp ON/OFF)
Cause Remedy
YES
YES
between CN-7 wiring harness or (After clean)
(10) and chassis poor contact
between CN-
Starting switch : ON Check resistance
7(10) and CN-9(4)
Engine : start between CN-9(4)
See : TABLE NO
and chassis YES
Starting switch : OFF wiring harness or (After clean)
See : TABLE
Check resistance poor contact
between CD-29 between CN-9(4)
NO
and chassis and CD-29
See : TABLE Defective sender Replace
NO
TRANS
TRANSMISSION OIL
CLUSTER TEMPERATURE SENDER
Ş
C
10 4
CN-7 CN-9 CD-29
Check resistance
YES MAX 1‫װ‬
NO MIN 1M‫װ‬
Check table
Temperature
50Ş
C 92Ş
C 120Ş
C 130Ş
C
Item
Unit resistance(‫)װ‬ 168.7 (34) 19.5 12.4
Tolerance 0Ş~ -10Ş (-) Ź3Ş +10Ş~ 0Ş
Angle -30Ş -8Ş +27Ş +30Ş
7-62
6. WHEN COOLANT TEMPERATURE GAUGE DOES NOT OPERATE
(Check coolant temperature lamp ON/OFF)
Cause Remedy
YES
YES
Check resistance wiring harness or (After clean)
between CN-7 poor contact
(11) and chassis
between CN-7
Starting switch : ON (11) and CN-3(7)
Engine : start Check resistance
See : TABLE between CN-3(7) YES
NO Disconnection in Repair or replace
and chassis
Before checking, poor contact
disconnect connector between CN-3(7)
See : TABLE
Check resistance and CN-13(8)
between CN-13
NO
(8) and chassis YES
Starting switch : OFF wiring harness or (After clean)
See : TABLE
Check resistance poor contact
between CD-8 between CN-13
NO
and chassis (8) and CD-8
See : TABLE Coolant overheat Check coolant
NO
TRANS
or defective temperature or
sender replace
CLUSTER WATER TEMPERATURE SENDER

Ş
C
11 7 8
CN-7 CN-3 CN-13 CD-8
Check resistance
YES MAX 1‫װ‬
NO MIN 1M‫װ‬
Check table
Temperature
(40Ş
C) 91Ş
C 105Ş
C 120Ş
C
Item
Unit resistance(‫)װ‬ 222 (41.3) 28 19.2
Tolerance Ź5Ş (-) Ź4.5 (-)
Angle -30Ş 0Ş +13Ş +30Ş
7-63
7. WHEN FUEL GAUGE DOES NOT OPERATE(Check warning lamp ON/OFF)
Cause Remedy
YES
YES
between CN-7 wiring harness or (After clean)
Starting switch : OFF between CN-7
See : TABLE (12) and CN-2(11)
Check resistance
between CN-2(11)
NO YES
and chassis Disconnection in Repair or replace
See : TABLE wiring harness or (After clean)
poor contact
Check resistance between CD-2(1)
between CD-2(2) and CN-2(11)
NO
and chassis
YES
See : TABLE Check circuit Repair or replace
Check resistance
between CD-2(2) (After clean)
between CD-2(2)
and chassis
NO and CD-2(1) with
chassis
See : TABLE Defective sensor Replace
NO
E F
FUEL
FUEL SENDER
CLUSTER
1
12 11 2
CD-2
CN-7 CN-2
Check resistance
YES MAX 1‫װ‬
NO MIN 1M‫װ‬
Check table
Temperature
Empty (1/2) Full
Item
Unit resistance(‫)װ‬ 95 (32.5) 7
Tolerance Ź2.5Ş Ź5Ş Ź2.5Ş
Angle -30Ş 0Ş +30Ş
7-64
8. WHEN GAUGES OF FUEL, HYDRAULIC OIL AND COOLANT INDICATE HIGH OR FULL
Cause Remedy
YES Defective cluster Replace
Check resistance
between CN-7
(13) and chassis
Starting switch : ON NO
Voltage : 20~28V
poor contact
between CN-7
(13) and chassis
CLUSTER
13
CN-7
Check resistance
YES MAX 1‫װ‬
NO MIN 1M‫װ‬
7-65
9. WHEN PARKING SOLENOID DOES NOT WORK
fuse No.6 is not blown out.
Cause Remedy
YES
Defective parking Replace
brake solenoid
Check voltage YES

between CN-71 Disconnection in Repair or replace
(2) and chassis wiring harness or (After clean)
poor contact
Starting switch : ON
Parking switch : ON-OFF
Check voltage between CS-17(8)
Voltage : 20~28V NO between CS-17 and CN-71(2)
(8) and chassis
YES
Parking switch : OFF Defective parking Replace
Voltage : 20~28V Check voltage switch
between CS-17
NO
(6) and chassis
NO
Voltage : 20~28V wiring harness or (After clean)
poor contact
between CS-17(6)
and CN-36(6)
PARKING SWITCH
8
FUSE
6
No.6
CS-17
CN-71
D-1
2
2
1
PARKING SOLENOID
7-66
10. TRANSMISSION IS NOT RETURNED TO NEUTRAL WHEN PARKING BRAKE IS APPLIED
fuse No.14(Transmission controller) and No.6 are not blown out.
Cause Remedy
YES Defective T/M Replace
controller
Check voltage
between CN-15 YES
(F) and chassis
Starting switch : ON poor contact
Parking switch : ON Check voltage
Prolix switch : OFF between CN-15
between CS-17
Voltage : 20~28V NO (F) and CS-17(1)
(1) and chassis
Voltage : 20~28V YES
Parking switch : ON Check voltage Defective switch Replace
between CS-17
NO
(5) and chassis Disconnection in Repair or replace
NO
poor contact
between CS-17(5)
and fuse No.6
CN-15
PARKING SWITCH
FUSE
6
No.6
5
1
CS-17
7-67
11. MACHINE DOES NOT TRAVEL
CONTROL UNIT
fuse No.1(Transmission controller) is not blown out.
CANB-H
CANF-H
CANF-T
CANB-L
VMGA2
CANF-L
VMGA1
ADM8
ADM7
VPE2
VPE1
ED10
ED11
ED12
ED13
AIP7
AIP6
VGS
AIP3
ED5
ED2
ED9
ED6
ED3
ED7
SD3
SD4
AU1
EU1
ER1
ED4
ED8
ER2
EF1
EF6
EF2
EF3
VPI
63
64
65
66
67
68
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
816
820
X1
Cause Remedy
YES
Defective clutch Replace
cut-off switch
CN-15
YES Check resistance CN-36
between CD-5
044 BY
205 BY
and chassis
Is there continuity
NO between CN-
Defective T/M Replace
15(E) and NO
chassis? controller
Defective T/M Replace

NO
Is voltage between controller
CN-15(F) and
chassis 20-28V? YES
Defective parking Replace
Starting switch : ON switch
Parking switch : OFF
Clutch cut-off Is voltage between
switch : ON
YES CS-17(1) and
chassis 20-28V?
FUSE BOX

NO
wiring harness or (After clean) CS-17
poor contact
between CN-15(F)
and CS-17(1)
Check resistance PARKING SW
YES MAX 1‫װ‬ CS-42

CN-8
CN-71
NO MIN 1M‫װ‬
PARK SOL
CD-5
D-1
CLUTCH CUT OFF
CLUTCH CUT-OFF SW
7-68
12. WHEN STARTING SWITCH IS TURNED ON, HEAD LAMP DOES NOT LIGHTS UP
fuse No.19 is not blown out and ON/OFF of bulb.
şAfter checking, connect the disconnected connectors again immediately unless otherwise specified. CN-36
Cause Remedy
YES
Defective bulb Replace
Check voltage
YES
between CL-3(1) -
(3) and CL-4(1) -(3)
Voltage : 20~28V Disconnection in Repair or replace
NO
Starting switch : ON wiring harness or (After clean)
Check voltage Head lamp switch : ON
poor contact
YES between CN-
10(4) and CN- between CN-10(4)-
8(11), (12) CL-3(1), 4(1) and
Voltage : 20~28V CL-3(3) - CN-8(11),
Starting switch : ON CL-4(3) - CN-8(12).
Head lamp switch : ON FUSE BOX
CL-3
NO CS-39
wiring harness or (After clean) CN-8
Check voltage
poor contact
between CS-11 LH HEAD LIGHT
between CN-10(4)
(7) and chassis
and CS-11(7)
CL-4
Head lamp switch :
YES
ON-OFF Defective Replace
ILL & HEAD LAMP SW
multifunction switch RH HEAD LIGHT
Check voltage CN-4

YES
between CS-11 Disconnection in Repair or replace
NO
(8) and chassis wiring harness or (After clean)
CL-41
Voltage : 20~28V poor contact
Starting switch : ON Check voltage between CS-11(8) HI BEAM PILOT LAMP
between CS-39 and CS-39(2)
NO
(2) and chassis
YES Defective head Replace switch
Check voltage lamp switch
between CS-39
NO CN-7 JT-28
(4) and chassis
NO
CS-11
poor contact
between CS-39(4)
and fuse No.19
MULTI FUNCTION SW EARTH
7-69
13. WHEN STARTING SWITCH IS TURNED ON, WIPER MOTOR DOES NOT OPERATE
fuse No.7 is not blown out. CHECK UNIT CN-36
Cause Remedy
CN-58
YES
Check voltage Defective front Replace
YES between front wiper motor
wiper motor and
chassis Poor connection of Replace
Check voltage Voltage : 20~28V
NO
YES chassis
between CN-21(5) Starting switch : ON
Wiper switch : 1st
and chassis
Voltage : 20~28V
Starting switch : ON Disconnection in Repair or replace
Check voltage Wiper switch : 1st NO
YES wiring harness or (After clean) FUSE BOX
between CS-12
between CS-12(4)
Voltage : 20~28V
Check voltage Starting switch : ON
and CN-21(5)
Wiper switch : OFF CR-26
between CS-12
WIPER RY Lo
(6) and chassis Defective wiper Replace
NO
switch
Voltage : 20~28V
Wiper switch : 1st Disconnection in Repair or replace
NO
poor contact
between CS-12(6)
CR-4
and fuse No.7
WIPER RY Hi
CS-11
CS-12
CS-5
CN-21
MULTIFUNCTION SWITCH FRONT WIPER
7-70
14. WHEN STARTING SWITCH ON DOES NOT OPERATE
şBefore carrying out below procedure, check all the related connectors are properly inserted and and
the fuse No.15 is not blown out. CN-36
Cause Remedy
YES
Defective cable Repair or replace
Check voltage (After clean)
YES assembly
between CN-60(2)
and chassis
Short circuit or Replace
Voltage : 20~28V NO
Check voltage defect of fusible
YES
between CR-1 link or defective
(M4) and chassis
battery relay
Voltage : 20~28V
Disconnection in Replace
NO
Check voltage wiring harness or
YES between CS-2
(1)[and CS-2(2)] poor contact
FUSE BOX
and chassis between CS-2(2) -
Voltage : 20~28V
CN-2(1)-CR-1
CR-1
(M4) 60R 60R 60B 60B
Disconnection in Replace BATT RY MASTER SW

Check voltage NO
wiring harness or
and specific
TO STARTER
gravity of battery poor contact
CN-60
between fuse No.
Specific gravity : MIN 1.28
Voltage : MIN 24V 13 and CS-2(1) or
defect of start
switch
Battery capacity Repair or replace

NO
too low (After clean) CN-1
CN-2
DO-1
CS-2
START SWITCH
7-71
15. WHEN STARTING SWITCH IS TURNED ON, WORK LAMP DOES NOT LIGHTS UP
şBefore carrying out below procedure, check all the related connectors are properly inserted, and the
fuse No.16 is not blown out.
Cause Remedy
YES CN-36
Check voltage Defective lamp Replace
YES between each
lamp(2) and
chassis Disconnection in Repair or replace
NO
Starting switch : ON poor contact
Check voltage
YES between CN-5(3) -
between CN-5(4),
(3) and chassis CL-22(2), CL23(2)
and CN-5(4) - CL-
Voltage : 20~28V 5(2), CL-6(2)
Check voltage Disconnection in Repair or replace
YES between CS-21 NO
(2), CS-20(2) and poor contact
chassis between CN-5(3) -
Voltage : 20~28V
CS-20(2) and CN-
5(4) - CS-21(2)
FUSE BOX
Check voltage CN-5
between CS-21 Defective work Replace switch
(6), CS-20(6) and NO
lamp switch
chassis
Voltage : 20~28V YES CL-6
wiring harness or (After clean) CS-21
FRONT WORK
Check voltage poor contact LIGHT,LH
between CS-21(6),
between fuse No. CL-5
NO CS-20(6) and fuse
16 and chassis
No.16 FRONT WORK
LIGHT,RH
Voltage : 20~28V
Starting switch : ON Short circuit of fuse Replace WORK LAMP FRONT
NO
CS-20
CL-22
REAR WORK
LIGHT,LH
CL-23
WORK LAMP REAR REAR WORK

LIGHT,RH
7-72
16. WHEN ENGINE DOES NOT START
şCheck supply of the power at engine stop solenoid while starting switch is ON.
şBefore carrying out below procedure, check all the related connectors are properly inserted. CONTROL UNIT
CN-36
şAfter checking, connect the disconnected connectors again immediately unless other wise specified.
şCheck forward reverse switch at neutral position.
ADM1
ADM5
SDDL
VPS2
VPS1
VPE2
AIP7
AIP6
AIP8
AIP4
AIP1
ER2
SD2
EU2
ED1
ED5
ED2
ED9
ED6
EF4
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
Cause Remedy
450
YES
Defective battery Check engine
system charge or
replace (After
CN-15
checking specific
G
C
D
H
A
B
K
E
F
J
gravity of battery)
YES
820 LY
Check voltage Defective magnet Replace
Check operation YES between starter of start motor
of start motor magnet coil and
chassis Defective start Replace
Starting switch : Start NO
Starting switch : Start relay
YES CR-5
‫ڞ‬
Check operation Check voltage FUSE BOX
NO of starter relay YES
between CR-5(4)
and chassis SAFETY RY
Starting switch : Start
Disconnection in Replace CN-45
Starting switch : OFF NO TO BATT
wiring harness or
Check operation poor contact
of start safety between CN-3(2)
NO
relay and CR-5(4) STARTER
CR-23
Check switch : Neutral YES
Defective relay Replace
Check voltage
START RY
between CR-5(3)
NO
and chassis
Starting switch : OFF NO
‫ڟ‬
YES
Defective start Replace
Check voltage relay
‫ڞ‬ between CR-23
CN-13
(1) and chassis
Disconnection in Repair or replace CN-3
Voltage : 20~28V NO
Starting switch : ON wiring harness or CN-79
poor contact
between CN-3(2)- FUEL SHUT OFF SOL
CR-23(1) CS-2
YES
wiring harness or
Check voltage poor contact
‫ڟ‬ between CN-15 between CN-15(B) START SWITCH
(B) and chassis and CR-5(3)
Defective DW-3 Replace
NO
7-73

HL730 3

Transféré par

Informations du document

Titre original

Copyright

Formats disponibles

Partager ce document

Partager ou intégrer le document

Options de partage

Avez-vous trouvé ce document utile ?

Ce contenu est-il inapproprié ?

Droits d'auteur :

Formats disponibles

HL730 3

Transféré par

Droits d'auteur :

Formats disponibles

WHEEL LOADER HYUNDAI HL730-3

HL730-3 Service Manual Open index screen

SECTION 3 POWER TRAIN SYSTEM

SECTION 4 BRAKE SYSTEM

SECTION 5 STEERING SYSTEM

SECTION 6 WORK EQUIPMENT

SECTION 7 ELECTRICAL SYSTEM

Structure and function

2. Convert 550mm into inches.

Millimeters to inches ‫ڟ‬

0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

Kilogram to Pound 1kg = 2.2046lb

0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84

0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378

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

0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980

7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1

14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0

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

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

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

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

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

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

LIVE WITH SAFETY

KEEP ROPS INSTALLED PROPERLY

Tooth Bucket Tire Bucket cylinder Hydraulic tank Engine Radiator

Description Unit Specification

Description Unit Specification

Description Unit Specification

Front frame assembly 808 1781

Model Deutz BF4M1012EC

Type Fixed displacement tandem gear pump

Type Fixed displacement tandem gear pump

4) MAIN CONTROL VALVE

5) REMOTE CONTROL VALVE

Type Pressure reducing type

Boom cylinder Bore diaźRod diaźStroke ‫ٻ‬105ź‫ٻ‬65ź710mm

1 Engine mounting bolt, nut M12ź1.75 12.4 Ź 2.5 89.7Ź 18.1

(2) Fine thread

Thread size Width across flat'mm( kgfşm lbfşft

Thread size Width across flat'mm( kgfşm lbfşft

ASTM D975 NO.1

Ɠ Use this sheet to record operational

1. Monitor indicator and gauge checks(Engine OFF)

ş Hourmeter and gauge check Ә Ә

2. Transmission, axle and engine linkages, neutral start

ş Transmission control lever and neutral Ә Ә

3. Monitor indicator and gauge checks(Engine running)

ş Monitor display and alternator output checks Ә Ә

ş Park brake capacity check Ә Ә

şTransmission oil warm up procedure Ә Ә

6. Hydraulic system checks

şHydraulic system warm up procedure Ә Ә

şSteering valve check Ә Ә

şOperating lights check Ә Ә

9. Cab components and vandal protection checks

şCab door latch check Ә Ә

1. POWER TRAIN COMPONENT OVERVIEW

Transmission Upper drive shaft Engine

The power train consists of the following components :

Y1 Y2 NFS Y3 NFS Y4 NFS Y5 Y6 NFS