HL740 7S

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

Group 2 Specifications ----------------------------------------------------------------------------------------------------- 1-10
Group 3 Operational Checkout Record Sheet --------------------------------------------------------------- 1-21
SECTION 2 ENGINE
Group 1 Structure and Function -------------------------------------------------------------------------------------- 2-1

Group 2 Engine speed and Stall rpm ----------------------------------------------------------------------------- 2-6
SECTION 3 POWER TRAIN SYSTEM

Group 2 Operational Checks and Troubleshooting ------------------------------------------------------- 3-47
Group 3 Test and Adjustments ---------------------------------------------------------------------------------------- 3-58
Group 4 Disassembly and Assembly ----------------------------------------------------------------------------- 3-61
SECTION 4 BRAKE SYSTEM

Group 3 Tests and Adjustments -------------------------------------------------------------------------------------- 4-28
Group 4 Disassembly and assembly ------------------------------------------------------------------------------ 4-31
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 ------------------------------------------------------------------------------------------ 7-25
Group 4 Electrical Component Specification --------------------------------------------------------------- 7-39
Group 5 Connectors ------------------------------------------------------------------------------------------------------- 7-46
Group 6 Troubleshooting ------------------------------------------------------------------------------------------------ 7-50
FOREWORD
1. STRUCTURE
This service manual has been prepared as an aid to improve the quality of repairs by giving the
serviceman an accurate understanding of the product and by showing him the correct way to
perform repairs and make judgements. Make sure you understand the contents of this manual and
use it to full effect at every opportunity.
This service manual mainly contains the necessary technical information for operations performed in
a service workshop.
For ease of understanding, the manual is divided into the following sections.
Structure and function

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Group 2 Specifications -----------------------------------------------------------------------------------------------------1-10
Group 3 Operational Checkout Record Sheet ---------------------------------------------------------------1-21
SECTION 1 GENERAL
GROUP 1 SAFETY HINTS
FOLLOW SAFE PROCEDURE

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

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

Unexpected machine movement can cause
serious injury.
Before performing any work on the wheel load-
WARN
er, attach a 「Do Do Not Operate
Operate」 tag on the
DO
right side controller lever. NOT
OPERATE
75791GE01
USE HANDHOLDS AND STEPS

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Before returning machine to customer, make
sure machine is functioning properly, especially
the safety systems. Install all guards and
shields.
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 73031GE22
replaced, not reused.
1-9
GROUP 2 SPECIFICATION
1. MAJOR COMPONENT
Bucket Tire Head light Hydraulic tank Radiator
Boom cylinder Main control valve Cab Air cleaner Counterweight
Precleaner(opt)
Bucket link Bell crank Bucket cylinder Main pump Rain cap(std) Engine Muffler
Boom Front axle Transmission Rear axle Fuel tank

7407B2SE01
1-10
2. SPECIFICATIONS
1) WITH TOOTH TYPE BUCKET
B
F
I
4990
J
H
3740
C
K
40
G
50
584 30
D
0
E
A
7407B2SE02
Description Unit Specification

Operating weight (canopy/cab) kg (lb) 10500/10730 (23100/23650)
Struck 1.7 (2.2)
Bucket capacity m3 (yd3)
Heaped 2.0 (2.6)
Overall length A 7385 (24' 3")
Overall width B 2600 (8' 6")
Overall height C 3190 (10' 6")
Ground clearance D 350 (1' 2")
Wheelbase E mm (ft-in) 2900 (9' 6")
Tread F 1900 (6' 3")
Dump clearance at 45˚ G 2675 (8' 9")
Dump reach (full lift) H 1120 (3' 8")
Width over tires I 2350 (7' 9")
Dump angle J 48
Degree (˚)
Roll back angle (carry position) K 49
Lift(With load) 5.5
Cycle time Dump(With load) sec 1.2
Lower(Empty) 2.8
Maximum travel speed km/hr (mph) 37.8 (23.5)
Braking distance 11 (36' 1")
m (ft-in)
Minimum turning radius (center of outside tire) 5.03 (16' 6")
Gradeability Degree (˚) 30
First gear 6.2 (3.9)
Second gear 11.4 (7.1)
Forward
Third gear 22.5 (14.0)
Travel speed Fourth gear km/hr (mph) 37.8 (23.5)
Reverse Second gear 12.0 (7.5)
1-11
2) WITH BOLT-ON CUTTING EDGE TYPE
B
F
I
4990
J
H
3740
C
40
G
K
50
578 30
D
0
E
A
7407B2SE03
Description Unit Specification

Operating weight (canopy/cabin) kg (lb) 10500/ 10730 (23100/23650)
Struck 1.8 (2.3)
Bucket capacity m3 (yd3)
Heaped 2.1 (2.7)
Overall length A 7265 (23' 10")
Overall width B 2550 (8' 4")
Overall height C 3190 (10' 6")
Ground clearance D 350 ( 1' 2")
Wheelbase E mm (ft-in) 2900 (9' 6")
Tread F 1900 (6' 3")
Dump clearance at 45˚ G 2760 (9' 1")
Dump reach (full lift) H 1045 (3' 5")
Width over tires I 2350 (7' 9")
Dump angle J 48
Degree (˚)
Roll back angle (carry position) K 49
Lift(With load) 5.5
Cycle time Dump(With load) sec 1.2
Lower(Empty) 2.8
Maximum travel speed km/hr (mph) 37.8 (23.5)
Braking distance 11 (36' 1")
m (ft-in)
Minimum turning radius (center of outside tire) 5.03 (16' 6")
Gradeability Degree (˚) 30
Second gear 11.4 (7.1)
Forward
Travel speed Fourth gear km/hr (mph) 37.8 (23.5)
Reverse Second gear 12.0 (7.5)
1-12
3. WEIGHT
Item kg lb
Front frame assembly 870 1920
Rear frame assembly 1210 2670
Front fender (LH & RH) 22 49
Counterweight 530 1170
Canopy assembly 360 790
Cab assembly 585 1290
Engine assembly 453 1000
Transmission assembly 380 840
Drive shaft (upper) 7 15
Drive shaft (front) 18 40
Drive shaft (center) 16 35
Drive shaft (rear) 13 29
Front axle (include differential) 970 2140
Rear axle (include differential) 980 2160
Tire (17.5-25, 12PR, L3) 130 290
Hydraulic tank assembly 170 370
Fuel tank assembly 200 440
Main pump assembly 37 82
Brake pump assembly 7 15
Main control valve 51 112
Boom assembly 770 1700
Bell crank assembly 205 450
Bucket link 38 84
2.1 m3 bucket, with bolt on cutting edge 940 2070
2.0 m3 bucket, with tooth 890 1960
2.0 m3 bucket, without tooth and cutting edge 830 1830
Boom cylinder assembly 100 220
Bucket cylinder assembly 112 250
Steering cylinder assembly 20 44
Seat 40 88
Battery 28 62
1-13
4. SPECIFICATION FOR MAJOR COMPONENTS
1) ENGINE
Item Specification
Model Cummins 6BTA5.9
Type 4-cycle turbocharged, aftercooled diesel engine
Control type Mechanical control
Cooling method Water cooling
Number of cylinders and arrangement 6 cylinders, in-line
Firing order 1-5-3-6-2-4
Combustion chamber type Direct injection type
Cylinder bore × stroke 102×120 mm (4.02"×4.72")
Piston displacement 5900 cc (360 cu in)
Compression ratio 17.3 : 1
Rated gross horse power 152 ps at 2200 rpm
Maximum gross torque at 1300 rpm 68 kgf·m (494 lbf·ft)
Engine oil quantity 15ℓ (3.96 U.S. gal)
Wet weight 453 kg (1000 lb)
High idling speed 2300 ± 50 rpm
Low idling speed 900 ± 50 rpm
Rated fuel consumption 164 g/ps·hr
Starting motor Prestolite electric (24V-6 kW)
Alternator Prestolite electric (24V-70 Amp)
Battery 2×12V×120Ah
1-14
2) MAIN PUMP
Specification
Item
Steering Loader
Type Fixed displacement tandem gear pump
Capacity 40.4 cc/rev 40.4 cc/rev
Maximum operating pressure 210 kgf/cm2 (2990 psi)
Rated oil quantity 89ℓ/min (23.5 U.S.gpm) 89ℓ/min (23.5 U.S.gpm)
Rated speed 2200 rpm
3) BRAKE PUMP
Item Specification
Type Fixed displacement gear pump
Capacity 9 cc/rev
Maximum operating pressure 180 kgf/cm2 (2560 psi)
Rated oil quantity 20ℓ/min (5.3 U.S.gpm)
Rated speed 2200 rpm
4) MAIN CONTROL VALVE
Item Specification
Type 2 spool
Operating method Hydraulic pilot assist
Main relief valve pressure 210 kgf/cm2 (2990 psi)
Overload relief valve pressure 240 kgf/cm2 (3410 psi)
5) REMOTE CONTROL VALVE
Item Specification
Type Pressure reducing type
Minimum 5.8 kgf/cm2 (82.5 psi)
Operating
Maximum 19 kgf/cm2 (270 psi)
Single operation stroke Lever 70 mm (2.8 in)
1-15
6) CYLINDER
Item Specification
Boom cylinder Bore dia×Rod dia×Stroke Ø120×Ø70×728 mm
Bucket cylinder Bore dia×Rod dia×Stroke Ø140×Ø75×505 mm
Steering cylinder Bore dia×Rod dia×Stroke Ø 65×Ø40×429 mm
7) DYNAMIC POWER TRANSMISSION DEVICES
Item Specification
Model ZF 4WG130
Converter Single-stage, single-phase
Type
Transmission Full-automatic power shift
Transmission Torque converter stall ratio 1.87 : 1
Gear shift Forward fourth gear, reverse third gear
Adjustment Electrical single lever type, kick-down system
Pump rated flow 95ℓ/min (25.1 U.S.gpm) at 2000 rpm
Drive devices 4-wheel drive
Axle Front Front fixed location
Rear Oscillation ±12˚ of center pin-loaded
Wheels Tires 17.5-25 12PR, L3
Travel Four-wheel, wet-disc type, full hydraulic
Brakes
Parking Spring applied, hydraulic released brake on front axle
Type Full hydraulic, articulated
Steering
Steering angle 40˚ to both right and left angle, respectively
1-16
5. TIGHTENING TORQUE OF MAJOR COMPONENT
No. Items Size kgf·m lbf·ft
1 Engine mounting bolt, nut (rubber, 2EA) M16×2.0 29.7 ± 4.5 215 ± 32.5
2 Engine mounting bolt, nut (rubber, 2EA) M20×2.5 57.9 ± 8.7 419 ± 62.9
3 Engine Engine mounling bolt (bracket, 14EA) M12×1.75 10.7 ± 1.6 77.4 ± 11.6
4 Radiator mounting bolt M16×2.0 29.7± 4.5 215 ± 32.5
5 Fuel tank mounting bolt, nut M16×2.0 29.7 ± 4.5 215 ± 32.5
6 Main pump housing mounting bolt M12×1.75 12.8 ± 3.0 92.6 ± 21.7
7 Brake pump housing mounting bolt M10×1.5 6.9 ± 1.4 49.9 ± 10.1
8 Main control valve mounting bolt M12×1.75 12.8 ± 3.0 92.6 ± 21.7
9 Steering unit mounting bolt M10×1.5 6.9 ± 1.4 49.9 ± 10.1
10 Priority valve mounting bolt M8×1.25 2.5 ± 0.5 18.1± 3.6
Hydraulic
11 Brake valve mounting bolt M8×1.25 2.5 ± 0.5 18.1± 3.6
system
12 Cut-off valve mounting bolt M12×1.75 12.8 ± 3.0 92.6 ± 21.7
13 Remote control lever mounting bolt M6×1.0 1.1±0.2 8.0 ± 1.4
14 Pilot supply unit mounting bolt M8×1.25 2.5 ± 0.5 18.1± 3.6
15 Safety valve mounting bolt M8×1.25 2.5 ± 0.5 18.1± 3.6
16 Hydraulic oil tank mounting bolt M16×2.0 29.7 ± 4.5 215 ± 32.5
17 Transmission mounting bolt, nut (rubber, 4EA) M20×2.5 57.9 ± 8.7 419 ± 62.9
18 Transmission mounting bolt (bracket, T/C side) M16×2.0 18.4 ± 2.0 133 ± 14.5
19 Power train Front axle mounting bolt, nut M24×2.0 100 ± 15 723 ± 108
20 system Rear axle support mounting bolt, nut M24×2.0 100 ± 15 723 ± 108
21 Tire mounting nut M22×1.5 79 ± 2.5 571± 18
22 Drive shaft joint mounting bolt, nut 3/8-24UNF 6 ± 0.8 43.4 ± 5.8
23 Counterweight mounting bolt M30×3.5 199 ± 29.9 1439 ± 216
24 Operator's seat mounting bolt M8×1.25 3.4 ± 0.7 24.6 ± 5.1
Others
25 Canopy mounting bolt (4EA) M27×3.0 55 ± 5 398 ± 36.2
26 Cabin mounting bolt (4EA) M27×3.0 55 ± 5 398 ± 36.2
1-17
6. TORQUE CHART
Use following table for unspecified torque.
1) BOLT AND NUT
(1) Coarse thread

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

8T 10T
Bolt size
kg·m lb·ft kg·m lb·ft
M 8×1.0 2.17 ~ 3.37 15.7 ~ 24.3 3.04 ~ 4.44 22.0 ~ 32.0
M10×1.25 4.46 ~ 6.66 32.3 ~ 48.2 5.93 ~ 8.93 42.9 ~ 64.6
M12×1.25 7.78 ~ 11.58 76.3 ~ 83.7 10.6 ~ 16.0 76.6 ~ 115
M14×1.5 13.3 ~ 18.1 96.2 ~ 130 17.9 ~ 24.1 130 ~ 174
M16×1.5 19.9 ~ 26.9 144 ~ 194 26.6 ~ 36.0 193 ~ 260
M18×1.5 28.6 ~ 43.6 207 ~ 315 38.4 ~ 52.0 278 ~ 376
M20×1.5 40.0 ~ 54.0 289 ~ 390 53.4 ~ 72.2 386 ~ 522
M22×1.5 52.7 ~ 71.3 381 ~ 515 70.7 ~ 95.7 512 ~ 692
M24×2.0 67.9 ~ 91.9 491 ~ 664 90.9 ~ 123 658 ~ 890
M30×2.0 137 ~ 185 990 ~ 1338 182 ~ 248 1314 ~ 1795
M36×3.0 192 ~ 260 1389 ~ 1879 262 ~ 354 1893 ~ 2561
1-18
2) PIPE AND HOSE (FLARE type)
Thread size Width across flat (mm) kgf·m lbf·ft
1/4" 19 4 28.9
3/8" 22 5 36.2
1/2" 27 9.5 68.7
3/4" 36 18 130
1" 41 21 152
1-1/4" 50 35 253
3) PIPE AND HOSE (ORFS type)

9/16-18 19 4 28.9
11/16-16 22 5 36.2
13/16-16 27 9.5 68.7
1-3/16-12 36 18 130
1-7/16-12 41 21 152
1-11/16-12 50 35 253
4) FITTING
1/4" 19 4 28.9
3/8" 22 5 36.2
1/2" 27 9.5 68.7
3/4" 36 18 130
1" 41 21 152
1-1/4" 50 35 253
1-19
7. RECOMMENDED LUBRICANTS
Use only oils listed below or equivalent.
Do not mix different brand oil.
Ambient temperature ˚C (˚F )
Capacity
Service point Kind of fluid -20 -10 0 10 20 30 40
ℓ(U.S. gal)
(-4) (14) (32) (50) (68) (86) (104)
SAE 30
SAE 10W
Engine oil pan Engine oil 16 (4.2)
SAE 10W-30
SAE 15W-40
SAE 10W-30
Transmission Oil 26 (6.7)
SAE 15W-40
Front : 17.7 (4.7)

Axle UTTO SAE 80W-90LS/API GL-5
Rear : 17.7 (4.7)
Tank: ISO VG 32
105 (27.7)
Hydraulic tank Hydraulic oil ISO VG 46
System:
165 (44) ISO VG 68
ASTM D975 NO. 1

Fuel tank Diesel fuel 223 (58.9)
ASTM D975 NO. 2
NLGI NO. 1
Fitting
Grease As required
(Grease nipple) NLGI NO. 2
Mixture of
antifreeze Ethylene glycol base permanent type
Radiator 30 (8.0)
and water
50 : 50
·SAE : Society of Automotive Engineers ★ Recommended oil list
·API : American Petroleum Institute - BP TERRAC SUPER TRANSMISSION 10W-30
·ISO : International Organization for Standardization - CASTROL AGRI TRANS PLUS 10W-30
·NLGI : National Lubricating Grease Institute - MOBILFLUID 426
·ASTM : American Society of Testing and Material - SHELL DONAX TD 10W-30
·UTTO Universal Tractor Transmission Oil - TOTAL DYNATRANS MPV
1-20
GROUP 3 OPERATIONAL CHECKOUT RECORD SHEET
·Owner :
·Date :
·Hours :
·Serial No. :
·Technician :
※ Use this sheet to record operational

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

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

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

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

· Monitor bypass circuit and seat belt indicator check □ □
· Monitor primary and secondary level check □ □
· Transmission oil warm up procedure □ □
· Transmission temperature gauge check □ □
1-21
4. Brake system and clutch cut off checks
· Park brake capacity check □ □

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

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

·Hydraulic pump performance check □ □
·Pilot control valve boom float check □ □
·Boom down solenoid valve check □ □
·Control valve lift check □ □
·Bucket rollback circuit relief valve check □ □
·Bucket dump circuit relief
Low pressure check □ □
High pressure check □ □
·Boom and bucket cylinder drift check □ □
·Boom down solenoid valve leakage check □ □
·Pilot controller check □ □
·Return to dig check □ □
·Boom height kickout check-if equipped □ □
1-22
7. Steering system checks
·Steering unit check □ □

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

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

·Cab door hold open latch check □ □
·Cab door release button check □ □
·Cab door lock check □ □
·Cab door window check □ □
·Cab window latch check □ □
·Steering column adjustment check □ □
·Seat and seat belt check □ □
·Air intake filter door check □ □
·Engine side panels check □ □
·Radiator cap access door check □ □
·Frame locking bar check □ □
·Boom lock check □ □
·Service decal check □ □
1-23
SECTION 2 ENGINE

Group 2 Engine speed and Stall rpm --------------------------------------------------------- - - - - - - - - - - ---------- 2-6
SECTION 2 ENGINE
GROUP 1 STRUCTURE AND FUNCTION
1. STRUCTURE
Turbocharger Injection pump
Exhaust outlet
connection Lifting bracket
Fuel filter
Belt tensioner
Fuel pump
Vibration damper
Oil filler
Valve cover Aftercooler
Starter
Water outlet
Fan drive
Flywheel housing
Lubricating oil filter

Alternator
Water inlet connection
Oil pan 7607B2EG04
· Direct 4-stroke, 6-cylinders, water-cooling and aftercooled diesel engine in installed, cylinder block
and cylinder head are made of case iron and turbocharger is attached.
2-1
2. SYSTEM DIAGRAMS
The following drawings show the flow through the engine systems.
1) FUEL SYSTEM
7607B2EG05
1 Fuel from supply tank

2 Fuel lift pump
3 Fuel filter/water separator
4 Low-pressure fuel supply lines
5 Cold start injection advance
6 Injection pump
7 Fuel drain manifold
8 High-pressure fuel supply lines
9 Closed nozzle injectors
10 Fuel return to supply tanks
2-2
2) LUBRICATING OIL SYSTEM
7607B2EG07
1 Gerotor lubricating oil pump 8 Filter bypass valve

2 Pressure regulating valve closed 9 Filter bypass valve closed
3 Pressure regulating valve open 10 Filter bypass valve open
4 From lubricating oil pump 11 To lubricating oil filter
5 To lubricating oil cooler 12 Full-flow lubricating oil filter
6 To lubricating oil pan 13 From lubricating oil filter
7 Lubricating oil cooler 14 Main lubricating oil rifle
7607B2EG08
1 Oil supply
2 Oil drain
The turbocharger receives filtered, cooled, and pressurized lubricating oil through a supply line from
the filter head. A drain line connected to the bottom of the turbocharger housing returns the lubricating
oil to the lubricating oil pan through a fitting in the cylinder block.
2-3
3) COOLING SYSTEM
7607B2EG09
※ Never operate the engine without a thermostat. Without a thermostat, the coolant will not
flow to the radiator and the engine will overheat.
(1) The illustrantion identifies the significant features of the coolant system.
① Sections A and B.
Coolant is drawn from the radiator by the integrally mounted water pump. The output from
the water pump empties into the oil cooler cavity of the cylinder block.
The coolant then circulates around each cylinder and crosses the block to the fuel pump
side of the engine.
1 Coolant inlet 4 Coolant flow past cylinder head
2 Pump Impeller 5 Coolant to cylinder head
3 Coolant flow past oil cooler
② Sections C and D.
Coolant then flows up into the cylinder head, crosses over the valve bridges, and down the
exhaust manifold side of the engine to the integral thermostat housing.
As the coolant flows across the head toward the thermostat housing, it provides cooling for
the injector. When the engine is below operating temperature, the thermostat is closed, and
the coolant flow bypasses the radiator and goes to the water pump inlet through internal
drillings in the block and cylinder head.
1 Coolant flow from the cylinder head 5 Coolant bypass passage
2 Coolant to the thermostat housing 6 Coolant flow to pump inlet
3 Coolant flow past injector 7 Bypass closed
4 Thermostat 8 Coolant flow back to radiator
When operating temperature is reached, the thermostat opens, blocking the bypass
passage to the water pump and opening the outlet to the radiator.
2-4
4) AIR INTAKE SYSTEM
7607B2EG10
1 Intake air inlet to turbocharger 4 Intake manifold

2 Turbocharger air to aftercooler 5 Intake valve
3 Aftercooler
5) EXHAUST SYSTEM
1 Exhaust valve 3 Turbocharger exhaust inlet

2 Exhaust manifold 4 Turbocharger exhaust outlet
7607B2EG11
2-5
GROUP 2 ENGINE SPEED & STALL RPM
1. TEST
TEST CONDITION
1) Normal temperature of the whole system
- Coolant : Approx 80˚C (176˚F)
- Hydraulic oil : 45 ± 5˚C (113 ± 10˚F)
- Transmission oil : 75 ± 5˚C (167 ± 10˚F)
2) Normal operating pressure : See page 6-49.
2. SPECIFICATION
SPECIFICATION
Engine speed, rpm
Remark
Low idle High idle Pump stall Converter stall Full stall
950±50 2300±50 2120±50 2080±50 1670±50
3. ENGINE
ENGINE RPM CHECK
Remark : If the checked data is not normal, it indicates that the related system is not working properly.
Therefore, it is required to check the related system pressure : See page 6-51.
1) Pump stall rpm
- Start the engine and raise the bucket
approx 45 cm (1.5 ft) as the figure.
- Press the accelerator pedal fully and
operate the bucket control lever to the
45cm
retract position fully.

- Check the engine rpm at the above
condition.
7407B2EG01
2) Convertor stall rpm

Released position
- Start the engine and lower the bucket on
the ground as the figure.
- Set the clutch cut off mode switch at the Clutch cut off switch
OFF position.
- Press the brake pedal and accelerator
pedal fully.
- Shift the transmission lever to the 4th
forward position.
- Check the engine rpm at the above 7407B2EG02
condition.
3) Full stall rpm
Released position
- Start the engine and raise the bucket
approx 45 cm (1.5 ft) as the figure.
- Set the clutch cut off mode switch at the Clutch cut off switch
OFF position.
- Press the brake pedal and accelerator
45cm
pedal fully .
- Shift the transmission lever to the 4th
forward position and operate the bucket
lever to the retract position fully. 7407B2EG03
- Check the engine rpm at the above

condition.
2-6
Group 1 Structure and Function --------------------------------------------------------------------------------------- 3-1

Group 2 Operational Checks and Troubleshooting -------------------------------------------------------- 3-47
Group 3 Test and Adjustments ----------------------------------------------------------------------------------------- 3-58
Group 4 Disassembly and Assembly ------------------------------------------------------------------------------- 3-61
1. POWER TRAIN COMPONENT OVERVIEW
Front drive shaft Upper drive shaft Engine
Front axle Transmission Rear axle

Center drive shaft Rear drive shaft
7407B3PT01
The power train consists of the following components:

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

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

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

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

TT = Torque of the turbine wheel
TR = Torque of the reaction member (stator)
Pump wheel TR
Turbine wheel
From the engine
TT
TP
To the gearbox
Starting nT = 0
condition 1 1.5 Reaction member 2.5
(Stator) Machine standing
still
Intermediate
condition 1 <1.5 <2.5 nT < n engine
Condition in the
coupling point 1 0 1 nT = 0.8n engine
7577APT100
3-4
3. TRANSMISSION
1) LAYOUT
12
11
2
10
3
15
4
14
6
13 7
7407APT03
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
16
19
3 13 18
4 17
7 6 5
7407B3PT02
1 Lifting lugs 12 Transmission-case cover

2 Input flange-input through universal shaft 13 Transmission case
3 Transmission suspension threads M20 14 Power take-off; Coaxial;
4 Output flange-converter side Engine-dependent
5 Oil drain plug with magnetic insert M38×1.5 15 Electro-hydraulic control
6 Model identification plate 16 Difference pressure switch for pressure filter
7 Attachment possibility for oil level tube 17 Transmission suspension threads M20
with oil dipstick (converter side) 18 Output flange-rear
9 Converter 19 Exchange filter (fine filter)
10 Converter bell housing 20 Filter head with connection for filter
11 Breather restriction switch
3-6
3) OPERATION OF TRANSMISSION
(1) Forward
① Forward 1st
In 1st forward, forward clutch and 1st clutch are engaged.
Forward clutch and 1st clutch are actuated by the hydraulic pressure applied to the clutch piston.
KR KR
KV IN
K4
K2
INPUT
K3 K1
KV
OUT
GEAR PATTERN
K2
K1 K3
K4
OUTPUT OUTPUT
7607PT04
3-7
② Forward 2nd
In 2nd forward, forward clutch and 2nd clutch are engaged.
Forward clutch and 2nd clutch are actuated by the hydraulic pressure applied to the clutch
piston.
KR KR
KV IN
K4
K2
INPUT
K3 K1
KV
OUT
GEAR PATTERN
K2
K1 K3
K4
OUTPUT OUTPUT
7607PT05
3-8
③ Forward 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
OUT
GEAR PATTERN
K2
K1 K3
K4
OUTPUT OUTPUT
7607PT06
3-9
④ Forward 4th
In 4th forward, 4th clutch and 3rd clutch are engaged.
4th clutch and 3rd clutch are actuated by the hydraulic pressure applied to the clutch piston.
KR KR
KV IN
K4
K2
INPUT
K3 K1
KV
OUT
GEAR PATTERN
K2
K1 K3
K4
OUTPUT OUTPUT
7607PT07
3-10
(2) Reverse
① Reverse 1st
In 1st reverse, reverse clutch and 1st clutch are engaged.
Reverse clutch and 1st clutch are actuated by the hydraulic pressure applied to the clutch piston.
KR KR
KV IN
K4
K2
INPUT
K3 K1
KV
OUT
GEAR PATTERN
K2
K1 K3
K4
OUTPUT OUTPUT
7607PT08
3-11
② Reverse 2nd
In 2nd reverse, reverse clutch and 2nd clutch are engaged.
Reverse clutch and 2nd clutch are actuated by the hydraulic pressure applied to the clutch
piston.
KR KR
KV IN
K4
K2
INPUT
K3 K1
KV
OUT
GEAR PATTERN
K2
K1 K3
K4
OUTPUT OUTPUT
7607PT09
3-12
③ Reverse 3rd
In 3rd reverse, reverse clutch and 3rd clutch are engaged.
Reverse clutch and 3rd clutch are actuated by the hydraulic pressure applied to the clutch piston.
KR KR
KV IN
K4
K2
INPUT
K3 K1
KV
OUT
GEAR PATTERN
K2
K1 K3
K4
OUTPUT OUTPUT
7607PT10
3-13
4) ELECTRO-HYDRAULIC SHIFT CONTROL WITH PROPORTIONAL VALVE
2 1 3
A A
Y6 Y1
Y5 Y2
B
Y4 Y3
3 6
2 6 1 4 11 9 10
Y5
SECTION A-A SECTION B-B

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

2 System pressure valve (16+2bar) 8 Duct plate
3 Housing 9 Oscillation damper
4 Cable harness 10 Follow-on slide
5 Cover 11 Pressure regulator
6 Valve block
Transmission control, see schedule of hydraulic circuit, electro-hydraulic control unit and measuring
points at page 3-2, 3-14 and 3-59.
The six clutches of the transmission are selected via the 6 proportional valves P1 to P6. The
proportional valve (pressure regulator unit) is composed of pressure regulator (e.g. Y1), follow-on
slide and vibration damper.
The control pressure of 9 bar for the actuation of the follow-on slides is created by the pressure
reducing valve. The pressure oil (16+2bar) is directed via the follow-on slide to the respective
clutch.
3-14
Due to the direct proportional selection with separated pressure modulation for each clutch, the
pressures to the clutches, which are engaged in the gear change, will be controlled. In this way, a
hydraulic intersection of the clutches to be engaged and disengaged becomes possible.
This is creating spontaneous shiftings without traction force interruption.
At the shifting, the following criteria are considered:
- Speed of engine, turbine, central gear train and output.
- Transmission temperature.
- Shifting mode (up-, down-, reverse shifting and speed engagement out of neutral).
- Load condition (full and part load, traction, overrun inclusive consideration of load cycles during
the shifting).
The main pressure valve is limiting the maximum control pressure to 16+2 bar and releases the
main stream to the converter and lubricating circuit.
In the inlet to the converter, a converter satety valve is installed which protects the converter from
high internal pressures (opening pressure 11bar).
Within the converter, the oil serves to transmit the power according to the well-known
hydrodynamic principle (see torque converter, page 3-3).
To avoid cavitation, the converter must be always completely filled with oil.
This is achieved by a converter back pressure back-up valve, rear-mounted to the converter, with
an opening pressure of at least 4.3bar.
The oil, escaping out of the converter, is directed to a oil cooler.
The oil is directed from the oil cooler to the transmission and from there to the lubricating oil circuit,
so that all lubricating points are supplied with cooled oil.
In the electro-hydraulic control unit are 6 pressure regulators installed.
5) GEAR SELECTOR (DW-3)

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

2
3
N
R
direction Forward (F)-Neutral (N)-Reverse
(R) by tilting the gear selector lever.
The gear selector is also available with
integrated kickdown push button.
For the protection from unintended start off,
a neutral interlock is installed.
N D
Position N - Gear selector lever blocked in
this position.
Position D - Driving. 73033TM17
3-15
6) ELECTRIC CONTROL UNIT
(1) Complete system
1 2
14 12
10
5 4 15 9
3
A
7
13
2
6
11
7407B3PT33
1 Transmission control unit(EST-37A)

2 Kickdown switch
3 Clutch cut off switch
4 Auto shift select switch
5 LCD
6 Gear selector(DW-3) with integrated kickdown switch
7 Power supply connection
8 Transmission
9 Cable to inductive transmitter - speed central gear train
10 Cable to inductive transmitter - speed turbine
11 Cable to inductive transmitter - speed engine
12 Cable to speed sensor output and speedometer
13 Cable to plug connection on the electro - hydraulic control unit
14 CAN-Connection
15 Wiring
(2) Description of the basic functions
The powershift transmissions is equipped is electronic transmission control unit(EST-37A), devel-
oped for it.
The system is processing the desire of the driver according to the following criteria.
·Gear determination depending on controller position, driving speed and load condition.
3-16
·Protection from operating errors as far as necessary, is possible via electronic protection
(programming).
·Protection from over-speeds(On the basis of engine and turbine speed).
·Automatic reversing(Driving speed-dependent).
·Pressure cut-off possible(Disconnecting of the drive train for maximum power on the power
take-off).
·Change-over possibility for Auto-/Manual mode.
·Kick down functions possible.
(3) Driving and shifting
(3
- Neutral position :
Neutral position will be selected via the controller.
After the ignition is switched on, the electronics remains in the waiting state. By the position
NEUTRAL of the controller, resp. by pressing the pushbutton NEUTRAL, the EST-37A becomes
ready for operation.
Now, a gear can be engaged.
- Starting :
The starting of the engine has always to be carried out in the NEUTRAL POSITION of the
controller.
For safety reasons it is to recommend to brake the machine securely in position with the parking
brake prior to start the engine.
After the starting of the engine and the preselection of the driving direction and the gear, the
machine can be set in motion by acceleration.
At the start off, the converter takes over the function of a master clutch.
On a level road it is possible to start off also in higher gears.
- Upshifting under load
Upshifting under load will be then realized if the machine can still accelerate by it.
- Downshifting under load
Downshifting under load will be realized if more traction force is needed.
- Upshifting in overrunning condition
In the overrunning mode, the upshifting will be suppressed by accelerator pedal idling position, if
the speed of the machine on a downgrade should not be further increased.
- Downshifting in overrunning condition
Downshiftings in overrunning mode will be then carried out if the machine should be retarded.
If the machine will be stopped and is standing with running engine and engaged transmission,
the engine cannot be stalled. On a level and horizontal roadway it is possible that the machine
begins to crawl, because the engine is creating at idling speed a slight drag torque via the con-
verter.
It is convenient to brake the machine at every stop securely in position with the parking brake.
At longer stops, the controller has to be shifted to the NEUTRAL POSITION.
At the start off, the parking brake has to be released. We know from experience that at a con-
verter transmission it might not immediately be noted to have forgotten this quite normal operat-
ing step because a converter, due to its high ratio, can easily overcome the braking torque of the
parking brake.
3-17
Temperature increases in the converter oil as well as overheated brakes will be the consequences
to be find out later.
Neutral position of the selector switch at higher machine speeds (above stepping speed) is not
admissible.
Either a suitable gear is to be shifted immediately, or the machine must be stopped at once.
(4) Independent calibration of the shifting elements (AEB)
(4
The AEB has the task to compensate tolerances (plate clearance and pressure level) which are
influencing the filling procedure of the clutches. For each clutch, the correct filling parameters are
determined in one test cycle for :
·Period of the quick-filling time
·Level of the filling compensating pressure
The filling parameters are stored, together with the AEB-program and the driving program in the
transmission electronics. Because the electronics will be separately supplied, the AEB-cycle must
be started only after the installation of both components in the machine, thus ensuring the correct
mating(Transmission and electronics).
※ It is imperative, to respect the following test conditions :
- Shifting position neutral
- Engine in idling speed
- Parking brake actuated
- Transmission in operating temperature
※ After a replacement of the transmission, the electrohydraulic control or the TCU in the machine,
the AEB-cycle must be as well carried out again.
The AEB-cylcle continues for about 3 to 4 minutes. The determined filling parameters are stored
in the EEProm of the electronics. In this way, the error message F6 shown on the display will be
cancelled also at non-performed AEB.
(5) Pressure cut-off
(5
In order to provide the full engine power for the hydraulic system, the control can be enlarged for
the function of a pressure cut-off in the 1st and 2nd speed. In this way, the pressure in the power-
shift clutches will be cut-off, and the torque transmission in the drive train will be eliminated by it.
This function will be released at the actuation of a switch, arranged on the brake pedal.
For a soft restart, the pressure will be build-up via a freely programmable characteristic line.
3-18
4. FAULT CODE
1) DEFINITION OF OPERATING MODES
(1) Normal
There's no failure detected in the transmission system or the failure has no or slight effects on
transmission control. TCU will work without or in special cases with little limitations. (See
following table)
(2) Substitute clutch control
TCU can't change the gears or the direction under the control of the normal clutch modulation.
TCU uses the substitute strategy for clutch control. All modulations are only time controlled.
(Comparable with EST 25)
(3) Limp-home
The detected failure in the system has strong limitations to transmission control. TCU can
engage only one gear in each direction. In some cases only one direction will be possible.
TCU will shift the transmission into neutral at the first occurrence of the failure. First, the operator
must shift the gear selector into neutral position.
If output speed is less than a threshold for neutral to gear and the operator shifts the gear selector
into forward or reverse, the TCU will select the limp-home gear.
If output speed is less than a threshold for reversal speed and TCU has changed into the limp-
home gear and the operator selects a shuttle shift, TCU will shift immediately into the limp-home
gear of the selected direction.
If output speed is greater than the threshold, TCU will shift the transmission into neutral. The
operator has to slow down the vehicle and must shift the gear selector into neutral position.
(4) Transmission-shutdown
TCU has detected a severe failure that disables control of the transmission.
TCU will shut off the solenoid valves for the clutches and also the common power supply (VPS1).
Transmission shifts to neutral. The park brake will operate normally, also the other functions
which use ADM1 to ADM8.
The operator has to slow down the vehicle. The transmission will stay in neutral.
(5) TCU-shutdown
TCU has detected a severe failure that disables control of system.
TCU will shut off all solenoid valves and also both common power supplies (VPS1, VPS2). The
park brake will engage, also functions are disabled which use ADM 1 to ADM 8.
The transmission will stay in neutral.
※ Ab
Abbreviations
breviations
OC : Open circuit
SC : Short circuit
OP mode : Operating mode
TCU : Transmission control unit
EEC : Electronic engine controller
PTO : Power take off
3-19
2) TRANSMISSION FAULT CODES
Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair
(Hex) possible reason for fault detection
11 Logical error at gear range signal TCU shifts transmission to · Check the cables from TCU to shift
TCU detected a wrong signal combination neutral lever
for the gear range OP-mode : Transmission · Check signal combinations of shift
·Cable from shift lever to TCU is broken shutdown lever positions for gear range
·Cable is defective and is contacted to ※ Failure cannot be detected in
battery voltage or vehicle ground systems with DW2/DW3 shift lever.
·Shift lever is defective Fault is taken back if TCU detects a
valid signal for the position
12 Logical error at direction select signal TCU shifts transmission to · Check the cables from TCU to shift
TCU detected a wrong signal combination neutral lever
for the direction OP-Mode : Transmission · Check signal combinations of shift
·Cable from shift lever to TCU is broken shutdown lever positions F-N-R
·Cable is defective and is contacted to ※ Fault is taken back if TCU detects a
battery voltage or vehicle ground valid signal for the direction at the
·Shift lever is defective shift lever
13 Logical error at engine derating device After selecting neutral, · Check engine derating device
TCU detected no reaction of engine while TCU change to OP mode ※ This fault is reset after power up of
derating device active limp home TCU
15 Logical error at direction select signal 2 TCU shifts transmission to · Check the cables from TCU to shift
shift lever neutral if selector active lever 2
TCU detected a wrong signal combination OP mode : Transmission · Check signal combinations of shift
for the direction shutdown if lever positions F-N-R
·Cable from shift lever 2 to TCU is broken elector active ※ Fault is taken back if TCU detects a
·Cable is defective and is contacted to valid neutral signal for the direction
battery voltage or vehicle ground at the shift lever
·Shift lever is defective
16 Logical error at axle connection OP mode : Normal · Check the cables from TCU to
Feedback axle connection measured by feedback axle connection switch
TCU and output signal axle connection · Check signals of the feedback axle
don't fit connection switch
·Axle can't be connected or disconnect-
ed due to mechanical problem
·One of the cables from feedback axle
connection switch to TCU is broken
21 S.C. to battery voltage at clutch cut off Clutch cut off function is · Check the cable from TCU to the
input disabled sensor
The measured voltage is too high: OP mode : Normal · Check the connectors
·Cable is defective and is contacted to · Check the clutch cut off sensor
battery voltage
·Clutch cut off sensor has an internal
defect
·Connector pin is contacted to battery
voltage
22 S.C. to ground or O.C. at clutch cut off Clutch cut off function is · Check the cable from TCU to the
input disabled sensor
The measured voltage is too low: OP mode : Normal · Check the connectors
·Cable is defective and is contacted to · Check the clutch cut off sensor
vehicle ground
·Cable has no connection to TCU
·Clutch cut off sensor has an internal
defect
·Connector pin is contacted to vehicle
ground or is broken
3-20
23 S.C. to battery voltage at load sensor R e t a r d e r f u n c t i o n i s · Check the cable from TCU to the
input affected TCU uses default sensor
The measured voltage is too high: load · Check the connectors
·Cable is defective and is contacted to OP mode : Normal · Check the load sensor
battery voltage · Check the assembly tolerances of
·Load sensor has an internal defect load sensor
·Connector pin is contacted to battery ※ Availability of retarder depends on
voltage default load
24 S.C. to ground or O.C. at load sensor R e t a r d e r f u n c t i o n i s · Check the cable from TCU to the
input affected TCU use default sensor
The measured voltage is too low: load · Check the connectors
·Cable is defective and is contacted to OP mode : Normal · Check the load sensor
vehicle ground · Check the assembly tolerances of
·Cable has no connection to TCU load sensor
·Load sensor has as internal defect ※ Availability of retarder depends on
·Connector pin is contacted to vehicle default load
ground or is broken
25 S.C. to batter y voltage or O.C. at No reaction, TCU use · Check the cable from TCU to the
transmi-ssion sump temperature sensor default temperature sensor
input OP mode : Normal · Check the connectors
The measured voltage is too high: · Check the temperature sensor
·Cable is defective and is contacted to
battery voltage
·Temperature sensor has an internal
defect
voltage or is broken
26 S.C. to batter y voltage or O.C. at No reaction, TCU uses · Check the cable from TCU to the
transmi-ssion sump temperature sensor default temperature sensor
The measured voltage is too low: · Check the temperature sensor
vehicle ground
defect
ground
retarder temperature sensor input default temperature sensor
The measured voltage is too high: OP mode : Normal · Check the connectors
·Cable is defective and is contacted to · Check the temperature sensor
battery voltage
defect
3-21
28 S.C. to ground at retarder temperature No reaction, TCU uses · Check the cable from TCU to the
sensor input default temperature sensor
vehicle ground
defect
ground
converter output temperature sensor default temperature sensor
The measured voltage is too high: · Check the temperature sensor
battery voltage
defect
30 S.C. to ground at conver ter output No reaction, TCU uses · Check the cable from TCU to the
temperature sensor input default temperature sensor
vehicle ground
defect
ground
31 S.C. to battery voltage or O.C. at engine OP mode : Substitute clutch · Check the cable from TCU to the
speed input control sensor
TCU measures a voltage higher than · Check the connectors
7.00V at speed input pin · Check the speed sensor
battery voltage
·Speed sensor has an internal defect
voltage or has no contact
32 S.C. to ground at engine speed input OP mode : Substitute clutch · Check the cable from TCU to the
TCU measures a voltage less than 0.45V control sensor
at speed input pin · Check the connectors
·Cable/connector is defective and is · Check the speed sensor
contacted to vehicle ground
3-22
33 Logical error at engine speed input OP mode : Substitute clutch · Check the cable from TCU to the
TCU measures a engine speed over a control sensor
threshold and the next moment the · Check the connectors
measured speed is zero · Check the speed sensor
·Cable/connector is defective and has · Check the sensor gap
bad contact ※ This fault is reset after power up of
·Speed sensor has an internal defect TCU
·Sensor gap has the wrong size
34 S.C. to battery voltage or O.C. at turbine OP mode : Substitute clutch · Check the cable from TCU to the
TCU measures a voltage higher than If a failure is existing at · Check the connectors
7.00V at speed input pin output speed, · Check the speed sensor
·Cable is defective and is contacted to TCU shifts to neutral
vehicle battery voltage OP mode : Limp home
35 S.C. to ground at turbine speed input OP mode : Substitute clutch · Check the cable from TCU to the
at speed input pin If a failure is existing at · Check the connectors
·Cable/connector is defective and is output speed, · Check the speed sensor
contacted to vehicle ground TCU shifts to neutral ※ This fault is reset after power up of
·Speed sensor has an internal defect OP mode : Limp home TCU
36 Logical error at turbine speed input OP mode : Substitute clutch · Check the cable from TCU to the
TCU measures a turbine speed over a control sensor
threshold and at the next moment the If a failure is existing at · Check the connectors
measured speed is zero output speed, · Check the speed sensor
·Cable/connector is defective and has TCU shifts to neutral · Check the sensor gap
bad contact OP mode : Limp home
37 S.C. to battery voltage or O.C. at internal OP mode : Substitute clutch · Check the cable from TCU to the
TCU measures a voltage higher than · Check the connectors
7.00V at speed input pin · Check the speed sensor
vehicle battery voltage
38 S.C. to ground at turbine speed input OP mode : Substitute clutch · Check the cable from TCU to the
at speed input pin · Check the connectors
·Cable/connector is defective and is · Check the speed sensor
3-23
39 Logical error at internal speed input OP mode : Substitute clutch · Check the cable from TCU to the
TCU measures a internal speed over a control sensor
threshold and at the next moment the · Check the connectors
measured speed is zero · Check the speed sensor
·Cable/connector is defective and has · Check the sensor gap
bad contact ※ This fault is reset after power up of
·Speed sensor has an internal defect TCU
3A S.C. to battery voltage or O.C. at output Special mode for gear · Check the cable from TCU to the
speed input selection sensor
TCU measures a voltage higher than OP mode : S u b s t i t u t e · Check the connectors
12.5V at speed input pin clutch control · Check the speed sensor
·Cable is defective and is contacted to If a failure is existing at
battery voltage turbine speed,
·Cable has no connection to TCU TCU shifts to neutral
·Speed sensor has an internal defect OP mode : lamp home
3B S.C. to ground at output speed input Special mode for gear · Check the cable from TCU to the
TCU measures a voltage less than 1.00V selection sensor
at speed input pin OP mode : Substitute clutch · Check the connectors
·Cable/connector is defective and is control · Check the speed sensor
contacted to vehicle ground If a failure is existing at
·Speed sensor has an internal defect turbine speed,
TCU shifts to neutral
OP mode : lamp home
3C Logical error at output speed input Special mode for gear · Check the cable from TCU to the
TCU measures a turbine speed over a selection sensor
threshold and at the next moment the OP mode : Substitute clutch · Check the connectors
measured speed is zero control · Check the speed sensor
·Cable/connector is defective and has If a failure is existing at · Check the sensor gap
bad contact turbine speed, ※ This fault is reset after power up of
·Speed sensor has an internal defect TCU shifts to neutral TCU
·Sensor gap has the wrong size OP mode : lamp home
3D Turbine speed zero doesn't fit to other - · Not used
speed signals
3E Output speed zero doesn't fit to other Special mode for gear · Check the sensor signal of output
speed signals selection speed sensor
If transmission is not neutral and the OP mode : Substitute clutch · Check the sensor gap of output
shifting has finished, control speed sensor
TCU measures output speed zero and If a failure is existing at · Check the cable from TCU to the
turbine speed or internal speed not equal turbine speed, sensor
to zero. TCU shifts to neutral ※ This fault is reset after power up of
·Speed sensor has an internal defect OP mode : lamp home TCU
3-24
71 S.C. to battery voltage at clutch K1 TCU shifts to neutral · Check the cable from TCU to the
The measured resistance value of the valve OP mode : Limp home gearbox
is out of limit, the voltage at K1 valve is too If failure at another clutch · Check the connectors from TCU to
high is pending the gearbox
·Cable/connector is defective and has TCU shifts to neutral · Check the regulator resistance*
contact to battery voltage OP mode : TCU shutdown · Check internal wire harness of the
·Cable/connector is defective and has gearbox
contact to another regulator output of * See page 3-40
the TCU
·Regulator has an internal defect
72 S.C. to ground at clutch K1 TCU shifts to neutral · Check the cable from TCU to the
is out of limit, the voltage at K1 valve is too If failure at another clutch · Check the connectors from gearbox
low is pending to TCU
contact to vehicle ground OP mode : TCU shutdown · Check internal wire harness of the
·Regulator has an internal defect gearbox
* See page 3-40
73 O.C. at clutch K1 TCU shifts to neutral · Check the cable from TCU to the
The measured resistance value of the OP mode : Limp home gearbox
valve is out of limit If failure at another clutch · Check the connectors from gearbox
·Cable/connector is defective and has no is pending to TCU
contact to TCU TCU shifts to neutral · Check the regulator resistance*
·Regulator has an internal defect OP mode : TCU shutdown · Check internal wire harness of the
gearbox
* See page 3-40
valve is out of limit, the voltage at K2 valve If failure at another clutch · Check the connectors from gearbox
is too high is pending to TCU
the TCU
75 S.C. to ground at clutch K2 · Check the cable from TCU to the
is out of limit, the voltage at K2 valve is too · Check the connectors from gearbox
If failure at another clutch
·Cable/connector is defective and has · Check the regulator resistance*
contact to vehicle ground · Check internal wire harness of the
OP mode : TCU shutdown
* See page 3-40
gearbox
* See page 3-40
3-25
the TCU
78 S.C. to ground at clutch K3 · Check the cable from TCU to the
is out of limit, the voltage at K3 valve is too · Check the connectors from gearbox
If failure at another clutch
·Cable/connector is defective and has · Check the regulator resistance*
contact to vehicle ground · Check internal wire harness of the
OP mode : TCU shutdown
* See page 3-40
gearbox
* See page 3-52
7A S.C. to battery voltage at converter
- -
clutch
7B S.C. to ground at converter clutch - -
7C O.C. at converter clutch - ※ Not used
7D S.C. ground at engine derating device Engine derating will be on · Check the cable from TCU to the
·Cable is defective and is contacted to until engine derating device
vehicle ground TCU power down even if · Check the connectors from engine
·Engine derating device has an internal fault vanishes (Loose derating device to TCU
defect connection) · Check the resistance* of engine
·Connector pin is contacted to vehicle OP mode : Normal derating device
ground ※ Not used
* See page 3-40
7E S.C. battery voltage at engine derating No reaction · Check the cable from TCU to the
device OP mode : Normal engine derating device
·Cable/connector is defective and is · Check the connectors from backup
contacted to battery voltage alarm device to TCU
·Engine derating device has an internal · Check the resistance* of backup
defect alarm device
* See page 3-40
3-26
7F O.C. at engine derating device No reaction · Check the cable from TCU to the
TCU detected a wrong voltage at the OP mode : Normal engine derating device
output pin, that looks like a O.C. for this · Check the connectors from engine
output pin derating device to TCU
·C a b l e i s d e fe c t i ve a n d h a s n o · Check the resistance* of engine
connection to TCU derating device
·Engine derating device has an internal * See page 3-40
defect
·Connector has no connection to TCU
the TCU
82 S.C. to ground at clutch K4 TCU shifts to neutral · Check the cable from TCU to the
The measured resistance value of the valve OP mode : Limp home engine derating device
* See page 3-40
83 O.C. at clutch K4 · Check the cable from TCU to the
The measured resistance value of the TCU shifts to neutral gearbox
valve is out of limit OP mode : Limp home · Check the connectors from gearbox
·Cable/connector is defective and has If failure at another clutch to TCU
contact to TCU is pending · Check the regulator resistance*
·Regulator has an internal defect TCU shifts to neutral · Check internal wire harness of the
OP mode : TCU shutdown gearbox
* See page 3-40
the TCU
85 S.C. to ground at clutch KV TCU shifts to neutral · Check the cable from TCU to the
* See page 3-40
3-27
86 O.C. at clutch KV TCU shifts to neutral · Check the cable from TCU to the
·Cable/connector is defective and has is pending to TCU
gearbox
* See page 3-40
87 S.C. to battery voltage at clutch KR TCU shifts to neutral · Check the cable from TCU to the
valve is out of limit, the voltage at KR valve is If failure at another clutch · Check the connectors from gearbox
too high is pending to TCU
contact to another regulator output of the * See page 3-40
TCU
88 S.C. to ground at clutch KR TCU shifts to neutral · Check the cable from TCU to the
is out of limit, the voltage at KR valve is too If failure at another clutch · Check the connectors from gearbox
* See page 3-40
89 O.C. at clutch KR TCU shifts to neutral · Check the cable from TCU to the
gearbox
* See page 3-40
91 S.C. to ground at relay reverse warning Backup alarm will be on · Check the cable from TCU to the
alarm until backup alarm device
TCU detected a wrong voltage at the TCU power down even if · Check the connectors from backup
output pin, that looks like a S.C. to vehicle fault alarm device to TCU
ground vanishes(Loose connect- · Check the resistance* of backup
·Cable is defective and is contact to ion) alarm device
vehicle ground OP mode : Normal * See page 3-40
·Backup alarm device has an internal
defect
ground
3-28
92 S.C. to battery voltage at relay reverse No reaction · Check the cable from TCU to the
warning alarm OP mode : Normal backup alarm device
TCU detected a wrong voltage at the · Check the connectors from backup
output pin, that looks like a S.C. to battery alarm device to TCU
voltage · Check the resistance* of backup
·Cable is defective and is contacted to alarm device
battery voltage * See page 3-40
·Backup alarm device has an internal
defect
voltage
93 O.C. at relay reverse warning alarm No reaction · Check the cable from TCU to the
TCU detected a wrong voltage at the OP mode : Normal backup alarm device
output pin, that looks like a O.C. for this · Check the connectors from backup
output pin alarm device to TCU
·C a b l e i s d e fe c t i ve a n d h a s n o · Check the resistance* of backup
connection to TCU alarm device
·Backup alarm device has an internal * See page 3-40
defect
94 S.C. to ground at relay starter interlock No reaction · Check the cable from TCU to the
TCU detected a wrong voltage at the OP mode : Normal stater interlock relay
output pin, that looks like a S.C. to vehicle · Check the connectors from starter
ground interlock relay to TCU
·Cable is defective and is connection to · Check the resistance* of starter
vehicle ground interlock relay
·Starter interlock relay has an internal * See page 3-40
defect
ground
95 S.C. to battery voltage at relay starter No reaction · Check the cable from TCU to the
interlock OP mode : Normal starter interlock relay
TCU detected a wrong voltage at the · Check the connectors from starter
output pin, that looks like a S.C. to battery interlock relay to TCU
voltage · Check the resistance* of starter
·C a b l e i s d e fe c t i ve a n d h a s n o interlock relay
connection to battery voltage * See page 3-40
·Starter interlock relay has an internal
defect
voltage
96 O.C. at relay starter interlock No reaction · Check the cable from TCU to the
TCU detected a wrong voltage at the OP mode : Normal starter interlock relay
output pin, that looks like a O.C. for this · Check the connectors from starter
output pin interlock relay to TCU
·C a b l e i s d e fe c t i ve a n d h a s n o · Check the resistance* of starter
connection to TCU interlock relay
·Starter interlock relay has an internal * See page 3-40
defect
3-29
97 S.C. to ground at park brake solenoid No reaction · Check the cable from TCU to the
TCU detected a wrong voltage at the OP mode : Normal park brake solenoid
output pin, that looks like a S.C. to vehicle · Check the connectors from park
ground brake solenoid to TCU
·Cable is defective and is connection to · Check the resistance* of park brake
vehicle ground solenoid
·Park brake solenoid has an internal * See page 3-40
defect
ground
98 S.C. to battery voltage at park brake No reaction · Check the cable from TCU to the
solenoid Optional : (Some custom- park brake solenoid
TCU detected a wrong voltage at the ers) · Check the connectors from park
output pin, that looks like a S.C. to battery TCU shifts to neutral brake solenoid to TCU
voltage caused by park brake feed · Check the resistance* of park brake
·Cable is defective and is connection to back solenoid
battery voltage OP mode : Normal * See page 3-40
·Park brake solenoid has an internal
defect
voltage
99 O.C. at park brake solenoid No reaction · Check the cable from TCU to the
TCU detected a wrong voltage at the Optional : Some park brake solenoid
output pin, that looks like a O.C. for this customers · Check the connectors from park
output pin TCU shifts to neutral brake solenoid to TCU
·C a b l e i s d e fe c t i ve a n d h a s n o caused by park brake feed · Check the resistance* of park brake
connection to TCU back solenoid
·Park brake solenoid has an internal OP mode : Normal * See page 3-40
defect
9A S.C. to ground at conver ter lock up No reaction · Check the cable from TCU to the
clutch solenoid OP mode : Normal converter clutch solenoid
TCU detected a wrong voltage at the · C h e ck t h e c o n n e c t o r s f r o m
output pin, that looks like a S.C. to vehicle converter clutch solenoid to TCU
ground · Check the resistance* of park brake
·Cable is defective and is contacted to solenoid
vehicle ground * See page 3-40
·Conver ter clutch solenoid has an
internal defect
ground
9B O.C. at converter lock up clutch solenoid Converter clutch always · Check the cable from TCU to the
TCU detected a wrong voltage at the open, converter clutch solenoid
output pin, that looks like a O.C. for this retarder not available · C h e ck t h e c o n n e c t o r s f r o m
output pin OP mode : Normal converter clutch solenoid to TCU
·C a b l e i s d e fe c t i ve a n d h a s n o · Check the resistance* of park brake
connection to TCU solenoid
·Conver ter clutch solenoid has an * See page 3-40
internal defect
3-30
9C S.C. to battery voltage at converter lock No reaction · Check the cable from TCU to the
up clutch solenoid OP mode : Normal converter clutch solenoid
TCU detected a wrong voltage at the · C h e ck t h e c o n n e c t o r s f r o m
output pin, that looks like a S.C. to battery converter clutch solenoid to TCU
voltage · Check the resistance* of converter
·Cable is defective and has no contacted clutch solenoid
to battery voltage * See page 3-40
·Conver ter clutch solenoid has an
internal defect
voltage
9D S.C. to ground at retarder solenoid No reaction · Check the cable from TCU to the
TCU detected a wrong voltage at the OP mode : Normal retarder solenoid
output pin, that looks like a S.C. to vehicle · Check the connectors from retarder
ground solenoid to TCU
·Cable is defective and is contacted to · Check the resistance* of retarder
·Retarder solenoid has an internal defect * See page 3-40
ground
9E O.C. at retarder solenoid No reaction · Check the cable from TCU to the
TCU detected a wrong voltage at the OP mode : Normal retarder solenoid
output pin, that looks like a O.C. for this · Check the connectors from retarder
output pin solenoid to TCU
·C a b l e i s d e fe c t i ve a n d h a s n o · Check the resistance* of retarder
·Retarder solenoid has an internal defect * See page 3-40
9F S.C. to batter y voltage at retarder No reaction · Check the cable from TCU to the
solenoid OP mode : Normal retarder solenoid
TCU detected a wrong voltage at the · Check the connectors from retarder
output pin, that looks like a S.C. to battery solenoid to TCU
voltage · Check the resistance* of retarder
·C a b l e i s d e fe c t i ve a n d h a s n o solenoid
·Retarder solenoid has an internal defect
voltage
3-31
A1 S.C. to ground at difflock or axle No reaction · Check the cable from TCU to the
connection solenoid OP mode : Normal difflock solenoid
TCU detected a wrong voltage at the · Check the connectors from difflock
output pin, that looks like a S.C. to vehicle solenoid to TCU
ground · Check the resistance* of difflock
·Cable is defective and is contacted to solenoid
·Difflock solenoid has an internal defect
ground
A2 S.C. to battery voltage at difflock or axle No reaction · Check the cable from TCU to the
connection solenoid OP mode : Normal difflock solenoid
output pin, that looks like a S.C. to battery solenoid to TCU
voltage · Check the resistance* of difflock
voltage
A3 O.C. at difflock or axle connection No reaction · Check the cable from TCU to the
solenoid OP mode : Normal difflock solenoid
output pin, that looks like a O.C. for this solenoid to TCU
output pin · Check the resistance* of difflock
connection to TCU * See page 3-40
A4 S.C. to ground at warning signal output No reaction · Check the cable from TCU to the
TCU detected a wrong voltage at the OP mode : Normal warning device
output pin, that looks like a S.C. to vehicle · Check the connectors from warning
ground device to TCU
·Cable is defective and is contacted to · Check the resistance* of warning
vehicle ground device
·Warning device has an internal defect * See page 3-40
ground
A5 O.C. voltage at warning signal output No reaction · Check the cable from TCU to the
TCU detected a wrong voltage at the OP mode : Normal warning device
output pin, that looks like a O.C. for this · Check the connectors from warning
output pin device to TCU
·C a b l e i s d e fe c t i ve a n d h a s n o · Check the resistance* of warning
connection to TCU device
·Warning device has an internal defect * See page 3-40
A6 S.C. to battery voltage at warning signal No reaction · Check the cable from TCU to the
output OP mode : Normal warning device
TCU detected a wrong voltage at the · Check the connectors from warning
output pin, that looks like a S.C. to battery device to TCU
voltage · Check the resistance* of warning
·Cable is defective and has is contacted device
to battery voltage * See page 3-40
·Warning device has an internal defect
voltage
3-32
B1 Slippage at clutch K1 TCU shifts to neutral · Check pressure at clutch K1
TCU calculates a differential speed at OP mode : Limp home · Check main pressure in the system
closed clutch K1. If this calculated value If failure at another clutch · Check sensor gap at internal speed
is out of range, TCU interprets this as is pending sensor
slipping clutch TCU shifts to neutral · Check sensor gap at output speed
·Low pressure at clutch K1 OP mode : TCU shutdown sensor
·Low main pressure · Check signal at internal speed
·Wrong signal at internal speed sensor sensor
·Wrong signal at output speed sensor · Check signal at output speed
·Wrong size of the sensor gap sensor
·Clutch is defective · Replace clutch
TCU calculates a differential speed at OP mode : Limp home Check main pressure in the system
·Clutch is defective Replace clutch
slipping clutch TCU shifts to neutral · Check sensor gap at turbine speed
·Wrong signal at turbine speed sensor · Check signal at turbine speed
·Clutch is defective Replace clutch
3-33
B5 Slippage at clutch KV TCU shifts to neutral · Check pressure at clutch KV
closed clutch KV. If this calculated value If failure at another clutch · Check sensor gap at internal speed
·Low pressure at clutch KV OP mode : TCU shutdown sensor
B6 Slippage at clutch KR TCU shifts to neutral · Check pressure at clutch KR
closed clutch KR. If this calculated value If failure at another clutch · Check sensor gap at internal speed
·Low pressure at clutch KR OP mode : TCU shutdown sensor
B7 Overtemp sump No reaction · Cool down machine
TCU measured a temperature in the oil OP mode : Normal · Check oil level
sump that is over the allowed threshold. · Check temperature sensor
B8 Overtemp retarder TCU disables retarder · Cool down machine
TCU measured a temperature in the OP mode : Normal · Check oil level
retarder oil that is over the allowed · Check temperature sensor
threshold
B9 Overspend engine Retarder applies
-
OP mode : Normal
BA Differential pressure oil filter No reaction · Check oil filter
TCU measured a voltage at differential OP mode : Normal · Check wiring from TCU to
pressure switch out of the allowed range differential pressure switch
·Oil filter is polluted · C h e ck d i f fe r e n t i a l p r e s s u r e
·Cable/connector is broken or cable/ switch(Measure resistance)
connector is contacted to battery voltage
or vehicle ground
·Differential pressure switch is defective
3-34
BB Slippage at converter lockup clutch · Check pressure at converter lockup
TCU calculates a differential speed at clutch
closed converter lockup clutch. If this · Check main pressure in the system
calculated value is out of range, TCU · Check sensor gap at engine speed
interprets this as slipping clutch sensor
·Low pressure at converter lockup clutch · Check sensor gap at turbine speed
·Low main pressure sensor
·Wrong signal at engine speed sensor · Check signal at engine speed
·Wrong signal at turbine speed sensor sensor
·Wrong size of the sensor gap · Check signal at turbine speed
·Clutch is defective sensor
· Replace clutch
BD S.C. to ground at engine brake solenoid No reaction · Check the cable from TCU to
TCU detected a wrong voltage at the OP mode : Normal engine brake solenoid
output pin, that looks like a S.C. to vehicle · Check the connectors from engine
ground brake solenoid to TCU
·Cable is defective and is contacted to · Check the resistance* of engine brake
·Engine brake solenoid has an internal * See page 3-40
defect
ground
BE S.C. to battery voltage at engine brake No reaction · Check the cable from TCU to the
output pin, that looks like a S.C. to battery · Check the connectors from engine
voltage brake solenoid to TCU
·Cable is defective and is contacted to · Check the resistance* of engine brake
battery voltage solenoid
defect
voltage
BF O.C. at engine brake No reaction · Check the cable from TCU to the
output pin, that looks like a O.C. for this · Check the connectors from engine
output pin brake solenoid to TCU
·C a b l e i s d e fe c t i ve a n d h a s n o · Check the resistance* of engine brake
defect
3-35
C3 Overtemp converter output No reaction · Cool down machine
TCU measured a oil temperature at the OP mode : Normal · Check oil level
converter output that is the allowed · Check temperature sensor
threshold
C4 S. C. t o g r o u n d a t j oy s t i ck s t a t u s No reaction · Check the cable from TCU to
indicator OP mode : Normal joystick status indicator
TCU detected a wrong voltage at the · Check the connectors from joystick
output pin, that looks like a S.C. to vehicle status indicator to TCU
ground · Check the resistance* of joystick
·Cable is defective and is contacted to status indicator
·Joystick status indicator has an internal
defect
ground
C5 S.C. to battery voltage at joystick status No reaction · Check the cable from TCU to
indicator OP mode : Normal joystick status indicator
TCU detected a wrong voltage at the · Check the connectors from joystick
output pin, that looks like a S.C. to battery status indicator to TCU
voltage · Check the resistance* of joystick
·Cable is defective and is contacted to status indicator
battery voltage * See page 3-40
·Joystick status indicator has an internal
defect
voltage
C6 O.C. at joystick status indicator No reaction · Check the cable from TCU to
TCU detected a wrong voltage at the OP mode : Normal joystick status indicator
output pin, that looks like a O.C. for this · Check the connectors from joystick
output pin status indicator to TCU
·C a b l e i s d e fe c t i ve a n d h a s n o · Check the resistance* of joystick
connection to TCU status indicator
·Joystick status indicator has an internal * See page 3-40
defect
·Connector pin has no connection to
TCU
3-36
D1 S.C. to battery voltage at power supply See fault codes No.21 to · Check cables and connectors to
for sensors 2C sensors, which are supplied from
TCU measures more than 6V at the pin AU1
AU1 (5V sensor supply) · Check the power supply at the pin
AU1(Should be appx. 5V)
· Fault codes No.21 to No.2C may be
reaction of this fault
D2 S.C. to ground at power supply for See fault codes No.21 to · Check cables and connectors to
sensors 2C sensors, which are supplied from
TCU measures less than 4V at the pin AU1
AU1 (5V sensor supply) · Check the power supply at the pin
AU1(Should be appx. 5V)
· Fault codes No.21 to No.2C may be
reaction of this fault
D3 Low voltage at battery Shift to neutral · Check power supply battery
Measured voltage at power supply is lower OP mode : TCU shutdown · Check cables from batteries to TCU
than 18V(24V device) · Check connectors from batteries to
TCU
D4 High voltage at battery Shift to neutral · Check power supply battery
Measured voltage at power supply is OP mode : TCU shutdown · Check cables from batteries to TCU
higher than 32.5V(24V device) · Check connectors from batteries to
TCU
D5 Error at valve power supply VPS1 Shift to neutral · Check fuse
TCU switched on VPS1 and measured OP mode : TCU shutdown · Check cables from gearbox to TCU
VPS1 is off or TCU switched off VPS1 and · Check connectors from gearbox to
measured VPS1 is still on TCU
·Cable or connectors are defect and are · Replace TCU
contacted to battery voltage
·Cable or connectors are defect and are
·Permanent power supply KL30 missing
·TCU has an internal defect
D6 Error at valve power supply VPS2 Shift to neutral · Check fuse
TCU switched on VPS2 and measured OP mode : TCU shutdown · Check cables from gearbox to TCU
VPS2 is off or TCU switched off VPS2 and · Check connectors from gearbox to
measured VPS2 is still on TCU
·Cable or connectors are defect and are · Replace TCU
contacted to battery voltage
·Cable or connectors are defect and are
·Permanent power supply KL30 missing
·TCU has an internal defect
3-37
E1 S.C. battery voltage at speedometer ※ Not used
-
output
E2 S.C. to ground or O.C at speedometer ※ Not used
-
output
E3 S.C. to battery voltage at display output No reaction · Check the cable from TCU to the
TCU sends data to the display and OP mode : Normal display
measures always a high voltage level on · Check the connectors at the display
the connector · Change display
·Cable or connectors are defective and
are contacted to battery voltage
·Display has an internal defect
E4 S.C. to ground at display output No reaction · Check the cable from TCU to the
TCU sends data to the display and OP mode : Normal display
measures always a high voltage level on · Check the connectors at the display
the connector · Change display
·Cable or connectors are defective and
are contacted to battery voltage
·Display has an internal defect
E5 Communication failure on DeviceNet Shift to neutral · Check Omron master
OP mode : TCU shutdown · Check wire of DeviceNet-Bus
· Check cable to Omron master
E6 DISPID1 timeout TCU select parameter set · Check display controller
Timeout of CAN-massage DISPID1 from with ID0 · Check wire of CAN-Bus
display controller OP mode : Limp home · Check cable display controller
·Interference on CAN-Bus
·CAN wire/connector is defective
·Can wire/connector is defective and has
contact to vehicle ground or battery
voltage
3-38
F1 General EEPROM fault No reaction · Replace TCU
TCU can't read non volatile memory OP mode : Normal ※ Often shown together with fault
·TCU is defective code F2
F2 Configuration lost Transmission stay neutral · Reprogram the correct configurat-
TCU has lost the correct configuration and OP mode : TCU shutdown ion for the vehicle (e.g. with cluster
can't control the transmission controller,...)
·Interference during saving data on non
volatile memory
·TCU is brand new or from another
vehicle
F3 Application error Transmission stay neutral · Replace TCU
Something of this application is wrong OP mode : TCU shutdown ※ This fault occurs only if an test
engineer did something wrong in
the application of the vehicle
F5 Clutch failure Transmission stay neutral · Check clutch
AEB was not able to adjust clutch filling OP mode : TCU shutdown ※ TCU shows also the affected clutch
parameters on the display
·One of the AEB-Values is out of limit
F6 Clutch adjustment data lost No reaction, · Execute AEB
TCU was not able to read correct clutch Default values : 0 for AEB
adjustment parameters Offsets used
·Interference during saving data on non OP mode : Normal
volatile memory
·TCU is brand new
3-39
3) MEASURING OF RESISTANCE AT ACTUATOR/SENSOR AND CABLE
(1) Actuator
2 G
76043PT19
Open circuit R12 = R1G = R2G = ∞

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

Short cut to ground R12 = 0; R1C = R2C = 0, R1P = R2P = ∞
Short cut to battery R12 = 0; R1C = R2C = 0, R1P = R2P = 0
3-40
5. AXLE
1) OPERATION
· The power from the engine passes through torque converter, transmission and drive shafts, and is
then sent to the front and rear axles.
· Inside the axles, the power passes from the bevel pinion to the bevel gear and is sent at right
angles. At the same time, the speed is reduced and passes through the both differentials to the
axle shafts. The power of the axle shafts is further reduced by planetary-gear-type final drives and
is sent to the wheels.
(1) Front axle
7407B3PT10
1 Final drive 2 Differential
(2) Rear axle
7407B3PT11
1 Final drive 2 Differential
3-41
2) DIFFERENTIAL
(1) Description 3
When the machine makes a turn, the
2 4
outside wheel must rotate faster than the
inside wheel. A differential is a device
which continuously transmits power to the
right and left wheels while allowing them
to turn a different speeds, during a turn.
The power from the drive shaft passes
through bevel pinion (1) and is transmitted
to the bevel gear (2). The bevel gear
changes the direction of the motive force
by 90 degree, and at the same time
reduces the speed. 1
It then transmits the motive force through
the differential (3) to the axle gear shaft 770-3 [3-26(1)]
(4).
(2) When driving straight forward

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

Swing
When turning, the rotating speed of the
Pinion gear
left and right wheels is different, so the
Side gear Side gear
pinion gear and side gear inside the
differential assembly rotate in accordance
with the difference between the rotating
speed of the left and right wheels.
T h e p owe r o f t h e c a r r i e r i s t h e n
transmitted to the axle gear shafts. Carrier
Pinion gear Ring gear
770-3 [3-26(3)]
3-42
3) TORQUE PROPORTIONING DIFFERENTIAL
(1) Function
① Because of the nature of their work,
4-wheel-drive loaders have to work in
places where the road surface is bad.
In such places, if the tires slip, the ability
to work as a loader is reduced, and also
the life of the tire is reduced.
The torque proportioning differential is
installed to overcome this problem.
In structure it resembles the differential of
an automobile, but the differential pinion
gear has an odd number of teeth.
Because of the difference in the
resistance from the road surface, the
position of meshing of the pinion gear
and side gear changes, and this
changes the traction of the left and right
tires.
(2) Operation
Spider rotating
① When traveling straight direction
(Equal resistance from road surface to
left and right tires)
Under this condition, the distances
involving the engaging points between
FL FR
right and left side gears and pinion-a and Engaging a b Engaging
point point
b-are equal and the pinion is balanced
as FL×a=FR×b. Thus, FL=FR, and
the right and left side gears are driven Left side gear Right side gear
with the same force. Pinion
770-3 (3-27)
3-43
② When traveling on soft ground
(Resistance from road surface to left and
right tires is different)
If the road resistance to the left wheel is
Spider rotating
smaller, the left side gear tends to rotate direction
forward, and this rotation changes the
engaging points between the side gears
and pinion. As a result, the distances
involving the engaging points becomes FL
Small road FR Large road
a>b. The pinion now is balanced as resistance a b resistance
FL×a=FR×b, where FL>FR. The right Engaging Engaging
side gear is driven with a greater force point point
than the left side gear. The torque can
Left side gear Right side gear
be increased by up to about 30% for Pinion
either side gear.
The pinion therefore does not run idle
and driving power is transmitted to both
side gears until the difference between
road resistance to the right and left
(770-7)3-27
wheels reaches about 30%.
3-44
4) FINAL DRIVE (front & rear)
1 2 3
73093PT17
1 Axle shaft 2 Ring gear

3 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) is transmitted to planetary gear
(3). The planetary gear rotates around the inside of a fixed ring gear (2) 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.
3-45
6. TIRE AND WHEEL
7407APT10
1 Wheel rim 3 O-ring 5 Side ring

2 Tire 4 Lock ring 6 Valve assembly
1) The tire acts to absorb the shock from the ground surface to the machine, and at the same time
they must rotate in contact with the ground to gain the power which drives the machine.
2) Various types of tires are available to suit the purpose. Therefore it is very important to select the
correct tires for the type of work and bucket capacity.
3-46
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
3-47
※ Transmission oil must be at operating temperature for these checks.
Item Description Service action

Transmission oil warm-up Start engine. Apply service brakes OK
procedure and release parking brake. Check completed.
Select Auto shift select switch to
manual mode (①).
Move gear selector lever to 3rd
speed.
Move gear selector lever to forward
1 "F" position.
2
Increase engine speed to high idle
for 30 seconds.
A
Move gear selector lever to neutral

"N" position and r un for 15
seconds.
1
4
2
3
Repeat procedure until
transmission temperature gauge
arrow points to bar above dial.
Gear selector lever and Move gear selector lever to each OK
neutral lock latch checks position. Check completed.
Engine OFF. 1
NOTE : Gear selector lever position

2
3
4
NOT OK
changes slightly as steer ing
Repair lock or replace
column is tilted.
switch.
FEEL : Lever must move freely
through all positions.
Engage neutral lock.
Apply slight effort to move lever into
forward (F) and reverse (R).
LOOK : Neutral lock must stay
engaged.
Automatic shifting check 1
2
F
Start engine. OK
3 N
Check completed.
4
R
Move gear selector lever to 4th

1
2 speed.
NOT OK
Turn auto shift select switch to Go to transmission error
automatic mode (②). code group at page 3-20~
A
3-39.
LOOK : Automatic sign on LCD.
Automatic sign Repair or replace the
Move gear selector lever to forward LCD or harness.
or reverse position.
Increase engine rpm.
LOOK : Speed on LCD must vary
with machine speed.
3-48
Transmission noise Run engine at approximately 1600 OK
check 1
2
rpm. Check completed.
3
Engine running.
4
Drive unit with transmission in each NOT OK

forward and reverse speed. Go to transmission makes
excessive noise, chapter 2
LISTEN : Transmission must not
in this group.
make excessive noise in any range.
Engine rpm must not "lug down" as
unit is shifted between gears.
Transmission "quick shift" Release parking brake and select OK
check auto shift select switch to manual Check completed.
Engine running. mode (①).
NOT OK
P
Shift to 2nd forward. Check connector at base

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

step lower speed.
Press gear selector lever kick down
1
switch once.
2
3
4
LOOK/FEEL : Transmission must

shift to original speed.
Select auto shift select switch to
automatic mode (②).
Drive machine at approximately
90% speed of max speed in each
gear (2nd or 3rd or 4th).
Shift to (2nd or 3rd or 4th) gear in
each forward and reverse speed
and press gear selector kick down
lever switch or RCV lever switch
once.
LOOK/FEEL : It shift down quickly
from current gear to one step lower
speed and recover to original
speed quickly when push the
switch one more time.
3-49
Forward, reverse and 4th Park unit on level surface. OK
speed clutch pack drag Check completed.
1
2
3 Apply service brakes.
check
4
NOT OK
※ Transmission must Move gear selector lever to neutral.
I f u n i t m ove s, r e p a i r
be warmed up for
Move gear selector lever to 1st. transmission.
this check.
Engine running. Release parking brake and service
brakes.
P
Run engine at low idle.
LOOK : Unit must not move in
either direction.
NOTE : If unit moves forward,
either the forward pack or the 4th
speed pack is dragging.
Transmission shift Run engine at approximately 1300 OK
modulation check 1
4
2
3
rpm. Check completed.
Engine running.
Put transmission in 1st forward, NOT OK
shift several times from forward to Go to unit shifts too fast,
reverse and reverse to forward. chapter 2 in this group.
Repeat check in 2nd gear.
LOOK : Unit must slow down and
change direction smoothly.
Torque converter check Start engine. Apply service brakes OK
1
4
2
3
and release parking brake. Check completed.
Move gear selector lever to 3rd NOT OK
speed. If stall rpm are too low or
too high, problem may be
Move gear selector control lever to
engine power or torque
forward "F" position.
converter.
Increase engine speed to high idle.
IF OK
LOOK : Torque converter stall rpm Replace transmission
must be within the following range. torque converter.
Stall rpm : 2080±50 rpm
Move gear selector control lever to
neutral "N" position and run for 15
seconds.
3-50
2. TROUBLESHOOTING
1) TRANSMISSION
※ Diagnose malfunction charts are arranged from most probable and simplest to verify, to least likely,
more difficult to verify. Remember the following steps when troubleshooting a problem :
Step 1. Operational check out procedure (See group 3 in section 1.)
Step 2. Operational checks (In this group.)
Step 3. Troubleshooting
Step 4. Tests and/or adjustments (See group 3.)
Problem Cause Remedy

Transmission slippage Low oil level. Add oil.
Wrong oil grade. Change oil.
Restricted transmission pump Remove and clean screen.
suction screen.
Leak in transmission control valve Remove valve and inspect gaskets.
or gasket.
Low transmission pump flow due Do transmission pump flow test.
to worn pump.
Weak or broken pressure regulat- Do transmission system pressure test.
ing valve spring.
Error code on display Something wrong in transmission. Go to transmission error code group at page
3-20~3-39.
3-51
Machine will not move Low oil level. Add oil.
Applied park brake. Check parking brake fuse.
Check continuity to parking brake switch.
No power to transmission contro- Check transmission controller fuse.
ller.
Malfunctioning parking brake Remove and inspect parking brake solenoid
solenoid valve. valve.
Check for power to solenoid valve.
Restricted orifice of PPC valve. Remove orifice and check for contamination
and/or plugging.
(Do not remove valve housing for this purpose.)
Excessive leakage in Do transmission element leakage test using
transmission element. system pressure.
Worn clutch disks. Repair transmission.
Low or no transmission See transmission pressure is low in this group.
pressure.
Service brake will not release. Do brake pedal operational check.
Do service and park system drag checks.
Failed torque converter. Do torque converter stall test.
If engine pulldown in normal, torque converter is
good.
Broken shafts or gears. Drain transmission to determine if large pieces
of metal contamination are present.
Broken drive shafts. Inspect drive shafts and universal joints for
external damage. Repair.
Broken ring or pinion gear. If drive shaft rotate with transmission in gear but
machine does not move, a differential failure is
indicated. Repair.
Machine does not Malfunctioning transmission Check solenoid valve.
engage in low gear control solenoid valve.
Stuck spool in transmission Remove and inspect transmission control valve
control valve. spools.
Stuck PPC valve. Remove end cover to inspect PPC valve.
Replace if necessary.
Malfunctioning transmission Check speed sensor.
speed sensor.
3-52
Transmission pressure is Low oil level. Check transmission oil level and refill if
low (all gears) necessary.
Failed transmission pressure Verify transmission system pressure. Do
switch. transmission system pressure test.
Plugged suction strainer. Transmission pump may be noisy if transmission
suction screen is clogged. Drain transmission.
Remove and clean suction screen.
Also, check condition of transmission filter.
Stuck transmission pressure Remove transmission pressure regulating valve.
regulating valve or broken spring. Inspect for damage (See transmission control
valve).
Failed control valve gasket. Inspect transmission control valve for external
leakage. Remove control valve.
Inspect or replace gasket.
Stuck PPC valve. Remove end cover to inspect modulation spool
and check torque on cap screws retaining
control valve to transmission.
Tr a n s m i s s i o n s y s t e m Failed transmission pump. Do pump flow test.
pressure is low (one or
Failed transmission control valve Inspect transmission control valve for external
two gears)
gasket. leakage. Remove control valve.
Inspect or replace gasket.
Leakage in clutch piston or seal Disassemble and repair.
ring.
Transmission shifts too Low oil level (aeration of oil). Add oil.
low
Low transmission pressure. Do transmission system pressure test.
Restricted transmission pump Remove and clean screen.
suction screen.
Low transmission pump flow. Do transmission pump flow test.
Excessive transmission Do transmission element leakage test using
element leakage. system pressure.
Stuck PPC valve. Remove end cover to inspect modulation spool.
Restricted PPC valve orifice. Remove orifice and inspect for contamination
and /or plugging.
Restricted oil passages between Remove control valve and inspect oil passage.
control valve and transmission
elements.
Incorrect transmission oil. Change oil (SAE 10W-30/15W-40)
3-53
Transmission shifts too Wrong transmission controller. Check if transmission controller has been
fast changed
System pressure too high. Do transmission system pressure test.
Stuck PPC valve. Remove and inspect PPC valve.
Replace if necessary. Also remove end cover
to inspect PPC valve and control valve housing.
Stuck or missing check valves. Inspect transmission control valve.
Missing O-r ing from end of Remove orifice and inspect port for O-ring.
modulation orifice.
Broken piston return spring. Disassemble and inspect clutch.
Incorrect transmission oil. Change oil (SAE 10W-30/15W-40).
Machine "creeps" War ped disks and plates in Check transmission.
in neutral transmission.
Transmission hydraulic High oil level. Transmission overfilled or hydraulic pump seal
system overheats leaking.
Low oil level. Add oil.
Wrong oil grade. Change oil.
Park brake dragging. Check for heat in park brake area.
Pinched, restricted or leaking lube Check cooler lines.
lines.
Machine operated in too high Operate machine in correct gear range.
gear range.
Malfunction in temperature gauge I n s t a l l t e m p e ra t u r e s e n s o r t h e ve r i f y
or sensor. temperature.
Do tachometer/temperature reader installation
procedure.
Restricted air flow through oil Do radiator air flow test.
cooler or radiator.
Failed oil cooler bypass valve (In Disassemble and inspect.
thermal bypass valve).
Failed thermal bypass valve. Remove thermal bypass valve and check to see
if machine still overheats. Do transmission oil
cooler thermal bypass valve test.
Internally restricted oil cooler. Do oil cooler restriction test.
Leakage in transmission hydraulic Do transmission system pressure, element
system. leakage test.
Malfunction in converter relief Do converter out pressure test.
valve.
Low transmission pump output. Do transmission pump flow test.
3-54
Excessive transmission Too low engine low idle. Check engine low idle speed.
noise (Under load or no
Wo r n p a r t s o r d a m a g e d i n Remove transmission suction screen. Inspect
load)
transmission. for metal particles.
Repair as necessary.
Warped drive line between engine Inspect drive line.
and torque converter.
Low or no lube. Do converter-out and lube pressure test. Do
transmission pump flow test.
Foaming oil Incorrect type of oil. Change oil.
High oil level. Transmission overfilled or hydraulic pump seal
leaking.
Low oil level. Add oil.
Air leak on suction side of pump. Check oil pickup tube on side of transmission.
Oil ejected from dipstick Plugged breather. Inspect breather on top of transmission.
Replace.
Machine vibrates Aerated oil. Add oil.
Low engine speed. Check engine speed.
Fa i l e d u n i ve r s a l j o i n t s o n Check universal joints.
transmission dr ive shaft or
differential drive shafts.
Machine lacks power and Engine high idle speed set too Check high idle adjustment.
acceleration low.
Incorrect transmission oil. Change oil.
Aerated oil. Add oil.
Low transmission pressure. Do transmission system pressure test.
Warped transmission clutch. Do transmission clutch drag checks.
Torn transmission control valve Inspect gasket.
gasket.
Brake drag. Do brake drag check.
Failed torque converter. Do torque converter stall speed test.
Low engine power. Do engine power test.
Torque conver ter stall Aerated oil. Put clear hose on thermal bypass outlet port.
RPM too high Run machine to check for bubbles in oil.
Stuck open converter relief valve. Do converter-out pressure test.
Leakage in torque converter seal. Do converter-out pressure test.
Torque converter not Replace torque converter.
transferring power (Bent fins,
broken starter).
3-55
Torque conver ter stall Low engine power. Do engine power test.
RPM too low
Mechanical malfunction. Remove and inspect torque converter.
Transmission pressure Low oil level. Add oil.
light comes ON when
Cold oil. Warm oil to specification.
shifting from forward to
reverse (all other gears Leak in reverse pack. Do transmission pressure, pump flow, and
OK) leakage check.
Transmission pressure Cold oil. Warm oil to specification.
light comes ON for each
No time delay in monitor. Do monitor check.
shift
Restriction in modulation orifice. Remove orifice and inspect for restriction and/or
plugging.
Stuck PPC valve. Remove and inspect.
Low transmission pressure circuit. Do transmission system pressure test.
Leak in transmission pressure Do converter out pressure test.

circuit.
Failed transmission pump. Do transmission pump flow test.
Clogged filter. Inspect filter. Replace.
3-56
2) DIFFERENTIAL / AXLE
Differential low on oil External leakage. Inspect axle and differential for leaks.
Excessive differential Low oil level in differential. Check oil. Remove drain plug and inspect for
and/or axle noise metal particles in differential case.
Disassemble and determine cause.
Incorrect type of oil. Change oil
Dragging brakes. Do brake check.
Failed pinion bearing. Remove and inspect pinion.
Check to ensure pinion housing was indexed.
Incorrect gear mesh pattern Remove pinion gear housing and inspect ring
between ring and pinion gear. and pinion gear.
Failed differential pinion gears Remove differential housing drain plug and
and/or cross shafts. inspect for metal particles. Disassemble and
inspect.
Failed axle bearing. Do axle bearing adjustment check.
M e c h a n i c a l fa i l u r e i n a x l e Remove differential. Inspect, repair.
planetary.
Oil seeping from outer Excessive end play in axle. Do axle bearing adjustment check.
axle seal
Worn outer bearing and/or cup. Disassemble and inspect outer axle bearing,
cup, spacer, and seal. Replace, if necessary.
Overfilled differential. Check differential oil return system for
excessive internal restriction.
Axle overheats Low differential oil. Add oil.
Overfilled differential. See differential overfills with oil in this group.
Brake drag. See brakes drag in this group.
3) DRIVE LINE
E x c e s s i v e d r i v e l i n e Yokes not in line on drive shafts. Inspect. Align drive shaft yokes.
vibration or noise
Worn front drive line support Inspect, repair.
bearing.
Bent drive shaft. Inspect all drive shafts. Replace.
Loose yoke retaining nuts (drive Inspect. Replace.
shafts wobble at high speed).
Rear axle oscillating support. Inspect, repair.
Lack of lubrication. Lubricate with proper grade of grease.
3-57
GROUP 3 TESTS AND ADJUSTMENTS
1. CLUTCH CUT-OFF PRESSURE SWITCH TEST

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

pressure switch
Brake valve 7707PT12
3-58
2. TRANSMISSION MEASURING POINTS AND CONNECTIONS
The measurements have to be carried out at hot transmission (about 80~95˚C).
48 47 21
54
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
7407B3PT15
1) OIL PRESSURE AND TEMPERATURE

Port Description Size
51 Converter inlet-opening pressure (11+2 bar) H M10×1.0
52 Converter outlet-opening pressure (4.3+3 bar) M14×1.5
53 Forward clutch (16+2 bar) KV B M10×1.0
55 Reverse clutch (16+2 bar) KR E M10×1.0
56 1st clutch (16+2 bar) K1 D M10×1.0
57 2nd clutch (16+2 bar) K2 A M10×1.0
58 3rd clutch (16+2 bar) K3 C M10×1.0
60 4th clutch (16+2 bar) K4 F M10×1.0
63 Converter outlet temperature 100˚C, short-time 120˚C M14×1.5
65 System pressure (16+2 bar) K M10×1.0
3-59
2) DELIVERY RATES
15 Connection to the oil cooler 1 5/6″-12UNF-2B
16 Connection from the oil cooler 1 5/6″-12UNF-2B
3) INDUCTIVE TRANSMITTER AND SPEED SENSOR

21 Inductive transmitter n turbine M18×1.5
34 Speed sensor n output and speedometer -
47 Inductive transmitter n central gear train M18×1.5
48 Inductive transmitter n engine M18×1.5
54 Filter contamination switch M14×1.5
4) CONNECTIONS
49 Plug connection on the hydraulic control unit -
68 Pilot pressure (option) J M16×1.5
69 System pressure (option) G M16×1.5
3-60
GROUP 4 DISASSEMBLY AND ASSEMBLY
1. CONTROL VALVE
1) DISASSEMBLY
(1) Illustration on the right shows the
complete control unit.
73073CV001
(2) Mark the installation position of the

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

S e p a ra t e d u c t p l a t e, 1 s t g a s ke t ,
intermediate plate and 2nd gasket from
the valve housing.
※ Special tool
Box spanner 5873 042 002
73073CV003
(4) Remove retaining clip.
73073CV004
3-61
(5) Loosen socket head screws.
Separate cover from housing and cable
harness.
※ Special tool
73073CV005
(6) Disassemble opposite cover.

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

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

locate housing provisionally, using
adjusting screws(Housing is under spring
preload).
Now, loosen remaining socket head
screws.
※ Special tool
Adjusting screws 5870 204 036
73073CV008
3-62
(9) Separate housing from valve housing by
loosening the adjusting screws uniformly.
※ Special tool
73073CV009
(10) Remove components.
73073CV010
(11) Remove opposite pressure regulators,

housing as well as components
accordingly.
73073CV011
3-63
2) ASSEMBLY
※ Check all components for damage and
renew if necessary.
Prior to the installation, check free travel of
all moving parts in the housing.
Spools can be exchanged individually.
Oil the components prior to the assembly.
Insert diaphragms with the concave side
showing upward until contact is obtained.
※ Installation position, see arrows.
73073CV015
(1) Illustration on the right shows the following

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

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

Assemble gasket (arrow 1) and housing
cover. Now, position the housing cover
uniformly, using adjusting screws, until
contact is obtained and remove cylindrical
pinss(assembly aid) again (see the next
figure).
※ Pay attention to the different housing covers.
Install recess Ø15 mm (arrow 2), facing
the spring of the pressure reducing valve.
Adjusting screws 5870 204 036 73073CV018
3-64
73073CV019
(4) Fasten housing cover by means of socket

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

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

(6) Illustration on the right shows the following
components.
1 Main pressure valve
2 Follow on slide
3 Vibration damper
73073CV022
3-65
(7) Install components according to figure (6).
Preload compression springs of the
follow-on slides and locate spool
provisionally by means of cylindrical pins
Ø5.0 mm (assembly aid), see arrows.
Install two adjusting screws.
Assemble gasket (arrow 1) and housing
cover, and position them uniformly against
shoulder, using adjusting screws.
※ Pay attention to the different housing
covers-install the recess Ø19 mm (arrow 73073CV023
2), facing the main pressure valve.
Now, fasten housing cover by means of
socket head screws.
Remove cylindrical pins(Assembly aid)
again.
※ Special tool
(8) Introduce pressure regulators and fix by

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

pressure regulators (6EA).
※ Pay attention to the installation position of
the cable harness, see also markings
(see figure (2), page 3-74).
73073CV025
3-66
(10) Introduce female connector against
shoulder, with the groove facing the guide
nose of the cover.
Install gasket (arrow) and fasten cover by
means of socket head screws.
※ Special tool
73073CV026
(11) Fix female connector by means of

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

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

(13) Insert screws (6EA) flush mounted into
the bore of the intermediate plate, see
arrow.
※ Pay attention to the installation position-
screws are showing upward (facing the
duct plate).
73073CV029
3-67
(14) Mount intermediate plate, with the
screens showing upward.
73073CV030
(15) Mount gasket Ⅱ.
73073CV031
(16) Mount duct plate and fasten it uniformly by

means of socket head screws.
※ Special tool
73073CV032
(17) Equip screw plug (8EA) with new O-rings

and install them.
※ The installation of the hydraulic control
unit is described, starting from page
3-139.
73073CV033
3-68
2. TRANSMISSION
1) DISASSEMBLY
(1) Remove filter unit
① Demount warning switch (arrow) from
filter head.
73073TM002
② Separate oil filter from filter head.

※ Special tool
Belt spanner 5870 105 005
73073TM003
③ Loosen hexagon head screws and

separate filter head from duct plate.
73073TM004
(2) Separate hydraulic control unit and duct

plate from gearbox housing
① Loosen socket head screws, install two
adjusting screws and separate control
unit from duct plate.
※ Special tool
Adjusting screw 5870 204 031
73073TM004
3-69
② Remove both gaskets as well as
intermediate plate.
※ Special tool
75773TM051
③ Loosen socket head screws and

hexagon nuts and separate duct plate
from gearbox housing.
Now, remove flat gasket.
※ Special tool
75773TM052
(3) Remove and disassemble converter

safety valve
① Pull converter safety valve out of the
housing bore.
75773TM053
② Illustration on the right shows the

required special tool for the
disassembling of the converter safety
valve.
1 Converter safety valve
※ Special tool
Assembly aid 5870 345 084
73073TM009
3-70
③ Preload compression spring carefully,
remove cylindrical pin (see on the right
figure) and demount components (see
on the below figure).
73073TM010
73073TM011
(4) Engine connection-Converter

① Remove lock plate and loosen hexagon
head screws.
Remove disk and pry input flange from
the shaft.
73073TM015
② Loosen screw connection.

※ Mark radial installation position of the
housing cover.
73073TM016
3-71
③ Separate cover along with converter from
the transmission, using lifting device.
※ Special tool
Set of eye bolts 5870 204 002
75773TM057
④ Press input shaft, respectively converter

out of the cover (ball bearing).
75773TM058
⑤ Squeeze circlip out and remove ball

bearing.
※ Special tool
Set of internal pliers 5870 900 013
75773TM059
⑥ Loosen hexagon head screws and

separate membrane from converter.
75773TM060
3-72
⑦ Loosen hexagon head screws and
separate input shaft from the membrane.
75773TM061
⑧ Remove inductive transmitter (n enging).
75773TM062
⑨ Loosen hexagon head screws and

remove converter housing.
75773TM063
(5) Remove transmission pump

① Loosen socket head screws.
75773TM064
3-73
② Apply separating device on the splines
runout of the stator shaft and pull pump
out of the housing bores, using two-leg
puller.
※ Special tool
Separating device 5870 300 024
Two-leg puller 5870 970 004
75773TM065
③ Separate transmission pump from stator.

Separate cam plate from pump.
※ If traces of wear should be encountered
in the pump housing or the cam disk, the
complete pump has to be renewed.
Now, fit cam disk again and fix it by
means of grooved pins (2EA).
75773TM066
④ Loosen hexagon head screws and

remove oil feed housing.
Now, remove flat gasket.
75773TM067
(6) Converter pressure valve

① Pull converter pressure valve out of the
housing bore.
73073TM028
3-74
② Illustration on the right shows the special
tool required for the disassembling of the
converter pressure valve.
1Converter pressure valve
※ Special tool
73073TM029
③ Preload compression spring carefully,

drive roll pin out and remove
components.
※ Special tool
73073TM030
④ Loosen hexagon head screws, demount

cover and remove flat gasket.
73073TM031
(7) Demount output, input and clutches

① Remove lock plate, loosen hexagon head
screws, and pry the converter-side
output flange from the shaft.
Now, pry shaft seal out of the housing
bore.
Tilt gearbox 180˚ and remove rear output
flange accordingly.
※ Special tool
Pry bar 5870 345 065 73073TM035
3-75
② Demount speed sensor as well as both
inductive transmitters (arrows).
73073TM036
③ Loosen hexagon nuts and remove the

two covers (arrows).
Loosen screw connection.
73073TM037
④ Drive both cylindrical pins (arrows) out.
73073TM038
⑤ Separate housing cover carefully from

gearbox housing, using lifting device.
※ Special tool
Lifting chain 5870 281 047
73073TM039
3-76
⑥ On the right figure shows the installation
position of the single clutches as well as
of the input and output.
KV Forward clutch
KR Reverse clutch
K1 1st speed clutch
K2 2nd speed clutch
K3 3rd speed clutch
K4 4th speed clutch
AN Input
AB Output 73073TM040
※ The following figures describe the

common removal of all clutches.
For this purpose, the housing cover,
combined with special tool is necessary.
The removal of single clutches without
help of the housing cover and the
handles is extremely difficult because of
the installation condition.
Besides, there is the danger of injuries.
※ Prior to the common removal of the
clutches, the output shaft must be
removed, see the below figure.
⑦ Loosen socket head screws and remove

output shaft as well as both oil baffle
plates.
73073TM042
3-77
⑧ Assemble housing cover carefully until
contact is obtained.
Fix all clutches in the housing cover,
using handles.
※ Special tool
Handle (6EA needed) 5870 260 010
73073TM201
⑨ Separate housing cover along with

clutches from gearbox housing, using
lifting device.
※ Special tool
73073TM200
⑩ Fasten housing cover on assembly car.
73073TM045
⑪ Tilt housing cover 180˚.

Remove handles.
※ Special tool
73073TM046
3-78
⑫ Remove K2 clutch.
73073TM047
⑬ Remove K1 clutch, at the same time, lift

K4 clutch.
73073TM048
⑭ Lift K3 clutch out of the housing cover.
73073TM049
⑮ Remove K4 clutch, at the same time lift

input slightly.
73073TM050
3-79
16 Separate KV and KR clutches together
with input from the housing cover.
73073TM051
17 Remove bearing outer race and pull

output shaft (power take-off) out of the
housing bore.
73073TM180
18 Squeeze rectangular ring (arrow) out and

separate ball bearing from shaft.
73073TM179
※ If contrary to the recommendation, the

tapered roller bearings of the clutches as
well as of the input and output would not
be renewed, the allocation of the inner
and outer races to the single assemblies
must at least be maintained.
※ Mark bearing inner and outer races
accordingly.
3-80
(8) Disassemble KV and KR clutch
※ The following figures show the
disassembly of the KV clutch.
The disassembly of the KR clutch is
analogous.
① Squeeze rectangular ring (arrow) out.
73073TM54
② Pull tapered roller bearing from the shaft.

Demount opposite tapered roller bearing
accordingly.
※ Special tool
Grab sleeve 5873 001 057
Basic set 5873 001 000
73073TM55
③ Separate plate carrier from shaft.

※ Special tool
Hammer 5870 280 004
73073TM56
④ Squeeze snap ring out and remove plate

pack.
73073TM57
3-81
⑤ Preload compression spring, squeeze
circlip out and remove components.
※ Special tool
Set of external pliers 5870 900 015
73073TM58
⑥ Lift piston by means of compressed air

out of the cylinder bore and remove it.
73073TM59
⑦ Remove both O-rings.
73073TM60
⑧ Squeeze inner circlip(Shaft) out.

※ Special tool
73073TM61
3-82
⑨ Locate idler gear by means of separating
device (see on the right figure) and press
it from the shaft (see on the below figure).
Remove released needle bearing.
※ Special tool
Separating device 5870 300 028
73073TM62
73073TM63
⑩ Squeeze circlip out and remove ball

bearing.
※ The disassembly of the KR clutch has to
be carried out accordingly.
※ Special tool
73073TM64
(9) Disassemble K1, K2 and K3 clutch

※ T h e fo l l o w i n g F i g u r e s s h o w t h e
disassembly of the K3 clutch.
The disassembly of the K1 and K2
clutches is analogous.
① Squeeze rectangular ring (arrow) out.
73073TM65
3-83
② Pull tapered roller bearing from the shaft.
Remove opposite tapered roller bearing
accordingly, see Figure ① , ②.
※ Special tool
(K3 on output side)
Basic set 5873 001 000
73073TM66
③ Remove running disk, axial needle cage

and axial washer.
73073TM67
④ Remove idler gear.
73073TM68
⑤ Remove both needle bearings as well as

axial bearing.
73073TM69
3-84
⑥ Squeeze snap ring out and remove plate
pack.
73073TM70
⑦ Preload compression spring, squeeze

※ Special tool
Assembly aid (K2 and K3) 5870 345 085
Assembly aid (K1) 5870 345 086
73073TM71
⑧ Press piston out of the plate carrier,

using compressed air.
73073TM72
⑨ Pry plate carrier from the shaft.

※ Special tool
Pry bar 5870 345 065
73073TM73
3-85
(10) Disassemble K4 clutch
① Squeeze rectangular ring out and pull
tapered roller bearing from the shaft.
Remove opposite tapered roller bearing
accordingly.
※ Special tool
Basic set 5873 001 000
73073TM74
② Squeeze circlip out and separate plate

carrier from the shaft.
※ Special tool
73073TM75
③ Squeeze snap ring out and demount

plate pack.
73073TM76
④ Preload compression spring, squeeze

Demount piston.
※ The separation of shaft and gear is not
possible (shrink fit).
※ Special tool
73073TM77
3-86
(11) Disassemble input shaft
① If necessary, press turbine shaft out of
the input shaft.
※ The turbine shaft is axially fixed by
means of a snap ring which will be
destroyed at the pressing out.
73073TM78
② Squeeze rectangular ring out and pull off

the tapered roller bearing.
Pull off the opposite tapered roller
bearing.
※ The separation of input shaft 1 and gear
2 is not possible (shrink fit).
※ Special tool
Basic set 5873 001 000
73073TM79
3-87
2) ASSEMBLY
※ If contrary to the recommendation, the
tapered roller bearings of the clutches as
well as of the input and output would not
be renewed, the allocation of the inner
and outer races to the single assemblies
must at least be maintained.
(1) Mount oil pipes
※ To ensure the correct assembly of the oil
pipes, the use of the specified special tool
is imperative. 73073TM090
① Install studs (arrows).

※ Insert studs with Loctite.
② Place distance tubes over the studs.
73073TM091
③ Insert suction tube 1, pressure pipe 2

and pressure pipe lubrication 3 into the
housing bores.
Fasten suction tube 1 and pressure pipes
2 provisionally by means of socket head
screw and hexagon nuts.
73073TM092
3-88
④ Locate both pressure pipes by means of
special device.
※ Special tool
Tension bar 5870 654 030
73073TM093
⑤ Tilt housing 180˚.

Roll in suction tubes as well as pressure
pipes (arrows) into the housing bores,
using special tool.
※ Pipe end of pressure pipes (arrows) must
be slightly below the housing plane face,
if necessary equalize.
※ Special tool
Rolling tool 5870 600 003
Rolling tool 5870 600 004 73073TM094
⑤ Tilt housing 180。.

Check installation position of the two
pressure pipes and correct if necessary.
※ Pipes must be located in the special
device without play and pressure.
Now, remove special device.
※ Special tool
Tension bar 5870 654 030
73073TM095
⑥ Equip screw plug with new O-ring and

install it.
73073TM096
3-89
⑦ Insert all bearing outer races into the
housing bore.
※ In the case that already run bearings are
reused, pay attention to the allocation of
the bearing outer races, see also Note,
page 3-101.
※ Pay attention to the corresponding
markings.
73073TM097
⑧ Insert both oil pipes (arrows) into the

housing cover, tilt housing cover 180。
and roll in oil pipes into the housing
bores.
※ The pipe end must be situated slightly
below the housing plane face.
※ Special tool
73073TM098
⑨ Install studs (M8×25, 27EA) according

to the figure on the right.
73073TM099
⑩ Insert set screws (2EA) into the housing

bores (arrows).
73073TM099A
3-90
Assemble
ssemble KV and KR clutch
The following figures describe the
assembly of the KV clutch.
Pre-assemble plate carrier (Figure ⑪~⑭)
⑪ Check function of the drain valve.
※ Ball may not seize, if necessary clean by
means if compressed air.
Insert both O-rings (arrows) scroll free
into the recesses of the piston and oil
them. 73073TM100
⑫ Assemble piston until contact is obtained.

※ Pay attention to the installation position,
see on the right figure.
73073TM101
⑬ Introduce compression spring along with

spring cup (2EA).
73073TM102
⑭ Preload compression spring and fix it by

means of circlip.
※ Special tool
73073TM103
3-91
KV, KR plate pack
※ The plate equipment, respectively
stacking of KV and KR clutch is identical.
The following draft shows the installation +0.2
2.5 mm
position of the components.
1 Plate carrier 1 3 5 3 6
2 Piston
3 Outer plate-one-sided coated
4 Inner plates
5 Outer plates-coated on both sides
6 Snap ring(Optional s = 2.1~4.2 mm)
7 End shim
※ Install outer plate 3 with the uncoated
side facing the piston, respectively the 4
end shim. 2 7
Install on the end shim side two outer
and inner plates each.
·Effective number of friction surfaces =18.
73033TM13
⑮ Adjust plate clearance = 2.5+0.2 mm.

※ For the adjustment of the plate clearance
there are snap rings of different thickness
available.
To ensure a faultless measuring result,
install plates for the moment without oil.
※ Introduce plate pack according to the
upper draft.
73073TM105
3-92
16 Mount end shim and squeeze snap ring
(e.g. s = 3.0 mm) in.
73073TM106
17Press end shim on with about 10kg and

measure DimensionⅠfrom the end face/
plate carrier to the end shim.
Dimension Ⅰ e.g. 7.25 mm
※ Special tool
Digital-Depth gauge 5870 200 072
73073TM107
18Press end shim against snap ring

(upward) until contact is obtained and
determine Dimension Ⅱ.
Dimension Ⅱ e.g. 4.75 mm
※ Special tool
73073TM108
EXAMPLE
Dimension Ⅰ 7.25 mm
Dimension Ⅱ - 4.75 mm
Difference = Plate clearance = 2.50 mm
※ In case of deviations from the required
plate clearance, correct by means of
corresponding snap ring (s = 2.1~4.2
mm).
Now, remove plate pack, oil and install it
again.
3-93
19Introduce idler gear until all inner plates
are accommodated.
※ This step makes the later assembling of
the idler gear easier.
Now, remove idler gear again.
73073TM109
20 Install stud (arrow).

※ Use Loctite.
73073TM110
21 Inser t ball bearing until contact is

obtained and fix it by means of circlip.
73073TM111
22 Assemble needle bearing.
73073TM112
3-94
23Press idler gear against shoulder.
※ Support it on the bearing inner race.
73073TM113
24 Fix idler gear axially by means of circlip.

※ At KR clutch there is no recess in the
shaft-assemble circlip until contact on the
bearing inner race is obtained.
※ Special tool
73073TM114
25Assemble pre-assembled plate carrier

until contact is obtained.
※ Only if the plate carrier plane face is
overlapping with the shaft collar, the
accommodation of all inner plates is
ensured, see on the below figure.
73073TM115
73073TM116
3-95
26 Press tapered roller bearing against
shoulder.
Install opposite tapered roller bearing.
73073TM117
27Check function of clutch by means of

compressed air.
※ At correctly installed components, the
closing, respectively opening of the
clutch is clearly audible.
73073TM118
(2) Assemble K1, K2 and K3 clutch

assemble of the K3 clutch.
The assembly of the K1 and K2 clutches
has to be carried out accordingly.
① Install stud (arrow).
※ Use Loctite.
73073TM125
② Assemble plate carrier until contact is

obtained.
73073TM126
3-96
③ Check function of the drain valve.
means of compressed air.
Insert both O-rings (Arrows) scroll free
into the piston recesses and oil them.
73073TM127
④ Introduce piston until contact is obtained.

73073TM128
⑤ Introduce compression spring along with

spring cup (2EA).
73073TM129
⑥ Preload compression spring and fix it by

means of circlip.
※ Special tool
Assembly aid (K2 and K3) 5870 345 085
Assembly aid (K1) 5870 345 086
73073TM130
3-97
K1, K2 and K3 plate pack
※ The K1, K2 and K3 plate stacking of
clutches are identical.
The following draft shows the installation 2.1
+0.2
mm
position of the components.
1 Plate carrier 1 3 5 6
2 Piston
4 Inner plates
6 Snap ring (optional s = 2.1~4.2 mm)
7 End shim
※ Install outer plate 3 with the uncoated
side facing the piston. 4
·Effective number of the friction surfaces 2 7
= 14.
73033TM15
⑦ Adjust plate clearance = 2.1+0.2 mm :

※ For the plate clearance adjustment there
are snap rings of different thickness
available.
install the plates for the moment without
oil.
※ Introduce plate pack according to the
upper draft.
73073TM135
⑧ Fit end shim and squeeze snap ring (e.g.

3.0 mm) in.
73073TM136
3-98
⑨ Press end shim on with about 10 kg, and
DimensionⅠ e.g. 8.20 mm
※ Special tool
73073TM137
⑩ Press end shim against snap

ring(Upward) until contact is obtained,
and determine DimensionⅡ.
DimensionⅡ e.g. 6.00 mm
※ Special tool
73073TM138
EXAMPLE :
DimensionⅡ e.g. - 6.00 mm
Difference = Plate clearance = 2.20 mm
corresponding snap ring (S =2.1~4.2 mm).
※ Now, demount plate pack, oil and install it
again.
⑪ Assemble running disk 1(50×70×4),

axial needle cage 2 and axial washer 3
(50×70×1).
※ Install running disk 1 with the chamfer
facing the axial needle cage.
73073TM139
3-99
⑫ Assemble both needle bearings.
73073TM140
⑬ Introduce idler gear until all inner plates

are accommodated.
73073TM141
⑭ Assemble axial washer 3 (50×70×1),

axial needle cage 2 and running disk 1
(50×70×4).
facing the axial needle cage.
※ Only if the running disk is overlapping
with the shaft collar, the accommodation
of all inner plates is ensured.
73073TM142
⑮ Press tapered roller bearing against

shoulder.
73073TM143
3-100
shoulder.
73073TM144
17Check function of the clutch by means of

compressed air.
73073TM145
(3) Assemble K4 clutch

① Undercool shaft (about -80 ˚C), heat gear
(about +120˚C) and assemble it until
73073TM150
② Locate gear axially by means of circlip.

※ Special tool
73073TM151
3-101
③ Install stud (arrow).
※ Use Loctite.
73073TM152
④ Check function of the drain valve.

means of compressed air.
Insert both O-rings (arrows) scroll free
into the piston recesses and oil them.
73073TM153
⑤ Introduce piston until contact is obtained.

73073TM154
⑥ Install compression spring and spring

cup (2EA), preload and fix by means of
circlip.
※ Special tool
73073TM155
3-102
K4 plate pack
The following draft shows the installation
+0.2
position of the components. 1.2 mm

1 Plate carrier
1 3 5 6
2 Piston
4 Inner plates
6 Snap ring (optional s = 2.1~4.2 mm) 7
7 End shim
※ Install outer plate 3 with the uncoated side
facing the piston. 4
·Effective number of friction surfaces = 2
10.
73033TM16
⑦ Adjust plate clearance = 1.2+0.2 mm :

※ For the plate clearance adjustment there
are snap rings of different thickness
available.
install the plates for the moment without
oil.
Introduce plate pack according to the
draft (see the preceding page).
73073TM160
⑧ Fit end shim and squeeze circlip (e.g. s

= 3.0 mm) in.
73073TM161
3-103
⑨ Press end shim on with about 10kg and
※ Special tool
73073TM162
⑩ Press end shim against snap ring

(Upward) until contact is obtained and
determine Dimension Ⅱ.
Dimension Ⅱ e.g. 6.00 mm
※ Special tool
73073TM163
EXAMPLE
DimensionⅡ e.g. - 6.00 mm
Difference = Plate clearance =1.20 mm
corresponding snap ring (s = 2.1~4.2 mm).
⑪ Introduce idler gear until all inner plates
are accommodated.
※ This step makes the later assembling of
the idler gear easier.
Now, remove idler gear again.
73073TM164
3-104
⑫ Assemble both axial washers as well as
needle cage.
※ Upper and lower axial washer have the
same thickness (50×70×1).
73073TM165
⑬ Assemble both needle bearings.
73073TM166
⑭ Assemble idler gear.
73073TM167
⑮ Assemble axial washer 3 (50×70×1)

needle cage 2 and running disk
1(50×70×4).
facing the needle cage.
73073TM168
3-105
16 Assemble pre-assembled plate carrier
until all inner plates are accommodated.
73073TM169
17Fix plate carrier axially by means of

circlip.
※ Special tool
Handle 5870 260 010
73073TM170

shoulder.
Install opposite tapered roller bearing.
73073TM171
19Check function of the clutch by means of

compressed air.
73073TM173
3-106
(4) Pre-assemble input shaft
① Undercool the input shaft (about -80˚C),
heat gear (about +120˚C) and assemble
it until contact is obtained.
73073TM174
② Fix gear axially by means of circlip.
73073TM175
③ Squeeze snap ring into the recess of the

turbine shaft.
73073TM176
④ Introduce turbine shaft until the snap ring

snaps into the recess of the input shaft-
turbine shaft is axially fixed.
73073TM177
3-107
⑤ Press both bearing inner races against
shoulder.
73073TM178
⑥ Install ball bearing.

Squeeze rectangular ring(Arrow) in and
hook it in.
73073TM179
⑦ Insert output shaft into the housing bore

until contact is obtained.
73073TM180
3-108
(5) Install pre-assembled output shaft and
clutches
common installation of all clutches.
For it, the housing cover, combined with
special tool is needed.
The assembly of single clutches without
housing cover and handles is extremely
difficult because of the installation
conditions.
Besides, there is the danger of injury.
① Insert all bearing outer races into the

housing cover until contact is obtained.
※ In the case that already run bearings are
reused, pay attention to the allocation of
the bearing outer races, see also Note,
page 3-101.
73073TM190
② Insert KR clutch, input shaft and KV

clutch together into the housing cover.
73073TM191
③ Install K4 clutch.
73073TM192
3-109
④ Install K3 clutch.
73073TM193
⑤ Position K1 clutch.
73073TM194
⑥ Insert K2 clutch.
73073TM195
⑦ Figure on the right shows the installation

position of the single clutches in the
housing cover.
73073TM196
3-110
⑧ Locate all clutches by means of handles.
※ Special tool
73073TM197
⑨ Squeeze rectangular rings (7 pieces, see

Arrows) in and hook them in.
Now, grease rectangular rings and align
them centrically.
73073TM198
⑩ Tilt housing cover 180˚.

Mount eye bolts, see Arrows.
※ Special tool
Eye bolt M20 (2EA) 0636 804 003
Eye bolt M16 (1EA) 0636 804 001
Puller device 5870 000 017
73073TM199
⑪ Install adjusting screws.

Position housing cover by means of lifting
device carefully on the gearbox housing
until contact is obtained, respectively
position the clutches in the gearbox
housing.
※ Pay attention to the overlapping of the oil
pipes with the bores in the housing cover.
※ Special tool
Lifting chain 5870 281 047 73073TM200
3-111
⑫ Remove handles again.
※ Special tool
73073TM201
⑬ Separate housing cover from gearbox

housing, using lifting device.
※ Special tool
73073TM202
(6) Output
① Assemble sheet and press both bearing
inner races against shoulder until contact
is obtained.
73073TM203
② Insert bearing outer race (arrow) into the

housing bore until contact is obtained.
73073TM204
3-112
③ Position screening plate.
73073TM205
④ Insert output shaft.
73073TM206
⑤ Fasten both sheets by means of socket

head screws (4EA).
※ Insert socket head screws with Loctite.
73073TM207
⑥ Squeeze rectangular rings (6EA) into the

recesses of the clutch shafts and hook
them in.
Now, grease rectangular rings and align
them centrically.
73073TM208
3-113
⑦ Insert both O-rings (arrows) into the
annular groove of the oil pipes and
grease them.
73073TM209
⑧ Cover mounting face with sealing

compound Loctite.
Install adjusting screws (S) and position
housing cover carefully against gearbox
housing until contact is obtained, using
lifting device.
※ Pay attention to the overlapping of the oil
pipe with the bores in the housing cover.
※ Special tool
Adjusting screws 5870 204 007 73073TM210
⑨ Install both cylindrical pins.
73073TM211
⑩ Fasten housing cover by means of

hexagon head screws.
※ Pay attention to the position of the fixing
plate, see Arrow.
73073TM212
3-114
⑪ Install shaft seal, with the sealing lip
facing the oil chamber.
※ By application of the prescribed driver,
the exact installation position is obtained.
Wet rubber-coated outer diameter with
spirit.
Grease sealing lip.
※ Special tool
Driver 5870 048 057
73073TM213
⑫ Heat the output flange (maximum 90˚C),

assemble it and fix it by means of washer
and hexagon head screws.
※ Wet contact area of washer with sealing
compound Loctite.
73073TM214
⑬ Fix hexagon head screws by means of

lock plate.
Install output flange on the converter side
accordingly (figure ⑪~⑬).
※ Special tool
Driver 5870 057 011
Handle 5870 260 002
73073TM215
(7) Converter pressure valve

① The illustration on the right shows the
components of the converter pressure
valve.
1 Piston
2 Compression spring
3 Valve insert
4 Roll pin
73073TM220
3-115
② Introduce compression spring and
piston, preload and fix them by means of
※ roll pin.
Special tool
Assembly aid 5870 345
084
73073TM221
③ Insert pre-assembled converter pressure

valve into the housing bore.
73073TM222
(8) Oil feed housing-Transmission pump

① Install two adjusting screws (arrows) and
mount flat gasket.
※ Special tool
73073TM223
② Mount oil feed housing and fix it

provisionally by means of washers and
※ Screw the hexagon head screws in only
until contact is obtained-do not tighten.
73073TM224
3-116
③ Install two adjusting screws and
introduce stator shaft until contact is
obtained.
※ Pay attention to the overlapping of the
bores.
※ Special tool
73073TM225
④ Install O-ring (arrow) and oil it.
73073TM226
⑤ Introduce transmission pump until

※ Pay attention to the overlapping of the
bores.
73073TM227
⑥ Equip socket head screws with new

O-rings (arrow).
※ Grease O-rings.
73073TM228
3-117
⑦ Fasten transmission pump by means of
socket head screws.
73073TM229
⑧ Fix oil feed housing finally by means of

hexagon head screws (mount flat
washers).
the fixing plate (arrow), see the next
figure.
73073TM230
73073TM231
⑨ Fit flat gasket and fasten cover by means

of hexagon head screws.
73073TM232
3-118
(9) Engine connection-Converter
① Fasten converter housing by means of
73073TM233
② Fasten input shaft, membrane and disk

by means of hexagon head screws.
73073TM234
③ Fasten membrane on the converter,

using hexagon head screws(Mount flat
washers).
※ Insert hexagon head screws with Loctite.
73073TM235
④ Introduce converter until contact is

obtained.
※ Impulse disk of the converter must be
centrally to the bore of the inductive
transmitter, see on the below figure.
Only in this way it is ensured that the
c o n ve r t e r h a s b e e n c o m p l e t e l y
introduced.
73073TM236
3-119
73073TM237
⑤ Inser t ball bearing until contact is

obtained and fix it by means of circlip.
※ Special tool
73073TM238
⑥ Assemble housing cover.

Install input flange, fit disk and pull cover
by means of hexagon head screws
evenly against shoulder.
※ Pay attention to the radial installation
position of the cover.
73073TM239
⑦ Fasten cover by means of hexagon head

screws and nuts on the conver ter
housing.
73073TM240
3-120
⑧ Fasten input flange finally and fix
hexagon head screws by means of lock
plate.
※ Special tool
Driver 5870 057 010
Handle 5870 260 002
73073TM241
(10) Converter safety valve

components of the converter safety
valve.
1 Plate
2 Ball
3 Compression spring
4 Valve insert
5 Valve sleeve
6 Cylindrical pin 73073TM245
② Assemble components according to

figure ①, preload and fix by means of
cylindrical pin.
※ Special tool
73073TM246
③ Insert converter safety valve into the

housing bore until contact is obtained.
73073TM247
3-121
(11) Fit duct plate
① Install both screw plugs (arrows),
※ Install new sealing rings.
73073TM248
② Install gasket, place duct plate against

shoulder and fasten it by means of
socket head screws and hexagon nuts
(mount flat washers).
73073TM249
(12) Fit hydraulic control unit

① Install two adjusting screws.
Mount gasket 1, intermediate plate 2 and
gasket 3.
the different gaskets, see also the
following draft.
※ Special tool
73073TM250
3
2
1
3-135(4) (740-7)
3-122
② Fasten complete control unit on the duct
plate, using socket head screws.
73073TM251
(13) Filter
components of the filter unit.
※ Install new O-rings (arrows)
73073TM252
② Fasten intermediate plate and filter head

by means of hexagon head screws
(mount flat washers).
73073TM253
③ Oil gasket and tighten exchange filter

hand-tight.
73073TM254
3-123
④ If necessary, install warning switch
(according to the version).
73073TM255
⑤ Insert O-ring (arrow) into the annular

groove of the oil feed covers.
73073TM256
⑥ Fasten the two covers (arrows) by means

of hexagon nuts (mount flat washers) on
the housing.
73073TM257
⑦ Mount oil level tube.

Install screw plug (arrow).
※ Install new gaskets.
·Torque limit (screw plug M26×1.5) :
8.16 kgf·m (59.0 lbf·ft)
73073TM258
3-124
(14) Speed sensor and inductive transmitter
① Grease O-ring, introduce speed sensor
(arrow) and fasten it by means of socket
head screw.
34 Speed-output and -speedometer
73073TM259
② Equip the inductive transmitters with new

O-rings and install them.
48 Speed-engine
47 Speed-central gear train
21 Speed-turbine
Install breather (arrow).
73073TM260
③ Install gasket and cover plate, arrow 1.

Equip screw plug (arrow 2) with new
O-ring and install it.
73073TM261
3-125
3. AXLE
1) SERVICE BRAKE DISASSEMBLY
7
1 8
3
44
2
5
6
9
10
11
12
12
13
13
14
7409RAX001
(1) Sling the arm to be removed and connect

it to a hoist.
Loosen and remove screws.
7409RAX002
(2) Note down their order of assembly and

remove the counterwasher (1). 1
7409RAX003
3-126
Down Side
7409RAX004
7409RAX005
(3) Remove braking discs (2)(3), noting down

direction of assembly.
※ If disks are not to be replaced, avoid 2
changing their position.
7409RAX006
(4) Remove the flange (4) complete with the

discs.
4
7409RAX007
3-127
(5) Noting down direction of assembly.
7409RAX008
(6) Remove braking discs, noting down

direction of assembly.
※ If disks are not to be replaced, avoid
7409RAX009
(7) Remove the reversal springs (7)
7409RAX010
reversal springs
7409RAX011
3-128
(8) Remove the adjusting screws (5)
5
7409RAX012
adjusting screws
7409RAX013
(9) S l o w l y i n t r o d u c e l o w - p r e s s u r e
compressed air through the connection
member for the service brake (P1), in 9
order to extract the piston (9).
※ Hold the piston (9) back, as it may be
suddenly ejected and damaged.
7409RAX014
P1 = service brake
7409RAX015
3-129
2) SERVICE BRAKE ASSEMBLING
1.02~1.53 kgf·m
Loctite 242
0.51~0.71 kgf·m
Loctite 242
7409RAX016
(1) Insert the stroke automatic regulation

springs (6); place them in line with the 6
piston (9).
7409RAX017
(2) Fit O-ring (11)(12) and back-up ring (10)

(13) onto the piston (11).
Lubricate the piston and the O-rings and
install the unit into the arm (14).
7409RAX018
3-130
(3) Using a plastic hammer, ram the piston
(9) into the arm (14).
9
※ Lightly hammer all around the edge in an
alternate sequence.
14
7409RAX019
(4) Fit the reversal springs (7) on the piston

(9).
Apply loctite 242 to the thread of the
adjustment screw.
Tighten with torque wrench setting of
0.51~0.71 kgf·m (3.69~5.14 lbf·ft).
7409RAX020
(5) Fit the adjusting screws (5).

Apply loctite 270 to the thread.
·Torque wrench setting :
0.51~0.71 kgf·m (3.69~5.14 lbf·ft)
7409RAX021
reversal spring
adjusting screws
7409RAX022
3-131
(6) Inser t the brake discs in the right First disc
sequence.
※ The first brake disc (2) to be inserted must
be of metal material.
2
7409RAX023
※ The second brake disc (3) to be inserted Second disc

must be of friction material.
7409RAX024
Metallic disc
Clutch disc
Differential side Arm side
※ Number of discs can change.

7409RAX025
3-132
(7) Install the flange (4) on the arm.
7409RAX026
(8) Insert the brake discs (2)(3) in the right Last disc
sequence.
※ The last brake disc to be inserted must be
of friction material.
2 3
7409RAX027
(9) Insert the intermediate disk (1).
1
7409RAX028
7409RAX029
3-133
(10) Check integrity and position of the
cylinder’s O-ring.
7409RAX030
(11) Cross tighten the nuts in two stages.

20.4~22.5 kgf·m (148~163 lbf·ft)
7409RAX031
3-134
3) HOW TO DISASSEMBLE THE PLANETARY REDUCTION
2
3
21
1 4
5
6
20
19 9
18 17 7
16
8 10
14
11
15
24
12
26
13
22
23
29
25 28
27 30
31
7409RAX032
(1) Remove oil-level plug (30) and the oil.
30
7409RAX033
(2) Remove the locking screws (31) of

planetary cover (29).
31
29
7409RAX034
3-135
(3) Using two screwdrivers or two levers
inserted in the slots provided, pry the
planetary cover (29) away from the wheel
hub (10).
29
7409RAX035
(4) Remove the cover (29).
29
7409RAX036
(5) Remove the axle half shaft (4).
7409RAX037
(6) Remove the safety spring rings (16) of the

16
planetary gears (14).
14
7409RAX038
3-136
(7) Remove the planetary gears (14).
14
7409RAX039
※ Note down direction of assembly of

planetary gears.
Down
7409RAX040
(8) Check the wear of the shim washer (28) .
28
7409RAX041
(9) Accurately check the O-ring (22).
22
7409RAX042
3-137
(10) Loosen the nuts (27) and remove them.
27
7409RAX043
(11) Remove the safety flange (26).
26
7409RAX044
(12) Using an extractor and applying a counter

pressure to the screws (25), disengage
the crown wheel (23) from the hub (10).
23
7409RAX045
(13) Remove the crown (23).
23
7409RAX046
3-138
(14) With the help of a hammer, shift the hub
(10) and the external bearing (13).
13
10
7409RAX047
(15) Extract the external bearing (13).
13
7409RAX048
(16) Using an extractor and applying a counter

pressure to the screws disengage the hub 10
(10).
7409RAX049
(17) Remove the internal bearing (8) and the

hub (10).
10
7409RAX050
3-139
(18) Remove the seal ring (7) from the hub
(10).
※ Note down direction of assembly.
※ The seal ring may not be reused.
7
10
7409RAX051
(19) Remove the internal bearing (8) and

sealing ring (7).
7
10
7409RAX052
(20) Remove the external thrust blocks of

bearings, using a pindriver.
※ Hammer in an alternate sequence to
prevent crawling and deformation of the
thrust blocks.
7409RAX053
(21) Remove the external thrust blocks of

bearings, using a pindriver.
※ Hammer in an alternate sequence to
prevent crawling and deformation of the
thrust blocks.
7409RAX054
3-140
(22) Using an extractor, remove seal ring (5)
and guide ring(6).
※ Note down the direction of assembly of
snap ring.
7409RAX055
Sealing
Sealing Ring (5)
Ring (5)
Oil Side
Oil Side
Guide
Guide Ring (6)
Ring (6)
7409RAX056
3-141
4) A S S E M B L I N G T H E P L A N E TA RY
REDUCTION
33.7~39.3
330 - 385 Nmkgf·m
Loctite 242
Loctite 242
7409RAX057
(1) Lubricate and fit the seal ring (5) and

guide ring(6) onto tool T3; install the rings
into the arm.
5 T3
Lubricate
7409RAX058
※ Pay particular attention to the direction of

Sealing
Sealing Ring (5)
Ring (5)
assembly of the rings.
Oil Side
Oil Side
Guide Ring
Ring (6)
(6)
7409RAX059
3-142
(2) Position the lower part of tool T1 and the
thrust block of the external bearing (13).
13
T1
7409RAX060
(3) Lubricate the seats of the bearings and

position the hub (10) on tool T1; position
the thrust block of the internal bearing (8).
T1
※ Check that the thrust block is correctly 8
oriented.
10
7409RAX061
(4) Fit the bearing (8) and seal ring (7) into
the internal thrust block.
8 7
7409RAX062
(5) Using special tool apply a repositionable

jointing compound for seals to the outer
surface of the sealing ring (7). Position the
sealing ring (7) in the hub (10).
※ Check that the ring (7) is correctly
oriented.
7409RAX063
3-143
(6) Install the wheel hub.
13
7409RAX064
(7) Install the external bearing (13).

※ Move the bearing to the limit stop by
hammering lightly all around the edge.
13
7409RAX065
(8) Install the crown wheel (23). 23
7409RAX066
(9) Fit the complete crown flange (23).

※ In order to fasten the flange (23), use a
plastic hammer and alternately hammer
on several equidistant points.
23
7409RAX067
3-144
(10) Install the security flange (26).
Using grease the surface of the safety
flange (26) that touches the crown wheel.
7409RAX068
(11) Coat the nuts (27) with loctite 242 and

screw them.
Tighten nuts (27) in two stages, using the 27
criss-cross method.
·Initial torque wrench setting :
33.7 kgf·m (244 lbf·ft)
·Final torque wrench setting :
39.3 kgf·m (284 lbf·ft)
7409RAX069
※ Check the condition and position of the

O-ring (12).
12
7409RAX070
(12) Fit shim washer (28) into spider cover

(29).
28
7409RAX071
3-145
(13) Insert the planet wheel gears (14) into the
cover (29).
16
Lock gears (14) into position by installing
the snap rings.
14
7409RAX072
(14) Accurately check the orientation.
Down
7409RAX073
(15) Fit the planetary carrier cover onto the

hub.
※ Check that the O-ring is in good condition
and in position.
7409RAX074
(16) Lock the planetary carrier cover by

tightening the screws.
·Torque wrench setting for screws :
3.57~5.1 kgf·m (25.8~36.9 lbf·ft)
31
7409RAX075
3-146
5) HOW TO REMOVE AND DISASSEMBLE THE DIFFERENTIAL UNIT
1 2
3 4
7
8 9
5 10
19
39 6 17 20
18
38
22
12
40 24
13
14
28 29 30 15 21
41
23
27
37
25 26
31
32
33
34
36
35 7409RAX076

it to a hoist.
Loosen and remove screws and nuts.
7409RAX077
(2) Only if need removing or adjusting.

Remove the screw (27).
7409RAX078
3-147
(3) Only if need removing or adjusting. 80˚C
Uniformly heat the ring nuts up to a
temperature of 80˚C.
7409RAX079
(4) Only if need removing or adjusting.

Using special tool T4 mark the position of
the ring nuts (2) (26).
2 26
T4
7409RAX080
(5) Loose he stud bolts (35)(41) and remove

two of them.
7409RAX081
(6) Disjoin the cover (38)(33) crown side.
38 33
7409RAX082
3-148
(7) Remove the cover and studs.
7409RAX083
(8) Extract the whole differential unit.
7409RAX084
(9) Remove the snap ring (30).
13
7409RAX085
(10) Remove the cap (29).
29
7409RAX086
3-149
(11) If the bearings need replacing, extract the 3 25
external thrust blocks of the bearings (3)
and (25) from middle cover (33)(38).
※ Accurately check the O-ring (37)(36).
33 38
O-ring 37 36
7409RAX087
(12) If the bearing need replacing, extract the

bearing (3). 3
7409RAX088
(13) If the bearing need replacing, extract the

bearing (25) from the differential carrier
(23).
25
23
7409RAX089
(14) Remove the fitting screws (4) of the crown

(6).
7409RAX090
3-150
(15) Remove the spacer (42) and the crown
4
(6).
7409RAX091
(16) Remove the screws (24) jointing the

differential unit half box .
24
7409RAX092
(17) Using a plastic hammer, take the half box

(23)(5) to pieces.
※ Note down the coupling marks.
23
7409RAX093
(18) Remove the upper half box (23).

23
7409RAX094
3-151
(19) Remove shoulder (22) and first planetary
gear (21). 22
21
7409RAX095
(20) Remove shafts (18), complete with planet

19 15
wheels (15)(19) and spherical shoulder
washers (14)(20). 18
14 20
7409RAX096
(21) Remove shafts (17), complete with planet

wheels (10)(12) and spherical shoulder 17
washers (9)(13).
10 12
9 13
7409RAX097
(22) Remove the 2nd planetary gear (8) and

shoulder ring (7).
8
7409RAX098
3-152
(23) The differential unit.
Sh = shafts (18)(17)
5
SW = spherical shoulder washers (9)(13)
(14)(20)
P = planetary gears (8)(21) 23
SR = shoulder ring (22)(7) P
23 = upper half box

SR
5 = half box crown side SH
S = planet wheels (10)(12)(15)(19) S SW
7409RAX099
3-153
6) HOW TO ASSEMBLE AND INSTALL
THE DIFFERENTIAL UNIT
7409RAX100
(1) Install the shoulder ring (7) and planetary

gear (8) into the halfbox (5).
7409RAX101
(2) Install the planetary gears (10)(12) and

spherical shoulder washers (9)(13) onto 17
the shafts (17).
Install the planetary set.
10 12
9 13
7409RAX102
3-154
(3) Install the planetary gears (15)(19) and
spherical shoulder washers (14)(20) onto
the shafts (18). 18
Install the planetary set.
15 19 14 20
7409RAX103
(4) Install the planetary gear (21) and 22

shoulder ring (22).
21
7409RAX104
(5) Mount the locking half-box (5) onto the

23
half-box (23)
7409RAX105
(6) Lock the half box with screws (24) coated Loctite 270
with loctite 270.
※ 1. The match marks on the two half-
boxes must correspond. 24
2. Use only new screws.
7409RAX106
3-155
(7) Fit the complete differential unit in a vice
and tighten the screws (24) holding the
two half boxes together to a torque of 8.16
24
kgf·m (59 lbf·ft).
※ Tighten screws using the alternate and
criss-cross method.
7409RAX107
(8) Install the spacer (4) and the crown (6).

4
7409RAX108
(9) Mount the gear ring (6) and fasten it to the Loctite 270
differential box with screws (4).
※ Use only new screws.
7409RAX109
(10) Lock the gear ring (6) by tightening the

screws (4) to a torque of 15.3 kgf·m (111
lbf·ft).
※ Use the alter nate and criss-cross
tightening method.
7409RAX110
3-156
Installation of the differential unit
(11) Position the differential unit under a press 100˚
and, using a driver with an adequate
diameter, install the first bearing (3).
3
7409RAX111
(12) Turn the unit upside down and install the

100˚
second bearing (25).
※ Pay particular attention; position a shim
with adequate diameter in order to 25
engage the internal ring of bearing

without engaging the cage.
7409RAX112
(13) Only if bearings are replaced.

Insert the thrust blocks of the bearings
into the intermediate covers.
7409RAX113
※ Thoroughly check the state of the O-ring

(36)(37).
36 37
7409RAX114
3-157
(14) Fit the intermediate cover (33) on
opposite side of ring gears : 35
lock cover with screws (35) coated with
loctite 242.
Tighten screws to a torque of 14.3 kgf·m
(103 lbf·ft). 28
33
7409RAX115
(15) Position the differential unit in the central

body with the help of a bar and fit the
middle cover.
7409RAX116
(16) Tighten the two safety screws “C” into the

main body (28) and install the 28
intermediate cover (38).
38
7409RAX117
(17) Tighten screws to a torque of 14.3 kgf·m

(103 lbf·ft).
7409RAX118
3-158
(18) Only if ring nuts have been removed. 1/4 turn
Tighten the ring nut (2) on gear ring side
until clearances between pinion and gear
ring are zeroed. Then, loosen by about
1/4 turn.
T4
2
7409RAX119
(19) Only if ring nuts have been removed.

Preload bearings with ring nut (26) on
non-gear ring side in order to increase the
torque of the pinion.
※ In the case of used bearings, check thrust
torque ; in the case of new bearings,
check continuous torque. T4
26
7409RAX120
(20) Apply torque meter TM to pinion nut and

check that torque will increase by
2 . 0 4 ~ 4 . 0 8 kgf·cm a s a r e s u l t o f
differential bearing preload.
·Example : pinion torque : TM
12.2~13.3 kgf·cm
·Pinion + differential torque :
14.3~17.3 kgf·cm
7409RAX121
(21) Introduce a comparator “A” with long

tracer through the hole provided for the
cap.
Position the tracer on the side of a tooth
of the gear ring, approximately 5 mm from
the outer rim; preload by about 1 mm and
zero the comparator.
A
7409RAX122
3-159
(22) As you hold the pinion in position, move Gap = 0.25 - 0.33 mm
the gear ring manually in both directions
to check clearance between pinion and
gear ring.
Standard clearance : 0.25 - 0.33 mm
7409RAX123
(23) If torque and/or pinion-gear ring clearance

is not within tolerance values and the ring
nuts have not been removed, mark the
position of the ring nuts (2)(26) and
remove the safety stops (1)(27).
1 27
2 26
7409RAX124
(24) Adjusting clearance between pinion and

gear ring.
To INCREASE: loosen the ring nut on
gear ring side and tighten the ring nut on
non-gear ring side by the same measure.
To DECREASE: perform the same
operations inversely.
To rotate ring nuts, use special wrench T4. T4
7409RAX125
(25) Engage screw (27) in the slot next to the

holes provided for the check screws.
Coat screws (27) with loctite 242 and
tighten to a torque of 2.45~2.65 kgf·m
(17.7~19.2 lbf·ft).
7409RAX126
3-160
(26) F i t t h e t o p p l u g a f t e r a p p l y i n g
repositionable jointing compound for seals
to the rims.
Install the snap ring.
7409RAX127
(27) Install the complete arm.
7409RAX128
(28) Torque wrench setting :

28.9~31.8 kgf·m (209~230 lbf·ft)
※ Tighten using the criss-cross method.
7409RAX129
3-161
7) DISASSEMBLY OF THE PINION
3
6
2
14
15
7
1
8
13
10 16
11
12
7409RAX130
(1) Remove both axle arms.
7409RAX131
(2) If disassembly is awkward, heat the check

nut (1) of the flange (10) at 80˚C.
※ Heating is meant to unloose the setting of 1
loctite on the nut (1). 10
7409RAX132
3-162
(3) Position tool T12, so as to avoid pinion
rotation.
Unloose and remove the nut (1); also
remove the O-ring (11).
T12
7409RAX133
10
11 10
7409RAX134
(4) Remove the flange (10) complete with

guard (2).
10
7409RAX135
(5) Remove the sealing ring (9).
9
7409RAX136
3-163
(6) Apply blocks T15 and, with the help of a
puller, extract the pinion (5) complete with
the internal bearing (6), the distance piece T15
(8) and shims (4)(7).
※ The thrust blocks of the bearings remain
in the central body (12).
12
5
7409RAX137
(7) Refer and keep to the positions marked

during disassembly.
7
8
4
6 5
7409RAX138
(8) Using a puller and a press, remove the

inner bearing (5) from the pinion (6).
7409RAX139
(9) Remove the thrust block of the external

bearing (3).
3
7409RAX140
3-164
(10) Insert a drift in the appropriate holes.
7409RAX141
(11) Remove the thrust block of the internal

6
bearing (6) as well as the shim washers
(4).
4
7409RAX142
(12) Remove the snap ring (15).
15
7409RAX143
(13) Remove the cap (14).
14
7409RAX144
3-165
8) ASSEMBLY OF THE PINION
D
I = 135 mm
S1
I = 178 mm S
S = 178 - ( I + D ) S = shims Ø 110 mm

S1 = shims Ø 50 mm
7409RAX145
Calculating pinion center distance

(1) Using a faceplate, reset a centesimal
comparator “DG” on a calibrated block
(whose known thickness is 42 mm).
Preload the comparator by about 3 mm.
42 mm
7409RAX146
(2) Bring inner bearing (6), complete with

thrust block, under comparator "DG".
※ Press the thrust block centrally and carry
out several measurements by rotating the
thrust block.
Example : 42 + 0.5 = 42.5 = "D".
7409RAX147
3-166
(3) Check nominal dimension “I” as marked
on the pinion. Add up to or subtract from
“I” the variation indicated as “Y” to obtain
the actual center distance “I”.
1 = 135
Example : I = 135 - 0.1 = 134.9
※ M5 = Match part number M5
-0.1=Y
7409RAX148
(4) Calculate shims “S” for insertion under the

thrust block of the inner bearing using the
following formula :
S = 178 - (I + D) where : 178 = fixed
dimension
I = actual pinion center distance
D = total bearing thickness ;
Example :
S = 178 - (134.9 + 42.5) = 0.6 mm.
7409RAX149
(5) Using special tool T10.

Partially insert the thrust block of the
bearings (3) (6) and shims (4) .
6
4
3
T10
7409RAX150
(6) Connect the tension rod to the press and

move the thrust block of bearings (3) (6)
into the seats.
Disconnect the press and remove the
tension rod.
※ Before starting the next stage, make sure
that the thrust block has been completely
inserted into its seat.
7409RAX151
3-167
Calculating pinion bearings rolling
torque
12
(7) Introduce tool T11 complete with bearings
(3) and (6) into the main body (12); tighten 6 3
by hand until a rolling torque is definitely
obtained.
T11
7409RAX152
(8) Introduce the tracer of a depth comparator

“DDG” into either side hole of tool T11.
Reset the comparator with a preload of
about 3 mm. A
DDG
A
T11
T11
7409RAX153
(9) Remove the comparator and take out tool

and bearing kits from the main body.
Reinstall every part, also introducing a 6
3
distance piece between bearings (3) and
(6). Tighten the entire pack by hand.
7409RAX154
(10) Introduce depth comparator “DDG” in tool

T11 and measure deviation “H” from the B
previous reset.
B
Example : H = A - B = 1.19 mm.
T11
7409RAX155
3-168
(11) Deviation “H” must be added to a set
value of 0.12~0.13 mm (X) to make up the
pack of shims “S1” (4) for insertion
between inner bearing (6) and distance
piece (8).
Dimension “S1” must be rounded off to
4
the higher 5/100.
Example : S1=H+X=1.19+(0.12~0.13)
=1.33~1.35 mm.
7409RAX156
(12) Heat the inner bearing (6) to about 100˚C

and fit it to the pinion (5).
※ Once the bearing has cooled down, lightly
lubricate bearing (6) with SAE 85W90 oil. 100˚C
5
7409RAX157
(13) Make sure that the bearing (6) is well set.
6
7409RAX158
(14) Refer and keep to the positions marked

during disassembly.
5
S1 4
3
2 6
1 7
8
9
S1 10
11
7409RAX159
3-169
(15) Fit the pinion (5), shim “S1” (7) and
distance piece (8) in the main body (12).
※ The finer shims must be placed in-
between the thicker ones.
5
12 8
7409RAX160
(16) Heat the external bearing (3) to a

temperature of about 100˚C and fi t it on
to the pinion (5) so as to complete the
pack as shown in the figure.
※ Lightly lubricate bearing (3) with SAE 3
85W90 oil.
7409RAX161
(17) Install the flange (10) onto the pinion (5)

without sealing ring.
5 10
7409RAX162
(18) Apply wrench to the ring nut (1) and bar-

hold T12 to the pinion (5).
Lock the wrench T12 and rotate the pinion
using a dynamometric wrench, up to a
minimum required torque setting of
81.6~102 kgf·m (590~738 lbf·ft)
T12
7409RAX163
3-170
(19) Apply onto the pinion (5) the bar-hold and
with the help of a torque meter, check the
torque of the pinion (5).
·Torque : 12.2~18.4 kgf·cm
※ If torque exceeds the maximum value,
then the size of shim “S1” (7) between the
bearing (6) and the distance piece (8)
needs to be increased.
If torque does not reach the set value,
7409RAX164
increase the torque setting of the ring nut
(1) in different stages to obtain a
maximum value of 81.6~102 kgf·m
(590~738 lbf·ft).
※ If torque does not reach the minimum
value, then the size of shim “S1” (7)
needs to be reduced.
※ When calculating the increase or
decrease in size of shim “S1”, bear in
mind that a variation of shim (4) of 0.01
mm corresponds to a variation of 6.12
kgf·cm in the torque of the pinion (5).
(20) Make positional marks across nut (1) and

pinion (5) tang ; then remove nut and
flange (10)
5
1
10
7409RAX165
(21) Apply Arexons rubber cement to the outer 12

surface of the new seal ring (9) and fit ring
in the main body (12) using driver T13.
9 T13
7409RAX166
3-171
(22) Fit the safety flange (2).
7409RAX167
(23) Oil seal ring lips and install flange (10). Loctite 242
Mount O-ring (11) and apply loctite 242 to
pinion tang; tighten nut (1).
10 11 1
7409RAX168
(24) Tighten the nut until the match marks

made at stage “a” line up.
T12
7409RAX169
3-172
9) D I S A S S E M B L E T H E S W I N G I N G
SUPPORT
Bushing cut positon
4
4
22
3
3
1
1
7409RAX170
(1) Remove the swinging support (3).
3
7409RAX171
(2) Remove the swinging support (3) on the

side opposite the drive.
3
7409RAX172
(3) Position the swinging support (3) under a

press and remove the complete bushing
(4).
7409RAX173
3-173
4
7409RAX174
(4) Remove the screws.
7409RAX175
(5) Disjoin the cover from the differential box

by alternatively forcing a screwdriver into
the appropriate slots.
7409RAX176

7409RAX177
3-174
10) ASSEMBLY THE SWINGING SUPPORT
7409RAX178
(1) Install the cover.
7409RAX179
(2) Lock the cover by tightening the screws.

Torque wrench setting for screws :
4.08~5.1 kgf·m (29.5~36.9 lbf·ft)
7409RAX180
※ If the bushing (4) is worn and needs

replacing, note down the assembly side of A
4
the connection notch "A".
reference direction A
7409RAX181
3-175
Bushing
Bushing cut position
cut positon
reference
direction A
7409RAX182
(3) Position the swinging support (3) under a

press and insert the complete bushing (4).
7409RAX183
(4) Install the swinging support (3). 3

※ Check that it is properly oriented.
7409RAX184
(5) Install the swinging support (4) on the side

opposite the drive.
7409RAX185
3-176
11) NEGATIVE BRAKE : ASSEMBLING NEGATIVE BRAKE DISKS
1
2
3 6
5
7
4 8
26
9 10
11
25 12
13
24 14
15
23 16
17
18
27 22 21 19
28 20
29
30
31
7409RAX186
Manual emergency release

(1) Loosen nuts (30) of screws (31) provided
for the mechanical and manual release of
the braking units, then move the nuts
backwards by approx. 8 mm.
25
29
26
30
27
31
7409RAX187
(2) Tighten screws (31) so as to fasten them

onto the pressure plate (23).
7409RAX188
3-177
(3) Using a wrench, tighten the screws (31) in
an alternate sequence by 1/4 turn at a
time so as to compress the belleville
washers (1) and disengage the braking
disks.
※ Tighten max. by one turn.
7409RAX189
Adjustment after manual release

(4) Remove screws complete with nuts and
seals.
Replace seals, apply grease to the screws
and install all parts into the arm.
7409RAX190
(5) Adjust screws (31) to obtain a jut of 30 ±

0.5 mm in relation to the arm.
7409RAX191
(6) Lock into position with nuts (30).

※ Hold screws (31) into position while
locking the nuts (30); after locking, check
the jut of screws (31) once more.
7409RAX192
3-178
11) NEGATIVE BRAKE : DISASSEMBLING
(1) Connect an external pump to the union
piece “P1” of the negative brake and
introduce a pressure of 21.4~35.7 kgf/cm2
(304~508 psi) to eliminate the pressure of
the belleville washers (1).
7409RAX193

it to a hoist.
Loosen and remove screws (31). 31
7409RAX194
(3) Remove arm together with brakes and

axle shafts; lay down the arm vertically.
Release pressure.
7409RAX195
(4) Remove the reversal springs (13)
13
7409RAX196
3-179
(5) Remove the adjusting screws (21) from
the counterwasher (23). 23
21
7409RAX197
(6) Note down their order of assembly and 23

remove the counterwasher (23).
Down
7409RAX198
(7) Loosen the studs in an alternate manner

and remove them.
7409RAX199
(8) Remove the cylinder (24). 24
7409RAX200
3-180
(9) Remove the centering device (26) in the
cylinder.
26
7409RAX201
(10) Remove the belleville washers (1).

※ Check the sense of direction of washers
(1).
1
7409RAX202
※ The O-rings (2) must be replaced each

time the unit is disassembled.
2
7409RAX203
member for the service brake (P2), in
Service Brake

7409RAX204
3-181
(12) Note down their order of assembly.
7409RAX205
member for the service brake (P1), in Down
3
7409RAX206
(14) Remove braking discs (14)(15)(16),

noting down direction of assembly.
※ If disks are not to be replaced, avoid
16
7409RAX207
(15) Remove the flange (17) complete with the

discs (20)(19)(18).
17
7409RAX208
3-182
14
15
16
17
18
19
20
7409RAX209
(16) Remove distance piece-braking discs (27)

and shims (28), noting down direction of 27
assembly.
※ Build a stack of washers and check the
measure.
28
7409RAX210
3-183
13) NEGATIVE BRAKE : ASSEMBLING SERVICE BRAKE AND SAHR
7409RAX211
SERVICE BRAKE
7409RAX212
Fix quote = 74.00 mm

Y = brake gap = 0.75 mm - 1.00 mm - 1.25 mm - 1.70 mm
(depending on axle confi guration)
X = intermediate disc distance example = 29.00 mm
V = brake discs pack example = 42.33 mm
S = adjust. shims = 74 mm - (x + y + v) =
example =
74-(29+1.25+42.33)
= 74-72.58
= 1.42 mm = S
7409RAX213
3-184
(1) Complete the O-rings and anti-extrusion
rings on all pistons.
※ The O-rings always have to be assembled
from the pressure facing side.
4
2
25
7409RAX214
(2) Check the position of the anti-extrusion (4)

3
and O-rings (2) (25).
install the unit (3) into the cylinder (24) .
Down
23
Down
7409RAX215

(3) into the cylinder (24).
※ Lightly hammer all around the edge in an 3
alternate sequence.
7409RAX216
(4) Fit O-ring (9) and anti-extrusion ring (10)

onto the piston (11). 24 11
install the unit into the cylinder (24).
7409RAX217
3-185
※ The O-rings always have to be assembled
from the pressure facing side.
11
Out
Out Sid
Side
10
9
7409RAX218

(11) into the cylinder (24).
11
※ Lightly hammer all around the edge in an
alternate sequence.
24
7409RAX219
(7) Position the belleville washers (1) and

engage the cylinder (24).
※ Check the sense of direction of belleville 24
1
washers (1) and relative centering.
Grease
7409RAX220
(8) Install the centering device (26) in the

cylinder.
26
7409RAX221
3-186
7409RAX222

cylinder’s O-ring (2).
2
7409RAX223
(10) Engage the cylinder (24).

※ Check the sense of direction of washers
(1) and relative centering.
Down
24
7409RAX224
(11) Insert the screws and tighten them Loctite 242

alternately.
Lock the cylinder.
7409RAX225
3-187
(12) Tightening the studs with a dynamometric
wrench set to a torque of 3.06~3.57
kgf·m (22.1~25.8 lbf·ft).
7409RAX226
Oil filling
7409RAX227
(13) Connect an external pump to the negative

b ra ke a n d i n t r o d u c e p r e s s u r e t o
21.4~35.7 kgf/cm2 (304~508 psi).
7409RAX228
Negative brake
Service brake
7409RAX229
3-188
(14) Insert the stroke automatic regulation
springs (22); place them in line with the 22
piston (23).
23
7409RAX230
(15) Insert the intermediate disk (23).
23
7409RAX231
(16) Fit the reversal springs (12)(13) on the 12

intermediate disk (23).
13
23
7409RAX232
(17) Apply loctite 242 to the thread of the

adjustment screw.
Tighten with torque wrench setting of
1.02~1.53 kgf·m (7.38~11.1 lbf·ft).
7409RAX233
3-189
(18) Y=brake gap
(0.75 mm 1.00 mm 1.25 mm 1.50 mm)
Y
depending on axle configuration.
Y 21
Y = BRAKE
BRAKE GAP
7409RAX234
(19) Fit the pin screws.

Apply loctite 270 to the thread.
0.51~0.71 kgf·m (3.69~5.16 lbf·ft)
7409RAX235
(20) Take the measure from the surface of the

intermediate disk to the cover sealing X
surface with 30.6 kgf/cm 2 (435 psi) of
pressure introduced.
Example : 29 mm
X
7409RAX236
(21) Put the brake disc pack including the shim 1000 Kg
under a press, load with 1000 kg and take V
the measure "V".
Example : V = 42.33 mm
7409RAX237
3-190
(22) Arm fix quote = 74 mm
74 mm
Arm fix quote = 74 mm

7409RAX238
(23) S = 74 mm - ( x + y + v ) = Thickness of Y = brake gap

shims to insert under the shim washer.
S 28
Example :
74 mm - ( 29 + 42.33 + 1.25) = S = 1.42 mm
S = 74 mm - (x + y + v)
7409RAX239
(24) Insert under the shim washer a thickness

of shims (28).
S 28
7409RAX240
7409RAX241
3-191
Metallic Disc Clutch Disc
Differential side Armside

Arm side
7409RAX242
(25) Install the friction disc (18) on the flange 18

(17) from arm side.
17
First
First Disc
Disc
18
7409RAX245
7409RAX244
3-192
(26) Install the metal disc (19) on the flange
19
(17) from arm side. 17
2˚ Disc
19
7409RAX243
(27) Install the friction disc (18) on the flange

18 20
from arm side and insert the group on the
19
u-joint.
17 20
3˚ Disc
18
7409RAX246
(28) Insert on the fl ange the discs (16)(15) 16

(14).
4°4˚Disc
Disc
16
7409RAX247
5˚ Disc Last Disc
15 14
7409RAX248
3-193
(29) Check the alignment of last disc (14) and
flange.
7409RAX249
14 15 16 18 19 20
7409RAX250
(30) Apply loctite 242 to the studs and tighten it

using a dynamometric wrench.
·Torque
Torque wrench setting :
3.06~3.57 kgf·m (22.1~25.8 lbf·ft)
7409RAX251

7409RAX252
3-194
(32) Check integrity and position of the arm’s
O-ring; install the complete arm.
※ To assist axle shaft centering, slightly
move the wheel hub.
7409RAX253
(33) Apply loctite 242 to the nuts and cross

tighten it in two stages.
·Torque wrench setting : 1
20.4~22.5 kgf·m (148~163 lbf·ft)
7409RAX254
3-195

Group 2 Operational Checks and Troubleshooting -------------------------------------------------------- 4-21
Group 4 Disassembly and Assembly ------------------------------------------------------------------------------ 4-31
1. OUTLINE
※ The brakes are operated by a pressure compensated, closed center hydraulic system.
Flow is supplied by a fixed displacement, gear type brake pump.
BRAKE SYSTEM
The fixed displacement brake pump supplies flow to the cut-off valve for service brake circuit and
park brake circuits. It flows to three accumulator. The accumulator has a gas precharge and an inlet
check valve to maintain a pressurized volume of oil for reserve brake applications.
Oil through the accumulator flows to the brake valves. The brake valve is a closed center design,
dual circuit operated by a pedal.
The front and rear brakes will operate simultaneously with only one brake pedal depressed.
The differential contains annular brake piston and double sided disk.
Brake pump flow also goes to the parking brake solenoid valve in cut-off valve.
The brake system contains the following components:
·Brake pump
·Parking brake solenoid valve in cut-off valve
·Cut-off valve
·Brake valve
·Accumulators
·Pressure switches
4-1
FULL POWER HYDRAULIC BRAKE
SYSTEM
ADVANTAGES - The full power hydraulic Response time
brake system has several advantages over Full power brake actuation VS
Air/Hydraulic brake actuation
traditional brake actuation systems. These
systems are capable of supplying fluid to a 1000
range of very small and large volume
service brakes with actuation that is faster 900
than air brake systems. Figure represents 800
a time comparison between a typical air/ Brake pressure
700 (Full power)
Brake torque(lb·in)
hydraulic and full power hydraulic brake
actuation system. 600
Brake pressure
Full power systems can supply significantly 500 (Air/hydraulic)
higher brake pressures with relatively low Brake torque
400
reactive pedal forces. The reactive pedal (Air/hydraulic)
force felt by the operator will be proportional 300
Brake torque
to the brake line pressure being generated. 200 (Full power)
This is referred to as brake pressure
modulation. 100
Another key design feature of full power
0 1 2 3 4
systems is the ability to control maximum
brake line pressure. In addition, because Time(seconds)
these systems operate with hydraulic oil,
filtration can be utilized to provide long
component life and low maintenance
operation.
Because these systems are closed center,
by using a properly sized accumulator,
emergency power-off braking that is
identical to power-on braking can be
achieved. These systems can be either
dedicated, where the brake system pump
supplies only the demands of the brake
system or non-dedicated, where the pump
supplies the demands of the brake system
as well as some secondary down stream
hydraulic device.
Another important note is that all seals
within these system must be compatible
with the fluid medium being used.
4-2
2. HYDRAULIC CIRCUIT
FRONT
39 REAR
18
21
9 BL1 BR1 BL2 BR2
8
T1 P1 T2 P2
17 17
7 A1 A2
19
PS
P1
T1
A3
16
B
PS1
20 MCV
P T
Return line
22
Steering system RCV lever
23 Return
line
24
25 26
7407B4BS01
2 Brake pump 18 Pressure switch 24 Hydraulic tank

7 Cut off valve 19 Pressure switch 25 Return filter
8 Brake valve 20 Pressure switch 26 Bypass valve
9 Dual brake pedal (opt) 21 Pressure switch 39 Axle
16 Accumulator 22 Line filter
17 Accumulator 23 Air breather
4-3
1) SERVICE BRAKE RELEASED
FRONT
39 REAR
18
21
9 BL1 BR1 BL2 BR2
8
T1 P1 T2 P2
17 17
7 A1 A2
19
PS
P1
T1
A3
16
B
PS1
20 MCV
P T
Return line
22
2 1
23 Return
line
24
25 26
7407B4BS02
When the pedal of brake valve (8) is released, the operating force is eliminated by the force of the
spring, and the spool is returned.
When the spool removes up, the drain port is opened and the hydraulic oil in the piston of axles
return to the tank (24).
Therefore, the service brake is kept released.
4-4
2) SERVICE BRAKE OPERATED
FRONT
39 REAR
18
21
9 BL1 BR1 BL2 BR2
8
T1 P1 T2 P2
17 17
7 A1 A2
19
PS
P1
T1
A3
16
B
PS1
20 MCV
P T
Return line
22
2 1
23 Return
line
24
25 26
7407B4BS03
When the pedal of brake valve (8) is depressed, the operating force overcomes the force of the
spring, and is transmitted to the spool. When the spool moves down, the inlet port is opened, and
at the same time the hydraulic oil controlled the pressure level by the cut-off valve (7) enters the
piston in the front and rear axles. Therefore, the service brake is applied.
4-5
3) PARKING BRAKE RELEASED
FRONT
39 REAR
18
21
9 BL1 BR1 BL2 BR2
8
T1 P1 T2 P2
17 B
17
A
7 A1 A2
19
PS
Parking brake switch
P1
T1
A3
16
B
PS1
20 MCV
P T
Parking Return line
brake solenoid 22
2 1
23 Return
line
24
25 26
7407B4BS04
When the parking brake switch is pressed B position, the solenoid valve is energized and the
hydraulic oil controlled the pressure level by the cut-off valve enters the parking brake. It overcomes
the force of the spring and pushes the piston rod. This releases the brake.
Therefore, the hydraulic oil pressure is applied to the parking brake piston in front axle through the
solenoid valve and the parking brake is kept released.
4-6
4) PARKING BRAKE OPERATED
FRONT
39 REAR
18
21
9 BL1 BR1 BL2 BR2
8
T1 P1 T2 P2
17 B
17
A
7 A1 A2
19
PS
Parking brake switch
P1
T1
A3
16
B
PS1
20 MCV
P T
Parking Return line
brake solenoid 22
2 1
23 Return
line
24
25 26
7407B4BS05
When the parking brake switch is pressed A position, the solenoid valve is deenergized and the
valve open the drain port.
At the same time, the hydraulic oil in the parking brake return to the tank through the solenoid
valve. When the piston rod is returned by the force of the spring, the parking brake is applied.
4-7
3. BRAKE PUMP
1) STRUCTURE
Port Port name Port size

A Inlet PF 3/4"
B Outlet PF 1/2"
B A
7407S4BS06
1 Shaft gear 7 Bushing 13 O-ring

2 Driven gear 8 Channel seal 14 Bolt
3 Front cover 9 Back up seal 15 Washer
4 Housing 10 Retainer seal 19 Nut
5 Rear cover 11 Snap ring 20 Washer
6 Bushing block 12 Dowel pin 21 Woodruff key
This gear pump have a maximum delivery pressure of 150 kgf/cm2.

The pressure loaded type gear pump is designed so that the clearance between the gear and the
bushing can be automatically adjusted according to the delivery pressure. Therefore, the oil leakage
from the bushing is less than that in the case of the fixed bushing type under a high discharge pressure.
Consequently, no significant reduction of the pump delivery occurs, even when the pump is operated
under pressure.
4-8
2) PRINCIPLE OF OPERATION
(1) Mechanism for delivering oil
The drawing at r ight shows the
operational principle of an external gear
pump in which two gears are rotating in
mesh.
The oil entering through the suction port Suction Discharge
is trapped in the space between two gear
teeth, and is delivered to the discharge
port as the gear rotates.
Except for the oil at the bottom of the gear
teeth, the oil trapped between the gear
teeth, is prevented from returning to the
suction side with the gears in mesh.
Since the gears are constantly delivering
oil, the oil delivered to the discharge port
is forced out of the port.
The amount of discharge increases with
the speed of rotation of the gear.
If there is no resistance in the oil passage
into which the discharged oil flows, the oil
merely flows through the passage,
producing no increase in pressure.
If however, the oil passage is blocked with
something like a hydraulic cylinder, there
will be no other place for the oil to flow, so
the oil pressure will rise. But the pressure
which rises in this way will never go
higher, once the hydraulic cylinder piston
starts moving because of the oil pressure.
As described earlier, the pump produces
the oil flow, but not the oil pressure. We
can therefore conclude that pressure is a
consequence of load.
In other words, the pressure depends on
a counterpart.
(770-3ATM) 4-9
4-9
(2) Internal oil leakage
Oil leaks from a place under higher
pressure to a place under lower pressure,
provided that a gap or a clearance exists
in between.
In the gear pump, small clearances are
provided between the gear and the case
and between the gear and the side plate
to allow the oil to leak out and to serve as
a lubricant so that the pump will be rge
protected from seizure and binding. ischa
D
The drawing at right shows how the
leaked oil flows in the pump. As such,
there is always oil leakage in the pump
from the discharge side (under higher
pressure) to the suction side. The delivery
n
of the pump is reduced by an amount uctio
S
equal to the pump discharge.
In addition, the delivery of the pump will
also decrease as the amount of oil
leakage increases because of expanded
radial clearance resulting from the wear of
pump par ts, the lower oil viscosity
resulting from increases in the oil
temperature, and the initial use of low
(770-3ATM) 4-10
viscosity oil.
4-10
(3) Forces acting on the gear
The gear, whose outer surface is
subjected to oil pressure, receives forces
jointing towards its center.
Due to the action of the delivery pressure,
the oil pressure in higher on the delivery
side of the pump, and due to suction
pressure, is lower on the suction side. In
the intermediate section, the pressure will
gradually lower as the position moves
from the delivery side to the suction side. Drive gear
This phenomenon is shown in the
drawing at right.
In addition, the gears in mesh will receive Suction Discharge
interacting forces. side side
These forces pushing the gears toward
the suction side are received by the
bearings. Since the gears are pressed Driven gear
toward the suction side by these forces,
the radial clearance becomes smaller on
the suction side in the case. In some
pumps, the clearance may become zero, Pressure distribution
thus allowing the gear teeth and the case
to come into light contact.
For this reason, an excessive increase in
the delivery pressure must be avoided,
since it will produce a large force which
will act on the gears, placing an overload
on the bearings, and resulting in a
shortened service life of the bearing or
(770-3ATM) 4-11
interference of the gear with the case.
4-11
4. BRAKE VALVE
1) STRUCTURE
17-2
18
17-3,17-4
17-1,17
19
23 22
24
21
2
31
20 8
9
25 29
25
16 14
15 7
5 13
30
12 6
3(Upper) 10
26
11
3(Lower)
1 4
7407S4BS07
1 Lower body 12 Oil seal 19 Bellows

2 Upper body 13 Spring guide 20 Lock pin 1
3 Spool 14 Snap ring 21 Torsion spring
4 Plug 15 Du bushing 22 Snap ring
5 Holder 16 Pedal plate 23 Hexagon bolt
6 Lower spring 17 Pedal assy 24 Hexagon nut
7 Upper spring 17-1 Pedal 25 Bolt
8 Main spring 1 17-2 Lock plate 26 Spring washer
9 Spring retainer 1 17-3 Hexagon bolt 29 Plate washer
10 O-ring 17-4 Plate washer 30 Snap ring
11 O-ring 18 Rubber cover 31 Taper plug
4-12
2) OPERATION
BL1 BR1 BL2 BR2
T1 P1 T2 P2
Hydraulic circuit

P1, P2 Pressure port PF 3/8
T1
BL1 T1, T2 Return port PF 3/8
P1 BR1, BR2 Brake cylinder port PF 3/8
BR1
BL1, BL2 Pressure switch port PF 1/4
BL2 T2
P2
BR2
7407S4BS08
· Brake pressure specification : 55±5 bar (780±70 psi)a
4-13
(1) Purpose
The purpose of the brake valve is to sensitively increase and decrease the braking pressure
when the brake pedal is actuated.
(2)
2) Ready position
When the braking system is ready for operation, its accumulator pressure acts directly on ports
(P1, P2) of the brake valve. A connection is established between ports (BR1, BR2) and ports (T1,
T2) so that the wheel brakes ports (BR1, BR2) are pressureless via the returns ports (T1, T2).
(3) Partial braking
(3
When the brake valve is actuated, an amount of hydraulic pressure is output as a ratio of the foot
force applied.
The spring assembly (8) beneath pedal plate (16) is designed in such a way that the braking
pressure changes depending on the angle. In the lower braking pressure range, the machine can
be slowed sensitively.
When the braking process is commenced, the upper spool is mechanically actuated via spring
assembly (8), and the lower spool is actuated hydraulically by spool. As spools (3) move
downward, they will first close returns (T1, T2) via the control edges, thus establishing a
connection between accumulator ports (P1, P2) and ports (BR1, BR2) for the wheel brake
cylinders. The foot force applied now determines the output braking pressure. The control spools
(3) are held in the control position by the force applied (Spring assembly above the spools and
the hydraulic pressure below the spool (Balance of forces).
After output of the braking pressure, spools (3) are in a partial braking position, causing ports (P1,
P2) and ports (T1, T2) to close and holding the pressure in ports (BR1, BR2).
(4) Full braking position
(4
When pedal is fully actuated, end position of the brakes is reached and a connection established
between accumulator ports (P1, P2) and brake cylinder ports (BR1, BR2). Returns (T1, T2) are
closed at this point.
When the braking process is ended, a connection is once again established between brake
cylinder ports (BR1, BR2) and return ports (T1, T2), closing accumulator ports (P1, P2).
The arrangement of spools in the valve ensures that even if one braking circuit fails the other
remains fully operational. This is achieved by means of the mechanical actuation of both spools
and requires slightly more pedal travel.
(5) Limiting the braking pressure
Pedal restriction bolt(23) on pedal plate(16) is used to limit the braking pressure.
(6) Failure of a circuit
In the event of the lower circuit failing, the upper circuit will remain operational. Spring assembly
(8) will mechanically actuate spool. In the event of the upper circuit failing, the lower circuit will
remain operational since the lower spool (3) is mechanically actuated by spring assembly (8) and
spool (3).
(7) Installation requirements
Return lines (T1, T2) must be connected directly to the tank.
The connecting lines must be installed is such a way as to permit proper bleeding.
4-14
(8) Maintenance of the brake valve
No special maintenance beyond the legal requirements is necessary.
When using high-pressure cleaners on the machine, please make sure that the water jet is not
aimed directly at the brake valve (to prevent damaging the bellows).
For safety reasons the whole of the brake valve must be replaced if parts other than those
listed above are damaged.
(9) Repair work
(9
When working on the braking system, always make sure that there is absolutely no pressure
in the system. Even when the engine is switched off there will be some residual pressure in
the system.
※ When doing repair work, make sure your environment is very clean.
Immediately close all open ports on the components and on pipes using plugs.
(10) Replacing the complete actuating mechanism
Carefully clamp the unit vertically in a fixture. The actuating mechanism can be removed by taking
out the three bolts. Make sure that spring assembly (8) does not fall out. When installing the new
actuating mechanism, make sure that spring assembly (8) is fitted in the right order. Tighten the
four bolts (25).
(11) Replacing the pedal cover
Pedal cover (18) is simply pulled of by hand. The new pedal cover is pushed over pedal (17) and
tightened manually. Fasten the bellows with the strap retainers.
(12) Replacing the bellows
To change bellows (19) it is advisable to remove pedal (17). For this purpose, loosen snap ring
(22) and knock out pin (20) using a mandrill. When knocking out the bolt, make sure that the
mandrill is applied to the side of the bolt without a knurl. Remove pedal (17) and bellows (19).
Now fit the new bellows and proceed in reverse order as described above. The upper portion of
bellows is fastened to piston, its lower portion to pedal plate (16) secure the bellows using clamps.
4-15
5. CUT-OFF VALVE
1) STRUCTURE
3
4 C B
2
D D
5
P1
T
T1
PS
P PS1 A A
C B
SECTION A - A SECTION B - B
1 2
3
A1 A2
1 PS
2
P1
A3
A3 T1
A1
1
B
PS1
A2
B
P T
SECTION C - C SECTION D - D HYDRAULIC CIRCUIT

5 7407B4BS11
1 Cut-off valve 4 Coil

2 Relief valve 5 Solenoid valve
3 Check valve
2) OPERATION
When the pump works, the oil under the pressure flows into P port.
The oil in P port is stored in the accumulator on A1, A2 port.
As the pressure on P line rises to 150 bar, the cut off valve (1) starts cut-offing and the oil in the P
port is unloaded. The pressure on P line goes down 120 bar by the minute leakage from valve and
other factors.
At this pressure, the cut-off valve starts cut-ining.
This process is repeated in the regular period of 30~40 seconds.
4-16
6. BRAKE ACCUMULATOR
1) STRUCTURE
31EC-02190 81L1-0004
Item
(item16) (item17)
Diameter 117 mm 110 mm
Mounting height 141 mm 164 mm
Norminal volume 0.75 ℓ 0.75 ℓ
Priming pressure 50 kgf/cm2 50 kgf/cm2
B Operating medium Oil Oil
Operating pressure Max 200 kgf/cm2 Max 150 kgf/cm2
A Thread M18×1.5 M18×1.5
Priming gas Nitrogen Nitrogen
C
A Fluid portion C Diaphragm
B Gas portion D Valve disk
D
75794BS09
2) OPERATION
(1) Purpose
Fluids are practically incompressible and are thus incapable of accumulating pressure energy. In
hydropneumatic accumulators, the compressibility of a gas is utilized to accumulate fluid. The
compressible medium used in the accumulators is nitrogen.
In braking systems, the purpose of the accumulators is to store the energy supplied by the
hydraulic pump. They are also used as an energy reserve when the pump is not working, as a
compensator for any losses through leakage, and as oscillation dampers.
(2) Operation
(2
The accumulator consists of a fluid portion (A) and a gas portion (B) with a diaphragm (C) as a
gas-tight dividing element. The fluid portion (A) is connected to the hydraulic circuit, causing the
diaphragm accumulator to be filled and the gas volume to be compressed as the pressure rises.
When the pressure falls, the compressed gas volume will expand, thus displacing the
accumulated pressure fluid into the circuit.
The diaphragm bottom contains a valve disk (D) which, if the diaphragm accumulator is
completely empty, closes the hydraulic outlet, thus preventing damage to the diaphragm.
3) Installation requirements
(3)
The accumulators can be fitted in the hydraulic circuit, directly on a component or in blocks on
suitable consoles.
They should be fitted in as cool a location as possible.
Installation can be in any position.
4-17
(4) Maintenance of the accumulator
The accumulator should be checked annually. It should be replaced if the initial gas pressure has
fallen by more than 30% (please refer to Performance testing and checking of the accumulator).
(5) Disposal of the accumulator
Before the accumulator is scrapped, its gas filling pressure must be reduced. For this purpose,
drill a hole through gas chamber (B) using a drill approx. 3mm in diameter. The gas chamber is
located on the side opposite the threaded port above the welding seam around the center of the
accumulator.
※ Wear safety goggles when doing this job.
(6) Performance testing and checking of the accumulator
The accumulator is gradually pressurized via the test pump; until the initial gas pressure is
reached, the hydraulic pressure in the accumulator will rise abruptly. This is apparent from gauge
M. If the initial gas pressure is more than 30% below the prescribed value, the accumulator needs
to be replaced. If the measuring process needs to be repeated, wait for intervals of 3 minutes
between the individual tests. Any accumulator whose initial gas pressure is insufficient must be
scrapped following the instructions under Disposal of the accumulator
accumulator.
The amount of initial gas pressure can also be checked from the vehicle. Start the vehicle's
engine. The pump will now supply oil to the accumulators. Until the initial gas pressure is
reached, the hydraulic pressure in the accumulator will rise abruptly. This is apparent from the
gauge in the cab. If the initial gas pressure is more than 30% below the prescribed value, that
initial pressure lies outside the permissible range for at least one of the accumulators fitted in the
vehicle. This accumulator can be traced only by using the method described above, i.e. all
accumulators have to be individually tested. The accumulator whose initial gas pressure is
insufficient must be replaced and scrapped following the instruction under Disposal of the
accumulator.
accumulator
Accumulator
Pressure gauge(M)
Ball valve for

shutting off pump flow
Safety valve
Ball valve for

reducing pressure
75794BS10
(7) Repair work

When working on the braking system, always make sure that there is absolutely no
pressure in the system. Even when the engine in switched off there will be some residual
pressure in the system.
For safety reasons the accumulators need to be replaced as a whole if damaged.
4-18
7. PRESSURE SWITCHES
1) STRUCTURE
Connector
H1
300mm
- Normally closed
H2
G
BRAKE STOP
- Normally open
H1
H1
H2 H2
G G
CHARGING PARKING, CLUTCH CUT OFF 7407B4BS17
2) TECHNICAL DATA
H1 H2 Adjusting range Actuating pressure Voltage
Item Type Medium G
mm mm kgf/cm2 kgf/cm2 V
Parking NC Oil M12×1.5 55 9 50 ~ 150 95 ± 5 Max 42
Charging NC Oil PF 1/4" 49 11 50 ~ 150 95 ± 5 Max 48
Brake stop NO Oil PF 1/4" 49.6 11 1 ~ 10 5±1 Max 32
Clutch cut-off NO Oil PF 1/4" 55 9 20 ~ 50 24 ± 2 Max 42
NC : Normally closed NO : Normally open
4-19
2) OPERATION
(1) Purpose
The pressure switches are used to visually or audibly warn the driver of the pressure within the
system.
(2) Make contact / circuit closer
The pressure switch can be fitted in the braking system or directly on one of its components.
The system pressure acts on an absorption area within the switch, making an electrical contact
as the pressure on that area is increased. The resulting current is used to activate a warning
facility, for instance.
(3) Break contact / circuit breaker
The pressure switch can be fitted in the braking system or directly on one of its components.
The system pressure acts on a absorption area within the switch, breaking an electrical contact
as the pressure on that area is increased. The current is now broken, e.g. to deactivate a warning
facility.
(4) Installation requirements
No special measures need to be taken.
(5) Maintenance of the pressure switch
When using high-pressure cleaners on the vehicle, please make sure that the water jet is not
directed at the pressure switch (corrosion of contacts).
(6) Repair work
When working on the braking system, always make sure that there is absolutely no
pressure in the system. Even when the engine is switched off there will be some residual
pressure in the system.
※ For safety reasons the pressure switch needs to be replaced as a whole if damaged.
4-20
1. OPERATIONAL CHECKS
This procedure is designed so the mechanic can make a quick check of the system using a minimum
amount of diagnostic equipment. If you need additional information, read structure and function
function,
Group 1.
At the end of each check, if no problem is found (OK), that check is complete or an additional check is
needed. If problem is indicated (NOT OK), you will be given repair required and group location.
If verification is needed, you will be given next best source of information:
Chapter 2 : Troubleshooting
Group 3 : Tests and adjustments
4-21
※Hydraulic oil must be at operating temperature for these checks (refer to page 6-49).
Parking brake capacity Start engine. OK
check Check completed.
Fasten seat belt.
Seat belt must be worn
NOT OK
while doing this check to Release parking brake and put
Inspect parking brake. Go
prevent possible injury mph transmission in 2nd gear forward.
to group 3.
when machine stops
Drive machine at 8 km/hr and
suddenly.
switch parking brake ON.
Release LOOK/FEEL : Machine must

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

Parking brake Turn parking brake to ON. OK
transmission lockout Check completed.
Place transmission in 1st forward.
check
NOT OK
Engine running. Slowly increase engine speed to
P
Go to transmission control
high idle.
circuit in section 3.
LOOK : Machine must not move.
4-22
Service brake pump flow Stop engine. OK
Operate brake pedal approximately
※ Hydraulic oil must be at
20 times. NOT OK
operating temperature
Start engine and run at low idle. Check for brake circuit
for the check.
leakage.
Engine OFF. Record number of seconds
required for low brake pressure Go to next page.
indicator lamp to go out.
IF OK
LOOK : Indicator lamp must go out I n s t a l l a c a p o n l i n e
in less than 4 seconds from time connected to inlet of brake
engine starts. valve and repeat pump
flow check.
NOTE : Indicator will not come on
approximately 1 second after If time does not decrease,
starting engine. check for wor n brake
pump.
Service brake capacity Turn clutch cut-off switch OFF. OK
Apply service brakes, release park
Engine running.
brake and put transmission in 2nd NOT OK
forward. Check brake pressure.
Increase engine speed to high idle. IF OK
Inspect brake disk.
LOOK : Machine may not move or
move at a very slow speed.
P
Repeat check three times to ensure

accurate results.
4-23
Brake accumulator S t a r t a n d r u n e n g i n e fo r 3 0 OK
precharge check seconds. Check completed.
※The axles and hydraulic
Stop engine and turn start switch to NOT OK
oil must be at operating
ON and wait 5 seconds. Make sure brake pedal is
temperature for this
not binding and keeping
check. NOTE : Engine oil pressure lamp
brakes partially engaged.
will be on due to no engine oil
pressure. Bleed brakes in group 3.
Count the number of times the C h e c k b r a k e s y s t e m
brake pedal can be fully depressed pressure.
before the low brake pressure
NOT OK
warning lamp comes ON.
If light comes ON with
LOOK : Warning lamp must come e n g i n e r u n n i n g ,
ON in 1~5 applications. accumulator has lost it's
charge. Inspect and
Start engine and operate at low
recharge accumulator.
idle.
Observe cluster while applying
brake pedal with maximum force.
LOOK/LISTEN : Brake pressure
indicator must not come ON.
Brake system leakage Start engine and wait 30 seconds. OK
Stop engine.
NOT OK
Wait 2 minutes.
If brake leakage is
Turn start switch to ON and wait 5 indicated with brakes
seconds. released, check leakage at
accumulator inlet check
LOOK : Brake oil pressure warning
valve and brake valve. If
lamp must not come ON within 2
brake leakage is indicated
minutes after stopping engine.
with brakes applied, check
for leakage at brake valve
and brake pistons.
Check individual
component leakage.
4-24
S e r v i c e b ra ke p e d a l Slowly depress brake pedal. OK
Listen for a hissing noise that
indicates oil is flowing to brake NOT OK
pistons. Inspect for debris under
brake pedal.
LISTEN/FEEL : A hissing noise
must be heard when pedal is
depressed.
Service and parking Position machine on gradual slope. OK
brake system drag Check completed.
Lower bucket approximately 50 mm
checks
(2 in) from ground.
Engine running NOT OK
Release parking and ser vice Adjust park brake.
brakes.
NOT OK
LOOK : Machine must move or
Check floor mat interfer-
coast.
ence to pedal or debris
P
NOTE : If machine does not move, build-up.

check brake pedals to be sure they
fully release when feet are removed IF OK
from pedals. Check for brake pressure
when brake is released.
Drive machine at high speed for
about 5 minutes.
Go to brake pressure test.
Brake drag is indicated if brake
areas in differential case are hot.
NOTE : Observe parking brake.
If disk is hot, parking brake drag is
indicated.
Clutch cut-off check Place clutch cut-off switch in ON OK
position. Check completed.
Release parking brake.
NOT OK
Run engine at half speed in 1st Adjust clutch cut-off switch.
forward.
Firmly depress brake pedal.
F E E L : Tr a n s m i s s i o n m u s t
disengage when brake pedal is
depressed at 30% of pedal stroke.
NOTE : Clutch cut-off switch can be
selected to operator preference to
match your loading needs.
4-25
2. TROUBLESHOOTING
1) SERVICE BRAKE
Diagnose malfunction charts are arranged from most probable and simplest to verify, to least likely,
more difficult to verify. Remember the following steps when troubleshooting a problem :
Step 1. Operational check out procedure (see section 1)
Step 2. Operational checks (in this group)
Step 4. Tests and adjustments (see group 3)

Poor or no brakes Brake accumulator charge low. Do brake accumulator check.
Brake pump standby pressure Do brake pump standby pressure test.
low.
Brake pressure low. Do brake valve pressure test.
Air in system. Bleed brakes.
Worn brake surface material. Inspect brake surface material.
Leakage in brake valve. Do brake valve leakage test.
Leakage in brake piston seal. Check for an over filled differential.
Apply brakes and check for leakage from check
plug.
※It is normal for the oil level to be slightly
above the check plug.
Aggressive brakes Internal restriction in circuit. Remove lines and components.
Clutch cut-off switch out of Adjust clutch cut-off switch.
adjustment.
Brake valve malfunction. Disassemble and inspect.
Low oil level. Check oil level.
Brakes drag Brake pedal not retur ning Inspect floor mat and pedal.
properly.
Debris holding valve partially Do brake valve pressure test.
open in brake valve.
Warped brake disk. Inspect brake disk.
Stuck brake piston. Repair.
Brakes lock up Brake valve malfunction. Clean or replace brake valve.
4-26
Brakes chatter Air in brake system. Do brake bleed procedure.
Worn brake surface material. Inspect brake surface material.
Wrong oil in differential. Drain.Refill.
H i s s i n g n o i s e w h e n Leakage in brake valve, or brake Do brake system leakage test.
brake pedal is held with piston.
engine stopped
Brake pressure warning M a l f u n c t i o n i n b r a k e l o w Replace switch.
light will not go out or pressure warning switch.
stays on excessively long
Brake accumulator pressure too Recharge accumulator.
after start-up
low.
L ow b r a ke p u m p s t a n d by Do brake pump standby pressure test.
pressure setting.
Leakage in pressure reducing Do pressure reducing valve manifold leakage
manifold block. test.
Leakage in brake system. Do brake system components leakage tests.
Worn brake pump. Do brake pump flow test.
Leakage in par king brake Do parking brake pressure test.
solenoid.
2) PARKING BRAKE MALFUNCTIONS

Brake will not hold Pads not adjusted correctly. Adjust parking brake.
Malfunctioning parking brake Inspect and replace.
solenoid.
Worn brake disk and / or brake Disassemble, inspect, repair.
pads.
Brake piston hangs up in bore. Remove and inspect. Repair.
Brake disk overheats Pads out of adjustment. Adjust parking brake.
Brake not released. Release parking brake.
Disassemble, inspect brake.
Repair if necessary.
Inspect for loosen or broken lines between brake
pressure switch and indicator on dash.
Parking brake indicator in Faulty wiring or switch. Inspect for loose or broken lines between brake
cluster does not come on pressure switch and indicator on dashboard.
when brake applied Inspect for a faulty indicator on dashboard.
Brake will not apply Pads out of adjustment. Adjust parking brake.
Malfunctioning wiring, switch, or Check electric circuit.
solenoid.
Restriction between brake valve Remove hose and inspect. Replace.
and brake.
4-27
1. PARKING BRAKE PERFORMANCE

1) MEASUREMENT
EASUREMENT CONDITION
(1) Tire inflation pressure : Specified pressure
(2) Road surface : Flat, dry, paved surface
with 1/5 (11˚20') gradient.
20%
(3) Machine : In operating condition gradient 11 20'
Item Standard value
Parking brake Keep machine on 20%
performance (11˚20') gradient 7407B4BS16
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.
20%
(3) Turn the parking brake switch ON, then 11 20' gradient
slowly release the service brake pedal
and the machine must be kept stopped.
※ The measurement must be made with
the machine facing either up or down
7407B4BS17
the slope.
4-28
2. ADJUSTMENT OF PARKING BRAKE
1) Remove screws complete with nuts and
seals. Replace seals, apply grease to the
screws and install all parts into the arm.
7409RAX190
2) Adjust screws (31) to obtain a jut of

30±0.5 mm in relation to the arm.
74095TA19
3) Lock into position with nuts (30).

※ Hold screws (31) into position while locking
the nuts (30) ; after locking, check the jut of
screws (31) once more.
74095TA20
4-29
3. HYDRAULIC BRAKE BLEEDING PROCEDURE
Escaping fluid under pressure can
penetrate the skin causing serious injury.
Avoid the hazard by relieving pressure
before disconnecting hydraulic or other
lines. Tighten all connections before
applying pressure. B
Search for leaks with a piece of cardboard.
Protect hands and body from high B
pressure fluids.
※ If an accident occurs, see a doctor
immediately. Any fluid injected into the skin
must be surgically removed within a few
hours or gangrene may result.
Doctors unfamiliar with this type of injury
should reference a knowledgeable medical
source.
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 oil tank filler tube
or container (A).
3) Start engine and run at low idle.
4) Push and hold brake pedal down until
brake bleeding procedure is complete.
※ If bubbles continue for more than 2
minutes, stop bleeding procedure.
Check for and correct problem, then
continue.
5) Open on bleed screw on differential and
axle assembly until hydraulic oil starts to Frame locking bar
flow. Close bleed screw when oil is free of
air. Release brake pedal.
6) Repeat steps 1)~5) for each bleed screw.
7) Push either brake pedal and hold down.
7407B4BS18
8) Check hydraulic oil level.
4-30
1. BRAKE PUMP
1) MAIN
AIN ASSEMBLY
b
a c
8
7
3 6
2
1
5
A Bushing block of assy direction

7407S4BS19
1 Housing 4 Driven gear 7 Washer

2 Bushing block sub assy 5 Front cover sub assy 8 Bolt
3 Drive gear 6 Rear cover
(1) You prepare all parts and clean it.

(2) You prepare M10 torque wrench, oil pump and 1, 2, 3, 5 sub assembly status.
(3) When you assemble, front cover sub assy (5) is based on a front view.
(4) Main assembly order
① Front cover sub assy (5) is based on a front view in drawing, check sense of rotation (CW) and
assembling shaft gear's upper direction.
② At first, one of bushing block sub assy (2) point to same position of figure. After you assemble
drive gear (3) and driven gear (4), assemble bushing block sub assy (2).
③ Put oil on the assembled parts (2, 3, 4), lubrication for the gear to rotate and assemble front
cover sub assy (5) to A direction.
④ Check the discharge port based on housing drawing and contamination of part's inside. Coated
oil parts are assembled in the direction vertical and horizontal.
⑤ Check suction port of rear cover (6) and assemble housing (1).
⑥ Washer (7) put in bolt (8), assemble in order of a-d-b-c and tighten bolts same order using torque
wrench.
·Tightening torque : 5.1 kgf·m (36.9 lbf·ft)
(5) Complete assembly.
(6) Dissembly is assembly's order in reverse.
(7) You proceed running-in using performance test device.
4-31
2) SUB ASSEMNLY
※ Beware of scratches, damages and foreign
materials.
※ Grease must have good lubricity and
viscosity.
※ You must prepare snap ring tool and
retainal seal special tool.
(1) Fron
Frontt cover assy
1
① After enough grease on the surface of Direction B
retainal seal (2). It is assembled front
cover (1) using retainal seal special tool. 2
3
※ Lip's direction toward A direction should
be assembled and because of the risk of
Direction A
damage should be used only special tool.
② After you put snap ring tool in 2 holes of Direction A Lip
snap ring (3), grasp it and snap ring (3) is

assembled front cover's groove using
Direction B
snap ring tool. 7407B4BS20
(2) Housing
① After enough grease on the surface of 1
D-rings (2), those should be assembled
grooves of housing's both sides closely. 2
※ Check point : A side of D-ring (2) should

2
be assembled side of housing (1) closely.
Face A
7407B4BS21
(3) Bushing block

① After enough grease on the surface of
channel seal (2), it should be assembled 2
groove of bushing block (1). 3
※ A side of channel seal(2) should be
assembled side of bushing block (1)
1
closely.
② After enough grease on the surface of
back-up seal (3), it should be assembled
groove of channel seal (2).
Face B Face A
※ A side of back-up seal (3) should be
assembled inside of channel seal (2)
closely. 7407B4BS22
4-32
Group 1 Structure and Function ---------------------------------------------------------------------------------- 5-1

Group 2 Operational Checks and Troubleshooting ---------------------------------------------------- 5-12
Group 3 Tests and Adjustments ----------------------------------------------------------------------------------- 5-20
Group 4 Disassembly and Assembly -------------------------------------------------------------------------- 5-27
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 :
·Steering pump
·Steering unit
·Overload valve block
·Priority valve
·Steering cylinders
The steering pump, the first pump of main pump, draws hydraulic oil from the hydraulic tank.
Outlet flow from the pump flows to the priority valve. The priority valve preferentially supplies flow, on
demand, to the steering unit. When the machine is steered, the steering unit routes flow to the steer-
ing cylinders to articulate the machine.
When the machine is not being steered, or if pump flow is greater than steering flow, the priority valve
supplies flow to the loader system.
That is, output flow from the steering pump enters into the main control valve for the operation of the
attachment.
5-1
10
LH RH
5
L
P 21MPa
LS
Brake system
MCV
CF EF A 1st pump
Return line B 2nd pump
6
LS
P
RCV lever
B A 1
31
23 Return
29 M1
line
A
P1
30 M2 24
P2
25 26
28
M
Parking brake solenoid
7407B5SE01
1 Main pump (steering) 23 Air breather 28 Motor pump (option)

5 Steering unit 24 Hydraulic tank 29 Check block (option)
6 Priority valve 25 Return filter 30 Pressure switch (option)
10 Steering cylinder 26 Bypass valve 31 Pressure switch (option)
5-2
1) NEUTRAL
10
LH RH
5
L
P 21MPa
LS
MCV
CF EF
6
D LS
P
RCV lever
Brake system
A 1
Return line
23 Return
line
24
25 26
7407B5SE02
· The steering wheel is not being operated so control spool (G) does not move.
· The oil from the steering pump (A) enters port P of the priority valve and the inlet pressure oil moves
the spool (D) to the right.
· Almost all of pump flow goes to the loader system (main control valve) through the EF port and partly
flows into the hydraulic tank (24) through the spool (G).
5-3
2) LEFT TURN
10
LH RH
5
L
E
R
P 21MPa
LS
MCV
CF EF
6
D LS
P
RCV lever
Brake system
1
Return line
23 Return
line
24
25 26
7407B5SE03
· 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.
· 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 (6) and flows into the gerotor (H).
· 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 (10).
· Oil returned from left and right cylinder returns to hydraulic tank through the spool of the steering unit.
When the above operation is completed, the machine turns to the left.
5-4
3) RIGHT TURN
10
LH RH
5
L
E
R
P 21MPa
LS
MCV
CF EF
6
D LS
P
RCV lever
Brake system
1
Return line
23 Return
line
24
25 26
7407B5SE04
· 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.
· 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 (6) and flows into the gerotor (H).
· Oil flow from the gerotor flows back into the spool (G) where it is directed out the right work port (R)
to the respective chamber of the steering cylinders (10).
· Oil returned from left and right cylinder returns to hydraulic tank through the spool of the steering unit.
When the above operation is completed, the machine turns to the right.
5-5
3. STEERING UNIT
1) STRUCTURE
7607SE17
1 Bearing 5 Gear wheel 9 Spool

2 Neutral position spring 6 Gear rim 10 Check valve
3 Cross pin 7 Sleeve 11 Distributor plate
4 Housing 8 Cardan shaft 12 End cover
2) OPERATION
The steering unit consists of a rotary valve and a rotary meter.
Via a steering column the steering unit is connected to the steering wheel of the machine.
When the steering wheel is turned, oil is directed from the steering system pump via the rotary
valve (spool and sleeve) and rotary meter (gear wheel set) to the cylinder ports L or R, depending
on the direction of turn. The rotary meter meters the oil flow to the steering cylinder in proportion to
the angular rotation of the steering wheel.
Spool (9) is connected directly to the drive shaft of steering wheel. It is connected to sleeve (7) by
cross pin (3) (not in contact with the spool when the steering wheel is at neutral) and neutral posi-
tion spring (2).
Cardan shaft(8) is meshed at the top with cross pin (3) and forms one unit with sleeve (7).
At the same time, it is meshed with gear rim (5) of the gerotor set by spline.
There are four ports in valve body. They are connected to the pump circuit, tank circuit, and the
head, and left and right steering cylinder. In addition, the pump port and tank port are connected
inside the body by the check valve. Therefore, if there is any failure in the pump of engine, oil can
be sucked in directly from the tank through the check valve.
5-6
4. PRIORITY VALVE
1) STRUCTURE
7 6 2 5 4 1 3
CF
LS
P EF
7407B5SE30
CF EF
P From main pump 1 - 1/16 - 12 UN
CF To steering unit P port 3/4 - 16 UNF
LS
EF To MCV 1 - 1/16 -12 UN
LS To steering unit LS port 7/16 - 20 UNF P
HYDRAULIC CIRCUIT
1 Body 4 Spring 7 O-ring

2 Spool 5 Orifice
3 Plug 6 Plug
5-7
2) OPERATION
(1) Neutral
5
CF 2 5 4
CF EF
LS
LS
P EF LOADER ACTUATED(D)
7407BSE20
The priority valve is a pressure control valve that maintains priority pressure to the closed center steer-
ing 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 (2) is pushed to the left (Viewed from sectional drawing at previous page)
by the spring (4). 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 (2) 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 (5) 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.
5-8
(2) Midturn
5
CF 2 5 4
CF EF
LS
LS
P EF FULL STEER RATED(D)
7407BSE21
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 (4) force move the spool (2) 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 (5) in the priority valve spool.
5-9
(3) Full turn
5
CF 2 5 4
CF EF
LS
LS
P EF
7407BSE22
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
(3), 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 loader control valve.
If the loader attachment is being operated while steering, the loader function will slow until the machine
reaches the steering stops. At that time, the loader cycle speed will increase until the machine is
steered again.
5-10
5. STEERING CYLINDER
1) STRUCTURE
3 9,8 12 6,5 7 11,10 4 2 1 13 14 15 16 17 25 24
22,23
19,20,21 18 7407SE07
1 Tube assembly 10 O-ring 19 U-bolt

2 Rod assembly 11 Back up ring 20 Hexagon nut
3 Gland 12 O-ring 21 Spring washer
4 Du bushing 13 Piston 22 Bushing
5 Rod seal 14 O-ring 23 Dust seal
6 Back up ring 15 Piston seal 24 Spherical bearing
7 Buffer ring 16 Wear ring 25 Retaining ring
8 Dust wiper 17 Piston nut
9 Snap ring 18 Pipe assembly
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).
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).
5-11
This procedure is designed so the service man can make a quick check of the steering system using
a minimum amount of diagnostic equipment. If you need additional information, prefer to structure
and function in group 1.
Locate system check in the left column and read completely, following this sequence from left to right.
At the end of each check, if no problem is found (OK), that check is complete or an additional check
is needed. If problem is indicated (NOT OK), you will be give repair required and group location. If
verification is needed, you will be give next best source of information :
·Chapter 2 : Troubleshooting
·Group 3 : Tests and adjustments
5-12
※Hydraulic oil must be at operating temperature for these checks (refer to page 6-49).
Steering unit check Run engine at low idle. OK
Check completed.
A
Turn steering wheel until frames are
at maximum right (A) and then left NOT OK
B
(B) positions. Go to next check.
L O O K : Fra m e s mu s t m ove
smoothly in both directions.
When steering wheel is stopped,
frames must stop.
FEEL : Excessive effort must not be
required to turn steering wheel.
NOTE : It is normal for steering to
drift from stops when steering
wheel is released.
Steering system leakage Turn steering wheel rapidly until OK
check frames are against stop. Check completed.
Heat hydraulic oil to Left Right Hold approximately 2 kg on steer- NOT OK
operating temperature.
ing wheel. Do steering system leakage
Run engine at high idle.
test in group 3 to isolate the
Count steering wheel revolutions
leakage.
for 1 minute.
Repeat test in opposite direction.
LOOK : Steering wheel should
rotate less than 5 rpm.
NOTE : Use good judgment;
Excessive steering wheel rpm does
not mean steering will be affected.
Steering unit low pres- Park machine on a hard surface. OK
sure check Check completed.
Hold brake pedal down.
NOT OK
Do steering unit 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.
Steering unit high pres- Steer to steering stop and release OK
sure check steering wheel. Check completed.
Roll bucket back and hold over NOT OK
relief and observe engine rpm. Priority pressure is set too
high. Do steering unit pres-
Turn steering wheel to steering
sure test in group 3.
stop and hold, observe engine rpm.
LOOK : Steering stall engine rpm
must be higher than hydraulic stall
rpm.
5-13
2. TROUBLESHOOTING
※ Diagnose malfunction charts are arranged from most probable and simplest to verify, to least
likely, more difficult to verify. Remember the following steps when troubleshooting a problem :
Step 1. Operational check out procedure (see group 3 in section 1)
Step 2. Operational checks (in this group)

No steering Low oil level. Add recommended oil.
Failed steering pump. Remove and inspect return filter for
metal pump particles.
Failed main pump drive. Do main pump flow test.
Stuck priority valve spool. Remove and inspect priority valve spool.
Broken priority valve spring. Remove and inspect spring.
Relief valve in steering unit stuck open. Do relief cartridge leakage test in group 3.
No hydraulic functions Stuck open system relief valve. Replace relief valve.
steering normal Locked safety valve. Unlock safety valve.
Plugged pilot line filter. Inspect and replace.
Failed hydraulic pump. Remove and inspect the pump.
Low secondary pressure of RCV. Check the pressure and replace if nec-
essary.
Fault or misadjusted pilot supply unit. Do pilot supply unit test
5-14
Slow or hard steering Too much friction in the mechanical parts of Lubricate bearings and joints of steering
the machine. column or repair if necessary.
Check steering column installation.
Cold oil. Warm the hydraulic oil.
Low steering unit pressure setting. Do steering unit pressure test.
Clean or replace cartridge in steering unit.
Worn hydraulic pump. Do hydraulic pump performance check .
Sticking priority valve spool. Remove and inspect.
Broken priority valve spring. Remove and inspect.
C o n s t a n t s t e e r i n g t o Air in system. Check for foamy oil.
maintain straight travel
Leakage in steering system. Do steering system leakage check.
Worn steering unit. Do steering system leakage check.
Do steering unit neutral leakage test in
group 3.
Leaf spring without spring force or broken. Replace leaf springs.
Spring in overload relief valve broken. Replace relief valve.
Gear wheel set worn. Replace gear wheel set.
Cylinder seized or piston seals worn. Replace defects parts.
S l o w s t e e r i n g w h e e l Leakage in steering unit gerotor. Do steering system leakage check.
movement will not cause
Worn steering unit gerotor. Do steering 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 with Broken steering column or splined cou- Remove and inspect.
no resistance and causes pling.
no frame movement
Lack of oil in steering unit. Start engine and check steering operation.
Leakage in steering system. Do steering system leakage test in group 3.
5-15
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 wheel Loose steering wheel nut. Tighten.
Worn or damaged splines on steering col- Inspect.
umn or unit.
Steering unit binding or Binding in steering column or misalignment Inspect.
steering wheel does not of column.
immediately return to neu-
High return pressure. Check for a pinched or damaged return
tral when released
line.
Contamination in steering unit. Inspect hydraulic filter for contamination.
Repair cause of contamination. Flush
hydraulic system.
Large particles of contamination in steering Inspect hydraulic filter for contamination.
unit. Repair cause of contamination. Flush
hydraulic system.
Steering unit locks up Large particles of contamination in steering Inspect hydraulic filter for contamination.
unit. Repair cause of contamination. Flush
hydraulic system.
★ Thermal shock Do priority valve LS port flow test in group
3. This oil flow provides a warm-up flow to
steering unit when not using the steering.
Worn or damaged steering unit. Repair or replace steering unit.
Abrupt steering wheel Improperly timed gerotor gear in steering Time gerotor gear.
oscillation unit.
Steering wheel turns by Lines connected to wrong port. Reconnect lines.
itself
Vibration in steering sys- High priority valve setting. Do priority valve pressure test.
tem or hoses jump
Neutral position of steering Steering column and steering unit out of Align the steering column with steering unit.
wheel cannot be obtained, line.
i.e. there is a tendency
Too little or no play between steering col- Adjust the play and, if necessary, shorten
towards "motoring"
umn and steering unit input shaft. the splines journal.
Pinching between inner and outer spools. Contact the nearest service shop.
★ Thermal shock is caused by a large temperature differential (approx 30˚C, 50˚F) between the
steering unit and hydraulic oil. If the steering is not operated for a long period of time and the orifice in
the bottom of the priority valve spool is plugged, the steering unit may bind up when the steering is
operated if the hydraulic oil is hot enough.
5-16
"Motoring" effect. Leaf springs are stuck or broken and have Replace leaf springs.
The steering wheel can therefore reduced spring force.
turn on its own.
Inner and outer spools pinch, possibly due Clean steering unit or contact the nearest
to dirt. service shop.
Return pressure in connection with the Reduce return pressure.
reaction between differential cylinder and
steering unit too high.
Oil is needed in the tank. Fill with clean oil and bleed the system.
Steering cylinder worn. Replace or repair cylinder.
Gear wheel set worn. Replace gear wheel set.
Spacer across cardan shaft forgotten. Install spacer.
5-17
Backlash Cardan shaft fork worn or broken. Replace cardan shaft.
Leaf springs without spring force or broken. Replace leaf springs.
Worn splines on the steering column. Replace steering column.
"Shimmy" effect. The Air in the steering cylinder. Bleed cylinder.
steered wheels vibrate. Find and remove the reason for air collec-
(Rough tread on tires tion.
gives vibrations)
Mechanical connections or wheel bearings Replace worn parts.
worn.
High priority valve setting pressure. Set pressure as regular value.
Steering wheel can be One or both shock valves are leaky or are Clean or replace defective of missing
turned slowly in one or missing in steering unit. valves.
both directions without
the steered wheels turn-
ing.
Steering is too slow and Insufficient oil supply to steering unit, pump Replace pump or increase number of revo-
heavy when trying to turn defective or number of revolutions too low. lutions.
quickly.
Relief valve setting too low. Adjust valve to correct setting.
Relief valve sticking owing to dirt. Clean the valve.
Spool in priority valve sticking owing to dirt. Clean the valve, check that spool moves
easily without spring.
Too weak spring in priority valve. Replace spring by a stronger.
"Kick back" in steering Fault in the system. Contact authorized man or shop.
wheel from system. Kicks
from wheels.
5-18
Heavy kick-back in steer- Wrong setting of cardan shaft and gear- Correct setting as shown in this manual.
ing wheel in both direc- wheel set.
tions.
Turning the steering wheel Hydraulic hoses for the steering cylinders Connect lines to correct ports.
activates the steered have been switched around.
wheels opposite.
Hard point when starting Spring force in priority valve too weak. Replace spring by a stronger.
to turn the steering wheel
Oil is too thick (cold). Let motor run until oil is warm.
Too little steering force Pump pressure too low. Correct pump pressure.
(possibly to one side only).
Too little steering cylinder. Fit a larger cylinder.
Piston rod area of the differential cylinder Fit cylinder with thinner piston rod or 2 dif-
too large compared with piston diameter. ferential cylinders.
Leakage at either input Shaft defective. Replace shaft seal.
shaft, end cover, gear-
Screws loose. Tighten screws.
wheel set, housing or top
part. Washers or O-rings defective. Replace.
5-19
1. HYDRAULIC OIL CLEAN UP PROCEDURE USING PORTABLE FILTER CADDY

※ Service equipment and tool.
·Portable filter caddy
·Two 3658 mm (12 ft) × 1" I.D. 100R1
hoses with 3/4 M NPT ends
·Quick disconnect fittings
·Discharge wand
·Various size fittings and hoses
※ Brake system uses oil from hydraulic oil
tank. Flush all lines in the steering sys-
tem.
Disassemble and clean major compon-
ents for steering system.
Steering components may fail if steering
system is not cleaned after hydraulic oil
tank contamination.
1) If hydraulic system is contaminated due to
a major component failure, remove and dis-
assemble steering cylinders to clean debris
from cylinders.
2) Install a new return filter element. Clean fil-
ter housing before installing new element.
※ For a failure that creates a lot of debris,
remove access cover from hydraulic oil
tank. Drain and clean hydraulic oil tank of
fill the specified oil to hydraulic oil tank
through upper cover.
3) To minimize oil loss, pull a vacuum in
hydraulic oil tank using a vacuum pump.
Connect filter caddy suction line to drain
port at bottom of hydraulic oil tank using
connector. Check to be sure debris has not
closed drain port.
4) Put filter caddy discharge line into hydraulic
oil tank filter hole so end is as far away from
drain port as possible to obtain a through
cleaning of oil.
5-20
5) Start the filter caddy. Check to be sure oil
is flowing through the filters.
Operate filter caddy approximately 10 min-
utes so oil in hydraulic oil tank is circulated
through filter a minimum of four times.
※ Hydraulic oil tank capacity 105ℓ(27.7 U.S
gal).
Leave filter caddy operating for the next
steps.
6) Start the engine and run it at high idle.
※ For the most effective results, cleaning
procedure must start with the smallest
capacity circuit then proceed to the next
largest capacity circuit.
7) Operate all functions, one at a time, through
a complete cycle in the following order:
clam, steering, bucket, and boom. Also
include all auxiliary hydraulic functions.
Repeat procedure until the total system
capacity has circulated through filter caddy
seven times, approximately 30 minutes.
Each function must go through a minimum
of three complete cycles for a through
cleaning for oil.
※ Filtering time for machines with auxiliary
hydraulic functions must be increased
because system capacity is larger.
8) Stop the engine. Remove the filter caddy.
9) Install a new return filter element.
10) Check oil level in hydraulic oil tank ; Add oil
if necessary.
5-21
2. TEST TOOLS
1) CLAMP-ON ELECTRONIC TACHOMET-
ER INSTALLATION
· Service equipment and tools
B
Tachometer
A : Clamp on tachometer.
Remove paint using emery cloth and
C
connect to a straight section of injec-
tion line within 100 mm (4in) of pump.
Finger tighten only-do not over tighten. D
B : Black clip (-). Connect to main
frame. A
C : Red clip (+). Connect to transducer.
D : Tachometer readout. Install cable. 75795SE32
2) DIGITAL THERMOMETER INSTALLATION

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

The display monitor tachometer is accurate
enough for test work.
mph
7807A3CD03
5-22
3. STEERING SYSTEM RESTRICTION TEST
· SPECIFICATION
Oil temperature 45±5˚C (113±9˚F)
Engine speed High idle
Maximum pressure 2MPa (20 bar, 290psi)
at steering unit
· GAUGE AND TOOL
Gauge 0~7 MPa (0~70 bar, 0~1000 psi) 2EA
· This test will check for restrictions in the
steering system which can cause overheat-
ing of hydraulic oil.
1) Install temperature reader.
(see temperature reader installation proce-
dure in this group).
2) Heat hydraulic oil to specifications.
(see hydraulic oil warm up procedure at P
page 6-49).
3) Connect fitting (A) and install gauge.
A
Do not operate steering or loader funct-
ions or test gauge may be damaged.
4) Run engine at specification and read pres-
sure gauges.
If pressure is more than specification at the
steering unit, inspect priority valve for a
stuck spool. Make sure orifice plugs
installed in ends of priority valve spool.
Check for plugged orifice in priority valve LS
port. 74033ASE16
5-23
4. STEERING UNIT LEAKAGE TEST
· SPECIFICATION
Maximum leakage 10ℓ/min (2.6 gpm) Cap fitting
· GAUGE AND TOOL T
Temperature reader
Measuring container (approx. 20ℓ) Steering unit
Stop watch
1) Install frame locking bar to prevent machine
from turning.
(see temperature reader installation proce-
dure in this group).
(see hydraulic oil warm up procedure at
page 6-49).
4) Disconnect return hose from fitting.
Install cap fitting.
5) Run engine at specifications. Rotate
steering wheel against locking bar using
approximately 1.2 kgf·m of force.
Measure oil flow from return hose for 1
Safety lock bar
minute.
6) Leakage is greater than specifications,
repair or replace steering unit. 7407B5SE09
5-24
5. STEERING UNIT PRESSURE TEST
· SPECIFICATION
Oil pressure 20.5~21.5 MPa LS
(205~215 bar, 2970~3100 psi) CF
· GAUGE AND TOOL

Gauge 0~35 MPa (0~350 bar, 0~5000 psi)
Temperature reader P
1) Connect test fitting and gauge to P port on

steering unit.
2) Install temperature reader (see installation
procedure in this group).
3) Install frame locking bar.
4) Heat hydraulic oil to specifications (see
hydraulic oil warm up procedure at page
6-49).
5) Run engine at specifications and turn
steering wheel rapidly hold approximately
22N (5lb force) pressure on wheel with
frames locked. Safety lock bar
※ If steering wheel is turned slowly, it will
continue to with the frames locked.
This will give an incorrect pressure read-
ing. Relief valve
If steering wheel continues to turn rapidly
with the frames locked, steering system
leakage is indicated.
A
6) Read pressure gauge. This is the steering B
unit relief pressure.

7) If pressure in not to specification, remove
the plug (A) from steering unit. Turn adjust-
ing screw (B) in relief cartridge using a hex
head wrench (8 mm) to adjust pressure. 7407B5SE10
If pressure cannot be adjusted to specifica-

tion, disassemble and inspect steering unit.
5-25
6. PRIORITY VALVE "LS" PORT FLOW
TEST
· SPECIFICATION
Engine speed Low idle
LS port flow(Approx) 0.5ℓ/min (0.13 gpm)
· GAUGE AND TOOL
Temperature reader
Measuring container
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 explana-
tion of thermal shock, page 5-16).
LS
A missing orifice can cause the pump to be
loaded to high pressure at all times causing B
overheating.
A
1) Install temperature reader. (See tempera-
ture reader installation procedure in this
group).
2) Heat hydraulic oil to specifications. (See
hydraulic oil warm up procedure at page
6-49).
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. 7407B5SE23
5-26
1. PRIORITY VALVE
1) STRUCTURE
7 6 2 5 4 1 3
CF
LS
P EF
7407B5SE24
1 Body 4 Spring 7 O-ring

2 Spool 5 Orifice
3 Plug 6 Plug
2) TOOLS
·Torque wrench (5 kgf·m)
·Hex socket wrench (1")
·Hex socket wrench (7/8")
·Hex wrench (7/32")
·Pincette
·Grease
5-27
3) DISASSEMBLY
※ Cleanliness is the primary means of
assuring satisfactory the priority valve life.
Select clean place.
Before removing the piping, clean the sur-
rounding area of valve ports.
(1) Fix the body (1) in a vise with copper or

lead sheets. P EF
Do not over tighten jaws.

(2) Loosen plug (3) for LS port.
7405S PV01
(3) Remove spring (4).

P EF
7405S PV02
(4) Remove plug (6) and separate O-ring (7)

individually. P EF
7405S PV03
5-28
(5) Remove the spool (2).
※ Can't remove the orifice (5) from spool (2), P EF
because the orifice was locked at the

spool.
7405S PV04
(6) The priority valve is now dismantled.
7405S PV05
5-29
4) ASSEMBLY
※ Clean all metal parts in clean solvent and
blow dry with air and correct any damage,
burrs and rust.
※ Do not wipe dry with cloth or paper towel.
※ Replace seals such as O-ring with new
ones as a rule and coat with grease.
Fix the body (1) in a vise.

(1)
※ Do not over tighten jaws. P EF
Insert the spool (2) in the body (1).

(2)
※ Secure the spool (2) remain in their
correct direction as the illustration.
※ Secure the spool (2) to move smoothly by
finger.
7405S PV06
(3) Install the O-ring (7) onto plug (6) and

install the plug (6) into the body (1). P EF
·Tighten torque : 6.1 kgf·m (44.3 lb·ft)
7405S PV07
(4) Insert the spring (4) into the body (1).

P EF
7405S PV08
5-30
(5) Install the O-ring (7) on plug (3) and install
the plug (6) into the housing (4). P EF
·Tighten torque : 6.1 kgf·m (44.3 lb·ft)
This completes assembly.
7405S PV09
5-31
5) TROUBLESHOOTING
Steering wheel is 1. Relief valve of steering unit is clogged with Disassembly, clean and reassembly.
heavy. 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 is a. Pump is faulty. Check pump.
heavy at engine
low idle)
(steering speed is b. Control pressure is low. Reset control pressure.
not high at engine
c. Piping is faulty. Replace piping.
high idle)
d. Pump is faulty. Check pump.
Abnormal noise 1. Relief valve of steering unit is clogged with Disassembly, clean and reassembly.
dirt.
Disassembly, clean and reassembly or
2. Spool is stuck.
replace.
Leakage 1. Loosen the plug. Retighten the specified torque.
2. O-ring is damaged. Replace.
5-32
2. STEERING UNIT
1) STRUCTURE
5
38 31
37 6
36
35 33
34 7
8
39 2
34
35 10
39 36
38 9
37 11
12
13
14
13
15
19
13
16
17
18
74095SE05
1 Dust seal ring 10 Cardan shaft 19 Screw

2 Housing, spool, sleeve 11 O-ring 31 Set of O-rings
3 Ball 12 Intermediate plate 33 Rolled pin
4 Thread bushing 13 O-ring 34 Screw
5 Roto glyd ring 14 Distributor plate 35 Shock valve
6 Bearing assembly 15 Gearwheel set 36 Spring
7 Ring 16 End cover 37 O-ring
8 Cross pin 17 Washer 38 Plug
9 Set of spring 18 Screw with pin 39 Housing, check valve
5-33
2) TOOLS
(1) Holding tool.
7405S STVLV38(1)
(2) Assembly tool for O-ring and kin-ring.
7405S STVLV38(2)
(3) Assembly tool for dust seal.
7405S STVLV38(3)
(4) Torque wrench 0-7.1 kgf·m (0-51.6 lb·ft).

13 mm socket spanner
12 mm screwdriver
6 mm screwdriver
2 mm screwdriver
Plastic hammer
Ratchet spanner
7405S STVLV38(4)
5-34
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).
7405S STVLV39(1)
(2) Remove the end cover, sideways.
7405S STVLV39(2)
(3) Lift the gearwheel set with spacer bushing

(and spacer if fitted) off the unit. Take out
the two O-rings.
7405S STVLV39(3)
(4) Remove spacer bushing and spacer(if

fitted) from the gearwheel.
7405S STVLV39(4)
5-35
(5) Remove cardan shaft.
7405S STVLV40(1)
(6) Remove distributor plate.
7405S STVLV40(2)
(7) Remove O-ring.
7405S STVLV40(3)
(8) Lift off intermediate plate.
7405S STVLV40(4)
5-36
(9) Remove O-ring.
7405S STVLV41(1)
(10) Screw out the threaded bushing.
7405S STVLV41(2)
(11) Remove cross pin.
7405S STVLV41(3)
(12) Shake out the ball (Ø8.5 mm).
7405S STVLV41(4)
5-37
(13) Pull sleeve and spool out of the housing.
7405S STVLV42(1)
(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.
7405S STVLV42(2)
(15) Carefully pull the spool out of the sleeve.
7405S STVLV42(3)
(16) Press the neutral position springs out of

their slots in the spool.
7405S STVLV42(4)
5-38
(17) Remove dust seal and O-ring.
7405S STVLV43(1)
(18) The steering unit is now completely

disassembled.
7405S STVLV43(2)
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.
5-39
4) ASSEMBLY
(1) Assemble spool and sleeve.
※ The sleeve and spool are correctly B A
assembled when
① The slots-in sleeve and spool-for the
neutral position springs are opposite
each other and
② One of the 3 T-shaped grooves (A) in the
spool is opposite one of the sets (B) of
small holes in the sleeve. 7405S STVLV44(1)
(2) Place the two flat neutral position springs

in the slot.
7405S STVLV44(2)
(3) Place the curved springs between the flat

ones and press them into place.
7405S STVLV44(3)
(4) Line up the spring set.
7405S STVLV44(4)
5-40
(5) Guide the spool into the sleeve.
7405S STVLV45(1)
(6) Press the springs together and push the

neutral position springs into place in the
sleeve.
7405S STVLV45(2)
(7) Line up the springs and center them.
7405S STVLV45(3)
(8) Guide the ring down over the sleeve.

※ The ring should be able to rotate-free of
the springs.
7405S STVLV45(4)
5-41
(9) Fit the cross pin into the spool/sleeve.
7405S STVLV46(1)
(10) Fit bearing races and needle bearing as

shown on below drawing.
7405S STVLV46(2)
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
7405S STVLV46(3)
(11) Grease O-ring and kin-ring with hydraulic

oil and place them on the tool. See next
page.
7405S STVLV46(4)
5-42
7405S STVLV47(1)
(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.
7405S STVLV47(2)
(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.
7405S STVLV47(3)
(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.
7405S STVLV47(4)
5-43
(15) The spool set will push out the assembly
tool guide. The O-ring is now in position.
7405S STVLV48(1)
(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.
7405S STVLV48(2)
(17) Put the ball into the hole indicated by the

arrow.
7405S STVLV48(3)
(18) Screw the threaded bushing lightly into

the bore. The top of the bushing must lie
just below the surface of the housing.
7405S STVLV48(4)
5-44
(19) Grease the O-ring with mineral oil
approximate viscosity 500 cSt at 20˚C
and place it in the groove.
7405S STVLV49(1)
(20) Place the intermediate plate so that the

channel holes match the holes in the
housing.
7405S STVLV49(2)
(21) Grease the O-ring with mineral oil

and place it in the groove.
7405S STVLV49(3)
(22) Place the distributor plate so that the

channel holes match the holes in the
intermediate plate and the housing.
7405S STVLV49(4)
5-45
(23) Guide the cardan shaft down into the bore
so that the slot is parallel with the
connection flange.
7405S STVLV50(1)
(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.
7405S STVLV50(2)
(25) Grease the two O-rings with mineral oil

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.
※ Turn the gear rim so that the smaller
diameter of the holes face the distributor
plate.
7405S STVLV50(3)
(26) Orientate the holes with a single screw.
7405S STVLV50(4)
5-46
(27) Place the end cover in position.
7405S STVLV51(3)
(28) Place the washers over the holes and the

rolled pin in the hole shown.
7405S STVLV51(4)
(29) Fit the other six screws. Cross - tighten all

the screws and the rolled pin with a
torque of 3 kgf·m(22 lb·ft). Steering
±0.6 ±4.4
unit can now be function tested.
7405S STVLV52(1)
(30) Turn the steering unit 180˚ and place the

dust seal ring in the housing.
7405S STVLV52(2)
5-47
(31) Fit the dust seal ring in the housing using
special tool and a plastic hammer.
7405S STVLV52(3)
(32) Press the plastic plugs into the connection

ports. Do not use a hammer.
7405S STVLV52(4)
5-48
3. VALVE BLOCK
1) STRUCTURE
31
33
38
37
36
35
39
34
35
39 36
37
38
P,T,L,R port PF 1/2

Shock valves 270-290 bar
7407SE12
31 Set of springs 36 Spring

33 Rolled pin 37 O-ring
34 Screw 38 Plug
35 Shock valve 39 Housing and check valve
5-49
2) TOOLS
(1) Hexagon socket spanner, 8 mm.
7405S OVLOAD63(1)
(2) Torque wrench, 0~7.1 kgf·m (0~51 lb·ft)

with 8 mm hexagon socket spanner.
7405S OVLOAD63(2)
(3) Adjustable wrench.
7405S OVLOAD63(3)
5-50
3) DISASSEMBLY
(1) Remove the rolled pin.
7405S OVLOAD64(1)
(2) Remove the plug (38) and O-ring (37).
838
737
7405S OVLOAD64(2)
(3) Remove the spring (36) and shock valve

(35). 636
535
7405S OVLOAD64(3)
(4) Remove the O-ring set (31).

1,2
31
7405S OVLOAD64(4)
5-51
(5) Remove the check valve (39).
939
7405S OVLOAD65(1)
(6) The overload valve is now disassembled.
7405S OVLOAD65(2)
5-52
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 (39).

9
39
7405S OVLOAD66(1)
(2) Fit the shock valve (35) and spring (36).

6
36
5
35
7405S OVLOAD66(2)
(3) Fit the O-ring (37) and screw the plug

(38). 8
38
37
7
7405S OVLOAD66(3)
5-53
(4) Fit the rolled pin.
7405S OVLOAD66(4)
(5) The overload valve is now assembled. It

can be checked for leakage separately or
when mounted on a steering unit.
7405S OVLOAD67(1)
(6) Locate the four O-rings between overload

valve and steering unit and fit these
components together.
7405S OVLOAD67(2)
(7) Tighten the hexagon socket screws with a

+0.5 +3.6
torque of 6.6 kgf·m(47.7 lb·ft).
0 0
7405S OVLOAD67(3)
5-54
(8) Press the plastic plugs into the connection
ports. The overload valve is now
assembled.
7405S OVLOAD67(4)
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.
5-55
4. STEERING CYLINDER
1) STRUCTURE
3 9,8 12 6,5 7 11,10 4 2 1 13 14 15 16 17 25 24
22,23
19,20,21 18
7407SE07
1 Tube assy 10 O-ring 18 Pipe assy

2 Rod assy 11 Back up ring 19 U-bolt
3 Gland 12 O-ring 20 Hexagon nut
4 Du bushing 13 Piston 21 Washer spring
5 Rod seal 14 O-ring 22 Bushing
6 Back up ring 15 Piston seal 23 Dust seal
7 Buffer ring 16 Wear ring 24 Spherical bearing
8 Dust wiper 17 Nylon nut 25 Retaining ring
9 Snap ring
5-56
2) TOOLS AND TIGHTENING TORQUE
(1) Tools
Tool name Remark

17 B
Spanner 32
41
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
kgf·m lbf·ft
Gland 3 M70 × 2.0 70 ± 7 506 ± 51
Piston nut 17 M27 × 2.0 75 ± 8 542 ± 58
Nut(Pipe assy) 18 M22 × 1.5 33 ± 3 239 ±21.7
Nut 20 M10 × 1.5 3.2 ± 0.3 23.1± 2.2
5-57
3) DISASSEMBLY
(1) Remove cylinder head and piston rod
① Hold the clevis section of the tube in a
vise.
※ Use mouth pieces so as not to damage
the machined surface of the cylinder
tube. Do not make use of the outside
piping as a locking means.
② Pull out piston rod (2) about 200 mm (7.1

in). Because the piston rod is rather
heavy, finish extending it with air
pressure after the oil draining operation. m
0m
20
7407ASE30
③ Loosen and remove the gland (3).

※ Cover the extracted piston rod (2) with
rag to prevent it from being accidentally
damaged during operation.
3
2
7407ASE31
④ Draw out gland (3) and piston rod (2)

assembly together from cylinder tube (1).
Lift
※ 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 been drawn out to
approximately two thirds of its length, lift Full straight Oil pan
it in its center to draw it completely. sideways
7407ASE32
5-58
※ Note that the plated surface of piston rod
(2) is to be lifted. For this reason, do not
use a wire sling and others that may
damage it, but use a strong cloth belt or
a rope.
⑤ Place the removed piston rod assembly

on a wooden V-block that is set level.
※ Cover a V-block with soft rag.
Piston rod assy
Wooden block
7407ASE33
(2) Remove piston and gland assembly

① Remove the nylon nut (17). 14 15 16 13 17
② Remove piston assembly (13), and
O-ring (14).
7407ASE34
④ Remove the gland (3) assembly from

piston rod (2). Lift with a crane
※ If it is too heavy to move, move it by
Plastic
striking the flanged part of gland (3) hammer 8,9 5,6 7 4
with a plastic hammer.
※ Pull it straight with cylinder head Full straight
assembly lifted with a crane.

Exercise care so as not to damage the
lip of rod bushing (4) and packing 3
(5,6,7,8,9) by the threads of piston rod 2
7407ASE35
(2).
5-59
(3) Disassemble the piston assembly
① Remove wear ring (16) and piston seal 15 16
(15).
※ Exercise care in this operation not to
damage the grooves.
7407ASE42
(4) Disassemble gland assembly

① Remove back up ring (11), and O-ring 8,9 12 5,6 7 10,11 4
(10).
② Remove O-ring (12).
③ Remove snap ring (9) and dust wiper (8).
④ Remove back up ring (6), rod seal (5).
⑤ Remove buffer ring (7).
※ Exercise care in this operation not to
damage the grooves.
7407ASE43
※ Do not remove seal and ring, if does not
damaged.
5-60
4) ASSEMBLY
(1) Assemble gland assembly
※ Check for scratches or rough surfaces if
found smooth with an oil stone.
① Coat the inner face of gland (3) with
hydraulic oil.
3
7407ASE44
② Coat dust wiper (8) with grease and fit

Press here
dust wiper (8) to the bottom of the hole of (Straight down)
dust wiper.
At this time, press a pad metal to the 8 Metal
metal ring of dust seal.
③ Fit snap ring (9) to the stop face.
7407ASE45
④ Fit back up ring (6) and rod seal (5) to

corresponding grooves, in that order.
⑤ Fit buffer ring (7).
※ Coat each packing with hydraulic oil
Wrong Right
before fitting it.
※ Insert the backup ring until onside of it is
inserted into groove.
7577ASE42
※ Rod seal (5) has its own fitting direction.

Therefore, confirm it before fitting them. Push bar
※ 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
7407ASE46
5-61
⑥ Fit back up ring (11) to gland (3).
※ Put the backup ring in the warm water of 4
30~50˚C.
10
⑦ Fit O-ring (10) to gland (3).
⑧ Fit bushing (4) to gland (3). 11
3
12
7407ASE47
(2) Assemble piston assembly

※ Check for scratches or rough surfaces.
If found smooth with an oil stone.
① Coat the outer face of piston (13) with
hydraulic oil. 13
7407ASE36
② Fit piston seal (15) to piston

※ Put the piston seal in the warm water of
60~100˚C for more than 5 minutes. 15
※ After assembling the piston seal, press
its outer diameter to fit in.
7407ASE48
③ Fit wear ring (16) to piston (13).

④ Fit O-ring (14) to piston (13). 14 15 16 13
7407ASE49
5-62
(3) Install piston and gland assembly
① Fix the piston rod assembly to the work Gland assembly Piston rod
bench.
② Apply hydraulic oil to the outer surface of
piston rod (2), the inner surface of piston
and gland.
③ Insert gland assembly to piston rod (2).
·Tightening torque : 70 ±7kgf·m
(506 ± 51lbf·ft)
7407ASE37
④ Fit piston assembly to piston rod.

Piston assembly
Piston rod
7407ASE38
⑤ Tighten nylon nut(17) to piston rod(2).

·Tightening torque : 75 ± 8kgf·m 2 17
(542 ± 58lbf·ft)
7407ASE39
5-63
(4) Overall assemble
Fix with a bar
① Place a V-block on a rigid work bench.
Mount the cylinder tube assembly (1) on Lift
it and fix the assembly by passing a bar
through the clevis pin hole to lock the
assembly.
② Insert the piston rod assembly in to the Straight
cylinder tube assembly, while lifting and
moving the piston rod assembly with a Apply liquid packing
7407ASE40
crane.
※ Be careful not to damage piston seal by
thread of cylinder tube.
※ Refer to the table of tightening torque.
7407ASE41
5-64
5. CENTER PIVOT PIN
1) CONSTRUCTION
Figure shows the construction of the center pivot pin assembly. This assembly serves to connect
the front frame with the rear frame; two sets of assemblies are provided, one each for the upper
and lower parts. The numbers in parentheses following the parts name denote the item numbers
shown in the figure in the disassembly and assembly procedures.
14,15 7 6 21
9
13 12
18
2
1
14,15 3,4 20
Clearance A
20 19
1
3,4
9 8
Clearance B 16,17
21 10 18 14,15
UPPER LOWER
7407B5SE13
1 Bearing 8 Collar 15 Hardened washer

2 Cover 9 Plate 16 Shim (0.1 t)
3 Shim (0.1 t) 10 Pin 17 Shim (0.5 t)
4 Shim (0.5 t) 12 Seal 18 Bushing
6 Pin 13 Seal 19 Cover
7 Collar 14 Hexagon bolt 20 Front frame
21 Rear frame
5-65
2) DISASSEMBLY
After supporting the front frame and the
rear frame as horizontally as possible using
wood blocks and jacks, disassemble as
fo l l o w s : I n o r d e r t o fa c i l i t a t e t h e
disassembly/assembly of the center pivot
pins, remove the drive shaft, hydraulic line
and steering cylinder first.
(1) Maintain the horizontal level of front frame
(20) and rear frame (21), and then UPPER
remove hexagon bolt (14), washer (15)
and plate (9). 14
9
(2) Take out upper pin (10) to the downside
using a metal punch.
20
21
10
7407B5SE14
(3) Maintain the front frame horizontal level,

remove hexagon bolts (14) and then LOWER
remove the plate (9) and shims (16, 17). 21
6
(4) Take out lower pin (6) to the upside using
a metal punch carefully.
(5) Jack up or lifting the front frame (20)
20
slightly, the collar (8) protrudes over the
8
rear frame.
Remove the collar (8).
9
(6) Lift the frame by passing the slinging wire 16,17
rope at four positions of front frame, in 14
7407B5SE15
order to separate it from the rear frame.
(7) Support the front frame safely.
5-66
(8) Remove bolt (14), washer (15) and then
UPPER
take out cover (2) and shims (3, 4).
14 13 2
(9) Take out dust seal (13) from the cover (2).
3,4
(10) Remove the bearing (1), and dust seal
(13).
13 7407B5SE16
(11) Remove bolt (14), washer (15) and then

take out cover (19) and shims (3, 4). LOWER
12 7
(12) Take out the dust seal (12) from the cover
(19). 1
(13) Remove the bearing (1), collar (7) and

dust seal (12).
3,4
19 12 14
7407B5SE17
3) INSPECTION
(1) Check the bearing sliding surface for excessive wear, scorching or scratches; replace if
necessary.
(2) Replace all dust seals (12,13) with new ones.
(3) Grind any pins (6, 10) dented with an oilstone or replace any pins abrasive excessively.
(4) Check inside cover (2, 19) and collar (7, 8) for dents or scratches; if any damage is found, correct
with a grinder or replace.
(5) The serviceable limit of pins and bushings is shown in the table below. Unit : mm
Std Serviceable limit

Item No. Name Remedy
dimension Outer dia Inner dia Clearance
6, 10 Pin 64.5 -
1 Tapered roller bearing 65 - 65.5 0.8 Replace
7, 8 Collar - 65.5
12, 13 Dust seal When removed Replace
5-67
4) ASSEMBLY
14,15 7 6 21
9
13 12
18
2
1
14,15 3,4 20
Clearance A
20 19
1
3,4
9 8
Clearance B 16,17
21 10 18 14,15
UPPER LOWER
7407B5SE18
Assemble the center pivot group by reversing the order of disassembly while paying close attention
to the following.
(1) Put the dust seal (12,13) into cover (2,19) and front frame (20).
※ Apply grease to the lip of the dust seal. Insert the dust seal so that the dust seal lip faces out and
punch four places on the outer circumference of the seal to lock it.
(2) Lower the temperature of the lower bearing cup to -75±5˚C (-103±9˚F ) and install it to front
frame until it contacts the bottom of the frame.
(3) Coat lightly with oil and install lower bearing in bore in front frame. Coat lightly with oil and install
upper bearing in bore in upper front frame.
(4) Place the cover (2, 19) and hold in place with bolt (14). At this time, adjust shims (3, 4) to press
the shoulder of bearing (1) against retainer.
· Adjustment method of clearance A
① Install bearing (1) and cover (2) without shim (3, 4)
Install four of bolt (14) so that each bolt is separated by 90 degrees.
·Tightening torque : 0.8~1.0 kgf·m (5.8~7.2 lbf·ft)
② Adjust shims (3, 4) in order to control the clearance A.
·Clearance A : Below 0.1 mm
·Shim thickness : 0.1 mm, 0.5 mm
5-68
(5) Apply grease to lower collar (8) and insert it to the lower of roller bearing.
(6) After setting the bearing so that its upper surface is horizontal, tighten the all the bolt (14).
After tightening, confirm that tapered roller bearing moves lightly ; if does not move smoothly, add
shims (3, 4).
· Tightening Torque : 9.8~15.8 kgf·m (70.9~114 lbf·ft)
· Apply loctite #243.
(7) Move the front frame and join it to the rear frame so that match the pin hole at the center.
(8) Apply grease to pin (10), bushing (18) and insert it into tapered roller bearing (1).
(9) Apply grease to lower collar (8) and insert it to the lower of roller bearing through rear frame (21).
(10) Apply grease to pin (6) and insert it into tapered roller bearing (1).
(11) Before tightening bolt (14), adjust shims (16, 17) in order to control the clearance between the
plate (9) and rear frame (21).
·Adjustment
Adjustment method of clearance B
① Install pin (6) and plate (9) without shim (16, 17).
Install four of bolt (14) so that each bolt is separated by 90 degrees.
·Tighting torque : 0.8~1.0 kgf·m (5.8~7.2 lbf·ft)
② Adjust shims in order to control the clearance B.
·Clearance B : 0.1~0.2 mm
·Shim thickness : 0.1 mm, 0.5 mm
(12) Tighten the all the bolts (14).
·Tightening Torque : 9.8~15.8 kgf·m (70.9~114 lbf·ft)
·Apply loctite #243.
5) TROUBLESHOOTING
Trouble Probable cause Remed
Capscrew for fixing steering valve is loose Retighten
Faulty center pivot pin mounting bolts Retighten
Shock is felt when steering
Center pivot pins have worn out Readjust or replace
Faulty hydraulic system See hydraulic system
Fault fixing of connecting capscrews Retighten
Center pins have worn out Readjust or replace
Shock is felt when moving
Bearings of support unit have worn out Retighten
backward or forward
Drive shaft damaged See drive system
Faulty transmission See transmission system
5-69
Group 1 Structure and Function ----------------------------------------------------------------------------------- 6-1

Group 2 Operational Checks and Troubleshooting ----------------------------------------------------- 6-35
Group 3 Tests and Adjustments ----------------------------------------------------------------------------------- 6-45
Group 4 Disassembly and Assembly --------------------------------------------------------------------------- 6-60
1. HYDRAULIC SYSTEM OUTLINE

The loader hydraulic system is a pilot operated, open center system which is supplied with flow from
the fixed displacement main hydraulic pump.
The polit control system is a low pressure, closed center hydraulic system which is supplied with flow
from the first(steering) pump.
The loader system components are :
·Main pump
·Main control valve
·Bucket cylinder
·Boom cylinders
·Pilot supply unit
·Remote control valve (Pilot control valve)
·Safety valve
The pilot supply unit consists of the pressure reducing valve, relief valve and accumulator.
Flow from the main hydraulic pump not used by the steering system leaves the priority valve EF port.
It flows to the inlet port plate of four blocks type main control valve.
The main control valve is open center system which routes flow to the boom, bucket or auxiliary
cylinders (not shown) when the respective spools are shifted.
Flow from the steering pump is routed to the pilot supply unit where the steering pump outlet
pressure is reduced to pilot circuit pressure. The pilot supply unit control valve flow to the remote
control valve.
The remote control valve routed flow to either end of each spool valve section in the main control
valve to control spool stroke.
A accumulator mounted on pilot supply unit supplies a secondary pressure source to operated
remote control valve so the boom can be lowered if the engine is off.
The return circuit for the main hydraulic system have return filter inside the hydraulic tank. The return
filter uses a filter element and a bypass valve. The bypass valve is located in the upside of filter.
6-1
32
33
10 11 12
FRONT REAR
Sp 4 B.D/F B.U IN OUT
LH RH LH RH T
A B T
18 P
1 3 4 2 5 6
21
9 BL1 BR1 BL2 BR2 3 T
8
T1 P1 T2 P2 3B
3A
BOOM
5 a3 BOOM UP DOWN b3
34
17 17 L FLOATING
27
2B
15 T
7 A1 A2
2A
19 R
a2
DUMP ROLL BACK
b2
P
PS
P1 T F2
T1
1B 14
A3 P 21MPa 1A
16 a1
AUX
b1
B LS F1
P2 13
PS1
3MPa
CF EF
20 U
P T 6 P
22 LS
P1 T
P
1 A : 1st(Steering) pump
2 B A
B : 2nd(Loader) pump
31
29 M1
23
A
P1
30 M2 24
P2 25 26
28
M
7407S6WE01
1 Main pump 13 Pilot supply unit 25 Return filter

2 Brake pump 14 Line filter 26 Bypass valve
3 Main control valve 15 Safety valve 27 Shockless valve
4 Remote control valve 16 Accumulator 28 Pump motor (opt)
5 Steering unit 17 Accumulator 29 Check valve (opt)
6 Priority valve 18 Pressure switch 30 Pressure switch (opt)
7 Cut off valve 19 Pressure switch 31 Pressure switch (opt)
8 Brake valve 20 Pressure switch 32 Ride control valve (opt)
9 Dual brake pedal (opt) 21 Pressure switch 33 Accumulator (opt)
10 Steering cylinder 22 Line filter 34 Pressure switch (opt)
11 Bucket cylinder 23 Air breather
12 Boom cylinder 24 Hydraulic tank
6-2
3. WORK EQUIPMENT HYDRAULIC CIRCUIT
11 12
4 B.D/F B.U IN OUT
LH RH
3 T T
P
1 3 4 2 5 6
3B
3A
BOOM
a3 BOOM UP DOWN b3
27
FLOATING
15 T
2B
2A P
DUMP ROLL BACK
a2 b2
F2
14
1B
1A
F1
a1
AUX
b1
P2 13
3MPa
U
P
P1 T
Priority valve EF port
Steering system
Brake system
1
Return line
23
24
25 26
7407B6WE02
1 Main pump 13 Pilot supply unit 25 Return filter

3 Main control valve 14 Line filter 26 Bypass valve
4 Remote control valve 15 Safety valve 27 Shockless valve
11 Bucket cylinder 23 Air breather
12 Boom cylinder 24 Hydraulic tank
6-3
1) WHEN THE RCV LEVER IS IN THE RAISE POSITION
11 12
4 B.D/F B.U IN OUT
LH RH
3 T T
P
1 3 4 2 5 6
3B
3A
BOOM
a3 BOOM UP DOWN b3
27
FLOATING
15 T
Load check valve
2B
2A P
DUMP ROLL BACK
a2 b2
F2
14
1B
1A
F1
a1
AUX
b1
P2 13
3MPa
U
P
P1 T
Steering system
Brake system
1
Return line
23
24
25 26
7407B6WE03
· When the RCV lever (4) is pulled back, the boom spool is moved to raise position by pilot oil
pressure from port 3 of RCV through shockless valve (27).
· The oil from main pump (1) flows into main control valve (3) and then goes to the large chamber of
boom cylinder (12) by pushing the load check valve of the boom spool.
· The oil from the small chamber of boom cylinder (12) returns to hydraulic oil tank (24) through the
boom spool at the same time.
· When this happens, the boom goes up.
6-4
2) WHEN THE RCV LEVER IS IN THE LOWER POSITION
11 12
4 B.D/F B.U IN OUT
3 Check valve T T
LH RH
P
1 3 4 2 5 6
3B
3A
BOOM
a3 BOOM UP DOWN b3
27
FLOATING 39 15 T
2B
2A P
DUMP ROLL BACK
a2 b2
F2
14
1B
1A
F1
a1
AUX
b1
P2 13
3MPa
U
P
P1 T
Steering system
Brake system
1
Return line
23
24
25 26
7407B6WE04
· When the RCV lever (4) is pushed forward, the boom spool is moved to lower position by pilot
pressure from port 1 of RCV through orifice connector (39).
· The oil from main pump (1) flows into main control valve (3) and then goes to small chamber of
boom cylinder (12) by pushing the load check valve of the boom spool.
· The oil returned from large chamber of boom cylinder (12) returns to hydraulic tank (24) through
the boom spool at the same time.
· When the lowering speed of boom is faster, the return oil from the large chamber of boom cylinder
combines with the oil from the pump through the check valve, and flows into the small chamber of
the cylinder.
This prevents cylinder cavitation by the negative pressure when the pump flow cannot match the
boom down speed.
6-5
3) WHEN THE RCV LEVER IS IN THE FLOAT POSITION
11 12
4 B.D/F B.U IN OUT
LH RH
3 T T
P
1 3 4 2 5 6
3B
3A
a3 BOOM UP b3
27 BOOM DOWN FLOATING
15 T
2B
2A P
DUMP ROLL BACK
a2 b2
F2
14
1B
1A
F1
a1
AUX
b1
P2 13
3MPa
U
P
P1 T
Steering system
Brake system
1
Return line
23
24
25 26
7407B6WE05
· When the RCV lever (4) is pushed further forward from the lower position, the pilot pressure
reaches to 13~15bar, then the boom spool is moved to floating position.
· The work ports (3A), (3B) and the small chamber and the large chamber are connected to the
return passage, so the boom will be lowered due to it's own weight.
· In this condition, when the bucket is in contact with the ground, it can be move up and down in
accordance with the shape of the ground.
6-6
4) WHEN THE RCV LEVER IS IN THE DUMP POSITION
11 12
4 B.D/F B.U IN OUT
LH RH
3 T T
P
1 3 4 2 5 6
3B
3A
BOOM
a3 BOOM UP DOWN b3
27
FLOATING
15 T
2B
2A P
DUMP ROLL BACK
a2 b2
F2
14
1B
1A
F1
a1
AUX
b1
P2 13
3MPa
U
P
P1 T
Steering system
Brake system
1
Return line
23
24
25 26
7407B6WE06
· If the RCV lever (4) is pushed right, the bucket spool is moved to dump position by pilot oil pressure
from port 2 of RCV.
· The oil from main pump (1) flows into main control valve (3) and then goes to the small chamber of
bucket cylinder (11) by pushing the load check valve of the bucket spool.
· The oil at the large chamber of bucket cylinder (11) returns to hydraulic tank (24).
· When this happens, the bucket is dumped.
· When the dumping speed of bucket is faster, the oil returned from the large chamber of bucket
cylinder combines with the oil from the pump, and flows into the small chamber of the cylinder.
This prevents cylinder cavitation by the negative pressure when the pump flow cannot match the
bucket dump speed.
6-7
5) WHEN THE RCV LEVER IS IN THE ROLL BACK (retract) POSITION
11 12
4 B.D/F B.U IN OUT
LH RH
3 T T
P
1 3 4 2 5 6
3B
3A
BOOM
a3 BOOM UP DOWN b3
27
FLOATING
15 T
2B
2A P
DUMP ROLL BACK
a2 b2
F2
14
1B
1A
F1
a1
AUX
b1
P2 13
3MPa
U
P
P1 T
Steering system
Brake system
1
Return line
23
24
25 26
7407B6WE07
· If the RCV lever (4) is pulled left, the bucket spool is moved to roll back position by pilot oil pressure
from port 4 of RCV.
· The oil from main pump (1) flows into main control valve (3) and then goes to the large chamber of
bucket cylinder by pushing the load check valve of the bucket spool.
· The oil at the chamber of bucket cylinder (11) returns to hydraulic tank (24).
· When this happens, the bucket roll back.
6-8
6) WHEN THE RCV LEVER IS IN THE HOLD POSITION
11 12
4 B.D/F B.U IN OUT
LH RH
3 T T
P
1 3 4 2 5 6
3B
3A
BOOM
a3 BOOM UP DOWN b3
27
FLOATING
15 T
2B
2A P
DUMP ROLL BACK
a2 b2
F2
14
1B
1A
F1
a1
AUX
b1
P2 13
3MPa
U
P
P1 T
Steering system
Brake system
1
Return line
23
24
25 26
7407B6WE08
· The oil from main pump (1) flows into main control valve (3)
· In this time, the bucket spool, the boom spool and the boom float spool are in neutral position, then
the oil supplied to main control valve (3) returns into hydraulic tank (24) through center bypass
circuit of each spool.
· In this condition, each cylinder keeps the neutral position, so the boom and the bucket is holded.
6-9
4. MAIN PUMP
1) STRUCTURE
6 1 2 8 3 4 5 7
10 11,12 13 9 14
15,17 16
P1 P2

P1 Pressure port (to steering valve) 1" split flange
P2 Pressure port (to MCV) 1" split flange
S Suction port 2" split flange
7407B6WE29
1 Cover 7 Driven gear set 13 Square seal

2 Housing 8 Connecting shaft 14 Dowel pin
3 Carrier 9 Thrust plate 15 Washer
4 Housing 10 Lip seal 16 Stud bolt
5 Cover 11 Rubber seal 17 Hexagon bolt
6 Drive gear set 12 Back up seal
6-10
2) OPERATION
The main hydraulic pump is a fixed displacement gear type pump. The pump is driven at engine
speed by the transmission. The pump shafts are supported by lip seal (10), front cover (1), housing
(2, 4) and rear cover (5). The thrust plate (9) are located between the gear surface and front cover
(1), housing (2, 4) and rear cover (5).
As the drive gear (6) turns the driven gears (7), the gear teeth come out of mesh. Oil flows from the
hydraulic tank through the inlet into the cavity between the gear teeth. As the gears continue to
rotate, the oil becomes trapped between the gear teeth and housing (2, 4).
The trapped oil is then carried to the pump outlet. Oil is forced out the outlet to supply the hydraulic
function. As the gears re-mesh, they form a seal to prevent oil from flowing between the gears and
back to the inlet.
The pump uses outlet pressure oil to load the thrust plate (9) against the gear faces. This controls
internal leakage to maintain pump displacement.
Outlet pressure fills the area bounded by the pressure balance moulded seals (13) to force the
thrust plate against the high pressure area or the gear faces.
6-11
5. REMOTE CONTROL VALVE
1) STRUCTURE
38
37
36
33
32
34
35
23
27
26 28
25 30
24 29
19 31
21 20
22 18
17
8
5 16
9 14
12
15
11
10 13
4
7 PF 1/4
49
6
3 47
2 48
UNC 9/16
1,46
39,40,41,42
45
41,42,43,44 7407S6WE28
1 Body 14 Rod seal 27 Nut 40 Rear holder

2 O-ring 15 O-ring 28 Plug 41 Terminal
3 Plug 16 Push rod 29 Nut 42 Seal wire
4 Spring 17 Plate 30 Set screw 43 Housing
5 Spring seat 18 Rod stopper 31 Nut 44 Rear holder
6 Spool 19 Bushing 32 Nut 45 Clip band
7 Spring seat 20 Rod 33 Handle bar 46 Plug
8 Stopper 21 Magnet 34 Nut 47 Connector
9 Spring 22 Plate 35 Boot 48 O-ring
10 Spring seat 23 Joint assy 36 Handle assy 49 O-ring
11 Spring 24 Joint assy 37 Nut
12 Spring seat 25 Plate 38 Spring washer
13 Plug 26 Washer 39 Housing
6-12
2) OPERATION
T P
B.D/F B.U IN OUT
1 34 2
HYDRAULIC CIRCUIT
(3 Electromagnetic locks) 36
38
35
24 20
21
(1) Hydraulic functional principle 16

4
Pilot devices with end position locks operate as
direct operated pressure reducing valves. 9
They basically comprise of handle (36), four
pressure reducing valves, body (1) and locks. 6
Each pressure reducing valve comprises of a
1
control spool (6), a control spring (9), a return
spring (4), push rod (16) and rod (20).
At rest, handle (36) is held in its neutral position by
return springs (4). Ports (1, 2, 3, 4) are connected 7407S6WE27
to tank port T via drilling.

When handle (36) is deflected, rod (20) is pressed against return spring (4) and control spring (9).
Control spring (9) initially moves control spool (6) downwards and closes the connection between
the relevant port and tank port T. At the same time the relevant port is connected to port P via
drilling. The control phase starts as soon as control spool (6) finds its balance between the force
from control spring (9) and the force, which results from the hydraulic pressure in the relevant port
(ports 1, 2, 3 or 4).
Due to the interaction between control spool (6) and control spring (9) the pressure in the relevant
port is proportional to the stroke of rod (20) and hence to the position of handle (36).
This pressure control which is dependent on the position of the handle (36) and the
characteristics of the control spring permits the proportional hydraulic control of the main
directional valves and high response valves for hydraulic pumps.
A rubber boot (35) protects the mechanical components in the housing from contamination.
6-13
(2) End position lock
Only those control ports, for which it is necessary to hold the handle in a deflected position are
equipped with end position locks.
Electromagnetic lock
When this threshold is overcome, a joint assy (24) contacts the magnet (21); if the magnet (21) is
energized, then handle (36) is held in its end position by magnetic force.
This lock is released automatically when the solenoid is deenergized.
6-14
6. MAIN CONTROL VALVE
1) STRUCTURE
20
19 1
39
11 6 40
21-1
4 6-1 38
23 3 34 36
25 35
30
24
21
8
16
5 8
33
18 8 11
1 37 9 29
32
22
21-1 13
8 31
26
2-1 28 13
2 14
40 21 4
12 19
27
12 15
14
4
19
10 20
7407B6WE45
1 Nut 14 Screw 28 Spool

2 Plug 15 Screw 29 Spool
2-1 O-ring 16 Anti void assy 30 Spring
3 O-ring 18 Spool cap 31 Spring
4 O-ring 19 Spool cap 32 Back up ring
5 Cap screw 20 Cap screw 33 Inlet section assy
6 Plug 21 Spool retainer 34 Spool section assy
6-1 O-ring 21-1 Back up ring 35 Spool section assy
8 O-ring 22 Spool retainer 36 Outlet section assy
9 Spring 23 Screw 37 Poppet
10 Main relief valve 24 Washer 38 Tie rod
11 Port relief valve 25 Spacer 39 Tie rod
12 Spring seat 26 Spring 40 Nut
13 Washer 27 Spring
6-15
STRUCTURE
A1 A2 A3
P
B1 B2 B3
3B
3A
BOOM
BOOM UP DOWN
a3 b3
FLOATING
2B
2A
DUMP ROLL BACK
a2 b2
1B
1A
AUX
a1 b1
b1(a1) b2(a2) b3(a3)

P
HYDRAULIC CIRCUIT
7407B6WE20

P From main pump 1 3/16 - 12UN
T To hydraulic tank 1 5/16 - 12UN
A1, B1 To auxiliary cylinder port 1 3/16 - 12UN
A2, B2 To bucket cylinder port 1 3/16 - 12UN
A3, B3 To boom cylinder port 1 3/16 - 12UN
a3, b3 Boom pilot port 9/16 - 18 UNF
a2, b2 Bucket pilot port 9/16 - 18 UNF
a1, b1 Auxiliary pilot port 9/16 - 18 UNF
6-16
2) BOOM SECTION OPERATION
(1) Spool in neutral
3B
3A
24Mpa BOOM UP BOOM DOWN

a3 b3
FLOATING
24Mpa
2B
2A
24Mpa DUMP ROLL BACK

a2 b2
3A 3B
a3 b3
Low pressure passage

7407B6WE11
If the remote control valve is not operated, the oil supplied from the pump port passes through the
neutral passage to the low pressure passage at the outlet section, and then returns to the tank port.
6-17
(2) Boom raise position
3B
3A
24Mpa BOOM UP
a3 b3
24Mpa
2B
2A

a2 b2
Load check valve(1)
SECTION A-A
3A 3B
A A
a3
b3

7407B6WE12
When the pilot pressure from remote control valve is supplied to the pilot port (a3), the spool moves to
the right and the neutral passage is closed.
The oil supplied from the pump pushes up the load check valve (1) and flow into boom cylinder port
(3A).
The pump pressure reaches proportionally the load of cylinder and fine control finished by shut off of
the neutral passage.
The return oil from cylinder port (3B) flows into the tank via the low pressure passage.
6-18
(3) Boom lower position
Check valve(2)
T
3B
3A
24Mpa BOOM DOWN

a3 b3
24Mpa
2B
2A

a2 b2
Load check valve(1)
SECTION A-A
3A 3B
A A
b3
a3

7407B6WE13
When the pilot pressure from remote control valve is supplied to the pilot port (b3), the spool moves to
the left and the neutral passage is closed.
The oil supplied from the pump pushes up the load check valve (1) and flow into boom cylinder port
(3B). The pump pressure reaches proportionally the load of cylinder and fine control finished by shut off
of the neutral passage.
The return oil from cylinder port (3A) flows into the tank via the low pressure passage.
When the lowering speed of boom is faster, the return oil from the large chamber of boom cylinder
combines with the oil from the pump through the check valve (2), and flows into the small chamber of
cylinder. This prevents cylinder cavitation by the negative pressure when the pump flow cannot match
the boom lowering speed.
6-19
(4) Boom float position
3B
3A
24Mpa FLOATING
a3 b3
24Mpa
2B
2A

a2 b2
3A 3B
b3
a3

7407B6WE14
If the remote control lever pushes further more, the pilot pressure from remote control valve rises over
13-15bar and then the boom lowering spool is pushed to the boom floating position, opening up the
neutral passage to tank and simultaneously (3A), (3B) → T.
In float position the boom drops quickly due to its own weight.
When the bucket touches the ground and the wheeled loader is moving, the bucket raised or lowered
following the unevenness of the ground due to the (3A), (3B) → T connecting.
6-20
3) BUCKET SECTION OPERATION
(1) Spool in neutral
24Mpa
2B
2A

a2 b2
21Mpa
2A 2B
a2 b2
7407B6WE15
If the remote control valve is not operated, the oil supplied from the pump port passage through the
neutral passage to the low pressure passage at the outlet section, and then return to the tank port.
6-21
(2) Retract (roll back) position
24Mpa
2B
2A
24Mpa ROLL BACK

a2 b2
Load check valve(1)

21Mpa
SECTION A-A
2A 2B
A A
b2
a2
7407B6WE16
When the pilot pressure from remote control valve is supplied to the pilot port (b2), the spool moves to
the left and the neutral passage is closed.
The oil supplied from the pump pushes up the load check valve (1) and flow into bucket cylinder port
(2B).
The pump pressure reaches proportionally the load of cylinder and fine control finished by shut off of
the neutral passage.
The return oil from cylinder port (2A) flows into the tank via the low pressure passage.
6-22
(3) Dump position
24Mpa
2B
2A
24Mpa DUMP
a2 b2
Load check valve(1)

21Mpa
SECTION A-A
2A 2B
A A
a2
b2
7407B6WE17
When the pilot pressure from remote control valve is supplied to the pilot port (a1), the spool
moves to the right and the neutral passage is closed.
The oil supplied from the pump pushes up the load check valve (1) and flow into bucket cylinder
port (2A).
The pump pressure reaches proportionally the load of cylinder and fine control finished by shut off
of the neutral passage.
The return oil from cylinder port (2B) flows into the tank via the low pressure passage.
6-23
4) PRESSURE SETTING
A good pressure gage must be installed in Relief valve Check valve Pilot section
poppet(D) poppet(K)
the line which is in communication with the
Pilot poppet(E) Lock nut
work port relief. A load must be applied in
a manner to reach the set pressure of the
relief unit.
(1) Main relief valve

① Loosen lock nut.
② Set adjusting nut to desired pressure Piston poppet(C) Housing O-ring
setting. Piston spring Pilot spring Adjust nut
③ If desired pressure setting cannot be
achieved, add or remove shims as
required. T
④ Tighten lock nut. 210 bar
220bar
⑤ Retest in similar manner as above.
P
7407AWE50
(2) Port relief valve

① Loosen lock nut.
Relief valve Check valve Pilot section
② Set adjusting screw to desired pressure poppet(D) poppet(K)
setting. Pilot poppet(E) Lock nut
③ Tighten lock nut.
④ Retest in similar manner as above.
Piston poppet(C) Pilot spring O-ring

Piston spring Housing Adjust screw
T
240bar
7407AWE51
6-24
5) MAIN RELIEF VALVE
(1) As relief
A D B K
The relief valve is in communication
between the high pressure port HP and
low pressure LP. Oil is admitted through
the hole in poppet C and because of the HP
differential area between diameters A and
B relief valve poppet D and check valve
LP
poppet K are tightly seated as shown in C
the first step.
E
The oil pressure in the high pressure port
Hp has reached the setting of the pilot
poppet spring force and unseats the pilot HP
poppet E and oil flows around the poppet
through the cross drilled holes and to the
LP
low pressure area LP.
D E
The loss of oil behind poppet C, effected
by the opening of pilot poppet E, causes
poppet C to move back and seat against
HP
pilot poppet E. This shuts off the oil flow
to the area behind relief valve poppet D,
LP
and causes a low pressure area internally.

C
D
The imbalance of pressure on the inside
as compared to that of the high pressure
port HP, forces the relief valve poppet D to HP
open and relieve the oil directly to the low
pressure chamber LP in the valve.
LP
7407AWE52
6-25
(2) As anti void
The anti-void unit supplies oil to the high

K G
pressure port HP when cavitation has
occurred. A lower pressure exists in the A
port HP compared to the low pressure
chamber LP. The difference between the HP
effective area of diameter A and G
causes imbalance of the check valve
LP
poppet K which unseats, thus allowing oil
from the low pressure chamber LP to
enter the port HP and fill the void. 7407AWE53
(3) As separate anti void
The anti-void check valve opens when M O-ring

cavitation occurs in the high pressure port
HP and supplies oil from the reservoir LP
to help fill this void. The poppet M is held
A1
A2
on its seat by the port pressure HP, acting HP

on the larger area behind the O-ring.
When pressure HP drops below LP
atmosphere, the tank pressure LP
Spring
operating on the annular area A1-A2 will
overcome the port pressure HP and the 7407AWE54
spring force to open the poppet. When the

void is eliminated the spring will return the
poppet which will then be tightly seated by
the port pressure HP.
6-26
6) PORT RELIEF VALVE
(1) As relief
A D LP B K
The relief valve is in communication
between the high pressure port HP and
low pressure LP. Oil is admitted through
the hole in poppet C and because of the HP
differential area between diameters A and
B relief valve poppet D and check valve
poppet K are tightly seated as shown in LP C
the first step.
LP E
The oil pressure in the high pressure port
Hp has reached the setting of the pilot
poppet spring force and unseats the pilot HP
poppet E and oil flows around the poppet
through the cross drilled holes and to the
low pressure area LP. LP
The loss of oil behind poppet C, effected D LP E

by the opening of pilot poppet E, causes
poppet C to move back and seat against
pilot poppet E. This shuts off the oil flow to HP
the area behind relief valve poppet D, and
causes a low pressure area internally.
LP C
The imbalance of pressure on the inside LP D

as compared to that of the high pressure
port HP, forces the relief valve poppet D to
open and relieve the oil directly to the low HP
pressure chamber LP in the valve.
LP
7407AWE55
6-27
7. PILOT OIL SUPPLY UNIT
1) STRUCTURE
5
1
P
2
U
T
6
P2 2
7607B6WE46
3MPa
U
P1 From steering pump 3/4-16UNF
4.5MPa P2 Pluging 3/4-16UNF

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

2 Reducing valve 5 Gasket
3 Seal kit 6 Relife valve
(2) OPERATION
The pilot supply manifold reduces the pressure from the high pressure circuit to a low pressure
circuit in order to supply the remote control valve.
The accumulator satisfies short term peak power demands and is a source of emergency power
in case of main circuit pressure failures.
The unit consists of the housing, the accumulator(4), the relief valve (6), the check valve and the
reducing valve (2).
The flow path is from the high pressure circuit through port P2 to the pressure reducing valve (2).
The pressure is reduced in the reducing valve (2) and oil passes the check valve into the
accumulator (4) and to the port U, which is connected with the remote control valve.
The pressure relief valve (6) protects the pilot circuit in case of the reducing valve (2) failures or
external increase of pressure.
6-28
8. BOOM AND BUCKET CYLINDER
The boom cylinders are two unit and the bucket cylinder is one unit. They use a bolt on rod guide.
The piston (12) threads on to the rod (2) and is retained by a nut (18).
The piston seals against the tube (1) with piston seal (15). Two wear rings (16) are located on each
side of the piston seal.
The gland(3, the rod guide) seals against the tube with an O-ring (10). The cylinder thread seals
against the rod with a lip type buffer ring (7) and a rod seal (5). A dust wiper (8) cleans the rod when
it is retracted.
1) BOOM CYLINDER
8,9 5,6 19 7 10,11 23 22 3 4 1 2 13,14 17 15 16 12 18
20 21 27, 28
24 , 25, 26
7407B6WE46
1 Tube assembly 11 Back up ring 21 Pipe assembly

2 Rod assembly 12 Piston 22 O-ring
3 Gland 13 O-ring 23 Bolt
4 Bushing 14 Back up ring 24 Clamp
5 Rod seal 15 Piston seal 25 Bolt
6 Back up ring 16 Wear ring 26 Spring washer
7 Buffer ring 17 Dust ring 27 Pin bushing
8 Dust wiper 18 Lock nut 28 Dust seal
9 Snap ring 19 Bolt
10 O-ring 20 Pipe assembly
6-29
2) BUCKET CYLINDER
8, 9 5, 6 7 25 24 3 10,11 4 1 2 12 13, 14 17 15 16 19 18
22
27, 26
23
20
7407B6WE47
1 Tube assembly 10 O-ring 19 Set screw

2 Rod assembly 11 Back up ring 20 Bolt
3 Gland 12 Piston 21 Band assembly
4 Bushing 13 O-ring 22 Pipe assembly
5 Rod seal 14 Back up ring 23 Pipe assembly
6 Back up ring 15 Piston seal 24 O-ring
7 Buffer ring 16 Wear ring 25 Bolt
8 Dust wiper 17 Dust ring 26 Pin bushing
9 Snap ring 18 Lock nut 27 Dust seal
6-30
9. HYDRAULIC OIL TANK
1) STRUCTURE
· The oil from the hydraulic tank is sent from the pump through main control valve to the cylinders.
In the return circuit, the oil from various parts merges.
· A part of oil is cooled in the oil cooler, passes through the hydraulic filter and returns to the
hydraulic tank (1).
· If the hydraulic return oil filter becomes clogged, return filter bypass valve (6) acts to allow the oil
to return directly to the hydraulic tank (1). This prevents damage to the hydraulic filter (5). The
bypass valve (6) is also actuated when negative pressure is generated in the circuit.
15 11,13 4 9
7
3
A
6
5
SECTION A - A
2,8
15 12,14 10
7407AWE58
1 Hydraulic tank wa 9 Socket bolt

2 Pipe assembly 10 Bolt
3 Sight gauge 11 Cover
4 Air breather 12 Cover
5 Element assembly 13 O-ring
6 Bypass valve 14 O-ring
7 Spring 15 Bolt
8 O-ring
6-31
2) RETURN OIL FILTER BYPASS VALVE
(1) When the filter is clogged

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

(19.3psi)
From MCV
7607B6WE47
6-32
3) AIR BREATHER
The air breather is equipped with the
capacity to perform three functions
simultaneously-as an air filter, breathing
valve, and as a lubrication opening.
(1) Preventing negative pressure inside the Air breather
tank
The tank is a pressurized sealed type, so
negative pressure is formed inside the
hydraulic tank when the oil level drops
during operations. When this happens,
the difference in pressure between the
tank and the outside atmospheric
pressure opens the poppet in the
breather, and air from the outside is let
into the tank or prevent negative pressure.
(2) Preventing excessive pressure inside
the tank
When the hydraulic cylinder is being
used, the oil level in the hydraulic system
increases and as temperature rises. If
the hydraulic pressure rises above the set
pressure, breather is actuated to release
the hydraulic pressure inside the tank. 7407AWE59
6-33
10. ACCUMULATOR
The accumulator is installed at the pilot oil
supply unit. When the boom is left the
raised position, and the control levers are
operated with the engine stopped the
pressure of the compressed nitrogen gas
inside the accumulator sends pilot pressure
to the control valve to actuate it and allow 1
the boom and bucket to come down under 2
their own weight. 3
Type of gas Nitrogen gas (N2)

Volume of gas 0.75 ℓ (0.2 U.S.gal)
Charging pressure of gas 16 kg/cm2 (228 psi)
Max actuating pressure 128 kg/cm2 (1820 psi) 1 Diaphragm
2 Steel pressure vessel
3 Closure button
7803AWE56
6-34
This procedure is designed so the mechanic can make a quick check of the system using a minimum
amount of diagnostic equipment. If you need additional information, read structure and function,
Group 1.
At the end of each check, if no problem is found (OK), that check is complete or an additional check is
needed. If problem is indicated (NOT OK), you will be given repair required and group location.
If verification is needed, you will be given next best source of information:
·Chapter 2 : Troubleshooting
·Group 3 : Tests and adjustments
6-35
※ Hydraulic oil must be at operating temperature for these checks (refer to page 6-49).

Hydraulic system warm-up Hold a hydraulic function over OK
procedure relief to heat oil. (don't keep relief Check completed.
condition over 5 seconds at a time)
Refer to page 6-49. Periodically cycle all hydraulic
functions to distribute warm oil.
Repeat procedure until oil is at
FEEL : Hydraulic reservoir must be
uncomfortable to hold your hand
against.
(approximately 40 ~50˚C)
Hydraulic pump With bucket flat on ground, actuate OK
performance check boom raise. Time how long it takes Check completed.
to raise boom to full height.
Heat hydraulic oil to NOT OK
operating temperature. LOOK : Boom must raise to full Go to steering unit high
Run engine at high idle. height in less than 5.5 seconds. pressure check at page
5-25.
IF OK
Do steering system
leakage check at page
5-24.
IF OK
Do main hydraulic pump
flow test at page 6-50.
Control valve lift check With bucket partially dumped, OK
Run machine at low idle. lower boom to raise front of Check complete.
machine.
NOT OK
Slowly move boom control lever Repair lift checks in loader
( R C V l eve r ) t o b o o m l owe r control valve.
position.
Slowly move bucket control lever
to bucket dump position.
LOOK : Boom must not raise
before moving down.
Bucket must not rollback before
dumping.
6-36
Bucket rollback circuit relief Position bucket at a 45˚ angle OK
valve check against an immovable object. Check complete.
Engage transmission in 3rd speed NOT OK
forward. Replace boom lower
check valve.
LOOK : Bucket angle must not
change.
Bucket dump circuit relief Raise front of machine which OK
valve low pressure check bucket at 45˚ angle. Go to next check.
Backdrag with bucket while NOT OK
observing bucket angle. Do loader system and
circuit relief valve test at
LOOK : Bucket must not rollback
page 6-51.
Pilot control valve float With the bucket partially dumped, OK
check lower boom to raise front of Check complete.
machine.
Run engine at low idle. NOT OK
Push control lever to the float
Do pilot control valve
detent position and release lever.
pressure test in group 3.
LOOK : Front of machine lower to
the ground and valve must remain
in float position when lever is
released.
Boom cylinder and S e t t h e b o o m a n d b u c k e t OK

bucket cylinder drift horizontal, then stop the engine. Check complete.
check
S t o p t h e e n g i n e, wa i t fo r 5 NOT OK
Heat hydraulic oil to minutes, then start measuring. Go to next check.
operating temperature. B
Measure the amount the lift and
dump cylinder rods retract during
A 15 minutes. (unloaded bucket)
A : Retraction of boom cylinder
rod
B : Retraction of bucket cylinder
rod
Boom cylinder must drift less than
22 mm
Bucket cylinder must drift less than
30 mm
6-37
Boom cylinder leakage Dump bucket until teeth or cutting OK
check edge is per pendicular to the Drift is approximately the
ground. same between first and
Heat hydraulic oil to
second measurement.
operating temperature. Raise boom until cutting edge is
about 1 m (3 ft) above ground.
Repair loader control valve
Stop engine. Measure drift from or circuit relief valve.
tooth or cutting edge to ground for
1 minute. NOT OK
If drift is considerably less
Wait 10 minutes.
on second measurement,
Measure drift from tooth or cutting repair cylinder.
edge to ground for 1 minute.
LOOK : Compare the drift rate
between the first measurement
and the second measurement.
Bucket cylinder leakage Raise bucket about 1 m (3 ft) off OK
check ground with bucket level. Drift is approximately the
same between first and
Heat hydraulic oil to Stop engine. Place a support
second measurement.
operating temperature. under boom.
Measure drift from tooth or cutting Repair loader control valve
edge to ground for 1 minute. or circuit relief valve at
page 6-51.
Wait 10 minutes.
Measure drift from tooth or cutting NOT OK
edge to ground for 1 minute. Drift is considerably less
on second measurement.
LOOK : Compare the drift rates
between the first measurement
Repair cylinder.
and the second measurement.
Check valve of safety Put bucket level and position about OK
valve leakage check 1.2 m (4 ft) above ground. Check complete.
Heat hydraulic oil to Place a piece of tape on cylinder
NOT OK
operating temperature. rod at least 51 mm (2 in) from rod
Check or replace safety
guide.
valve.
Run engine at low idle in safety-
release position.
LOOK : Bucket must not drift up.
Pilot control valve Stop engine. Turn key switch to OK
OFF position. Check completed.
(RCV lever) check
Move control lever to all positions
NOT OK
and then release.
Repair pilot control valve.
LOOK : Lever must return to
neutral when released from all
positions.
6-38
Bucket leveler Position bucket fully dumped just OK
(positioner) check (option) above ground level. Check complete.
Run engine at low idle. Move control lever to bucket NOT OK
leveler detent position and release. Do bucket leveler checks.
LOOK : Bucket must rollback to
the level position and control lever
must return to neutral.
If bucket is in a rolled back position
when key is turned ON, control
lever must be returned to neutral
manually if placed in the bucket
leveler detent position.
After bucket is dumped once,
bucket leveler will work normally.
Boom height kickout Position bucket flat on ground. OK
check (option) Check complete.
Move control lever to boom raise
Run engine at low idle. detent position and release. NOT OK
Do boom height kickout
LOOK : Boom must raise to the
check.
set height and stop.
Control lever must return to
neutral.
Cycle time check Function Operating condition. Maximum cycle time
Heat hydraulic oil to Boom raise Bucket flat on ground to full height. 5.4sec
Boom lower Full height to level ground. 3.0sec
Bucket dump Boom at full height. 1.2sec
Bucket rollback Boom at full height. 1.7sec
Steering [No. of Frame stop to frame stop. 3.6 turns
turns]
OK
Check complete.
NOT OK
Go to slow hydraulic
functions in group 2.
6-39
※ MEASURING BOOM AND BUCKET CYCLE TIME
1) MEASUREMENT CONDITION
·Coolant temperature : Inside operating range
·Steering position : Neutral
·Hydraulic temperature : 40~50˚C
·Bucket : Unloaded
·Engine speed : High idling
2) MEASURING TOOL
· Stop watch (1EA)
3) MEASURING PROCEDURE
(1) LIFTING TIME OF BOOM Lifting time of boom
Set the bucket near the maximum tilt back

position and at the lowest position on the
ground. Raise the bucket and measure
the time taken for bucket to reach the
maximum height of the boom.
7407B6WE35
(2) LOWERING TIME OF BOOM

Set the bucket horizontal with the boom at Lowering time of boom
the maximum height, lower the bucket and
measure the taken for the bucket to reach
the lowest position on the ground.
7407B6WE36
(3) DUMPING TIME OF BUCKET

Raise the boom to the maximum height Dumping time of bucket
Rollback time of bucket
and measure the time taken for the bucket
to move from the maximum tilt back
position to the maximum dump position
(4) ROLL BACK TIME OF BUCKET
Raise the boom to the maximum height
and measure the time taken for the bucket
to reach the maximum tilt back position. 7407B6WE37
6-40
2. TROUBLESHOOTING
※ Diagnose malfunction charts are arranged from most probable and simplest to verify, to least
likely, more difficult to verify. Remember the following steps when troubleshooting a problem :
Step 1. Operational check out procedure (see section 1)

Step 2. Operational checks (see group 2)
Noisy hydraulic pump Low oil supply or wrong viscosity. Fill reservoir with recommended oil.
Plugged or pinched suction line. Clean or replace line.
Air in oil. Check for foamy oil. Tighten
connections.
Replace O-rings and or lines.
Plugged suction strainer. Inspect and clean strainer in reservoir.
Loose or missing hydraulic line clamps. Tighten or replace clamps.
Hydraulic lines in contract with frame. Inspect and repair.
Worn or damaged pump. Do hydraulic pump performance check
in group 2. Do hydraulic pump flow test
in group 3.
No or Slow hydraulic Failed or worn hydrualic pump. Do performance check.
functions
Cold oil. Warm oil up.
Slow engine speed. Adjust engine speed.
Check high idle speed.
Suction line air leak. Check for foamy oil.
Low oil supply. Add recommended oil.
Wrong oil viscosity. Use recommended oil.
Oil leaking past cylinders or control Check cylinder drift in group 2.
valve.
Blocked or damaged line. Inspect lines.
Faulty pilot control valve (RCV). Do pilot control valve (RCV) pressure
test in group 3.
Binding loader control valve (MCV) Inspect valve.
spool.
Faulty steering unit. Check steering unit specification.
6-41
No steering or hydraulic Low oil level. Add recommended oil.
function
Failed hydraulic pump. Remove and inspect return filter for
metal pump particles.
Failed main hydraulic pump drive. Remove main hydraulic pump and
inspect drive gear.
No hydraulic functions Failed hydraulic pump. Remove and inspect return filter for
steering normal metal pump particles, or replace the
pump.
Failed line filter. Remove and inspect line filter for RCV.
Faulty safety valve. Safety valve leakage test or ON, OFF
function test.
Stuck open port relief valve. Replace relief valve.
Boom float function Low pilot control pressure. Do pressure reducing valve pressure
does not work test in group 3.
Faulty pilot control valve (RCV). Replace relief valve.
Loader control valve (MCV) spool Do pressure reducing valve pressure
binding in bore. test in group 3.
One hydraulic function Faulty pilot control valve (RCV). Do pilot control valve pressure test.
does not work. Inspect and repair valve.
Stuck open port relief valve. Replace relief valve.
Oil leaking past cylinder packings. Do boom and bucket cylinder leakage
test in group 3.
Blockage in oil lines or valve. Inspect lines for damage.
Disconnect and inspect lines for internal
blockage.
Loader control valve (MCV) spool stuck Inspect and repair valve.
in bore.
Low hydraulic power Leakage within work circuit. Do cylinder drift check in group 2.
Low system relief valve (main relief Do loader system and port relief valve
valve) setting. pressure test in group 3.
Low port relief valve setting. Do loader system and port relief valve
pressure test in group 3.
Leaking system relief valve. Remove and inspect valve.

Worn hydraulic pump. Do hydraulic pump performance check
in group 2.
Faulty pilot control valve (RCV). Do pilot control valve pressure test in
group 3.
6-42
Function drifts down Leaking cylinders. Do cylinder leakage checks in group 3.
Leaking seals in circuit relief valve (port Inspect seals. Replace relief valve.
relief valve) or valve stuck open.
Leaking loader control valve (MCV). Repair or replace valve section.
Boom drifts up Leakage in boom down spool. Remove and inspect boom down spool.
Boom down does not Safety valve not operated. Operate valve.
work (engine off)
Stuck pilot control valve. Inspect.
Faulty line filter. Remove and inspect filter.
Accumulation not operated. Inspect.
MCV spool stuck. Inspect and repair valve.
Oil overheats Low oil viscosity in hot weather. Use recommended oil.
Excessive load. Reduce load.
Holding hydraulic system over relief. Reduce load.
Leakage in work circuit. Do boom and bucket cylinder leakage
test in group 3.
Plugged fins in oil cooler. Inspect and clean oil cooler.
Internally plugged oil cooler. Do hydraulic oil cooler restriction test.
Incorrect system or circuit relief valve Do loader system and circuit relief valve
setting. pressure test in group 3.
Restriction in oil lines or loader control Inspect for dented or kinked lines.
valve (MCV).
Malfunctioning steering valve. Do hydraulic system restriction test in
group 3.
Leaking system main relief valve. Do hydraulic system restriction test in
group 3.
Remove and inspect valve and seals.
Worn hydraulic pump (internal leakage). Do hydraulic pump performance check
in group 2.
Function drops before Stuck open lift check valve. Do control valve lift check in group 2.
raising when valve is
activated
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.
6-43
※ 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 1-24, Recommended lubricants
lubricants..) Never mix oil of
different makes of kinds.
7) To change the hydraulic oil, use a clean vessel and funnel for pouring it into the tank. Never use
cloth because it might cause the presence of lint in the circuit.
8) When removing the hydraulic equipment, be sure to put plugs or caps on hoses, tube lines and
ports. Also, enter mating marks for later identification.
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.
When overhauling the hydraulic equipment replace all O-rings, backup rings, etc. with new ones.
Assemble O-rings with grease or vaseline applied.
After installing the equipment, add more hydraulic oil to make up for that lost during disassembly.
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.
6-44
1. HYDRAULIC OIL CLEAN UP PROCEDURE USING PORTABLE FILTER CADDY

※ Service equipment and tool
·Portable filter caddy
·Two 4000 mm × 1in 100R1 Hoses
·Quick disconnect fittings.
·Discharge wand
·Various size fittings.
※ Brake system uses oil from hydraulic oil
tank. Flush all lines in the brake, pilot,
steering system and cut off system.
Disassemble and clean major
components for brake and steering
system. Remove and clean pilot caps
from main control valve.
Brake and steering components may fail
if brake and steering system is not
cleaned after hydraulic oil tank
contamination.
1) If hydraulic system is contaminated due to
a major component failure, remove and
disassemble steering cylinders to clean
debris from cylinders.
2) Install a new return filter element. Inspect
filter housing before installing new element.
※ For a failure that creates a lot of debris,
remove access cover from hydraulic oil
tank. Drain and clean hydraulic oil tank of
fill the specified oil to hydraulic oil tank
through upper cover.
3) To minimize oil loss, pull a vacuum in
hydraulic oil tank using a vacuum pump.
Connect filter caddy suction line to drain
port at bottom of hydraulic oil tank using
connector. Check to be sure debris has not
closed drain port.
4) Put filter caddy discharge line into hydraulic
oil tank filler hole so end is as far away from
drain port as possible to obtain a thorough
cleaning of oil.
6-45
5) Start the filter caddy. Check to be sure oil is
flowing through the filters.
Operate filter caddy approximately 10
minutes so oil in hydraulic oil tank is
circulated through filter a minimum of four
times.
※ Hydraulic oil tank capacity : 105 ℓ(27.7
U.S. gal)
Leave filter caddy operation for the next
steps.
6) Start the engine and run it at high idle.
※ For the most effective results, cleaning
procedure must start with the smallest
capacity circuit then proceed to the next
largest capacity circuit.
7) Operate all functions, one at a time,
through a complete cycle in the following
order: Clam, steering, bucket, and boom.
Also include all auxiliary hydraulic functions.
Repeat procedure until the total system
capacity has circulated through filter caddy
seven times, approximately 30 minutes.
Each function must go through a minimum
of three complete cycles for a through
cleaning for oil.
※ Filtering time for machines with auxiliary
hydraulic functions must be increased
because system capacity is larger.
8) Stop the engine. Remove the filter caddy.
9) Install a new return filter element.
10) Check oil level in reservoir; Add oil if
necessary.
6-46
2. BOOM HEIGHT KICKOUT ADJUSTMENT
1) Lift the boom up to a desired height, set the
boom control lever at hold, then stop the
engine.
Be careful lest work equipment fall down.
Put the hydraulic safety lock lever in the Boom
LOCK position.
Proximate switch
7707WE20
2) Loosen nuts and bolts then tighten them

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

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

ground. Then lift the bucket to a desired Hydraulic safety lever
height by using the control lever and Unlock Lock
release the hand.
Confirm the lever automatically returns to
the neutral position and the boom (the
bucket) stop at the adjusted position.
7407B5TA05-1
6-47
3. TEST TOOLS
1) CLAMP-ON ELECTRONIC TACHOMETER
INSTALLATION
·Service equipment and tools
B
Tachometer
A : Clamp on tachometer.
Remove paint using emery cloth and
C
connect to a straight section of injection
line within 100 mm (4 in) of pump. Finger
Tighten only-do not over tighten. D
B : Black clip ( - ). Connect to main frame.
C : Red clip (+). Connect to transducer. A
D : Tachometer readout. Install cable.
75795SE32
2) DIGITAL THERMOMETER INSTALLATION

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

The display monitor tachometer is accurate
enough for test work.
mph
7807A3CD03
6-48
4. HYDRAULIC OIL WARM UP PROCEDURE
1) Install temperature reader (see temperature
reader installation procedure in this group).
2) Run engine at high idle.

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

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

Attention B
A
1) Before carrying out any maintenance work
the accumulators must be unloaded (zero
pressure).
2) For this, loosen the nut (A) and bolt (B)
counterclockwise with 10 mm spanner.
※ The accumulator will be unloaded (zero
pressure) in less than a minute.
3) The lifting system must firstly be secured
against lowering.
Ride control valve
7607S6WE28
4) After carrying out maintenance work, screw
the bolt (B) and nut (A).
·Tightening torque
A : 2.04 kgf·m (14.8 lbf·ft)
6-49
5. MAIN HYDRAULIC PUMP FLOW TEST
· SPECIFICATION
Engine speed 2100±25 rpm Flow meter
Test pressure 210±5 bar (2990 psi)
Maximum pump flow 178ℓ/min (47 gpm) To MCV
· FLOW METER GAUGE AND TOOL

Gauge 0~35 MPa (0~350 bar, 0~5000 psi)
P
Temperature reader EF
1) Make test connections.

Priority valve
(see temperature reader installation
procedure in this group)
Hyd tank
(see hydraulic oil warm up procedure in this
group)
4) Run engine at test specifications.
5) Close flow meter loading valve to increase
pressure to test specifications.
6) Read flow meter.
7) If flow is below specifications, check suction
line and suction pressure for abnormality
before removing pump. 7407B6WE31
6-50
6. LOADER
L ADER SYSTEM AND PORT RELIEF
VALVE PRESSURE TEST
· SPECIFICATION
Oil temperature (40~50˚C)
D U R
Relief valve Engine speed Relief pressure
210±10 kg/cm2
System (M) High
(2990±140 psi)
Boom 240±10 kg/cm2
Low
raise (U) (3410±140 psi)
M
Bucket 240±10 kg/cm2
Low
rollback (R) (3410±140 psi)
Bucket 240±10 kg/cm2
Low Main control valve
dump (D) (3410±140 psi)
· Gauge and tool

Gauge 0~35 MPa (0~350 bar, 0~5000 psi)
M : System (main) relief valve
R : Bucket rollback relief
D : Bucket dump relief
U : Boom raise relief To MCV
1) Install fitting and pressure gauge to test

port in pump delivery line.
procedure in this group)
group)
Hyd tank
4) To check the system relief (M), run engine
at high idle. Lower boom to bottomed
position.
Slowly activate boom down function while
watching pressure gauge. If pressure is not
to specification, loosen lock nut on system
relief valve (M) and adjust to specification. 7407B6WE23
6-51
※ Do not adjust the system relief valve
above 210 kg/cm2 (2990 psi). Damage to
the pump will result from excessive
pressure settings.
5) To check the bucket dump, bucket rollback,
boom down and boom raise, adjust the
system relief valve to 250 kg/cm2 (3560 psi).
Run engine to maintain 800 ~ 850rpm when
hydraulic function is activated over relief.
Activate the function to be checked with the
cylinder bottomed. Read the pressure
gauge.
If pressure is not to specification cycle relief
valve over relief 10 times to flush.
Read pressure gauge again. Turn screw to
adjust valve to specification.
※ Do not work machine with system relief
adjusted above specification or structural
damage may occur.
6) Adjust system relief valve to specification.
6-52
7. HYDRAULIC SYSTEM RESTRICTION
TEST
· SPECIFICATION
Maximum pressure 2 MPa (20 bar, 285 psi)
at steering unit.
Maximum pressure 1 MPa (10 bar, 145 psi)
at main control valve
· GAUGE AND TOOL
Gauge 0~7 MPa (0~70 bar, 0~1000 psi) 2EA
This test will check for restrictions in the
hydraulic system which can cause
overheating of hydraulic oil.
T

procedure in this group) Steering unit

group)
3) Connect fitting and gauge to steering unit.
4) Connect fitting and gauge to main control
valve.
Do not operate steering or loader funct-
ions or test gauge may be damaged.
5) Run engine at specification and read
pressure gauges.
If pressure is more than specification at the Main control valve
loader control valve, check for a kinked,
dented or obstructed hydraulic line. Check
loader control valve for a binding spool.
If pressure is more than specification at the
steering unit, inspect neutral condition of
the steering unit 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. 7407B6WE24
6-53
8. LOADER CYLINDER DRIFT TEST
· SPECIFICATION
B
Boom horizontal
Bucket horizontal
Bucket unloaded A
Item Standard value
Retraction of boom
22 mm
cylinder rod A : Retraction of bucket cylinder rod
Retraction of bucket B : Retraction of boom cylinder rod
30 mm
cylinder rod
· GAUGE AND TOOL
Stop watch
Temperature reader
Put the hydraulic safety lock lever in the
lock position.
Do not go under the work equipment.
1) Set the boom and bucket horizontal, then
stop the engine.
2) Stop the engine, wait for 5 minutes, then
start measuring.
3) Measure the amount the boom and bucket
cylinder rods retract during 15 minutes.
7577AWE31
6-54
9. BOOM AND BUCKET CYLINDER LEAKAGE TEST
· SPECIFICATION
Maximum leakage 15 mℓ/min (1/2 oz/min)
· GAUGE AND TOOL
Temperature reader
Stop watch
Measuring container
1) Fasten temperature sensor to head end
port of cylinder to be tested. Cover sensor
with a shop towel.
2) Heat hydraulic oil to specifications (see
hydraulic oil warm up procedure in this
group).
Never work under raised equipment
unless it is supported with a hoist or
support stands.
3) Full extend the cylinder to be tested. If
testing the boom cylinders, restrain boom in
the fully raised position using a hoist or a
stand.
※ Check cylinders for leakage in the fully
extended position only. In the retracted
position contacts the end of the cylinder
and seals off piston seal leakage.
4) Remove and plug cylinder rod end hose or
line.
5) Run engine at slow idle. Activate control
lever to extend cylinder for 1 minute over
relief while measuring leakage for open
port.
If leakage is within specification, excessive
cylinder drift is caused by leakage in the
(770-3ATM) 6-56
loader control valve or circuit relief valve.
6-55
10. PILOT CONTROL VALVE P
PRESSURE
RESSURE TEST
· SPECIFICATION
Begin metering 1/4" of lever travel
Pressure in detent :
Boom float detent 1.9 MPa (19 bar)
Pressure at detent position :
Boom power down 13~17bar
Boom raise 13~17bar
Bucket rollback 13~17bar
Bucket dump 13~17bar
· GAUGE AND TOOL
Gauge 0~7 MPa (0~70 bar, 0~1000 psi)
As the control lever is moved from neutral,
the pilot pressure will suddenly jump up to
approximately 5.8bar at 1/4in. travel. The
pressure should then increase smoothly to
the specification at the FEEL position (or
3/4 lever travel), and then jump up about
430psi as the lever is moved into detent.
This test will determine if adequate pilot
pressure is available to move the loader
control valve spools.
※ The FEEL position is when lever is
moved to feel the ramp of the detent
before lever passes into detent position.
1) Lower boom to ground.
2) Connect gauge to the pilot pressure port of
function to be checked.
3) Install temperature reader (see temperature
reader installation procedure in this group).
4) Heat hydraulic oil to specification (see
hydraulic oil warm up procedure in this
7607B6WE41
group).
6-56
11. PILOT OIL SUPPLY UNIT PRESSURE
PRESSURE TEST
· SPECIFICATION
Engine speed Low idle and stop
Pilot pressure setting
30~35 bar (430~500 psi)
Relief valve setting pressure 45 bar
Accumulator precharging pressure 16 bar
· GAUGE AND TOOL
Gauge 0~7 MPa (0~70 bar, 0~1000 psi)
The pilot supply unit consist of the pressure
reducing valve, the relief valve and an
accumulator. This regulates pressure to the
pilot control circuit.
1) Connect gauge to test port on the screw
coupling.
2) I n s t a l l t e m p e r a t u r e r e a d e r ( S e e
temperature reader instakkation procedure
in this group).
3) Heat hydraulic oil to specification (see
U
hydraulic oil warm up procedure in this T P2
group).
4) Run engine at loe idle for 1 minute and stop
engine, wait for 5 minutes, Then start
measuring.
5) If pressure in not within specifiactions,
replace valve.
7707WE26
6-57
12. CYCLE TIME TEST
· SPECIFICATION
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 3.0
Bucket dump Boom at full height 1.2
Bucket rollback Boom at full height 1.7
Steering (number of turns) Frame stop to stop 3.6 turns
Hydraulic pump performance cycle time.

Function Operating conditions Maximum cycle time (seconds)
Bucket flat on ground to full height
Boom raise 8.0
while holding steering over relief
6-58
13. HYDRAULIC OIL FILTER INSPECTION
PROCEDURE
1) Lower the bucket to the ground, stop the
engine, move the control lever back and
forth several times, and clean all over the
upper surface of the hydraulic oil tank.
2) Remove the bolts and take out the filter
case cover and O-ring.
3) Remove the spring and bypass valve.
4) Remove the filter element from the tank. Cover
O-ring
5) Check the element and the filter case Spring
bottom for debris. Excessive amounts of By-pass valve
brass and steel particles can indicate a
Return filter
failed hydraulic pump or a pump failure in
process. A rubber type of material can
indicated cylinder packing or other packing
failure.
※ The hydraulic oil filter in the filter case of
the hydraulic oil tank should be replaced
every 250 operating hours or more often.
When the filter element is replaced,
please keep as follows.
(1) Clean the inside of the filter case.
(2) Place new element in the proper positions
inside the filter case.
(3) Install the bypass valve and spring.
Make sure the element stand upright, and
check for complete contact of the element
bottom with the filter case bottom.
(4) Install the O-ring and filter case covers.
Tighten them with bolt. Replace the
O-ring with new one if damaged.sa 7407B6MI20
6-59
1. MAIN PUMP
1) STRUCTURE
3
9
6
9
13
11
12
14
17
15
2
14 16
13
11
12
1 5
13
11
12
14
9
7
10
9
8
4
14
13
11
12 7407B6WE48
1 Front cover 7 Driven gear set 13 Square seal

2 Housing 8 Connector shaft 14 Dowel pin
3 Carrier 9 Thrust plate 15 Washer
4 Housing 10 Lip seal 16 Stud bolt
5 Rear cover 11 Rubber seal 17 Hex nut
6 Drive gear set 12 Back up seal
6-60
2) MANDATORY REPLACEMENT PARTS
Discard all seals including square seals, lip seals, rubber seals and back up seals. Fit new seals on
reassembly. Thrust plates should also be replaced with new items from seal kit.
3) HANDLING/STORAGE
HANDLING/STORAGE
While disassembling pump, ensure no surfaces are scored or marked in any way. A rubber
surfaced table will be beneficial. All components must be placed in a clean, dry and safe area.
Leakage will be created by scratches on components. If parts are to be left for any period ensure
they are not exposed to dirt, dust and corrosion. Keep gears separate from each other in protective
boxes.
4) INSPECTION
INSPECTION OF PARTS
Wash all parts in a solvent and dry.
(1) Cover, housing and carrier
The pump must be replaced if the damage listed is present.
Feature Damage
Corrosion, nicks or burrs (slight burrs can be removed using and india
Surfaces
stone)
Machined sealing lnterfaces Scores, cracks or corrosion
(2) Gears
The pump must be replaced if the damage listed is present.
Feature Damage
Corrosion, nicks or burrs (slight burrs can be removed using an lndia
Surfaces stone).
Wear due to seal (s)
Journals Pitting, wear, sufficient wear to change outside diameter
Tooth Cracks or heavy scoring or chipped
Splines/keyways Distortion of wear
End faces Wear, cracks
(3) Bolts/studs
The pump should be replaced if the damage listed is present.
Feature Damage
Corrosion, nicks or burrs(slight burrs can be removed using an lndia
Surfaces
stone), cracks or scoring, distortion or damage to thread form
6-61
5) ASSEMBLY
(1) Prepare sub assembled parts (front and
rear cover, carrier, housing, thrust plate).
※ Grease must be spreaded slightly on each
seal.
7407B6MP01
(2) Put section sub assembly on the

assembly table.
Assemble dowel pins.
7407B6MP02
(3) Assembly gear housing and thrust plate.

※ Check the contact status of square seal.
Arrow
mark
Inlet
Push a thrust plate down on front cover. 7407B6MP03
(4) Mount a jig on the shaft end to protect lip

seal.
Assemble drive gear.
7407B6MP04
6-62
(5) Assemble driven gear.
Spread hydraulic fluid around gear set.
7407B6MP05
(6) Assemble thrust plate. Seal is on the left side of gears.

Rotate the shaft gear and check status of
gear set.
Assemble dowel pins and connector shaft.
7407B6MP06
(7) Assemble sub assy of carrier.

Inlet hole is located on the right side.
※ Outlet drill hole is located at the bottom of
carrier. Sub assy of piggy back type carrier
is the same.
7407B6MP07
(8) Assemble gear housing and thrust plate.

※ Check the contact status of square seal. Inlet
7407B6MP08
6-63
(9) Assemble drive gear set.
Spread hydraulic fluid around gear set.
7407B6MP09
(10) Assemble thrust plate.

Rotate the shaft gear and check status of
gear set.
Assemble dowel pins and connector
shaft.
7407B6MP10
(11) Assemble the rear cover.

Check the contact status of square seal.
Outlet
7407B6MP11
(12) Assemble stud bolt and washer.

※ Washer : smooth - convex side up
※ Keep bolts in dry condition after washing.
7407B6MP12
6-64
(13) Nuts are pre-assemble by hand.
7407B6MP13
(14) Use air impact to assemble nuts.

At this time, assemble nuts diagonally.
7407B6MP14
(15) Use torque wrench to assemble.

·Tightening torque : 15 kgf·m
(108 lbf·ft)
7407B6MP15
6-65
2. MAIN CONTROL VAVLE
1) STRUCTURE
20
19 1
39
11 6 40
21-1
4 6-1 38
23 3 34 36
25 35
30
24
21
8
16
5 8
33
18 8 11
1 37 9 29
32
22
21-1 13
8 31
26
2-1 28 13
2 14
40 21 4
12 19
27
12 15
14
4
19
10 20
7407B6WE45
1 Nut 14 Screw 28 Spool

2 Plug 15 Screw 29 Spool
2-1 O-ring 16 Anti void assy 30 Spring
3 O-ring 18 Spool cap 31 Spring
4 O-ring 19 Spool cap 32 Back up ring
5 Cap screw 20 Cap screw 33 Inlet section assy
6 Plug 21 Spool retainer 34 Spool section assy
6-1 O-ring 21-1 Back up ring 35 Spool section assy
8 O-ring 22 Spool retainer 36 Outlet section assy
9 Spring 23 Screw 37 Poppet
10 Main relief valve 24 Washer 38 Tie rod
11 Port relief valve 25 Spacer 39 Tie rod
12 Spring seat 26 Spring 40 Nut
13 Washer 27 Spring
6-66
2) ASSEMBLY AND DISASSEMBLY
(1) Lay out valve components on a clean, flat
working surface. The inlet assembly will
include an O-ring, and the spool section
(s) include an O-ring, a load check poppet
and a load check spring. Tools required
for basic valve assembly include 3/4 and
11/16 open or box end wrenches and a
torque wrench with thin wall sockets.
7406S MCV05(1)
(2) Assemble tie rod nuts to one end of each

tie rod with one or two threads showing.
Insert tie rods through tie rod holes of inlet
(large tie rod at top). Lay inlet on end with
tie rods up, place O-ring into position.
7406S MCV05(2)
(3) Place first spool section (O-ring side up)

on inlet section, position O-ring and insert
load check poppet (nose down) and
spring (behind poppet) into load check
cavity as shown. Repeat this procedure
for each spool section ; The load check
springs are compressed by the following
sections during assembly.
7406S MCV05(3)
(4) Position end section on last spool section

as shown and hand tighten tie rod nuts.
The end section on picture is a "turn
around" section without ports. Universal
outlet/power beyond section and power
beyond and closed center sections are
also used as end sections. These end
sections do not have O-ring grooves.
7406S MCV05(4)
6-67
(5) Position valve assembly with the mounting
pads of the end sections on a flat surface.
To obtain proper alignment of end
sections relative to the spool sections
apply downward pressure to the end
sections ; Snug tie rod nuts to about 10
lbf·ft.
Final torque the two 11/16 nuts to 48±5
lbf·ft ; Final torque the 3/4 nut to 74±8
7406S MCV06(1)
lbf·ft. Check for proper spool movement.
(6) Install auxilliary valves and plugs and

torque to proper specifications.
General assembly notes :
A. Lever assemblies can be installed on
section before or after complete valve
assembly.
B. The load check and spring may be
omitter from assembly in certain circuit
conditions (i.e., motor spools).
7406S MCV06(2)
6-68
3. REMOTE CONTROL VALVE
1) STRUCTURE
36
13
45 38 15
37 14
16
33 8
5
34
9
7
,
41,42,43,44 35 6
4
32
12
27
26 28 11
1,3,4 1 10
4
25 3 2
3
2
29 T
24 30 4 1
31 3 2
2 1
1,3,4
23
46
4 1
22 49 49
3 2
20 47 47
19 19
21 48
18 48
1,3,4
2
39,40,41,42
17
7407S6WE48
1 Body 14 Rod seal 27 Nut 40 Rear holder

2 O-ring 15 O-ring 28 Plug 41 Terminal
3 Plug 16 Push rod 29 Nut 42 Seal wire
4 Spring 17 Plate 30 Set screw 43 Housing
5 Spring seat 18 Rod stopper 31 Nut 44 Rear holder
6 Spool 19 Bushing 32 Nut 45 Clip band
7 Spring seat 20 Rod 33 Handle bar 46 Plug
8 Stopper 21 Magnet 34 Nut 47 Connector
9 Spring 22 Plate 35 Boot 48 O-ring
10 Spring seat 23 Joint assy 36 Handle assy 49 O-ring
11 Spring 24 Joint assy 37 Nut
12 Spring seat 25 Plate 38 Spring washer
13 Plug 26 Washer 39 Housing
6-69
2) DISASSEMBLY
(1) Remove the boot (35) and loosen nut
(34).
· Tool : spanner 19 mm
7607BRCV01
7607BRCV02
(2) Remove nut (32).
7607BRCV03
6-70
(3) Disassemble plate kit.
7607BRCV04
(4) Remove rod (20).
7607BRCV05
(5) Remove joint assembly (23).

7607BRCV06
(6) Disassemble plate (22).
7607BRCV07
6-71
(7) Disassemble magnet (21) and rod stopper
(18).
7607BRCV08
(8) Disassemble plate (17).
7607BRCV09
(9) Disassemble plug kit.
7607BRCV10
(10) Disassemble spring (4) and spool kit.
7607BRCV11
6-72
(11) Disassemble plug (2).
· Tool : wrench 10 mm
7607BRCV12
6-73
3) ASSEMBLY
(1) Coat oil on O-ring and mount plug (3) into
body assembly (1).
7607BRCV13
(2) Tighten the plug (3).

· Tool : wrench 10 mm
· Tightening torque (M14) :
30±3 kgf·m (217±21.7 lbf·ft)
7607BRCV14
(3) Assemble spring (4).
7607BRCV15
(4) Assemble spool kit.
7607BRCV16
6-74
(5) Assemble plug kit.
7607BRCV17
(6) Assemble plate (17).
7607BRCV09
(7) Assemble magnet (21) at port 1, 3 and 4.

Assemble rod stopper (18) at port 2.
Important
7607BRCV19
(8) Confirm port 2 on the bottom of the body.
7607BRCV20
6-75
(9) Assemble plate (22).
7607BRCV21
(10) Assemble joint assembly (23) and put

grease on joint pin lightly.
· Tools : spanner 17 mm
45±4.5 kgf·m (325±32.5 lbf·ft)
7607BRCV22
7607BRCV23
(11) Assemble rod (20).
7607BRCV24
6-76
(12) Assemble plate kit.
Put a bit of grease on rod (20) and Joint
(24).
7607BRCV04
(13) Assemble nut (32).

40±4 kgf·m (289±28.9 lbf·ft)
7607BRCV03
7607BRCV02
6-77
(14) Assemble nut (34).
40±4 kgf·m (28±28.9 lbf·ft)
7607BRCV01
(15) Assemble the boot (35).
7607BRCV25
6-78
Group 1 Component Location ----------------------------------------------------------------------------------------- 7-1

Group 2 Electrical Circuit -------------------------------------------------------------------------------------------------- 7-4
Group 3 Monitoring System --------------------------------------------------------------------------------------------- 7-25
Group 4 Electrical Component Specification ------------------------------------------------------------------ 7-39
Group 5 Connectors --------------------------------------------------------------------------------------------------------- 7-46
Group 6 Troubleshooting -------------------------------------------------------------------------------------------------- 7-50
GROUP 1 COMPONENT LOCATION
1. LOCATION 1
· Canopy type
6 10
7 11
8 12
9 13
14
1
2 16
3 15 17
4
5
18
7407B7EL02
1 Horn switch 7 Motor pump switch (opt) 13 Auto shift select switch
2 Multi function switch 8 Ride control switch (opt) 14 Clutch cut off switch
3 Hazard switch 9 Buzzer stop switch 15 Machine control unit (MCU)
4 AEB switch 10 Parking brake switch 16 T/M control unit (TCU)
5 Kick down switch 11 Main light switch 17 Fuse box
6 Starting switch 12 Work lamp switc h 18 Relay board
7-1
· Cab type (option)
Cab roof
Front 1
LH Side
2 Cab roof
3
11
4 12
13
5 14
15
16 20 22
6 17
7 18
8 19
9 9
A
E
B
10
23
21
7407B7EL02-1
1 Radio & USB/MP3 player 9 Kick down switch 17 AEB switch

2 Aircon & heater switch 10 Starting switch 18 Buzzer stop switch
3 Rear wiper / washer switch 11 Parking brake switch 19 Motor pump switch (opt)
4 Beacon switch (opt) 12 Main light switch 20 T/M control unit (TCU)
5 USB socket 13 Work load button 21 Fuse box
6 Horn switch 14 Auto shift select switch 22 Relay board
7 Multi function switch 15 Clutch cut off switch 23 Machine control unit (MCU)
8 Hazard switch 16 Ride control switch (opt)
7-2
2. LOCATION 2
1 2 3 4
6 7
8
5
15
+
-
9 10 11 12 13 14
7407S7EL02
1 Proximate switch (opt) 6 Coolant temperature sensor 11 Battery

2 Proximate switch (opt) 7 Pressure oil switch 12 Rear combi lamp
3 Horn 8 Head lamp 13 Back buzzer
4 Switch board 9 Battery relay 13 Number plate lamp
5 Start relay 10 Fuel sender 14 Work lamp
7-3
GROUP 2 ELECTRICAL CIRCUIT
· Canopy type (1/2)

5W 33 MCU BRAKE PS PARKING
EM'CY PUMP MOTOR SW WARNING
CLUTCH CUT-OFF SW
3R 34 PS
CLUTCH CUT-OFF PS
RESISTER
MECHANICAL ENG(GND)
HYD TEMP SENDER

STEERING RY
SPEEDMETER SIG.
AIR COND."ON"SIG
BUZZER
REVERSE FAN SOL
RIDE CONT. AUTO
STEERING P/P PS
TACHO SENSOR+
REVERSE FAN SIG
2
9
3Br 31 R 35
TACHO SENSOR-
PROGRAM DUMP
COOLANT TEMP
RIDE CONT. ON
B
Pa
Pa
A
ENGINE OIL PS
AUTO SEL.TCU
MAIN PUMP PS
WIPER INT SIG

FUEL SENDOR
FAN CLUTCH+
STOP LAMP PS
AUTO SEL.SW
STEERING RY
POWER IG(NC)
POWER IG(NC)
NEUTRAL SIG
FAN CLUTCH-
PARKING SIG
FUEL HEATER
87a 87 85
HOUR METER
PREHEATER
30 86
OPTION PS 2
OPTION PS 1
CD-26
SAFETY RY
AIR FILTER
CD-3
ALT LEVEL
SERVICE
BRAKE PS
WIPER RY
WASH SIG
CN-26
SERIAL-H
SERVICE
SERIAL-L
CN-98
RS232 RX
RS232 TX
BUZZER
2
POWER2
2
1
1
OPTION
OPTION
OPTION
OPTION
POWER1
10
CR-37
CAN-H
IG 24V
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
1
OTMP1
CAN-L
CS-75
Bat24V
2
1
C
B
A
GND
CN-170A
ODP2
ODP1
87a
CN-170
GND
10A
20A
20A
20A
10A
30A
30A
20A
30A
20A
30A
20A
30A
20A
30A
10A
10A
10A
10A
10A
10A
10A
30
86
10A
85
20A
87
10A
5A
5A
5A
10
NC
1
2
3
8
9
7
6
4
70E B
V
L
2
RW
1
CN-58
CN-59
JUMP TO CIRCUIT (2/2)
G
V
70A
125
126
ILLUMINATION LAMP
ILLUMINATION LAMP
EM'CY STEERING/RIDE CON.
NEUTRAL RY/JOYSTICK F/R
27
26
24
23
21
28
25
20
36
35
34
33
32
31
30
29
22
19
11
17
14
18
16
15
13
12
10
23
22
21
20
6
7
5
4
3
2
1
GrW
8
9
OrW
19
18
17
16
15
14
13
12
11
10
SERVICE POWER1
SERVICE POWER1
OrW
53G
9
8
7
1
B
2
6
3
R
52F
4
27A
B
BACK.STOP LAMP
BEACON SOCKET
115
G
Or
G
B
G19 B
G23
SPARE FUSE 1
CLUSTER/MCU
G19
SPARE FUSE 2
SPARE FUSE 3
SPARE FUSE 4
SPARE FUSE 5
SPARE FUSE 7
SPARE FUSE 6
G35
OrW
GrW
OrW
WOr
GOr
GOr
16A
BOr
BOr
G13
106
174
ROr
24A ROr
WORK LAMP
FUSE BOX
174
RW
YW
128
G12
177
906
64E
TURN LAMP
HEAD LAMP
Or
Or
1L
START KEY
Br
W
72A Br
G
910 Y
Y
V
L
L
CLUSTER
PARKING
G21
ILL.LAMP
907
100
101
102
103
J014
J010
J011
J009
J015
J012
J013
J016
J017
104
106
107
108
109
110
111
112
175
115
116
117
118
119
121
122
124
125
126
J003
J004
J008
J007
J002
J001
J006
CN-36
J029
J027
J028
J020
J021
J023
J024
J025
J026
J019
J022
J018
73
57
53
52
55
70
27
HORN
CR-35
MCU
RCV
TCU
TCU
86 30 87a
B G17
85
BrW
3Br 31
ROr
ROr
VW
GW
OrW
WOr
GrW
WOr
GrW
GrW
YW
ROr
ROr
LW
GY
CN-9 TO: FRONT HARNESS
GW
SH
VOr
3Or
RW
RW
YW
VW
RW
LW
87
Or
LW
W
W
Gr
CS-59
V
Y
Y
W
W
Br
L
W
G
G
906 R
G35 B
L
L
L 153
CN-126
86 B G35 116 GOr
1 1 MAIN PUMP PS
85 87 87a
10 10
11E
161
159
158
134
3Or 21 9
16K
182
108
107
28A
12
154
155
10
13
19
21
4
3
1
G
11
15
16
22
24
26
13
68
66
67
2
17
27
28
29
30 R 1K 124
7E
90
29
24
2
81
83
85
82
74
51
49
5
6
9 2 2 STEERING PUMP PS
16F GrW
POWER RY 8 TO:PC 3 3 STEERING MOTOR RY
8 128 OrW
6 7 4 4 STEERING MOTOR RY
2
6 5 5 NC
7 WOr 3 130 LW
5 5 6 6 BOOM DOWN PS
1 131 G
4 SH 182 7 7 BUCKET LEVELER
132 Br
3 SH 187
8 8 BOOM KICK OUT
133 Or
2 9 9 BOOM DOWN PS
GrW 118 155 W
1 10 10 ATT. UNLOCK SOL
70 B
11 11 STEERING PS(GND)
AUTO/MANUAL SW 154 GW
12 12 ATT. LOCK SOL
ST C
6
5 CS-2
6 CN-10
GrW 157 2H R
BR ACC
3 5 1 1 PROXIMITY SW 24V
68 V
2 4 2 2 HEAD LIGHT Hi
B
1
L 153 G23 B
3 3 3 GND
H
4
153 B
0, I
L G24
2 4 4 GND
Or 21E 177 B
H0 I
1 5 5 PROXIMITY SW(GND)
7A ROr
6 6 ILLUMINATION RH
6A RW
7 7 ILLUMINATION LH
134 GW
START SWITCH 8 8 HEAD LIGHT Lo
67 Y
9 9 TURN LAMP LH
66 Or
10 10 TURN LAMP RH
152 BW
11 11 GND TM
144 BOr
12 12 STD B/DETNT(-)
13 13
G21 2B
14 14 HEAD LIGHT GND
129 V
15 15 HORN
36 CN-134
6
DIAGNOSTIC
5
47 BW
4
36E B
3
44 Gr
2
28E L
1
CN-157
36 B
1 VM1-GND
36A B
2 VM2-GND
37 B
3 VMG1-SPEED PICK-UP COM
38 BOr
4 VMG2-SPEED SENSOR OUTPUT
39 ROr
8 VPS2-RIDE CONT. RY(+)
40 LW
9 AIP5-GEAR BOX Y5
41 YW
10 AIP2-GEAR BOX Y1
6 ADM3-TM ERROR
43 W
12 VPS1-GEAR BOX VPS1(+)
43A W
CN-148 13 VPS1-GEAR BOX VPS1(+)
54E B 44 Gr
C 15 SDDK-DIAGNOSTIC
53F G 45 WOr
B 17 ER3-SW FILTER RESTRICTION
52E V 46 BOr
A 49 ER2-SENSOR TEMP CONVERTER
47 BW
18 EUPR-DIAGNOSTIC
DATA LINK 48 W
19 EF1-SPEED PICK-UP ENG
49 RW
20 ED3-SHIFT LEVER-X1A-B3
50 YW
21 ED10-PARKING BRAKE SW(+)
51 VOr
22 ED7-SHIFT LEVER-X1D-KD
22A R
23 VPE1-CONTINUANCE 24V
52A V
25 CANF_H
53A G
26 CANF_L
53A G
27 CANF_T
54A SH
28 VGS-CAN SHIELD
55 Or
29 ED11-SW AUTO/MANU SIG(+)
CL-7 B 56 OrW
G11 32 AIP3-GEAR BOX Y3
1 Y
BEACON SOCKET G 5
57
36 SD4-SPEED METER CLUSTER
2 58 BW
39 ER1-GEAR BOX TEMP
59 W
41 EF2-SPEED PICK-UP TURBIN
60 W
42 EF3-SPEED PICK-UP GEAR
74 Br
43 ED4-SHIFT LEVER X2B-FWD
28 L
45 VPI-POWER IG
75 BOr
46 VMGA2-GEAR BOX TEMP(COM)
76 G
51 AIP6-GEAR BOX Y6
77 V
55 AIP4-GEAR BOX Y4
78 Gr
56 AIP1-GEAR BOX Y2
79 GOr
57 ADM5-RY RIDE CONT.(-)
80 Br
62 EF4-SPEED SENSOR(SIG)
81 LW
63 ED1-SHIFT LEVER X1C-B1
82 GrW
64 ED5-SHIFT LEVER X2C-REV
83 L
65 ED2-SHIFT LEVER X1B-B2
84 Gr
66 ED9-CLUTCH CUT-OFF SW(+)
85 W
67 ED6-SHIFT LEVER X2D-NEU
22 R
86 BOr
44 ED8-FWD-JOYSTICK
87 Or
31 ED13-REV-JOYSTICK
17 G
30 ED14-NEU-JOYSTICK
88 BOr
52 ADM1-START INTERLOCK RY(-)
89 WOr
5 ADM4-REVERSE DRIVE RY(-)
90 LW
7 ADM2-JOYSTICK SELECT LAMP(-)
91 OrW
59 ADM5-JOYSTICK SELLECTER(+)
TM CONTROLER
CN-6
1 1 NC
75 BOr
2 2 GEAR BOX -TEMP(COM)
48 W
3 3 ENG.PICK-UP SENSOR
37 B 4 4 ENG.PICK-UP SENSOR
CR-55 45 WOr 5 5 FILTER RESTRICTION
86 30 87a 46 BOr
B G17 6 6 TEMP CONVERTER
85
R 63 7 7 NC
87 58 BW
L 180 8 8 GEAR BOX -TEMP
86 76 G
85 87 87a Gr 15 9 9 GEAR BOX -Y6
30 40 LW
10 10 GEAR BOX -Y5
WORK LAMP REAR RY 77 V
11 11 GEAR BOX -Y4
56 OrW
CS-36 B G35 12 12 GEAR BOX -Y3
10 78 Gr
9 10 13 13 GEAR BOX -Y2
R 1G 43 W
9 14 14 GEAR BOX -VPS1+
41 YW
8 15 15 GEAR BOX -Y1
8
6 7
2
ROr
CN-5
6 907
7 L 180 1 1 ENGINE OIL
5 5 70F B
1 2 2 GND-MCU
4 111 Br
3 3 HYD TEMP SENSOR
3 117 BOr
4 4 AIR CLEANER SW
2 110 V
R 1E 5 5 FUEL SENDOR
1 59 W
6 6 TURBIN PICK-UP SENSOR
WORK LAMP SW 37A B
910 Y
CS-21 G35 8 8 ENGINE TEMP
B 38 BOr
9 10 10 9 9 SPEED SENSOR-VMG2
R 1H 80 Br
9 10 10 SPEED SENSOR-EF4(2)
4 28F L
8 11 11 SPEED SENSOR-24V
2 R 1 37E B
7 12 12 INTER GEAR PICK-UP SENSOR
60 W
7 1 6 13 13 INTER GEAR PICK-UP SENSOR
5 R 35
5 14 14 ENGINE RPM
YW 11
4 15 15 ENGINE RPM
3
161 CN-4
I 0
W
2
OrW 10 1 1
1
2 2 AC CONDENSOR FAN
ILL & HEAD LAMP SW 153 L
3 3 START RELAY
151 BW 4 4 START RELAY
112 YW 5 5 ALTERNATOR
6 6 AC R/DRYER
7 7 AC R/DRYER
8 8 AC COMP
148 L
9 9 BACK BUZZER
6 RW
10 10 ILLUMINATION
66A Or
11 11 RH TURN LAMP
7 ROr
12 12 ILLUMINATION
67A Y
13 13 LH TURN LAMP
63 R
14 14 WORK LAMP
72 Br
15 15 STOP LAMP
CN-1
34 3R
1 1 MASTER SW
33 5W
2 2 FUSIBLE LINK
G35
G35
G35
G17
G17
GrW 16E
BOr 73A
104
GrW 157
156
WOr 122
130
127
OrW 119
BW 151
GOr 121
17A
109
1N
1R
1S
WOr 3A
WOr 3E
LW 12A
GY 159
WOr 3F
158
129
YW 50
148
GrW 16
17
BOr 88
BOr 73
84
19
13
WOr 89
LW 12
G62
168
144
152
131
132
Br
LW
Or
2A
B
Y
B
R
86
87
B
VW
62
61
BrW
G62
Or 133
156
G
G
VOr 51A
B
2
V
GOr 79
ROr 39
OrW 91
1V
17
2E
R
61
62
Gr
B
G
62A
61A
G17
G25
2G
LW 12H
196
LW 12E
Gr 196
BOr
2F
BOr
BW
BW
CS-55
G25
72
Br
127
CS-42
CR-5
Or
CS-17
CR-58
W
CR-38
Br
W
R
R
G
R
B
CR-11
L
CR-2
L
4
3
6
5
2
10 10
1
7
R
G
8
9
CD-5
87
30
85
86
10 10
10 10
87a
87
87
30
85
6 7
86
30
85
8
6
5 5
6 7
86
4
87a
8
6
5 5
9
87a
4
2
3
9
1
1
B 85
87
30
85
86
E 86
L 87
87a
W
Br
Gr
R
R
1
2
B
L
B
Y
B
CR-59
85 87 87a
3
85 87 87a
85 87 87a
CN-160
CR-40
85 87 87a
CR-41
87
30
85
86
87a
CD-4
CN-71
87
87
30
JOYSTICK SELECT 10
85
30
12
11
85
86
86
CR-63
86 30
87a
87a
6
5
4
3
2
1
8
9
7
86 30
86 30
DO-4
DO-5
Pa
86 30
1
G
2
C B A
87
30
85
86
85 87 87a
87a
1
1
2
2
85 87 87a
85 87 87a
ILLUMINATION
24V(DETEND)
24V(HANDLE)
86 30
85 87 87a
Pa CLUTCH FLASHER
KICK DOWN
86 30
86 30
9
7
8
BUCKET(-)
2
1
9
9
7
8
7
2
8
2
UNIT
86 30
NEUTRAL
CUT-OFF SAFETY RY NEUTRAL RY BACK-UP RY
BOOM(-)
PARKING HORN RY CLUTCH CUT-OFF SW PARKING SW RIDE CONTROL SW
FWD
GND
S - +
REV
RIDE CONTROL RY
NC
BOOM UP RY BUCKET RY
STOP LAMP RY STOP
LAMP RCV LEVER 7407S7EL00
7-4
· Canopy type (2/2)
ILLUMINATION 12
FROM BATT. RY
NC 11
CN-110 JOYSTICK SELECT 10
8 7
1
2
F/R COM
KICK DOWN
9
8
M
CN-79 R GND 7
MOTOR RY
21
21LF -70130
HOLD R A 6 BUCKET(-) 6
2B G1
GND B C 4 BK- BK+ 3
2W 23 5 BOOM(-) 5
PULL W B CD-40
5 BO- BO+2 4 NEUTRAL 4 5A B
CN-19 2 Pa
ENGINE STOP SOL 3 FWD 3 4 OrW OrW 1 3 G
6 FL- FL+ 1 1 1
2 REV 2 3 GrW GrW 2
1 24V 1
SOL 2
STR PUMP PS
CONT.VALVE BOOM DOWN 2 G G 3
3
CN-114 CN-160 1 GOr GOr 4 CD-39
4
Pa
CN-136
10 B B 5 5 B
5 2 Pa
4 GOr
CD-41
CL-3 6 1
2
1
15A GW
6 Lo
1
2
12A V MAIN PUMP PS
OR
4 Hi
B
START RY EMERGENCY STEERING HARNESS
OR
LW
5
14 G
CN-45 CR-23 3 C
2
3
3W G32 B
E
CL-3
2
2
1
M B G1 15A GW
ABL
M 3R
BW 17
16 Y
1 T 1 LW
CN-18
1
LW 6 12A V
6
4
Lo
Hi
HEAD LIGHT LH 1A LW
2
Or 9
5
B+ CD-18 3 B
3
B G1 14 G
3 C
STARTER CL-4 G32 B
15 GW 4 2 E
ABL
20 ROr CN-10 6 Lo 16 Y
R 11 12 V 1 T
1 FUSE
Pa
2 MULTIFUNCTION SW
1
2
V 12
4 Hi
RIDE CONTROL HARNESS HEAD LIGHT LH
5
FROM BATT.RY ENGINE OIL PS B G1 13 ROr
3 GND 3 3 C
15R 4 B G11 G31 B
CN-74 GND 4 2 E CN-178
ABL
17 Or GW 1
R 22 22 R 5 GND T 2 CN-140
B+ 2 5 1 B
YW ROr 13 3 1 GW GW 18
18A 3W/300
6 ILLUMINATION(FUSE) 1 1
G 1 6 HEAD LIGHT RH
4 RW 14 2 W W 19
NC 7 ILLUMINATION(FUSE) 7 ATT. LOCK 2
~ 3
FI 3
RS-1 GW 15 3 B B G14 CN-20
YW 18 8 MULTIFUNCTION SW 8 3 G11 B
U L 2 Y 16 CN-177 2
9 MULTIFUNCTION SW 9 W 2 5 V
P 1 Or 17 2 1
10 MULTIFUNCTION SW 10 B 3A
ALT CD-8 11 NC
1 HORN
11
2 ATT. UNLOCK CN-25
12 NC 12 G12 B
C 2
CN-28 19 Y
1
13 NC 13
B G31
QUICK COUPLER HARNESS 5A V
1
VW 24 14 GND 14
1 5 G11 CN-20
B G1 ENGINE COLLENT TEMP 15 HORN RY 15
V B
2
5 V CN-9 CL-4
G1
1 GOr 1 15 GW
1 MCU 1 6 Lo
AC COMP HORN G 2 12 V
17
18
24
20
19
21
25
2 MCU 2 4 Hi
G12
CN-25 3
GrW 2
5
B 3 FUSE
ROr
2
BW
YW
VW
OrW 2 13 ROr
5A V 4 EM'CY STEERING RY 4 3 C
Y
R
B
1 G31 B
CN-13
5 E
ENGINE HARNESS 5 NC 2
ABL
LW 6 17 Or
12
11
10
7
8
5
2
3
1
4
6
9
6 RIDE CONTROL SW 6 1 T
G 7
FRONT HARNESS(STD) 7 BUCKET RY 7
Br 8
HEAD LIGHT RH
908 ROr
8
BW
YW
8 BOOM UP RY Or 9
909 Y
9
42 B
9 RIDE CONT. RY
22 L
W 19
10 ATT. UNLOCK SW 10
18
19
B 10
11 GND(MCU) 11
GW 18
12 ATT. LOCK SW 12
FUSIBLE LINK
CN-1 CN-60 CN-10 CN-100
3R 1 1 3R R 11 11 R
1 FUSE BOX 1 1 1 FUSE 1 1 B
5W 2 2 5W V 12 G21 B
2 FUSE BOX 2 2 2 MULTIFUNCTION SW 2 3 E
B G1 8 Br
3 GND 3 4 S
4 B G11
GND 4 BOOM KICK OUT
CL-23A CL-23 B G21
40 R 5 GND 5
2 2 2 ROr 13
G6 B 6 ILLUMINATION(FUSE) 6
1 1 1 RW 14
7 ILLUMINATION(FUSE) 7 CN-101
WORK LAMP RH 8 MULTIFUNCTION SW GW 15 11A R
8 1 B
CL-22A CL-22 Y 16 G22 B
40A R 9 MULTIFUNCTION SW 9 3 E
CN-4 2 2 2 Or 17 7 G
G6 B 10 MULTIFUNCTION SW 10 4 S
1 1 1
1 NC 1 11 GND TM 11 BUCKET LEVELER
CR-1 G13
2 AC CON FAN RY 2 WORK LAMP LH 12 STD B/DETENT(-) 12
B
L 22 22 L
3 START KEY SW-br 3 13 NC 13
BW 18 G11 B B G31
4 RELAY-ANTI RESTART 4 14 GND 14
YW 19 V 5
5 MCU-ALTERNATOR 5 BATTERY 15 HORN RY 15
6 AC CONTROLLER 6 BATT. RY
7 AC COMP RY 7 FRONT HARNESS(OPTION)
8 AC COMP RY OUT 8 TO STARTER
L 35 22 L
9 BACK-UP RY OUT 9 2
RW 36 G11 B
10 FUSE-ILLUMINATION 10 1
Or 37
11 MULTI-FUNCTION SW -RH 11 DO-2
ROr 38
12 FUSE-ILLUMINATION 12
Y 39
13 MULTI-FUNCTION SW -LH 13
R 40
14 WORK LAMP RY 14
Br 41
15 STOP LAMP SW 15
OPTION CS-77
CD-1 MULTI FUNCTION SWITCH SHIFT LEVER
43 Br 1
2 CLUSTER 154 GW
AD7
AD6
AD5
AD4
AD3
AD2
AD1
CN-5 C 2
Y 7
B 5
WB 8
42
BG 3
BW 2
B
VM
VP
ROr 908 1
ED
1 MCU-ENGINE OIL PS 1 3
MIRROR HEATED
PROGRAM DUMP
B1
B3
B2
AS
R
V
B 42 HYD. TEMP
Lo
2 GND-MCU 2 4
ILLUMINATION
Br 43
2 1
R
3 MCU-HYD TEMP 5
O
CD-10
L
3
F
HIGH BEAM
16K GrW
\U+f058
F/R SIGNAL
BOr 44 BOr
Lo Hi F
44
COM_GND
4 MCU-AIR CLEANER 6
BATT. 24V
SERIAL_H
B+
4
C
RS232 RX
SERIAL_L
RS232 TX
Pa
RH TURN
LH TURN
4 3
V 45 42A B 7 2
5 MCU-FUEL SENDOR 5 6
IG 24V
IG 24V
W 46
O
6 TCU-EF2 8
OUTPUT SIGNAL
GND
GND
AIR-CLEANER
O J
6
G \U+f058
I
ROr
2 1
7E
NC
NC
NC
BWG C
B 47
C
7 TCU-VMG1 9
Hi
J
HO
7
R
Y 909 G35 B 10
X1
9
X2
CN-56
8 MCU-ENGINE TEMP CD-46 10
RW
8
BVi
BY
AD5(R) C
D
A
D
C
B
4 3
Gr
W
L
BOr 48 48 BOr
14
16
18
19
12
13
10
17
15
11
20
9 TCU-VMG2 9 ATT.LOCK SW
9
7
8
6
3
2
5
4
1
AD6(N)
AD4(F)
Y
Br 49 49 Br
AD1
AD2
AD3
2
6
1
3
5
4
10 TCU-EF4 10
ED1(VP)
2
2 1
AD7(KD)
L 50
N
11 FUSE-TCU 50 L CS-78
11 3
BrW
ROr
ROr
RW
LW
CS-11
CS-12
CS-5
Or
B 51
W
W
G
Br
R
12 1
B
TCU-VMG1 HAZARD SW
V
B
4
5
L
5
12
1
3
4 3
4
1
3
2
7
W 52
SPEED SENSOR OUTPUT 155 W
13 TCU-EF3 CS-82 2
2
8
7
9
13 CD-47(BLACK)
911
912
182
108
107
181
181
901
901
903
7E
D
90
24
29
29
68
66
67
K
14 MCU-TACHO 14 51 B 1 3
BrW
GW
YW
GY
2
CN-158
CN-159
W
Or
L
X1
X2
15 MCU-TACHO 15 52 W 2 4
C
D
D
B
A
B
A
1
3 5
11E
159
161
134
158
INTER GEAR PICK-UP CL-21 16K GrW
68
66
67
13
10 10
CN-6 36A 4 6
5 5
7 6
RW
CS-41
2 1
GrW
CD-27(GRAY)
RW
VOr
LW
1 NC 1 G6 B 5 5 7 6 2
Br
W
3
2
6
1
L
9
46 W 1 7
2 TCU-VMGA2 BOr 58 1 6 8
2
47 B NUMBER PLATE LAMP 2 7E ROr
28A
W 54 9
3 TCU-EF1 3 2 6 7
51
81
83
49
85
82
74
ROr
901
BrW 902
903
182
BrW
BrW
B 55 CD-2 8 G35 B 10 9
Or
4 TCU-VMG1 4 TURBIN PICK-UP 8 10
B
42E B
5 TCU-ER3 WOr 56 1 9
5 ATT.UNLOCK SW
G35
45 V
158
158
CD-17
7E
67
66
G
R
2
B
6 TCU-ER2 BOr 57 9 10 10
6 W
CN-14
54
1 FUEL SENDER
7 NC
CN-169
1
2
AEB SET
3
4
5
6
7 55 B
8 BW 53 2
TCU-ER1 SWITCH
4
3
1
2
8 CN-65
9 TCU-AIP6 G 59 ENG. PICK-UP G6 B
9 1
LW 60
10 TCU-AIP5 10 CD-48 35 L
2
V 61 56 WOr
11 TCU-AIP4 11 1 CS-80
12 TCU-AIP3 OrW 62 58E BOr BACK BUZZER 1
12 2 Pa
Gr 63
13 TCU-AIP1 13 CL-16 2
W 64 FILTER RESTRICTION 36 RW
14 TCU-VPS1 14 4 C 3
YW 65 CD-49 37 Or
15 TCU-AIP2 15 58A 3 T 4
BOr B 1
2 G6 5 5
C 2 E
57 BOr 7
41
11E
G35
Br
159
161
134
BrW 158
28A
1
182
108
107
181
GrW 16K
GW 154
155
13
68
66
67
ROr 7E
90
ROr 24
29
51
81
83
49
85
GrW 82
74
1 S 2
TEMP CONVERTER 6 7
LW
GW
VOr
VW
YW
RW
REAR COMBI RH
GY
LW
W
Or
8
B
W
CN-112
Br
L
W
V
L
CL-15 9
16
58 BOr 38 ROr 9 10 10
J002
J001
J006
J004
J007
J008
J003
J009
J010
J011
J012
J013
J014
J015
J016
J017
J018
J019
J020
J021
J022
J023
J024
J025
J026
J027
J028
J029
9 TEMP 4 C
53 BW 39 Y
64 W
8 TEMP
G6 B
3 T BUZZER STOP
FWD REV
59 G
7 VPS1(+)
41A
2 E SWITCH
1 2 3 4 1 2 3 Br
6 Y6 1 S
60 LW Y5
5 Y5
G11
61 V Y2 REAR COMBI LH
4 Y4 Y3
62 OrW
3 Y3 Y6 JUMP TO CIRCUIT(1/2)
65 YW
2 Y2 Y4
63 Gr
1 Y1 Y1
GEARBOX EARTH1
TRANSMISSION
7407S7EL00-1
7-5
· Cap type (1/2, opt)
5W 33 MCU
EM'CY PUMP MOTOR SW BRAKE PS PARKING WARNING RESISTER
PS
10 CLUTCH CUT-OFF SW
3R 34
CLUTCH CUT-OFF PS
MECHANICAL ENG(GND)
STEERING RY BUZZER
27 HYD TEMP SENDER

REVERSE FAN SOL
2
20 SPEEDMETER SIG.
3Br 31 R 35
AIR COND."ON"SIG
REVERSE FAN SIG
RIDE CONT. AUTO

TACHO SENSOR+
16 TACHO SENSOR-
PROGRAM DUMP
B
Pa
Pa
A
26 COOLANT TEMP
RIDE CONT. ON
STEERING P/P PS
14 ENGINE OIL PS
17 AUTO SEL.TCU
15 MAIN PUMP PS
STOP LAMP PS
WIPER INT SIG

POWER IG(NC)
POWER IG(NC)
FUEL SENDOR
23 FAN CLUTCH+
87a 87 85
30 86
11 AUTO SEL.SW
FUEL HEATER
STEERING RY
NEUTRAL SIG
24 FAN CLUTCH-
HOUR METER
CD-26
OPTION PS 2
OPTION PS 1
PREHEATER
CD-3
SAFETY RY
PARKING SIG
13 AIR FILTER
CN-26
SERVICE SERVICE
25 ALT LEVEL
CN-98
WIPER RY
WASH SIG
RS232 RX
SERIAL-H
2
RS232 TX
2
1
1
SERIAL-L
BRAKE PS
POWER POWER
10
21 BUZZER
CR-37
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
OPTION
OPTION
OPTION
OPTION
1
CS-75
2
OTMP1
C
Bat24V
B
A
18 CAN-H
12 IG 24V
19 CAN-L
CN-170A
ODP2
ODP1
87a
CN-170
10A
20A
20A
20A
10A
30A
30A
20A
30A
20A
30A
20A
30A
20A
30A
10A
10A
10A
10A
10A
10A
10A
22 GND
10A
10A
20A
GND
30
86
85
87
5A
5A
5A
10
1
2
3
8
9
JUMP TO CIRCUIT(2/2)
7
6
4
70E B
V
NC
L
2
RW
1
CN-58
CN-59
G
V
70A
125
126
BEACON/REAR WORK LAMP
ILLUMINATION LAMP
ILLUMINATION LAMP
EM'CY STEERING/RIDE CON.
CASSETTE/ROOM LAMP
FRONT WORK LAMP
NEUTRAL RY/JOYSTICK F/R
28
36
35
34
33
32
31
30
29
23
22
21
20
6
7
5
4
3
2
1
GrW
8
9
OrW
19
18
17
16
15
14
13
12
11
10
OrW
53G
9
8
7
B
1
5
2
6
3
R
52F
4
27A
B
BACK.STOP LAMP
AIR-CON/HEATER
115
AIR-CON/HEATER
G
SERVICE POWER
Or
G
B
G19 B
CIGAR LIGHTER
G23
CLUSTER/MCU
G19
G35
OrW
GrW
OrW
WOr
GOr
GOr
GOr
16A
BOr
BOr
G13
106
174
ROr
24A ROr
FUSE BOX
174
RW
YW
128
G12
177
LW
906
64E
TURN LAMP
HEAD LAMP
Or
Or
Gr
1L
START KEY
Br
W
72A Br
G
910 Y
CASSETTE
V
L
L
CLUSTER
PARKING
G21
ILL.LAMP
SPARE
907
100
101
102
103
104
105
106
107
108
109
110
111
112
175
115
116
117
118
119
120
121
122
124
125
126
SPARE
J014
J010
J011
J009
J030
J037
J033
J031
J036
J015
J012
J013
J016
J017
J034
J035
CN-36
WIPER
73
57
53
52
55
70
27
69
HORN
J003
J004
J008
J007
J002
J001
J006
J029
J027
J028
J020
J021
J023
J024
J025
J026
J019
J022
J018
CR-35
MCU
RCV
TCU
TCU
86 30 87a
B G17
85
BrW
3Br 31
ROr
ROr
GW
LW
OrW
WOr
GrW
WOr
GrW
GrW
YW
Or
ROr
ROr
LW
GY
GW
SH
VOr
3Or
RW
RW
YW
VW
163 Br
R
Gr
RW
LW
87
Or
LW
162 G
G
CN-9 TO: FRONT HARNESS
W
W
CS-59
2L
Gr
V
Y
Y
W
W
Br
L
W
G
G
906 R
R
Y
G35 B
L
CN-126
L
L 153 GOr
86 B G35 116
1 1 MAIN PUMP PS
172
10 10
173
85 87 87a
11E
161
159
158
134
120
21
64E
3Or 9
16K
182
108
107
28A
12
154
155
10
13
15
19
20
21
4
3
1
G
11
16
22
24
25
26
14
68
66
67
69
2
14
17
27
28
29
30
R 124
8
30 1K
7E
90
29
24
9
81
83
85
82
74
51
49
5
6
9 2 2 STEERING PUMP PS
16F GrW
POWER RY 8 TO:PC 3 3 STEERING MOTOR RY
8 128 OrW
6 7 4 4 STEERING MOTOR RY
2 129 V
6 5 5 HORN
7 WOr 3 130 LW
5 5 6 6 BOOM DOWN PS
1 131 G
4 SH 182 7 7 BUCKET LEVELER
132 Br
3 SH 187
8 8 BOOM KICK OUT
133 Or
2 9 9 BOOM DOWN PS
GrW 118 155 W
1 10 10 ATT. UNLOCK SOL
70 B
11 11 STEERING PS(GND)
AUTO/MANUAL SW 154 GW
12 12 ATT. LOCK SOL
ST C
6
5 CS-2
6 CN-10
GrW 157 2H R
BR ACC
3 5 1 1 PROXIMITY SW 24V
68 V
2 2 2 HEAD LIGHT Hi
B
1 4
L 153 G23 B
3 3 3 GND
H
4
153 B
0, I
L G24
2 4 4 GND
Or 21E 177 B
H0 I
1 5 5 PROXIMITY SW(GND)
7A ROr
6 6 ILLUMINATION RH
6A RW
CR-33 7 7 ILLUMINATION LH
134 GW
START SWITCH 86 30 87a 8 8 HEAD LIGHT Lo
BW 186 67 Y
85 9 9 TURN LAMP LH
BrW 176 66 Or
87 10 10 TURN LAMP RH
L 9G 152 BW
86 11 11 GND TM
85 87 87a L 9F 144 BOr
30 12 12 GND STD
AC CONDENSOR FAN RY 13 13
G21 2B
14 14 HEAD LIGHT GND
15 15
CN-11 36 CN-134
B 96A
DIAGNOSTIC
1 AC CONTROLLER GND 1 6
2 BLOWER MOTOR GND B 96 5
2 47 BW
2L 9 4
3 AC 24V 3 36E B
4 4 3
44 Gr
5 AC CONTROLLER B+
R 25 2
5 28E L
Y 145 1
6 AC COMP 6
BW 186
7 AC CONDENSOR FAN 7
8 ILLUMINATION R 1A CN-157
8
36 B
1 VM1-GND
CR-7 36A B
87a 2 VM2-GND
86 30 37 B
V 146 3 VMG1-SPEED PICK-UP COM
85 38 BOr
VW 147 4 VMG2-SPEED SENSOR OUTPUT
87 39 ROr
L 9E
VW 147
145
BrW 176
146
8 VPS2-RIDE CONT. RY(+)

86 40 LW
85 87 87a L 9A 9 AIP5-GEAR BOX Y5
30 41 YW
10 AIP2-GEAR BOX Y1
AIR-CON RY
V
Y
6 ADM3-TM ERROR
CR-26 43 W
G 162
86 30 87a 43A W
GOr 105 CN-148 Gr
85 54E B 44
W 8 C 15 SDDK-DIAGNOSTIC
87 53F G 45 WOr
W 8A B 17 ER3-SW FILTER RESTRICTION
86 52E V 46 BOr
85 87 87a R 173 173 R A 49 ER2-SENSOR TEMP CONVERTER
30 47 BW
18 EUPR-DIAGNOSTIC
DATA LINK 48 W
WIPER RY LO RY 19 EF1-SPEED PICK-UP ENG
162 G 49 RW
CR-4 YW
W 8E 8 W 50
86 30 87a 21 ED10-PARKING BRAKE SW(+)
B G13 51 VOr
85 22 ED7-SHIFT LEVER-X1D-KD
G 172 172 G 22A R
87 23 VPE1-CONTINUANCE 24V
Br 163 Br 52A V
86
163 25 CANF_H
85 87 87a L 14A 53A G
30 26 CANF_L
27 CANF_T
WIPER RY HI RY 54A SH
28 VGS-CAN SHIELD
55 Or
TO: CABIN HARNESS CN-7 56 OrW
29 ED11-SW AUTO/MANU SIG(+)
G 30 32 AIP3-GEAR BOX Y3
CASSETTE IG24V 1 1 Y
RW 57
WORK LAMP FRONT 2 171 36 SD4-SPEED METER CLUSTER
2 58 BW
Y 20 39 ER1-GEAR BOX TEMP
CASSETT B+/ROOM LAMP 3 3 59 W
4 4 41 EF2-SPEED PICK-UP TURBIN
60 W
5 5 42 EF3-SPEED PICK-UP GEAR
B 74 Br
178 43 ED4-SHIFT LEVER X2B-FWD
GND (CASSETTE) 6 6 L
R 28
ILLUMINATION 7 1 45 VPI-POWER IG
7 75 BOr
B 179 46 VMGA2-GEAR BOX TEMP(COM)
GND 8 8 G
76
9 9 51 AIP6-GEAR BOX Y6
B 77 V
GND 10 179 55 AIP4-GEAR BOX Y4
10 78 Gr
G 5A 56 AIP1-GEAR BOX Y2
BEACON SW 11 11 GOr
B 79
GND 12 179 57 ADM5-RY RIDE CONT.(-)
12 80 Br
13 13 62 EF4-SPEED SENSOR(SIG)
R 81 LW
63 63 ED1-SHIFT LEVER X1C-B1
WORK LAMP REAR 14 14 GrW
82
15 15 64 ED5-SHIFT LEVER X2C-REV
83 L
84 Gr
CN-8 85 W
L 14 67 ED6-SHIFT LEVER X2D-NEU
REAR WIPER 24V 1 1 R
V 22
WIPER SW-WASHER 2 166 68 VPE2-CONTINUANCE 24V
2 86 BOr
W 165 44 ED8-FWD-JOYSTICK
WIPER SW-PF 3 3 Or
Or 87
WIPER SW-ON 4 4 164 31 ED13-REV-JOYSTICK
17 G
5 5 30 ED14-NEU-JOYSTICK
88 BOr
6 6 52 ADM1-START INTERLOCK RY(-)
89 WOr
7 7 5 ADM4-REVERSE DRIVE RY(-)
90 LW
OPTION 8 8 7 ADM2-JOYSTICK SELECT LAMP(-)
91 OrW
59 ADM5-JOYSTICK SELLECTER(+)
OPT
86 30 87a
G16
85
B TM CONTROLER
RW 171 CN-6
CR-3 87
G 170 1 1 NC
86 75 BOr
85 87 87a Gr 15 2 2 GEAR BOX -TEMP(COM)
30 48 W
3 3 ENG.PICK-UP SENSOR
WORK LAMP FRONT 37 B 4 4 ENG.PICK-UP SENSOR
CR-55 45 WOr 5 5 FILTER RESTRICTION
86 30 87a 46 BOr
B G17 6 6 TEMP CONVERTER
85 7
R 63 7 NC
87 58 BW
L 180 8 8 GEAR BOX -TEMP
86 76 G
85 87 87a Gr 5 9 9 GEAR BOX -Y6
30 40 LW
10 10 GEAR BOX -Y5
77 V
WORK LAMP REAR 11 11 GEAR BOX -Y4
56 OrW
CS-36 B G36 12 12 GEAR BOX -Y3
78 Gr
9 10 10 R 1G 43
13 13 GEAR BOX -Y2
9 W
14 14 GEAR BOX -VPS1+
41 YW
8 15 15 GEAR BOX -Y1
8
6 7
2
6
R 1F
907 ROr
CN-5
7 R 1E 1 1 ENGINE OIL
5 5 70F B
1 2 2 GND-MCU
4 111 Br
3 3 HYD TEMP SENSOR
3 117 BOr
L 180 4 4 AIR CLEANER SW
2 110 V
G 170 5 5 FUEL SENDOR
1 59 W
37A B
WORK LAMP SW 7 7 TURBIN PICK-UP SENSOR
CS-21 910 Y
G35 8 8 ENGINE TEMP
B 38 BOr
9 10 10 9 9 SPEED SENSOR-VMG2
R 1H 80 Br
9 10 10 SPEED SENSOR-EF4(2)
4 28F L
8 11 11 SPEED SENSOR-24V
2 R 1 37E B
7 12 12 INTER GEAR PICK-UP SENSOR
60 W
7 1 6 13 13 INTER GEAR PICK-UP SENSOR
5 R 35
5 14 14 ENGINE RPM
YW 11
4 Y 145 15 15 ENGINE RPM
3 V 146
161 CN-4
I 0
W
2 VW 147
OrW 10 1 1
1 BrW 176 176 BrW
2 2 AC CONDENSOR FAN
ILL & HEAD LAMP SW 153 L
3 3 START RELAY
151 BW 4 4 START RELAY
112 YW 5 5 ALTERNATOR
145 Y
6 6 AC R/DRYER
146 V
7 7 AC R/DRYER
147 VW
8 8 AC COMP
148 L
9 9 BACK BUZZER
6 RW
10 10 ILLUMINATION
66A Or
11 11 RH TURN LAMP
7 ROr
CN-138 67A
12 12 ILLUMINATION
VW 13A Y
24V 24V A 13 13 LH TURN LAMP
B G53
GND B 14 14
Or 167 72 Br
12V 12V C 15 15 STOP LAMP
DC/DC CONVERTER
CN-139
Or 167
2
B G53
1
12V SOCKET
CL-2 64A
Or
R 1T
B G53
CIGAR
B B
34 3R
CN-1
1 1 MASTER SW
33 5W
2 2 FUSIBLE LINK
G35
G35
G35
14E
164
G17
165
G17
GrW 16E
BOr 73A
104
GrW 157
156
WOr 122
130
G4
127
OrW 119
BW 151
GOr 121
17A
109
1N
1R
1S
WOr 3A
WOr 3E
LW 12A
GY 159
WOr 3F
158
129
YW 50
148
GrW 16
G3
G3
17
166
BOr 88
BOr 73
69
84
19
13
WOr 89
LW 12
G62
168
144
152
131
132
Or
Br
LW
W
Or
R
B
2A
B
Y
R
L
B
R
86
87
B
VW
62
61
BrW
G62
Or 133
156
17E
G
G
Gr
VOr 51A
B
2
V
B
L
V
GOr 79
ROr 39
OrW 91
1V
2E
61
R
62
Gr
B
G
62A
61A
G17
G25
2G
LW 12H
196
LW 12E
Gr 196
BOr
2F
BOr
BW
BW
CS-55
G25
72
Br
127
Or
CS-42
CR-5
CN-102
CS-17
CR-58
W
CR-38
Br
W
R
R
G
R
B
G
L
CR-11
CR-2
L
4
3
6
5
2
10 10
1
7
R
CN-103
CN-22
8
9
CD-5
87
30
85
86
10 10
10 10
87a
87
5
87
30
6
85
4
6 7
86
30
85
8
6
5 5
2
6 7
86
3
87a
1
6
5 5
9
87a
4
2
3
9
1
1
B 85
87
30
85
86
E 86
L 87
87a
W
Br
Gr
1
1
2
R
R
B
L
B
1
2
Y
B
CR-59
85 87 87a
3
85 87 87a
85 87 87a
CN-114
85 87 87a
CR-40
CR-41
87
30
85
86
87a
Lo 5
1
M
3
2
Hi 4
CD-4
CN-71
JOYSTICK SELECT 10
12
11
87
87
30
85
30
86
85
86
86 30
6
5
4
3
2
1
87a
87a
CR-63
8
9
7
86 30
86 30
DO-5
DO-4
Pa
86 30
G
1
2
C B A
87
30
85
86
85 87 87a
1
1
87a
2
E
2
B
Pf
85 87 87a
85 87 87a
R/WASHER F/WASHER
ILLUMINATION
86 30
24V(DETEND)
24V(HANDLE)
85 87 87a
Pa CLUTCH FLASHER
86 30
86 30
KICK DOWN
M
7
8
2
BUCKET(-)
9
9
7
8
7
2
UNIT
2
1
86 30
CUT-OFFF
NEUTRAL
HORN RY SAFETY RY NEUTRAL RY BACK-UP RY
BOOM(-)
PARKING CLUTCH CUT-OFF SW PARKING SW RIDE CONTROL SW
FWD
GND
S - +
REV
RIDE CONTROL RY
NC
REAR WIPER BOOM UP RY BUCKETRY
STOP LAMP RY STOP
LAMP RCV LEVER
7407S7EL01
7-6
· Cap type (2/2, opt)
CL-3
15A GW
RESISTOR RELAY(HI) RELAY(M2) 6 Lo
INLET M/ACT TEMP M/ACT MODE(D/FOOT) MODE(VENT) 12A V
4 Hi
3 M 1 M 4 2 7
3 M 1 M 4 2 7 BLOWER 14 G
5
7
3
7
1
3 C
Lo 1
4
ML 2
MH 3
5 5 G32 B
M
2 E
Hi
ABL
2
2
16 Y
5
6
7
5
6
7
5
6
7
1
2
3
4
5
6
7
1
2
3
4
1
2
3
4
1
2
3
4
1 T
1
2
3
4
1
2
1
1
4
4
2
3
2
3
HEAD LIGHT LH
GW
WR
BW
WB
BG
BG
GB
GB
GL
YB
LR
LB
Y
YBr
YW
LG
CL-4
YW
BG
RY
RY
2B
YB
L
L
20A
GW
L
15
9A
9B
21
22
17
20
18
19
23
24
25
16
15
AC-11 CN-10 6 Lo
AC-1
36A
ILLUMINATION 12 R 11 12 V
26
35
27
33A
1 FUSE
32
36
6B
6A
29
33
36
28
35
1 4 Hi
NC 11
18 18 V 12
Y 23 2 MULTIFUNCTION SW 2 5
CN-110 17 17 CONDENSER FAN B G1 13 ROr
JOYSTICK SELECT 10 LW 24 3 GND
16 3 3 C
1 F/R COM 9 16 COMPRESSOR(DPS) B G11 G31 B
YW 25 4 GND 4 2 E
ABL
8 7 15 15 BLOWER RELAY(HI) Or
2 KICK DOWN 8 BOr 26 5 GND 5
17
1 T
GND 7 14 14 BLOWER RELAY(M2) ROr 13
21LF -70130
YW 27 6 ILLUMINATION(FUSE) 6 HEAD LIGHT RH

6 BUCKET(-) 6 13 13 BLOWER RELAY(M1) RW 14
BK+ 3 LW 28 7 ILLUMINATION(FUSE) 7
4 BK- 12 12 BLOWER RELAY(LO)
5 BOOM(-) 5 Y 29 8 MULTIFUNCTION SW 8
GW 15
4 NEUTRAL 11 11 MODE M/ACT(PBR) Y 16
5 BO- BO+2 4 LW 30 9 MULTIFUNCTION SW
10 10 MODE M/ACT(M-) 9
3 FWD 3 WOr 31 10 MULTIFUNCTION SW 10
Or 17
6 FL- FL+ 1 9 9 MODE M/ACT(M+)
2 REV 2
CN-11 NO. DESTINATION BW 32 11 NC 11
1,2 BR 8 8 MODE M/ACT(FOOT)
1 24V 1
1 1 GND(CONTROLLER) GY 33 12 NC 12
32 2B 7 7 MODE M/ACT(DEF)
CN-114 CN-160 2 2 GND(BLOWER) Y 34 13 NC 13
6 RY 6 6 MOTOR ACT(REF) B G31
3 3 FUSE(IG) G 35 14 GND 14 CN-20
10 RW 5 5 TEMP M/ACT(PBR) V 5 G11 B
4 4 MCU BOr 36 15 HORN RY 15 2
33 2R 4 4 TEMP MOTOR ACT(-) 5 V
5 5 FUSE(Battery) L 37 1
30 LW 3 3 TEMP MOTOR ACT(+)
6 6 DPS(COMPRESSOR) 2
BW 38
2 INLET MOTOR(FRE) CN-23 HORN
31 LY
WOr 39 BEACON LAMP 17 W
7 7 CONDENSOR FAN 1 1 INLET MOTOR(REC) 1 CN-25
5 G 18 L G12 B
2
8
7
8
9
8 ILLUMINATION 2 2
5A V
AIR CON BEACON 1
AC-22 AC-2 SPEAKER LH
14 14 NC LAMP
M
13 13 NC
FRONT HARNESS(STD)
WB 15
BW 16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
GB 10
10 10
1
2
3
4
5
6
8
9
CS-23
12 12 NC CN-24 FROM BATT. RY
CL-7
GW
BrR
WR
YBr
RW
RW
19
LW
BG
BG
BG
GB
9
OR
BR
BR
RY
8
GL
YB
LG
YB
LR
LB
LY
1
1
9
2
4
G
5
6
8
7
Y
11 11 NC
GW 40 20 GY
1.25LgB
10 10 NC 2
1.25G
9
GW 40
9 DUCT SENSOR(GND) M
10
11
12
13
14
15
16
17
18
10
11
12
13
14
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
GY
GY
SPEAKER RH
B
BW 41
R
G7 B
8 8 DUCT SENSOR(+) MOTOR RY
BLOWER RELAY(M1)
BLOWER RELAY(M2)
COMPRESSOR(DPS)
DUCT SENSOR(GND)
BLOWER RELAY(LO)
MODE M/ACT(FOOT)
INLET MOTOR(REC)
BLOWER RELAY(HI)
TEMP MOTOR ACT(+)
INLET MOTOR(FRE)
TEMP MOTOR ACT(-)
MODE M/ACT(PBR)
MODE M/ACT(DEF)
REVERSE FAN SIG
G1
7H
22
22
TEMP M/ACT(PBR)
7 7 NC
MOTOR ACT(REF)
CONDENSER FAN
DUCT SENSOR(+)
9
MODE M/ACT(M+)
MODE M/ACT(M-)
1
2
R 42 CN-27
6 6 POWER IG 17
ILLUMINATION
G 43 W
5 5 ILLUMINATION 1 S.L+ CD-40
BATTERY(+)
BATTERY(+)
RW 44 1 G
2 ACC 5A B
POWER IG
4 4 BATTERY(+) 7 CN-19 2 Pa
RW 45 R
3 3 BATTERY(+) 3 ILL+ 4 OrW OrW 1 3 G
19 OR 1 1
DUCT 2
BrW 46
2 GND 4 S.R+ 3 GrW GrW 2
SOL
GND
GND
6A B 2
SENSOR BrW 47 STR PUMP PS
NC
NC
NC
NC
NC
1 1 GND 5 ILL- CONT.VALVE BOOM DOWN 2 G G 3
18 L 3
6 S.L- 1 GOr GOr 4 CD-39
3 Y 4
CN-136
AC & HEATER CONTROLLER
Pa
CN-79 R GY
7 B+ 10 B
5
B 5 5 B
2
21 20
8 Pa
R A S.R- 4 GOr
CD-41
HOLD 6 1
2B G1 6 B
2
1
GND B C 9 GND
CAB HARNESS
1
2
2W 23
PULL RADIO & USB/MP3 PLAYER MAIN PUMP PS
OR
W B
B
ENGINE STOP SOL EMERGENCY STEERING HARNESS
OR
LW
2
3
CN-7 CL-3
2
1
G 1 15A GW
1 FUSE-CASSETTE 1 CN-18 6 Lo
RW 2 1 LW LW 6 12A V
2 WORK LAMP RY FRONT 2 1 4 Hi
Y 3 1A LW Or 9
3 FUSE-CASSETTE/ROOM LAMP 3 CN-27A 2 5
513 RW 3 B B G1 14 G
USB CONNECTOR
4 4 1 USB 5V 3 3 C
514 Or G32 B
5 2 USB D- 4 2 E
ABL
5 B 6 515 GOr 16 Y
START RY
6 GND 6
7
R 7 516 OrW
3
4
USB D+
USB GND
RIDE CONTROL 1 T
HEAD LIGHT LH
7 ILLUMINATION B G21
CN-45 3W
CR-23 8 GND 8 5 NC
517 W
M B G1 9 NC 9 6 AUX_L
CN-178
M 3R
BW 17 10 GND 10
B
G
G1
9
518
519
R
LW
7 AUX_R 2
GW 1
CN-140
11 8 AUX_GND B 3 1 GW GW 18
11 FUSE BOX B G27
1 1
B+ 12 2 W W 19
CD-18 12 GND 514 Or ATT. LOCK 2
13 1 USD D- 3 B B G14 CN-20
STARTER 13 R 10 515 GOr 3 G11 B
20 ROr 2 USD D+ CN-177 2
USB PORT
14 WORK LAMP REAR 14 W 2
516 OrW 2
5 V
1
15 15 3 USB GND
Pa 517 W B 3A
4 AUX S1 1 HORN
FROM BATT.RY ENGINE OIL PS CN-8 518 R
L 13
5 AUX S2 ATT. UNLOCK CN-25
CN-74 15R
1 FUSE BOX 1
V 14
513
519
RW
LW
6 USB +(5V) QUICK COUPLER G12 B
2
CL-5
CL-6
R 22 22 R 2 5A V
B+ 2 2 REAR WASHER 10 AUX GND 1
1
2
2
W 15
18A YW 3W/300
3
G 1 3 WIPER PF Or 16 CN-27B
NC 4 4 WIPER ON SIG 4 CN-9 CL-4
~ 3
FI 3 RS-1 5 GOr 1 15 GW
U YW 18 5 CL-1 1 MCU 1
G 2 12
6 Lo
L 2 6 3A Y V
6 2 2 MCU 2 4 Hi
P 1 21 GrW 2
7 7 Or 1 3 5
CD-8 3 FUSE OrW 2 13 ROr
ALT 8 8 G2 B 4 EM'CY STEERING RY 4 3 C
2 V 5 G31 B
5 HORN RY 5 2 E
ABL
C ROOM LAMP LW 6 17 Or
CN-28 19 Y 6 RIDE CONTROL SW 6 1 T
VW 24 1 CL-30 7
G 7
1 3E Y 7 BUCKET RY HEAD LIGHT RH
B G1 ENGINE COLLENT TEMP 21A Or
2
8 BOOM UP RY 8
Br 8
1 Or 9
G1
9 RIDE CONT. RY 9
G3 B W 19
G8
10
7A
15
14
13
10 ATT. UNLOCK SW
16
AC COMP
17
18
24
20
19
21
25
B 10
AC COND FAN
11 GND(MCU) 11
G30
G21
G22
G24
G23
G29
GW 18
10E
10F
Or
Pa
RW 2F
RW 2A
RW 2E
12
V
ROr
L
CS-1
BW
YW
VW
12 ATT. LOCK SW
R/DRY
RW 2
M
21 Or
Y
R
B
CN-83
CN-29
CN-13
CS-35
ENGINE HARNESS
R
B
R
B
B
CN-10 CN-100
10 10
5
4
1
6
2
12
11
3
10
7
8
5
2
3
1
4
6
9
11
1
11
2
1 FUSE R R
1 1 B
CL-51
CL-52
CL-61
CL-62
CL-23
CL-22
DOOR SW V 12 G21 B
6
3
2 MULTIFUNCTION SW
BrW
2 3 E
1
2
2
0,
ROr
I
BW
YW
B G1 8 Br
B
3 GND 3 4 S
V
Y
Y
4 B G11
L
GND
G12
4 BOOM KICK OUT

28
B G21
908
909
5 GND 5
18
0 I
19
22
32
33
1
8
ROr 13
WORK LAMP-REAR 6 ILLUMINATION(FUSE) 6
REAR WIPER WORK LAMP L/H WORK LAMP R/H RW 14
7 ILLUMINATION(FUSE) 7 CN-101
FUSIBLE LINK 21LD-60150 21LD-60150 GW 15 11A R
8 MULTIFUNCTION SW 8 1 B
CN-1 CN-60 Y 16 G22 B
3R 1 1 3R 9 MULTIFUNCTION SW 9 3 E
1 FUSE BOX 1 1 Or 17 7 G
5W 2 2 5W OPTION 10 MULTIFUNCTION SW 10 4 S
2 FUSE BOX 2 2
11 GND TM 11 BUCKET LEVELER
B G13
12 GND STD 12
13 NC 13
B G31
14 GND 14
15 NC 15
FRONT HARNESS(OPTION)
CN-4
1 NC 1
BrW 28 CR-1
2 AC CON FAN RY 2
L 22 22 L
3 START KEY SW-br 3
BW 18 G11 B
4 REALY-ANTI RESTART 4
YW 19
5 MCU-ALTERNATOR 5 BATTERY
Y 32 BATT. RY
6 AC CONTROLLER 6
V 33
7 AC COMP RY 7
8 AC COMP RY OUT 8
VW 34 TO STARTER
L 35 22 L
9 BACK-UP RY OUT 9 2
RW 36 G11 B
10 FUSE-ILLUMINATION 10 1 OPTION
Or 37
11 MULTI-FUNCTION SW -RH 11 DO-2 SHIFT LEVER CS-77
ROr 38 MULTI FUNCTION SWITCH
12 FUSE-ILLUMINATION 12 1
CLUSTER
AD7
AS AD6
R AD5
V AD4
B3 AD3
B2 AD2
B1 AD1
Y 39 154 GW
13 2
Y 7
MULTI-FUNCTION SW -LH 13
B 5
WB 8
BG 3
BW 2
VM
VP
ED
R 40
14 WORK LAMP RY 14 3
MIRROR HEATED
PROGRAM DUMP
Br 41
Lo
15 STOP LAMP SW 15 4
ILLUMINATION
4 3 2 1 4 3 2 1 4 3 2 1
R
5
O
L
HIGH BEAM
F
R
L
CD-1
F/R SIGNAL
FRONT WIPER 16K GrW
\U+f058
COM_GND
Lo Hi F
BATT. 24V
6
SERIAL_H
RS232 RX
SERIAL_L
RS232 TX
43 Br
B+
C
RH TURN
LH TURN
2
CN-5 42 B
C 7 6 2
IG 24V
IG 24V
OUTPUT SIGNAL
1 MCU-ENGINE OIL PS ROr 908 1
O
8
GND
GND
1
O J
G \U+f058
I
HYD. TEMP ROr
NC
NC
NC
B 42 7E
BWG C
2 GND-MCU
C
9
Hi
2
J
HO
M
R
Br 43 G35 B 10
X1
9
CN-56
3 MCU-HYD TEMP
X2
3 CD-10 10
RW
BVi
BY
AD5(R) C
AD6(N) D
A
D
C
AD4(F) B
A
Gr
BOr
W
BOr 44 44
L
4 MCU-AIR CLEANER ATT.LOCK SW
14
16
18
19
12
13
10
17
15
11
20
4
E
Pa
Pf
9
7
8
6
3
2
5
4
5 Lo
4 Hi
V 45 42A B
Y
5
AD1
AD2
AD3
4
6
MCU-FUEL SENDOR
2
6
1
3
5
4
5
ED1(VP)
2
3
1
AD7(KD)
W 46
N
6 TCU-EF2 6 AIR-CLEANER CS-78
BrW
ROr
ROr
RW
CS-11
CS-5
CS-12
LW
B 47
CN-21
Or
7
W
W
TCU-VMG1
G
Br
R
HAZARD SW 1
V
B
4
5
L
1
7
4
1
3
2
6
2
1
5
7
8 Y 909 155 W
MCU-ENGINE TEMP 8 CD-46 CS-82 2
2
8
7
9
911
912
182
108
107
181
181
901
901
903
BOr 48 BOr
D
7E
48
90
24
29
29
68
66
67
K
9 TCU-VMG2 9 1 1 3
VOr
BrW
GW
LW
YW
VOr
GY
Gr
Br
CN-159
Br 49
Or
49
CN-158
Br
G
10 TCU-EF4
X1
X2
V
Y
G
2 4
B
10 2
C
D
D
B
A
B
A
L 50 50 L
11 FUSE-TCU 11 3 3 5
11E
159
161
134
158
16K GrW
G1
B
68
66
67
51
17
18
19
20
38
14
26
27
38
28
12 TCU-VMG1
10 10
12 4 6
5 5
7 6
CS-41
SPEED SENSOR OUTPUT 1
GrW
W 52
RW
VOr
13 TCU-EF3
LW
13 CD-47(BLACK) 5 5 7 6 2
Br
W
3
7
6
1
L
9
14
901
BrW 902
903
182
14 51 B 6 8
2 2 7E ROr
28A
15 15 52 W 6 7 9
51
81
83
49
85
82
74
ROr
1
BrW
BrW
8 G35 B 10 9
Or
CL-21 8 10
B
B
INTER GEAR PICK-UP
CN-6 36A RW 9 ATT.UNLOCK SW
G35
2
CN-169
158
158
CD-27(GRAY)
7E
67
66
1 NC G6 B 9 10 10
CN-14
1 46 W 1
4
3
1
2
2 TCU-VMGA2 BOr 58 1
2
1
2
3
4
5
6
54 47 B NUMBER PLATE LAMP AEB SET
3 TCU-EF1 W 2
3 SWITCH
4 TCU-VMG1 B 55 CD-2
4 TURBIN PICK-UP 42E B
5 TCU-ER3 WOr 56 1
5 45 V
BOr 57 CD-17 2
6 TCU-ER2 6 54 W CS-80
1
G61
7 NC 7 55 B FUEL SENDER 1
8 TCU-ER1 BW 53 2
8 CN-65 2
9 TCU-AIP6 G 59 ENG. PICK-UP G6 B 3
B
9 1
LW 60
10 TCU-AIP5 10 CD-48 35 L
2 4
V 61 56 WOr 1
11 TCU-AIP4 11 1 5 5
OrW 62 58E BOr BACK BUZZER 7
12 TCU-AIP3
11E
120
G35
172
163
173
159
161
134
BrW 158
28A
162
182
108
107
181
12 6
69
GrW 16K
2
GW 154
155
Pa
14
68
66
67
ROr 7E
90
ROr 24
29
51
81
83
49
85
GrW 82
74
8
13 TCU-AIP1 Gr 63 2
13 FILTER RESTRICTION CL-16 6 7
8
LW
64 36 RW
GW
VOr
YW
W
RW
LW
GY
14 TCU-VPS1
LW
W
Gr
Or
8
Br
G
14
B
W
R
C
W
Br
L
W
G
Y
L
L
YW 65 37 Or
15 TCU-AIP2 15 CD-49 3 T 9
58A BOr
2 G6 B 9 10 10
C 2 E
J002
J001
J006
J004
J007
J008
J003
J030
J031
J033
J009
J034
J035
J036
J037
J010
J011
J012
J013
J014
J015
J016
J017
J018
J019
J020
J021
J022
J023
J024
J025
J026
J027
J028
J029
57 BOr
1 41 Br
1 S BUZZER STOP
TEMP CONVERTER
REAR COMBI RH SWITCH
CN-112
16 CL-15
58 BOr 38 ROr
9 TEMP 4 C
53 BW 39 Y
8 TEMP 3 T
64 W REV G6 B
7 VPS1(+) FWD 2 E
59
60
G
LW
6 Y6
Y5
1 2 3 4 1 2 3 41A Br
1 S JUMP TO CIRCUIT(1/2)
5 Y5
G11
61 V Y2
4 Y4 REAR COMBI LH
62 OrW Y3
3 Y3 Y6
65 YW
2 Y2 Y4
63 Gr
1 Y1 Y1
GEARBOX EARTH1
TRANSMISSION
7407S7EL01-1
7-7
MEMORANDUM
7-8
1. ILLUMINATION CIRCUIT
1) OPERATING FLOW
Fuse box (No. 2) Illumination switch [CS-21 (1)] Switch ON, 1st step
[CS-21 (7)] All switch indicator lamp ON
[CS-21 (5)] Fuse box (27)] I/conn [CN-4 (12)] LH Combi clearance lamp ON [CL-15 (4)]
I/conn [CN-10 (6)] RH Head lamp ON [CN-4 (3)]
Cluster [CN-56 (17)] All cluster gauge & LCD llamp ON
Hazard AEB set and buzzer stop switch indicator lamp ON
Fuse box (28)] I/conn [CN-4 (10)] Number plate lamp ON [CL-21 (2)]
RH combi clearance lamp ON [CL-16 (4)]
I/conn [CN-10 (7)] LH head lamp ON [CL-3 (3)]
2) CHECK POINT
Engine Key switch Check point Voltage
① - GND (switch input)
② - GND (switch output)

OFF ON 20~25V
③ - GND (to light)
④ - GND (to cluster)
※ GND : Ground
7-9
ILLUMINATION CIRCUIT
FUSE BOX
BEACON SOCKET 20A
1
10 OrW ILL.LAMP 20A
2
HEAD LAMP 20A
3
BACK/STOP LAMP 10A
4
24
CLUSTER 10A
25
SPARE FUSE 7 10A
26
7 ROr ILLUMINATION LAMP 5A
27
6 RW ILLUMINATION LAMP 5A
28
CN-36
R 35
CL-3
6 LO
3 4 Hi
5
14 G
3 C
G32 B
ABL
2 E
1 1 T
2 HEAD LIGHT LH
3
2 4 CL-4
5 6 LO
ILL & HEAD LAMP SW
B G35
7A
6A
ROr
RW
6
ROr
RW
13
14
3 4 Hi
9 10 10 R 1H
7 5
13 ROr
9 8 3 C
4 8 G31 B
ABL
2 R 1 9 2 E
7 10 1 T
7 1 6 11 HEAD LIGHT RH
5 R 35
5 12
4 13
B G31
3
3 14 NUMBERPLATE LAMP
II I 0
2 36A RW
OrW 10
15 2
1 G6 B
CN-10 1
CS-21 CL-21
3
1
1 2 RH COMBI REAR
3 36 RW
4 C
4
3 T
5 G6 B
2 E
6
1 S
ALL SWITCH INDICATOR LAMP ON 7
8
CL-16
9
6 RW RW 36
10 3 LH COMBI REAR
11
7 ROr ROr 38 38 ROr
12 4 C
13 3 T
G6 B
14 2 E
15 1 S
CN-4 CL-15
CN-56
CS-82 8 NC
18 NC
9 10 10
9
8 19 COM_GND
8
6 7 15 SERIAL_L
2
6 14 SERIAL_H
7
5 5 16 F/R SIGNAL
1
4
3 11 GND
2 12 GND
1
AEB SET SW 7 MIRROR HEATED
3 BATT. 24V
2 IG 24V
1 IG 24V
13 NC
9 PROGRAM DUMP
10 RS232 TX
CS-80
CS-41
20 RS232 RX
10 10
10 10
9
8
6 7
6
5 5
4
3
2
1
9
8
6 7
6
5 5
4
3
2
1
6 HIGH BEAM
7E ROr
17 ILLUMINATION
5 RH TURN
8
2
7
1
8
2
7
1
9
4 LH TURN
BUZZER STOP SW HAZARD SW
4 CLUSTER
7607S7EL03
7-10
2. HEAD LIGHT CIRCUIT
1) OPERATING FLOW
Fuse box (No.3) Head light switch [CS-21 (4)] Light switch ON, 2nd step [CS-21 (2)]
Multi function switch [CS-11(8)]
Multi function switch MIDDLE [CS-11(7)] I/conn [CN-10 (8)]
LH Head light low beam ON [CL-3 (6)]
RH Head light low beam ON [CL-4 (6)]
Multi function switch DOWN [CS-11(6)] I/conn [CN-10 (2)]
LH Head light high beam ON [CL-3 (4)]
RH Head light high beam ON [CL-4 (4)]
Cluster high beam pilot lamp ON [CN-56 (6)]
2) CHECK POINT

① - GND (switch input)
② - GND (switch output)
③ - GND (multi function input)
④ - GND (multi function output)
OFF ON 20~25V
⑤ - GND (multi function output)
⑥ - GND (low beam)
⑦ - GND (high beam)
⑧ - GND (passing B+)
※ GND : Ground
7-11
HEAD LIGHT CIRCUIT
FUSE BOX
BEACON SOCKET 20A
1
ILL.LAMP 20A
2
11 YW HEAD LAMP 20A
3
BACK/STOP LAMP 10A
4
24
CLUSTER 10A
25
SPARE FUSE 7 10A
26
ILLUMINATION LAMP 5A
27
28
CN-36
CL-3
15A GW
6 LO
12A V
7 4
5
Hi
CN-10
3 C
ILL & HEAD LAMP SW 1 G32 B
ABL
68 V V 12 2 E
2
9 10 10
9 1 3 1 T
4 8 4 HEAD LIGHT LH
2
7 5 6
7 1 6 6 CL-4
5 15 GW
5 7 6 LO
YW 11 134 GW GW 15 12 V
4 8 4 Hi
3 9 5
W 161
II I 0
2 13 3 C
B G31 G31 B
1
ABL
14 2 E
CS-21 15 1 T
HEAD LIGHT RH
2
CN-56
8 NC
18 NC
19 COM_GND
15 SERIAL_L
14 SERIAL_H
16 F/R SIGNAL
11 GND
12 GND
CLUSTER
5 7 MIRROR HEATED
11E
68
134
161
3
8 BATT. 24V
4 3
2 IG 24V
YW
V
GW
W
1 IG 24V
13 NC
CS-11
CS-12
CS-5
1
2
3
4
5
6
1
2
3
4
5
6
7
8
9 PROGRAM DUMP
10 RS232 TX
20 RS232 RX
4
5
3
1
6
2 Gr
6
Y
BWG C
W
G II
BVi I
RW
L
BY
HO
68 V
Hi
J
C
O J
6 HIGH BEAM
I
O
Lo Hi F
II
17 ILLUMINATION
5 RH TURN
B+
4 LH TURN
R
L
O
R
I
Lo
WB 8
BG 3
BW 2
B 5
Y 7
MULTI FUNCTION SWITCH
7607B7EL04
7-12
3. WORK LIGHT CIRCULT
1) OPERATING FLOW
※ Illumination switch : ON position
(1) Work lamp switch ON
ILL & head lamp switch [CS-21 (7)] Work lamp switch indicate lamp ON
Work lamp switch [CS-36 (1)→(5)]
Rear work lamp relay[CR-55 (30)→(87)] I/conn [CN-4 (14)]
I/conn [CL-23A] RH Rear work lamp ON [CL-23 (2)]
I/conn [CL-22A] LH Rear work lamp ON [CL-22 (2)]
2) CHECK POINT

① - GND (work lamp power input)
OFF ON ② - GND (work lamp power output) 20~25V
③ - GND (rear work lamp)
※ GND : Ground
7-13
WORK LIGHT CIRCUIT
FUSE BOX
· Canopy type 5 G BEACON SOCKET 20A
1
10 OrW ILL.LAMP 20A
2
HEAD LAMP 20A
3
BACK/STOP LAMP 10A
4
HORN 30A
5
SPARE FUSE 1 30A
6
SERVICE POWER 1 20A
7
PARKING 30A
8
SPARE FUSE 2 20A
9
15 Gr WORK LAMP 30A
10
EMER STEER/RIDE CON 20A
11
CN-36
CL-7
B G11
1
BEACON SOCKET G 5
2
2
REAR WORK LAMP
86 30 87a
B G17 1
85 2
R 63
87 3
L 180
86 4
85 87 87a Gr 5
30 5
CR-55 6
7
1 8 CL-23A WORK LAMP-RH
WORK LAMP SW 9 2
40 R
2 2
B G35 10 G6 B
9 10 10 R 1G 1 1 1
9 11
12 CL-23
4 8
2 13 CL-22A WORK LAMP-LH
7 R 40 40A R
R 1F 14 2 2 2
7 1 6 G6 B
L 180 15 1 1 1
5 5
CN-4 CL-22
4
G1
3
II I 0
2
G 1E
1
CS-36 EARTH 1
ILL & HEAD LAMP SW

9 10 10
9
4 8
2 R 1
7
7 1 6
5 5
4
3
II I 0
2
OrW 10
1
CS-21
7407B7EL05
7-14
WORK LIGHT CIRCUIT
· Cab type (opt)
FUSE BOX
5 G BEACON/RR WORK LAMP 20A
1
10 OrW ILL.LAMP 20A
2
HEAD LAMP 20A
3
BACK/STOP LAMP 10A
4
HORN 30A
5
AIR-CON/HEATER 30A
6
CIGAR LIGHTER 20A
7
PARKING 30A
8
WIPER 20A
9
15 Gr FR WORK LAMP 30A
10
11
CN-36
OPT
FRONT WORK LAMP
RW 2
1
B G21
2
CL-51
FRONT WORK LAMP
RW 2A
1
B G22
2
2 CL-52
OPT
FRONT WORK LAMP

86 30 87a
B G16
85 1
RW 171 RW 2
87 2 1
G 170
86 3 2
85 87 87a Gr 15
30 4 CL-5
CR-3 5
6
7 B G21
1 8
9 B G1
10
11 B G27
12 OPT
REAR WORK LAMP
2 13
14
R 10
1
RW 2E
1
REAR WORK LAMP B G23
15 2 2
86 30 87a
B G17 CN-7 CL-6 CL-61
85 REAR WORK LAMP
R 63
87 RW 2F
L 180 1
86 B G24
85 87 87a Gr 5
2
30 CL-62
CR-55
1 WORK LAMP-LH
10E R
WORK LAMP SW 1
B G36 G29 B
9 10 10 R 1G
2
9 CL-22
4 8
2
7
R 1F
3
7 1 6
5 R 1E WORK LAMP-RH
5 10F R
4 1
G30 B
3 2
R 180
II I 0
2 CL-23
G 170
1
CS-36
ILL & HEAD LAMP SW

B G35
9 10 10 R 1H
9
4 8
2 R 1
7
7 1 6
5 5
4
3
II I 0
2
OrW 10
1
CS-21
7407B7EL05-1
7-15
4. STARTING CIRCUIT
1) OPERATING FLOW
Battery(+) terminal Fusible link [CN-60 (1)]
I/conn [CN-1 (1)] Fuse box (No.15) Start switch [CS-2(1)]
Power relay [CR-35(30)]
※ The gear selector lever is neutral position. It is necessary condition before the starting.
The gear selector has an output signal which is activated whenever the shift lever is in the neutral
position. This signal can be used to control a relay and prevent engine from starting whenever the
shift lever is not in the neutral position.
(1) When start key switch is in ON position
Start switch ON Start switch [CS-2(2)] I/conn [CN-4(3)]
I/conn [CN-13(11) Engine stop solenoid [CN-79(A)]
Battery relay [CR-1]
Battery relay operating(All power is supplied with the electric component)
Start switch [CS-2 (3)] Power relay [CR-35(30)→(87)]
Fuse box (No.23) MCU [CN-58(12)]
(2) When start key switch is in START position

Start switch START [CS-2 (5)] Start safety relay [CR-5 (30)→(87)] I/conn [CN-4 (4)]
I/conn[CN-13 (7)] Start relay [CR-23] +
Starter (terminal B and M connector of start
motor)
2) CHECK POINT
① - GND (battery B+)
② - GND (fusible link)
③ - GND (start key B terminal)
④ - GND (start key BR terminal)
Running ON 20~25 V
⑤ - GND (i/conn CN-4 (3))
⑥ - GND (start key ST terminal)
⑦ - GND (start safety relay output)
⑧ - GND (start key ACC terminal)
※ GND : Ground
※ MCU : Machine control unit
7-16
STARTING CIRCUIT
SHIFT LEVER T/M CONTROL UNIT MCU

WARNING
HYD TEMP SENDER
FAN CLUTCH +
CLUTCH CUT-OFF PS
SAFETY RY
BUZZER
COOLANT TEMP
WIPER RY
STEERING RY
ALT LEVEL
FUEL SENSOR
PREHEATER
SERIAL-H
NEUTRAL SIG
FAN CLUTCH -
ADM2-JOYSTICK SELECT LAMP(-)
ADM5-JOYSTICK SELLECTER(+)
CLUTCH CUT-OFF SW
SERIAL-L
GND
AUTO SEL.SW
AD7
AD6
AD5
AD4
AD3
AD2
AD1
ADM1-START INTERLOCK RY(-)
AIR FILTER
ENGINE OIL PS
IG 24V
BUZZER
ED9-CLUTCH CUT-OFF SW(+)
ADM4-REVERSE DRIVE RY(-)

VM
VP
ED
ED6-SHIFT LEVER X2D-NEU

3BR 31
ED2-SHIFT LEVER X1B-B2

B1
B3
B2
AS
VPE2-CONTINUANCE 24V
R
V
CN-26
FUSE BOX
2 1
ED14-NEU-JOYSTICK
ED13-REV-JOYSTICK
ED8-FWD-JOYSTICK
F
2
1
10
4 3
11
OUTPUT SIGNAL
RW
W
2 1
17 G NEUTRAL RY/JOYSTICK F/R 10A
12
R
X1
X2
27A
115
SERVICE POWER 1 30A
AD5(R) C
D
A
D
C
B
4 3
22
21
23
35
34
24
36
31
26
32
25
33
27
30
29
28
11
12
10
13
14
NEUTRAL RY 13
TURN LAMP
AD6(N)
AD4(F)
G 17 20A
AD1
AD2
AD3 30 14
65
66
67
68
44
31
30
52
59
ED1(VP)
2 1
AD7(KD)
5
7
CN-58
N
SPARE FUSE 3
BOr
85
86 87a 87
5A
RW
G 17A 3R 34
Or
W
CN-157 15
W
4 3
BOr 73 21 3Or START KEY 30A
87
104
115
16
73
27
D
85
K
BOr 88 TCU 10A
85
CN-158
CN-159
17
C
C
D
D
B
A
B
A
SPARE FUSE 4 10A
87a 30 86
X1
X2
18
CR-38 CLUSTER / MCU 10A
19
W
SAFETY RY SPARE FUSE 5 20A

20
GrW 157 SPARE FUSE 6
30 10A
85
21
85
86 87a 87
BOr 73A
RCV 10A
BW 151 22
87 27 RW MCU 10A
Or 104 23
85 TCU 10A
24
87a 30 86 CLUSTER 10A
25
7 CR-5 SPARE FUSE 7 10A
26
27
28
CN-36
FUSIBLE LINK 2
34 3R 3R 1 1 3R
1 1
5W 2 2 5W
Fuse No.2 2 2
CN-1 CN-60
1
BATT RY
22 L
G11 B
BATTERY
CR-1
5
1 1 DO-2
22 L
2 2 2
G11 B
153 L L 22 1
3 3
151 BW BW 18
4 4
5 5
6 6
BW 18 BW 17
7 7
8 8
9 9
157
153
153
21E
8 4 10
L 22
10
R 21
11 11
GrW
Or
12 12
6 3 13 CN-13
B
3Br
L
21
14
CS-2
G17
31
153
3Or
15
6
5
4
3
2
1
ENGINE STOP SOL

CN-4 R 21
HOLD R A
CR-35
2B G1
87a 85 87 86 30 B GND B C
0, I 2W 23
1
PULL W B
87a CN-79
30 87
86 85
H 0 I II
4
6
5
3
2
H
C ST ACC BR
POWER RY START SWITCH
STARTER CR-23
3W B G1
M
M BW 17
3R
B+
CN-45
7407S7EL06
7-17
5. CHARGING CIRCUIT
When the starter is activated and the engine is started, the operator releases the key switch to the
ON position.
Charging current generated by operating alternator flows into the battery through the battery relay
(CR-1).
The current also flows from alternator to each electrical component and controller through the fuse
box.
1) OPERATING FLOW
(1) Warning flow
Alternator [CN-74 (L)] I/conn [CN-13 (8)] I/conn [CN-4 (5)] MCU [CN-58 (25)]
Cluster charge warning lamp ON
(2) Charging flow
Alternator Starter [CN-45 (B+)] Battery relay [CR-1]
Battery(+) terminal Charging
Fusible link [CN-60 (1)] I/conn [CN-1 (1)] Fuse box
2) CHECK POINT

① - GND (battery)
② - GND (battery relay)
③ - GND (alternator B+)
OFF ON 20~28V
④ - GND (alternator D+)
⑤ - GND (MCU)
⑥ - GND (fuse box)
※ GND : Ground
※ MCU : Machine control unit
7-18
CHARGING CIRCUIT
FUSE BOX
BEACON SOCKET 20A
1
ILL.LAMP 20A
2
HEAD LAMP 20A
3
BACK.STOP LAMP 10A
4
HORN 30A
5
SPARE FUSE 1 30A
SERVICE POWER 1 20A

6
6
7
PARKING 30A FUSIBLE LINK
8 3R 1 1 3R
SPARE FUSE 2 20A 1 1
9 5W 2 2 5W
WORK LAMP 30A 2 2
10
CN-1 CN-60
11 2 1
NEUTRAL RY/JOYSTICK F/R 10A
12
SERVICE POWER 1 30A
13 BATT RY
TURN LAMP 20A
14
SPARE FUSE 3 5A
15
START KEY 30A BATTERY
16
TCU 10A CR-1
17
CN-36
MCU
HYD TEMP SENDER
CLUTCH CUT-OFF PS
SPEEDMETER SIG.
RIDE CONT. AUTO

SAFETY RY
COOLANT TEMP
WIPER RY
STEERING RY
ALT LEVEL
FUEL SENSOR
TACHO SENSOR+
PREHEATER
SERIAL-H
MAIN PUMP PS
WASH SIG
NEUTRAL SIG
AIR CON."ON"SIG
CAN-H
AUTO SEL.TCU
CAN-L
CLUTCH CUT-OFF SW
STEERING P/P PS
RIDE CONT. ON
WIPER INT SIG
PARKING SIG
SERIAL-L
GND
BUZZER
IG 24V
AUTO SEL.SW
FAN CLUTCH +
BRAKE PS
TAHCO SENSOR -
AIR FILTER
ENGINE OIL PS
FAN CLUTCH -
23
35
34
24
36
31
26
32
25
33
27
21
20
30
29
28
22
17
19
11
18
16
12
10
13
15
14
1
2
3
6
8
4
5
7
9
CN-58
112 YW
5
STARTER
M
M
B+
CN-45
1
2
3
1 4
2 5
3 6
4 7
112 YW YW 19 19 YW YW 18
5 8
6 9 3
7 10
R 22
8 11 15R
ALTERNATOR
9 12 R 22 22 R
B+ 2
10 CN-13 18A YW
1
3W/300
G
NC 4
11 ~3 FI 3
RS-1
YW 18
12 U L 2
P 1
13
14 CN-74
15 4
CN-4
7407S7EL07
7-19
6. ELECTRIC PARKING, DECLUTCH CIRCUIT
1) OPERATING
PERATING FLOW
(1) Parking OFF
Fuse box (No.8) Parking switch OFF [CS-17 (6)→(8)] Parking solenoid ON (activated)
Parking brake released (by hydraulic pressure)
[CS-17 (5)→(7)] T/M control unit[CN-157 (21)]
(2) Parking
(2 Parking ON
Fuse box (No.8) Parking switch ON Parking solenoid [CN-71] OFF
Parking brake applied [By spring force]
(3) Declutch ON
(3
Fuse box (No.8) Clutch cut-off switch ON lutch cut-off switch ON [CS-42 (5)→(1)]
MCU [CN-58 (10)→(29)] if service brake applied Service brake pressure switch
ON [CD-5] T/M control unit [CN-157 (66)] Declutch
2) CHECK POIN
POINT
① - GND (parking switch input)
② - GND (parking switch output)
③ - GND (parking switch input)
④ - GND (parking switch output)
Running ON 20~25V
⑤ - GND (parking solenoid)
⑥ - GND (clutch cut-off pressure switch)
⑦ - GND (clutch cut-off switch input)
⑧ - GND (clutch cut-off switch output)
※ GND : Ground
7-20
5
7
2
9
9
9
8
8
7
2
7
2
1
1
II I 0
PARKING SW
6
6
5
5
4
1
2
3
4
5
1 6
7
4 8
9
10 10
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
10 10
10 10
CS-21
ILL & HEAD LAMP SW
CS-42
CS-17
CLUTCH CUT-OFF SW
R
B
Y
B
OrW
R
R
YW
OrW
WOr
WOr
WOr
10
1H
3
2
8
7
50
3F
3A
3E
1N
1R
119
127
G35
G34
1
19 EF1-SPEED PICK-UP ENG
ELECTRIC PARKING,
50 YW
21 ED10-PARKING BRAKE SW(+)
22 ED7-SHIFT LEVER-X1D-KD
T/M CONTROL UNIT
25 CANF_H
26 CANF_L
27 CANF_T
28 VGS-CAN SHIELD
63 ED1-SHIFT LEVER X1C-B1

PARKING, DECLUTCH CIRCU
64 ED5-SHIFT LEVER X2C-REV

CIRCUIT
IT
7-21
G25 B
84 Gr
1 2
127 Y
CN-71
67 ED6-SHIFT LEVER X2D-NEU
PARKING SOL
CN-157
5
NEUTRAL SIG
MCU
SAFETY RY
CN-58
2
Pa B 70E PREHEATER
1
V 125 WIPER RY
CD-26 STEERING RY
PARKING PS
SERIAL-H
SERIAL-L
2 109 G
CLUTCH CUT-OFF PS
Pa 109 G
36 35 34 33 32 31 30 29 28
1
84 Gr
FUEL SENSOR
CLUTCH
CD-5
CUT-OFF PS
3
AUTO SEL.SW
119 OrW
CLUTCH CUT-OFF SW
6
TACHO SENSOR+
WOr
11 10 9 8
WIPER INT SIG

RIDE CONT. ON
RIDE CONT. AUTO
CN-36
HORN
WASH SIG
ILL.LAMP
7 6 5 4
PARKING
FUSE BOX
AIR CON."ON"SIG
3
HEAD LAMP
STEERING P/P PS
125 V
SPARE FUSE 2
BEACON SOCKET
SPARE FUSE 1
PARKING SIG
2 1
BRAKE PS
BACK/STOP LAMP
SERVICE POWER 1
7407B7EL08
30A
10A
20A
30A
20A
20A
20A
20A
20A
2
1
7
3
9
8
4
6
5
7. WIPER AND WASHER CIRCUIT (Cab type)
1) OPERATING FLOW
Fuse box (No. 9)] Wiper relay [CR-4 (30)→(87a)] Front wiper motor [CN-21 (1)]
Wiper relay Lo [CR-26 (86), (87)]

Multi function switch [CS-12 (6)]
I/conn [CN-8 (1)] Rear wiper & washer switch [CS-35 (1)]
Rear wiper motor [CN-102 (1)]
(1) Front washer switch ON
① Washer switch ON [CS-12(6)→(2)] Washer operating
MCU [CN-58 (5)→(33)] Front wiper relay Lo
[CR-26 (87)→(30)] Front wiper motor [CN-21 (5)]
Wiper motor operating (low)
(2) Front wiper switch ON

① INT position
Wiper switch ON [CS-12 (6)→(1)] MCU [CN-58 (8)→(33)] Wiper relay Lo [CR-26 (87)→(30)]
Front wiper motor [CN-21(5)] Front wiper motor intermittently operating
② Lo position
Wiper switch ON [CS-12 (6)→(4)] Wiper relay Lo [CR-26 (87a)→(30)]
Front wiper motor [CN-21 (5)] Front wiper motor operating (low)
③ Hi position
Wiper switch ON [CS-12 (6)→(3)] Wiper relay Hi [CR-4(30)→(87)]
Front wiper motor [CN-21(4)] Front wiper motor operating (high)
(3) Auto-parking (when switch OFF)
Switch OFF Fuse box (No. 9) Wiper relay Hi [CR-4 (30)→(87a)]
Front wiper motor [CN-21 (1)→(2)] Multi function switch [CS-12 (5)→(4)]
Wiper relay Lo [CR-26 (87a)→(30)] Front wiper motor [CN-21 (5)] Wiper moter stop
(4) Rear wiper and washer switch
① Wiper switch ON (1st step)
Wiper switch ON [CS-35 (1)→(6)] I/conn [CN-8 (4)] Rear wiper motor [CN-102(5)]
Rear wiper motor operating
② Washer switch ON (2nd step)
Washer switch ON [CS-35 (1)→(3)] I/conn [CN-8 (2)] Rear washer tank [CN-103(2)]
Washer operating
2) CHECK POINT
Condition Check point
① - GND (front wiper switch power input) ⑥ - GND (wiper relay power input)
Engine : Stop ② - GND (rear wiper switch power input) ⑦ - GND (front washer power output)
Key switch : ON ③ - GND (wiper relay power input) ⑧ - GND (rear washer power output)
Voltage : 20~25V ④ - GND (front wiper motor Lo power input) ⑨ - GND (front wiper motor power output)
⑤ - GND (front wiper motor High power input) ⑩ - GND (rear wiper motor power output)
※ GND : Ground
7-22
CS-35
B G8
9 10 10
9
W 15
3 8
7
8 Or 16
6 6
1 M
5 6 5 Lo
8 Or 164
10
4 7 5 4 Hi
0,I
V 14 4
3 6 G4 B
3 1B
5 165 W
2 2 2Pf
L 13 14E L
II I 0
4
REAR WIPER & WASHER SW

1 1 3E
REAR WIPER
16 Or 164 Or
3
15 W
2
165 W CN-102
14 V 166 V
8
1
13 L 14 L
CN-8
2
WIPER AND WASHER CIRCUIT (cab type)
36 NEUTRAL SIG
MCU
35 SAFETY RY
34 PREHEATER
105 GOr
33 WIPER RY
32 STEERING RY
CN-22 31 SERIAL-H
G3
M 1 30 SERIAL-L
Gr 69
2 29 CLUTCH CUT-OFF PS
FRONT
WASHER
28 FUEL SENSOR
27 HYD TEMP SENDER
CN-103 26 COOLANT TEMP
B G3
M 1 25 ALT LEVEL
V 166
2 24 FAN CLUTCH -
REAR
WASHER
23 FAN CLUTCH +
22 GND
21 BUZZER
20 SPEEDMETER SIG.
19 CAN-L
18 CAN-H
17 AUTO SEL.TCU
16 TAHCO SENSOR -
15 MAIN PUMP PS
14 ENGINE OIL PS
13 AIR FILTER
12 IG 24V
11 AUTO SEL.SW
10 CLUTCH CUT-OFF SW
9 TACHO SENSOR+
120 LW
Lo Hi F 8 WIPER INT SIG
L 7 RIDE CONT. ON
O 6 RIDE CONT. AUTO
69 Gr
R 5 WASH SIG
B 5
B+ 4 AIR CON."ON"SIG
3 STEERING P/P PS
7-23
2 PARKING SIG
1 BRAKE PS
CN-58
I
WB 8
C
CS-11
Lo 1
Y 7
W 6 2
Hi
BW 2 L 3
4
BG 3 BWG C 4
5
R 6
II 7
I
1
9
8
O
O J
CS-12
G II 5
MULTI FUNCTION SWITCH
6
BVi I 3 L 14
5
L 4 VOr 38
4
J G 20
3
C BY 1 Br 19
2
W RW 6 Gr 18
1
2 Gr LW 17
HO Y
CS-5
7
14
L
HORN
WIPER
ILL.LAMP
PARKING
FUSE BOX
HEAD LAMP
FR WORK LAMP
CN-21
CIGAR / MIRROR
W 28
3E 1
AIR-CON / HEATER
BACK / STOP LAMP
VOr 38
2Pf 2
B G1
1B 3
30A
10A
20A
30A
20A
G 27
30A
30A
20A
30A
BEACON/RR WORK LAMP 20A
4 R 26
2
1
7
3
9
8
4
6
5
10
4 Hi 5
CN-36
FRONT WIPER
M
5 Lo 6
8
8A
162
105
173
8E
5
172
163
14A
G13
R
6
W
W
B
G
W
Br
GOr
4
3
85
87
86
30
85
87
86
30
CR-4
87a
87a
CR-26
30 86
30 86
87a 87 85
87a 87 85
WIPER RY HI
WIPER RY LO
7407B7EL09
HAZARD, TURN AND ROTARY CIRCUIT
1
2
3 1
4 REAR COMBI RH 2 CAB TYPE
5 36 RW 3
4 C
6 37 Or 4 BEACON LAMP
3 T 22 GY
7 G6 B 5
2 E FUSE BOX
G1 B
8 1 S 6 5 G BEACON/RR WORK LAMP 20A
R 7 1
9 CL-16 ILL & HEAD LAMP 7 CL-7
RW 36 B G21 ILL. LAMP 20A
10 8 2
66A Or Or 37 REAR COMBI LH HEAD LAMP 20A
11 9 3
7 ROr ROr 38 38 ROr BACK/STOP LAMP 10A
12 4 C 10 4
67A Y Y 39 39 Y G 5 G 5A HORN 30A
13 3 T 11 5
G6 B
14 2 E 12 AIR-CON/HEATER 30A
6
CN-4 1 S
13 CIGAR LIGHTER 30A
CL-15 7
14 PARKING 30A
8
15 WIPER 20A
CN-7 9
FR WORK LAMP 30A
10
11
NEUTRAL RY/JOYSTICK F/R 5A
12
SERVICE POWER 30A
13
19 R TURN LAMP 20A
14
RADIO/ROOM LAMP 5A
15
START KEY 30A
FLASHER UNIT 16
158 BrW TCU 10A
87 L 17
85 B G
19 R
CN-36
G17 B
86 E
CLUSTER
CR-11
8 NC
18 NC
19 COM_GND
15 SERIAL_L
14 SERIAL_H
16 F/R SIGNAL
11 GND
12 GND
7 MIRROR HEATED
3 BATT. 24V
2 IG 24V
1 IG 24V
13 NC
9 PROGRAM DUMP
10 RS232 TX
20 RS232 RX
67
66
158
Y
Or
BrW
6 HIGH BEAM
7E ROr
17 ILLUMINATION
CS-5
CS-12
CS-11
66 Or
5 RH TURN
7
2
3
1
4
3
1
2
5
4
67 Y
4 LH TURN
CN-56
4
5
3
1
6
2 Gr
6
Y
G35
158
158
BWG C
7E
G II
66
67
BVi I
RW
L
BY
1
G7
7H
GY 22
9
HO
2 HEAD LIGHT-LH
BrW
BrW
ROr
Hi
J
Or
C
O J
W
G
R
B
3 6 LO
I
O
Lo Hi F
II
CS-41
CS-23
4 4 Hi
10
10 10
9
8
7
6
5
4
3
2
1
9
8
7
6
5
4
3
2
1
5 5
B+
7A ROr 3 C
10
6
5
5
6
R
L
ABL
O
2 E
7
I
16 Y
Lo
1 T
8
WB 8
BG 3
BW 2
CL-3
B 5
67 Y Y 16
Y 7
9
66 Or Or 17
10
9
9
8
2
7
1
8
2
7
1
HEAD LIGHT-RH
HAZARD SWITCH BEACON LAMP SWITCH MULTI FUNCTION SWITCH 11 6 LO
12 4 Hi
CAB TYPE 5
CN-10
3 C
ABL
2 E
17 Or
1 T
CL-4
7407S7EL10
7-24
GROUP 3 MONITORING SYSTEM
1. CLUSTER
1) STRUCTURE
The gauges panel consists of gauges and monitors as shown below, to warn the operator in case
of abnormal machine operation or conditions for the appropriate operation and inspection.
· Gauges : Indicate operating status of the machine.
· Warning lamp : Indicate abnormality of the machine.
· Pilot lamp : Indicate operating status of the machine.
※ The monitor installed on this machine does not entirely guarantee the condition of the machine.
Daily inspection should be performed according to chapter 6, MAINTENANCE.
MAINTENANCE.
※ When the monitor provides a warning immediately check the problem, and perform the
required action.
Warning lamp High beam pilot lamp

Ride control pilot lamp(AUTO) Right turning pilot lamp
Left turning pilot lamp Parking brake warning lamp
Ride control pilot lamp(ON) Hyd oil temp warning lamp
Brake fail warning lamp Clutch cut off pilot lamp
T/M oil temp warning lamp Battery charging warning lamp
Steering warning lamp Preheater pilot lamp
(Emergency) Fuel low level warning lamp
Steering warning lamp FNR select pilot lamp
(Primary)
Engine overheat Air cleaner warning lamp
warning lamp T/M error warning lamp
Engine oil pressure
warning lamp
LCD
mph
Km/h
Hyd oil temp gauge

T/M oil temperature gauge
Battery volt meter Speedometer
Engine coolant temperature gauge Fuel gauge
7607B3CD02
1) SPEEDOMETER
(1) The speedometer displays the speed of machine in mph and
km/h.
mph
7807A3CD03
7-25
2) FUEL GAUGE
(1) This gauge indicates the amount of fuel in the fuel tank.
(2) Fill the fuel when the indicator moves E point, refuel as soon as
possible to avoid running out of fuel.
※ If the gauge indicates below E point even though the machine
is on the normal condition, check the electric device as that
7807A3CD04 can be caused by the poor connection of electricity or sensor.
3) ENGINE COOLANT TEMPERATURE GAUGE

(1) This indicates the temperature of coolant.
Red
·Red range : Above 104˚C (219˚F )
(2) Keep idling engine at low speed until the indicator is in the
operating range.
Operating
(3) If the indicator is in the red range, turn OFF the engine, check
range 7807A3CD05 the radiator and engine.
4) TRANSMISSION OIL TEMPERATURE GAUGE

(1) This range indicates the temperature of transmission oil.
Red
(2) Keep idling engine at low speed until the indicator is in the
operating range.
Operating (3) If the indicator is in the red range, it means the transmission is
range 7807A3CD06 overheated. Be careful that the indicator does not move into the
red range.
5) BATTERY VOLT METER

(1) This gauge indicates the voltage in the charging system when
Red
the engine is running.
(2) If the indicator is below 24V (yellow range), it means that the
electricity is being discharged. If the indicator is above 30V (red
range), an unusually high voltage may damage the alternator.
Operating
range Check the charging system in both cases.
7807A3CD08
6) HYD OIL TEMPERATURE GAUGE

(1) This range indicates the temperature of hydraulic oil.
Red
(2) Keep idling engine at low speed until the indicator is in the oper-
ating range.
Operating (3) If the indicator is in the red range, reduce the load on the system.
range If the gauge stays in the red range, stop the machine and check
7807A3CD08
the cause of the problem.
7-26
7) WARNING LAMP
(1) When all warning lamp or fault codes are being displayed, this
warning lamp will flash.
(2) When this warning lamp flashes, machine must be checked or
serviced as soon as possible.
77073CD09
8) DIRECTION PILOT LAMP

(1) This lamp flashes when the signal indicator lever is moved.
77073CD10
9) HIGH BEAM PILOT LAMP

(1) This lamp works when the illuminating direction is upward.
(2) This lamp comes ON when the dimmer switch is operated, e.g.,
when passing another vehicle.
77073CD12
10) PARKING BRAKE WARNING LAMP

(1) When the parking brake is actuated, the lamp lights ON.
※ Check the lamp is OFF before driving.
77073CD13
11) PREHEATER PILOT LAMP

(1) This lamp lights ON when start switch is turned clockwise to the
ON position. Light will turn off after approximately 5~45 seconds,
depending on engine temperature, indicating that preheating is
completed.
(2) When the lamp goes out the operator should start cranking the
77073CD14 engine.
7-27
12) CLUTCH CUT OFF PILOT LAMP
(1) When the clutch cut off switch is pressed, the lamp lights ON.
77073CD65
13) BRAKE FAIL WARNING LAMP

(1) The lamp lights ON when the oil pressure of service brake drops
below the normal range.
(2) When the lamp is ON, stop the engine and check for its cause.
※ Do not operate until any problems are corrected.
77073CD16
14) ENGINE OVERHEAT WARNING LAMP

(1) This lamp is turned ON when the temperature of cooling water is
over the normal temperature (104˚C, 219˚F).
(2) Check the cooling system when the lamp is ON.
77073CD17
15) ENGINE OIL PRESSURE WARNING LAMP

(1) This lamp is comes ON after starting the engine because of the
low engine oil pressure.
(2) If the lamp comes ON during engine operation, shut OFF engine
immediately. Check engine oil level.
77073CD18
16) TRANSMISSION ERROR WARNING LAMP

(1) This lamp lights ON and the LCD display show the error codes
when an error occurs in the transmission.
(2) Immediately pull the machine to a convenient stop. Stop the
engine. Investigate the cause.
※ Consult a HYUNDAI dealer to investigate the cause.
77073CD19
※ Do not operate until the cause has been corrected.
7-28
17) AIR CLEANER WARNING LAMP
(1) This lamp operates by the vacuum caused inside when the filter
of air cleaner is clogged.
(2) Check the filter and clean or replace it when the lamp is ON.
77073CD20
18) HYD OIL TEMPERATURE WARNING LAMP

(1) This warning lamp operates and the buzzer sounds when the
temperature of hydraulic oil is over 105˚C (221˚F).
(2) Check the hydraulic oil level when the lamp is turned ON.
(3) Check for debris between oil cooler and radiator.
77073CD21
19) BATTERY CHARGING WARNING LAMP

(1) This lamp is ON when key ON, it is turned OFF after starting the
engine.
(2) Check the battery charging circuit when this lamp comes ON,
during engine operation.
77073CD22
20) FUEL LOW LEVEL WARNING LAMP

(1) Fill the fuel immediately when the lamp is turned ON.
77073CD23
21) TRANSMISSION OIL TEMPERATURE WARNING LAMP

(1) This lamp informs the operator that transmission oil is above the
specified temperature.
(2) When this lamp lights up during operation, stop the engine and
check the machine.
75793CD35
7-29
22) FNR SELECT PILOT LAMP (option)
(1) The lamp comes ON when FNR select button on the optional
FNR remote control lever is pressed.
7807A3CD24
23) STEERING WARNING LAMP (option)

(1) Primary
This lamp indicates that the primary steering has failed. When
the indicators come on and the action alarm sounds, steer the
machine immediately to a convenient location and stop the
machine. Stop the engine and investigate the cause.
※ Do not operate the machine until the cause has been
77073CD66
corrected.
(2) Emergency
This lamp indicates the emergency steering system is active.
※ Immediately pull the machine to a convenient stop and stop
the engine.
※ The emergency steering system can be manually tested.
77073CD15
Refer to page 7-36.
24) RIDE CONTROL PILOT LAMP (option)

(1) Auto ride control
This lamp lights ON when push in the bottom of the ride control
switch (auto position).
※ Refer to page 7-36.
75793CD33
(2) Manual ride control

This lamp lights ON when push in the top of the ride control
switch (manual position).
※ Refer to page 7-36.
75793CD34
7-30
25) LCD
(1) The LCD (2.8 inch) can be used with the gear selector.
It indicates speed and driving direction.
1 3
2 No Symbol Meaning Remark
F, N, R Forward, neutral, reverse
1 1 1, 2, 3, 4 Actual gear Actual gear
4 P Parking brake mode active
5
Forward, reverse Automatic mode
7607B3CD39
2
Gear range Automatic mode
T/M fault code Fault code display

3 -
AEB mode AEB mode display
4 - Engine rpm Current engine rpm display
5 - Hourmeter Hourmeter display
· Display during AEB mode

Symbol Meaning
ST Start AEB
K1~K4, KV, KR Calibrating clutch K1~K4, KV or KR respectively
OK* Calibration for all clutches finished
Spanner and Kx* Kx couldn't be calibrated, AEB finished

Engine speed too low
△E
- Raise engine speed
Engine speed too high
▽E
- Lower engine speed
Transmission oil temperature too low
△T
- Heat up transmission
Transmission oil temperature too high
▽T
- Cool down transmission
FO* Output speed not zero
FN* Shift lever not in neutral position
FP* Parking brake not applied

* : Transmission stays in neutral, you have to restart the TCU (ignition off/on).
7-31
2. SWITCHES
·Canopy
Canopy type
Starting switch Parking brake switch

Pump motor switch(option) Main light switch
Ride control switch(option) Work lamp switch
Buzzer stop switch Auto shift select switch
Kick down switch Clutch cut off switch
Horn button
Multi function switch
Hazard switch
AEB switch
Kick down switch
7407B3CD29
7-32
·Cab
Cab type (option)
USB socket
Beacon switch(option)
Rear wiper/washer switch
Work lamp switch Clutch cut off switch

Main light switch Ride control switch(option)
Parking brake switch AEB switch
Buzzer stop switch
Front
Pump motor switch(option)
LH SIDE
Auto select switch
A
E
B
Kick down switch
Horn button
Multi function switch
Hazard switch
Kick down switch
7407B3CD29-1
7-33
1) STARTING SWITCH
(1) There are three positions, OFF, ON and START.
· (OFF) : None of electrical circuits activate.
· (ON) : All the systems of machine operate.
· (START) : Use when starting the engine.
Release key immediately after starting.
※ Key must be in the ON position with engine running maintain
77073CD41
electrical and hydraulic function and prevent serious machine
damage.
2) HAZARD SWITCH
OFF (1) Use for parking, or roading machine.
ON
※ If the switch is left ON for a long time, the battery may be
discharged.
OFF
ON
7607B3CD48
3) CLUTCH CUT OFF SWITCH

(1) This switch is pressed, it will cut off the clutch when brake operates.
※ Be careful not to use this switch when driving on a slope.
7607B3CD49
4) PARKING BRAKE SWITCH

(1) This switch is pressed, the parking brake will start to operate and
the gauge panel warning lamp will comes ON.
※ When operating the gear selector lever, be sure to release the
P
parking brake. If the machine is operated with the parking brake

engaged, the brake will overheat and may cause the brake
P
system to go out of order.

7607B3CD50
5) MAIN LIGHT SWITCH

(1) This switch use to operates the clearance lamp and head light by
two step.
·First step : Clearance lamp and cluster illumination lamp
comes ON. Also, the below indicator lamp comes
ON.
7607B3CD51
·Second step : Head light comes ON.
7-34
6) WORK LAMP SWITCH
(1) This switch turns ON the working lamps located on the canopy and
rear cowl.
7607B3CD52
7) 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
7607B3CD53
buzzer stopped.
If not, stop engine and check the system which the lamp is ON.
8) AUTO SHIFT SELECT SWITCH

1 (1) Manual mode ( 1 )
2 Press the bottom of the switch for the manual mode of the autoshift
function. The operator selects the desired speed and the desired
A
direction in the manual mode with the gear selector lever.

1 (2) Automatic mode ( 2 )
2
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
A
into forward or reverse in order to activate the autoshift function.

7607B3CD54
9) AEB SWITCH
(1) This switch use to start AEB setting.
(2) AEB mode controls the disk clearance of the transmission
B
E
A
automatically.
※ Refer to page 7-31
B
E
A
7607B3CD55
7-35
10) RIDE CONTROL SWITCH (option)
(1) AUTO position
Push in the top of the ride control switch in order to turn on the
automatic ride control. The automatic ride control automatically
turns on when the travel speed exceeds a preset speed of
approximately 9.5 km/h. The automatic ride control automatically
shuts off during low speed travel mode.
7607B3CD56
(2) ON position
Push in the bottom of the ride control switch in order to turn on the
system for ride control. The ride control will smooth the ride of the
machine during travel.
7607B3CD57
(3) MIDDLE position

Push the ride control switch to the middle position in order to turn off
the system for the ride control.
7607B3CD58
11) PUMP MOTOR SWITCH (option)

(1) The emergency steering system can be manually tested.
Push the pump motor switch in order to determine if the emergency
steering and the emergency steering lamp are functional.
(2) When the switch is pushed, the emergency steering pump motor
will run.
The emergency steering lamp will light. If the emergency steering
77073CD52
lamp does not light, do not operate the machine.
12) BEACON SWITCH (cab type)

(1) This switch turns ON the rotary light on the cab.
77073CD50
7-36
13) REAR WIPER AND WASHER SWITCH (cab type)
(1) The switch use to operates the rear wiper and washer by two step.
·First
First step : The rear wiper operates.
·Second
Second step : The washer liquid is sprayed and the rear wiper is
operated only while pressing. If release the
switch, return to the first step position.
77073CD47
14) USB SOCKET (cab type)

(1) MP3 player can be connected to the USB port.
(2) In addition, it is possible to use input port for ear phone or other
instruments, implements etc.
AUX USB
HB1003CD63
15) CAB LAMP SWITCH (cab type)

(1) This switch turns ON the cab room lamp.
73033CD24
16) HORN BUTTON

(1) If you press the button on the top of the multifunction switch, the
Horn button
horn will sound.
73033CD28A
7-37
17) KICK DOWN SWITCH
(1) It shifts down quickly from current gear to one step lower speed by
Kick down switch
pushing the switch and recover to original speed quickly when push
the switch one more time.
7807ACD34
18) MULTI FUNCTION SWITCH

O J ⅠⅡ (1) Front wiper and washer switch
① When the switch is in J position, the wiper moves intermittently.
② When placed in Ⅰ or Ⅱ position, the wiper moves continuously.
③ If you press a button at the end of the lever, washer liquid will be
sprayed and the wiper will be activated 2-3 times.
73033CD29
※ Check the quantity of washer liquid in the tank. If the level of
the washer liquid is LOW, add the washer liquid (In cold, winter
days) or water. The capacity of the tank is 1 liter.
Up
(2) Dimmer switch
① This switch is used to turn the head lights direction.
M ② Switch positions
·Up : To flash for passing
Down
·Middle : Head lights low beam ON
73033CD30 ·Down : Head lights high beam ON
③ If you release the switch when it's in up position, the switch will
return to middle.
Left turning
(3) Turning switch
① This switch is used to warn or signal the turning direction of the
machine to other vehicles or equipment.
② Push the lever up for turning left, pull the lever down for turning
right.
Right turning
73033CD31
7-38
GROUP 4 ELECTRICAL COMPONENT SPECIFICATION
Part name Symbol Specifications Check item
Gravity
12V × 100Ah 1.280 over : over charged
Battery
(2EA) 1.280 ~ 1.250 : normal
1.250 below : discharged
Rated load : 24V Coil resistance

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

Fusible link 24V 60A nal and each connector pin
1 0Ω: normal
CN-60
H BR ACC ST C
23 56
H 0 I II 4
Resistance between each pin
B-BR : 24V 1A
Key off : ∞Ω(for each pin)
Start key 0, I 1
B-ACC : 24V 10A
B Key on : 0Ω(for pin 1-2 & 1-3)
B-ST : 20V 40A
1 2 3 4 5 6 Start : 0Ω(for pin 1-5)
CS-2
2
Pa Resistance
Pressure switch 1 N.C Type
0Ω: normal (close)
CD-3 CD-26 CD-39 CD-41
2
Pa Resistance
Pressure switch 1 N.O Type
∞Ω: normal (open)
CD-5 CD-40 CD-48
7-39
1
Parking brake,
2 Resistance
attach lock, 24V 1A
normal : 15~25Ω
unlock solenoid CN-71 CN-177
CN-178
Air cleaner Pa 635 mmH2O Resistance

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

Ride control
1 24V 1.2A ※ Check resistance
valve
about 24Ω
CN-136
Resistance at fuel levels

full level : 50Ω
1 9/12 level : 200Ω
Fuel sender -
2 6/12 level : 350Ω
3/12 level : 500Ω
CD-2
empty : 700Ω
30
87a 87 85
86
87 Resistance
85
87a 30 86 normal : about 160Ω
Relay
24V 20A (for pin 85~86)
(5pin) CR-2 CR-5 CR-35 CR-37 CR-38
0Ω(for pin 30~87)
CR-40 CR-41 CR-55 CR-58 CR-59
CR-63 ∞Ω(for pin 30~87)
· Cab type : CR-4, CR-7, CR-25,
CR-26, CR-33
7-40
2 Resistance
Hydraulic C
- normal : ∞Ω
temperature 1
105。C over : 0Ω
CD-1
Speaker 1 Resistance
4Ω 20W
(Cab type) 2 normal : 4Ω
CN-23(LH)
CN-24(RH)
7
3
1
10
4
12
9
11
1 8 7 11
Resistance at switch off position
Switch ∞Ωbetween pin 1-5 and 2-6
12 10 4 9 3 12 24V 8A
(Locking type) 0Ωbetween pin 5-7 and 6-8
CS-17 CS-36 CS-41 CS-42
CS-59 CS-80 CS-82
· Cab type : CS-23
12
12
Resistance at switch off position

3
4
Switch ∞Ωbetween pin 1-5 and 2-6

(Non-locking 24V 8A
1
11
9
7
0Ωbetween pin 5-7 and 6-8

11
12
type)
9
4
6
1
3
CS-21 CS-35 (cab type)
1 Work lamp
Work lamp, 24V 70W
Room lamp, 2
Number plate lamp Resistance
(cab type) CL-1 CL-22
CL-21 CL-6 CL-23
CL-22 24V 10W normal : 1.2Ω
Numbaer plate CL-5 CL-51
CL-30 CL-21CL-52
CL-23
lamp Room lamp
CL-61 CL-62
· Cab type : CL-1 24V 10W
7-41
Beacon lamp M 24V 70W Resistance

(cab type) (H1 TYPE) normal : 1.1Ω
CL-7
A 24V 24V Resistance

DC/DC B GND 12V 3A 8.8Ω(for pin A-B)
Converter C 12V
12V
7.7Ω(for pin B-C)
CN-138
Operation by external power

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

SPK FRT RH-
SPK FRT LH-
REMOCON+
Radio & MP3/ Resistance

BACK UP+
TEL MUTE
ANT 12V
USB player 24V 20W+20W Power ON : 4Ω+4Ω

GND
GND
ACC
ILL+
ILL-
NC
NC
(cab type) (for pin 1-6, 4-8)

10
11
12
13
14
15
16
8
1
2
3
4
5
6
7
CN-27
24V 0.5A Resistance

Back up buzzer
110dB normal : 5.2Ω
CN-65
7-42
M 1 Resistance
Washer pump
2 24V 2.5A normal : 26.4 Ω
(cab type)
(for pin1-2)
CN-103
CN-22 (FR)CN-22
CN-103 (RR)
E 3 1
Pf 2 2
B 1 3
4 24V 1.5A
Wiper motor Hi 4 5
2-speed -
(cab type) M Lo 5 6
Auto parking
CN-21 (FR) CN-102 (RR)
B
Cigar lighter A Coil resistance
24V 5A 1.4W
(cab type) normal : about 1MΩ
1
CL-2
B+
G
~3
D+ Voltage
Alternator U W 24V 90A
normal : 24~28V
CN-74
B+
G
NC 4
~3
FI 3
U
L 2
Starter P 1 24V-4.5kW Operating or not
CN-45
1 Resistance
Aircon
24V 79W
compressor normal : 13.4Ω
CN-28
7-43
Coil resistance
normal : 1-2Ω
Start relay 24V 300A Switch connection
∞Ωat normal open position
CR-23 0Ωwhen engaged
M Resistance at each switch posi-

Blower 1
24V 9.5A tion
(cab type) 2 normal : 0.5-2Ω
Door switch Resistance

24V 2W
(cab type) normal : about 5MΩ
CS-1
3 E
G 24V
2 B
Flasher unit 1 L
85 ~ 190 C/M -
50dB
CR-11
6 Lo
4 Hi 24V 75W/70W
5
3 C
(H4 TYPE) Resistance
Head lamp
2 E 24V 4W normal : a fewΩ
ABL
1 T
(T4W)
CL-3 (LH) CL-4 (RH)
4 C
24V 5W
3 T
Combi lamp (R5W)
2 E -
(rear) 1 S
2×24V 21W
(P21W)
CL-15(LH)
CL-15 CL-16
CL-16 (RH)
7-44
2
24V 200mA
Warning buzzer 1 -
90±5dB (ℓm)
CN-26
A A
B Resistance
Resistor 4W
C B A - B : 120Ω
CN-98
7-45
GROUP 5 CONNECTORS
1. CONNECTOR DESTINATION
Connector No. of Connector part No.
Type Destination
number pin Female Male
CN-1 58 2 I/conn (Main harness-Frame harness) S813-030200 S813-130200
CN-4 AMP 15 I/conn (Main harness-Frame harness) 2-85262-1 368301-1
CN-5 AMP 15 I/conn (Frame harness-Main harness) 2-85262-1 368301-1
CN-6 AMP 15 I/conn (Main harness-Frame harness) 2-85262-1 368301-1
CN-7 AMP 15 I/conn (Main harness-Cab harness) 2-85262-1 368301-1
CN-8 AMP 8 I/conn (Main harness-Cab harness) S816-008002 S816-108002
CN-9 AMP 12 I/conn (Main harness-Front harness) S816-012002 S816-112002
CN-10 AMP 15 I/conn (Main harness-Front harness) 2-85262-1 368301-1
CN-11 DEUTSCH 8 I/conn (Main harness-Aircon harness) DT06-8S -
CN-13 Econoseal J 12 I/conn (Frame harness-Engine harness) S816-012002 S816-112002
CN-18 Econoseal J 4 I/conn (Ride control harness-Front harness) S816-004002 S816-104002
CN-20 Molex 2 Horn 36825-0211 -
HW070
CN-21 6 Front wiper motor 6189-0133 -
sealed
CN-22 SWP 2 Front washer tank S814-002000 -
CN-23 KET 2 Speaker (LH) 7123-1520 -
CN-24 KET 2 Speaker (RH) 7123-1520 -
CN-25 Molex 2 Horn 36825-0211 -
CN-26 250 2 Warning buzzer S810-002202 -
CN-27 PA 9 Cassette and radio S811-009003 -
CN-28 MWP 1 Aircon compressor NMWP01F-B -
CN-29 KET 2 Receiver drier MG640795 -
CN-36 - - Fuse box 21N8-20041 -
CN-45 Ring term 2 Starter R14-10/R55-6 -
CN-56 AMP 20 Cluster 174047-2 -
CN-58 Econoseal III 36 Controller (MCU) 344111-1 -
CN-59 AMP 23 Controller (MCU) 770680-1 -
CN-60 58 2 Fusible link 21EA-40171 S813-130200
CN-65 DEUTSCH 2 Back up buzzer DT06-2S-EP06 -
CN-71 DEUTSCH 2 Parking solenoid DT06-2S-EP06 -
R125-2/R55-6/
CN-74 Ring term 3 Alternator
R14-6
-
CN-83 NMWP 32 Aircon fan PB625-02027 -
7-46
Type Destination
CN-98 DEUTSCH 2 Resistor DT04-3P-EP10 DT04-3P-E004
CN-100 Econoseal J 3 Boom kick out S816-003002 S816-103002
CN-101 Econoseal J 3 Bucket leveler S816-003002 S816-103002
CN-102 HW090 6 Rear wiper motor 6189-01330 -
sealed
CN-103 SWP 2 Rear washer tank S814-002000 -
CN-112 - 16 Gear box 21L7-60290 -
CN-114 Econoseal J 12 Joy stick S816-012002 -
CN-126 DEUTSCH 4 MCU back-up DT06-4S-EP06 DT04-4P-E004
CN-136 DEUTSCH 2 Ride control solenoid DT06-2S-EP06 -
CN-138 DEUTSCH 3 DC/DC Converter DT06-3S-EP06 -
CN-139 DEUTSCH 2 12V socket - DT04-2P-E005
CN-148 DEUTSCH 3 CAN data link DT06-3S-EP06 DT04-3P-E004
CN-157 AMP 68 T/M control unit 962175 -
CN-158 PACKARD 4 Gear shift lever - 1201-0974
CN-159 PACKARD 4 Gear shift lever 1201-5797 -
CN-169 DEUTSCH 4 Cluster back-up DT06-4S-EP06 DT04-4P-E004
CN-170 250 2 Service power S810-002202 -
Relay
CR-1 Ring term - Battery relay S820-104002 -
CR-2 HELLA 5 Horn relay 8JA003526-001 -
CR-3 AMP 5 Front work lamp relay VCFM-1002 -
CR-4 AMP 5 Wiper relay (Hi) VCFM-1002 -
CR-5 HELLA 5 Safety relay 8JA003526-001 -
CR-7 AMP 5 Aircon relay VCFM-1002 -
CR-11 HELLA 5 Flasher unit 8JA003526-001 -
CR-23 KET 2 Start relay 1 ST710289-2 -
CR-24 Shur 1 Preheater relay S822-014000 -
CR-25 HELLA 5 Power relay 8JA003526-001 -
CR-36 250 4 Preheater relay S810-004202 -
CR-40 HELLA 5 Detent bucket 8JA003526-001 -
CR-41 HELLA 5 Detent boom up 8JA003526-001 -
CR-55 250 4 Rear work lamp relay S810-004202 -
CR-58 HELLA 5 Back up buzzer 8JA003526-001 -
CR-63 HELLA 5 Stop lamp 8JA003526-001 -
7-47
Type Destination
Switch
CS-1 Shur 1 Door switch S822-014004 -
CS-2 SWP 6 Start key switch S814-006000 -
CS-5 Shur 1 Horn switch S822-014000 -
CS-11 SWP 8 Multi function switch S814-008000 -
CS-12 SWP 6 Multi function switch S814-006000 -
CS-17 SWF 10 Parking switch 593757 -
CS-21 SWF 10 Main light switch 593757 -
CS-23 SWF 10 Beacon switch 593757 -
CS-35 SWF 10 Rear wiper switch 593757 -
CS-36 SWF 10 Work lamp switch 593757 -
CS-41 SWF 10 Hazard switch 593757 -
CS-42 SWF 10 Clutch cut off switch 593757 -
CS-55 SWF 10 Ride control switch 593757 -
CS-59 SWF 10 Auto/manual switch 593757 -
CS-75 SWF 10 Steering pump switch 593757 -
CS-80 SWF 10 Buzzer stop switch 593757
CS-82 SWF 10 AEB set switch 539757 -
Light
CL-2 250 3 Cigar lighter S810-003202 -
CL-3 DEUTSCH 2 Head light DT06-6S -
CL-4 DEUTSCH 2 Head light DT06-6S -
CL-5 DEUTSCH 2 Work light (LH) - DT06-2S-EP06
CL-6 DEUTSCH 2 Work light (RH) - DT06-2S-EP06
CL-7 250 2 Beacon socket S810-002202 -
CL-15 SWP 4 Combi lamp (RR, LH) S814-004000 -
CL-16 SWP 4 Combi lamp (RR, RH) S814-004000 -
CL-21 SWP 2 Numberplate lamp S814-002000 -
CL-22 DEUTSCH 2 Work light (LH) - DT04-2P-E005
CL-23 DEUTSCH 2 Work light (RH) - DT04-2P-E005
CL-24 SWP 2 Turn lamp (LH) S814-002000 -
CL-25 SWP 2 Turn lamp (RH) S814-002000 -
CL-30 KET 2 Room lamp MG610392 -
CL-32 DEUTSCH 2 Rear work light (RH) - DT04-2P-E005
CL-33 DEUTSCH 2 Rear work light (LH) - DT04-2P-E005
7-48
Type Destination
Sensor, sender
CD-1 AMP 2 Hyduaulic oil temp sendor 85202-1 -
CD-2 SWP 2 Fuel sendor S814-002000 -
CD-3 Rubber cap 2 Brake fail pressure switch 21EA-00310 -
CD-4 DEUTSCH 3 Stop lamp pressure switch DT06-3S-EP06 -
CD-5 Rubber cap 2 Clutch cut off pressure switch 21EA-00310 -
CD-8 AMP 2 Coolant temp switch 85202-1 -
CD-10 Ring term 2 Air cleaner switch S820-105000 -
CD-17 AMP 2 Engine pick-up sensor 85202-1 -
CD-26 Rubber cap 2 Parking pressure switch 21EA-00310 -
CD-27 AMP 2 Turbin pick up sensor 85202-5 -
CD-35 PACKARD 2 Fuel filter 1204-0753 -
CD-39 Rubber cap 2 Main pump pressure switch 21EA-00310 -
CD-40 Rubber cap 2 Steering pump pressure switch 21EA-00310 -
CD-41 Rubber cap 2 Boom down pressure switch 21EA-00310 -
CD-46 AMP 3 Output speed sensor 282087 -
CD-47 AMP 2 Gear chain senser 85202-5 -
CD-48 AMP 2 Oil filter 282080 -
CD-49 AMP 2 Converter sensor 85202-1 -
7-49
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
7-50
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
7-51
No. of
pin
6 13 1 7
13
1 7 6 13
S811-013002 S811-113002
1 9
8 17
17
1 9 8 17
S811-017002 S811-117002
110 21 1 11
21
1 11 1
10 21
S811-021002 S811-121002
7-52
3) J TYPE CONNECTOR
No. of
pin Receptacle connector (female) Plug connector (male)
1 2
1
2 12
S816-002001 S816-102001
2 3 1
3 1 2
S816-003001 S816-103001
3 1 4 2
4 2 3 1
S816-004001 S816-104001
8 5 2
6 3 1
8 5 2 6 3 1
S816-008001 S816-108001
7-53
4) SWP TYPE CONNECTOR
No. of
pin Receptacle connector (Female) Plug connector (male)
1 1
S814-001000 S814-101000
2 1
1 2
S814-002000 S814-102000
3 1
2 1 23
S814-003000 S814-103000
2 4 1 3
1 3 2 4
S814-004000 S814-104000
7-54
No. of
3 6 1 4
3 6
1 4
S814-006000 S814-106000
4 8 1 5
4 8
1 5
S814-008000 S814-108000
4 12 1 9
12
4 12
1 9
S814-012000 S814-112000
3 14 11
1
14
1 11 3 14
S814-014000 S814-114000
7-55
5) CN TYPE CONNECTOR
No. of
1 1
S810-001202 S810-101202
2 2
1 1
S810-002202 S810-102202
3 2
1 2 1 3
S810-003202 S810-103202
2 4 1 3
1 3 2 4
S810-004202 S810-104202
7-56
No. of
3 6 1 4
1 4 3 6
S810-006202 S810-106202
4 8 1 5
1 5 4 8
S810-008202 S810-108202
7-57
6) ITT SWF CONNECTOR
No. of
10
1 12
11
SWF589790
7) HW090 SEALED CONNECTOR

No. of
6 3
4
6
6189-0133
8) MWP02F-B CONNECTOR
No. of
2 1
2
PH805-02028
7-58
9) AMP ECONOSEAL CONNECTOR
No. of
12
1
12
13 24
36
25
24 36 1
13
36
25
344111-1
344111-1 344108-1
344108-1
10) AMP TIMER CONNECTOR

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

No. of
12 1 6
7 12
174045-2
7-59
12) KET 090 WP CONNECTORS
No. of
2 1
MG640795
13) ITT SWF CONNECTOR

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

No. of
1
1
NMWP01F-B
7-60
15) DEUTSCH DT CONNECTORS
DT 06 - 3S - ★★★★
Modifications (see below)

Number of contacts (P : Pin, S : Socket)
04 : Receptacle, 06 : Plug
Deutsch connetors
※ Modification
E003 : Standard end cap - gray
E004 : Color of connector to be black
E005 : Combination - E004 & E003
EP04 : End cap
EP06 : Combination P012 & EP04
P012 : Front seal enhancement - connectors color to black for 2, 3, 4 & 6pin
No. of
1 2 2 1
2
DT06-2S DT04-2P
2 1 1 2
3 3
DT06-3S DT04-3P
4 1 1 4
3 2 2 3
DT06-4S DT04-4P
7-61
No. of
6 1 1 6
4 3 3 4
DT06-6S DT04-6P
4 5 5 4
1 8
8 1
DT06-8S DT04-8P
7 6
6 7
12
1 12 12 1
DT06-12S DT04-12P
7-62
16) ECONOSEAL J TYPE CONNECTORS
No. of
S816-001002 S816-101002
1 2 1
2
S816-002002 S816-102002
S816-003002 S816-103002
S816-004002 S816-104002
7-63
No. of
S816-006002 S816-106002
S816-008002 S816-108002
10
S816-010002 S816-110002
12
S816-012002 S816-112002
7-64
No. of
15
368301-1 2-85262-1
17) METRI-PACK TYPE CONNECTOR

No. of
pin
12040753
18) DEUTSCH MCU CONNECTOR

No. of
Receptacle connector (Female) Plug connector (Male)
pin
5
1 6
11 1
10
2
3
11 4
5
21
6
40 21 31
32
7
8
9
33 10
34
35
31 36
37
20
30
20
38
39
35 40
36
30
40
DRC26-40SA/B/C
7-65
GROUP 6 TROUBLESHOOTING
1. WHEN STARTING SWITCH IS TURNED ON, CLUSTER AND MONITOR LAMP DOES NOT
LIGHT UP
·Before carrying out below procedure, check all the related connectors are properly inserted and the
fuse [CN-36] No.25 is not blown out and ON/OFF of bulb.
·After checking, connect the disconnected connectors again immediately unless otherwise
specified.
Cause Remedy
YES
Defective cluster Replace
Check voltage
between CN-56
(1, 2) and
chassis
NO Disconnection in Repair or
wiring harness or replace
poor contact (after clean)
between
CN-56 (1, 2) and
fuse No.25
CLUSTER
1
FUSE
2
No.25
CN-56
Check voltage
YES 20 ~ 30 V
NO 0V
7607B7EL26
7-66
2. WHEN BATTERY LAMP LIGHTS UP (engine is started)
·Before carrying out below procedure, check all the related connectors are properly inserted.
specified.
Cause Remedy
YES
Check voltage Defective Replace
YES controller
between CN-58
(25) and chassis
NO Disconnection in Repair or replace
Voltage : 27.5~30V wiring harness or (after clean)
poor contact
Check voltage between CN-58
YES between CN-4
(25) and CN-4 (5)
(5) and chassis
YES
Voltage : 26~30V Disconnection in Repair or replace
wiring harness or (after clean)
Check voltage poor contact
Check voltage between CN-13 between CN-13
NO
between (8) and chassis (8) and CN-4 (5)
alternator
terminal "L" and Disconnection in Repair or replace
chassis NO
Voltage : 26~30V poor contact
Starting switch : ON
between CN-13
(8) and alternator
terminal " L"
Defective alternator Replace

NO
CONTROLLER(MCU)
ALTERNATOR
25 5 8 " L " TERMINAL
CN-4 CN-13
CN-58
Check valtage
YES 20 ~ 30 V
NO 0V 7407S7EL27
7-67
3. WHEN PARKING SOLENOID DOES NOT WORK
fuse [CN-36] No.8 is not blown out.
·After checking, connect the disconnected connectors again immediately unless otherwise specified.
Cause Remedy
YES Defective parking Replace
brake solenoid
Check voltage
between CN-71
YES Defective parking Replace
(2) and chassis Check voltage switch
Starting switch : ON between CS-17
NO
Parking switch : ON-OFF (6) and chassis
Voltage : 20~30V Disconnection in Repair or replace
NO
Voltage : 20~30V wiring harness or (after clean)
poor contact
between CS-17
(6) and Fuse
No.8
PARKING SWITCH
8 2
1
5
CN-71
6
CS-17 FUSE
No.8
7707EL24
7-68
4. TRANSMISSION IS NOT RETURNED TO NEUTRAL WHEN PARKING BRAKE IS APPLIED
fuse [CN-36] No.17 (T/M control unit) and [CN-36] No.8 are not blown out.
specified.
Cause Remedy
YES
Defective T/M Replace
control unit
Check voltage YES

Disconnection in Repair or replace
between CN-157
(21) and chassis
poor contact
Starting switch : ON Check voltage between CN-157
Parking switch : ON between CS-17
Voltage : 20~30V NO (7) and chassis (21) and CS-17(7)
YES
Voltage : 20~30V Defective switch Replace
Parking switch : ON Check voltage
between CS-17
NO
(5) and chassis
Disconnection in Repair or replace
NO
Voltage : 20~30V wiring harness or (after clean)
poor contact
between CS-17 (5)
and fuse No.8
PARKING SWITCH
FUSE
6
5 No.8
7 T/M CONTROL UNIT
CS-17 21
CN-157
Check resistance
YES MAX 1Ω
7807AEL17
NO MIN 1MΩ
7-69
5. MACHINE DOES NOT TRAVEL
fuse [CN-36] No.17 (transmission controller) is not blown out.
specified.
·Wiring diagram : See page 7-21.
Cause Remedy
YES
Defective clutch Replace
cut-off switch
Check resistance
YES
between CD-5
and chassis
Is there continuity
NO
between CN-157
(66) and chassis? Defective T/M Replace
NO
control unit
Is voltage between
Defective T/M Replace
CN-157(21) and NO
chassis 20-28V? control unit
Starting switch : ON YES

Parking switch : OFF Defective Replace
Clutch cut-off parking switch
switch : ON Is there continuity
between CS-17(7)
YES
and chassis?
Disconnection Repair or replace

NO
wiring harness (after clean)
or poor contact
between CN-157
(21) and CS-17 (7)
Check resistance
YES MAX 1Ω
NO MIN 1MΩ
7-70
6. WHEN STARTING SWITCH IS TURNED ON, WIPER MOTOR DOES NOT OPERATE · Cap type
fuse [CN-36] No.9 is not blown out.
·After checking, connect the disconnected connectors again immediately unless otherwise MCU
HYD TEMP SENDER
FAN CLUTCH +
CLUTCH CUT-OFF PS
SPEEDMETER SIG.
RIDE CONT. AUTO

SAFETY RY
COOLANT TEMP
WIPER RY
STEERING RY
ALT LEVEL
FUEL SENSOR
TACHO SENSOR+
PREHEATER
SERIAL-H
WASH SIG
AIR CON."ON"SIG
NEUTRAL SIG
FAN CLUTCH -
CAN-H
AUTO SEL.TCU
CAN-L
MAIN PUMP PS
CLUTCH CUT-OFF SW
STEERING P/P PS
RIDE CONT. ON
WIPER INT SIG
PARKING SIG
SERIAL-L
GND
BUZZER
AUTO SEL.SW
BRAKE PS
TAHCO SENSOR -
AIR FILTER
ENGINE OIL PS
IG 24V
specified.
FUSE BOX
BEACON/RR WORK LAMP 20A
1
Cause Remedy ILL.LAMP 20A
2
YES HEAD LAMP 20A
23
35
34
24
36
31
32
26
25
33
27
21
20
30
29
28
22
17
19
11
18
16
12
10
13
15
14
1
2
3
6
8
4
5

HL740 7S

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HL740 7S

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CONTENTS

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

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

SECTION 3 POWER TRAIN SYSTEM

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

SECTION 4 BRAKE SYSTEM

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

SECTION 5 STEERING SYSTEM

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

SECTION 6 WORK EQUIPMENT

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

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

Structure and function

2. Convert 550 mm into inches.

0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

Kilogram to Pound 1kg = 2.2046lb

0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84

0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378

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

0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980

7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1

14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0

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

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

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

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

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

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

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

FOLLOW SAFE PROCEDURE

WEAR PROTECTIVE CLOTHING

WARN OTHERS OF SERVICE WORK

USE HANDHOLDS AND STEPS

Be careful of slippery conditions on platforms,

WORK IN CLEAN AREA

PROTECT AGAINST FLYING DEBRIS

PROTECT AGAINST NOISE

SUPPORT MACHINE PROPERLY

SERVICE COOLING SYSTEM SAFELY

HANDLE FLUIDS SAFELY-AVOID FIRES

BEWARE OF EXHAUST FUMES

REMOVE PAINT BEFORE WELDING OR

SERVICE MACHINE SAFELY

STAY CLEAR OF MOVING PARTS

AVOID HEATING NEAR PRESSURIZED

PREVENT BATTERY EXPLOSIONS

USE TOOLS PROPERLY

damaged rims or missing lug bolts and nuts.

USE PROPER LIFTING EQUIPMENT

DISPOSE OF FLUIDS PROPERLY

LIVE WITH SAFETY

KEEP ROPS INSTALLED PROPERLY

Bucket Tire Head light Hydraulic tank Radiator

Boom cylinder Main control valve Cab Air cleaner Counterweight

Boom Front axle Transmission Rear axle Fuel tank

Description Unit Specification

Description Unit Specification

4) MAIN CONTROL VALVE

5) REMOTE CONTROL VALVE

7) DYNAMIC POWER TRANSMISSION DEVICES

No. Items Size kgf·m lbf·ft

Use following table for unspecified torque.