Manual de Serviço Hyundai Hl740-7

HL740 (TM) -7 manual de serviço Página 1 de 1
RODA DE CARREGADOR HL740 (TM) -7

APRESENTAÇÃO
CONTEÚDO
SEÇÃO 1
GERAL
Grupo 1 Dicas de segurança
Grupo 2 Especificações
Grupo 3 Operação Caixa Folha de Registo
SECÇÃO 2
MOTOR
Grupo 1 Estrutura e função
SECÇÃO 3
SISTEMA DE TREM DE FORÇA
Grupo 2 Verificações Operacionais e resolução de problemas
Grupo 3 Teste e Ajustes
Grupo 4 Desmontagem e Montagem
SECÇÃO 4
SISTEMA DE FREIO
SECÇÃO 5
SISTEMA DE GOVERNO
SECÇÃO 6
EQUIPAMENTO DE TRABALHO
SECÇÃO 7
SISTEMA ELÉTRICO
Grupo 1 Localização dos componentes
Grupo 2 Circuito Elétrico
Grupo 3 Sistema de Monitorização
Grupo 4 Elétrico Componente Especificação
Grupo 5 Conectores
Grupo 6 Solução De Problemas
file:///C:/Users/valdelei/AppData/Local/Temp/VGERVIEN.htm 19/06/2015
SECTION 1 GENERAL
Group 1 Safety Hints 1-1

Group 2 Specifications 1-10
Group 3 Operational Checkout Record Sheet 1-25
SECTION 1 GENERAL
GROUP 1 SAFETY HINTS
FOLLOW SAFE PROCEDURE

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

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

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

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

Before starting a job :
½ Clean work area and machine.
½ Make sure you have all necessary tools to do
your job.
½ Have the right parts on hand.
½ 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:
½ Park machine on a level surface.
½ Lower bucket to the ground.
½ Turn key switch to OFF to stop engine. Remove
key from switch.
½ Move pilot control shutoff lever to locked position.
½ 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:
½ If you sand or grind paint, avoid breathing the
dust. Wear an approved respirator.
½ 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 fluids.
73031GE14
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 other
materials. 73031GE16
PREVENT BATTERY EXPLOSIONS

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

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

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

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

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

Make certain all parts are reinstalled correctly if the
roll-over protective structure(ROPS) is loosened or
removed for any reason. Tighten mounting bolts
to proper torque.
The protection offered by ROPS will be impaired if
ROPS is subjected to structural damage, is
involved in an overturn incident, or is in any way
altered by welding, bending, drilling, or cutting. A
damaged ROPS should be replaced, not reused. 73031GE22
1-9
GROUP 2 SPECIFICATION
1. MAJOR COMPONENT(HL740-7)
Bucket Tire Hydraulic tank Radiator
Boom Main control valve Cab Air cleaner Counterweight
Bucket link Bell crank Bucket cylinder Main pump Precleaner Engine Muffler
Boom cylinder Front axle Steering cylinder Transmission Rear axle Fuel tank
74072SP01
1-10
MAJOR COMPONENT(HL740TM-7)
Bucket Tire Hydraulic tank Radiator Counterweight
Boom cylinder Main control valve Cab Air cleaner Battery
Bucket link Link Bucket cylinder Main pump Precleaner Muffler Engine
Boom Front axle Steering cylinder Transmission Rear axle Fuel tank
740TM72SP01
1-11
2. SPECIFICATIONS
1) WITHOUT TOOTH AND CUTTING EDGE TYPE BUCKET(HL740-7)
F
B
5070
H
3830
3050
K
C
G
40
50
3
5855 0
D
E 2000
A
74072SP02
Description Unit Specification

Operating weight kg(lb) 11500(25350)
Struck 1.7(2.2)
Bucket capacity m3(yd3)
Heaped 2.0(2.6)
Overall length A 7180(23' 7")
Overall width B 2550( 8' 4")
Overall height C 3260(10' 8")
Ground clearance D 417( 1' 4")
Wheelbase E mm(ft-in) 2900( 9' 6")
Tread F 1900( 6' 3")
Dump clearance at 45° G 2920( 9' 7")
Dump reach(Full lift) H 935( 3' 1")
Width over tires I 2430( 8' 0")
Dump angle J 48
Degree (°)
Roll back angle(Carry position) K 47
Lift(With load) 5.5
Cycle time Dump(With load) sec 1.2
Lower(Empty) 2.8
Maximum travel speed km/hr(mph) 38.2(23.8)
Braking distance 12(39' 4")
m(ft-in)
Minimum turning radius(Center of outside tire) 5.03(16' 6")
Gradability Degree (°) 30
First gear 6.9(4.3)
Second gear 12.6(7.9)
Forward
Third gear 24.0(15.0)
Travel speed Fourth gear km/hr(mph) 38.2(23.8)
First gear 7.3(4.5)
Reverse Second gear 13.3(8.3)
1-12
WITHOUT TOOTH AND CUTTING EDGE TYPE BUCKET(HL740TM-7)
B
F
J
5070
H
3830
3050
K
C
G
40
50
3
D
5855 0
E 2000
A
740TM72SP02

Struck 1.6(2.1)
Heaped 1.9(2.5)
Tread F 1900( 6' 3")
Dump angle J 50
Degree (°)
Lift(With load) 5.5
Lower(Empty) 2.7
m(ft-in)
First gear 6.9(4.3)
Forward
First gear 7.3(4.5)
1-13
2) WITH BOLT-ON CUTTING EDGE TYPE BUCKET(HL740-7)
B
F
J
5070
H
3830
3050
K
C
G
40
50
5885 30
D
E 2000
A
74072SP03

Struck 1.78(2.3)
Heaped 2.1(2.7)
Overall length A 7270(23'10")
Tread F 1900( 6' 3")
Dump angle J 48
Degree (°)
Lift(With load) 5.5
Lower(Empty) 2.8
m(ft-in)
First gear 6.9(4.3)
Forward
First gear 7.3(4.5)
1-14
WITH BOLT-ON CUTTING EDGE TYPE BUCKET(HL740TM-7)
B
F
J
5150
H
3990
3050
K
C
G
40
50
3
D
5920 0
E 2000
A
740TM72SP03

Struck 1.7(2.2)
Heaped 2.1(2.7)
Tread F 1900( 6' 3")
Dump angle J 50
Degree (°)
Lift(With load) 5.5
Lower(Empty) 2.7
m(ft-in)
First gear 6.9(4.3)
Forward
First gear 7.3(4.5)
1-15
3) WITH TOOTH TYPE BUCKET(HL740-7 ONLY)
J
B
F
I
5070
H
3830
3050
K
C
G
40
50
3
5945 0
D
E 2000
A
74072SP04

Struck 1.7(2.2)
Heaped 2.0(2.6)
Tread F 1900( 6' 3")
Dump clearance at 45° G 2770( 9'11")
Dump angle J 48
Degree (°)
Lift(With load) 5.5
Lower(Empty) 2.8
m(ft-in)
First gear 6.9(4.3)
Forward
Fourth gear km/hr(mph) 38.2(23.8)
Travel speed
First gear 7.3(4.5)
1-16
3. WEIGHT
HL740-7 HL740TM-7 HL740-7 HL740TM-7
Item
kg lb
Front frame assembly 850 990 1870 2180
Rear frame assembly 1240 2710
Front fender(LH & RH) 25 55
Rear fender(LH & RH) 36 79
Counterweight 520 770 1150 1700
Cab assembly 820 1810
Engine assembly 430 950
Transmission assembly 400 880
Drive shaft(Upper, engine to transmission) 8.5 19
Drive shaft(Front) 21 46
Drive shaft(Center) 20 44
Drive shaft(Rear) 14 31
Front axle(Include differential) 580 1280
Rear axle(Include differential) 580 1280
Tire(4EA) 330 730
Hydraulic tank 180 400
Fuel tank 300 660
Main pump assembly 32 71
Main control valve 22 49
Boom assy 730 660 1610 1460
Bell crank assy 230 - 510 -
Bucket link 37 42 82 93
Quick coupler - 210 - 460
Bucket, with bolt on cutting edge 980 910 2160 2010
Bucket, with tooth 920 - 2030 -
Without tooth and cutting edge 830 790 1830 1740
Boom cylinder assembly(2EA) 97 210
Bucket cylinder assembly 120 47 270 100
Steering cylinder assembly(2EA) 19 42
Quick coupler cylinder assembly - 5.5 - 12
Seat 40 88
Battery 28 62
1-17
4. SPECIFICATION FOR MAJOR COMPONENTS
1) ENGINE
Item Specification
Model Cummins QSB5.9-C

Type 4-cycle turbocharged diesel engine
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 Ý stroke 102Ý 120mm(4.02"Ý 4.72")
Piston displacement 5880cc(359cu in)
Compression ratio 18.1 : 1
Rated gross horse power 140hp at 2200rpm
Maximum gross torque at 1400rpm 60kgf½ m(434lbf½ ft)
Engine oil quantity 16˜ (4.2 U.S. gal)
Dry weight 432kg(952lb)
High idling speed 2330 · 50rpm
Low idling speed 950 · 50rpm
Rated fuel consumption 226g/kw½ hr
Starting motor Nippondenso 228000-7902 (24V)
Alternator Delco Remy 22SI(24V-70Amp)
Battery 2Ý 12VÝ 100Ah
1-18
2) MAIN PUMP
Item Specification
Type Fixed displacement tandem helical gear pump
Capacity 46+36cc/rev
Maximum operating pressure 220kgf/cm2(3129psi)
Rated operating speed 2200rpm
Rated output flow 177˜ /min(46.8U.S.gpm)
3) FAN AND BRAKE PUMP

Specification
Item
Fan Brake
Type Fixed displacement tandem helical gear pump
Capacity 16.8cc/rev 8.2cc/rev
Maximum operating pressure 150kgf/cm2(2130psi)
Rated operating speed 2200rpm
Rated output flow 35˜ /min(9.2U.S.gpm) 17˜ /min(4.5U.S.gpm)
4) MAIN CONTROL VALVE

Item Specification
Type 2 spool(sectional block)
Operating method Hydraulic pilot assist
Main relief valve set pressure 220kgf/cm2(3129psi)
Overload relief valve set pressure 240kgf/cm2(3414psi)
5) REMOTE CONTROL VALVE
Item Specification
Type Joystick(or with aux lever)

Minimum 3.7kgf/cm2(52.6psi)
Control pressure
Maximum 30kgf/cm2(427psi)
6) CYLINDER
Item Specification
Boom cylinder Bore diaÝ Rod diaÝ Stroke Þ 120Ý Þ 70Ý 738mm
Bucket cylinder Bore diaÝ Rod diaÝ Stroke Þ 140Ý Þ 75Ý 505mm
Steering cylinder Bore diaÝ Rod diaÝ Stroke Þ 65Ý Þ 40Ý 429mm
Quick coupler cylinder Bore diaÝ Rod diaÝ Stroke Þ 50Ý Þ 25Ý 79mm
1-19
7) DYNAMIC POWER TRANSMISSION DEVICES
Item Specification
Model ZF 4WG160
Torque converter
Type Single-stage, single-phase
Type Full-automatic power shift
Transmission Gear shift Forward fourth gear, reverse third gear
Adjustment Electrical single lever type, kick-down system
Drive devices 4-wheel drive
Axle Front Front fixed location
Rear Oscillation · 12°of center pin-loaded
Wheels Tires 20.5-25, 16PR(L3)
Travel Four-wheel, wet-disc type, full hydraulic
Brakes Spring applied, hydraulic released brake on front
Parking axle
Type Full hydraulic, articulated
Steering
Steering angle 40°to both right and left angle, respectively
1-20
5. TIGHTENING TORQUE OF MAJOR COMPONENT
No Items Size kgf½ m lbf½ ft
1 Engine mounting bolt(2EA) M20Ý 2.5 57.9· 8.7 419· 62.9

2 Engine mounting bolt(Bracket) M12Ý 1.75 10.7· 1.6 77.4· 11.6
3 Radiator mounting bolt M16Ý 2.0 29.7· 4.5 215· 32.5
Engine
4 Fuel tank mounting bolt M16Ý 2.0 29.7· 4.5 215· 32.5
5 Air cleaner mounting bolt(4EA) M 8Ý 1.5 2.5· 0.5 18.1· 3.6
6 Air cleaner mounting bolt(Bracket) M12Ý 1.75 12.3· 2.5 89.0· 18.1
7 Main pump housing mounting bolt M12Ý 1.75 12.8· 3.0 92.6· 21.7
8 Main control valve mounting bolt M12Ý 1.75 12.8· 3.0 92.6· 21.7
9 Steering unit mounting bolt M10Ý 1.5 6.9· 1.4 49.9· 10.1
10 Priority valve M 8Ý 1.25 2.5· 0.5 18.1· 3.6
11 Brake valve mounting bolt M 8Ý 1.25 2.5· 0.5 18.1· 3.6
Hydraulic
12 system Fan and brake pump mounting bolt M10Ý 1.5 6.9· 1.4 49.9· 10.1
13 Cut-off valve mounting bolt M12Ý 1.75 12.8· 3.0 92.6· 21.7
14 Remote control lever mounting bolt M 6Ý 1.0 1.1· 0.2 8.0· 1.4
15 Pilot supply unit mounting bolt M 8Ý 1.25 2.5· 0.5 18.1· 3.6
16 Safety valve M 8Ý 1.25 2.5· 0.5 18.1· 3.6
17 Hydraulic oil tank mounting bolt M16Ý 2.0 29.7· 4.5 215· 32.5
18 Transmission mounting bolt(Bracket, front) M20Ý 2.5 57.9· 8.7 419· 62.9
19 Transmission mounting bolt(Bracket, rear) M16Ý 2.0 18.4· 2.0 133· 14.5
20 Power train Front axle mounting bolt, nut M24Ý 2.0 100· 15 723· 109
21 system Rear axle support mounting bolt, nut M24Ý 2.0 100· 15 723· 109
22 Tire mounting nut(20.5-25 16PR, L3) M22Ý 1.5 70· 2.0 506· 15
23 Drive shaft joint mounting bolt 3/8-24UNF 6.0· 0.8 43.4· 5.8
24 Counterweight mounting bolt, nut M30Ý 2.0 199· 29.9 1439· 216
25 Others Operator’s seat mounting bolt M 8Ý 1.25 3.4· 0.8 24.6· 5
26 ROPS Cab mounting bolt(4EA) M24Ý 3.0 27.5· 2.5 199· 18.1
1-21
6. TORQUE CHART
Use following table for unspecified torque.
1) BOLT AND NUT
(1) Coarse thread
8T 10T
Bolt size
kgf½ m lbf½ ft kgf½ m lbf½ ft
M 6 Ý 1.0 0.85 ~ 1.25 6.15 ~ 9.04 1.14 ~ 1.74 8.2 ~ 12.6
M 8 Ý 1.25 2.0 ~ 3.0 14.5 ~ 21.7 2.73 ~ 4.12 19.7 ~ 29.8
M10 Ý 1.5 4.0 ~ 6.0 28.9 ~ 43.4 5.5 ~ 8.3 39.8 ~ 60
M12 Ý 1.75 7.4 ~ 11.2 53.5 ~ 79.5 9.8 ~ 15.8 71 ~ 114
M14 Ý 2.0 12.2 ~ 16.6 88.2 ~ 120 16.7 ~ 22.5 121 ~ 167
M16 Ý 2.0 18.6 ~ 25.2 135 ~ 182 25.2 ~ 34.2 182 ~ 247
M18 Ý 2.5 25.8 ~ 35.0 187 ~ 253 35.1 ~ 47.5 254 ~ 343
M20 Ý 2.5 36.2 ~ 49.0 262 ~ 354 49.2 ~ 66.6 356 ~ 482
M22 Ý 2.5 48.3 ~ 63.3 350 ~ 457 65.8 ~ 98.0 476 ~ 709
M24 Ý 3.0 62.5 ~ 84.5 452 ~ 611 85.0 ~ 115 615 ~ 832
M30 Ý 3.5 124 ~ 168 898 ~ 1214 169 ~ 229 1223 ~ 1655
M36 Ý 4.0 174 ~ 236 1261 ~ 1703 250 ~ 310 1808 ~ 2242
(2) Fine thread

8T 10T
Bolt size
kgf½ m lbf½ ft kgf½ m lbf½ ft
M 8 Ý 1.0 2.17 ~ 3.37 15.7 ~ 24.3 3.04 ~ 4.44 22.0 ~ 32.0
M10 Ý 1.25 4.46 ~ 6.66 32.3 ~ 48.2 5.93 ~ 8.93 42.9 ~ 64.6
M12 Ý 1.25 7.78 ~ 11.6 76.3 ~ 83.7 10.6 ~ 16.0 76.6 ~ 115
M14 Ý 1.5 13.3 ~ 18.1 96.2 ~ 130 17.9 ~ 24.1 130 ~ 174
M16 Ý 1.5 19.9 ~ 26.9 144 ~ 194 26.6 ~ 36.0 193 ~ 260
M18 Ý 1.5 28.6 ~ 43.6 207 ~ 315 38.4 ~ 52.0 278 ~ 376
M20 Ý 1.5 40.0 ~ 54.0 289 ~ 390 53.4 ~ 72.2 386 ~ 522
M22 Ý 1.5 52.7 ~ 71.3 381 ~ 515 70.7 ~ 95.7 512 ~ 692
M24 Ý 2.0 67.9 ~ 91.9 491 ~ 664 90.9 ~ 123 658 ~ 890
M30 Ý 2.0 137 ~ 185 990 ~ 1338 182 ~ 248 1314 ~ 1795
M36 Ý 3.0 192 ~ 260 1389 ~ 1879 262 ~ 354 1893 ~ 2561
1-22
2) PIPE AND HOSE(FLARE TYPE)
Thread size(PF) Width across flat(mm) kgf½ m lbf½ ft
1/4" 19 4 28.9
3/8" 22 5 36.2
1/2" 27 6 43.4
3/4" 36 12 86.8
1" 41 14 101
3) PIPE AND HOSE(ORFS TYPE)
Thread size(UNF) Width across flat(mm) kgf½ m lbf½ ft
13/16-16" 24 4.4 32.5

1-3/16-12" 36 9.3 67.3
1-7/16-12" 41 13.2 95.5
1-11/16-12" 50 18.3 132.4
2-12" 55 22.6 163.5
4) FITTING
Thread size(PF) Width across flat(mm) kgf½ m lbf½ ft
1/4" 19 4 28.9
3/8" 22 5 36.2
1/2" 27 6 43.4
3/4" 36 13 94.0
1" 41 15 109
1-23
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
˜ (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
Torque converter SAE 10W-30

Transmission Oil 25(6.6)
SAE 15W-40
Front : 39(10.3)
Axle Gear oil SAE 80W-90LSD/API GL-5
Rear : 39(10.3)
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 228(60.2)
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 and water 35(9.2)
50 : 50
1-24
GROUP 3 OPERATIONAL CHECKOUT RECORD SHEET
½ Owner :
½ Date :
½ Hours :
½ Serial No. :
½ Technician :
ଖ Use this sheet to record operational
checkout results.
Perform the operational check before
installing any test equipment. 7407GE01
OK NOT
Item Comments
OK
1. Monitor indicator and gauge checks(Engine OFF)
½ Hourmeter and gauge check

½ Battery check
½ Monitor indicator circuit check
½ Monitor turn signals and warning indicator check
2. Transmission, axle and engine linkages, neutral start

switch and reverse warning alarm switch checks
½ Transmission control lever and neutral

½ Neutral start and reverse warning
½ Alarm circuit checks
½ Engine speed control linkage check
3. Monitor indicator and gauge checks(Engine running)
½ Monitor display and alternator output checks

½ Monitor bypass circuit and seat belt indicator check
½ Monitor primary and secondary level check
½ Transmission oil warm up procedure
½ Transmission temperature gauge check
1-25
4. Brake system and clutch cut off checks
½ Park brake capacity check

½ Park brake transmission lockout check
½ Service brake pump flow check
½ Service brake capacity check
½ Brake accumulator precharge check
½ Brake system leakage check
½ Service brake pedal check
½ Service and park brake system drag check
½ Clutch cut off check
5. Driving checks
½ Transmission oil warm up procedure

½ Transmission noise check
½ Speedometer check
½ Transmission kick down system check
½ 1st, 2nd, 3rd and 4th speed clutch pack drag check
½ Transmission pressure, pump flow and leakage check
½ Transmission shift modulation check
½ Torque converter check
½ Engine power check
6. Hydraulic system checks
½ Hydraulic system warm up procedure

½ Hydraulic pump performance check
½ Pilot control valve boom float check
½ Boom down solenoid valve check
½ Control valve lift check
½ Bucket rollback circuit relief valve check
½ Bucket dump circuit relief
Low pressure check
High pressure check
½ Boom and bucket cylinder drift check
½ Boom down solenoid valve leakage check
½ Pilot controller check
½ Return to dig check
½ Boom height kickout check-if equipped
1-26
7. Steering system checks
½ Steering valve check

½ Steering system leakage check
½ Priority valve
Low check pressure
High check pressure
8. Accessory checks
½ Operating lights check

½ Work light check
½ Brake light check
½ Cab light check
½ Horn circuit check
½ Windshield washer and wiper check
½ Defroster blower check
½ Heater/Air conditioner blower check
½ Heater functional check
½ Air conditioner functional check
½ Start aid system check
9. Cab components and vandal protection checks
½ Cab door latch check

½ Cab door hold open latch check
½ Cab door release button check
½ Cab door lock check
½ Cab door window check
½ Cab window latch check
½ Steering column adjustment check
½ Seat and seat belt check
½ Air intake filter door check
½ Engine side panels check
½ Radiator cap access door check
½ Frame locking bar check
½ Boom lock check
½ Service decal check
1-27
SECTION 2 ENGINE
Group 1 Structure and Function 2-1

SECTION 2 ENGINE
GROUP 1 STRUCTURE AND FUNCTION
1. STRUCTURE
Oil fill
Front lift bracket
Starting motor Lube oil filter

Cool heater
starting aid Water inlet connection
Flywheel
Oil pan
Turbocharger exhaust
outlet connection
Turbocharger air
inlet connection
Fuel filter
Fan drive Cab heater plumbing
Oil level gauge

Crankcase breather
Engine front
support
Oil pressure
7407EG01
½ Direct 4-stroke, 6-cylinders, water-cooling and charge air cooled diesel engine in installed, cylinder
block and cylinder head are made of case iron and turbocharger is attached.
2-1
2. SYSTEM DIAGRAMS
The following drawings show the flow through the engine systems.
1) Fuel system
1 Fuel from supply tank
2 Electronic lift pump
3 Fuel filter and water separator
4 Low pressure supply lines
5 Injection pump
6 Fuel drain manifold
7 High pressure supply lines
8 Closed nozzle injectors
9 Fuel return to supply tank
7577EG02
2) Lubricating oil system

1 Lubricating oil pump
2 Pressure regulating valve closed
3 Pressure regulating valve open
4 From lubricating oil pump
5 To lubricating oil cooler
6 To lubricating oil pan
7 Lubricating oil cooler
8 Filter bypass valve
9 Filter bypass valve closed
10 Filter bypass valve open
11 To lubricating oil filter
12 Lubricating oil filter
13 From lubricating oil filter
7577EG03
14 Main lubricating oil rifle
(1) Lubrication for the turbocharger

1 Lubricating oil supply
2 Lubricating oil drain
7577EG04
2-2
(2) Lubrication for the power components
1 To valve train
3 From lubricating oil cooler
4 Conneting rod journal
5 To connecting rod bearing
6 Crankshaft main journal
7 From main lubricating oil rifle
8 To camshaft
9 To piston cooling nozzle.
7577EG05
(3) Lubrication for the overhead

2 Rocker lever support
3 Transfer slot
4 Rocker lever shaft
5 Rocker lever bore
6 Rocker lever
7607EG06
3) Cooling system
Views A and B
1 Coolant inlet A B
2 Pump lmpeller
3 Coolant flows past lubricating oil cooler
4 Coolant flows past cylinders
5 Coolant flow to cylinder head
7577EG07A,B
Views C and D
1 Coolant flow from the cylinder head C D
2 Coolant flow to thermostat housing
3 Coolant flow past injector
4 Thermostat
5 Coolant bypass passage
6 Coolant flow to water pump inlet
7 Coolant bypass closed
8 Coolant flow back to radiator
7577EG07C,D
2-3
4) Air intake system
1 Intake air inlet to turbocharger
2 Turbocharger air to charge air cooler
3 Charge air cooler
4 Intake manifold
5 Intake valve
7577EG08
5) Exhaust system
1 Wastegate closed
2 Wastegate open
3 Exhaust valve
4 Exhaust manifold
5 Turbocharger exhaust inlet
6 Turbocharger exhaust outlet
7577EG09
6) Compressed air system

1 Air in
2 Air out
3 Coolant in
4 Coolant out
5 Lubricating oil in
6 Lubricating oil out is internal to the gear
housing
7607EG10
2-4
SECTION 3 POWER TRAIN SYSTEM

Group 2 Operational Checks and Troubleshooting 3-66
Group 3 Tests and Adjustments 3-77
Group 4 Disassembly and Assembly 3-80
SECTION 3 POWER TRAIN SYSTEM
1. POWER TRAIN COMPONENT OVERVIEW
Front drive shaft Upper drive shaft Engine
Front axle Center drive shaft Transmission Rear drive shaft Rear axle
7407PT01
The power train consists of the following components :

½ Transmission
½ Front, upper, center and rear drive shafts
½ 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 counter shaft type
power shift transmission. A disk type parking brake is located in the front axle.
The transmission outputs through universal joints to three drive shaft assemblies. The front drive shaft
is a telescoping shaft which drives the front axle. The front axle is mounted directly to the loader front
frame. The front axle is equipped with limited slip differential.
The rear axle is mounted on an oscillating pivot. The rear axle is equipped with conventional differential.
The power transmitted to front axle and rear axle is reduced by the pinion gear and ring gear of
differential. It then passes from the differential to the sun gear shaft(Axle shaft) of final drive.
The power of the sun gear is reduced by a planetary mechanism and is transmitted through the
planetary hub to the wheel.
3-1
HYDRAULIC CIRCUIT
K4 KR K1 K3 KV K2
F 60 E 55 D 56 C 58 B 53 A 57
P1 P2 P3 P4 P5 P6
B D B D B D B D B D B D
Y1 Y2 NFS Y3 NFS Y4 NFS Y5 Y6 NFS

NFS NFS
Pressure
Temp reducing
sensor valve
9 bar
System
pressure
valve
Valve block control circuit 16+2 bar
Converter
Relief Filter
valve
9 bar
Oil cooler Bcak
pressure
valve
Bypass 3.5 bar Pump
valve 16+2 bar
1.5 bar
Oil sump
Lubrication
Main oil circuit
76043PT18
NFS Follow-on slide P3 Proportional valve clutch K1

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

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

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

about the same speed as
pump wheel.
(760) 3-4
3-4
3. TRANSMISSION
1) LAYOUT
12
1
11
2
10
4
9
15
14
13
7607PT03
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
8
3 13 18
4 17
7 6 5
7407PT02
1 Lifting lugs 11 Breather

2 Input flange-input through universal shaft 12 Transmission-case cover
3 Transmission suspension threads M20 13 Transmission case
4 Output flange-converter side 14 Power take-off; Coaxial;
5 Oil drain plug with magnetic insert M38Ý 1.5 Engine-dependent
6 Model identification plate 15 Electro-hydraulic control
7 Attachment possibility for oil level tube 16 Oil level tube with oil dipstick
with oil dipstick(Converter side) 17 Transmission suspension threads M20
8 Attachment possibility for emergency 18 Output flange-rear
steering pump 19 Exchange filter(Fine filter)
9 Cover 20 Filter head with connection for filter
10 Converter bell housing restriction switch
3-6
3) OPERATION OF TRANSMISSION
(1) Forward
ཛ 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
ཛྷ 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
ཝ 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
ཞ 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
ཛ 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
ཛྷ 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
ཝ 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 measuring points, hydraulic schematic and electro-hydraulic
control unit at page 3-2, 3-14 and 3-78.
The six clutches of the transmission are selected through the 6 proportional valves P1 to P6. The
proportional valve(Pressure regulator-unit) consists of pressure regulator(e.g. Y1), booster valve
oscillation damper.
The pilot pressure of 9 bar for the control of the follow-on slides is created by the reducing valve.
The pressure oil (16+2bar) is directed through the follow-on slide to the corresponding clutch.
3 - 14
By the direct proportional selection with separate pressure modulation for each clutch, the
pressures to the clutches, taking part in the gear change, are controlled. In this way, a hydraulic
overlab of the clutches to be engaged and disengaged is achieved.
This is leading to fast shiftings without traction force interruption.
At the shifting, the following criteria are considered:
- Speed of engine, turbine, central gear train and output.
- Transmission temperature.
- Shifting mode(Up-, down-, reverse shifting and gear engaging from neutral).
- Load level(Full- and partial load, traction, coasting inclusive consideration of load cycles during the
shifting).
The system pressure valve is limiting the maximum control pressure to 16+2 bar and releases the
main stream to the converter and lubricating circuit.
A converter relief valve is installed in the converter inlet, which protects the converter against high
internal pressures(Opening pressure 9bar).
Within the converter, the oil transfers the power transmission according to the well-known
hydrodynamic principle(See torque converter, page 3-3).
In order to avoid cavitation, the converter must be always completely filled with oil.
This is achieved by a converter back pressure valve, following the converter, with an opening
pressure of about 3.5bar.
The oil, escaping from the converter, is directed to a oil cooler.
The oil is directed from the oil cooler to the transmission and from there to the lubricating-oil circuit
so that all lubricating points are supplied with cooled oil.
In the electro-hydraulic control unit there are 6 pressure regulators installed.
5) GEAR SELECTOR(DW-3)
The gear selector is designed for the
mounting on the left side of the steering
column. The positions(Speeds) 1 to 4 are
F
selected by a rotary motion, the driving 1
2
3
N
4
direction Forward(F)-Neutral(N)-Reverse(R) R
by tilting the gear selector lever.

The gear selector is also available with
integrated kickdown control knob.
A neutral lock is installed as protection
against inadvertent drive off.
N D
Position N - Gear selector lever blocked in
this position.
Position D - Driving. 73033TM17
3 - 15
6) LCD
Cluster 1( ) LCD
1
2( ) MENU
M 2 - Display main menu
MENU
- Return to the normal display

BACK
3
3( ) BACK
4
NEXT
Return to the previous menu
5
SELECT
4( ) NEXT
Move to the next selection
5( ) SELECT
77073CD72
Activate the currently chosen item
(1) Normal display
TYPE 1 TYPE 2
1
c
a e 3
2 d
b
6 4
5
77073CD73
No Symbol Meaning Remark
Forward, reverse, neutral LCD type 1, Display during AEB mode

F, R, N Forward, reverse, neutral LCD type 2, Display during AEB mode
1
1, 2, 3, 4 Actual gear -
P Parking brake mode active -
a Wiper motor intermittently operating -
2 When operating intermittently, it
b -
shows an operating time interval.
c, d Up and down shifting c : Forward, d : Reverse
3 Automatic mode
e Pre-selected gear -
HOUR
4 Hour meter Display the total operation hours of the machine

COOLANT
5 C Engine coolant temperature Display in accordance with selected items
AUT Ride control mode active Ride control switch AUTO position, see page 7-35
6 ON Ride control mode active Ride control switch ON position, see page 7-35
(Option)
OFF Ride control mode turn off Ride control switch MIDDLE position, see page 7-35
ଖ Both type1 and type2 are LCD modes and they can be changed each other by operator’s selection.
3 - 16
(2) Display map
Normal Main menu Sub menu Activate item

Press MENU Press ACCESSORY Press ACCESSORY
M
ACCESSORY JOB TIMER JOB TIMER
CLOCK HOURMETER
ON
USER STOP WATCH
OFF
ADJUSTMENT ODOMETER
DIAGNOSTICS LIGHT CONT RESET
Previous Press Previous Press Previous Press

menu menu menu
77073CD74
Main group Sub group Meaning Display on LCD

Accessory ½ Measure the various job time. JOB HOUR
Job timer
½ Press : Display ON OFF or RESET.
½ Measures time in seconds.
Stop watch ½ -
Press : Start. Press again : Stop.
LATEST-DIS
Latest ½ Distance until recent times. Km
Odometer TOTAL-DIS
Total ½ Total distance. Km
½ Control of LCD display luminosity.

Light control -
½ Brightness control : , .
Clock ½ When 12H or 24H is selected, the current
Time set hour appears.
½ , : input, : setting.
PM
Clock ON/OFF ½ : Clock display ON or OFF.
1
½ Alarm setting. It is possible to set 3 alarms.
Alarm 2
½ Stop alarming : or buzzer stop switch.
3
User
½ Raise the idle rpm to 1200rpm automatically
Alternate idle -
to warm up the engine.
Mode 1 ½ Automatic travelling speed is applied from 1st

(1st-4th) to 4th gear. -
Auto 1/2
Mode 2 ½ Automatic travelling speed is applied from
(2nd-4th) 2nd to 4th gear. -
Mode 1 ½ Press button once : Shift down, press button
(Down/Up) again ; shift up. -
Quick
shift Mode 2 ½ Press button every time : Shift to lower gear
(Down) respectively. -
Auto ½ ON : Transmission auto condition.
Select ½ OFF : Transmission semi-auto condition.
Aux-sw
Clutch ½ ON : Clutch cut-off is activated. -
Cut-off ½ OFF : Clutch cut-off is cancelled.
3 - 17
Main group Sub group Meaning Display on LCD display
Adjustment Unit ½ Choose between metric and inch unit display.
TOTAL-DIS TOTAL-DIS
Km Mile
Wiper ½ When using the intermittent function of wiper

Intermittence motor, it regulates operation time.
½ Regulate idle rpm.
Alternate RPM ½ Press , : Adjust idle rpm increments -
(or decrement) by 25rpm.
Pulse ½ Press : Modification. -
AEB ½ It controls the disk interval of the transmission. -

½
English : Display in English.
ENG/KOR ½ -
Korean : Display in Korean.
½
Type 1 : Indicate with the symbol.
Display 1/2 ½
Type 2 : Indicate with a letter. ,
Diagnostics Fault ½
Error code display.
-
Code ½
Refer to page 3-19.
Machine ½
Hydraulic temperature and battery voltage HYD BATT-VOLT
Monitor display. C V
½ Press : Display ON or OFF.
Fault ½ Error code display. -
Code ½ Refer to page 3-20~24.
½ Engine coolant temperature display COOLANT
Monitor
Engine ½ Press : Display ON or OFF. C
Fault ½ Error code display.

-
Code ½ Refer to page 3-25~53.
OIL TEMP
Transmis- Transmission oil temperature display.
Monitor F
sion ½ Press : Display ON or OFF.
3 - 18
(3) Fault code
When selecting the fault code menu, it shows all of the fault codes which mean abnormal
conditions of present time.
Press ଖ To go out from fault explanation window,

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

011 Power input voltage high Above 38V
012 Alternator voltage low Below 5V
Electrical 013 Alternator voltage high Above 36V
system 014 Buzzer circuit open or short to ground
015 Buzzer circuit short to power
016 Wiper relay open or short to ground
017 Wiper relay short to power
Hydraulic 020 Hydraulic oil temperature sensor open or short to power
system 021 Hydraulic oil temperature sensor short to ground
030 Fuel level sensor open or short to power
031 Fuel level sensor short to ground
Engine 032 Safety relay open or short to ground Restarting prevention
system 033 Safety relay short to power Restarting prevention
034 Cooling fan driving valve open or short to ground
035 Cooling fan driving valve short to power
050 Auto select switch supply power open or short to power
051 Auto select switch supply power short to ground
T/M system
052 Clutch cutoff supply power open or short to power
053 Clutch cutoff supply power short to ground
Steering 060 Emergency steering relay open or short to ground Option
system 061 Emergency steering relay short to power Option
070 MCU communication error
Communication 071 TCU communication error
072 ECM communication error
080 Speedometer output signal(from TCU) bad
081 MCU memory error
Others 082 MCU clock error
083 MCU clock battery error
084 Monitor memory error
MCU : Machine control unit TCU : Transmission control unit ECM : Engine control module
3 - 19
(4) Engine fault code information
Fault code No. Reason Effect(only when fault code is active)

ECM internal hardware error. Possible no effect or engine may run rough or not
111 start.
No engine speed or position signal detected at Engine power derate.
115
pin 17 of the engine harness. Possible white smoke.
No engine speed or position signal detected at No engine speed and position backup for main
121
pin 9 of the engine harness speed/position sensor.
High voltage detected at the boost pressure Engine will derate to no-boost fueling.
122
sensor signal pin 45 of the engine harness.
Low voltage detected at boost pressure sensor Engine will derate to no-boost fueling.
123
signal pin 45 of the engine harness.
High voltage detected at throttle position signal Engine idles when idle validation switch indicates
131 pin 30 of the machine harness. idle and ramps up to a default set speed when
the idle validation switch indicates off-idle.
Low voltage detected at throttle position signal Engine idles when idle validation switch indicates
132 pin 30 of the machine harness. idle and ramps up to a default set speed when
the idle validation switch indicates off-idle.
High voltage detected at remote throttle position Engine will not respond to remote throttle input.
133
signal pin 9 of the machine harness.
Low voltage detected at remote throttle position Engine will not respond to remote throttle input.
134
signal pin 9 of the machine harness.
High voltage detected at oil pressure signal pin Default value used for oil pressure.
135
33 of the engine harness. No engine protection for oil pressure.
Low voltage detected at oil pressure signal pin 33 Default value used for oil pressure.
141
of the engine harness. No engine protection for oil pressure.
Oil pressure signal indicates oil pressure below Power and/or speed derate and possible engine
143 the low engine protection limit. shutdown if engine protection shutdown feature
is enabled.
High voltage detected at coolant temperature Default value used for coolant temperature.
144
signal pin 23 of the engine harness. No engine protection for coolant temperature.
Low voltage detected at coolant temperature Default value used for coolant temperature.
145
signal pin 23 of the engine harness. No engine protection for coolant temperature.
Coolant temperature signal indicates coolant Power derate and possible engine shutdown
146 temperature has exceeded the minimum engine feature is enabled.
protection limit.
Coolant temperature signal indicates coolant Speed derate and possible engine shutdown if
151 temperature has exceeded the maximum engine engine protection shutdown feature is enabled.
protection limit.
High voltage detected at intake manifold Default value used for intake manifold temperature.
153 temperature signal pin 34 of the engine harness. No engine protection for intake manifold temperature.
Low voltage detected at intake manifold temper- Default value used for intake manifold temperature.
154
ature signal pin 34 of the engine harness. No engine protection for intake manifold temperature.
Intake manifold air temperature signal indicates Speed derate and possible engine shutdown if
155 intake manifold air temperature is above the engine protection shutdown feature is enabled.
maximum engine protection limit.
Air conditioner clutch driver signal indicates a Air conditioner clutch will not operate.
191
short to ground when commanded on.
211 Machine specific fault code has occurred. No effect on engine performance.
High voltage detected at ambient air pressure Engine power derate.
221
signal pin 32 of the engine harness.
Engine speed signal indicates engine speed has Fuel to injectors disabled until engine speed falls
234
exceeded the overspeed limit. below the overspeed limit.
Coolant level signal at pin 37 of the engine Power and/or speed derate and possible engine
235 harness indicates coolant level is low. shutdown if engine protection shutdown feature
is enabled.
3 - 20
Vehicle speed signal on pins 8 and 18 of the EEngine speed limited to "Max. Engine Speed
machine harness has been lost. without VSS". Cruise control, gear-down
241 protection and the road speed governor will not
work. Trip information data that is based on
mileage will be incorrect.
Possible tampering has been detected on the Engine speed limited to " Max. Engine Speed
vehicle speed circuit pins 8 and 18 of the mach- without VSS". Cruise control, gear-down
242 ine harness protection and the road speed governor will not
work. Trip information data that is based on
mileage will be incorrect.
Error detected in the exhaust brake relay enable Exhaust brake will not work.
243
circuit at pin 42 of the engine harness.
Error detected in fan clutch relay enable circuit at Electronic control; module(ECM) can not control
245
pin 41 of the engine harness. the engine cooling fan. Fan will remain on or off.
High voltage detected at the fuel temperature Default value used for fuel temperature.
263 sensor signal pin 35 of the engine harness. Possible low power.
Fuel pump control module indicates the fuel Power derate.
261 temperature has exceeded the pump protection
limit.
High or low voltage detected at the fuel temperat- Default value used for fuel temperature.
264 ure sensor signal circuit inside the pump controll- Possible low power.
er.
High voltage detected at main engine ECM will use the engine position signal as a
283 speed/position sensor voltage supply pin 8 of the backup. Possible white smoke and power loss.
engine harness.
Low voltage detected at main engine speed/ po- ECM will use the engine position signal as a
284 sition sensor voltage supply pin 8 of the engine backup.
harness. Possible white smoke and power loss.
The ECM expected information from a At least one multiplexed device will not operate
285 multiplexed device but did not receive it soon properly.
enough or did not receive it at all.
The ECM expected info from a multiplexed At least on multiplexed device will not operate
286 device but only received a portion of the properly.
necessary information
The machine vehicle electronic control unit The engine will only idle.
287
(VECU) detected a fault with its throttle pedal.
The machine vehicle electronic control unit The engine will not respond to the remote
288
(VECU) detected a fault with its remote throttle. throttle.
High voltage detected at machine pressure Default value used for machine pressure. Lose
297 signal pin 48 of the machine harness. ability to control machine pressure.
Low voltage detected at machine pressure signal Default value used for machine pressure. Lose
298
pin 48 of the machine harness. ability to control machine pressure.
Engine shutdown by device other than key switch No action taken by the ECM.
before proper engine cool down resulting in
299
filtered load factor above maximum shutdown
threshold.
Power to the real time clock has been interrupted Time stamp in ECM powerdown data will be
319 and its setting is no longer valid incorrect.
Auxiliary speed signal frequency indicates the Engine will go to idle and lose ability to control
349 frequency is above a calibrated threshold value. speed of the auxiliary device.
Low voltage detected at engine position sensor Default value used for sensors connected to this
+5 VDC supply, pin 10 of the engine harness. +5 VDC supply. Engine will derate to no-boost
352 fueling and loss of engine protection for oil
pressure, intake manifold pressure, and ambient
air pressure.
3 - 21
High current detected at the fuel pump control Fueling to the injectors disabled and engine is
361 valve. shut down.
Low or no voltage detected at the fuel pump Engine will lose power and may shut down.
362 control valve.
No fuel control valve movement detected by the Engine power loss.
363 fuel pump controller.
No communications or invalid data transfer rate Engine will run at a backup mode set speed
detected on data link between ECM and fuel when throttle is off-idle.
364 pump controller at pins 4 and 13 of the engine
harness.
Low voltage detected at fuel pump controller Engine may lose power and may shut down.
365 supply voltage circuit.
Fuel pump controller battery voltage measureme- Engine will lose power and may shut down.
366 nt is outside the range between 6 and 24 VDC.
Fuel pump speed/position sensor signal lost. Fueling to injectors disabled and engine will shut
367 down.
The fuel pump controller can not achieve the tim- Significant engine power loss.
368 ing value being commanded by the engine ECM.
Fuel pump controller does not detect engine Significant engine power loss.
369 position pulse at pin 7 of the engine harness. Possible white smoke.
Fuel pump controller detects continuous voltage If communication is lost between the ECM and
at idle select pin 16 of the engine harness or fuel fuel pump controller, engine will only operate at a
372 pump controller detects and open circuit or short speed slightly higher than idle, regardless of
circuit to ground at idle select pin 16 of the engine throttle position.
harness.
High voltage detected at fuel shut off signal pin 6 Fueling to injectors is disabled and engine will
373 of the engine harness. shut down.
Fuel pump controller has detected an internal Response will vary from some power loss to the
374 error. engine shutting down.
Engine ECM is commanding a fueling or timing Possible no effect or engine may exhibit some
375 value that the pump can not achieve. power loss.
No calibration in the fuel pump controller. Fueling to injectors disabled and engine will shut
376 down.
Fuel pump controller is not powering down when Equipment batteries may be drained low during
377
key switch power is removed from the ECM. long shutdown periods.
Error detected in cold start aid relay 1 enable Intake air heater can not be fully energized by the
381 circuit at pin 41 of the machine harness. ECM.
Possible white smoke and/or hard starting.
Error detected in cold start aid relay 2 enable Intake air heater can not be fully energized by
382 circuit at pin 31 of the machine harness. the ECM.
Possible white smoke and/or hard starting.
High voltage detected at machine harness sens- Sensors connected to this +5 VDC supply(i.e.
385
or +5 VDC supply pin 10 of the machine harness. remote throttle position sensor) will not function.
High voltage detected at the engine harness Default value used for sensors connected to this
sensor +5 VDC supply pin 10 of the engine +5 volts supply. Engine will derate to no-boost
386 harness. fueling and loss of engine protection for oil
pressure, intake manifold temperature, and
coolant temperature.
High voltage detected at the throttle position Engine idles when idle validation switch indicates
387 sensor +5 VDC supply pin 29 of the machine idle and ramps up to a default set speed when
harness. idle validation switch indicates off-idle.
Error detected in power supply relay enable Possible no effect on performance or engine may
391
circuit at pin 43 of the engine harness. not run.
3 - 22
Oil pressure signal indicates oil pressure elow the Speed derate and possible engine shutdown if
415 very low engine protection limit. engine protection shutdown feature is enagled.
Water-in-fuel signal indicates the water in the fuel Excessive water in the fuel can lead to severe
418 filter needs to be drained. fuel sysm damage.
Voltage detected simultaneously on both the No engine protection for coolant level.
coolant level high and low signal pins 27 and 37
422 of the engine harness or no voltage detected on
either pin.(Fault is active for switch type coolant
level sensors only)
Low voltage detected at water-in-fuel signal pin No water-in-fuel protection.
429 40 of the machine harness.
Idle validation signals on pins 25 and 26 of the No effect on performance, but loss of idle
machine harness indicate voltage detected validation.
431 simultaneously on both pins or no voltage
detected on either pin.
Idle validation signal at pin 26 of the machine Engine will only idle.
harness indicates the throttle is at the idle
position when the throttle position signal at pin 30
of the machine harness indicates the throttle is
432 not at the idle position...OR...idle validation signal
at pin 26 of the machine harness indicates the
throttle is not at the idle position when the throttle
position signal at pin 30 of the machine harness
indicates the throttle is at the idle position.
Boost pressure signal indicates boost pressure is Possible overfueling during acceleration.
high when other engine parameters(i.e. speed Increase in black smoke.
433 and load) indicate boost pressure should be
low...OR...boost pressure is low when other
engine parameters indicate it should be high.
All data gathered by the ECM since the last key None on performance. Fault code table, trip
on(i.e.faults, trip information data. etc.)was not information data, maintenance monitor data,
434 stored to permanent memory at the last key off. trending data and user activated datalogger data
may be inaccurate.
Voltage detected at ECM power supply pins 38, Engine will die or run rough.
441 39, 40 and 50 of the engine harness indicates the
ECM supply voltage fell below 6 VDC.
Voltage detected at ECM power supply pins 38, None on performance.
39, 40 and 50 of the engine harness indicates the
442
ECM supply voltage is above the maximum
system voltage level.
Low voltage detected at throttle position sensor Engine idles when idle validation switch indicates
443 +5 VDC supply pin 29 of the machine harness. idle and ramps up to a default set speed when
idle validation switch indicates off-idle.
Low voltage detected at machine harness sensor Sensors connected to this +5 VDC supply (i.e.
444
+5 VDC supply pin 10 of the machine harness. remote throttle position sensor) will not function.
Intake manifold temperature signal indicates Power derate and possible engine shutdown if
488 intake manifold temperature is above the minm- engine protection shutdown feature is enabled.
um engine protection limit.
Auxiliary device speed signal on pins 8 and 18 of Lose ability to control the speed of the auxiliary
489 the OEM harness is out of range of the ECM device.
threshold.
High voltage detected at the auxiliary +5 VDC Auxiliary device will not function.
515 sensor supply voltage pin 49 of the engine
harness.
Low voltage detected at the auxiliary +5 VDC Auxiliary device will not function.
516 sensor supply voltage pin 49 of the engine
harness.
3 - 23
A mechanically stuck fuel control valve has been Engine may shut down.
517
detected by the fuel pump controller.
Error detected on the high speed governor droop Operator can not select alternate high speed
524 selection switch in put pin 24 of the engine governor droop. Normal droop is used.
harness.
Error detected in the dual output driver "A" circuit The device being controlled by the dual output
527
pin 5 of the machine harness. driver "A"signal will not function properly.
Error detected on the torque curve selection Operator can not select alternate torque curves.
528
switch input pin 39 of the machine harness. Normal torque curve is used.
Error detected in the dual output driver "B" circuit The device being controlled by the dual output
529
pin 1 of the engine harness. driver "B" signal will not function properly.
Idle validation signals on pins 25 and 26 of the Engine will only idle.
551 machine harness indicate voltage detected
simultaneously on both pins.
Software has initiated an engine shutdown based Engine will shutdown.
599
on machine sensor inputs
ECM detected the engine has initiated a No effect.
611 protection shutdown or has been keyed off while
above a specified load limit.
Error detected in the output device driver(VGT or Can not control the VGT or transmission, depend-
768 transmission shift modulation signal) signal pin ing on application.
21 of the machine harness.
ଖ Some fault codes are not applied to this machine.
3 - 24
(5) Display during AEB mode
Symbol Meaning Remarks
K1~K4, KV, KR Calibrating clutch K1~K4, KV

or KR respectively
- And Kx Wait for start, initialization of
clutch Kx, x : 1, 2, 3, 4, V, R
And Kx Fast fill time determination of
clutch Kx
= And Kx Compensating pressure
determination of clutch Kx
OK Calibration for all clutches Transmission stays in neutral, you have to restart the
finished TCU(Ignition off/on) after removing AEB-Starter
STOP AEB cancled(Activation Transmission stays in neutral, you have to restart the
stopped) TCU(Ignition off/on)
STOP and Kx AEB stopped, clutch Kx can't Transmission stays in neutral, you have to restart the
be calibrated TCU(Ignition off/on)
Spanner and Kx Kx couldn't be calibrated, AEB Transmission stays in neutral, you have to restart the
finished TCU(Ignition off/on)
ଠE Engine speed too low,
- Raise engine speed
ଢE Engine speed too high,
- Lower engine speed
ଠT Transmission oil temperature
too low,
- Heat up transmission
ଢT Transmission oil temperature
too high,
- Cool down transmission
FT Transmission temperature not Transmission stays in neutral, you have to restart the
in defined range during TCU(Ignition off/on)
calibration
FB Operating mode not NORMAL Transmission stays in neutral, you have to restart the
or transmission temperature TCU(Ignition off/on)
sensor defective or storing of
calibrated values to EEPROM
has failed
FO Output speed not zero Transmission stays in neutral, you have to restart the
TCU(Ignition off/on)
FN Shift lever not in neutral Transmission stays in neutral, you have to restart the
position TCU(Ignition off/on)
FP Park brake not applied Transmission stays in neutral, you have to restart the
TCU(Ignition off/on)
STOP AEB-Starter was used incorrect Transmission stays in neutral, you have to restart the
or is defective. Wrong device TCU(Ignition off/on)
or wrong cable used
AEB mode : It controls the disk internal of the transmission, automatically.
Refer to page 7-28, 29.
3 - 25
(6) Definition of operating modes
ཛ 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)
ཛྷ 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)
ཝ 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.
ཞ 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.
ཟ 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.
(7) Abbreviations
OC : Open circuit
SC : Short circuit
OP mode : Operating mode
TCU : Transmission control unit
EEC : Electronic engine controller
PTO : Power take off
3 - 26
(8) Table of fault codes
Fault code Int. code Meaning of the fault code
(Hex) (Dec) possible reason for fault detection Reaction of the TCU Possible steps to repair Remarks
11 48 Logical error at gear range signal TCU shifts transmission to •Check the cables from TCU to Failure cannot be detected in
TCU detected a wrong signal combination neutral shift lever systems with DW2/DW3 shift
for the gear range OP-mode : Transmission •Check signal combinations of lever
•Cable from shift lever to TCU is broken shutdown shift lever positions for gear Fault is taken back if TCU
•Cable is defective and is contacted to range detects a valid signal for the
battery voltage or vehicle ground position
•Shift lever is defective
12 46 Logical error at direction select signal TCU shifts transmission to •Check the cables from TCU to Fault is taken back if TCU
TCU detected a wrong signal combination neutral shift lever detects a valid signal for the
for the direction direction at the shift lever
•Cable from shift lever to TCU is broken OP-Mode : Transmission •Check signal combinations of
•Cable is defective and is contacted to shutdown shift lever positions F-N-R
battery voltage or vehicle ground
13 95 Logical error at engine derating device After selecting neutral, TCU •Check engine derating device This fault is reset after power
TCU detected no reaction of engine while change to OP mode limp home up of TCU
derating device active
15 176 Logical error at direction select signal 2 shift TCU shifts transmission to •Check the cables from TCU to Fault is taken back if TCU
lever neutral if selector active shift lever 2 detects a valid neutral signal
TCU detected a wrong signal combination OP mode : Transmission •Check signal combinations of for the direction at the shift
for the direction shutdown if selector shift lever positions F-N-R lever
•Cable from shift lever 2 to TCU is broken active
•Cable is defective and is contacted to
battery voltage or vehicle ground
16 178 Logical error at axle connection OP mode : Normal •Check the cables from TCU to
Feedback axle connection measured by TCU feedback axle connection switch
and output signal axle connection don't fit •Check signals of the feedback
•Axle can't be connected or disconnected axle connection switch
due to mechanical problem
•One of the cables from feedback axle
connection switch to TCU is broken
3-27
21 32 S.C. to battery voltage at clutch cut off input Clutch cut off function is disabled •Check the cable from TCU to
The measured voltage is too high: OP mode : Normal the sensor
•Cable is defective and is contacted to •Check the connectors
battery voltage •Check the clutch cut off sensor
•Clutch cut off sensor has an internal defect
•Connector pin is contacted to battery voltage
22 29 S.C. to ground or O.C. at clutch cut off input Clutch cut off function is disabled •Check the cable from TCU to
The measured voltage is too low: OP mode : Normal the sensor
•Cable is defective and is contacted to •Check the connectors
vehicle ground •Check the clutch cut off sensor
•Cable has no connection to TCU
•Clutch cut off sensor has an internal
defect
•Connector pin is contacted to vehicle
ground or is broken
23 S.C. to battery voltage at load sensor input Retarder function is affected •Check the cable from TCU to Availability of retarder
The measured voltage is too high: TCU uses default load the sensor depends on default load
•Cable is defective and is contacted to OP mode : Normal •Check the connectors
battery voltage •Check the load sensor
•Load sensor has an internal defect •Check the assembly tolerances
•Connector pin is contacted to battery voltage of load sensor
24 S.C. to ground or O.C. at load sensor input Retarder function is affected •Check the cable from TCU to Availability of retarder
The measured voltage is too low: TCU use default load the sensor depends on default load
•Cable is defective and is contacted to OP mode : Normal •Check the connectors
vehicle ground •Check the load sensor
•Cable has no connection to TCU •Check the assembly tolerances
•Load sensor has as internal defect of load sensor
ground or is broken
3-28
25 33 S.C. to battery voltage or O.C. at transmission No reaction, TCU use default •Check the cable from TCU to
sump temperature sensor input temperature the sensor
The measured voltage is too high: OP mode : Normal •Check the connectors
•Cable is defective and is contacted to •Check the temperature sensor
battery voltage
•Temperature sensor has an internal defect
•Connector pin is contacted to battery
voltage or is broken
26 30 S.C. to battery voltage or O.C. at transmission No reaction, TCU uses default •Check the cable from TCU to
sump temperature sensor input temperature the sensor
The measured voltage is too low: OP mode : Normal •Check the connectors
vehicle ground
ground
27 76 S.C. to battery voltage or O.C. at retarder No reaction, TCU uses default •Check the cable from TCU to
temperature sensor input temperature the sensor
battery voltage
28 74 S.C. to ground at retarder temperature No reaction, TCU uses default •Check the cable from TCU to
sensor input temperature the sensor
vehicle ground
•Connector pin is contacted to vehicle ground
3-29
27 76 S.C. to battery voltage or O.C. at converter No reaction, TCU uses default •Check the cable from TCU to
output temperature sensor input temperature the sensor
battery voltage
28 74 S.C. to ground at converter output No reaction, TCU uses default •Check the cable from TCU to
temperature sensor input temperature the sensor
vehicle ground
31 38 S.C. to battery voltage or O.C. at engine OP mode : Substitute clutch control •Check the cable from TCU to
speed input the sensor
TCU measures a voltage higher than 7.00V •Check the connectors
at speed input pin •Check the speed sensor
battery voltage
•Speed sensor has an internal defect
voltage or has no contact
32 34 S.C. to ground at engine speed input OP mode : Substitute clutch control •Check the cable from TCU to
TCU measures a voltage less than 0.45V at the sensor
speed input pin •Check the connectors
•Cable/connector is defective and is •Check the speed sensor
contacted to vehicle ground
3-30
33 42 Logical error at engine speed input OP mode : Substitute clutch control •Check the cable from TCU to This fault is reset after power
TCU measures a engine speed over a the sensor up of TCU
threshold and the next moment the •Check the connectors
measured speed is zero •Check the speed sensor
•Cable/connector is defective and has bad •Check the sensor gap
contact
•Sensor gap has the wrong size
34 39 S.C. to battery voltage or O.C. at turbine OP mode : Substitute clutch control •Check the cable from TCU to
speed input If a failure is existing at output the sensor
TCU measures a voltage higher than 7.00V speed, •Check the connectors
at speed input pin TCU shifts to neutral •Check the speed sensor
•Cable is defective and is contacted to OP mode : Limp home
vehicle battery voltage
35 35 S.C. to ground at turbine speed input OP mode : Substitute clutch control •Check the cable from TCU to This fault is reset after power
TCU measures a voltage less than 0.45V at If a failure is existing at output the sensor up of TCU
speed input pin speed, •Check the connectors
•Cable/connector is defective and is TCU shifts to neutral •Check the speed sensor
contacted to vehicle ground OP mode : Limp home
36 43 Logical error at turbine speed input OP mode : Substitute clutch control •Check the cable from TCU to
TCU measures a turbine speed over a If a failure is existing at output the sensor
threshold and at the next moment the speed, •Check the connectors
measured speed is zero TCU shifts to neutral •Check the speed sensor
•Cable/connector is defective and has bad OP mode : Limp home •Check the sensor gap
contact
3-31
37 40 S.C. to battery voltage or O.C. at internal OP mode : Substitute clutch control •Check the cable from TCU to
speed input the sensor
TCU measures a voltage higher than 7.00V •Check the connectors
at speed input pin •Check the speed sensor
vehicle battery voltage
38 36 S.C. to ground at turbine speed input OP mode : Substitute clutch control •Check the cable from TCU to
TCU measures a voltage less than 0.45V at the sensor
speed input pin •Check the connectors
•Cable/connector is defective and is •Check the speed sensor
39 44 Logical error at internal speed input OP mode : Substitute clutch control •Check the cable from TCU to This fault is reset after power
TCU measures a internal speed over a the sensor up of TCU
threshold and at the next moment the •Check the connectors
measured speed is zero •Check the speed sensor
•Cable/connector is defective and has bad •Check the sensor gap
contact
3A 41 S.C. to battery voltage or O.C. at output Special mode for gear selection •Check the cable from TCU to
speed input OP mode : Substitute clutch control the sensor
TCU measures a voltage higher than 12.5V If a failure is existing at turbine •Check the connectors
at speed input pin speed, •Check the speed sensor
•Cable is defective and is contacted to TCU shifts to neutral
battery voltage OP mode : lamp home
3-32
3B 37 S.C. to ground at output speed input Special mode for gear selection •Check the cable from TCU to
TCU measures a voltage less than 1.00V at OP mode : Substitute clutch control the sensor
speed input pin If a failure is existing at turbine •Check the connectors
•Cable/connector is defective and is speed, •Check the speed sensor
contacted to vehicle ground TCU shifts to neutral
•Speed sensor has an internal defect OP mode : lamp home
3C 45 Logical error at output speed input Special mode for gear selection •Check the cable from TCU to This fault is reset after power
TCU measures a turbine speed over a OP mode : Substitute clutch control the sensor up of TCU
threshold and at the next moment the If a failure is existing at turbine •Check the connectors
measured speed is zero speed, •Check the speed sensor
•Cable/connector is defective and has bad TCU shifts to neutral •Check the sensor gap
contact OP mode : lamp home
3D 71 Turbine speed zero doesn't fit to other - - Not used

speed signals
3E 72 Output speed zero doesn't fit to other Special mode for gear selection •Check the sensor signal of This fault is reset after power
speed signals OP mode : Substitute clutch control output speed sensor up of TCU
If transmission is not neutral and the shifting If a failure is existing at turbine •Check the sensor gap of
has finished, speed, output speed sensor
TCU measures output speed zero and TCU shifts to neutral •Check the cable from TCU to
turbine speed or internal speed not equal to OP mode : lamp home the sensor
zero.
3-33
71 22 S.C. to battery voltage at clutch K1 TCU shifts to neutral •Check the cable from TCU to
The measured resistance value of the valve is OP mode : Limp home the gearbox
out of limit, the voltage at K1 valve is too high If failure at another clutch is •Check the connectors from
•Cable/connector is defective and has pending TCU to the gearbox
contact to battery voltage TCU shifts to neutral •Check the regulator resistance* * See Chapter (9)
•Cable/connector is defective and has OP mode : TCU shutdown •Check internal wire harness of
contact to another regulator output of the the gearbox
TCU
•Regulator has an internal defect
72 10 S.C. to ground at clutch K1 TCU shifts to neutral •Check the cable from TCU to
out of limit, the voltage at K1 valve is too low If failure at another clutch is •Check the connectors from
•Cable/connector is defective and has pending gearbox to TCU
contact to vehicle ground TCU shifts to neutral •Check the regulator resistance* * See Chapter (9)
•Regulator has an internal defect OP mode : TCU shutdown •Check internal wire harness of
the gearbox
73 16 O.C. at clutch K1 TCU shifts to neutral •Check the cable from TCU to
The measured resistance value of the valve OP mode : Limp home the gearbox
is out of limit If failure at another clutch is •Check the connectors from
•Cable/connector is defective and has no pending gearbox to TCU
contact to TCU TCU shifts to neutral •Check the regulator resistance* * See Chapter (9)
the gearbox
is out of limit, the voltage at K2 valve is too If failure at another clutch is •Check the connectors from
high pending gearbox to TCU
•Cable/connector is defective and has TCU shifts to neutral •Check the regulator resistance* * See Chapter (9)
contact to battery voltage OP mode : TCU shutdown •Check internal wire harness of
•Cable/connector is defective and has the gearbox
contact to another regulator output of the
TCU
3-34
the gearbox
the gearbox
TCU
the gearbox
3-35
the gearbox
7A 78 S.C. to battery voltage at converter clutch - -
7B 79 S.C. to ground at converter clutch - -
7C 80 O.C. at converter clutch - - Not used
7D 166 S.C. ground at engine derating device Engine derating will be on until •Check the cable from TCU to Not used
•Cable is defective and is contacted to TCU power down even if fault the engine derating device
vehicle ground vanishes(Loose connection) •Check the connectors from Not used
•Engine derating device has an internal defect OP mode : Normal engine derating device to TCU
•Connector pin is contacted to vehicle ground •Check the resistance* of engine * See Chapter (9)
derating device
7E 168 S.C. battery voltage at engine derating No reaction •Check the cable from TCU to
device OP mode : Normal the engine derating device
•Cable/connector is defective and is •Check the connectors from
contacted to battery voltage backup alarm device to TCU
•Engine derating device has an internal •Check the resistance* of * See Chapter (9)
defect backup alarm device
7F 167 O.C. at engine derating device No reaction •Check the cable from TCU to
TCU detected a wrong voltage at the output OP mode : Normal the engine derating device
pin, that looks like a O.C. for this output pin •Check the connectors from
•Cable is defective and has no connection engine derating device to TCU
to TCU •Check the resistance* of * See Chapter (9)
•Engine derating device has an internal engine derating device
defect
•Connector has no connection to TCU
3-36
TCU
The measured resistance value of the valve is OP mode : Limp home the engine derating device
the gearbox
the gearbox
TCU
3-37
85 14 S.C. to ground at clutch KV TCU shifts to neutral •Check the cable from TCU to
the gearbox
86 20 O.C. at clutch KV TCU shifts to neutral •Check the cable from TCU to
the gearbox
87 27 S.C. to battery voltage at clutch KR TCU shifts to neutral •Check the cable from TCU to
is out of limit, the voltage at KR valve is too high If failure at another clutch is •Check the connectors from
contact to battery voltage TCU shifts to neutral •Check the regulator resistance* * See Chapter (9)
•Cable/connector is defective and has contact OP mode : TCU shutdown •Check internal wire harness of
to another regulator output of the TCU the gearbox
88 15 S.C. to ground at clutch KR TCU shifts to neutral •Check the cable from TCU to
out of limit, the voltage at KR valve is too low If failure at another clutch is •Check the connectors from
the gearbox
89 21 O.C. at clutch KR TCU shifts to neutral •Check the cable from TCU to
the gearbox
3-38
91 1 S.C. to ground at relay reverse warning Backup alarm will be on until •Check the cable from TCU to
alarm TCU power down even if fault the backup alarm device
TCU detected a wrong voltage at the output vanishes(Loose connection) •Check the connectors from
pin, that looks like a S.C. to vehicle ground OP mode : Normal backup alarm device to TCU
•Cable is defective and is contact to vehicle •Check the resistance* of * See Chapter (9)
ground backup alarm device
•Backup alarm device has an internal defect
92 3 S.C. to battery voltage at relay reverse No reaction •Check the cable from TCU to
warning alarm OP mode : Normal the backup alarm device
TCU detected a wrong voltage at the output •Check the connectors from
pin, that looks like a S.C. to battery voltage backup alarm device to TCU
•Cable is defective and is contacted to •Check the resistance* of * See Chapter (9)
battery voltage backup alarm device
•Backup alarm device has an internal
defect
voltage
93 2 O.C. at relay reverse warning alarm No reaction •Check the cable from TCU to
TCU detected a wrong voltage at the output OP mode : Normal the backup alarm device
•Cable is defective and has no connection backup alarm device to TCU
•Backup alarm device has an internal defect backup alarm device
94 4 S.C. to ground at relay starter interlock No reaction •Check the cable from TCU to
TCU detected a wrong voltage at the output OP mode : Normal the stater interlock relay
pin, that looks like a S.C. to vehicle ground •Check the connectors from
•Cable is defective and is connection to starter interlock relay to TCU
vehicle ground •Check the resistance* of * See Chapter (9)
•Starter interlock relay has an internal defect starter interlock relay
ground
3-39
95 6 S.C. to battery voltage at relay starter No reaction •Check the cable from TCU to
interlock OP mode : Normal the starter interlock relay
pin, that looks like a S.C. to battery voltage starter interlock relay to TCU
•Cable is defective and has no connection •Check the resistance* of * See Chapter (9)
to battery voltage starter interlock relay
•Starter interlock relay has an internal defect
96 5 O.C. at relay starter interlock No reaction •Check the cable from TCU to
TCU detected a wrong voltage at the output OP mode : Normal the starter interlock relay
•Cable is defective and has no connection starter interlock relay to TCU
•Starter interlock relay has an internal defect starter interlock relay
97 7 S.C. to ground at park brake solenoid No reaction •Check the cable from TCU to
TCU detected a wrong voltage at the output OP mode : Normal the park brake solenoid
•Cable is defective and is connection to park brake solenoid to TCU
vehicle ground •Check the resistance* of park * See Chapter (9)
•Park brake solenoid has an internal defect brake solenoid
ground
98 9 S.C. to battery voltage at park brake No reaction •Check the cable from TCU to
solenoid Optional : (Some customers) the park brake solenoid
TCU detected a wrong voltage at the output TCU shifts to neutral caused by •Check the connectors from
pin, that looks like a S.C. to battery voltage park brake feed back park brake solenoid to TCU
•Cable is defective and is connection to OP mode : Normal •Check the resistance* of park * See Chapter (9)
battery voltage brake solenoid
•Park brake solenoid has an internal defect
voltage
3-40
99 8 O.C. at park brake solenoid No reaction •Check the cable from TCU to
TCU detected a wrong voltage at the output Optional : Some customers the park brake solenoid
pin, that looks like a O.C. for this output pin TCU shifts to neutral caused by •Check the connectors from
•Cable is defective and has no connection park brake feed back park brake solenoid to TCU
to TCU OP mode : Normal •Check the resistance* of park * See Chapter (9)
•Park brake solenoid has an internal defect brake solenoid
9A 66 S.C. to ground at converter lock up No reaction •Check the cable from TCU to
clutch solenoid OP mode : Normal the converter clutch solenoid
pin, that looks like a S.C. to vehicle ground converter clutch solenoid to
•Cable is defective and is contacted to TCU
vehicle ground •Check the resistance* of park * See Chapter (9)
•Converter clutch solenoid has an internal brake solenoid
defect
9B 67 O.C. at converter lock up clutch solenoid Converter clutch always open, •Check the cable from TCU to
TCU detected a wrong voltage at the output retarder not available the converter clutch solenoid
pin, that looks like a O.C. for this output pin OP mode : Normal •Check the connectors from
•Cable is defective and has no connection converter clutch solenoid to
to TCU TCU
•Converter clutch solenoid has an internal •Check the resistance* of park * See Chapter (9)
defect brake solenoid
9C 68 S.C. to battery voltage at converter lock No reaction •Check the cable from TCU to
up clutch solenoid OP mode : Normal the converter clutch solenoid
pin, that looks like a S.C. to battery voltage converter clutch solenoid to
•Cable is defective and has no contacted TCU
to battery voltage •Check the resistance* of * See Chapter (9)
•Converter clutch solenoid has an internal converter clutch solenoid
defect
3-41
9D 81 S.C. to ground at retarder solenoid No reaction •Check the cable from TCU to
TCU detected a wrong voltage at the output OP mode : Normal the retarder solenoid
•Cable is defective and is contacted to retarder solenoid to TCU
•Retarder solenoid has an internal defect retarder solenoid
ground
9E 82 O.C. at retarder solenoid No reaction •Check the cable from TCU to

TCU detected a wrong voltage at the output OP mode : Normal the retarder solenoid
•Cable is defective and has no connection retarder solenoid to TCU
•Retarder solenoid has an internal defect retarder solenoid
9F 83 S.C. to battery voltage at retarder No reaction •Check the cable from TCU to
solenoid OP mode : Normal the retarder solenoid
pin, that looks like a S.C. to battery voltage retarder solenoid to TCU
to battery voltage retarder solenoid
•Retarder solenoid has an internal defect
3-42
A1 84 S.C. to ground at difflock or axle No reaction •Check the cable from TCU to
connection solenoid OP mode : Normal the difflock solenoid
pin, that looks like a S.C. to vehicle ground difflock solenoid to TCU
•Cable is defective and is contacted to •Check the resistance* of * See Chapter (9)
vehicle ground difflock solenoid
•Difflock solenoid has an internal defect
A2 85 S.C. to battery voltage at difflock or axle No reaction •Check the cable from TCU to
connection solenoid OP mode : Normal the difflock solenoid
pin, that looks like a S.C. to battery voltage difflock solenoid to TCU
to battery voltage difflock solenoid
•Difflock solenoid has an internal defect
A3 86 O.C. at difflock or axle connection solenoid No reaction •Check the cable from TCU to
TCU detected a wrong voltage at the output OP mode : Normal the difflock solenoid
•Cable is defective and has no connection difflock solenoid to TCU
•Difflock solenoid has an internal defect difflock solenoid
A4 96 S.C. to ground at warning signal output No reaction •Check the cable from TCU to
TCU detected a wrong voltage at the output OP mode : Normal the warning device
•Cable is defective and is contacted to warning device to TCU
•Warning device has an internal defect warning device
3-43
A5 97 O.C. voltage at warning signal output No reaction •Check the cable from TCU to
TCU detected a wrong voltage at the output OP mode : Normal the warning device
•Cable is defective and has no connection warning device to TCU
•Warning device has an internal defect warning device
A6 98 S.C. to battery voltage at warning signal No reaction •Check the cable from TCU to
output OP mode : Normal the warning device
pin, that looks like a S.C. to battery voltage warning device to TCU
•Cable is defective and has is contacted to •Check the resistance* of * See Chapter (9)
battery voltage warning device
•Warning device has an internal defect
voltage
3-44
B1 60 Slippage at clutch K1 TCU shifts to neutral •Check pressure at clutch K1

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

sensor
•Replace clutch

sensor
•Replace clutch
3-45

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

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

clutch KR. If this calculated value is out of If failure at another clutch is system
•Low pressure at clutch KR TCU shifts to neutral speed sensor
sensor
•Replace clutch
3-46
B7 87 Overtemp sump No reaction •Cool down machine

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

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

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

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

TCU calculates a differential speed at closed lockup clutch
converter lockup clutch. If this calculated •Check main pressure in the
value is out of range, TCU interprets this as system
slipping clutch •Check sensor gap at engine
•Low pressure at converter lockup clutch speed sensor
•Low main pressure •Check sensor gap at turbine
•Wrong signal at engine speed sensor speed sensor
•Wrong signal at turbine speed sensor •Check signal at engine speed
sensor
•Replace clutch
3-47
BD 169 S.C. to ground at engine brake solenoid No reaction •Check the cable from TCU to
TCU detected a wrong voltage at the output OP mode : Normal engine brake solenoid
•Cable is defective and is contacted to engine brake solenoid to TCU
vehicle ground •Check the resistance* of engine * See Chapter (7)
•Engine brake solenoid has an internal brake solenoid
defect
BE 171 S.C. to battery voltage at engine brake No reaction •Check the cable from TCU to
TCU detected a wrong voltage at the output OP mode : Normal the engine brake solenoid
pin, that looks like a S.C. to battery voltage •Check the connectors from
•Cable is defective and is contacted to engine brake solenoid to TCU
battery voltage •Check the resistance* of engine * See Chapter (7)
•Engine brake solenoid has an internal defect brake solenoid
BF 170 O.C. at engine brake No reaction •Check the cable from TCU to
TCU detected a wrong voltage at the output OP mode : Normal the engine brake solenoid
•Cable is defective and has no connection engine brake solenoid to TCU
to TCU •Check the resistance* of engine * See Chapter (7)
•Engine brake solenoid has an internal brake solenoid
defect
3-48
C3 91 Overtemp converter output No reaction •Cool down machine

TCU measured a oil temperature at the OP mode : Normal •Check oil level
converter output that is the allowed threshold •Check temperature sensor
C4 129 S.C. to ground at joystick status indicator No reaction •Check the cable from TCU to
TCU detected a wrong voltage at the output OP mode : Normal joystick status indicator
•Cable is defective and is contacted to joystick status indicator to TCU
vehicle ground •Check the resistance* of *See chapter (9)
•Joystick status indicator has an internal joystick status indicator
defect
C5 131 S.C. to battery voltage at joystick status No reaction •Check the cable from TCU to
indicator OP mode : Normal joystick status indicator
pin, that looks like a S.C. to battery voltage joystick status indicator to TCU
•Cable is defective and is contacted to •Check the resistance* of *See chapter (9)
battery voltage joystick status indicator
•Joystick status indicator has an internal
defect
C6 130 O.C. at joystick status indicator No reaction •Check the cable from TCU to
TCU detected a wrong voltage at the output OP mode : Normal joystick status indicator
•Cable is defective and has no connection joystick status indicator to TCU
to TCU •Check the resistance* of *See chapter (9)
•Joystick status indicator has an internal joystick status indicator
defect
•Connector pin has no connection to TCU
3-49
D1 54 S.C. to battery voltage at power supply See fault codes No.21 to 2C •Check cables and connectors Fault codes No.21 to No.2C
for sensors to sensors, which are supplied may be reaction of this fault
TCU measures more than 6V at the pin AU1 from AU1
(5V sensor supply) •Check the power supply at the
pin AU1(Should be appx. 5V)
D2 55 S.C. to ground at power supply for See fault codes No.21 to 2C •Check cables and connectors Fault codes No.21 to No.2C
sensors to sensors, which are supplied may be reaction of this fault
TCU measures less than 4V at the pin AU1 from AU1
(5V sensor supply) •Check the power supply at the
pin AU1(Should be appx. 5V)
D3 53 Low voltage at battery Shift to neutral •Check power supply battery

Measured voltage at power supply is lower OP mode : TCU shutdown •Check cables from batteries to
than 18V(24V device) TCU
•Check connectors from
batteries to TCU
D4 52 High voltage at battery Shift to neutral •Check power supply battery

Measured voltage at power supply is higher OP mode : TCU shutdown •Check cables from batteries to
than 32.5V(24V device) TCU
•Check connectors from
batteries to TCU
D5 57 Error at valve power supply VPS1 Shift to neutral •Check fuse

TCU switched on VPS1 and measured OP mode : TCU shutdown •Check cables from gearbox to
VPS1 is off or TCU switched off VPS1 and TCU
measured VPS1 is still on •Check connectors from
•Cable or connectors are defect and are gearbox to TCU
contacted to battery voltage •Replace TCU
•Cable or connectors are defect and are
•Permanent power supply KL30 missing
•TCU has an internal defect
3-50
D6 58 Error at valve power supply VPS2 Shift to neutral •Check fuse

TCU switched on VPS2 and measured OP mode : TCU shutdown •Check cables from gearbox to
VPS2 is off or TCU switched off VPS2 and TCU
measured VPS2 is still on •Check connectors from
•Cable or connectors are defect and are gearbox to TCU
contacted to battery voltage •Replace TCU
•Cable or connectors are defect and are
•Permanent power supply KL30 missing
•TCU has an internal defect
3-51
E1 91 S.C. battery voltage at speedometer - - Not used

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

output
E3 S.C. to battery voltage at display output No reaction •Check the cable from TCU to
TCU sends data to the display and OP mode : Normal the display
measures always a high voltage level on the •Check the connectors at the
connector display
•Cable or connectors are defective and are •Change display
contacted to battery voltage
•Display has an internal defect
E4 S.C. to ground at display output No reaction •Check the cable from TCU to
TCU sends data to the display and OP mode : Normal the display
measures always a high voltage level on the •Check the connectors at the
connector display
•Cable or connectors are defective and are •Change display
contacted to battery voltage
•Display has an internal defect
E5 93, 104 Communication failure on DeviceNet Shift to neutral •Check Omron master
OP mode : TCU shutdown •Check wire of DeviceNet-Bus
•Check cable to Omron master
E5 104 DISPID1 timeout TCU select parameter set with •Check display controller
Timeout of CAN-massage DISPID1 from ID0 •Check wire of CAN-Bus
display controller OP mode : Limp home •Check cable display controller
•Interference on CAN-Bus
•CAN wire/connector is defective
•Can wire/connector is defective and has
contact to vehicle ground or battery voltage
3-52
F1 51 General EEPROM fault No reaction •Replace TCU Often shown together with
TCU can't read non volatile memory OP mode : Normal fault code F2
•TCU is defective
F2 56 Configuration lost Transmission stay neutral •Reprogram the correct

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

TCU was not able to read correct clutch Default values : 0 for AEB
adjustment parameters Offsets used
•Interference during saving data on non OP mode : Normal
volatile memory
•TCU is brand new
3-53
(9) Measuring of resistance at actuator/sensor and cable
ཛ 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)
ཛྷ Cable
U
Bat
P(Power supply)
TCU
1 Actuator/
2 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 - 54
7) ELECTRIC CONTROL UNIT
(1) Complete system
2
1
12
10
5 4
3 9
7
A
13
2
6
11
14
7407PT03
1 Control unit(EST-37A)
2 Kickdown switch
3 Clutch cut off switch
4 Auto select switch
5 LCD
6 Gear selector(DW-3) with integrated kickdown switch
7 Supply-system connection
8 Transmission
9 Cable to inductive transmitter - speed central gear train
10 Cable to inductive transmitter - speed turbine
11 Cable to inductive transmitter - speed engine
12 Cable to speed sensor output and speedometer
13 Cable to plug connection on the electro - hydraulic control unit
14 Brake pressure sensor/load sensor
(2) Description of the basic functions
The powershift-reversing transmissions will be equipped with the electronic transmission control
unit(EST-37A), developed for them.
The system is processing the wishes of the driver according to the following criteria.
½ Speed definition as a function of gear selector position, driving speed and load level.
3 - 55
½ Protection against operating errors, as far as possible and practical.
½ Protection against overspeeds(On the basis of engine and turbine speed).
½ Reversing-automatic system(Driving speed-dependent).
½ Pressure cut off(Disconnecting of the drive train for maximum power on the power take-off).
½ Switch for manual or automatic operation.
½ Reversing function button, respectively kickdown function.
(3) Gearshifts
The control unit(EST-37A) is shifts the required speeds fully-automatically under consideration of
the following criteria.
½ Gear selector position
½ Driving speed
½ Load level
At the same time, the following speeds are picked up by the control unit(EST-37A).
½ n Engine
½ n Turbine
½ n Central gear train
½ n Output
- Neutral position
Neutral position is selected through the gear selector.
After the ignition is turned on, the electronics remains in the waiting state; By the position neutral
of the gear selector, respectively by pressing on the key neutral, the control unit(EST-37A)
becomes ready for operation.
Now, a speed can be engaged.
- Speed engagement
In principle, the speed, adapted to the driving speed(At standing, or rolling machine), will be
engaged. The engagement is realized in dependence on load and rotational speed.
- Upshifting under load
Upshifting under load will be then realized if the machine can still accelerate by it.
- Downshifting under load
Downshifting under load will be realized if more traction force is needed.
- Upshifting in coasting condition
In the coasting condition, the upshifting will be suppressed if the speed of the machine on a slope
shall not be further increased.
- Downshifting in coasting condition
Downshiftings in the coasting condition will be realized if the machine shall be retarded.
- Reversing
At speeds below the reversing limit, direct reversing can be carried out at any time in the speeds
1F 1R and 2F 2R(As a rule, this is the maximum driving speed of the 2nd speed).
3 - 56
Reversings in the speeds 3 and 4 are realized dependent on the driving speed.
- Above the programmed reversing limit, the machine is braked down by downshifts of the
electronic control unit(EST-37A) to the permitted driving speed, and only then, the reversing into
the correspondingly preselected speed will be carried out.
- Below the permitted driving speed, the reversing is carried out immediately.
(4) Specific kickdown function
By means of the kickdown-button, integrated in the gear selector, it is at any time possible to
select in the speeds 2F and 2R(i.e. position 2 of the gear selector, at automatic mode also in the
2nd speed of the automatic range) the 1st speed by a short touch. This kickdown state can be
cancelled by :
1. Pressing the kickdown-button again
2. Realization of a reversal operation
3. Change of the gear selector position by the following modification
Gear selector(DW-3) - (Rotation) of the driving position 1...4.
The kickdown function will be always terminated by shifting to neutral.
(5) Clutch cut off
Especially at wheel loaders, the clutch cut off can be activated through a switch signal. It is
interrupting the power flow in the transmission as long as this signal is active. Besides, this
function can be used for the transmission-neutral shifting at applied hand brake or as emergency-
stop(In this case, a restarting is only possible through the gear selector-neutral position).
3 - 57
5. AXLE
1) OPERATION
½ The power from the engine passes through torque converter, transmission and drive shafts, and is
then sent to the front and rear axles.
½ 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
73033AX01A
1 Final drive 2 Differential 3 Axle
(2) Rear axle
73033AX01B
1 Final drive 2 Differential 3 Axle
3 - 58
2) SECTION OF FRONT AXLE DIFFERENTIAL(LIMITED SLIP)
(1) Structure
1 2 3
6 5
7803ASPT15
1 Axle shaft 4 Clutch

2 Case 5 Side gear
3 Pinion gear 6 Pinion shaft
2) Operation
No driving When driving
N F
Ramp
Pinion shaft F
7803ASPT16
When the differential case is rotated, pinion shaft is moved up on the ramp by the resistance force of
tires as the figure, and then force P is generated. This force P becomes the engaging force of clutch.
ཛ When travelling straight(equal resistance from road surface to left and right tires). Under this
condition, both clutch are engaged and the left and right side gears are driveb wutg tge sane
firce.
ཛྷ When travelling on soft ground(Resistance from road surface to right tire is smaller). At rotating
speed of right tire becomes faster than left due to the smaller resistance of right tive, right clutch
is engaged and torque of faster rotating right axle shaft is added to left axle shaft through
diffenenting gear case.
3 - 59
3) SECTION OF REAR AXLE DIFFERENTIAL(CONVENTIONAL)
2 1
76043PT19
1 Bevel pinion 3 Side gear(Differential) 5 Bevel gear

2 Shaft 4 Sun gear
3 - 60
4) DIFFERENTIAL
(1) Description 3
When the machine makes a turn, the 2 4
outside wheel must rotate faster than the
inside wheel. A differential is a device
which continuously transmits power to the
right and left wheels while allowing them
to turn a different speeds, during a turn.
The power from the drive shaft passes
through bevel pinion(1) and is transmitted
to the bevel gear(2). The bevel gear
changes the direction of the motive force
by 90 degree, and at the same time
1
reduces the speed.
It then transmits the motive force through
the differential(3) to the axle gear shaft(4). (740-3A) 3-26(1)
(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.
(740-3A) 3-26(2)
(3) When turning

Swing
When turning, the rotating speed of the
Pinion gear
left and right wheels is different, so the
Side gear Side gear
pinion gear and side gear inside the
differential assembly rotate in accordance
with the difference between the rotating
speed of the left and right wheels.
The power of the carrier is then
transmitted to the axle gear shafts. Carrier
Pinion gear Ring gear
(740-3A) 3-26(3)
3 - 61
5) TORQUE PROPORTIONING DIFFERENTIAL
(1) Function
ཛ 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
ཛ When traveling straight(Equal direction
resistance from road surface to left and
right tires)
Under this condition, the distances
involving the engaging points between
FL FR
right and left side gears and pinion-a and Engaging a b
Engaging
point point
b-are equal and the pinion is balanced as
FLÝ a=FRÝ b. Thus, FL=FR, and the
right and left side gears are driven with
Left side gear Pinion Right side gear
the same force.
(740-3A) 3-27
3 - 62
ཛྷ When traveling on soft ground
(Resistance from road surface to left and
right tires is different)
If the road resistance to the left wheel is
Spider rotating
smaller, the left side gear tends to rotate direction
forward, and this rotation changes the
engaging points between the side gears
and pinion. As a result, the distances
involving the engaging points becomes FL
Small road FR
Large road
a>b. The pinion now is balanced as FL resistance a b resistance
Ý a=FRÝ 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
(740-3A) 3-27
wheels reaches about 30%.
3 - 63
6) FINAL DRIVE(Front & rear)
7403APT03
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(2). The planetary gear rotates around the inside of a fixed ring gear(3) and in this way
transmits rotation at a reduced speed to the planetary carrier.
This power is then sent to the wheels which are installed to the planetary carriers.
3 - 64
6. TIRE AND WHEEL
1
(740-3A) 3-30
1 Wheel rim 3 O-ring 5 Side ring

2 Tire 4 Lock ring 6 Valve assembly
1) The tire acts to absorb the shock from the ground surface to the machine, and at the same time
they must rotate in contact with the ground to gain the power which drives the machine.
2) Various types of tires are available to suit the purpose. Therefore it is very important to select the
correct tires for the type of work and bucket capacity.
3 - 65
GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING
1. POWER TRAIN OPERATIONAL CHECKS

This procedure is designed so that the mechanic can make a quick check of the system using a
minimum amount of diagnostic equipment. If you need additional information, read Structure and
function, Group 1.
A location will be required which is level and has adequate space to complete the checks.
The engine and all other major components must be at operating temperature for some checks.
Locate system check in the left column and read completely, following the sequence from left to right.
Read each check completely before performing.
At the end of each check, if no problem is found(OK), that check is complete or an additional check is
needed. If problem is indicated(NOT OK), you will be given repair required and group location.
If verification is needed, you will be given next best source of information :
Chapter 2 : Troubleshooting
Group 3 : Tests and adjustments
3-66
ଖ Transmission oil must be at operating temperature for these checks.
Item Description Service action
Transmission oil warm- Start engine. Apply service OK

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

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

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

check Check completed.
Move gear selector lever to 4th
speed.
1
4
2
3
F
N
R NOT OK
Go to transmission error
Turn full automatic switch ON.
code group at page 3-25~
LOOK : Automatic sign on
Automatic sign 3-53.
display.
Repair or replace the
Move gear selector lever to display or harness.
forward or reverse position.
Increase engine rpm.
LOOK : Speed(2nd~4th) on
display must vary with machine
speed.
3-67
Transmission noise Run engine at approximately OK

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

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

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

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

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

1
4
2
3
brakes and release parking brake. Check completed.
Move gear selector lever to 3rd NOT OK
speed. If stall rpm are too low or
too high, problem may be
Move gear selector control lever
engine power or torque
to forward "F" position.
converter.
Increase engine speed to high
IF OK
idle.
Replace transmission
LOOK : Torque converter stall torque converter.
rpm must be within the following
range.
Stall rpm : 2240· 70rpm
Move gear selector control lever

to neutral "N" position and run for
15 seconds.
3-69
2. TROUBLESHOOTING
1) TRANSMISSION
ଖ 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
3-25~3-53.
3-70
Machine will not move Low oil level. Add oil.

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

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

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

low
Low transmission pressure. Do transmission system pressure test.
Restricted transmission pump Remove and clean screen.
suction screen.
Low transmission pump flow. Do transmission pump flow test.
Excessive transmission Do transmission element leakage test using
element leakage. system pressure.
Stuck PPC valve. Remove end cover to inspect modulation spool.
Restricted PPC valve orifice. Remove orifice and inspect for contamination
and /or plugging.
Restricted oil passages between Remove control valve and inspect oil passage.
control valve and transmission
elements.
Incorrect transmission oil. Change oil(SAE 10W-30/15W-40)
3-72
Transmission shifts too Wrong transmission controller. Check if transmission controller has been
fast changed
System pressure too high. Do transmission system pressure test.
Stuck PPC valve. Remove and inspect PPC valve.
Replace if necessary. Also remove end cover to
inspect PPC valve and control valve housing.
Stuck or missing check valves. Inspect transmission control valve.
Missing O-ring from end of Remove orifice and inspect port for O-ring.
modulation orifice.
Broken piston return spring. Disassemble and inspect clutch.
Incorrect transmission oil. Change oil(SAE 10W-30/15W-40)
Machine "creeps" Warped disks and plates in Check transmission.

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

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

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

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

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

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

circuit.
Failed transmission pump. Do transmission pump flow test.
Clogged filter. Inspect filter. Replace.
3-75
2) DIFFERENTIAL / AXLE
Differential low on oil External leakage. Inspect axle and differential for leaks.
Excessive differential Low oil level in differential. Check oil. Remove drain plug and inspect for
and/or axle noise metal particles in differential case.
Disassemble and determine cause.
Incorrect type of oil. Change oil
Dragging brakes. Do brake check.
Failed pinion bearing. Remove and inspect pinion.
Check to ensure pinion housing was indexed.
Incorrect gear mesh pattern Remove pinion gear housing and inspect ring
between ring and pinion gear. and pinion gear.
Failed differential pinion gears Remove differential housing drain plug and
and/or cross shafts. inspect for metal particles. Disassemble and
inspect.
Failed axle bearing. Do axle bearing adjustment check.
Mechanical failure in axle Remove differential. Inspect, repair.
planetary.
Oil seeping from outer Excessive end play in axle. Do axle bearing adjustment check.
axle seal
Worn outer bearing and/or cup. Disassemble and inspect outer axle bearing,
cup, spacer, and seal. Replace, if necessary.
Overfilled differential. Check differential oil return system for excessive
internal restriction.
Axle overheats Low differential oil. Add oil.

Overfilled differential. See differential overfills with oil in this group.
Brake drag. See brakes drag in this group.
3) DRIVE LINE
Excessive drive line Yokes not in line on drive shafts. Inspect. Align drive shaft yokes.
vibration or noise
Worn front drive line support Inspect, repair.
bearing.
Bent drive shaft. Inspect all drive shafts. Replace.
Loose yoke retaining nuts(Drive Inspect. Replace.
shafts wobble at high speed).
Rear axle oscillating support. Inspect, repair.
Lack of lubrication. Lubricate with proper grade of grease.
3-76
GROUP 3 TESTS AND ADJUSTMENTS
1. CLUTCH CUT-OFF PRESSURE SWITCH TEST

The setting pressure of the clutch cut-off
pressure switch should be suited with the
specification. The rated pressure is 25kgf/cm2.
For the detailed method for pressure
adjusting, refer to page 4-22.
BL1
Clutch cut off

pressure switch
Brake valve
7707PT12
3-77
2. TRANSMISSION MEASURING POINTS AND CONNECTIONS
The measurements have to be carried out at hot transmission(About 80~95°
C ).
48 47 21
34
65 51 68
69 49
H J
K
G
57 60
A F
B E 16
53 55 15
C D
58 56 52,63
VIEW X VIEW Y
73033TM04
1) OIL PRESSURE AND TEMPERATURE
Port Description Size
51 Converter inlet-opening pressure(9bar) H M10Ý 1

52 Converter outlet-opening pressure(3.5bar) M14Ý 1.5
53 Forward clutch(16+2bar) B M10Ý 1
55 Reverse clutch(16+2bar) E M10Ý 1
56 1st clutch(16+2bar) D M10Ý 1
57 2nd clutch(16+2bar) A M10Ý 1
58 3rd clutch(16+2bar) C M10Ý 1
60 4th clutch(16+2bar) F M10Ý 1
63 Converter outlet temperature 100°C , short-time 120°C M14Ý 1.5
65 System pressure(16+2bar) K M10Ý 1
3 - 78
2) DELIVERY RATES
15 Connection to oil cooler 1 5/16"-12UNF-2B

16 Connection from the oil cooler 1 5/16"-12UNF-2B
3) INDUCTIVE TRANSMITTER AND SPEED SENSOR
21 Inductive transmitter n turbine M18Ý 1.5

34 Speed sensor n output and speedometer -
47 Inductive transmitter n central gear train M18Ý 1.5
48 Inductive transmitter n engine M18Ý 1.5
4) CONNECTIONS
49 Plug connection on the hydraulic control unit -

68 Pilot pressure(Option) J M16Ý 1.5
69 System pressure(Option) G M16Ý 1.5
3-79
GROUP 4 DISASSEMBLY AND ASSEMBLY
1. CONTROL VALVE
1) DISASSEMBLY
(1) Illustration on the right shows the
complete control unit.
(2) Mark the installation position of the

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

Separate duct plate, 1st gasket,
intermediate plate and 2nd gasket from
the valve housing.
¡ Special tool
Box spanner 5873 042 002
(4) Remove retaining clip.
3-80
(5) Loosen socket head screws.
Separate cover from housing and cable
harness.
¡ Special tool
(6) Disassemble opposite cover.

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

fixing plate and pressure regulators(3EA).
¡ Special tool
(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
3-81
(9) Separate housing from valve housing by
loosening the adjusting screws uniformly.
¡ Special tool
(10) Remove components.
(11) Remove opposite pressure regulators,

housing as well as components
accordingly.
3-82
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.
(1) Illustration on the right shows the following

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

¡ Preload compression spring of the follow-
on slides and locate spool provisionally by
means of cylindrical pins ¤“5.0mm
(Assembly aid), see arrows.
(3) Install two adjusting screws.

Assemble gasket(Arrow 1) and housing
cover. Now, position the housing cover
uniformly, using adjusting screws, until
contact is obtained and remove cylindrical
pins(Assembly aid) again(See the next
figure).
¡ Pay attention to the different housing covers.
Install recess ¤“15mm (Arrow 2), facing the
spring of the pressure reducing valve.
3-83
(4) Fasten housing cover by means of socket
head screws.
¡⁄Torque limit : 0.56kgf¡⁄m(4.06lbf¡⁄ft)
¡ Special tool
(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
Pre assemble opposite side

(6) Illustration on the right shows the following
components.
1 Main pressure valve
2 Follow on slide
3 Vibration damper
3-84
(7) Install components according to figure (6).
Preload compression springs of the follow-
on slides and locate spool provisionally by
means of cylindrical pins ¤“5.0mm
(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 ¤“19mm(Arrow
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
(9) Introduce cable harness and connect

pressure regulators(6EA).
¡ Pay attention to the installation position of
the cable harness, ass also markings
(See figure(2), page 3-74).
3-85
(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
(11) Fix female connector by means of

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

gasket ¥ .
¡ Pay attention to the different gaskets, see
on the right figure and (15).
¡ Special tool
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).
3-86
(14) Mount intermediate plate, with the screens
showing upward.
(15) Mount gasket ¥–.
(16) Mount duct plate and fasten it uniformly by

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

and install them.
¡ The installation of the hydraulic control unit
is described, starting from page 3-135.
3-87
2. TRANSMISSION
1) DISASSEMBLY
(1) Remove filter unit
¤ Demount warning switch(Arrow) from
filter head.
¤ŁSeparate oil filter from filter head.

¡ Special tool
Belt spanner 5870 105 005
¤ØLoosen hexagon head screws and

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

duct plate from gearbox housing
¤ Loosen socket head screws, install two
adjusting screws and separate control
unit from duct plate.
¡ Special tool
Adjusting screw 5870 204 031
3-88
¤Ł Remove both gaskets as well as
intermediate plate.
¡ Special tool
¤Ø Loosen socket head screws and

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

safety valve
¤ Pull converter safety valve out of the
housing bore.
¤Ł 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
3-89
¤ØPreload compression spring carefully,
remove cylindrical pin(See on the right
figure) and demount components(See on
the below figure).
(4) Engine connection-Converter

¤ Remove lock plate and loosen hexagon
head screws.
Remove disk and pry input flange from
the shaft.
¤ŁLoosen screw connection.

¡ Mark radial installation position of the
housing cover.
3-90
¤Ø Separate cover along with converter from
the transmission, using lifting device.
¡ Special tool
Set of eye bolts 5870 204 002
¤Œ Press input shaft, respectively converter

out of the cover(Ball bearing).
¤º Squeeze circlip out and remove ball

bearing.
¡ Special tool
Set of internal pliers 5870 900 013
¤ Loosen hexagon head screws and

separate membrane from converter.
3-91
separate input shaft from the membrane.
¤ Remove inductive transmitter(n Enging).

remove converter housing.
(5) Remove transmission pump

¤ Loosen socket head screws.
3-92
¤Ł 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
¤Ø 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).
¤Œ Loosen hexagon head screws and

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

¤ Pull converter pressure valve out of the
housing bore.
3-93
¤Ł Illustration on the right shows the special
tool required for the disassembling of the
converter pressure valve.
1 Converter pressure valve
¡ Special tool
¤Ø Preload compression spring carefully,

drive roll pin out and remove
components.
¡ Special tool
¤Œ Loosen hexagon head screws, demount

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

¤ 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
3-94
¤Ł Demount speed sensor as well as both
inductive transmitters(Arrows).
¤Ø Loosen hexagon nuts and remove the

two covers(Arrows).
Loosen screw connection.
¤Œ Drive both cylindrical pins(Arrows) out.
¤º Separate housing cover carefully from

gearbox housing, using lifting device.
¡ Special tool
Lifting chain 5870 281 047
3-95
¤ 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
¡ 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.
¤ Loosen socket head screws and remove

output shaft as well as both oil baffle
plates.
3-96
¤ 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
¤ Separate housing cover along with

clutches from gearbox housing, using
lifting device.
¡ Special tool
¤ Fasten housing cover on assembly car.
¤æ Tilt housing cover 180¡£

.
Remove handles.
¡ Special tool
3-97
¤ Remove K2 clutch.
¤ Remove K1 clutch, at the same time, lift

K4 clutch.
¤ Lift K3 clutch out of the housing cover.
¤ı Remove K4 clutch, at the same time lift

input slightly.
3-98
§ Separate KV and KR clutches together
with input from the housing cover.
§æ Remove bearing outer race and pull

output shaft(Power take-off) out of the
housing bore.
§ Squeeze rectangular ring(Arrow) out and

separate ball bearing from shaft.
¡ 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.
3-99
(8) Disassemble KV and KR clutch
¡ The following figures show the
disassembly of the KV clutch.
The disassembly of the KR clutch is
analogous.
¤ Squeeze rectangular ring(Arrow) out.
¤Ł 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
¤Ø Separate plate carrier from shaft.

¡ Special tool
Hammer 5870 280 004
¤Œ Squeeze snap ring out and remove plate

pack.
3-100
¤º Preload compression spring, squeeze
circlip out and remove components.
¡ Special tool
Set of external pliers 5870 900 015
¤ Lift piston by means of compressed air

out of the cylinder bore and remove it.
¤ Remove both O-rings.
¤ Squeeze inner circlip(Shaft) out.

¡ Special tool
3-101
¤ 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
¤ Squeeze circlip out and remove ball

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

¡ The following Figures show the
disassembly of the K3 clutch.
The disassembly of the K1 and K2
clutches is analogous.
¤ Squeeze rectangular ring(Arrow) out.
3-102
¤Ł Pull tapered roller bearing from the shaft.
Remove opposite tapered roller bearing
accordingly, see Figure ¤ , ¤Ł.
¡ Special tool
(K3 on output side)
Basic set 5873 001 000
¤Ø Remove running disk, axial needle cage

and axial washer.
¤Œ Remove idler gear.
¤º Remove both needle bearings as well as

axial bearing.
3-103
¤ Squeeze snap ring out and remove plate
pack.
¤ Preload compression spring, squeeze

¡ Special tool
Assembly aid(K2 and K3) 5870 345 085
Assembly aid(K1) 5870 345 086
¤ Press piston out of the plate carrier, using

compressed air.
¤ Pry plate carrier from the shaft.

¡ Special tool
Pry bar 5870 345 065
3-104
(10) Disassemble K4 clutch
¤ 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
¤Ł Squeeze circlip out and separate plate

carrier from the shaft.
¡ Special tool
¤Ø Squeeze snap ring out and demount

plate pack.
¤Œ Preload compression spring, squeeze

Demount piston.
¡ The separation of shaft and gear is not
possible(Shrink fit).
¡ Special tool
3-105
(11) Disassemble input shaft
¤ 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.
¤ŁSqueeze 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
3-106
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.
¤ Install studs(Arrows).
¡ Insert studs with Loctite.
¤Ł Place distance tubes over the studs.
¤Ø 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.
3-107
¤Œ Locate both pressure pipes by means of
special device.
¡ Special tool
Tension bar 5870 654 030
¤º 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
.
¤º 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
¤ Equip screw plug with new O-ring and

install it.
3-108
¤ 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.
¤ 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
¤ Install studs (M8¡¿25, 27EA) according

to the figure on the right.
¤ Insert set screws(2EA) into the housing

bores(Arrows).
3-109
Assemble KV and KR clutch
The following figures describe the
assembly of the KV clutch.
Pre-assemble plate carrier(Figure ¤æ~¤ )
¤æCheck 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.
¤ Assemble piston until contact is obtained.

¡ Pay attention to the installation position,
see on the right figure.
¤ Introduce compression spring along with

spring cup(2EA).
¤ Preload compression spring and fix it by

means of circlip.
¡ Special tool
3-110
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 = 2.1~4.2mm)
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.
¤Œ Adjust plate clearance = 2.5+0.2mm.

¡ 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.
3-111
§ Mount end shim and squeeze snap
ring(e.g. s = 3.0mm) in.
§æ Press end shim on with about 10kg and

measure Dimension¥ from the end
face/plate carrier to the end shim.
Dimension ¥ e.g. 7.25mm
¡ Special tool
Digital-Depth gauge 5870 200 072
§ Press end shim against snap ring

(Upward) until contact is obtained and
determine Dimension ¥ –.
Dimension ¥–e.g. 4.75mm
¡ Special tool
EXAMPLE
Dimension ¥ 7.25mm
Dimension ¥– - 4.75mm
Difference = Plate clearance = 2.50mm
¡ In case of deviations from the required
plate clearance, correct by means of
corresponding snap ring(s = 2.1~4.2mm).
Now, remove plate pack, oil and install it
again.
3-112
§ 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.
§ Install stud(Arrow).
Use Loctite.
¡ ¡⁄Torque limit : 1.73kgf¡⁄m(12.5lbf¡⁄ft)
§ı Insert ball bearing until contact is

obtained and fix it by means of circlip.
§ Assemble needle bearing.
3-113
§ Press idler gear against shoulder.
¡ Support it on the bearing inner race.
§ł 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
§ø Assemble 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.
3-114
§œ Press tapered roller bearing against
shoulder.
Install opposite tapered roller bearing.
§ß Check function of clutch by means of

compressed air.
¡ At correctly installed components, the
closing, respectively opening of the clutch
is clearly audible.
(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.
¤ Install stud(Arrow).
¡ Use Loctite.
¤Ł Assemble plate carrier until contact is

obtained.
3-115
¤Ø Check function of the drain valve.
means of compressed air.
Insert both O-rings(Arrows) scroll free into
the piston recesses and oil them.
¤Œ Introduce piston until contact is obtained.

¤º Introduce compression spring along with

spring cup(2EA).
¤ 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
3-116
K1, K2 and K3 plate pack
¡ The K1, K2 and K3 plate stacking of
clutches are identical.
The following draft shows the installation +0.2
2.1 mm
position of the components.
1 Plate carrier 1 3 5 6
2 Piston
4 Inner plates
6 Snap ring(Optional s = 2.1~4.2mm)
7 End shim
¡ Install outer plate 3 with the uncoated
side facing the piston. 4
¡⁄Effective number of the friction surfaces 2 7
= 16.
¤ Adjust plate clearance = 2.1+0.2mm :

¡ 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.
¤ Fit end shim and squeeze snap ring(e.g.

3.0mm) in.
3-117
¤ Press end shim on with about 10kg, and
Dimension¥ e.g. 8.20mm
¡ Special tool
¤ Press end shim against snap

ring(Upward) until contact is obtained,
and determine Dimension¥–.
Dimension¥– e.g. 6.00mm
¡ Special tool
EXAMPLE :
Dimension¥– e.g. - 6.00mm
Difference = Plate clearance = 2.20mm
corresponding snap ring(S =2.1~4.2mm).
¡ Now, demount plate pack, oil and install it
again.
¤æ 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.
3-118
¤ Assemble both needle bearings.
¤ Introduce idler gear until all inner plates

are accommodated.
¤ 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.
¤ı Press tapered roller bearing against

shoulder.
3-119
§ Press tapered roller bearing against
shoulder.
§æ Check function of the clutch by means of

compressed air.
is clearly audible.
(3) Assemble K4 clutch

¤ Undercool shaft(About -80¡£ C ), heat
gear(About +120¡£ C) and assemble it until
contact is obtained.
¤Ł Locate gear axially by means of circlip.

¡ Special tool
3-120
¤Ø Install stud(Arrow).
¡ Use Loctite.
¤Œ Check function of the drain valve.

means of compressed air.
Insert both O-rings(Arrows) scroll free
into the piston recesses and oil them.
¤º Introduce piston until contact is obtained.

¤ Install compression spring and spring

cup(2EA), preload and fix by means of
circlip.
¡ Special tool
3-121
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 = 2.1~4.2mm) 7
7 End shim
¡ Install outer plate 3 with the uncoated side
facing the piston.
4
¡⁄Effective number of friction surfaces = 2
10.
¤ Adjust plate clearance = 1.2+0.2mm :

¡ 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).
¤ Fit end shim and squeeze circlip(e.g. s =

3.0mm) in.
3-122
¤ Press end shim on with about 10kg and
¡ Special tool
¤ Press end shim against snap ring

(Upward) until contact is obtained and
determine Dimension ¥–.
Dimension ¥– e.g. 6.00mm
¡ Special tool
EXAMPLE
Dimension¥– e.g. - 6.00mm
Difference = Plate clearance =1.20mm
corresponding snap ring(S = 2.1~4.2mm).
¤æ 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.
3-123
¤ Assemble both axial washers as well as
needle cage.
¡ Upper and lower axial washer have the
same thickness(50¡¿70¡¿1).
¤ Assemble both needle bearings.
¤ Assemble idler gear.
¤ı Assemble axial washer 3(50¡¿70¡¿1)

needle cage 2 and running disk 1(50¡¿70
¡¿4).
facing the needle cage.
3-124
§ Assemble pre-assembled plate carrier
until all inner plates are accommodated.
§æ Fix plate carrier axially by means of

circlip.
¡ Special tool
Handle 5870 260 010
§ Press tapered roller bearing against

shoulder.
Install opposite tapered roller bearing.
§ Check function of the clutch by means of

compressed air.
is clearly audible.
3-125
(4) Pre-assemble input shaft
¤ Undercool the input shaft(About -80¡£ C),
heat gear(About +120¡£ C) and assemble it
¤Ł Fix gear axially by means of circlip.
¤Ø Squeeze snap ring into the recess of the

turbine shaft.
¤Œ Introduce turbine shaft until the snap ring

snaps into the recess of the input shaft-
turbine shaft is axially fixed.
3-126
¤º Press both bearing inner races against
shoulder.
¤ Install ball bearing.

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

3-127
(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.
¤ 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.
¤Ł Insert KR clutch, input shaft and KV

clutch together into the housing cover.
¤ØInstall K4 clutch.
3-128
¤Œ Install K3 clutch.
¤º Position K1 clutch.
¤ Insert K2 clutch.
¤ Figure on the right shows the installation

position of the single clutches in the
housing cover.
3-129
¤ Locate all clutches by means of handles.
¡ Special tool
¤ Squeeze rectangular rings(7 pieces, see

Arrows) in and hook them in.
Now, grease rectangular rings and align
them centrically.
¤ 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
¤æInstall 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
3-130
¤ Remove handles again.
¡ Special tool
¤ Separate housing cover from gearbox

housing, using lifting device.
¡ Special tool
(6) Output
¤ Assemble sheet and press both bearing
inner races against shoulder until contact
is obtained.
¤Ł Insert bearing outer race(Arrow) into the

housing bore until contact is obtained.
3-131
¤Ø Position screening plate.
¤Œ Insert output shaft.
¤ºFasten both sheets by means of socket

head screws(4EA).
¡ Insert socket head screws with Loctite.
¤ Squeeze rectangular rings(6EA) into the

recesses of the clutch shafts and hook
them in.
Now, grease rectangular rings and align
them centrically.
3-132
¤ Insert both O-rings(Arrows) into the
annular groove of the oil pipes and
grease them.
¤ 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
¤ Install both cylindrical pins.
¤ Fasten housing cover by means of

hexagon head screws.
¡ Pay attention to the position of the fixing
plate, see Arrow.
3-133
¤æ 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
¤ 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.
¤ Fix hexagon head screws by means of

lock plate.
Install output flange on the converter side
accordingly(Figure ¤æ~¤ ).
¡ Special tool
Driver 5870 057 011
Handle 5870 260 002
(7) Converter pressure valve

¤ The illustration on the right shows the
components of the converter pressure
valve.
1 Piston
2 Compression spring
3 Valve insert
4 Roll pin
3-134
¤Ł Introduce compression spring and piston,
preload and fix them by means of roll pin.
¡ Special tool
¤Ø Insert pre-assembled converter pressure

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

¤ Install two adjusting screws(Arrows) and
mount flat gasket.
¡ Special tool
¤Ł 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.
3-135
¤Ø Install two adjusting screws and introduce
stator shaft until contact is obtained.
¡ Pay attention to the overlapping of the
bores.
¡ Special tool
¤Œ Install O-ring(Arrow) and oil it.
¤º Introduce transmission pump until contact

is obtained.
¡ Pay attention to the overlapping of the
bores.
¤ Equip socket head screws with new O-

rings(Arrow).
¡ Grease O-rings.
3-136
¤ Fasten transmission pump by means of
socket head screws.
¤ Fix oil feed housing finally by means of

hexagon head screws(Mount flat
washers).
the fixing plate(Arrow), see the next
figure.
¤ Fit flat gasket and fasten cover by means

of hexagon head screws.
3-137
(9) Engine connection-Converter
¤ Fasten converter housing by means of
¤Ł Fasten input shaft, membrane and disk

by means of hexagon head screws.
¤Ø Fasten membrane on the converter,

using hexagon head screws(Mount flat
washers).
¡ Insert hexagon head screws with Loctite.
¤Œ 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
converter has been completely
introduced.
3-138
¤º Insert ball bearing until contact is
obtained and fix it by means of circlip.
¡ Special tool
¤ 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.
¤ Fasten cover by means of hexagon head

screws and nuts on the converter
housing.
3-139
¤ Fasten input flange finally and fix
hexagon head screws by means of lock
plate.
¡ Special tool
Driver 5870 057 010
Handle 5870 260 002
(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
¤ŁAssemble components according to

figure ¤ , preload and fix by means of
cylindrical pin.
¡ Special tool
¤ØInsert converter safety valve into the

housing bore until contact is obtained.
3-140
(11) Fit duct plate
¤ Install both screw plugs(Arrows),
¡ Install new sealing rings.
¤Ł Install gasket, place duct plate against

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

¤ Install two adjusting screws.
Mount gasket 1, intermediate plate 2 and
gasket 3.
the different gaskets, see also the
following draft.
¡ Special tool
3
2
1
3-141
¤Ł Fasten complete control unit on the duct
plate, using socket head screws.
(13) Filter
components of the filter unit.
¡ Install new O-rings(Arrows)
¤Ł Fasten intermediate plate and filter head

by means of hexagon head screws
(Mount flat washers).
¤Ø Oil gasket and tighten exchange filter

hand-tight.
3-142
¤Œ If necessary, install warning switch
(According to the version).
¤º Insert O-ring(Arrow) into the annular

groove of the oil feed covers.
¤ Fasten the two covers(Arrows) by means

of hexagon nuts(Mount flat washers) on
the housing.
¤ Mount oil level tube.

Install screw plug(Arrow).
¡ Install new gaskets.
¡⁄Torque limit(Screw plug M26¡¿1.5) :
8.16kgf¡⁄m(59.0lbf¡⁄ft)
3-143
(14) Speed sensor and inductive
transmitter
¤ Grease O-ring, introduce speed
sensor(Arrow) and fasten it by means of
socket head screw.
34 Speed-output and -speedometer
¤Ł 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).
¤Ø Install gasket and cover plate, arrow 1.

Equip screw plug(Arrow 2) with new O-
ring and install it.
3-144
3. AXLE
1) BRAKES
WEAR CHECK AND REPLACEMENT OF
BRAKE DISCS
(1) Use till minimum thickness of s = 4.5mm.
(2) Loose fixing nuts and remove horizontally

the axle housing.
(3) Remove brake discs.

¡ If the brake discs must not been replaced,
remove the complete pack without
changing the position of the discs.
(4) For assembling proceed in opposite

sense, align lubrification holes.
3-145
(5) Adjustment of brake disc gap. Adjusting
bolts counterclockwise and turn them a
3/4 revolution clockwise ; This
corresponds to a gap of 0.75mm between
the brake discs.
(6) Remove brake pistons.
(7) Install O-rings and brake pistons.

¡ Observe that neither the pistons nor the
cylinders have gratches or incrostations.
(8) Tight checking with compressed air at

0.5~1bar for 10 minutes each side.
3-146
Loctite 222
Loctite 270
3.1~3.6kgf¡⁄m
(22~26lbf¡⁄ft)
Loctite 270
3-147
2) SAFETY BRAKE
(1) Introduce in the hydraulic circuit 25~35 bar
pressure, then remove the axle housing.
(2) Loose the 4 assembling stud bolts and

disassemble the intermediate covers.
(3) Disassembling of spring applied safety

brake pistons. Reassemble the
components in opposite sense.
(4) Check quote of cover.
3-148
2- 45.5
22.5
60
4
(5) Remove brake discs.
(6) For assembling align lubrification holes of

brake discs.
(7) Remove pinion and ring gear.
3-149
(8) Assemble of internal leverism.
(9) Introduce in the hydraulic circuit 25~35

bar pressure and assemble the axen.
Loctite 222
2.5~2.9kgf¡⁄m(18~21lbf¡⁄ft)
2.0kgf¡⁄m(14.7lbf¡⁄ft)
Loctite 270
3.1~3.6kgf¡⁄m(22~26lbf¡⁄ft)
Loctite 270
Loctite 222
3-150
ADJUSTMENT
(1) Introduce pressure in the hydraulic circuit
with 25~35 bar.
Remove bolt and locking plate.
(2) Turn the pinion with 0.82kgf¡⁄m(5.9lbf¡⁄ft)

torque counterclockwise till it stops. Adjust
the gap between the brake discs by
turning 3 complete revolutions clockwise.
(3) Adjust the bolts to unlock the safety brake

at 47mm and lock the counter nut.
+
-
47
m
m
3-151
DISASSEMBLY
(1) Actuate the hydraulic circuit with ƒSbar.
See following page.
ADJUSTMENT
(1) See brake disk play adjustment on page
3-146. Near the adjuster screw to the
level until the idle stroke has been
eliminated (Internal spring action).
(2) Mount the brake cylinder after

pressurizing and adjust the screw so that
the two levers rest on the end of travel
screws.
Now tighten the lock nut using loctite 242.
(3) Pressure according to the type of cylinder

and spring load curve. Curve(mm) ƒS
14bar 30bar 52bar
100
90
80
70
60
50
40
30
20
10
N 0 500 1000 1500 2000 2500 3000 3500 4000
3-152
PARKING BRAKE ADJUSTMENT OF CAT 3
AXLES WITH ADJUSTABLE MECHANICAL
STOPS.
1. Free both transmission levers from the
control wire and from further connections.
2. Apply an 0.8~1.0kgf load to the levers so
that the lever rests on the thruster disk
without deforming the lever mechanisms.
3. Once in this position, set the adjuster 0.8~1.0kgf
0.8~1.0 kgf
screws of the stops in contact with the
levers without deforming the lever
mechanisms.
4. Reconnect the control wires to the levers
once this position has been obtained.
5. Check that both transmission levers rest
against the stop screws during the brake
disengagement phase.
3-153
3) WHEEL HUB
DISASSEMBLING AND ASSEMBLING
(1) Disassembling of wheel hub.
(2) Disassembling the crown wheel

¤ Use partially threaded M18¡¿1.5 screws
to support the puller.
3-154
¤Ł Assembling of wheel hub
a. Installation of outer races of taper roller
bearings.
b. Assembling of bearing.
c. Fitting of seal.
d. Fitting of wheel studs.
3-155
¤Ø Assembling of wheel hub, seal and
center rings.
3-156
4) WHEEL HUB ONTO AXLE HOUSING
(1) Fitting the gear rim on the wheel center.
(2) M18¡¿1.5, 10K screws. Mount with loctite

270.
Clamping torque 46.9~47.4kgf¡⁄ m
(339~343lbf¡⁄ft).
3-157
(3) Torque of new bearings with seal : From
3.1~4.1kgf¡⁄m(22~30lbf¡⁄ft).
3-158
5) WHEEL CENTER VERSION WITH 10
PILOT BOLTS
(1) Demounting the wheel center version with
10 pilot bolts.
(2) Clamping torque for bolts M18¡¿1.5, 10K

46.9~47.4kgf¡⁄m(339~343lbf¡⁄ft).
Torque of new bearings with seal : From
3.1~4.1kgf¡⁄m(22~30lbf¡⁄ft).
3-159
6) PLANETARY REDUCTION 6.23
(1) Disassembly
3-160
(2) Reassembly
(3) Check the reference numbers.

Torque the screws at 32.1~32.6kgf¡⁄m
(232~236lbf¡⁄ft).
3-161
3-162
7) FINAL DRIVE 244-143
DEMOUNTING
(1) Use partially tightened screws as pullers.
(2) Lock the ring nut then remove the hub

gear.
(3) Disassembly the hub cover.

Replace the retaining ring.
ASSEMBLY
(1) Assembling the stud bolts.
3-163
(2) Dust excluder and oil ring.
(3) Mounting the bearings.
(4) Heat the gear to 140¡£

C for assembly.
3-164
(5) Tighten the ring nut at 81.6~91.8kgf¡⁄m
(590~664lbf¡⁄ft) using loctite 270.
(6) Chamfer the ring nut.
(7) Pinion assembly.
(8) Assembly with loctite 275 on the surfaces.

Take great care to clean the surfaces.
3-165
ASSEMBLY AND ADJUSTMENT
(1) Preassembly with the same shims as
those removed during disassembly, or
with 1.00mm shims.
(2) Axle shaft oil seal assembly.

¤ Check the rotation torque applied
tangentially to the wheel studs, which
must be max 14.3~20.4kgf(With ring).
To correct, add or remove shims
considering that a 0.05mm variation
cause a variation of ~2.0kgf.
¤Ł Assembly using loctite 275.

Tighten the screws with a torque wrench
23.4~23.8kgf¡⁄m(170~172lbf¡⁄ft).
AX114
3-166
Loctite 242
Loctite 242
Loctite 270
A
Loctite 242
A
Loctite 270
Loctite 270
3-167
8) REAR AXLE BEVEL PINION SUPPORT
(1) Removal of bevel pinion support.
(2) Flange input.
(3) Flanged to the reduction gear.
(4) Demounting the bearing plus thrust

plates.
3-168
(5) Assemble the external races.
Taper roller bearings.
Check cover measurement A.
(6) Determination of shim pack S1 for the

preload of the taper roller bearings S1 = B
- C + X.
X = Value to add in order to obtain the
correct preload of the taper roller bearings.
ƒS T26/P65 Flange input.

C
B
ƒS ƒS
Value X = See figure. I = 13.5mm

X = 0.09~0.11mm
270
ctite
Lo
60~80kgf¡⁄m
3-169
(7) Assembly of bevel pinion support and
seal.
(8) Fitting the dust guard on the flange.
(9) Assembly with loctite 242.
3-170
FLANGE INPUT VERSION
(1) Tighten the nut with a torque wrench.
(2) Check rotation torque : See figure

S1
I=135mm 12-13 N¡⁄cm
3-171
9) FRONT AXLE PINION SUPPORT
(1) Demounting the pinions and bearing
plates.
(2) How to establish shims S2 to position the

bevel pinion. Insert the dummy bearing
and check the difference(Photo ¤Œ) after
having zeroed the instrument on a surface
plate with a 20mm shim(Photo ¤Ø).
Measured difference corresponds to S2.
Add or remove the differential shims when
the center distances differ from
150mm(Dimension stamped on the
pinion).
Example
Center distance : 149.8
Shims = (150 -149.8) + S2
I=150 S2
Loctite 510
Loctite 242
51~71kgf¡⁄m(369~516lbf¡⁄ft)
"I" Dimension stamped at

rear of pinion
Loctite 510
3-172
(3) Establishing the pinion bearing preload
shims. See page 3-118 and figure.
C
B
Loctite 242
51~71kgf¡⁄m(369~516lbf¡⁄ft)
(4) Check the measurement(Photo ¤ ) after

having mounted the shims and thrust
plate. It must be 0.10mm~0.15mm less
than zero. This difference is annulled by
the effect of bearing interference in the
definitive assembly.
(5) Chamfer.
3-173
(6) Check the final center distance and stamp
it on the cover.
3-174
10) 276 -176 -143 AXLE ADJUSTMENT OF
BEVEL GEAR SET
(1) Determination of shim pack S2 for
adjustment of bevel pinion position : S2 =
(I + A) - (D + r).
Photo ¤Ł= D, Photo ¤ = ¤“/2 = r

Photo ¤Ø = I (Dimension stamped on the
pinion).
Photo ¤Œ = A (Dimension stamped on the

cover pinion).
A
A=28.60
¤Œ
(2) Assembly of bevel pinion support with A

shim pack S2. S2
Loctite 270
I=135
S1
4
26
r= /2 D
3-175
(3) Assembling central axle housing.
¡ Be careful not to damage the tight
surfaces of the O-rings while inserting the
differential case into the central axle
housing.
Play : 0.18~0.25
(4) Screw in the adjusting nuts to obtain

approximate 0.20~0.27mm backlash
between the teeth of the bevel gear set,
without preloading the taper roller
bearings. Check the rotating torque of
pinion and differential. Tighten nut on
opposite site to the crown wheel to obtain
a 0.05~0.07kgf¡⁄m(0.37~0.52lbf¡⁄ft) higher
rotating torque on the pinion.
(5) Mark both ring nuts. To adjust the

backlash move ring nuts only. Loosen the
one on bevel crown wheel side and
tighten the opposite one for the equal
measure if the backlash is too low ;
Viceversa if the backlash is too high.
3-176
(6) Mount locking tabs in the best position
and punch in place.
3-177
11) DIFFERENTIAL HOUSING
(1) Removal of the differential from the axle.
¡ Replace the fitting bolts of the crown wheel

every time that they have to be removed.
36.5mm 25.5mm
3-178
(2) Mounting sun wheels and planet gears.
(3) Insert the spring pins half way up the pin.
(4) Torque all bolts M12¡¿35¡¿1.25-10K and

M12¡¿30¡¿1.25-10K with a torque
wrench bolts clamping torque
13.8~14.1kgf¡⁄m(100~102lbf¡⁄ft).
Use loctite 270.
3-179
REAR
Loctite 270
Loctite 222
Loctite 270
Loctite 222
FRONT
Loctite 222
Loctite 242
Loctite 270
Loctite 222
Loctite 242
3-180
12) CENTRAL PART OF FRONT AXLE
DISASSEMBLY
(1) Demount the intermediate cover on the
opposite side to the gear rim and insert
tool.
(2) Slacken the screws. Insert tool and pull

out the differential housing. Remove the
gear rim from the pinion bearing side.
T24
P64
ASSEMBLY
(1) Center the gear rim on tool.
3-181
(2) Insert the differential housing with tool and
torque the screws.
(3) Take care to prevent damage to the brake

retention zones when assembling the
parts.
(4) Mount the intermediate cover on the gear

rim side using tools. Fit on the other
intermediate cover.
3-182
Loctite 222
Loctite 270
Loctite 510 Loctite 270
Loctite 222
3-183
SECTION 4 BRAKE SYSTEM

Group 4 Disassembly and assembly 4-33
SECTION 4 BRAKE SYSTEM
1. OUTLINE
ଖ 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:
½ Brake pump
½ Parking brake solenoid valve in cut off valve.
½ Cut-off valve
½ Brake valve
½ Accumulators
½ Pressure switches
4-1
FULL POWER HYDRAULIC BRAKE
SYSTEM
ADVANTAGES - The full power hydraulic Response time
brake system has several advantages over Full power brake actuation VS
Air/Hydraulic brake actuation
traditional brake actuation systems. These
systems are capable of supplying fluid to a 1000
range of very small and large volume
service brakes with actuation that is faster 900
than air brake systems. Figure represents 800
a time comparison between a typical Brake pressure
700 (Full power)
air/hydraulic and full power hydraulic brake
Brake torque(lb½ in)

actuation system. 600
Brake pressure
Full power systems can supply significantly 500 (Air/hydraulic)
higher brake pressures with relatively low Brake torque
400
reactive pedal forces. The reactive pedal (Air/hydraulic)
force felt by the operator will be proportional 300
Brake torque
to the brake line pressure being generated. 200 (Full power)
This is referred to as brake pressure
modulation. 100
Another key design feature of full power
0 1 2 3 4
systems is the ability to control maximum
brake line pressure. In addition, because Time(Seconds)
these systems operate with hydraulic oil,
filtration can be utilized to provide long
component life and low maintenance
operation.
Because these systems are closed center,
by using a properly sized accumulator,
emergency power-off braking that is
identical to power-on braking can be
achieved. These systems can be either
dedicated, where the brake system pump
supplies only the demands of the brake
system or non-dedicated, where the pump
supplies the demands of the brake system
as well as some secondary down stream
hydraulic devise.
Another important note is that all seals
within these system must be compatible
with the fluid medium being used.
4-2
2. HYDRAULIC CIRCUIT
FRONT
39 REAR
17
20
BL1 BR1 BL2 BR2
8
T1 P1 T2 P2
15 15
7 A1 A2
18
PS
P1
T1
A3
16
B
PS1
19 MCV
P T
Parking Return line
brake solenoid 21
Steering system RCV lever
Fan drive motor
2 1
24
Return
line
25
26 27
7407BS01
1 Main pump 17 Pressure switch 24 Air breather

2 Brake & fan pump 18 Pressure switch 25 Hydraulic tank
7 Cut off valve 19 Pressure switch 26 Return filter
8 Brake valve 20 Pressure switch 27 Bypass valve
15 Accumulator 21 Line filter 39 Axle
16 Accumulator
4-3
1) SERVICE BRAKE RELEASED
FRONT
39 REAR
17
20
BL1 BR1 BL2 BR2
8
T1 P1 T2 P2
15 15
7 A1 A2
18
PS
P1
T1
A3
16
B
PS1
19 MCV
P T
Return line
21
Fan drive motor
2 1
24 Return
line
25
26 27
7407BS02
When the pedal of brake valve(8) is released, the operating force is eliminated by the force of the
spring, and the spool is returned.
When the spool removes up, the drain port is opened and the hydraulic oil in the piston of axles
return to the tank(25).
Therefore, the service brake is kept released.
4-4
2) SERVICE BRAKE OPERATED
FRONT
39 REAR
17
20
BL1 BR1 BL2 BR2
8
T1 P1 T2 P2
15 15
7 A1 A2
18
PS
P1
T1
A3
16
B
PS1
19 MCV
P T
Return line
21
Fan drive motor
2 1
24 Return
line
25
26 27
7407BS03
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
17
20
BL1 BR1 BL2 BR2
8
T1 P1 T2 P2
15 15
B
A
7 A1 A2
18
PS
P1
T1 Parking brake switch

A3
16
B
PS1
19
MCV
P T
Parking Return line
brake solenoid 21
Fan drive motor
2 1
24 Return
line
25
26 27
7407BS04
When the parking brake switch is pressed B position, the solenoid valve is energized and the
hydraulic oil enters the front axle. It overcomes the force of the spring and pushes the piston rod.
This releases the brake.
Therefore, the hydraulic oil pressure is applied to the parking brake piston in front axle through the
solenoid valve and the parking brake is kept released.
4-6
4) PARKING BRAKE OPERATED
FRONT
39 REAR
17
20
BL1 BR1 BL2 BR2
8
T1 P1 T2 P2
15 15
B
A
7 A1 A2
18
PS
P1
T1 Parking brake switch

A3
16
B
PS1
19 MCV
P T
Parking Return line
brake solenoid 21
Fan drive motor
2 1
24 Return
line
25
26 27
7407BS05
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 return to the tank through the solenoid valve. When the piston
rod is returned by the force of the spring, the parking brake is applied.
4-7
3. BRAKE PUMP(+FAN PUMP)
1) STRUCTURE
17 Brake pump
16
2
3 11
13
14 15
23 18
22 19
21 18
7
18
1716 3 10
3
A 9 A
12
14
15 18
20
6
1 5
8
Fan pump 4
7707BS19
1 Body 9 Driven gear 17 Backing ring

2 Body 10 Driver gear 18 Body O-ring
3 Dowel pin 11 Driven gear 19 Intermediate plate
4 Front cover 12 Bushing 20 Coupling
5 Shaft seal 13 Bushing 21 Rear cover
6 Bushing 14 Bushing seal 22 Spring washer
7 Bushing 15 Backing ring 23 Screw
8 Driver gear 16 Bushing seal
This gear pump have a maximum delivery pressure of 150kgf/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 right shows the
operational principle of an external gear
pump in which two gears are rotating in
mesh.
The oil entering through the suction port is Suction Discharge
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.
scha
Di
The drawing at right shows how the
leaked oil flows in the pump. As such,
there is always oil leakage in the pump
from the discharge side(under higher
pressure) to the suction side. The
n
delivery of the pump is reduced by an ctio
Su
amount equal to the pump discharge.
In addition, the delivery of the pump will
also decrease as the amount of oil
leakage increases because of expanded
radial clearance resulting from the wear of
pump parts, the lower oil viscosity
resulting from increases in the oil
temperature, and the initial use of low
(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,
thus allowing the gear teeth and the case Pressure distribution
to come into light contact.
For this reason, an excessive increase in
the delivery pressure must be avoided,
since it will produce a large force which
will act on the gears, placing an overload
on the bearings, and resulting in a
shortened service life of the bearing or
(770-3ATM) 4-11
interference of the gear with the case.
4-11
4. BRAKE VALVE
1) STRUCTURE
18
17-2 17-3,17-4
17-1
19
23 22
24
21
2
20 8,32,33
9
25
30
25
16 14
15 7
5 13
31
12 6
1,27,28,29 10
26
4
11
3
7707BS21
1 Lower body 13 Spring guide 22 Stop ring

2 Upper body 14 Stop ring 23 Hexagon bolt
3 Spool 15 Bushing 24 Hexagon nut
4 Plug 16 Pedal plate 25 Bolt
5 Holder 17-1 Pedal 26 Spring washer
6 Lower spring 17-2 Lock plate 27 Plastic plug
7 Upper spring 17-3 Hexagon bolt 28 Name plate
8 Main spring 1 17-4 Plain washer 29 Screw
9 Spring retainer 1 18 Rubber 30 Plain washer
10 O-ring 19 Cover 31 Stop ring
11 O-ring 20 Lock pin 1 32 Spring retainer 2
12 Oil seal 21 Torsion spring 1 33 Main spring 2
4-12
2) OPERATION
BL1 BR1 BL2 BR2
T1 P1 T2 P2
Hydraulic circuit
Porte Port name Port size
T1 P1, P2 Port PF3/8

BL1
T1, T2 Drain port PF3/8
P1
BR1, BR2 Brake cylinder port PF3/8
BR1
BL1 Pressure switch port PF1/4
T2 BL2 Pressure switch port M12Ý 1.5
BL2
P2
BR2
7707BS22
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) Ready position
When the braking system is ready for operation, its accumulator pressure acts directly on ports
(P1, P2) of the brake valve. A connection is established between ports(BR1, BR2) and ports(T1,
T2) so that the wheel brakes ports(BR1, BR2) are pressureless via the returns ports(T1, T2).
(3) Partial braking
When the brake valve is actuated, an amount of hydraulic pressure is output as a ratio of the foot
force applied.
The spring assembly(8) beneath base plate(16) is designed in such a way that the braking
pressure changes depending on the angle. In the lower braking pressure range, the machine
can be slowed sensitively.
When the braking process is commenced, the upper spool is mechanically actuated via spring
assembly(8), and the lower spool is actuated hydraulically by spool. As spools(3) move
downward, they will first close returns(T1, T2) via the control edges, thus establishing a
connection between accumulator ports(P1, P2) and ports(BR1, BA2) for the wheel brake
cylinders. The foot force applied now determines the output braking pressure. The control
spools(3) are held in the control position by the force applied(Spring assembly above the spools
and the hydraulic pressure below the spool(Balance of forces).
After output of the braking pressure, spools(3) are in a partial braking position, causing ports(P1,
P2) and ports(T1, T2) to close and holding the pressure in ports(BR1, BR2).
(4) Full braking position
When pedal is fully actuated, end position of the brakes is reached and a connection established
between accumulator ports(P1, P2) and brake cylinder ports(BR1, BR2). Returns(T1, T2) are
closed at this point.
When the braking process is ended, a connection is once again established between brake
cylinder ports(BR1, BR2) and return ports(T1, T2), closing accumulator ports(P1, P2).
The arrangement of spools in the valve ensures that even if one braking circuit fails the other
remains fully operational. This is achieved by means of the mechanical actuation of both spools
and requires slightly more pedal travel.
(5) Limiting the braking pressure
Pedal restriction bolt(23) on base plate below pedal is used to limit the braking pressure.
(6) Failure of a circuit
In the event of the lower circuit failing, the upper circuit will remain operational. Spring assembly
(8) will mechanically actuate spool(28). In the event of the upper circuit failing, the lower circuit
will remain operational since the lower spool(31) is mechanically actuated by spring assembly(21)
and spool(28).
(7) Installation requirements
Return lines(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
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.
ଖ When doing repair work, make sure your environment is very clean.
Immediately close all open ports on the components and on pipes using plugs.
(10) Replacing the pedal cover
Pedal cover(18) is simply pulled of by hand. The new pedal cover is pushed over pedal(17) and
tightened manually. Fasten the bellows with the strap retainers.
(11) Replacing the complete actuating mechanism
Carefully clamp the unit vertically in a fixture. The actuating mechanism can be removed by
taking out the four bolts. Make sure that spring assembly(8) does not fall out. When installing the
new actuating mechanism, make sure that spring assembly(8) is fitted in the right order. Tighten
the four bolts(25).
(12) Replacing the bellows
To change bellows(19) it is advisable to remove pedal(17). For this purpose, loosen retaining ring
(22) and knock out pin(20) using a mandrill. When knocking out the bolt, make sure that the
mandrill is applied to the side of the bolt without a knurl. Remove pedal(17) and bellows(19).
Now fit the new bellows and proceed in reverse order as described above. The upper portion of
bellows is fastened to piston(5), its lower portion to base plate(1) secure the bellows using
clamps.
4-15
5. CUT-OFF VALVE
1) STRUCTURE
3 4
5 C B
D D
P1
T
T1
PS
P PS1 A A
C B
SECTION A - A SECTION B - B
1 2
A1 A2
PS
P1
A3
A3 T1
A1
PS1
A2
B
P T
SECTION C - C SECTION D - D HYDRAULIC CIRCUIT
7407BS11
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 or A2 port.
As the pressure on P line rises to 150bar, the cut off valve(1) starts cut-offing and the oil in the P
port is unloaded. The pressure on P line goes down 120bar by the minute leakage from valve and
other factors.
At this pressure, the cut-off valve starts cut-ining.
This process is repeated in the regular period of 30~40 seconds.
4-16
6. BRAKE ACCUMULATOR
1) STRUCTURE
81L1-0004 31EC-02190
Item
(Item15) (Item16)
Diameter 121mm 136mm
Mounting height 146mm 160mm
Norminal volume 0.75˜ 1.0˜
Priming pressure 50kgf/cm2 50kgf/cm2
Operating medium Oil Oil
B
Operating pressure Max 210kgf/cm 2
Max 200kgf/cm2
Thread M18Ý 1.5 M18Ý 1.5
A
C Priming gas Nitrogen Nitrogen
A Fluid portion C Diaphragm

D B Gas portion D Valve disk
(770-3ATM) 4-22
2) OPERATION
(1) Purpose
Fluids are practically incompressible and are thus incapable of accumulating pressure energy. In
hydropneumatic accumulators, the compressibility of a gas is utilized to accumulate fluid. The
compressible medium used in the accumulators is nitrogen.
In braking systems, the purpose of the accumulators is to store the energy supplied by the
hydraulic pump. They are also used as an energy reserve when the pump is not working, as a
compensator for any losses through leakage, and as oscillation dampers.
(2) Operation
The accumulator consists of a fluid portion (A) and a gas portion (B) with a diaphragm (C) as a
gas-tight dividing element. The fluid portion (A) is connected to the hydraulic circuit, causing the
diaphragm accumulator to be filled and the gas volume to be compressed as the pressure rises.
When the pressure falls, the compressed gas volume will expand, thus displacing the
accumulated pressure fluid into the circuit.
The diaphragm bottom contains a valve disk (D) which, if the diaphragm accumulator is
completely empty, closes the hydraulic outlet, thus preventing damage to the diaphragm.
The accumulators can be fitted in the hydraulic circuit, directly on a component or in blocks on
suitable consoles.
They should be fitted in as cool a location as possible.
Installation can be in any position.
4-17
(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.
ଖ Wear safety goggles when doing this job.
(6) Performance testing and checking of the accumulator
The accumulator is gradually pressurized via the test pump; until the initial gas pressure is
reached, the hydraulic pressure in the accumulator will rise abruptly. This is apparent from gauge
M. If the initial gas pressure is more than 30% below the prescribed value, the accumulator
needs to be replaced. If the measuring process needs to be repeated, wait for intervals of 3
minutes between the individual tests. Any accumulator whose initial gas pressure is insufficient
must be scrapped following the instructions under Disposal of the accumulator.
The amount of initial gas pressure can also be checked from the vehicle. Start the vehicle's
engine. The pump will now supply oil to the accumulators. Until the initial gas pressure is
reached, the hydraulic pressure in the accumulator will rise abruptly. This is apparent from the
gauge in the cab. If the initial gas pressure is more than 30% below the prescribed value, that
initial pressure lies outside the permissible range for at least one of the accumulators fitted in the
vehicle. This accumulator can be traced only by using the method described above, i.e. all
accumulators have to be individually tested. The accumulator whose initial gas pressure is
insufficient must be replaced and scrapped following the instruction under Disposal of the
accumulator.
Accumulator M
Safety valve
A
(770-3ATM) 4-23
4-18
(7) Repair work
pressure in the system. Even when the engine in switched off there will be some residual
For safety reasons the accumulators need to be replaced as a whole if damaged.
4-19
7. PRESSURE SWITCHES
1) STRUCTURE
½ Normally closed
H1
½ Normally open
H2
(770-3ATM) 4-25
½ Technical data
H1 H2 Adjusting range Adjusting pressure Voltage

Item Type Medium G
mm mm kgf/cm2 kgf/cm2 V
Parking NC Oil M12Ý 1.5 55 9 10 ~ 20 13 · 1 Max 42

Charging NC Oil M12Ý 1.5 55 9 50 ~ 150 100 · 10 Max 42
Brake stop NO Oil M12Ý 1.5 55 9 1 ~ 10 5· 1 Max 42
Clutch cut-off NO Oil PF 1/4" 55 9 20 ~ 50 24 · 2 Max 42
NC : Normally closed NO : Normally open
4-20
2) OPERATION
(1) Purpose
The pressure switches are used to visually or audibly warn the driver of the pressure within the
system.
(2) Make contact / circuit closer
The pressure switch can be fitted in the braking system or directly on one of its components.
The system pressure acts on an absorption area within the switch, making an electrical contact as
the pressure on that area is increased. The resulting current is used to activate a warning facility,
for instance.
(3) Break contact / circuit breaker
The pressure switch can be fitted in the braking system or directly on one of its components.
The system pressure acts on a absorption area within the switch, breaking an electrical contact
as the pressure on that area is increased. The current is now broken, e.g. to deactivate a
warning facility.
No special measures need to be taken.
(5) Maintenance of the pressure switch
When using high-pressure cleaners on the vehicle, please make sure that the water jet is not
directed at the pressure switch(Corrosion of contacts).
(6) Repair work
pressure in the system. Even when the engine is switched off there will be some residual
ଖ For safety reasons the pressure switch needs to be replaced as a whole if damaged.
4-21
(7) Adjusting and testing pressure switch
The adjusting screw located between the two contact plugs can be set to the desired value within
a certain range. For adjusting range, please refer to the table Technical data on the previous
page.
After making the adjustment, the adjusting screw should be secured using wax or a similar
material.
(-)
(+) Screw
(770-3ATM) 4-25
4-22
1. OPERATIONAL CHECKS
This procedure is designed so the mechanic can make a quick check of the system using a minimum
amount of diagnostic equipment. If you need additional information, read structure and function,
Group 1.
If verification is needed, you will be given next best source of information:
4-23
ଖHydraulic oil must be at operating temperature for these checks(Refer to page 6-50).
Parking brake capacity Start engine. OK

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

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

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

Service brake capacity Check completed.
Apply service brakes, release
check
park brake and put transmission NOT OK
Engine running. Check brake pressure in
in 2nd forward.
group 3.
Increase engine speed to high
idle. IF OK
Inspect brake disk, see
LOOK : Machine may not move group 3.
or move at a very slow speed.
Repeat check three times to
ensure accurate results.
4-25
Brake accumulator Start and run engine for 30 OK
precharge check seconds. Check completed.
ଖ The axles and
Stop engine and turn start switch NOT OK
hydraulic oil must be at
to ON and wait 5 seconds. Make sure brake pedal is
operating temperature
not binding and keeping
for this check. NOTE : Engine oil pressure lamp
brakes partially engaged.
will be on due to no engine oil
pressure. Bleed brakes in group 3.
Count the number of times the Check brake system
brake pedal can be fully depressed pressure in group 3.
before the low brake pressure
NOT OK
warning lamp comes ON.
If light comes on with
LOOK : Warning lamp must come engine running,
on in 1-5 applications. accumulator has lost it's
charge. Inspect and
Start engine and operate at low
recharge accumulator,
idle.
group 3.
Observe cluster while applying
brake pedal with maximum force.
LOOK/LISTEN : Brake pressure
indicator must not come ON.
Brake system leakage ON Start engine and wait 30 seconds. OK

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

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

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

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

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

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

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

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

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

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

performance (11¶20') gradient 7407BS06
2) MEASURING PROCEDURE
(1) Start the engine and drive the machine
straight up a 1/5 gradient with the bucket
unloaded.
(2) Depress the service brake, place the gear
selector lever in neutral, then stop the
engine.
(3) Turn the parking brake switch ON, then 20%
slowly release the service brake pedal 11 20' gradient
and the machine must be kept stopped.
ଖ The measurement must be made with the
machine facing either up or down the
slope. 7407BS07
2. EXTERNAL BRAKE INSPECTION

Remove axle housing and inspect for wear of
brake disks.
Replace brake disks if oil grooves of facing
material are no longer visible.
7407BS08
4-31
3. HYDRAULIC BRAKE BLEEDING PROCEDURE
Escaping fluid under pressure can
penetrate the skin causing serious injury.
Avoid the hazard by relieving pressure
before disconnecting hydraulic or other
lines. Tighten all connections before
B
applying pressure.
Search for leaks with a piece of
cardboard. Protect hands and body from
high pressure fluids.
ଖ If an accident occurs, see a doctor
immediately. Any fluid injected into the
skin must be surgically removed within a
few hours or gangrene may result.
Doctors unfamiliar with this type of injury
should reference a knowledgeable
medical source.
Two people are required to bleed brake
system oil, one to operate brake valve and
other to open and close bleed screws.
A
1) Install frame locking bar. Engage parking
brake.
2) Put a clear plastic tube on bleed screw(B)
to route low to hydraulic reservoir filler tube
or container(A).
3) Start engine and run at low idle.
4) Push and hold brake pedal down until
brake bleeding procedure is complete.
ଖ If bubbles continue for more than 2
minutes, stop bleeding procedure.
Check for and correct problem, then
continue. Safety lock bar
5) Open on bleed screw on differential and

axle assembly until hydraulic oil starts to
flow. Close bleed screw when oil is free of
air. Release brake pedal.
6) Repeat steps 1-5 for each bleed screw.
7) Push either brake pedal and hold down.
8) Check hydraulic oil level. 7407BS09
4-32
1. BRAKE PUMP
1) STRUCTURE
17 Brake pump
16
2
3 11
13
14 15
23 18
22 19
21 18
7
18
1716 3 10
3
A 9 A
12
14
15 18
20
6
1 5
8
Fan pump 4
7707BS19
1 Body 9 Driven gear 17 Backing ring

2 Body 10 Driver gear 18 Body O-ring
3 Dowel pin 11 Driven gear 19 Intermediate plate
4 Front cover 12 Bushing 20 Coupling
5 Shaft seal 13 Bushing 21 Rear cover
6 Bushing 14 Bushing seal 22 Spring washer
7 Bushing 15 Backing ring 23 Screw
8 Driver gear 16 Bushing seal
4-33
2) DISASSEMBLY
17
16
2
3 11
13
14 15
23 18
22 19
21 18
7
18
1716 3 10
3
A 9 A
12
14
15 18
20
6
1 5
8
4
7707BS25
ଖ Before disassembling ensure that the unit itself, bench and tools are thoroughly clean.
(1) Lightly mark the rear cover(21), body(2) and plate(19) to ensure reassembly in the correct
position.
(2) Remove the bolts(23) and separate the brake pump unit from the fan pump using a soft faced
hammer.
(3) Remove splined coupling(20).
(4) Remove the plate(19) from the body(2), free from plate using a soft faced hammer.
(5) Remove the backing ring(15), the seal element(14) and the body O-ring(18).
(6) Remove the rear cover(21) from the body(2).
(7) Remove the backing ring(17), the seal element(16) and the body O-ring(18).
ଖ Before removing the internal components each bushing(7, 13) must be marked to denote its
location within the body. On the plain area of the bush away from the seal location, lightly mark.
(8) With the unit laying on its side grasp hold of the drive shaft(10) and pull it squarely out of the
body(2) bringing the bushing(13) with it.
(9) Remove the driven gear(11) and the remaining bushing(7).
4-34
3) INSPECTION AND REPAIR
(1) Assessment
Each components should be thoroughly cleaned, carefully examined and assessed for suitability
re-use. Below is a guide for inspecting the various components.
(2) Body
ཛ Inspect the body bore cut-in where both gears wipe into the body.
ཛྷ The body can only be re-used if the cut-in is bright and polished in appearance and the depth
does not exceed 0.15mm(0.006").
ཝ The body should be replaced if the surface is scored, has a matt appearance or shows signs that
the tip of the gears have dug in and torn away the surface material.
ཞ The body should be inspected to ensure that there is no superficial damage which may adversely
effect performance or sealing. Pay particular attention to the port threads and body O-ring seal
recesses.
(3) Plate and cover
ཛ The inner surfaces should be inspected to ensure that there is no unusual wear or scoring in the
regions where the body O-rings and backing rings contact, which result in external leakage.
ཛྷ Check the shaft seal recess for scoring or damage that could result in oil leakage around the
outer diameter of the shaft seal. Replacement shaft seals can be refitted with Loctite hydraulic
sealant to overcome slight damage in this area.
(4) Bushes
ཛ The side faces which abut the gears should be perfectly flat showing no sign of scoring.
Characteristically there are bright polished areas on this surface caused by loading against the
gear side faces, which is often more pronounced on the low pressure side. The bush should be
replaced if there is any general scoring or fine scoring with a matt appearance or tearing of the
surface material. Often there is a witness where the tips of the opposing gears have wiped an
overlap reassembling a half moon shape. There must be no noticeable wear step as it is critical
that the bush side face is completely flat to the gear side face.
ཛྷ The bearing liners are acceptable providing that they are not scored or show other damage. The
general outside area of the bush should not show any prominent signs of wear.
(5) Gears
ཛ The gear side faces should be examined for bruising or scoring. Often operation on
contaminated fluid shows scoring between the root of the gear and the journal undercut, which
leaves a wear step. If a wear step can be felt, coincidental with the root diameter, by drawing a
sharp pointed tool across the surface from the undercut outwards towards the tip of the gear,
then the gear is unserviceable.
ཛྷ The gear teeth should then be carefully examined to ensure that there are no signs of bruising or pitting.
ཝ The journal bearing surfaces should be completely free from scoring or bruising. The surface
should appear highly polished and smooth to touch.
ཞ Examine the area where the shaft seal lips run on the drive shaft, this shows up as a polished
ring or rings. If a noticeable groove can be felt or there is scoring the shaft should be replaced.
ཟ Provided the drive shaft is not damaged from the drive-coupling and the gears have not been
harmed as described above, then the gears can be re-used. If, however, the gears are
damaged they must be replaced as a matched pair.
འ As a matter of good practice, when pumps have been disassembled, all the seals should be
replaced. It is most important that only the genuine seals are used.
4-35
4) ASSEMBLY
17
16
2
3 11
13
14 15
23 18
22 19
21 18
7
18
1716 3 10
3
A 9 A
12
14
15 18
20
6
1 5
8
4
7707BS25
ଖ Ensure that all parts are perfectly clean and lightly lubricate the bushes and gears with hydraulic
oil(Ensure body O-ring recess and end faces remain free from oil). This will assist with their
assembly when they are later fitted into the body.
(1) Refit the bushing(7) into the undowelled end of the body(2) from where they were removed.
(2) Place the rear cover(21) against the body(2) and then stand the assembly on the cover so that
the hollow dowels are uppermost, i.e. the bushing should be at the bottom with the bushings
against the cover.
(3) Fit the drive shaft(10) and driven gear(11) back into their original positions in the body(2).
(4) Refit the plate bushing(13) into their original bores.
(5) Fit the new body O-ring(18).
(6) Fit the new seal element(14) and backing ring(15) to the bushing.
(7) Carefully refit the plate(19) to the body(2). If the plate(19) is not fitted squarely the backup
seal(14) may become misplaced and trapped, resulting in internal damage if the unit is run in this
condition.
4-36
ASSEMBLY
17
16
2
3 11
13
14 15
23 18
22 19
21 18
7
18
1716 3 10
3
A 9 A
12
14
15 18
20
6
1 5
8
4
7707BS25
(8) Fit coupling(20) to the plate(19).

(9) Holding the whole unit together carefully turn it over, making sure it is supported on the spacer
plate(19) not the shaft.
(10) Slide off the rear over and fit seals as in(5) and (6) above.
(11) Fit the rear cover(21), taking care not to dislodge the backup seal(16) and bolt(23) the unit
together.
½ Tightening torque : 4.8kgf½ m(35lbf½ ft)
ଖ Pour a small amount of oil into a port and check that the shaft can be rotated without undue force
using a smooth jawed hand wrench hooked around the shaft or a suitable half coupling locked
against the key.
4-37
5) RUNNING-IN
Pressure gauge
Test unit Variable

Microbic restrictor
filter
Flow
meter
Relief valve
Strainer
Tank
(730TM-3C) 4-48
(1) A unit which has been re-assembled with either new gears, bushes or body, must be carefully
run-in before it is subjected to full working conditions.
(2) Ideally this should be done on a test rig(See figure) where pressure can be gradually applied and
any wipings from the body cut-in arrested by filters.
(3) It is recommended that the unit is run-in at 1500rpm, initially, at zero pressure for one minute then
in stages with the pressure increased by 500psi every minute, until maximum rated pressure has
been attained. Frequently check the system temperature, ensuring that it does not exceed the
maximum permissible figure of 80¶C. If the temperature exceeds the system or unit specification
the test must be delayed and operated off-load until acceptable temperatures are obtained.
4-38
SECTION 5 STEERING SYSTEM

SECTION 5 STEERING SYSTEM
1. OUTLINE
The steering system of this machine consists of a fixed-displacement pump supplying a load sensing
steering system and an open center loader system.
The components of the steering system are :
½ Steering pump(1st pump)
½ Steering unit
½ Overload valve block
½ Priority valve
½ 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
steering cylinders to articulate the machine.
When the machine is not being steered, or if pump flow is greater than steering flow, the priority
valve supplies flow to the loader system.
That is, output flow from the steering pump enters into the first pump of main pump for the operation
of the attachment.
5-1
2. HYDRAULIC CIRCUIT
LH RH
5
L
P 21MPa
LS
Brake system 31 34
MCV
CF EF A 1st pump
Return line B 2nd pump
6
LS
P
RCV lever
Fan drive motor
2 B A 1
31
32 24
30 CF EF Return
line
LS
25
P
29 33 26 27
Parking brake solenoid
7407SE01
1 Main pump 24 Air breather 30 Priority valve(option)

2 Brake & fan pump 25 Hydraulic tank 31 Check valve(option)
5 Steering unit 26 Return filter 32 Check valve(option)
6 Priority valve 27 By pass valve 33 Pressure switch(option)
9 Steering cylinder 29 Emergency pump kit(option) 34 Pressure switch(option)
5-2
1) NEUTRAL
LH RH
5
L
P 21MPa
LS
MCV
CF EF
6
D LS
P
RCV lever
Brake system Fan drive motor
2 1
Return line
24 Return
line
25
26 27
7407SE02
The steering wheel is not being operated so control spool(G) does not move.
The oil from the steering pump enters port P of the priority valve and the inlet pressure oil moves the
spool(D) to the right.
Oil flow into LS port to the hydraulic tank(25) through orifice and return filter.
So, the pump flow is routed to the loader system(Main control valve) through the EF port.
5-3
2) LEFT TURN
LH RH
5
L
P 21MPa
LS
MCV
CF EF
6
D LS
P
RCV lever
2 1
Return line
24 Return
line
25
26 27
7407SE03
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(9).
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
LH RH
5
L
E
R
P 21MPa
LS
MCV
CF EF
6
D LS
P
RCV lever
2 1
Return line
24 Return
line
25
26 27
7407SE04
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 workport to the
respective chamber of the steering cylinders(9).
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
21 2 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
7407SE05
1 Dust seal ring 11 O-ring 21 Complete relief valve without seat

2 Housing, spool, sleeve 12 Intermediate plate 31 Set of o-rings
3 Ball 13 O-ring 33 Rolled pin
4 Thread bushing 14 Distributor plate 34 Screw
5 Roto glyd ring 15 Gearwheel set 35 Shock valve
6 Bearing assembly 16 End cover 36 Spring
7 Ring 17 Washer 37 O-ring
8 Cross pin 18 Screw with pin 38 Plug
9 Set of spring 19 Screw 39 Housing, check valve
10 Cardan shaft
5-6
2) OPERATION
9 10
2 39
A A
14
15
16
SECTION A - A
7407SE06
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 is connected directly to the drive shaft(10) of steering wheel. It is connected to sleeve by cross
pin(8) (not in contact with the spool when the steering wheel is at neutral) and neutral position spring(9).
Cardan shaft(10) is meshed at the top with cross pin(8) and forms one unit with sleeve.
At the same time, it is meshed with gear rim 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.
5-7
4. PRIORITY VALVE
1) STRUCTURE
1 2 4 3 9 5 2 6
7405S 5-6
1 Plug 4 Housing 8 Drive screw

2 O-ring 5 Spring 9 Orifice
3 Spool 6 Plug
5-8
2) OPERATION
(1) Neutral
9
CF 3 9 5
CF EF
LS
LS
P EF LOADER ACTUATED(D)
7405S 5-7
The priority valve is a pressure control valve that maintains priority pressure to the closed center
steering valve. With the steering valve 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(3) is pushed to the left(Viewed from sectional drawing at previous page)
by the spring(5). The passage to the EF port is blocked while the passage to the CF port is open.
When the machine is first started, all pump flow is routed to the steering valve 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(3) to shift to the right against the spring and open the EF port.
As long as the steering valve is in neutral, just enough pressure is maintained at the steering valve 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(9) and into the LS port.
It flows through the steering valve LS passage which is routed to return when the steering valve is in
neutral. This provides a warm-up circuit for the steering valve to prevent binding of the steering valve
due to oil temperature extremes.
5-9
(2) Midturn
9
CF 3 9 5
CF EF
LS
LS
P EF FULL STEER RATED(D)
7405S 5-8
When the machine is steered, load sensing pressure from the steering valve flows through the orifices
LS port in the priority valve. Load sensing pressure plus spring(5) force move the spool(3) 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 valve.
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 valve. 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 valve. 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
valve. Some flow is also supplied from the CF port through orifice(9) in the priority valve spool.
5-10
(3) Full turn
9
CF 3 9 5
CF EF
LS
LS
P EF
7405S 5-9
When the machine is steered to a full turn, the frames bottom against the steering stops.
Pressure to the steering valve(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.
5-11
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 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 Spring washer
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
2) OPERATION
This machine use to cross connected cylinder for steering operation.
The steering cylinder use a gland(3) to remove piston and sealed seals. Dust wiper(8) located on
the in side of the gland protects cylinder inner parts from dust. The piston(13) is fastened to the
rod(2) by a nut(17).
The piston uses a single wear ring(16) with a piston seal(15) to seal between the piston and tube.
The gland seals against the tube with two O-rings. The rod is sealed against the gland with a rod
seal(5).
5-12
This procedure is designed so the service man can make a quick check of the steering system using
a minimum amount of diagnostic equipment. If you need additional information, prefer to structure
and function in group 1.
Locate system check in the left column and read completely, following this sequence from left to right.
If verification is needed, you will be given next best source of information :
5-13
ଖHydraulic oil must be at operating temperature for these checks(Refer to page 6-55).
Steering unit check Run engine at low idle. OK

Check completed.
A
Turn steering wheel until frames
are at maximum right(A) and then NOT OK
left(B) positions. Go to next check.
B
LOOK : Frames must move
smoothly in both directions.
When steering wheel is stopped,
frames must stop.
FEEL : Excessive effort must not
be required to turn steering
wheel.
NOTE : It is normal for steering to
drift from stops when steering
wheel is released.
Steering system leakage Turn steering wheel rapidly until OK
check Left Right frames are against stops. Check completed.
Heat hydraulic oil to
operating temperature. Hold approximately 2kgf on NOT OK
Run engine at high idle. steering wheel. Do steering system
leakage test in group 3 to
Count steering wheel revolutions isolate the leakage.
for 1 minute.
Repeat test in opposite direction.
LOOK : Steering wheel should
rotate less than 5rpm.
NOTE : Use good judgment;
Excessive steering wheel rpm
does not mean steering will be
affected.
Priority valve low Park machine on a hard surface. OK
pressure check Check completed.
Hold brake pedal down.
NOT OK
Run engine at high idle. Do priority valve pressure
Steer machine to the right and left test in group 3.
as far as possible.
LOOK : Machine must turn at
least half way to the right and left
stops.
5-14
Priority valve high Steer to steering stop and release OK

pressure check wheel. Check completed.
Run engine at high idle.
Roll bucket back and hold over NOT OK
relief and observe engine rpm. Priority pressure is set
too high. Do priority valve
Turn wheel to steering stop and pressure test in group 3.
hold, observe engine rpm.
LOOK : Steering stall engine rpm
must be higher than hydraulic stall
rpm.
5-15
2. TROUBLESHOOTING
ଖDiagnose malfunction charts are arranged from most probable and simplest to verify, to least
likely, more difficult to verify. Remember the following steps when troubleshooting a problem :
Step 1. Operational check out procedure(See group 3 in section 1)
No steering Low oil level. Add recommended oil.

Restricted suction line. Check.
Failed hydraulic pump. Remove and inspect return filter for metal
pump particles.
Failed main hydraulic pump drive. Remove main hydraulic pump and
inspect drive gear.
Stuck priority valve spool. Remove and inspect priority valve spool.
Broken priority valve spring. Remove and inspect spring.
Relief valve in steering unit stuck open. Do relief cartridge leakage test in group 3.
Failed hydraulic lines. Check.
Slow or hard steering Too much friction in the mechanical parts Lubricate bearings and joints of frame or
of the machine. cylinders or repair if necessary.
Check steering column installation.
Cold oil. Warm the hydraulic oil.
Low priority valve pressure setting. Do priority valve pressure test in group 3.
Worn hydraulic pump. Do hydraulic pump performance check.
Sticking priority valve spool. Remove and inspect.
Broken priority valve spring. Remove and inspect.
Pinched or restricted LS line. Inspect line. Do priority valve LS port
flow test in group 3.
Low system relief valve setting. Test and adjust if necessary.
Low overload relief valves setting. Test and adjust if necessary.
5-16
Constant steering to Air in system. Check for foamy oil.

maintain straight travel
Leakage in steering system. Do steering system leakage check.
Worn steering unit. Do steering unit neutral leakage test in
group 3.
Leaf spring without spring force or Replace leaf springs.
broken.
Spring in overload relief valve broken. Replace overload relief valve.
Gear wheel set worn. Replace gear wheel set.
Cylinder seized or piston seals worn. Replace defects parts.
Slow steering wheel Leakage in steering system. Do steering system leakage check.
movement will not cause
Worn steering unit gerotor. Do steering unit leakage check.
any frame movement
Steering wheel can be Leakage in steering system. Do steering system leakage check.
turned with frames
against steering stop
Steering wheel turns Broken steering column or splined of Remove and inspect.
with no resistance and steering unit.
causes no frame
Lack of oil in steering unit. Start engine and check steering
movement
operation.
Leakage in steering system. Do steering system leakage test in group
3.
Erratic steering Air in oil. Check for foamy oil.
Low oil level. Add recommended oil.
Sticking priority valve spool. Remove and inspect spool.
Loose cylinder piston. Remove rod to inspect piston.
Damaged steering unit. Remove and inspect.
Spongy or soft steering Air in oil. Check for foamy oil.
Low oil level. Add recommended oil.
Free play at steering Loose steering wheel nut. Tighten.
wheel
Worn or damaged splines on steering Inspect.
column or valve.
Steering unit binding or Binding in steering column or Inspect.
steering wheel does not misalignment of column.
immediately return to
High return pressure. Check for a pinched or damaged return
neutral when released
line.
Contamination in steering unit. Inspect hydraulic filter for contamination.
Repair cause of contamination. Flush
hydraulic system.
5-17
Steering unit locks up Large particles of contamination in Inspect hydraulic filter for contamination.
steering unit. Repair cause of contamination. Flush
hydraulic system.
ଘ Thermal shock Do priority valve LS port flow test in

group 5. This oil flow provides a warm-
up flow to steering unit when not using
the steering.
Worn or damaged steering unit. Repair or replace steering unit.
Abrupt steering wheel Improperly timed gerotor gear in steering Time gerotor gear.
oscillation unit.
Steering wheel turns by Lines connected to wrong port. Reconnect lines.
itself
Worn or damaged steering unit. Repair or replace steering unit.
Vibration in steering High priority valve setting. Do priority valve pressure test in group 3.
system or hoses jump
Neutral position of Steering column and steering unit out of Align the steering column with steering
steering wheel cannot be line. unit.
obtained, i.e. there is a
Too little or no play between steering Adjust the play and, if necessary, shorten
tendency towards
column and steering unit input shaft. the splines journal.
"motoring"
Pinching between inner and outer Contact the nearest service shop.
spools.
"Motoring" effect. Leaf springs are stuck or broken and Replace leaf springs.
The steering wheel can have therefore reduced spring force.
turn on its own
Inner and outer spools pinch, possibly Clean steering unit or contact the
due to dirt. nearest service shop.
Return pressure in connection with the Reduce return pressure.
reaction between differential cylinder and
steering unit too high.
Backlash Cardan shaft fork worn or broken. Replace cardan shaft.
Leaf springs without spring force or Replace leaf springs.
broken.
Worn splines on the steering column. Replace steering column.
Jerky steering LS port orifice missing. Inspect orifice.
Orifice in top end of priority valve spool Disassemble and inspect.
missing.
ଘ 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.
5-18
"Shimmy" effect Air in the steering cylinder. Bleed cylinder.

The steered wheels Find and remove the reason for air
vibrate collection.
(Rough tread on tires gives
Mechanical connections or wheel Replace worn parts.
vibrations.)
bearings worn.
High priority valve setting pressure. Set pressure as regular value.
Steering wheel can be Oil is needed in the tank. Fill with clean oil and bleed the system.
turned the whole time
Steering cylinder worn. Replace or repair cylinder.
without the steered
wheels moving Gear wheel set worn. Replace gear wheel set.
Spacer across cardan shaft forgotten. Install spacer.
Steering wheel can be One or both anticavitation valves are Clean or replace defect or missing
turned slowly in one or leaky or are missing in overload relief valves.
both directions without valves.
the steered wheels
One or both overload relief valves are Clean or replace.
turning
leaky.
Steering is too slow and Insufficient oil supply to steering unit, Replace pump or increase number of
heavy when trying to pump defective or number of revolutions revolutions.
turn quickly too low.
Relief valve setting too low. Adjust valve to correct setting.
Relief valve sticking owing to dirt. Clean the valve.
Spool in priority valve sticking owing to Clean the valve, check that spool moves
dirt. easily without spring.
Too weak spring in priority valve. Replace spring by a stronger.
"Kick back" in steering Fault in the system. Contact authorized man or shop.
wheel from system
Kicks from wheels
Heavy kick-back in Wrong setting of cardan shaft and Correct setting as shown in group 4.
steering wheel in both gear-wheel set.
directions
Turning the steering Hydraulic hoses for the steering cylinders Connect lines to correct ports.
wheel activates the have been switched around.
steered wheels opposite
Hard point when starting Spring force in priority valve too weak. Replace spring by a stronger.
to turn the steering
Air in LS and / or PP line. Bleed LS and PP line.
wheel
Clogged orifices in LS or PP side in Clean orifices in spool and in connecting
priority valve. plugs for LS and PP.
Oil is too thick(Cold). Let machine run until oil is warm.
Too little steering force Pump pressure too low. Correct pump pressure.
5-19
1. HYDRAULIC OIL CLEAN UP PROCEDURE USING PORTABLE FILTER CADDY
ଖ Service equipment and tool

½ Portable filter caddy
½ Two 4000mm Ý 1" 100R1 Hoses
½ Quick disconnect fittings
½ Discharge wand
½ Connectors
ଖ Steering system use oil from hydraulic
oil tank. Flush all lines in the steering
system.
ଖ 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
disassemble steering cylinders to clean
debris from cylinders.
2) Install a new return filter element. Inspect
filter before installing new element.
ଖ For a failure that creates a lot of debris,
remove access cover from hydraulic oil
tank. Drain and clean hydraulic oil tank
of fill the specified oil to hydraulic oil
tank through upper cover.
3) To minimize oil loss, pull a vacuum in
hydraulic oil tank using a vacuum pump.
Connect filter caddy suction line to drain
port at bottom of hydraulic oil tank using
connector. Check to be sure debris has not
closed drain port.
4) Put filter caddy discharge line into hydraulic
oil tank filler hole so end is as far away from
drain port as possible to obtain a thorough
cleaning of oil.
5-20
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.
ଖ Hydraulic tank capacity : 105˜ (27.7U.S.
gal)
Leave filter caddy operating for the next
steps.
6) Start the engine and run it at high idle.
ଖ 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.
ଖ 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 TACHOMETER

INSTALLATION
½ Service equipment and tools
Tachometer
A : Clamp on tachometer
B
Remove paint using emery cloth and
connect to a straight section of injection D
C
line within 100mm(4in) of pump. Finger
tighten only-do not over tighten.
B : Black clip(-). Connect to main frame.
C : Red clip(+). Connect to transducer. A
D : Tachometer readout. Install cable. 73035SV01
2) DIGITAL THERMOMETER INSTALLATION

Digital thermometer
A : Temperature probe
Fasten to a bare metal line using a tie A
band. Wrap with shop towel.
B : Cable B
C : Digital thermometer C
73035SV02
3) DISPLAY MONITOR TACHOMETER

The display monitor tachometer is accurate
enough for test work.
7707SE06
5-22
3. STEERING SYSTEM RESTRICTION TEST
½ SPECIFICATION
Oil temperature 45· 5° C(113· 9°F)
Engine speed High idle
Maximum pressure 20Mpa(20bar, 285psi)
at steering unit
½ GAUGE AND TOOL
Gauge 0~7.0Mpa(0~70bar, 0~1000psi) 1EA
½ This test will check for restrictions in the

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

reader installation procedure in this group.) P
2) Heat hydraulic oil to specifications.(See

hydraulic oil warm up procedure at page A
6-55.)
3) Connect fitting(A) and gauge to steering
unit.
Do not operate steering or loader
functions or test gauge may be
damaged.
4) Run engine at specification and read
pressure gauges.
If pressure is more than specification at the
steering unit, inspect priority valve for a
stuck spool. Make sure orifice plugs are
installed in ends of priority valve spool.
Check for plugged orifice in priority valve LS
port. 7303ASE16
5-23
4. STEERING UNIT LEAKAGE TEST
½ SPECIFICATION
Oil temperature 45· 5°C (113· 9°F )
Maximum leakage 10˜ /min Cap fitting
½ GAUGE AND TOOL

Temperature reader
Measuring container(Approx 20˜ ) Steering unit
Stop watch
1) Install frame locking bar to prevent machine

from turning.
2) Install temperature reader.
(See temperature reader installation
procedure in this group.)
hydraulic oil warm up procedure at page
6-55.)
4) Disconnect return hose from fitting.
Install cap fitting.
5) Run engine at specifications. Rotate
steering wheel against locking bar using
approximately 1.2kg½ 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. 7407SE09
5-24
5. STEERING UNIT PRESSURE TEST
½ SPECIFICATION
Relief pressure 20.5~21.5Mpa
(205~215bar, 3200~3300psi) LS
½ GAUGE AND TOOL

CF
Gauge 0~35.0Mpa(0~350bar, 0~5000psi)
Temperature reader
P
1) Connect test fitting and gauge to P port on
steering unit.
installation procedure in this group.)
3) Install frame locking bar.
6-55.)
5) Run engine at specifications and turn
steering wheel rapidly hold approximately
22N(5lb force) pressure on wheel with
frames locked.
ଖ If steering wheel is turned slowly, it will
continue to with the frames locked. Safety lock bar
This will give an incorrect pressure
reading.
If steering wheel continues to turn
rapidly with the frames locked, steering Relief valve
system leakage is indicated.
6) Read pressure gauge. This is the steering

unit relief pressure. A
7) If pressure in not to specification, remove

the plug(A) from steering unit. Turn
adjusting screw in relief cartridge using a
hex head wrench to adjust pressure.
If pressure cannot be adjusted to
specification, disassemble and inspect
steering unit. 7407SE10
5-25
6. PRIORITY VALVE "LS" PORT FLOW TEST
½ SPECIFICATION
A
Engine speed Low idle LS
LS port flow(Approx) 0.5˜ /min(0.13gpm)

½ GAUGE AND TOOL
B
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 explanation of
thermal shock, page 5-18).
A missing orifice can cause the pump to be

loaded to high pressure at all times causing
overheating.
1) Install temperature reader.(See

temperature reader installation procedure in
this group.)
6-55.)
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. 7303ASE09
5-26
1. PRIORITY VALVE
1) STRUCTURE
1 2 4 3 9 5 2 6
7405S 5-6
1 Plug 4 Housing 8 Drive screw

2 O-ring 5 Spring 9 Orifice
3 Spool 6 Plug
2) TOOLS
½ Torque wrench(5kgf½ m)
½ Hex socket wrench(1")
½ Hex socket wrench(7/8")
½ Hex wrench (7/32")
½ Pincette
½ Grease
5-27
3) DISASSEMBLY
ଖ Cleanliness is the primary means of
assuring satisfactory the priority valve life.
Select clean place.
Before removing the piping, clean the
surrounding area of valve ports.
(1) Fix the housing(4) in a vise with copper or

P EF
lead sheets.
Do not over tighten jaws.
(2) Loosen plug(6) for LS port.
7405S PV01
(3) Remove spring (5).

P EF
7405S PV02
(4) Remove Plug(1) and separate O-ring(2)

P EF
individually.
7405S PV03
5-28
(5) Remove the spool(3).
ଖ Can't remove the orifice(9) from spool(3), 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
ଖ Clean all metal parts in clean solvent and
blow dry with air and correct any damage,
burrs and rust.
ଖ Do not wipe dry with cloth or paper towel.
ଖ Replace seals such as O-ring with new
ones as a rule and coat with grease.
Fix the housing(4) in a vise.

(1)
ଖ Do not over tighten jaws. P EF
Insert the spool(3) in the housing(4).

(2)
ଖ Secure the spool(3) remain in their correct
direction as the illustration.
ଖ Secure the spool(3) to move smoothly by
finger.
7405S PV06
(3) Install the O-ring(2) onto plug(1) and istall

P EF
the plug(1) into the housing(4).
½ Tighten torque : 6.1kgf½ m(44.3lb½ ft)
7405S PV07
(4) Insert the spring(5) into the housing(4).

P EF
7405S PV08
5-30
(5) Install the O-ring(2) on plug(6) and install
the plug(6) into the housing(4). P EF
½ Tighten torque : 6.1kgf½ m(44.3lb½ ft)
This completes assembly.
7405S PV09
5-31
5) TROUBLESHOOTING
Steering wheel 1. Relief valve of steering unit is clogged Disassembly, clean and reassembly.
is heavy with dirt.
2. Spool is stuck. Disassembly, clean and reassembly or
replace.
3. Orifice of plug and spool is clogged. Disassembly, clean and reassembly.
(Steering wheel a. Pump is faulty. Check pump.
is heavy at
engine low idle)
(Steering speed b. Control pressure is low. Reset control pressure.

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

2. O-ring is damaged. Replace.
5-32
2. STEERING UNIT
1) STRUCTURE
21
VALVE BLOCK
2 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
7407SE11
1 Dust seal ring 11 O-ring 21 Complete relief valve without seat

2 Housing, spool, sleeve 12 Intermediate plate 31 Set of o-rings
3 Ball 13 O-ring 33 Rolled pin
4 Thread bushing 14 Distributor plate 34 Screw
5 Roto glyd ring 15 Gearwheel set 35 Shock valve
6 Bearing assembly 16 End cover 36 Spring
7 Ring 17 Washer 37 O-ring
8 Cross pin 18 Screw with pin 38 Plug
9 Set of spring 19 Screw 39 Housing, check valve
10 Cardan shaft
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 0-7.1kgf m(0-51.6lb ft).

13mm socket spanner
12mm screwdriver
6mm screwdriver
2mm 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(Þ 8.5mm).
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.
ଖ The sleeve and spool are correctly B A
assembled when
ཛ The slots-in sleeve and spool-for the
neutral position springs are opposite
each other and
ཛྷ One of the 3 T-shaped grooves(A) in the
spool is opposite one of the sets(B) of
7405S STVLV44(1)
small holes in the sleeve.
(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.

ଖ 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.
ଖ 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· 0.6kgf m(22· 4.4lb ft). Steering 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, 8mm.
7405S OVLOAD63(1)
(2) Torque wrench, 0~7.1kgf m(0~51lb ft)

with 8mm 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).

8
38
7
37
7405S OVLOAD64(2)
(3) Remove the spring(36) and shock

valve(35). 6
36
5
35
7405S OVLOAD64(3)
(4) Remove the O-ring set(31).

1,2
31
7405S OVLOAD64(4)
5-51
(5) Remove the check valve(39).
39
9
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).

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

36
6
35
5
7405S OVLOAD66(2)
(3) Fit the O-ring(37) and screw the plug(38).
38
8
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

torque of 6.6+0.5
0 kgf m(47.7+3.6
0 lb ft).
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
kgf½ m lbf½ ft
Gland 3 M70 Ý 2.0 70 · 7 506 · 51
Nylon nut 17 M27 Ý 2.0 75 · 8 542 · 58
Nut(Pipe assy) 18 M22 Ý 1.5 30 · 3 217 · 21.7
Nut 20 M10 Ý 1.5 3.2 · 0.3 23.1· 2.2
5-57
3) DISASSEMBLY
(1) Remove cylinder head and piston rod
ཛ Hold the clevis section of the tube in a
vise.
ଖ 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.
ཛྷ Pull out piston rod(2) about 200mm

(7.1in). Because the piston rod is
rather heavy, finish extending it with air m
0m
20
pressure after the oil draining operation.
7405S 5-65(1)
ཝ Loosen and remove the gland(3).

ଖ Cover the extracted piston rod(2) with Wrench
rag to prevent it from being accidentally
damaged during operation.
3
2
7405S 5-65(2)
ཞ Draw out gland(3) and piston rod (2)

assembly together from cylinder tube(1).
Lift
ଖ 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 it in its center to Full straight Oil pan
draw it completely. sideways
7405S 5-65(3)
5-58
ଖ 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.
ཟ Place the removed piston rod assembly

on a wooden V-block that is set level.
ଖ Cover a V-block with soft rag. Piston assy
Wooden block
7405S 5-66(1)
(2) Remove piston and gland assembly

ཛ Remove the nylon nut(17). 14 15 16 13 17
ཛྷ Remove piston assembly(13), and O-
ring(14).
7405S 5-66(2)
ཞ Remove the gland(3) assembly from

piston rod(2). Lift with a crane
ଖ If it is too heavy to move, move it by Plastic 8,9 5,6
hammer
striking the flanged part of gland(3) with 7 4
a plastic hammer.
Full straight
ଖ Pull it straight with cylinder head
assembly lifted with a crane.
Exercise care so as not to damage the lip
of rod bushing(4) and packing (5,6,7,8,9)
by the threads of piston rod(2). 3 2
7405S 5-66(3)
5-59
(3) Disassemble the piston assembly
ཛ Remove wear ring(16) and piston seal 15 16
(15).
ଖ Exercise care in this operation not to
damage the grooves.
7405S 5-67(1)
(4) Disassemble gland assembly

ཛ Remove back up ring(11), and O-ring 8,9 12 5,6 7 10,11 4
(10).
ཛྷ Remove O-ring(12).
ཝ Remove snap ring(9) and dust wiper(8).
ཞ Remove back up ring(6), rod seal(5).
ཟ Remove buffer ring(7).
damage the grooves.
7405S 5-67(2)
ଖ Do not remove seal and ring, if does not
damaged.
5-60
4) ASSEMBLY
(1) Assemble gland assembly
ଖ Check for scratches or rough surfaces if
found smooth with an oil stone.
ཛ Coat the inner face of gland(3) with
hydraulic oil.
3
7405S 5-68(1)
ཛྷ Coat dust wiper(8) with grease and fit Press here

dust wiper(8) to the bottom of the hole of (Straight down)
dust wiper. Metal
At this time, press a pad metal to the 8
metal ring of dust seal.
ཝ Fit snap ring(9) to the stop face.
7405S 5-68(2)
ཞ Fit back up ring(6) and rod seal(5) to

corresponding grooves, in that order.
ཟ Fit buffer ring(7).
ଖ Coat each packing with hydraulic oil Wrong Right
before fitting it.
ଖ Insert the backup ring until onside of it is
inserted into groove.
7405S 5-68(3)
ଖ Rod seal(5) has its own fitting direction.

Therefore, confirm it before fitting them. Push bar
ଖ 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
7405S 5-68(4)
5-61
འ Fit back up ring(11) to gland (3).
ଖ Put the backup ring in the warm water of
30~50°C . 4
ཡ Fit O-ring(10) to gland(3). 10
ར Fit O-ring(12) to gland(3). 11
3
12
7405S 5-69(1)
(2) Assemble piston assembly

ଖ Check for scratches or rough surfaces.
If found smooth with an oil stone.
ཛ Coat the outer face of piston(13) with
hydraulic oil.
7405S 5-69(2)
ཛྷ Fit piston seal(15) to piston

ଖ Put the piston seal in the warm water of
60~100°C for more than 5 minutes. 15
ଖ After assembling the piston seal, press
its outer diameter to fit in.
7405S 5-69(3)
ཝ Fit wear ring(16) to piston(13).

ཞ Fit O-ring(14) to piston(13). 14 15 16 13
7405S 5-69(4)
5-62
(3) Install piston and gland assembly
ཛ Fix the piston rod assembly to the work
Gland assembly Piston rod
bench.
ཛྷ Apply hydraulic oil to the outer surface of
piston rod(2), the inner surface of piston
and gland.
ཝ Insert gland assembly to piston rod(2).
7405S 5-70(1)
ཞ Fit piston assembly to piston rod.

½ Tightening torque : 50· 5kgf½ m Piston assembly
(362· 36lbf½ ft) Piston rod
7405S 5-70(2)
ཟ Tighten nylon nut(17) to piston rod(2).

½ Tightening torque : 75· 8kgf½ m 2 17
(542· 58lbf½ ft)
7405S 5-70(3)
5-63
(4) Overall assemble Fix with a bar
ཛ Place a V-block on a rigid work bench.
Mount the cylinder tube assembly(1) on it Lift
and fix the assembly by passing a bar
through the clevis pin hole to lock the
assembly.
Straight
ཛྷ Insert the piston rod assembly in to the
cylinder tube assembly, while lifting and
moving the piston rod assembly with a Apply liquid packing
7405S 5-71(1)
crane.
ଖ Be careful not to damage piston seal by
thread of cylinder tube.
ཝ Match the bolts holes in the cylinder
head flange to the tapped holes in the Tube
cylinder tube assembly and tighten
socket bolts to a specified torque. Piston rod
ଖ Refer to the table of tightening torque.
Wrench
Gland
7405S 5-71(2)
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
20
19
1
3,4
9 8
16,17
21 10 18 14,15
UPPER LOWER
7707SE13
1 Bearing 9 Plate 16 Shim(0.1T)

2 Retainer 10 Pin 17 Shim(0.5T)
3 Shim(0.1T) 12 Seal 18 Bushing
4 Shim(0.5T) 13 Seal 19 Retainer
6 Pin 14 Hexagon bolt 20 Front frame
7 Collar 15 Hardened washer 21 Rear frame
8 Collar
5-65
2) DISASSEMBLY
After supporting the front frame and the
rear frame as horizontally as possible using
wood blocks and jacks, disassemble as
follows: In order to facilitate the
disassembly/assembly of the center pivot
pins, remove the drive shaft, hydraulic line
and steering cylinder first.
(1) Maintain the horizontal level of front
frame(20) and rear frame(21), and then
14
remove hexagon bolt(14) and plate(9). 9
(2) Take out upper pin(10) to the downside

using a metal punch.
20
21
10
7707SE14
(3) Maintain the front frame horizontal level,

remove hexagon bolts(14) and then 21
6
remove the plate(9) and shims(16,17).
(4) Take out lower pin(6) to the upside using
a metal punch carefully.
20
(5) Jack up or lifting the front frame(20) 8
slightly, the collar(8) protrudes over the
rear frame. 9
Remove the collar(8). 16,17
14
(6) Lift the frame by passing the slinging wire 7707SE15
rope at four positions of front frame, in
order to separate it from the rear frame.
(7) Support the front frame safely.
5-66
(8) Remove bolt(14) and then take out
retainer(2) and shims(3,4). 14 13 2
(9) Take out dust seal(13) from the retainer (2). 3,4
(10) Remove the bearing(1), and dust

seal(13).
1
13
7707SE16
(11) Remove bolt(14) and then take out 12 7

retainer(19) and shims(3,4).
1
(12) Take out the dust seal(12) from the
retainer(19).
(13) Remove the bearing(1), collar(7) and dust
seal(12). 3,4
19 12 14
7707SE17
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 retainer(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 dimension Remedy
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
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 retainer(2, 19) and front frame(20).
ଖ Apply grease to the lip of the dust seal. Insert the dust seal so that the dust seal lip faces out and
punch four places on the outer circumference of the seal to lock it.
(2) Lower the temperature of the lower bearing cup to -75 5°C (-103 9°F ) and install it to front
frame until it contacts the bottom of the frame.
(3) Coat lightly with oil and install lower bearing in bore in front frame. Coat lightly with oil and install
upper bearing in bore in upper front frame.
(4) Position the upper retainer(2) and hold in place with bolt(14). At this time, adjust shims(3,4) to
press the shoulder of bearing(1) against retainer.
Shim thickness : 0.1mm, 0.5mm
(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 bolt.
After tightening, confirm that tapered roller bearing moves lightly ; if does not move smoothly, add
shims(3,4).
Tightening Torque : 9.8~15.8kgf m(70.9~114lbf ft)
(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) Position the plate(9) and hold in place with bolt(14).
Apply locktite #243.
(12) Before tightening bolt(14), adjust shims(16,17) in order to control the clearance between the
plate(9) and rear frame(21).
Shim thickness : 0.1mm, 0.5mm
Apply Locktite #243.
5-68
5) TROUBLESHOOTING
Trouble Probable cause Remedy
Shock is felt when steering Capscrew for fixing steering valve is loose Retighten
Faulty center pivot pin mounting bolts Retighten
Center pivot pins have worn out Readjust or replace
Faulty hydraulic system See hydraulic system
Shock is felt when moving Fault fixing of connecting capscrews Retighten
backward or forward
Center pins have worn out Readjust or replace
Bearings of support unit have worn out Retighten
Drive shaft damaged See drive system
Faulty transmission See transmission system
5-69
SECTION 6 WORK EQUIPMENT

SECTION 6 WORK EQUIPMENT
1. HYDRAULIC SYSTEM OUTLINE

The loader hydraulic system is a pilot operated, open center system which is supplied with flow from
the fixed displacement main hydraulic pump.
The pilot control system is a low pressure, closed center hydraulic system which is supplied with flow
from the first(Steering) pump.
The loader system components are :
½ Main pump
½ Main control valve
½ Bucket cylinder
½ Boom cylinders
½ Pilot supply unit
½ Remote control valve(Pilot control valve)
½ 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 a tandem version spool type, open center valve which routes flow to the
boom, bucket or auxiliary cylinders(Not shown) when the respective spools are shifted.
Flow from the steering pump(The first pump) is routed to the pilot supply unit where the steering
pump outlet pressure is reduced to pilot circuit pressure. The pilot supply unit flow to the remote
control valve.
The remote control valve routed flow to either end of each spool valve section in the main control
valve to control spool stroke.
A accumulator mounted on pilot supply unit supplies a secondary pressure source to operated
remote control valve so the boom can be lowered if the engine is off.
The return circuit for the main hydraulic system have return filter inside the hydraulic tank. The return
filter uses a filter element and a bypass valve. The bypass valve is located in the upside of filter.
6-1
2. HYDRAULIC CIRCUIT(HL740-7)
36
P 37
9 10 11 G2 B1 T B
FRONT REAR
T 4 B.D/F B.U IN OUT
LH RH LH RH
35
T
A1 G1 G A
17 P
1 3 4 2 5 6
20
8 BL1 BR1 BL2 BR2 3 T
T1 P1 T2 P2 3B
3A 24MPa
BOOM
5 a3 BOOM UP DOWN b3
38
15 15 L FLOATING
24MPa
28
2B
14 T
7 A1 A2
2A
18 R
a2 24MPa
DUMP ROLL BACK
b2
P
PS
24MPa
P1 T F2
T1
1B 13
A3 P 21MPa 1A
16 a1
AUX
b1
24MPa
B LS F1
34
P2 12
PS1 31
3MPa
CF EF
19 22MPa U
P T 6 P
21 LS
P1 T
P
1 A : 1st(Steering) pump
2 B A
B : 2nd(Loader) pump
31
32 24
30 CF EF
LS
25
T P
P
29 26 27 22
33 23
7407WE01
1 Main pump 14 Safety valve 27 By pass valve

2 Fan+Brake pump 15 Accumulator 28 Shockless valve
3 Main control valve 16 Accumulator 29 Emergency pump kit(Option)
4 Remote control valve 17 Pressure switch 30 Priority valve(Option)
5 Steering unit 18 Pressure switch 31 Check valve(Option)
6 Priority valve 19 Pressure switch 32 Check valve(Option)
7 Cut off valve 20 Pressure switch 33 Pressure switch(Option)
8 Brake valve 21 Line filter 34 Pressure switch(Option)
9 Steering cylinder 22 Fan drive motor 35 Ride control valve(Option)
10 Bucket cylinder 23 Oil cooler 36 Accumulator(Option)
11 Boom cylinder 24 Air breather 37 Safety valve(Option)
12 Pilot supply unit 25 Hydraulic tank 38 Pressure switch(Option)
13 Line filter 26 Return filter
6-2
HYDRAULIC CIRCUIT(HL740TM-7)
38 37 G2 B1 T B P 39
30 9 10 11
T
FRONT REAR
LH RH LH RH LH RH A1 G A
G1
17
4 B.D/F B.U IN OUT
20 29 A B
BL1 BR1 BL2 BR2 3 T

T
8 P T
P
T1 P1 T2 P2 3B 1 3 4 2 5 6
3A 24MPa
BOOM
5 a3 BOOM UP DOWN
b3
L
FLOATING
12MPa
15 15 28
2B
40 14 T
7 A1 A2
2A
ROLL
18 R
a2 24MPa
BACK DUMP
b2
P
PS
24MPa
P1
T F2
1B
T1 13
A3 P 21MPa 1A
16 AUX
a1 24MPa b1
B LS F1
36
P2 12
33
PS1
3MPa
CF EF
19 6
22MPa U
P T P
21 LS
P1 T
P
2 1 B A A : 1st(Steering) pump
B : 2nd(Loader) pump
33 34
32 CF EF
24
LS
25
T P
P
31 26 27
35 23 22
C
7407WE02
1 Main pump 15 Accumulator 28 Shockless valve

2 Fan+Brake pump 16 Accumulator 29 Solenoid valve
3 Main control valve 17 Pressure switch 30 Quick coupler cylinder
4 Remote control valve 18 Pressure switch 31 Emergency pump kit(Option)
5 Steering unit 19 Pressure switch 32 Priority valve(Option)
6 Priority valve 20 Pressure switch 33 Check valve(Option)
7 Cut off valve 21 Line filter 34 Check valve(Option)
8 Brake valve 22 Fan motor 35 Pressure switch(Option)
9 Steering cylinder 23 Oil cooler 36 Pressure switch(Option)
10 Bucket cylinder 24 Air breather 37 Ride control valve(Option)
11 Boom cylinder 25 Hydraulic tank 38 Accumulator(Option)
12 Pilot supply unit 26 Return filter 39 Safety valve(Option)
13 Line filter 27 By pass valve 40 Pressure switch(Option)
14 Safety valve
6-3
3. WORK EQUIPMENT HYDRAULIC CIRCUIT
10 11
4 B.D/F B.U IN OUT
LH RH
3 T T
P
1 3 4 2 5 6
3B
3A 24MPa
BOOM
a3 BOOM UP DOWN b3
28
FLOATING
24MPa
14 T
2B
2A P
DUMP ROLL BACK
a2 24MPa b2
F2
24MPa 13
1B
1A
F1
a1 24MPa
AUX
b1
P2 12
3MPa
U
22MPa
P
P1 T
Priority valve EF port
Steering system
Brake system
1
Return line
24
25
T P
26 27
7407WE03
1 Main pump 12 Pilot supply unit 25 Hydraulic tank

3 Main control valve 13 Line filter 26 Return filter
4 Remote control valve 14 Safety valve 27 Bypass valve
10 Bucket cylinder 24 Air breather 28 Shockless valve
11 Boom cylinder
6-4
1) WHEN THE RCV LEVER IS IN THE RAISE POSITION
10 11
4 B.D/F B.U IN OUT
LH RH
3 T T
P
1 3 4 2 5 6
3B
3A 24MPa
BOOM
a3 BOOM UP DOWN b3
FLOATING
24MPa
28 14 T
2B
Load check valve
2A P
DUMP ROLL BACK
a2 24MPa b2
F2
24MPa 13
1B
1A
F1
a1 24MPa
AUX
b1
P2 12
3MPa
U
22MPa
P
P1 T
Steering system
Brake system
2 1
Return line
24
25
T P
26 27 22
23
7407WE04
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(28).
The oil from main pump(1) flows into main control valve(3) and then goes to the large chamber of
boom cylinder (11) by pushing the load check valve of the boom spool through center bypass circuit
of the bucket spool.
The oil from the small chamber of boom cylinder(11) returns to hydraulic oil tank(25) through the
boom spool at the same time.
When this happens, the boom goes up.
6-5
2) WHEN THE RCV LEVER IS IN THE LOWER POSITION
10 11
4 B.D/F B.U IN OUT
Check valve
LH RH
3 T T
P
1 3 4 2 5 6
3B
3A 24MPa
BOOM
a3 BOOM UP DOWN b3
24MPa FLOATING 39 14
28 T
2B Load
check
2A valve
P
DUMP ROLL BACK
a2 24MPa b2
F2
24MPa 13
1B
1A
F1
a1 24MPa
AUX
b1
P2 12
3MPa
U
22MPa
P
P1 T
Steering system
Brake system
2 1
Return line
24
25
T P
26 27 22
23

7407WE05
When the RCV lever(3) 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 and then goes to small chamber of boom
cylinder(11) by pushing the load check valve of the boom spool through center bypass circuit of the
bucket spool.
The oil returned from large chamber of boom cylinder(11) returns to hydraulic tank(25) through the
boom spool at the same time.
When the lowering speed of boom is faster, the return oil from the large chamber of boom cylinder
combines with the oil from the pump through the 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.
6-6
3) WHEN THE RCV LEVER IS IN THE FLOAT POSITION
10 11
4 B.D/F B.U IN OUT
LH RH
3 T T
P
1 3 4 2 5 6
3B
3A 24MPa
BOOM
a3 BOOM UP DOWN b3
FLOATING
24MPa
28 14 T
2B
2A P
DUMP ROLL BACK
a2 24MPa b2
F2
24MPa 13
1B
1A
F1
a1 24MPa
AUX
b1
P2 12
3MPa
U
22MPa
P
P1 T
Steering system
Brake system
2 1
Return line
24
25
T P
26 27 22
23
7407WE06
When the RCV lever(4) is pushed further forward from the lower position, the pilot pressure
reaches to 13-15 bar, 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.
6-7
4) WHEN THE RCV LEVER IS IN THE DUMP POSITION
10 11
4 B.D/F B.U IN OUT
LH RH
3 T T
P
1 3 4 2 5 6
3B
3A 24MPa
BOOM
a3 BOOM UP DOWN b3
FLOATING
24MPa
28 14 T
2B
2A P
DUMP ROLL BACK
a2 24MPa b2
F2
24MPa
Load
13
check
1B valve
1A
F1
a1 24MPa
AUX
b1
P2 12
3MPa
U
22MPa
P
P1 T
Steering system
Brake system
2 1
Return line
24
25
T P
26 27 22
23
7407WE07
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(10) by pushing the load check valve of the bucket spool.
The oil at the large chamber of bucket cylinder(10) returns to hydraulic tank(25) through the bucket
spool.
When this happens, the bucket is dumped.
When the dumping speed of bucket is faster, the oil returned from the large chamber of bucket
cylinder combines with the oil from the pump, and flows into the small chamber of the cylinder.
bucket dump speed.
6-8
5) WHEN THE RCV LEVER IS IN THE ROLL BACK(retract) POSITION
10 11
4 B.D/F B.U IN OUT
LH RH
3 T T
P
1 3 4 2 5 6
3B
3A 24MPa
BOOM
a3 BOOM UP DOWN b3
FLOATING
24MPa
28 14 T
2B
2A P
DUMP ROLL BACK
a2 24MPa b2
F2
24MPa
Load 13
check
1B valve
1A
F1
a1 24MPa
AUX
b1
P2 12
3MPa
U
22MPa
P
P1 T
Steering system
Brake system
2 1
Return line
24
25
T P
26 27 22
23

7407WE08
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(10) returns to hydraulic tank(25) through the bucket spool.
When this happens, the bucket roll back.
When the rolling speed of bucket is faster, the return oil from the small chamber of bucket cylinder
combines with the oil from the pump, and flows into the large chamber of the cylinder.
bucket rolling speed.
6-9
6) WHEN THE RCV LEVER IS IN THE HOLD POSITION
10 11
4 B.D/F B.U IN OUT
LH RH
3 T T
P
1 3 4 2 5 6
3B
3A 24MPa
BOOM
a3 BOOM UP DOWN b3
FLOATING
24MPa
28 14 T
2B
2A P
DUMP ROLL BACK
a2 24MPa b2
F2
24MPa 13
1B
1A
F1
a1 24MPa
AUX
b1
P2 12
3MPa
U
22MPa
P
P1 T
Steering system
Brake system
2 1
Return line
24
25
T P
26 27 22
23
7407WE09
The oil from main pump(1) flows into main control valve(3).
In this time, the bucket spool and the boom spool are in neutral position, then the oil supplied to
main control valve(3) returns into hydraulic tank(25) through center bypass circuit of each spool.
In this condition, each cylinder keeps the neutral position, so the boom and the bucket is holded.
6-10
4. MAIN PUMP OPERATION
1) STRUCTURE
21
20
13
11 12
22
19
15
8
7 14
6
17
18
9
16
8 15
7 14
6 13
12
11
10
1
2
7407WE12
1 Shaft seal 11 Wearplate 17 Spline coupling

2 Adapter 12 O-ring seal 18 Rear driven gear
6 Back up seal 13 Back up seal 19 Rear drive gear
7 O-ring seal 14 Interface seal 20 Stud
8 Wearplate 15 Dowel 21 Flanged nut
9 Front drive gear 16 Front body 22 Rear body
10 Front driven gear
6-11
2) OPERATION
The main hydraulic pump is a fixed displacement helical gear type pump. The pump is drive at
engine speed by the transmission. The pump shafts are supported by shaft seal(1) adapter(2),
front body(16) and rear body(22). The wearplate(8, 11) are located between the gear surface and
adapter(1), rear body(22) and front body(16).
As the drive gear(9) and (19) turns the idler gears(10, 18), the gear teeth come out of mesh. Oil
flows from the hydraulic tank through the inlet into the cavity between the gear teeth. As the gears
continue to rotate, the oil becomes trapped between the gear teeth and front body(16).
The trapped oil is the oil is then carried to the pump outlet. Oil is forced out the outlet to supply the
hydraulic function. As the gears re-mesh, they form a seal to prevent oil from flowing between the
gears and back to the inlet.
.
The pump uses outlet pressure oil to load the wearplate(8, 11) against the gear faces. This controls
intemal leakage to maintain pump displacement.
Outlet pressure fills the area bounded by the pressure balance moulded seals(6, 7) to force the
wearplate against the high pressure area or the gear faces.
6-12
5. REMOTE CONTROL VALVE
1) STRUCTURE
17
29
B
50 28
26
12
4 1
24 2 13
3
5 6
23
27 4 7
2 2
21
1
3
A
4 1
3 2
8
15
47 25
16
10 9
30
14
18
15 19
20
11
49
22
A
B 7403AWE11
1 Spring pack 12 Prefeel cage assy 23 O-ring

2 Spring pack 13 Spindle retainer 24 Wiper seal
3 Spring 14 Spindle 25 Plug
4 Plunger assy 15 Nut 26 Collar
5 Plunger assy 16 Lever assy 27 Handle adapter
6 Plunger assy 17 Handle 28 Nut
7 Plunger assy 18 Universal joint assy 29 Nut
8 Body 19 Screw 30 Insulation tube
9 Prefeel kit 20 Connector assy 47 Nut
10 Prefeel kit 21 Rubber boot 49 Spacer
11 Prefeel kit 22 Solenoid 50 Handle assy
6-13
2) OPERATION
13
14
12
11
10
9
8
7
6
5
4
3
2
1
7406S 6-14A
B.D/F B.U IN OUT Port Port name Port size

1 Boom down 1/4 BSPP
2 Bucket dump 1/4 BSPP
T
3 Boom raise 1/4 BSPP
P
4 Bucket crowd 1/4 BSPP
1 3 4 2
P Supply pressure 1/4 BSPP
HYDRAULIC CIRCUIT T Tank 1/4 BSPP
1 Aluminum body 6 Plunger guide 11 Hold coil

2 Pressure reducing spool 7 Roll pin 12 Armature plate
3 Pressure reducing body 8 Prefeel ball carrier 13 Control lever
4 Return spring 9 Plunger 14 Rubber boot
5 Metering spring 10 Prefeel spindle
6-14
(1) Neutral position
Z
8
Y
4
Tank gallery
X
Inlet pressure
(30bar)
Service port
(740-3A) RCV01
The rubber boot(14) fitted between the control lever(13) and the valve protects the working parts from
external contamination. The return spring(4) holds the plunger(8) in its most upwardly position keeping
the lever vertical. In this position all four service ports are connected to the tank gallery and hence to the
tank port.
6-15
(2) Metering position
(740-3A) RCV03
By selecting the control lever(13) the plunger(9) is progressively selected until the spool(2) dead band X
is taken up. During this interval the service port is still connected to the tank gallery. Any further
selection of the control lever(13) will ;
ཛ Cause the four metering holes in the spool(2) to open slightly, allowing pressure to be raised at the
service port. This increase in pressure then counteracts the load produced by the metering spring(5)
closing off the opening until an equilibrium is maintained. The pressure raised at the service port is
proportional to the rate of the metering spring. The initial jump in pressure is caused by the preload in
the metering spring(5) and can be altered as required simply by adjusting the shimming.
ཛྷ Cause the service port to shut off to the rank gallery.
6-16
(3) End of metering
(740-3A) RCV04
After the plunger(9) has been displaced a distance of X+Y, the plunger roll pin(7) is just contacting the
top of the spool(2). Any further selection of the control lever(13) will cause the four metering holes in the
spool(2) to open independently of the pressure.
Thus any selection of the control lever(13) past X+Y will cause the service pressure to increase
immediately to inlet pressure.
6-17
(4) Fully selected
12
11
10
(740-3A) RCV05
Selecting the control lever(13) now will maintain the service port pressure at inlet until the armature
plate(12) contacts on the hold coil(11). However, just prior to this, the ramp on the prefeel spindle(10)
reacts against the three springs in the prefeel ball carrier(8).
This produces a sharp increase in operator load(Prefeel), ensuring that the service is not accidentally
selected through to detent.
6-18
6. MAIN CONTROL VALVE
1) STRUCTURE
20
17 1
6 39
19
11 7
4 40
3 38
23 21 34
13 8 36
30 35
25
24
5 8
16
17 33 11
18 8
1 37 9
29
32
22
8 13
31
28 26
2 13
40 21 14
13 4
12 19
27
13
14
4
19
17
17 15
20
10
7403AWE12
1 Special nut 15 Cap screw 29 Spool

2 Plug 16 Anti void assy 30 Spring
3 O-ring 17 Retainer 31 Spring
4 O-ring 18 Spool cap 32 Back up ring
5 Cap screw 19 Spool cap 33 Inlet housing
6 Plug 20 Cap screw 34 Housing
7 O-ring 21 Retainer 35 Housing
8 O-ring 22 Retainer 36 Outlet housing
9 Spring 23 Shoulder screw 37 Poppet
10 Main relief valve 24 Flat washer 38 Tie rod
11 Port relief valve 25 Spacer 39 Tie rod
12 Spacer 26 Spring 40 Special nut
13 Flat washer 27 Spring
14 Shoulder screw 28 Spool
6-19
STRUCTURE
P T
A1 A2
B1 B2
b1(a1) b2(a2)
a1 A1 B1 a2 A2 B2
240bar 240bar 240bar

Port Port name Port size
P From main pump 1 3/16-12UN
220bar
T To hydraulic tank 1 5/16-12UN
A1, B1 To bucket cylinder port 1 3/16-12UN
P T
A2, B2 To boom cylinder port 1 3/16-12UN
a1, b1 Bucket pilot port 9/16-18UNF
a2, b2 Boom pilot port 9/16-18UNF
b1 b2
HYDRAULIC CIRCUIT
7406S6-14 20
6-20
2) BOOM SECTION OPERATION
(1) Spool in neutral
2B
2A
24Mpa BOOM UP BOOM DOWN

a2 b2
FLOATING
24Mpa
1B
1A
24Mpa DUMP ROLL BACK

a1 b1
2A 2B
a2 b2
Low pressure passage

7406S6-18 21
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.
6-21
(2) Boom raise position
2B
2A
24Mpa BOOM UP
a2 b2
24Mpa
1B
1A

a1 b1
Load check valve(1)
SECTION A-A
2A 2B
A A
a2
b2

7406S6-19 22
When the pilot pressure from remote control valve is supplied to the pilot port(a2), the spool moves to
the right and the neutral passage is closed.
The oil supplied from the pump pushes up the load check valve(1) and flow into boom 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.
6-22
(3) Boom lower position
Check valve(2)
T
2B
2A
24Mpa BOOM DOWN

a2 b2
24Mpa
1B
1A

a1 b1
Load check valve(1)
SECTION A-A
2A 2B
A A
b2
a2

7406S6-20 23
When the pilot pressure from remote control valve is supplied to the pilot port(b2), the spool moves to
the left and the neutral passage is closed.
The oil supplied from the pump pushes up the load check valve(1) and flow into boom cylinder port(2B).
neutral passage.
The return oil from cylinder port(2A) 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.
6-23
(4) Boom float position
2B
2A
24Mpa FLOATING
a2 b2
24Mpa
1B
1A

a1 b1
2A 2B
b2
a2

7406S6-21 24
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(2A), (2B) 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 (2A), (2B) T connecting.
6-24
3) BUCKET SECTION OPERATION
(1) Spool in neutral
24Mpa
1B
1A

a1 b1
22Mpa
1A 1B
a1 b1
7406S 6-22 25
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.
6-25
(2) Retract(Roll back) position
24Mpa
1B
1A
24Mpa ROLL BACK

a1 b1
Load check valve(1)

22Mpa
SECTION A-A
1A 1B
A A
b1
a1
7406S6-23 26
When the pilot pressure from remote control valve is supplied to the pilot port(b1), the spool moves to
the left and the neutral passage is closed.
The oil supplied from the pump pushes up the load check valve(1) and flow into bucket cylinder
port(1B).
neutral passage.
The return oil from cylinder port(1A) flows into the tank via the low pressure passage.
6-26
(3) Dump position
24Mpa
1B
1A
24Mpa DUMP
a1 b1
Load check valve(1)

22Mpa
SECTION A-A
1A 1B
A A
a1
b1
7406S 6-24
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(1A).
neutral passage.
The return oil from cylinder port(1B) flows into the tank via the low pressure passage.
6-27
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
ཛ Loosen lock nut.
ཛྷ Set adjusting nut to desired pressure
setting. Piston poppet(C) Housing O-ring
ཝ If desired pressure setting cannot be Piston spring Pilot spring Adjust nut
achieved, add or remove shims as
required.
T
ཞ Tighten lock nut.
220bar
ཟ Retest in similar manner as above.
7406S 6-25(1)
(2) Port relief valve

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

Piston spring Housing Adjust screw
T
240bar
7406S 6-25(2)
6-28
5) MAIN RELIEF VALVE
(1) As relief
The relief valve is in communication
between the high pressure port HP and
A D B K
low pressure LP. Oil is admitted through
the hole in poppet C and because of the
differential area between diameters A and
HP
B relief valve poppet D and check valve
poppet K are tightly seated as shown in
LP
the first step.
C
The oil pressure in the high pressure port

HP has reached the setting of the pilot
E
poppet spring force and unseats the pilot
poppet E and oil flows around the poppet
through the cross drilled holes and to the
HP
low pressure area LP.
LP
The loss of oil behind poppet C, effected

by the opening of pilot poppet E, causes D E
poppet C to move back and seat against
pilot poppet E. This shuts off the oil flow
to the area behind relief valve poppet D, HP
and causes a low pressure area internally.
LP
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
7406S 6-27
6-29
(2) As anti void
The anti-void unit supplies oil to the high
pressure port HP when cavitation has K G
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 poppet K
LP
which unseats, thus allowing oil from the
low pressure chamber LP to enter the port
HP and fill the void. 7406S 6-28(1)
(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 7406S 6-28(2)
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.
6-30
6) PORT RELIEF VALVE
(1) As relief
The relief valve is in communication
A D LP B K
between the high pressure port HP and
low pressure LP. Oil is admitted through
the hole in poppet C and because of the
differential area between diameters A and HP
B relief valve poppet D and check valve
poppet K are tightly seated as shown in
the first step. LP C
The oil pressure in the high pressure port

LP E
HP has reached the setting of the pilot
poppet spring force and unseats the pilot
poppet E and oil flows around the poppet
through the cross drilled holes and to the HP
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
LP 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
open and relieve the oil directly to the low HP
pressure chamber LP in the valve.
LP
7406S 6-30
6-31
(2) As anti void
The anti-void unit supplies oil to the high
pressure port HP when cavitation has A LP K G
occurred. A lower pressure exists in the
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 poppet K
which unseats, thus allowing oil from the LP
low pressure chamber LP to enter the port
HP and fill the void. 7406S 6-31(1)
(3) As separate anti void

The anti-void check valve opens when M O-ring
cavitation occurs in the high pressure port LP
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 7406S 6-31(2)
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.
6-32
7. PILOT OIL SUPPLY UNIT
1) STRUCTURE
5
1
P
2
U
T
6
(740-3A ₆䌖) PILOT SUPPLY UNIT
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.
6-33
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 nylon 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
19 7 10,11 23 22 3 4 1 2 13,14 17 15 16 12 18
6,5
9,8
20 24 25,26 21 27,28
7407WE10
1 Tube assy 11 Back up ring 21 Pipe assy

2 Rod assy 12 Piston 22 O-ring
3 Gland 13 O-ring 23 Socket bolt
4 Bushing 14 Back up ring 24 Pipe clamp
5 Rod seal 15 Piston seal 25 Hexagon bolt
6 Back up ring 16 Wear ring 26 Spring washer
7 Buffer ring 17 Dust ring 27 Bushing
8 Dust wiper 18 Nylon nut 28 Dust seal
9 Snap ring 19 Socket bolt
10 O-ring 20 Pipe assy
6-34
2) BUCKET CYLINDER
7 25 24 3 11,10 4 1 2 14,13 17 15 16 12 19
6,5 18
9,8
22
21
26,27
20 23
7407WE11
1 Tube assy 10 O-ring 19 Set screw

2 Rod assy 11 Back up ring 20 Socket bolt
3 Gland 12 Piston 21 Band assy
4 Bushing 13 O-ring 22 Pipe assy
5 Rod seal 14 Back up ring 23 Pipe assy
6 Back up ring 15 Piston seal 24 O-ring
7 Buffer ring 16 Wear ring 25 Socket bolt
8 Dust wiper 17 Dust ring 26 Bushing
9 Snap ring 18 Nylon nut 27 Dust seal
6-35
9. HYDRAULIC OIL TANK
1) STRUCTURE
½ 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.
½ A part of oil is cooled in the oil cooler(If equipped), passes through the hydraulic filter and returns
to the hydraulic tank(1).
½ 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
7407WE13
1 Hydraulic tank 6 By pass valve 11 Cover

2 Pipe assy 7 Spring 12 Cover
3 Sight gauge 8 O-ring 13 O-ring
4 Air breather 9 Socket bolt 14 O-ring
5 Element assy 10 Bolt 15 Bolt
6-36
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 : 1.36kg/cm2
(19.3psi)
From MCV
(740-3A) 6-33
6-37
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.
Element
(1) Preventing negative pressure inside Body
Socket bolt
the tank
The tank is a pressurized sealed type, so
negative pressure is formed inside the
hydraulic tank when the oil level drops
during operations. When this happens,
the difference in pressure between the
tank and the outside atmospheric
pressure opens the poppet in the
breather, and air from the outside is let
into the tank or prevent negative pressure.
(2) Preventing excessive pressure inside
the tank
When the hydraulic cylinder is being used,
the oil level in the hydraulic system
increases and as temperature rises. If the
hydraulic pressure rises above the set
pressure, breather is actuated to release
the hydraulic pressure inside the tank.
7407WE14
6-38
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˜ (0.2 U.S.gal)
Charging pressure of gas 16kg/cm2(228psi)
Max actuating pressure 30kg/cm2(427psi)
1 Diaphragm
2 Closure button
3 Steel pressure vessel
7803AWE56
6-39
This procedure is designed so the mechanic can make a quick check of the system using a minimum
amount of diagnostic equipment. If you need additional information, read Structure and function,
Group 1.
If verification is needed, you will be given next best source of information:
6-40
ଖ Hydraulic oil must be at operating temperature for these checks(Refer to page 6-55).
Hydraulic system warm- Hold a hydraulic function over OK

up procedure relief to heat oil.(Don't keep relief Check completed.
Run engine at high idle. condition over 5 seconds at a
Refer to page 6-55. time)
Periodically cycle all hydraulic
functions to distribute warm oil.
Repeat procedure until oil is at
operating temperature.
FEEL : Hydraulic tank must be
uncomfortable to hold your hand
against.
(Approximately 45~55°C)
Hydraulic pump With bucket flat on ground, OK
performance check actuate boom raise. Time how Check completed.
Heat hydraulic oil to long it takes to raise boom to full
NOT OK
operating temperature. height.
Go to steering unit high
Run engine at high idle.
LOOK : Boom must raise to full pressure check at page
height in less than 6.5 seconds. 5-26.
IF OK
Do steering unit leakage
check at page 5-25.
IF OK
Do main hydraulic pump
flow test at page 6-56.
Control valve lift check With bucket partially dumped, OK

Run machine at low idle. lower boom to raise front of Check complete.
machine.
NOT OK
Slowly move boom control Repair lift checks in main
lever(RCV lever) to boom lower control valve.
position.
Slowly move bucket control lever
to bucket dump position.
LOOK : Boom must not raise
before moving down.
Bucket must not rollback before
dumping.
6-41
Bucket rollback circuit Position bucket at a 45°angle OK

relief valve check against an immovable object. Check complete.
Engage transmission in 3rd speed NOT OK
forward. Replace boom lower
check valve.
LOOK : Bucket angle must not
change.
Bucket dump circuit Raise front of machine which OK
relief valve low pressure bucket at 45°angle. Go to next check.
check
Backdrag with bucket while NOT OK
observing bucket angle. Do loader system and
circuit relief valve test at
LOOK : Bucket must not rollback
page 6-57.
Pilot control valve float With the bucket partially dumped, OK
check lower boom to raise front of Check complete.
Run engine at low idle. machine.
NOT OK
Push control lever to the float
Do pilot control valve
detent position and release lever.
pressure test in group 3.
LOOK : Front of machine lower to
the ground and valve must remain
in float position when lever is
released.
Boom cylinder and Set the boom and bucket OK
bucket cylinder drift horizontal, then stop the engine. Check complete.
check
Stop the engine, wait for 5 minutes, NOT OK
then start measuring. Go to next check.
Measure the amount the lift and
B
dump cylinder rods retract during

A 15 minutes.(Unloaded bucket)
A : Retraction of boom cylinder
rod
B : Retraction of bucket cylinder
rod
B Boom cylinder must drift less than
30mm(HL740-7); 40mm(HL740TM-7)
A
Bucket cylinder must drift less than
30mm.
6-42
Boom cylinder leakage Dump bucket until teeth or cutting OK

check edge is perpendicular to the Drift is approximately the
Heat hydraulic oil to ground. same between first and
operating temperature. second measurement.
Raise boom until cutting edge is
about 1m(3ft) above ground. Repair main control valve
or circuit relief valve.
Stop engine. Measure drift from
tooth or cutting edge to ground for NOT OK
1 minute. If drift is considerably less
on second measurement,
Wait 10 minutes.
repair cylinder.
Measure drift from tooth or cutting
edge to ground for 1 minute.
LOOK : Compare the drift rate
between the first measurement
and the second measurement.
Bucket cylinder leakage Raise bucket about 1m(3ft) off OK
check ground with bucket level. Drift is approximately the
Heat hydraulic oil to same between first and
Stop engine. Place a support
operating temperature. second measurement.
under boom.
Repair main control valve
Measure drift from tooth or cutting
or circuit relief valve at
edge to ground for 1 minute.
page 6-57.
Wait 10 minutes.
NOT OK
Measure drift from tooth or cutting Drift is considerably less
edge to ground for 1 minute. on second measurement.
LOOK : Compare the drift rates Repair cylinder.
between the first measurement
and the second measurement.
Check valve of safety Put bucket level and position OK
valve leakage check about 1.2m(4ft) above ground. Check complete.
Place a piece of tape on cylinder NOT OK
rod at least 51mm(2in) from rod Check or replace safety
guide. valve.
Run engine at low idle in safety-
release position.
LOOK : Bucket must not drift up.
Pilot control valve Stop engine. Turn key switch to OK
(RCV lever) check OFF position. Check completed.
Move control lever to all positions
NOT OK
and then release.
Repair pilot control valve.
LOOK : Lever must return to
neutral when released from all
positions.
6-43
Bucket leveler Position bucket fully dumped just OK

(Positioner) check above ground level. Check complete.
Move control lever to bucket NOT OK
leveler detent position and Do bucket leveler checks
release. in group 3.
LOOK : Bucket must rollback to
the level position and control lever
must return to neutral.
If bucket is in a rolled back
position when key is turned ON,
control lever must be returned to
neutral manually if placed in the
bucket leveler detent position.
After bucket is dumped once,
bucket leveler will work normally.
Boom height kickout Position bucket flat on ground. OK
check Check complete.
Move control lever to boom raise
detent position and release. NOT OK
Do boom height kickout
LOOK : Boom must raise to the
check in group 3.
set height and stop.
Control lever must return to
neutral.
Cycle time check Function Operating condition. Maximum cycle time
Heat hydraulic oil to HL740-7 HL740TM-7
Run engine at high idle. Boom raise Bucket flat on ground to full height. 6.5sec 6.5sec
Boom lower Full height to level ground. 3.2sec 3.2sec

(Float)
Bucket dump Boom at full height. 1.5sec 1.7sec
Bucket rollback Boom at full height. 2.0sec 2.5sec
Steering(No. of Frame stop to frame stop. 2.5sec(4.5 turns)

turns)
OK
Check complete.
NOT OK
Go to slow hydraulic
functions in group 3.
6-44
ଖ MEASURING BOOM AND BUCKET CYCLE TIME
1. MEASUREMENT CONDITION
½ Coolant temperature : Inside operating range
½ Steering position : Neutral
½ Hydraulic temperature : 45~55°C
½ Bucket : Unloaded
½ Engine speed : High idling
2. MEASURING TOOL
½ Stop watch(1 EA)
3. MEASURING PROCEDURE
Lowering time of boom
1) LIFTING TIME OF BOOM
Set the bucket near the maximum tilt back
position and at the lowest position on the
ground. Raise the bucket and measure the
time taken for bucket to reach the
maximum height of the boom.
7407WE18
2) LOWERING TIME OF BOOM

Lifting time of boom
Set the bucket horizontal with the boom at
the maximum height, lower the bucket and
measure the time taken for the bucket to
reach the lowest position on the ground.
7407WE19
3) DUMPING TIME OF BUCKET

Dumping time of bucket
Raise the boom to the maximum height and
Rollback time of bucket
move from the maximum tilt back position
to the maximum dump position
4) ROLL BACK TIME OF BUCKET
Raise the boom to the maximum height and
reach the maximum tilt back position. 7407WE20
6-45
2. TROUBLESHOOTING
ଖ Diagnose malfunction charts are arranged from most probable and simplest to verify, to
least likely, more difficult to verify. Remember the following steps when troubleshooting a
problem :
Step 1. Operational check out procedure(See section 1)

Noisy hydraulic pump Low oil supply or wrong viscosity. Fill reservoir with recommended oil.
Plugged or pinched suction line. Clean or replace line.
Air in oil. Check for foamy oil. Tighten
connections.
Replace O-rings and or lines.
Loose or missing hydraulic line clamps. Tighten or replace clamps.
Hydraulic lines in contract with frame. Inspect and repair.
Worn or damaged pump. Do hydraulic pump performance check
in group 2. Do hydraulic pump flow test
in group 3.
No or Slow hydraulic Failed or worn hydrualic pump. Do performance check.

functions
Cold oil. Warm oil up.
Slow engine speed. Adjust engine speed control linkage.
Check high idle speed.
Suction line air leak. Check for foamy oil.
Low oil supply. Add recommended oil.
Wrong oil viscosity. Use recommended oil.
Oil leaking past cylinders or control Check cylinder drift in group 2.
valve.
Blocked or damaged line. Inspect lines.
Faulty or misadjusted pilot oil supply Do pilot oil supply unit pressure test in
unit. group 3.
Faulty pilot control valve(RCV). Do pilot control valve(RCV) pressure
test in group 3.
Binding main control valve spool. Inspect valve.
Faulty priority valve. Check priority valve specification.
6-46
No steering or hydraulic Low oil level. Add recommended oil.
function
Failed hydraulic pump. Remove and inspect return filter for
metal pump particles.
Failed main hydraulic pump drive. Remove main hydraulic pump and
inspect drive gear.
No hydraulic functions Failed hydraulic pump. Remove and inspect return filter for
steering normal metal pump particles, or replace the
pump.
Failed pilot line filter. Remove and inspect line filter for RCV.
Faulty safety valve. Safety valve leakage test or ON, OFF
function test.
Stuck open system and port relief Replace relief valve.
valve.
Faulty or misadjusted pilot supply unit. Do pilot supply unit pressure test in
group 3.
Boom float function Low pilot control pressure. Do pilot supply unit pressure test in
does not work group 3.
Faulty pilot control valve(RCV). Do pilot control valve pressure test.
Main control valve spool binding in Do pressure reducing valve pressure
bore. test in group 3.
One hydraulic function Faulty pilot control valve(RCV). Do pilot control valve pressure test.
does not work
Stuck open port relief valve. Replace relief valve.
Oil leaking past cylinder packings. Do boom and bucket cylinder leakage
test in group 3.
Blockage in oil lines or valve. Inspect lines for damage.
Disconnect and inspect lines for internal
blockage.
Main control valve spool stuck in bore. Inspect and repair valve.
Low hydraulic power Leakage within work circuit. Do cylinder drift check in group 2.
Low system relief valve(Main relief Do loader system and port relief valve
valve) setting. pressure test in group 3.
Low port relief valve setting. Do loader system and port relief valve
pressure test in group 3.
Faulty or misadjusted pilot oil supply Do pilot oil supply unit pressure test in
unit . group 3.
Leaking system relief valve. Remove and inspect valve.
Worn hydraulic pump. Do hydraulic pump performance check
in group 2.
Faulty pilot control valve(RCV). Do pilot control valve(RCV) pressure
test in group 3.
6-47
Function drifts down Leaking cylinders. Do cylinder leakage checks in group 2.

Leaking seals in circuit relief valve(Port Inspect seals. Replace relief valve.
relief valve) or valve stuck open.
Leaking loader control valve. Repair or replace valve section.
Boom drifts up Leakage in boom down spool. Remove and inspect boom down spool.
Boom down does not Safety valve not operated. Operate valve.
work
Stuck pilot control valve. Inspect.
Engine off.
Faulty line filter. Remove and inspect filter.
Accumulation not operated. Inspect.
Main control valve spool stuck. Inspect and repair valve.
Oil overheats Low oil viscosity in hot weather. Use recommended oil.
Excessive load. Reduce load.
Holding hydraulic system over relief. Reduce load.
Leakage in work circuit. Do boom and bucket cylinder leakage
test in group 3.
Plugged fins in oil cooler. Inspect and clean oil cooler.
Internally plugged oil cooler. Do hydraulic oil cooler restriction test.
Incorrect system or circuit relief valve Do loader system and circuit relief valve
setting. pressure test in group 3.
Restriction in oil lines or main control Inspect for dented or kinked lines.
valve. Do hydraulic system restriction test in
group 3.
Pinched or restricted priority valve LS Run engine at low idle. Steer machine
line. back and forth. If engine load
decreases while steering, a restricted
LS line or priority valve malfunction is
indicated.
Do priority valve LS port flow test in
group 3.
Malfunctioning priority valve. Do hydraulic system restriction test in
group 3.
Leaking system main relief valve. Remove and inspect valve and seals.
Worn hydraulic pump(Internal leakage). Do hydraulic pump performance check
in group 2.
Function drops before Stuck open lift check valve. Do control valve lift check in group 2.
raising when valve is
activated
6-48
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.
6-49
ଖ 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.) Never mix oil of
different makes of kinds.
7) To change the hydraulic oil, use a clean vessel and funnel for pouring it into the tank. Never use
cloth because it might cause the presence of lint in the circuit.
8) When removing the hydraulic equipment, be sure to put plugs or caps on hoses, tube lines and
ports. Also, enter mating marks for later identification.
9) Disassemble and/or assemble the hydraulic equipment only in a clean place free of dust. When
disassembling, be careful about the interchangeability of parts, and clean the disassembled parts
with pure and clean mineral cleansing oil. Clean the internal passages as well. After the parts have
dried, wipe them off with a clean lint-free cloth.
10) When overhauling the hydraulic equipment replace all O-rings, backup rings, etc. with new ones.
Assemble O-rings with grease or vaseline applied.
11) After installing the equipment, add more hydraulic oil to make up for that lost during disassembly.
12) Tighten joints correctly. Loose joints will cause the hydraulic oil to leak. If the oil leaks, the tank oil
level drops and air gets sucked in, so the pump will break down. Also loose joints in suction lines
will take air in and might cause abnormal noise, malfunction or damage to pumps.
6-50
1. HYDRAULIC OIL CLEAN UP PROCEDURE USING PORTABLE FILTER CADDY
ଖ Service equipment and tool

½ Portable filter caddy
½ Two 4000mm Ý 1in 100R1 Hoses
½ Quick disconnect fittings.
½ Discharge wand
½ Various size fittings.
ଖ Loader system uses oil from hydraulic
oil tank. Flush all lines in the loader,
pilot system. Disassemble and clean
major components for hydraulic system.
1) If hydraulic system is contaminated due to a
major component failure, remove and
disassemble steering cylinders to clean
debris from cylinders.
2) Install a new return filter element. Clean
filter housing before installing new element.
ଖ 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 -51
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.
ଖ Hydraulic tank capacity : 105˜ (27.7U.S.
gal)
Leave filter caddy operation for the next
steps.
6) Start the engine and run it at high idle.
ଖ 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.
ଖ Filtering time for machines with auxiliary
hydraulic functions must be increased
because system capacity is larger.
8) Stop the engine. Remove the filter caddy.
9) Install a new return filter element.
10) Check oil level in hydraulic oil tank ; Add oil

if necessary.
6 -52
2. BOOM HEIGHT KICKOUT ADJUSTMENT
1) Start the engine. 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. Boom
With the attachment raised, proper
support must be provided for the
attachment and/or linkage.
Put the hydraulic safety lock lever in the Proximate switch
7707WE20
LOCK position.
2) Loosen the bolts(or nuts). Move the plate

(or proximity switch) so that the boom is in Bolt
line with the center of the sensing surface of Nut
proximity switch.
Then tighten the bolts(or nuts). Boom
Plate
7707WE21
3) Loosen the nuts so that a clearance

between the plate and the probe of the
proximity switch are maximum 6mm. Max 6mm
Boom
7707WE22
4) To check the adjustment, start the engine.

Neutral Detent
Position the bucket on the ground. Then lift position
the bucket to a desired height by using the
control lever and release the hand. Confirm
the lever automatically returns to the neutral
position and the boom(the bucket) stop at
the adjusted position.
7407WE21
6 -53
3. TEST TOOLS
1) CLAMP-ON ELECTRONIC TACHOMETER
INSTALLATION
Tachometer
A : Clamp on tachometer.
Remove paint using emery cloth and B
D
connect to a straight section of injection
C
line within 100mm(4in) of pump. Finger
tighten only-do not over tighten.
B : Black clip(-). Connect to main frame.
C : Red clip(+). Connect to transducer. A
D : Tachometer readout. Install cable.
73035SV01
2) DIGITAL THERMOMETER INSTALLATION

Digital thermometer
A : Temperature probe. A
Fasten to a bare metal line using a tie
band. Wrap with shop towel.
B
B : Cable. C
C : Digital thermometer.
73035SV02
3) DISPLAY MONITOR TACHOMETER

The display monitor tachometer is accurate
enough for test work.
7707SE06
6 -54
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(45· 5¶C ).
6 -55
5. MAIN HYDRAULIC PUMP FLOW TEST
½ SPECIFICATION
Oil temperature 45· 5¶C (113· 41¶F )
Flow meter
Engine speed 2330· 50rpm
Test pressure 220· 10bar(3190psi)
Maximum pump flow 170˜ /min(44.9gpm) To MCV
½ FLOW METER GAUGE AND TOOL

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

3) Heat hydraulic oil to specifications.
(See hydraulic oil warm up procedure in this
group.) Hyd tank
4) Run engine at test specifications.
5) Close flow meter loading valve to increase
pressure to test specifications.
6) Read flow meter.
7) If flow is below specifications, check suction
line and suction pressure for abnormality
before removing pump. 7407WE22
6 -56
6. LOADER SYSTEM AND PORT RELIEF VALVE PRESSURE TEST
Â SPECIFICATION
Oil temperature(40~50äC )
Relief valve Engine speed Relief pressure
220Ü5kgf/cm2
System(M) High
(3130Ü70psi)
Boom 240Ü5kgf/cm2 D U R
Low
raise(U) (3410Ü70psi)
Bucket 240Ü5kgf/cm2
Low
rollback(R) (3410Ü70psi)
HL740-7 : M
240Ü5kgf/cm2
Bucket (3410Ü70psi)
dump(D) Low Main control valve
HL740TM-7 :
120Ü5kgf/cm2
(1710Ü70psi)
Â Gauge and tool

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

delivery line.
Main pump
3) Heat hydraulic oil to specifications.
Hyd tank
group.)
4) To check the system relief valve(M), run
engine at high idle. Lower boom to
bottomed position.
Slowly activate boom down function while
watching pressure gauge. If pressure is not
to specification, loosen lock nut on system
relief valve(M) and adjust to specification. 7407WE23
6 -57
ଖ Do not adjust the system relief valve
above 250kgf/cm2 (3560psi). Damage to
the pump will result from excessive
pressure settings.
5) To check the bucket dump, bucket rollback,
and boom raise, adjust the system relief
valve to 250kgf/cm2 (3560psi).
Run engine to maintain 800~850rpm when
hydraulic function is activated over relief.
Activate the function to be checked with the
cylinder bottomed. Read the pressure
gauge.
If pressure is not to specification cycle relief
valve over relief 10 times to flush.
Read pressure gauge again. Turn screw to
adjust valve to specification.
ଖ Do not work machine with system relief
adjusted above specification or
structural damage may occur.
6) Adjust system relief valve to specification.
6 -58
7. HYDRAULIC SYSTEM RESTRICTION TEST
½ SPECIFICATION
Maximum pressure at steering unit
2MPa(20bar, 285psi)
Maximum pressure at main control valve
1MPa(10bar, 145psi)
½ GAUGE AND TOOL
Gauge 0~7MPa(0~70bar, 0~1000psi) 2EA
This test will check for restrictions in the
hydraulic system which can cause
overheating of hydraulic oil. T

reader installation procedure in this group.)
hydraulic oil warm up procedure in this
group.)
3) Connect gauge to steering unit.
4) Connect fitting and gauge to main control
valve.
Do not operate steering or loader
functions or test gauge may be T
damaged.
5) Run engine at specification and read
pressure gauges.
main control valve, check for a kinked,
dented or obstructed hydraulic line. Check
main control valve for a binding spool.
block, inspect neutral condition of the
steering valve and priority valve for a stuck
spool. Make sure orifice plugs are installed
in ends of priority valve spool.
Check for plugged orifice in priority valve LS
port and dynamic signal orifice on the spool
of priority valve. 7403AWE18
6 -59
8. LOADER CYLINDER DRIFT TEST
HL740-7
½ SPECIFICATION
A
Boom horizontal
Bucket horizontal
Bucket unloaded
Item Standard value
B
Retraction of boom HL740-7 : 30mm
cylinder rod HL740TM-7 : 40mm
Retraction of bucket
30mm HL740TM-7
cylinder rod
½ GAUGE AND TOOL

Stop watch
Temperature reader
Put the safety lock lever in the lock
position.
Do not go under the work equipment.
1) Set the boom and bucket horizontal.
2) Stop the engine, then start measuring. A : Retraction of bucket cylinder rod
3) Measure the amount the boom and bucket B : Retraction of boom cylinder rod
cylinder rods retract during 15 minutes.
(740-3A) 6-56, 7430AWE21
6 -60
9. BOOM AND BUCKET CYLINDER LEAKAGE TEST
½ SPECIFICATION
Oil temperature 45· 5¶C(113· 9¶F)
Engine speed Low idle
Maximum leakage 12cc/10min
½ GAUGE AND TOOL
Temperature reader
Stop watch
Measuring container
1) Fasten temperature sensor to head end
port of cylinder to be tested. Cover sensor
with a shop towel.
group.)
Never work under raised equipment
unless it is supported with a hoist or
support stands.
3) Full extend the cylinder to be tested. If
testing the boom cylinders, restrain boom in
the fully raised position using a hoist or a
stand.
ଖ Check cylinders for leakage in the fully
extended position only. In the retracted
position contacts the end of the cylinder
and seals off piston seal leakage.
4) Remove and plug cylinder rod end hose or
line.
5) Run engine at low idle. Activate control
lever to extend cylinder for 1 minute over
relief while measuring leakage for open
port.
If leakage is within specification, excessive
cylinder drift is caused by leakage in the
main control valve or circuit relief valve.
(740-3A) 6-57
6 -61
10. PILOT CONTROL VALVE PRESSURE TEST
½ SPECIFICATION
Engine speed Low idle
Begin metering 1/5 of lever travel
Boom float detent pressure 17~30bar
RCV
ଘ
Pressure at feel position :
Boom power down 13~17bar
Boom raise 13~18bar
Bucket rollback 13~18bar
Boom power down pressure ~17bar
Boom raise pressure ~18bar
Bucket roll back pressure ~18bar
Bucket dump pressure ~18bar
½ GAUGE AND TOOL
Gauge 0~7MPa(0~70bar, 0~1000psi)
ଘ As the control lever is moved from neutral,
the pilot pressure will suddenly jump up to
approximately 3.7bar at 1/5 travel. The
pressure should then increase smoothly to
the specification at the FEEL position(Or
4/5 lever travel).
This test will determine if adequate pilot
pressure is available to move the loader Hyd tank
control valve spools.
ଖ 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 Pilot line filter
function to be checked.
4) Heat hydraulic oil to specification. 7407WE24
group.)
6 -62
5) Run engine at specification. Activate
function to be checked and record pressure
reading.
ଖ If boom raise or bucket rollback FEEL
positions are not operation due to boom
or bucket position, plug boom float
detent wires into bucket leveler solenoid
or boom height kickout solenoid. This
will provide a feel position on the control
lever.
6 -63
11. PILOT OIL SUPPLY UNIT PRESSURE TEST
½ SPECIFICATION
Engine speed Low idle and stop
Pilot pressure setting 30~35bar(430~500psi)
Relief valve setting pressure
45bar
Accumulator precharging pressure
16bar
½ GAUGE AND TOOL
P2
Gauge 0~7MPa(0~70bar, 0~1000psi) U
T
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 block.
3) Heat hydraulic oil to specification.(See
Pilot line filter
group.)
4) Run engine at low idle for 1 minute and
stop engine, wait for 5 minutes. Then start
measuring.
5) If pressure in not within specifications,
replace valve. The valve is staked and
should not be adjusted. 7407WE25
6 -64
12. CYCLE TIME TEST
½ SPECIFICATION
Maximum cycle time(Seconds)
Function Operating conditions
HL740-7 HL740TM-7
Boom raise Bucket flat on ground to full height 6.5
Boom lower(Float) Full height to ground level 3.2 3.2
Bucket dump Boom at full height 1.5 1.7
Bucket rollback Boom at full height 2.0 2.5
Steering(Number of turns) Frame stop to stop 2.5(4.5 turns)
Hydraulic pump performance cycle time.
Function Operating conditions Maximum cycle time(Seconds)
Bucket flat on ground to full height

Boom raise 7.0
while holding steering over relief
6 -65
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(1) and take out the filter
1
case cover(2) and O-ring(3).
3) Remove the spring(4) and bypass valve(5). 2
3
4) Remove the filter element(6) from the tank.
4
5) Check the element and the filter case
5
bottom for debris. Excessive amounts of
brass and steel particles can indicate a 6
failed hydraulic pump or a pump failure in
process. A rubber type of material can
indicated cylinder packing or other packing
failure.
ଖ The hydraulic oil filter in the filter case of
the hydraulic oil tank should be
replaced every 250 operating hours(For
the first replacement, at 50 hours) or
more often. When the filter element is
replaced, please keep as follows.
(1) Clean the inside of the filter case.
(2) Place new element in the proper positions
inside the filter case.
(3) Install the bypass valve and spring.
Make sure the element stand upright, and
check for complete contact of the element
bottom with the filter case bottom.
(4) Install the O-ring and filter case covers.
Tighten them with bolt. Replace the O-
ring with new one if damaged.
7407WE26
6 -66
1. MAIN PUMP
1) STRUCTURE
21
20
13
11 12
22
19
15
8
7 14
6
17
18
9
16
8 15
7 14
6 13
12
11
10
1
2
7407WE12
1 Shaft seal 11 Wearplate 17 Spline coupling

2 Adapter 12 O-ring seal 18 Rear driven gear
6 Back up seal 13 Back up seal 19 Rear drive gear
7 O-ring seal 14 Interface seal 20 Stud
8 Wearplate 15 Dowel 21 Flanged nut
9 Front drive gear 16 Front body 22 Rear body
10 Front driven gear
6 -67
2) DISASSEMBLY
21
20
13
11 12
22
19
15
8
7 14
6
17
18
9
16
8 15
7 14
6 13
12
11
10
1
2
7407WE12
ଖ Plug all ports prior to cleaning and disassembling pump to prevent ingress of debris or
contamination.
ଖ Clean the pump thoroughly with a solvent, ensuring no loose debris or contamination remains on
the unit.
ଖ Mark each interface and then separate into individual pump sections.
(1) Securely clamp pump horizontally on one port face, ensuring that no damage is sustained to the
port face and remove the stud(20) and nut(21).
(2) Remove the front adaptor(2) from the body(16) using a pulling tool centred on the drive shaft(9).
ଖ Under NO circumstances attempt to prise or chisel cover from body as such action could damage
the machined sealing faces.
(3) Remove and discard the shaft seal(1) from adaptor making sure that no damage is sustained to
the surface of the seal bore.
(4) Unclamp pump and place it vertically with drive shaft up.
(5) Before removing wearplate from the body mark it using a soft pencil or a felt-tip pen to ensure
correct reassembly. Remove wearplate(8) complete with O-ring seal(7) and back up seal(6).
6 -68
DISASSEMBLY
21
20
13
11 12
22
19
15
8
7 14
6
17
18
9
16
8 15
7 14
6 13
12
11
10
1
2
7407WE12
(6) Mark the gears using a soft pencil or felt-

tip pen to ensure assembly in the same
relative position, see figure on the right,
then withdraw the drive shaft/gear(9) and
driven gear(10) separately to prevent
jamming.
(7) Again, to ensure correct assembly, mark
remaining wearplate(11) using a soft
pencil or a felt-tip pen. Remove wearplate
from body complete with O-ring seal(12) 7607WE34
and back up seal(13).

(8) Discard interface seal(14).
(9) Having separated into individual pumps,
proceed as per paragraph (1)~(7).
6 -69
3) MANDATORY REPLACEMENT PARTS
Discard all seals including interface seals, shaft seals, wear plate seals and back up seals. Fit new
seals on reassembly. Wearplates should also be replaced with new items from seal kit.
4) HANDLING/STORAGE
While disassembling pump, ensure no surfaces are scored or marked in any way. A rubber
surfaced table will be beneficial. All components must be placed in a clean, dry and safe area.
Leakage will be created by scratches on components. If parts are to be left for any period ensure
they are not exposed to dirt, dust and corrosion. Keep gears separate from each other in
protective boxes.
5) INSPECTION OF PARTS
Wash all parts in a solvent and dry.
(1) Adaptor housing and cover
The pump must be replaced if the damage listed is present.
Feature Damage
Corrosion, nicks or burrs(slight burrs can be removed
Surfaces
using and india stone)
Machined sealing lnterfaces Scores, cracks or corrosion
Bearing Loose
(2) Gears
Feature Damage
Surfaces using an lndia stone).
Wear due to seal(s)
Journals Pitting, wear, sufficient wear to change outside diameter
Tooth Cracks or heavy scoring or chipped
Splines/keyways Distortion of wear
End faces Wear, cracks
6 -70
(3) Floating wear plates
Feature Damage
Corrosion, nicks or burrs, amounts of scoring,erosion

Surfaces or any cracks, discoloration caused by overheating
Removing burrs or minor scoring from Scoring of wear plate.

end faces and teeth of the gears.
(4) Bolts/Studs
The pump should be replaced if the damage listed is present.
Feature Damage

Surfaces using an lndia stone), cracks or scoring,
distortion or damage to thread form
(5) Plain bearings

Feature Damage
Surfaces Cracks or socring

PTEF Coating Worn-bronze, sub-layer showing
Bearing Loose in housing/cover
(6) Coupling
This must be replaced if damage listed is present.
Feature Damage
Surfaces Corrosion, nicks or burrs, erosion, cracks or pitting

Splines Distorted or badly worn
6 -71
6) ASSEMBLY
21
20
13
11 12
22
19
15
8
7 14
6
17
18
9
16
8 15
7 14
6 13
12
11
10
1
2
7407WE12
ଖ It is critical that the wearplates are assembled into the pump with regard to the following:
-The seal side of the wearplate must be adjacent to the adaptor or body.
-The high pressure side of the wearplate must be adjacent to the outlet port.
ଖ This must take place in a clean dry area, ensuring that all parts are clean and free from
contamination or loose particles. Lightly oil all surfaces.
(1) Place body vertically with gear pockets upper most.
(2) Slide wearplate(11) complete with O-ring seal(12) and back up seal(13) down through the housing
to the bottom of the gear pockets.
ଖ Be sure to refit the wearplate the same as that marked from this position during disassembly.
(3) Fit the gears(18,19) within the housing taking care to replace as marked, with the teeth
reassembled to their original related position.
(4) Fit the wearplate(8) complete with O-ring seal(7) and back up seal(6).
ଖ Be sure to refit the wearplate the same as that marked from this position during disassembly.
6 -72
ASSEMBLY
21
20
13
11 12
22
19
15
8
7 14
6
17
18
9
16
8 15
7 14
6 13
12
11
10
1
2
7407WE12
(5) Fit new interface seal(14) into groove in body.

(6) Proceed as per paragraph(1)~(5).
(7) Fit adaptor(2) over the drive gear(9) and fit stud(22).
(8) Securely clamp unit and tighten nut(21) to half torque and then full torque.
½ Tightening torque : 23.2kgf½ m(168lbf½ ft)
(9) Fit shaft seal(1) using appropriate tooling, in correct position and orientation.
(10) Pour a little clean hydraulic oil into the ports.
6 -73
2. RCV LEVER
1) STRUCTURE
17
29
B
50 28
26
12
4 1
24 2 13
3
5 6
23
27 4 7
2 2
21
1
3
A
4 1
3 2
8
15
47 25
16
10 9
30
14
18
15 19
20
11
49
22
A
B 7403AWE11
1 Spring 12 Prefeel cage assy 23 O-ring

2 Spring 13 Spindle retainer 24 Wiper seal
3 Spring 14 Spindle 25 Plug
4 Plunger assy 15 Nut 26 Collar
5 Plunger assy 16 Lever assy 27 Handle adapter
6 Plunger assy 17 Handle 28 Nut
7 Plunger assy 18 Universal joint assy 29 Nut
8 Body 19 Screw 30 Insulation tube
9 Prefeel kit 20 Connector assy 47 Nut
10 Prefeel kit 21 Rubber boot 49 Spacer
11 Prefeel kit 22 Solenoid 50 Handle assy
6 -74
2) DISASSEMBLY AND ASSEMBLY
(1) Detach the rubber boot(21) from the
retainer collar and lift the boot clear from 21
the selector assembly.
The capscrew(19) can now be easily
accessed.
Selector assy
7406S 6-78(1)
(2) Loosen and remove all four M6

capscrews(19).
½ Tightening torque : 1.0kgf½ m(7.2lbf½ ft)
19
7406S 6-78(2)
(3) The upper portion of the valve, from the

mounting plate upwards, can now be
detached and placed to one side. Upper portion
ଖ The magnets will still be connected to the of valve
connector.
7406S 6-78(3)
(4) Remove the ball carriers off of the spindle

guide - carefully detach the spindle
guides, being careful to ensure that no
contamination enters the valve. Spindle
ଖ The spindle guide are retained by guide
interference between the body and the
guide O-ring.
7406S 6-78(4)
6 -75
(5) The spindle guides can now be replaced.
The O-rings on the spindle guide must be
replaced before the valve is reassembled. O-ring
7406S 6-79
Reassembly is the opposite of

disasembly.
6 -76
3. MAIN CONTROL VALVE
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 -77
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 10lbf½ ft.
Final torque the two 11/16 nuts to 48·
5lbf½ ft ; Final torque the 3/4 nut to 74·
8lbf½ ft. Check for proper spool movement.
7406S MCV06(1)
6) Install auxilliary valves and plugs and

torque to proper specifications.
ଖ 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 -78
4. BOOM AND BUCKET CYLINDER
1) BOOM CYLINDER
19 7 10,11 23 22 3 4 1 2 13,14 17 15 16 12 18
6,5
9,8
20 24 25,26 21 27,28
7407WE10
1 Tube assy 11 Back up ring 21 Pipe assy

2 Rod assy 12 Piston 22 O-ring
3 Gland 13 O-ring 23 Socket bolt
4 Bushing 14 Back up ring 24 Pipe clamp
5 Rod seal 15 Piston seal 25 Hexagon bolt
6 Back up ring 16 Wear ring 26 Spring washer
7 Buffer ring 17 Dust ring 27 Bushing
8 Dust wiper 18 Nylon nut 28 Dust seal
9 Snap ring 19 Socket bolt
10 O-ring 20 Pipe assy
6 -79
2) BUCKET CYLINDER
7 25 24 3 11,10 4 1 2 14,13 17 15 16 12 19
6,5 18
9,8
22
21
26,27
20 23
7407WE11
1 Tube assy 10 O-ring 19 Set screw

2 Rod assy 11 Back up ring 20 Socket bolt
3 Gland 12 Piston 21 Band assy
4 Bushing 13 O-ring 22 Pipe assy
5 Rod seal 14 Back up ring 23 Pipe assy
6 Back up ring 15 Piston seal 24 O-ring
7 Buffer ring 16 Wear ring 25 Socket bolt
8 Dust wiper 17 Dust ring 26 Bushing
9 Snap ring 18 Nylon nut 27 Dust seal
6 -80
3) TOOLS AND TIGHTENING TORQUE
(1) Tools
Tool name Remark
8 B
Allen wrench
12
Spanner 19
(-) Driver Small and large sizes
Torque wrench Capable of tightening with the specified torques
(2) Tightening torque

Torque
Part name Item Size
kgf½ m lbf½ ft
Bucket cylinder 20
M14Ý 2.0Ý 55 15· 2 108· 14.5
Boom cylinder 19
Socket head bolt
Bucket cylinder 25
M10Ý 1.5Ý 45 5.4· 0.5 39· 3.6
Boom cylinder 23
Bucket cylinder M64Ý 3.0 150· 15 1085· 108
Nylon nut 18
Boom cylinder M48Ý 2.0 250· 25 1808· 181
Hex head bolt Boom cylinder 25 M12Ý 1.75Ý 40 5.5· 0.6 40· 4.3
6 -81
4) DISASSEMBLY
(1) Remove gland and piston rod
ཛ 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.
ཛྷ Pull out piston rod(2) about 200mm

(7.8 in). Because the piston rod is rather
200mm
heavy, finish extending it with air
pressure after the oil draining operation.
(740-3A) 6-76(1)
ཝ Loosen and remove socket bolts(19) of

Hexagon
the gland(3) in sequence. socket wrench
ଖ Cover the extracted piston rod(2) with
rag to prevent it from being accidentally
damaged during operation.
3
19!
2
Cover here
with rag
(740-3A) 6-76(2)
ཞ Draw out gland(3) and piston rod (2)

assembly together from cylinder tube(1).
Lift 1
ଖ Since the piston rod assembly is heavy
in this case, lift the tip of the piston rod(2)
with a crane or some means and draw it
out. However, when piston rod(2) has 3 2
been drawn out to approximately two
Oil pan
thirds of its length, lift it in its center to Pull straight
sideways
draw it completely.
(740-3A) 6-76(3)
6 -82
ଖ 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.
ཟ Place the removed piston rod assembly

on a wooden V-block that is set level.
ଖ Cover a V-block with soft rag. Piston rod assy
Wooden block
(740-3A) 6-77(1)
(2) Remove piston and gland assembly

ཛ Remove the nylon nut(18). 13,14 17 15 12 16 18
ཛྷ Remove piston assembly(12) and O-ring
(13), back up ring(14).
(740-3A) 6-77(2)
ཝ Remove the gland assembly from piston

Lift with a crane
rod(2).
ଖ If is too heavy to move, move it by Plastic 3 4 2
Hammer
striking the flanged part of gland(3) with a
plastic hammer. Pull straight
ଖ Pull it straight with gland assembly lifted
with a crane.
Exercise care so as not to damage the lip
of rod bushing(4) and packing(5, 6, 7, 8,
(740-3A) 6-77(3)
9) by the threads of piston rod(2).
6 -83
(3) Disassemble the piston assembly
ཛ Remove wear ring(16), dusting(17), and 17 15 16
piston seal (15).
damage the grooves.
(740-3A) 6-78(1)
(4) Disassemble gland assembly

ཛ Remove back up ring(11) and O-ring 8,9 5,6 7 11 10 4
(10).
ཛྷ Remove snap ring(9) and dust wiper(8).
ཝ Remove back up ring(6), rod seal(5) and
buffer ring(7).
damage the grooves.
ଖ Do not remove seal and ring, if does not
(740-3A) 6-78(2)
damaged.
6 -84
5) ASSEMBLY
(1) Assemble gland assembly
ཛ Coat the inner face of gland(3) with
hydraulic oil.
3
(740-3A) 6-79(1)
ཛྷ Coat dust wiper(8) with grease and fit

Press here
dust wiper(8) to the bottom of the hole of (Straight down)
dust wiper.
Metal
ཝ At this time, press a pad metal to the
8
metal ring of dust seal.
Fit snap ring(9) to the stop face.
(740-3A) 6-79(2)
ཞ Fit back up ring(6), rod seal(5) and buffer

ring(7) to corresponding grooves, in that
order.
ଖ Coat each packing with hydraulic oil
Wrong Right
before fitting it.
ଖ Insert the backup ring until onside of it is
inserted into groove.
(740-3A) 6-79(3)
ଖ Rod seal(5) has its own fitting direction.

Therefore, confirm it before fitting them.
Push bar
ଖ Fitting rod seal(5) up side down may
damage its lip. Therefore check the
correct direction that is shown in fig.
5
(740-3A) 6-79(4)
6 -85
ཟ Fit back up ring(11) to gland(3).
ଖ Put the backup ring in the warm water of
~
30 50° C.
11
འ Fit O-ring(9) to gland(3).
10
(740-3A) 6-80(1)
(2) Assemble piston assembly

12
ཛ Coat the outer face of piston(12) with
hydraulic oil.
(740-3A) 6-80(2)
ཛྷ Fit piston seal(15) to piston

ଖ Put the piston seal in the warm water of
~
60 100° C for more than 5 minutes.
15
ଖ After assembling the piston seal, press

its outer diameter to fit in.
(740-3A) 6-80(3)
ཝ Fit wear ring(16), dust ring(17) to

piston(12). 17 15 16 12
ཞ Fit O-ring(13) and backup ring(14) to
piston(12).
(740-3A) 6-80(4)
6 -86
(3) Install piston and gland assembly
ཛ Fix the piston rod assembly to the work Gland assembly
bench.
Piston rod
ཛྷ Apply hydraulic oil to the outer surface of
piston rod(2), the inner surface of piston
and gland.
ཝ Insert gland assembly to piston rod(2).
(740-3A) 6-81(1)
ཞ Fit piston assembly to piston rod.

Piston assembly
Piston rod
(740-3A) 6-81(2)
ཟ Tighten nylon nut(18) to piston rod(2)

½ Tightening torque:250· 25kgf½ m 2 18
(1808· 181lbf½ ft)
(740-3A) 6-81(3)
6 -87
(4) Overall assemble Fix with a bar
ཛ Place a V-block on a rigid work bench.
Mount the cylinder tube assembly(1) on it
Lift
and fix the assembly by passing a bar
through the clevis hole to lock the
assembly.
ཛྷ 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 (740-3A) 6-82(1)
crane.
ଖ Be careful not to damage piston seal by
thread of cylinder tube.
ཝ Match the bolts holes in the cylinder Tube
head flange to the tapped holes in the
cylinder tube assembly and tighten
socket bolts to a specified torque. Piston rod
ଖ Refer to the table of tightening torque. Hexagon
socket bolt
Gland
(740-3A) 6-82(2)
6 -88
SECTION 7 ELECTRICAL SYSTEM
Group 1 Component Location 7-1

Group 2 Electrical Circuit 7-3
Group 3 Monitoring System 7-21
Group 4 Electrical Component Specification 7-37
Group 5 Connectors 7-44
Group 6 Troubleshooting 7-61
SECTION 7 ELECTRICAL SYSTEM
GROUP 1 COMPONENT LOCATION
1. LOCATION 1
7
8 Cab roof
1
2
9 15
10 16
11 17
Front
12 18
LH SIDE
3 13
4 14
5
6
A
7407EL02
1 Buzzer stop switch 7 Radio & cassette 13 12V socket

2 Beacon switch(option) 8 Aircon & heater switch 14 Starting switch
3 Horn button 9 Work lamp switch 15 Auto select switch
4 Multi function switch 10 Main light switch 16 Clutch cut off switch
5 Cluster 11 Parking brake switch 17 Ride control switch(option)
6 Gear selector lever 12 Hazard switch 18 Rear wiper/washer switch
7-1
2. LOCATION 2
1 2 3 4 5
6
7
18
10
8 9
17
16
15
11 12 13 14
7407EL02-1
1 Proximity switch 7 Front turn lamp 13 Rear combi lamp

2 Proximity switch 8 Fuse box 14 Back up buzzer
3 Horn 9 Machine control unit(MCU) 15 Number plate lamp
4 Work lamp 10 Transmission coutrol unit(TCU) 16 Master switch
5 Switchs 11 Start relay 17 Rear combi lamp
6 Head lamp 12 Battery 18 Fuel sender
7-2
8
7
6
5
4
3
2
1
START SWITCH
H BR ACC ST C
24V
5
6
2
3
H0 I
86
86
86
86
86
RIDE
85
85
85
85
85
3
3
3
3
3
3
1
1
1
1
1
1
12V
1
AC 24V
Pa
Pa
M33 0.85 BW
30
30
30
30
30
AC COMP
2
4
4
4
4
4
4
2
2
2
2
2
2
C01A 0.85 G
24V
12V
CR-6
CR-3
CR-2
CR-7
87 87a
87 87a
87 87a
87 87a
87 87a
CR-5
CR-4
GND
BUZZER
2
1
1
1
CR-35
CR-30
DO-4
DO-3
2
2
1
ILLUMINATION
CR-26
CR-40
CR-41
0, I
1
BRAKE PS
2
2
1
1
WARNING
SAFETY RY
CN-26 B
CONTROL RY
CN-138
WIPER RY LO
12V SOCKET
PARKING PS
CN-139
CD-3
BUCKET
87a
87a
87a
87a
87a
A
CN-71
4
4
4
4
86
4
86
86
4
86
86
85
85
85
85
85
30
30
30
30
30
1
2
3
1
2
3
1
2
3
1
2
3
87
C
B
1
2
3
87
87
1
2
3
87
87
CD-26
AIR-CON RY
BACK-UP RY
HORN RY
BOOM UP
WIPER RY HI
AC CONTROLLER GND
AC CONTROLLER B+
6
AC CONTROLLER B+
5
1
2
4
PARKING SOL.
3
AC CONDENSOR FAN
DC/DC CONVERTER
WORK LAMP REAR

BLOWER MOTOR GND
CS-2
WORK LAMP FRONT
L
1 M42C 1.25 BrW
UNIT
B
G 2 M11 1.25 R
E
1
7
8
6
5
3
2
FLASHER
3 G62 1.25 B
CN-11
EARTH 1
CR-11
R08 0.85
G34 1.25
T32 0.85
T22 0.85
G32 1.25
M50 1.25
M53 0.85
R09 0.85
M48 0.85 L
M44 0.85
G28 0.85
G27 0.85
M43 1.25
CN-22
M26 0.85
R07 0.85 G
G33 1.25 B
M47 0.85 W
G25 1.25 B
M21 0.85 L
G29 1.25 B
R05 0.85 V
G21 1.25 B
M49 0.85 G
G58 0.85 B
G59 0.85 B
M43 1.25 R
E05 0.85 R
M45 0.85 W
M39 0.85 G
G26 1.25 B
R10C 0.85 R
Br
M38 0.85 Br
G31 1.25 B
R10B 0.85 R
M52 0.85 L
M51 0.85 W
C03 1.25 Or
B
G22 1.25 B
F03 0.85 Y
M14A 1.25 L
M46 0.85 R
M50 1.25 Or
Br
C04 1.25 Br
M08A 1.25 W
Gr
EF08 0.85 W
M45A 0.85 W
F05 0.85 LW
Or
Or
M22 0.85 Gr
M07A 1.25 V
M27C 0.85 R
1
M37 1.25 GY
M07B 1.25 V
M45B 0.85 W
M56B 0.85 L
M05C 1.25 L
M05B 1.25 L
R17 0.85 BOr
G54 1.25 B
T37C 0.85 W
M10A 1.25 Gr
G18 0.85 B
F12 0.85 V
R
M10B 1.25 Gr
ROr
B
F/WASHER
B
T34B 0.85 GrW

Gr
M 2 M27B 0.85 R
M25 0.85 VOr
M04B 1.25 Or
M01 1.25 WOr
M03 2.0 R
G15 2.0 B
M05A 2.0 L
F06 1.25 Y
G02 1.25 B
CN-103
M04A 1.25 Or
RF53A 1.25 W
1 G53 1.25 B
M 2 M56A 0.85 L
R/WASHER
CS-51
10 10 G07 0.85 B
9
GROUP 2 ELECTRICAL CIRCUIT
EARTH 2
9 C05A 0.85 R
8
8
6 7
2
6
EARTH5
7 CN-36
5 5 M09A 0.85 W
1 BEACON LAMP 20A
4 C07 1.25 G 1
ILL.LAMP 10A
3 2
M17 1.25 OrW
20A
AUTO/MANUAL SW
2 M03 2.0 R HEAD LAMP

M15 1.25 YW 3
1 M32 0.85 Y M04 1.25 Or BACK/STOP LAMP 10A
M08 1.25 W 4
M05 2.0 L HORN/CONVERTER 30A
C01B 0.85 G M07 1.25 V 5
AIR-CON/HEATER 20A
CS-42 M07 1.25 V 6
M05 2.0 L
10 G09 0.85 B M06 0.85 W CIGAR 20A
9 10 M18 0.85 Or 7
9 C05J 0.85 R T28 0.85 R SWITCH 10A
M09 0.85 W 8
8
8 F/R WIPER 20A
6 7 M14 1.25 L 9
2 WORK LAMP 30A
6 M08 1.25 W 10
7 M10 1.25 Gr
5 5 M09C 0.85 W M09 0.85 W OPTION 10A
1 M60 0.85 GrW 11
M01 1.25 WOr
4 M10 1.25 Gr CASSETTE/BUZZER 5A

C01B 0.85 G 12
3 M11 1.25 R
PREHEATER 30A
2 M13 1.25 LOr 13
CLUTCH CUT-OFF SW
TURN LAMP 20A

1 M31 0.85 GrW C02 0.85 Y 14
M11 1.25 R
RF53 1.25 W RADIO/ROOM LAMP 5A
C02 0.85 Y 15
START KEY 30A
CS-39 M04 1.25 Or 16
E18 0.85 LW 10A
TCU
G19 0.85 B M12 0.85 ROr T28 0.85 R 17
9 10
ECM 10A
10 9
C05B 0.85 R E16A 0.85 W E16A 0.85 W 18

8
4 M13 1.25 LOr CLUSTER 10A

2 M12 0.85 ROr 19
7
C05C 0.85 R M60 0.85 GrW AC & HEATER 10A

20
6
7 1 RF51 1.25 G M03 2.0 R

SPARE 10A
5
5 M02 1.25 BrW M14 1.25 L 21

ECM 5A
4
M15B 1.25 YW M15 1.25 YW E18 0.85 LW 22

3
R10A 0.85 R RCV 10A

R10A 0.85 R 23
2
0 I
ILL & HEAD LAMP SW
M41 1.25 W M16 1.25 Br CONTROLLER 10A

24
1
M17 1.25 OrW M17 1.25 OrW M16 1.25 Br

TCU 10A
T18D 0.85 L T18D 0.85 L 25
CLUSTER 10A
M18 0.85 Or M06 0.85 W 26
CS-41 C07 1.25 G ILL,F/L,R/R 5A
RF51 1.25 G 27
10 10 G10 0.85 B ILL.F/R,R/L 5A
9
RF53 1.25 W 28
9 C05D 0.85 R
8
8
6 7
2
6 M42B 1.25 BrW M02 1.25 BrW
7
5 5 M42A 1.25 BrW F21 3.0 W
1
4 F22 5.0 R
HAZARD SW
3
2 RF50D 0.85 Or CN-98
1 RF52 0.85 L ET02B 0.85 G A A
ET01B 0.85 V B
C
RESISTER
B
CS-3
9 10 G11 0.85 B
10 9
C05L 0.85 R F07 0.85 GrW

8
3 M54 0.85 W M25 0.85 VOr T37B 0.85 W NEUTRAL SIG

7
M26 0.85 Gr M21 0.85 L SAFETY RY

8
6
6 M55 0.85 Or M16A 1.25 Br PREHEATER

1
5
M22 0.85 Gr M22 0.85 Gr WIPER RY

4
STEERING RY
I0,
M21 0.85 L
3
M56 0.85 L M24 0.85 W(tw) SERIAL-H

2
0 I
M40 0.85 BW M35 0.85 B(tw) SERIAL-L

1
M14C 1.25 L ET02 0.85 G(sh) M34 0.85 ROr CLUTCH CUT-OFF PS
REAR WIPER & WASHER SW
ET01 0.85 V(sh) F04 0.85 OrW FUEL SENSOR

M34 0.85 ROr F08 0.85 WOr HYD TEMP SENDER
CS-50 M29 0.85 Gr COOLANT SIG
10 G12 0.85 B C06 0.85 L EF20 0.85 RW ALT LEVEL
9 10
9 C05E 0.85 R T37B 0.85 W F10 0.85 V(sh) FAN CLUTCH-
8 M53 0.85 Br T30 0.85 W(tw) F09 0.85 G(sh) FAN CLUTCH+
8
4 7 M28 0.85 Y M27 0.85 R G42 1.25 B GND
2
6 F09 0.85 G(sh) M33 0.85 BW BUZZER
CONTROLLER
7
3 5 F25 0.85 WOr T30 0.85 W(tw) SPEEDMETER SIG.
1
4 M60A 0.85 GrW M33 0.85 BW ET02 0.85 G(sh) CAN-L
3 M60B 0.85 GrW F10 0.85 V(sh) ET01 0.85 V(sh) CAN-H
RIDE CONTROL SW
2 R06 0.85 LW M32 0.85 Y T29 0.85 Y AUTO SEL.TCU
1 M29 0.85 Gr F13B 0.85 Br TACHO SENSOR-
T29 0.85 Y F26 0.85 Gr STEERING PS
EF20 0.85 RW ENG OIL PS
CS-20 F08 0.85 WOr F07 0.85 GrW AIR FILTER
9 10 G13 0.85 B F26 0.85 Gr M16A 1.25 Br IG 24V
10 9
C05F 0.85 R M30 0.85 Y M32 0.85 Y AUTO SEL.SW
8
4 F04 0.85 OrW M31 0.85 GrW CLUTCH CUT-OFF SW
2
7
36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
M59 0.85 Y M28 0.85 Y TACHO SENSOR+

8
6
7 1 M31 0.85 GrW M30 0.85 Y WIPER INT SIG
5
7
5 M51 0.85 W M29 0.85 Gr RIDE CONT. ON

6
4
C05G 0.85 R M24 0.85 W(tw) M28 0.85 Y RIDE CONT. AUTO
3
5
WORK LAMP SW
M35 0.85 B(tw) M27 0.85 R WASH SIG
2
4
0 I
M52 0.85 L C06 0.85 L BUZZER STOP
1
3
C05H 0.85 R F11 shield F25 0.85 WOr STEERING P/P PS

2
T39 0.85 B(tw) M26 0.85 Gr PARKING SIG

CN-58
ET03B shield M25 0.85 VOr BRAKE PS

CS-17
10 10 G17 0.85 B F13B 0.85 Br STOP LAMP P/S
9
9 C05K 0.85 R CN-97 M40 0.85 BW HOURMETER
23 19 15
8 M44 0.85 L 4 GND(MECHANICAL)

8 CN-48
8
6 7 T26 0.85 YW 3 M64 0.85 W MODE

2
E
7
6 M09E 0.85 W M40 0.85 BW 2 M63 0.85 L RS-RX

CN-59
7 h
B
5 1 RS-TX
6
5 M09F 1.25 W M16B 0.85 Br M62 0.85 G

HOUR
METER
1
4 GND
5
M61 0.85 B
PARKING SW
3
2
1
OPTION
M64 0.5 R TX-PC

M35 0.85 B(tw) 12 12 M62 0.5 B GND
11 11 RF51A 0.5 G ILL.
CLUSTER
RF51A 0.85 G 10 10 T40 0.5 RW T/M ERROR
EARTH 3
T40 0.85 RW 9 9 M35 0.5 B SERIAL-L
M59 0.85 Y 8 8 M24 0.5 W SERIAL-H
R13B 0.85 V 7 7 G44 0.5 B GND
DO-1 G41 0.85 B 6 6 G43 0.5 B G45 0.5 B GND
1 M48C 0.85 L M24 0.85 W(tw) 5 5 M63 0.5 BrW RX-PC
20 19 17 16 15 14 12 11 10 9
2 R10M 0.85 R RF52A 0.85 L 4 4 M65 0.5 G FWE

8
RF50A 0.85 Or 3 3 N.C

7
DO-2 M12 0.85 ROr 2 2 M59 0.5 Y WORK LAMP

6
1 M47C 0.85 W M06 0.85 W 1 1 R13B 0.5 Br HIGH BEAM

5
2 R10N 0.85 R CN-12 RF50A 0.5 Or RH TURN

4
RF52A 0.5 L LH.TURN

3
CN-114 M12 0.5 RY 24V PER.
7-3
2
1 R10E 0.85 R M06 0.5 W M06B 0.5 W 24V IG

5 BL- BL+ 1
1
2 R10F 0.85 R CN-95 M06A 0.5 W 24V IG

CN-51
6 BK- BK+ 2
3 R10G 0.85 R 4
7 FL- FL+ 3
4
EARTH4
R10D 0.85 R 3
5 M47A 0.85 W 2
6 M48A 0.85 L 1 CS-5
4 8
7 G68 0.85 B M37 1.25 GY
Y HO
8 T27A 0.85 VOr
1
JOY STICK M30 0.85 Y 2 Gr W

M37 1.25 GY 14 14 M27A 0.85 R 6 RW C
2 3
M30 0.85 Y 13 13 M38 0.85 Br 1 BY J

4
CN-111 M27A 0.85 R 12 12 M39 0.85 G

5
1 R10L 0.85 R M38 0.85 Br 11 11 M40 0.85 VOr 4 L I

6
2 R10K 0.85 R M39 0.85 G 10 10 M14D 1.25 L ^Z

3 BVi
3 R10J 0.85 R 9 9 CS-12
5 G O J
4 8
MULTI FUNCTION SWITCH
T27B 0.85 VOr M14D 1.25 L 8

O
5 M47B 0.85 W M41 1.25 W 7 7 M41 1.25 W 8 I
6 M48B 0.85 L R14 0.85 RW 6 6 R14 0.85 RW 7 ^Z
7 G67 0.85 B R13A 1.25 V 5 5 R13A 1.25 V 6 R
8 R10H 0.85 R M15A 1.25 YW 4 4 M15A 1.25 YW 5 C BG 3
M42 1.25 BrW 3 3 M42 1.25 BrW 4 4 BWG
RF50B 0.85 Or 2 2 RF50B 0.85 Or 3 L BW 2
CL-2 Hi
RF52B 0.85 L 1 1 RF52B 0.85 L 2
B 6 W Lo Y 7
M18A 0.85 Or CN-7 1
A RF53B 1.25 W CS-11
C
CIGAR
1 G52 1.25 B WB 8
LIGHTER
CR-46
3 4 4 E07 1.25 VOr
EARTH 6
3 E19 0.85 V B+
M
B 5
2 M13A 1.25 LOr R
Pf
B
E
1 2 1 G56 1.25 B O
L
FRONT WIPER
Hi 4
2
3
Lo 5
FUEL WARMER
Lo Hi F
CR-42 6 5 4 3 2 1
3 4 4 E06 0.85 G
CN-21
3 E09 0.85 L
2 M13B 1.25 LOr
1 2 1
SHIFT LEVER
G61 1.25 B
X2
PREHEATER RY
14 14
AD5 C
M46 0.85 R 13 13 M46 0.85 R AD4 B
M49 0.85 G 12 12 M49 0.85 G AD6 D
G51 1.25 B 11 11 G51 1.25 B ED1(VP) A
1
E 3 M14B 1.25 L 10 10
X1
2
Pf 2 M54 0.85 W M45C 0.85 W 9 9 M45C 0.85 W AD7(KD) D
3
B 1 G55 1.25 B T27C 0.85 VOr 8 8 T27C 0.85 VOr D
AD1 C
4
T33 0.85 LW 7 7 T33 0.85 LW C
AD2 B
5
Hi 4 M55 0.85 Or T35 0.85 L 6 6 B
REAR WIPER
T35 0.85 L
6
M Lo 5 T25 0.85 RW 5 5 T25 0.85 RW A AD3 A
CN-102 T37A 0.85 W 4 4 CN-121 AD7
T34A 0.85 GrW 3 3 AS AD6
T31 0.85 Br 2 2 R AD5
T18C 0.85 L 1 1 CN-122 V AD4
CD-4 T37A 0.85 W D
CN-13 B3 AD3
Pa 2 M08B 1.25 W T34A 0.85 GrW C B2 AD2
1 F13A 0.85 Br T31 0.85 Br B
B1 AD1
T18C 0.85 L A
STOP LAMP
3 4 1 2 4 1 2 3 4 2 3 1 ED
D N B F VP
CD-5 K OUTPUT SIGNAL VM
2 M34 0.85 ROr
EARTH 8
Pa
1 T36 0.85 WOr
CLUTCH
CUT-OFF
12 12
11 11
R15 0.85 Y 10 10 R15 0.85 Y
CN-144 M18B 0.85 Or 9 9 M18B 0.85 Or
6 E15 0.85 BW 8 8
6
5 E13 0.85 G R16 0.85 W 7 7 R16 0.85 W
ON IDLE
4 E12 0.85 L G23 0.85 B 6 6 G23 0.85 B
4
3 E11 0.85 Or G35 0.85 B 5 5 G35 0.85 B
1 2 E10 W(tw) 4 4
HL740TM-7 ONLY
1 E14 B(tw) 3 3
2 2 2
M18D 0.85
M18C 0.85
1 1
LINEAR THROTTLE
3
Or
CN-19
Or
5
OFF IDLE
9
7
6
3
9
7
6
3
5
1
5
1
8
4
2
8
4
2
10
10
CS-53
CS-52
10
10
6
6
ATT.LOCK
ATT.UNLOCK
9
9
2
2
T05
T45
T38
T09
T08
T20
T21
T19
T04
T06
T07
0.85
0.85
0.85
0.85
0.85
E11 0.85
0.85
0.85
0.85
E12 0.85
E13 0.85
0.85
0.85
E14 0.85
E10 0.85
EARTH 7
0.85
F11 shield
F22 5.0 R
F21 3.0 W
ET03 shield
T18 0.85 L
V
T16 0.85 R
E06 0.85 G
E19 0.85 V
F03 0.85 Y
F12 0.85 V
T17 0.85 Br
L
G
W
Gr
Or
E09 0.85 L
E16 0.85 W
E17 0.85 W
F13 0.85 Br
F06 1.25 Y
E05 0.85 R
LW
EF08 0.85 W
E15 0.85 BW
YW
F05 0.85 LW
Or
F26 0.85 Gr
BOr
BOr
E18 0.85 LW
WOr
WOr
C07
C06
C05
G83
G81
G82
RF52C 0.85 L
F04 0.85 OrW

EF20 0.85 RW
RF51C 1.25 G
E07 1.25 VOr

RF53C 1.25 W
F08 0.85 WOr

F07 0.85 GrW
F25 0.85 WOr
RF50C 0.85 Or
B(tw)
F10 0.85 V(sh)
F09 0.85 G(sh)
T10 0.85 W(tw)
T12 0.85 W(tw)

T11 0.85 W(tw)
W(tw)
T13A 0.85 B(tw)

T13B 0.85 B(tw)
T13C 0.85 B(tw)
ET01C 0.85 V(sh)
ET02D 0.85 G(sh)
G66 0.85
R07 0.85
R05 0.85
R15 0.85
R16 0.85
G64 0.85
G63 0.85
R10 0.85
1.25
0.85
0.85
0.85
0.85
0.85
R17 0.85
R09 0.85
R08 0.85
G65 0.85
R06 0.85
T39 0.85
C02 0.85 Y
L
B
B
B
R
C01 0.85 G
B
V
Y
B
B
C04 1.25 Br
G
R
R13 1.25 V
W
C03 1.25 Or
Br
Or
G71 0.85
R14 0.85 RW
LW
BOr
RF50 0.85 Or
RF53D 1.25 W
RF51D 1.25 G
RF52D 0.85 L
ET02A 0.85
ET01A 0.85
B
B(tw)
G73 0.85 B
T35 0.85 L
T04 0.85 V
T13 0.85 B
G72 0.85 B
T16 0.85 R
T06 0.85 G
T23 0.85 Gr
T17 0.85 Br
1
2
T37 0.85 W
T29 0.85 Y
T32 0.85 Gr
T23 0.85 Gr
T20 0.85 Gr
T18B 0.85 L
14
14
9
8
6
5
3
9
8
6
5
3
12
11
10
12
11
10
T31 0.85 Br
12
12
7
4
1
13
7
4
1
7
7
CN-2
13
11
10
11
10
15
15
T21 0.85 Or
15
15
2
2
13
13
8
6
5
4
8
6
5
4
2
2
T24 0.85 BW
T28A 0.85 R
14
3
1
14
3
1
9
9
T28B 0.85 R
T33 0.85 LW
T05 0.85 LW
T18A 0.85 L
T19 0.85 YW
T26 0.85 YW
T24 0.85 BW
T07B 0.85 W
T40 0.85 RW
ET03A shield
T25 0.85 RW
T07A 0.85 W
T09 0.85 BOr

T45 0.85 BOr
T27 0.85 VOr

T22 0.85 ROr
CN-3
CN-6
CN-14
CN-1
T08 0.85 WOr
T34 0.85 GrW

T38 0.85 WOr
T36 0.85 WOr

ET02C 0.85 G
T12 0.85 W(tw)
T11 0.85 W(tw)

T10 0.85 W(tw)
T30 0.85 W(tw)
V(sh)
G(sh)
2
1
8
7
5
9
6
4
2
3
1
14
9
8
6
5
3
10
12
12
11
10
11
12
13
7
4
1
11
10
15
8
6
5
4
2
3
1
9
8
7
6
5
4
3
2
1
9
8
7
6
5
4
3
2
1
9
8
7
6
5
4
3
2
1
9
8
7
6
5
4
3
2
1
CN-8
CN-5
14
13
12
11
10
15
14
13
12
11
10
15
14
13
12
11
10
15
14
13
12
11
10
CN-10
TWIST
9
8
4
3
2
1
6
4
3
5
1
2
17
68
67
66
65
64
63
62
57
56
55
51
46
45
43
42
41
39
36
32
29
28
27
26
25
23
22
21
20
19
18
15
13
12
52
10
49
CN-53
9
8
7
6
5
4
3
2
1
9
8
7
6
5
4
3
2
1
9
8
7
6
5
4
3
2
1
ECM
ECM
ECM
ECM
15
12
11
10
12
11
10
14
13
12
11
10
CAN L
CAN T
R/DRY
R/DRY
CAN H
ILL.RH
ILL. LH
CN-52
AC COMP
VPI
BRAKE PS
EF4
EF3
EF2
EF1
ER2
FUSIBLE LINK
ED6
ED9
ED2
ED5
ED1
ED4
ER1
SD4
ED7
ED3
ER3
FUSIBLE LINK
VM2
VM1
AIR FILTER
VGS
T/M FILTER
AIP1
AIP4
AIP6
AIP3
AIP2
AIP5
STOP LAMP
ED10
ED11
VPE2
VPE1
VPS1
VPS1
VPS2
ON IDLE SW
GND
ADM1
GND
GND
GND
GND
GND
GND
ADM5
EUPR
SDDK
WORK LAMP
BATT.RELAY
VMG2
VMG1
FAN CLUTCH
FAN CLUTCH
FAN CLUTCH
OFF IDLE SW
TO FRONT
GEAR BOX Y2
GEAR BOX Y4
GEAR BOX Y6
GEAR BOX Y3
GEAR BOX Y1
GEAR BOX Y5
HORN
THROTTLE 5V
VMGA2
POS. RETURN
START RELAY
FUEL SENDER
CANF_L
CANF_T
ILL. L.H
ALTERNATOR I
CANF_H
SENSOR GEAR
TURN LAMP LH
FUEL WARMER
ILL. R.H
TURN LAMP RH
THROTTLE SIG.
MAIN PUMP PS
GEAR BOX GND
PREHEATER RY
GEAR BOX VPSI
SPEED SENSOR
SPEED SENSOR
SPEED SENSOR
SENSOR TURBIN
SENSOR GEAR-T
GEAR BOX TEMP
CONTROL UNIT
SENSOR ENGINE
ECM PREHEATER
BACK UP BUZZER
ATT.LOCK
TO CABIN
GND(SOL.)
SENSOR TURBIN-T
SENSOR ENGINE-T
HIGH BEAM
HEAD LAMP
HYD TEMP SENSOR
THROTTLE RETURN
ROOM LAMP
ATT.UNLOCK
STEERING PUMP PS
ILLUMINATION
SENSOR CONVERTER
BUZZER STOP
WORK LAMP F
WORK LAMP R
BEACON LAMP
PROXIMITY SW
L.H TURN LAMP

R.H TURN LAMP
CASSETTE ACC
BOOM KICK OUT

BOOM DOWN PS
BOOM DOWN PS
RADIO B+/ROOM LAMP
BUCKET LEVELER
7407EL00
INLET M/ACT TEMP M/ACT MODE(D/FOOT) MODE(VENT) RESISTOR RELAY(HI) RELAY(M2) BUZZER STOP SW BEACON LAMP SW
1
2
1
2
8
8
7
7
9
9
2 7 2 7 BLOWER CN-23
1 4 1 4
3
3
1
1
3 M 7 M 3 M 7 M
4
C13 1.25 W 1
5 5 WORK LAMP REAR WORK LAMP FRONT
4
4
2
2
DOOR SW 2
MH 3
ML 2
Hi
C11 1.25 L
Lo 1
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
T/M ONLY
M
CL-3 SPEAKER LH
1
2
3
4
5
6
5
6
10
10
1
2
1
1
4
4
2
3
2
3
R14B 1.25 RW 1 Lo
1
1
2
3
3
2
2
2
9
9
1
2
4
2
4
1
1
1
5
6
8
5
6
8
7
7
GW
BG
LR
Y
BG
GL
GB
WR
Y
LB
YB
GB
BW
WB
2 Hi
10
10
SOL.LOCK R13A 1.25 V
CS-55
CL-22
CL-7
CS-34
CL-23
CS-23
CL-5
CL-6
LG
YW
YBr
L
1 G51 1.25 BOr R51 1.25 G 3 C CN-24
2B
L
YB
R
RY
L
BG
R
RY
YW
ROTARY LAMP
21
22
17
20
18
19
9A
23
24
25
9B
16
15
20A
2 R15 1.25 Y G02 1.25 B 4 E C12 1.25 OR 1
26
35
27
32
36
36A
29
33
6B
36
28
6A
35
HEAD LIGHT LH C10 1.25 GY 2
33A
CN-124
Or
Or
Br
Br
GY
B
B
Or
B
B
L
B
B
SPEAKER RH
GY
G
SOL.UNLOCK CL-24
1 G52 1.25 BOr G03 1.25 B 1
2 R16 1.25 W R52 1.25 L 2
CN-125 COMBI LH G02 1.25 B G

CN-27
C08A 1.25 GY
G23 1.25 B
C09 1.25
C08B 1.25
G24 1.25
G25 1.25
C08 1.25
C03B 1.25
C03A 1.25
G12 1.25
G11 1.25
C06 1.25
G22 1.25
G13 1.25
C04B 1.25
C04A 1.25
C07 1.25
CN-20 C13 1.25 W 1 S.L+
G04 1.25 B 1 C01 1.25 G 2 ACC
R05A 1.25 V 2 C05 1.25 R 3 ILL+
4 CN-11 NO. DESTINATION C12 1.25 OR 4 S.R+
HORN 1,2 BR
3 G09 1.25 B 1 1 GND(CONTROLLER) G03 1.25 B 5 ILL-
32 2B
2 R09 1.25 Or CN-25 2 2 GND(BLOWER) C11 1.25 L 6 S.L-
6 RY
1 R06 1.25 LW G12 1.25 B 1 3 3 FUSE(IG) C02A 1.25 Y 7 B+
3,4 RW
CN-18 R05B 1.25 V 2 4 4 FUSE(Battery) C10 1.25 GY 8 S.R-
33 2R
5 5 FUSE(Battery) CN-5 G04 1.25 B 9 GND
30 LW
6 6 DPS(COMPRESSOR) 1 FUSE BOX 1 C01 1.25 G CASSETTE RADIO
31 LY
CN-8 CL-4 7 7 CONDENSOR FAN 2 WORK LAMP R. RY 2 C04 1.25 Br
5 G
1 1 R16 1.25 W R14A 1.25 RW 1 Lo 8 8 ILLUMINATION FUSE BOX 3 C02 1.25 Y
CONTROLLER 3
2 RELAY 2 R17 1.25 BOr R13B 1.25 V 2 Hi AIR CON 4 WORK LAMP F. RY 4 C03 1.25 Or CL-1
3 R15 1.25 Y R53 1.25 W 3 C 5 C02B 1.25 Y 2
3 FUSE BOX 5
4 RELAY 4 G11 1.25 B 4 E 6 GND 6 G01 1.25 B C09A 1.25 Or 1
1
2
3
4
5
6
8
9
17
20
24
31
5 HORN RY 5 R05 1.25 V HEAD LIGHT RH 7 SWITCH ILL. 7 C05 1.25 R B
9
8
G06 1.25 B
6
WB 15
BW 16
LR
BG 18
GL 19
Y
GW 21
BG 22
WR 23
LB
YB 25
LG 26
YBr 27
BG 28
YB 29
LW 30
LY
BR
BR
RW
RW
G
RY
BrR
GB
6 RIDE CONT.SW R06 1.25 LW 8 GND 8 G10 1.25 B
ROOM LAMP
7 BUCKET RY 7 R07 1.25 G CL-25 9 CONTROLLER 9 C06 1.25 L
8 R08 1.25 Br G13 1.25 B 1 10 G21 1.25 B
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
8 BOOM UP RY 10 GND
10
11
12
13
14
15
16
17
18
10
11
12
13
14
1.25G
1.25LgB
9 RIDE CONT.RY 9 R09 1.25 Or R50 1.25 Or 2 11 FUSE BOX 11 C07 1.25 G CL-30
10 10 COMBI RH 12 12 C02C 1.25 Y 2
1
2
11 GND 11 G08 1.25 B 13 13 C09B 1.25 Or 1
12 12 14 14
G05 1.25 B B
15 15
CN-10 CN-100
1 FUSE BOX 1 R10 1.25 R R10A 1.25 R 1 B DUCT
2 2 SENSOR
G16 1.25 B 3 E
INLET MOTOR(REC)
INLET MOTOR(FRE)
TEMP MOTOR ACT(+)
TEMP MOTOR ACT(-)
TEMP M/ACT(PBR)
MOTOR ACT(REF)
MODE M/ACT(DEF)
MODE M/ACT(FOOT)
MODE M/ACT(M+)
MODE M/ACT(M-)
MODE M/ACT(PBR)
BLOWER RELAY(LO)
BLOWER RELAY(M1)
BLOWER RELAY(M2)
BLOWER RELAY(HI)
COMPRESSOR(DPS)
CONDENSER FAN
GND
GND
BATTERY(+)
BATTERY(+)
ILLUMINATION
POWER IG
NC
DUCT SENSOR(+)
DUCT SENSOR(GND)
NC
NC
NC
NC
NC
3 GND 3 4 S
G05 1.25 B R08 1.25 Br
4 GND 4 G60 1.25 B AC & HEATER CONTROLLER AC-11
BOOM KICK OUT AIR CONDITIONER
5 GND 5 G18 1.25 B 18
6 6 17
Or
Or
Br
Br
C44 1.25 Y C44 1.25 Y CONDENSER FAN
B
B
B
B
7 ILL. SW (FUSE) 7 R51 1.25 G CN-101 16 C43 1.25 LW C43 1.25 LW COMPRESSOR(DPS)
8 ILL. SW (FUSE) 8 R53 1.25 W R10B 1.25 R 1 B 15 C42 1.25 YW C42 1.25 YW BLOWER RELAY(HI)
9 MULTI FUNCTION SW 9 R13 1.25 V G17 1.25 B 3 E 14 C41 1.25 BOr C41 1.25 BOr BLOWER RELAY(M2)
10 MULTI FUNCTION SW 10 R14 1.25 RW R07 1.25 G 4 S 13 C40 1.25 YW C40 1.25 YW BLOWER RELAY(M1)
11 MULTI FUNCTION SW 11 R52 1.25 L BUCKET LEVELER 12 C39 1.25 LW C39 1.25 LW BLOWER RELAY(LO)
G16 1.25
C03C 1.25
G14 1.25
C03D 1.25
G15 1.25
C04C 1.25
C04D 1.25
G17 1.25
12 MULTI FUNCTION SW 12 R50 1.25 Or

SOL-RIDE CONT. 11 C38 1.25 Y C38 1.25 Y MODE M/ACT(PBR)
B G32
1 10 C37 1.25 LW C37 1.25 LW MODE M/ACT(M-)
OR 18A
CD-40 2 9 C36 1.25 WOr C36 1.25 WOr MODE M/ACT(M+)
1
1
1
1
B
2
2
2
2
5A
8 9 10 11 12 13 14 15 16 17 18
8 C35 1.25 BW C35 1.25 BW MODE M/ACT(FOOT)

2 Pa CN-137
CL-33
CL-36
CL-32
CL-35
7
3 BR 7 C34 1.25 GY C34 1.25 GY MODE M/ACT(DEF)

1
6
6 C33 1.25 Y C33 1.25 Y MOTOR ACT(REF)

CN-17
5
5 C32 1.25 G C32 1.25 G TEMP M/ACT(PBR)

OR 3 STR PUMP PS SOL CONT.VALVE 4
4
FRONT SIDE 1 C31 1.25 BOr WORK LAMP FRONT WORK LAMP REAR C31 1.25 BOr TEMP MOTOR ACT(-)
B G31
1
3
Y 4 3 C30 1.25 L C30 1.25 L TEMP MOTOR ACT(+)

2 CD-39 OR 18
2
5 B 2 2 C29 1.25 BW OPTION C29 1.25 BW INLET MOTOR(FRE)

B 5
3 2 1
1
Pa CN-136 C28 1.25 WOr C28 1.25 WOr INLET MOTOR(REC)

4 L
4 1 AC-1
AC-22
MAIN PUMP PS 14 NC
CD-41 13 NC
OR 18
1 12 NC
Pa OR 17
2 11 NC
10 NC
9 10 11 12 13 14
BOOM DOWN 9 C27 1.25 GW C27 1.25 GW DUCT SENSOR(GND)

8
EMERGENCY STEERING 8 C26 1.25 BW C26 1.25 BW DUCT SENSOR(+)

7
7 NC
6
6
C25 1.25 R C25 1.25 R POWER IG
17
17A
G31
5
5
C24 1.25 G C24 1.25 G ILLUMINATION

4
4 C23 1.25 RW C23 1.25 RW BATTERY(+)
OR
W
B
3
3
C22 1.25 RW C22 1.25 RW BATTERY(+)

2
2
CN-12 C21 1.25 BrW C21 1.25 BrW GND

1
1 2 3 4 1 C20 1.25 BrW C20 1.25 BrW GND

1
CN-18
2 E16 1.25 W AC-2
3 E13 1.25 G
4 E12 1.25 L
5 E11 1.25 Or
6 E10 1.25 W(tw)
7 E14 1.25 B(tw) F21 3.0 W 1
8 E17 1.25 W F22 5.0 R 2 RIDE CONTROL CAB SIDE
9 CN-60
10 E18 1.25 LW
11
MASTER SW
12 E15 1.25 BW CR-1 B G
13 E09 1.25 L R4
R1
14 E07 1.25 VOr F23C 1.25 L
15 G79 1.25 B R2 R3
BATTERY
BATT. RY CS-0
12
11 E06 1.25 G TO STARTER
10 F23B 1.25 L 2
CN-92
9 EF08A 1.25 W EF20A 1.25 RW 1
TO PREHEATER RY E18 0.85 LW A VEHICLE KEY SW INPUT
8 EF20B 1.25 RW DO-3
7 E16D 0.85 W B BATT. 24V
E05 1.25 R
6 E16B 0.85 W C BATT. 24V
5 2 E16C 0.85 W D BATT. 24V

E19 1.25 V F23A 1.25 L
4 1 E17A 0.85 W M BATT. 24V
G78 1.25 B
E17B 0.85 W S BATT. 24V
3 E03 shield DO-2
G01 0.85 B E BATT. GROUND
2 E02 1.25 G(sh)
G02 0.85 B F BATT. GROUND
1 E01 1.25 V(sh) F23 1.25 L 2
G03 0.85 B H BATT. GROUND
CN-4 F12 1.25 V 1
G04 0.85 B P BATT. GROUND
DO-1
G05 0.85 B W BATT. GROUND
CN-83
M N FAN CLUTCH
G08 1.25 B G26 1.25 B 1
E19 0.85 V J FUEL WARMER
EF08B 1.25 W 2
G02 1.25 B AIR-CON FAN
CN-1 CN-99
1 E01B 0.85 V A A
F21 3.0 W
2 F22 5.0 R CN-17 E02B 0.85 G B
F25 1.25 WOr 1 C

B
CN-2 F26 1.25 Gr 2
1 CONTROLLER 1 E01 1.25 V(sh) EARTH1 G06 1.25 B 3
2 CONTROLLER CN-94
2 E02 1.25 G(sh) EARTH2 4
3 CONTROLLER E01A 0.85 V A
3 E03 shield
4 CONTROLLER 4 F25 1.25 WOr CN-75 E02A 0.85 G B
5 CONTROLLER 5 F10 1.25 V(sh) F10 1.25 V(sh) 2 E03 Shield C
6 FUSE BOX 6 F09 1.25 G(sh) F09 1.25 G(sh) 1
7 CONTROLLER 7 F11 shield F11 shield FAN CLUTCH CN-93
8 CONTROLLER 8 F26 1.25 Gr SHIELD
9 PREHEATER RY. 9 E09 1.25 L 10
10 AIR-CON RY. E22 0.85 V 40 WIF
10 EF08 1.25 W EARTH4
11 SAFETY RY. 11 CD-1 E15A 0.85 BW 20 ENG.RETURN
E05 1.25 R
12 CONTROLLER 12 E14 0.85 B(tw) 19 THROTTLE POSITION RETURN
F08 1.25 WOr F08 1.25 WOr 1
13 CONTROLLER E13 0.85 G 25 OFF IDLE SW
13 F07 1.25 GrW G03 1.25 B 2
14 FUEL WARMER RY. E12 0.85 L 26 ON IDLE SW
14 E07 1.25 VOr
15 AIR-CON ASS'Y
TEMP SENSOR 29 THROTTLE POSITION +5V
15 F06 1.25 Y E11 0.85 Or
(HYD) THROTTLE POSITION SIG.
E10 0.85 W(tw) 30
CN-3 31 COLD START AID
1 FUSE BOX 1 F53 1.25 W CD-10 E09 0.85 L 41 COLD START AID
2 MULTI FUNCTION SW. 2 CN-12
F52 1.25 L F07 1.25 GrW Pa
3 PREHEATER RY. 3 1 1
E06 1.25 G G05 1.25 B
4 CONTROLLER 4 2 FUSE BOX 2 E16 1.25 W CD-35
EF20 1.25 RW AIR FILTER
5 PRESS SW. 5 3 PEDAL 3 E13 0.85 G E22 0.85 V A
F13 1.25 Br
6 START KEY 6 4 PEDAL 4 E12 0.85 L E15B 1.25 B/W B Pa
F12 1.25 V
7 BACK-UP RY 7 CN-29 5 PEDAL 5 E11 0.85 Or
F03 1.25 Y FUEL FILTER
8 CONTROLLER 8 F04 1.25 OrW F06 1.25 Y 2 PA 6 PEDAL 6 E10 0.85 W(tw)
9 FUSE BOX 9 E18 1.25 LW F05 1.25 LW 1 7 PEDAL 7 E14 0.85 B(tw)
10 WORK LAMP RY. 10 8 FUSE BOX 8 E17 1.25 W CN-28
11 MULTI FUNCTION SW.
R/DRY 9
11 F50 1.25 Or 9 E08 1.25 W 1
12 FUSE BOX 12 F51 1.25 G 10 FUSE BOX 10 E18 0.85 LW
13 CONTROLLER 13 E17 1.25 W CL-21 11 11
AIR COMP.
14 CONTROLLER 14 E16 1.25 W F53A 1.25 W S 12 PEDAL 12 E15 0.85 BW
15 CONTROLLER 15 E19 1.25 V G71 1.25 B E 13 PREHEATER RY. 13 E09 0.85 L CN-96
14 FUEL WARMER RY. 14 E07 1.25 VOr E07 1.25 VOr 2
T16 1.25 R 1 NUMBER PLATE LAMP
OUTPUT SPEED 15 15 G13 1.25 B
T17 1.25 Br 2 1
SENSOR CD-2
CN-14 T18 1.25 L 3
1 PEDAL
FUEL WARMER
1 E13 1.25 G CD-51 G72 1.25 B 1
2 PEDAL 2 E12 1.25 L F04 1.25 OrW 2 CN-4
3 PEDAL 1 CONTROLLER 1
TO BATT. RELAY
3 E11 1.25 Or T13B 1.25 B(tw) 2 INTERN.GEAR FUEL SENDER E01 0.85 V(sh)
4 PEDAL 4 1 PICK-UP 2 CONTROLLER 2 E02 0.85 G(sh)
E10 1.25 W(tw) T11 1.25 W(tw)
5 PEDAL CN-65 3 CONTROLLER 3 E03 Shield
5 E14 1.25 B(tw) CD-50
CR-24
6 1 4 4
6 G73 1.25 B
7 PEDAL 2 TURBIN 2 5 FUEL WARMER RY. 5 E19 0.85 V E06 1.25 G
7 E15 1.25 BW T13C 1.25 B(tw) F03 1.25 Y
8 TCU 8 1 PICK-UP 6 6
T13C 1.25 B(tw) T10 1.25 W(tw) BACK BUZZER
9 TCU 9 CD-27 7 SAFETY RY. 7 E05 1.25 R
T13B 1.25 B(tw)
10 AIR-CON RY. 8 CONTROLLER/BATT.RY 8 E20 1.25 RW HEATER RELAY
10 F05 1.25 LW PREHEATER
11 TCU 11 2 ENGINE 9 AIR-CON RY. 9 E08 1.25 W
T13A 1.25 B(tw) T13A 1.25 B(tw) CL-16
12 TCU 12 1 PICK-UP 4 C 10 10
T10 1.25 W(tw) T12 1.25 W(tw) F51 1.25 G
13 TCU 13 CD-17 3 T 11 PREHEATER RY. 11 E06 1.25 G
T11 1.25 W(tw) F50 1.25 Or
14 TCU 14 12 12 STARTER
T12 1.25 W(tw) G74 1.25 B 2 E
15 15 T38 1.25 WOr 1 F13A 1.25 Br 1 S CR-23 M
M
2 Pa FILTER 1
T09C 1.25 BOr G11 1.25 B
CN-6 COMBI LAMP 2
CD-52 E05 1.25 R
1
RH B+ M
TCU 1 T16 1.25 R B
2 TCU 2 T17 1.25 Br START RELAY CN-45
3 TCU 3 T18 1.25 L CD-15 CL-15
15 R
4 4 T45 1.25 BOr 1 F53B 1.25 W 4 C ENGINE SIDE

5 TCU 5 T05 1.25 LW T09B 1.25 BOr 2 F52 1.25 L 3 T
CN-74
(CONVERTER)
6 TCU 6 T19 1.25 YW G75 1.25 B 2 E B+ G
7 TCU TEMP SENSOR
7 T07 1.25 W F13B 1.25 Br 1 S 3 ENGINE(CUMMINS) SIDE
8 TCU 8 T21 1.25 Or E20 1.25 RW I
COMBI LAMP U
9 TCU 9 T08 1.25 WOr GND
LH
10 TCU 10 T09 1.25 BOr GEARBOX ALT
11 TCU 11 T06 1.25 G 16
12 TCU 12 T04 1.25 V T09A 1.25 BOr 9 VMGA2
13 TCU 13 T20 1.25 Gr T08 1.25 WOr 8 TEMP
14 TCU 14 T38 1.25 WOr T07 1.25 W 7 VPS1(+)
15 TCU 15 T45 1.25 BOr T06 1.25 G 6 Y6
T05 1.25 LW 5 Y5 GND
T04 1.25 V 4 Y4
T21 1.25 Or 3 Y3
T20 1.25 Gr 2 Y2 EARTH3
FRAME SIDE T19 1.25 YW 1 Y1
CN-112
TRANSMISSION
7407EL01
7-4
1. ILLUMINATION CIRCUIT
1) OPERATING FLOW
Fuse box (No.2) Illumination switch [CS-39(1)] Switch ON, 1st step
I/conn [CS-39(7)] All switch indicator lamp ON
I/conn [CS-39(5)] Fuse box(27) I/conn [CN-3(12)] RH Combi clearance lamp ON [CL-16(4)]
I/conn [CN-10(7)] LH Head lamp ON [CL-3(3)]
I/conn [CN-12(10)] Cluster [CN-51(17)] All cluster gauge
and LCD lamp ON
Fuse box(28) I/conn [CN-3(1) Number plate lamp ON [CL-21(S)]
LH Combi clearance lamp ON [CL-15(4)]
I/conn [CN-10(8)] RH Head lamp ON [CL-4(3)]
2) CHECK POINT
Engine Key switch Check point Voltage
ཛ - GND (Switch input)

ཛྷ - GND (Switch output)
OFF ON 20~25V
ཝ - GND (To light)
ཞ - GND (To cluster)
ଖ GND : Ground
7-5
ILLUMINATION CIRCUIT
FUSE BOX
BEACON LAMP 20A
1
M17 1.25 OrW ILL.LAMP 10A
2
HEAD LAMP 20A
3
BACK/STOP LAMP 10A
4
24
TCU 10A
25
CLUSTER 10A
26
RF51 1.25 G ILL,F/L,R/R 5A
27
RF53 1.25 W ILL.F/R,R/L 5A
28
CN-36
LH HEAD LIGHT
3 1 Lo
2 Hi
R51 1.25 G
3 E
G02 1.25 B
4 C
2 1 CL-3
2
ILL & HEAD LAMP SW 3
G19 0.85 B
9 10 10 C05B 0.85 R
4
9 5 RH HEAD LIGHT
2
4 8
C05C 0.85 R RF51D 1.25 G
6
R51 1.25 G
3 1 Lo
7 7 2 Hi
7 RF53D 1.25 W R53 1.25 W G11 1.25 B
1 6 8 3 E
5 M02 1.25 BrW R53 1.25 W
5 9 4 C
4 10 CL-4
3 11
II I 0
2 NUMBERPLATE LAMP
M17 1.25 OrW 12 F53A 1.25 W
1 CN-10 S
G71 1.25 B
CS-39 E
RF53C 1.25 W R53 1.25 W CL-21
1 3
1 2 RH COMBI LAMP
3 F51 1.25 G
4 C
4
3 T
5 G74 1.25 B
2 E
6
ALL SWITCH INDICATOR LAMP ON 1 S
7
CL-16
8
9 3 LH COMBI LAMP
10
F53B 1.25 W
11 4 C
RF 51C 1.25 G
12 3 T
G75 1.25 B
13 2 E
14 1 S
CN-3 CL-15
CLUSTER
12 20 TX-PC
11 19 GND
RF51A 0.85 G RF51A 0.5 G
10 17 ILL.
9 16 T/M ERROR
8 15 SERIAL-L
14 SERIAL-H
7
4 6
12 GND
11 GND
5 10 RX-PC
4 9 FWE
3 8 N.C
7 WORK LAMP
2 6 HIGH BEAM
1 5 RH TURN
CN-12 4 LH.TURN
3 24V PER.
2 24V IG
1 24V IG
CN-51
7407EL03
7-6
2. HEAD LIGHT CIRCUIT
1) OPERATING FLOW
Fuse box(No.3) Head light switch [CS-39(4)] Light switch ON, 2nd step [CS-39(2)]
I/conn [CN-7(7)] Multi function switch [CS-11(8)]
Multi function switch MIDDLE [CS-11(7)] I/conn [CN-7(6)] I/conn [CN-10(10)]
LH Head light low beam ON [CL-3(1)]
RH Head light low beam ON [CL-4(1)]
Multi function switch DOWN [CS-11(6)] I/conn[CN-7(5)]
I/conn[CN-10(9)] LH Head light high beam ON[CL-3(2)]
RH Head light high beam ON[CL-4(2)]
I/conn[CN-12(7)] Cluster high beam pilot lamp ON[CN-51(6)]
2) CHECK POINT
ཛ - GND (Switch input)

ཛྷ - GND (Switch output)
ཝ - GND (Multi function input)
ཞ - GND (Multi function output)
OFF ON 20~25V
ཟ - GND (Multi function output)
འ - GND (Low beam)
ཡ - GND (High beam)
ར - GND (Passing B+)
ଖ GND : Ground
7-7
HEAD LIGHT CIRCUIT
FUSE BOX
BEACON LAMP 20A
1
ILL.LAMP 10A
2
M15 1.25 YW HEAD LAMP 20A
3
BACK/STOP LAMP 10A
4
24
TCU 10A
25
CLUSTER 10A
26
ILL,F/L,R/R 5A
27
ILL.F/R,R/L 5A
28
CN-36
LH HEAD LIGHT
R14B 1.25 RW
1 Lo
R13A 1.25 V
2 Hi
3 E
ILL & HEAD LAMP SW 1 G02 1.25 B
4 C
2
9 10 10 1
9 3 CL-3
4 8 4 G60 1.25 B
2 RH HEAD LIGHT
7 5 R14A 1.25 RW
1 Lo
7 1 6 6 7 R13B 1.25 V
2 Hi
5 5 7
M15B 1.25 YW 3 E
4 8 G11 1.25 B
R13 1.25 V 4 C
3 9
M41 1.25 W R14 0.85 RW
II I 0
2 10 CL-4
1 11
CS-39 12
CN-10 6
2
CLUSTER
CN-7
20 TX-PC
10
11
12
13
14
1
2
3
4
5
6
7
8
9
R13B 0.85 V
19 GND
ILL.
4 17
16 T/M ERROR
15 SERIAL-L
14 SERIAL-H
12 GND
CN-12
11 GND
11
12
10
7
9
6
5
3
4
2
8
10 RX-PC
9 FWE
8 N.C
R13B 0.5 Br 7 WORK LAMP
6 HIGH BEAM
5 RH TURN
4 LH.TURN
M15A 1.25 YW
3 24V PER.
R14 0.85 RW
R13A 1.25 V
2 24V IG
M41 1.25 W
1 24V IG
4 CN-51
3
5 8
CS-11
5
8
4
7
3
2
1
BWG 4
W6
Hi
C
Lo
Hi
B+
C
F
R
L
O
R
L
7 Y Lo
2 BW
8 WB
3 BG
5B
MULTI FUNCTION SW
7407EL04
7-8
3. WORK LIGHT CIRCUIT
1) OPERATING FLOW
ଖ Illumination switch : ON position
(1) Work lamp switch ON (1st step)
ILL & head lamp switch [CS-39(7)]
Work lamp switch[CS-20(1)] (5) Front work lamp relay[CR-3(2)˧(4)] I/conn[CN-5(4)]
LH Front work lamp ON[CL-6(2)]
RH Front work lamp ON[CL-5(2)]
(7) I/conn[CN-12(8)] Cluster[CN-51(7)] Work light pilot
lamp ON
Work lamp switch[CS-20(9)] Work lamp switch indicator lamp ON
(2) Work lamp switch (2nd step)
Work lamp switch [CS-20(4)˧(2)] Rear work lamp relay [CR-6(2)˧(4)]
I/conn [CN-5(2)] LH Rear work lamp ON [CL-22(2)]
RH Rear work lamp ON [CL-23(2)]
2) CHECK POINT
ཛ - GND (Work lamp power input)

ཛྷ - GND (Work lamp power output)
OFF ON 20~25V
ཝ - GND (Front work lamp)
ཞ - GND (Rear work lamp)
ଖ GND : Ground
7-9
WORK LIGHT CIRCUIT
FUSE BOX
BEACON LAMP 20A
1
2
HEAD LAMP 20A
3
BACK/STOP LAMP 10A
4
HORN/CONVERTER 30A
5
AIR-CON/HEATER 20A
6
CIGAR 20A
7
SWITCH 10A
8
F/R WIPER 20A
9
M10 1.25 Gr WORK LAMP 30A
10
OPTION 10A
11
CN-36
OPT
FRONT WORK LAMP
C03D 1.25 Or
2
G15 1.25 B
1
CL-36
FRONT WORK LAMP
C03C 1.25 Or
2
2 G14 1.25 B
1
CL-35
1 1
2 FRONT WORK
FR WORK LAMP RY 3 LAMP,LH
C03 1.25 Or C03 1.25 Or C03A 1.25 Or
3 4 4 4 2
M51 0.85 W G11 1.25 B
3 5 G01 1.25 B 1
M10A 1.25 Gr 6 CL-6
2 3
G21 1.25 B 7
1 2 1 FRONT WORK
8
CR-3 LAMP,RH
9 C03B 1.25 Or
2
10 G12 1.25 B
11 1
12 CL-5
OPT
13 REAR WORK LAMP
14 C04C 1.25 Br
15 2
G16 1.25 B
1
CN-5
2 CL-32
REAR WORK LAMP
RR WORK LAMP RY C04D 1.25 Br
2
C04 1.25 Br G17 1.25 B
3 4 4 1
M52 0.85 L
3 CL-33
M10B 1.25 Gr
2
G22 1.25 B REAR WORK
1 2 1 LAMP,LH
CR-6 G24 1.25 B
1
1 C04B 1.25 Br
2
WORK LAMP SW CL-22
G13 0.85 B
9 10 10
9 C05F 0.85 R 4
4 8 REAR WORK
2 M59 0.85 Y LAMP,RH
7 G25 1.25 B
1
7 1 6 C04A 1.25 Br
M51 0.85 W 2
5 5
C05G 0.85 R CL-23
4
3
M52 0.85 L
II I 0
2 CLUSTER
1 C05H 0.85 R 20 TX-PC
CS-20 19 GND
17 ILL.
CS-39
16 T/M ERROR
15 SERIAL-L
9 10 10 14 SERIAL-H
9 12 12 GND
4 8 11 GND
2 C05C 0.85 R 11
7 10 RX-PC
10 9 FWE
7 1 6 9
5 M59 0.5 Y 8 N.C
5 WORK LAMP
8 7
4 7 6 HIGH BEAM
3 6 5 RH TURN
II I 0
2 4 LH.TURN
M17 1.25 OrW 5 3 24V PER.
1
4 2 24V IG
ILL & HEAD LAMP SW : ON(1st step) 3 1 24V IG
2 CN-51
1
CN-12
7407EL05
7-10
4. CHARGING CIRCUIT
When the starter is activated and the engine is started, the operator releases the key switch to the
ON position.
Charging current generated by operating alternator flows into the battery through the battery
relay(CR-1).
The current also flows from alternator to each electrical component and controller through the fuse
box.
1) OPERATING FLOW
(1) Warning flow
Altermator [CN-74(I)] I/conn [CN-4(8)] I/conn [CN-3(4)] Controller [CN-58(25)]
Cluster charge warning lamp ON
(2) Charging flow
Alternator Starter [CN-45(B+)] Battery relay [CR-1]
Battery(+) terminal Charging
I/conn [CN-60(1),(2)] I/conn [CN-1(1),(2)] Fuse box
2) CHECK POINT
ཛ - GND (Battery)
ཛྷ - GND (Battery relay)
ཝ - GND (ALT B+)
Running ON 20~28V
ཞ - GND (ALT I)
ཟ - GND (Controller)
འ - GND (Fuse box)
ଖ GND : Ground
7-11
CHARGING CIRCUIT
CONTROLLER
HYD TEMP SENDER

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

COOLANT SIG
SAFETY RY
BUZZER STOP
WIPER RY
STEERING RY
ALT LEVEL
FUEL SENSOR
TACHO SENSOR+
PREHEATER
SERIAL-H
WASH SIG
NEUTRAL SIG
CAN-H
AUTO SEL.TCU
REMOTE FAN(+)
CAN-L
REMOTE FAN(-)
STEERING PS
CLUTCH CUT-OFF SW
STEERING P/P PS
ENG OIL PS
RIDE CONT. ON
WIPER INT SIG
PARKING SIG
SERIAL-L
GND
BUZZER
AUTO SEL.SW
BRAKE PS
TAHCO SENSOR -
AIR FILTER
IG 24V
23
35
34
24
36
31
26
25
32
33
27
21
20
30
29
28
22
17
19
11
18
16
12
10
13
15
14
1
2
3
6
8
4
5
7
9
CN-58
EF20 0.85 RW
5 FUSE BOX
BEACON LAMP 20A
1
ILL.LAMP 10A
2
HEAD LAMP 20A
3
BACK/STOP LAMP 10A
4
HORN/CONVERTER 30A
5
AIR-CON/HEATER 20A
6 6
CIGAR 20A
7
SWITCH 10A
8 F22 5.0 R
F/R WIPER 20A 2 2
9 F21 3.0 W
WORK LAMP 30A
1 1
10
OPTION 10A CN-1 CN-60
11
CASSETTE/BUZZER 5A
12
PREHEATER 30A
13
TURN LAMP 20A
14
RADIO/ROOM LAMP 5A
15
START KEY 30A
16
TCU 10A
17
ECM 10A
18
CLUSTER 10A
19
AC & HEATER 10A
20 1
SPARE 10A BATTERY MASTER SW
21
ECM 5A BATT RY
22 R4 B G
RCV 10A
23
CONTROLLER 10A R3
24 CS-0
TCU 10A
25
CLUSTER 10A
CR-1
26
ILL. F/L,R/R 5A 2
27
ILL. F/R,R/L 5A
28
CN-36
STARTER
M
1
2
3 B+ M
4 3 CN-45
15 R
1 5 ALTERNATOR
2 6
B+ G
3 7
EF20 0.85 RW EF20 1.25 RW E20 1.25 RW 3
4 8 I
U
5 9 GND
6 10 CN-74
7 11 4
8 12
9 CN-4
10
11
12
13
14
CN-3
7407EL07
7-12
5. STARTING CIRCUIT
1) OPERATING FLOW
Battery(+) terminal Battery relay(R4 terminal) Fusible link [CN-60(1)]
I/conn [CN-1(1)] Fuse box (No.15) Start switch [CS-2(1)]
ଖ The gear selector lever is neutral position. It is necessary condition before the starting.
The gear selector has an output signal which is activated whenever the shift lever is in the neutral
position. This signal can be used to control a relay and prevent engine from starting whenever the
shift lever is not in the neutral position.
(1) When start key switch is in ON position
Start switch ON Start switch [CS-2(2)] I/conn [CN-3(6)] Battery relay [CR-1]
Battery relay operating(All power is supplied with the electric component)
Start switch [CS-2(3)] Fuse box [No.23] Fuse box (No.22)
I/conn [CN-3(9)] I/conn [CN-12(10)] ECM[CN-92(A)]
(2) When start key switch is in START position
Start switch START [CS-2(5)] Start safety relay [CR-5(30)] Start safety relay [CR-5(87)]
I/conn [CN-2(11)] [CN-4(7)] Start relay [CR-23(2)]
Starter(Terminal B+ and M connector of start motor)
2) CHECK POINT
ཛ - GND (Battery B+)

ཛྷ - GND (Fusible link)
ཝ - GND (Start key B terminal)
ཞ - GND (Start key BR terminal)
Running ON ཟ - GND (I/conn CN-3(6)) 20~25V
འ - GND (Start key ST terminal)
ཡ - GND (Start safety relay output)
ར - GND (Controller)
ལ - GND (Start key ACC terminal)
ଖ GND : Ground
ଖ ECM : Electronic control module
7-13
STARTING CIRCUIT
CONTROL UNIT CONTROLLER
GND
CAN-L
CAN-H
IG 24V
BUZZER
SERIAL-H
SERIAL-L
WIPER RY
WASH SIG
ALT LEVEL
BRAKE PS
SAFETY RY
AIR FILTER
ENG OIL PS
PREHEATER
PARKING SIG
NEUTRAL SIG
STEERING RY
COOLANT SIG
STEERING PS
BUZZER STOP
FUEL SENSOR
AUTO SEL.SW
FAN CLUTCH(-)
VMGA2
AIP6
AIP4
AIP1
AUTO SEL.TCU
WIPER INT SIG
VPI
EF4
VPE2
FAN CLUTCH(+)
ED1
ED5
ED2
ED9
ED6
ADM5
RIDE CONT. ON
TACHO SENSOR+
STEERING P/P PS
RIDE CONT. AUTO
TAHCO SENSOR -
CLUTCH CUT-OFF PS
SPEEDMETER SIG.
CLUTCH CUT-OFF SW
HYD TEMP SENDER
45
46
51
55
56
57
62
63
64
65
66
67
68
1
2
3
8
4
5
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
FUSE BOX
CN-52 14
VM OUTPUT SIGNAL K A CN-58 RADIO/ROOM LAMP 5A
VP F B N D B 15
1 2 3 4 1 2 3 4 1 2 3 4 C M04 1.25 Or START KEY 30A
ED 16
8
T37 0.85 W
AD1 B1 D TCU 10A
AD2 B2 17
T37B 0.85 W
CN-121 ECM 10A
EF20 0.85 RW
AD3 B3 18
AD4 V CLUSTER 10A
19
AD5 R A 1 AC & HEATER 10A
SAFETY RY 20
AD6 AS B 2 M43 1.25 R
30 SPARE 10A
AD7 C 3 21
T37A 0.85 W T37C 0.85 W 85
A AD3 D 4 86 87a 87 ECM 5A
E05 0.85 R 22
M01 1.25 WOr
B AD2 CN-122 5 87 RCV 10A

M21 0.85 L 23
C AD1 6 85 CONTROLLER 10A
D AD7(KD) 7 24
X1 87a 30 86 TCU 10A
8 25
A ED1(VP) 9
7 CR-5 CLUSTER 10A
26
D AD6 10 ILL,F/L,R/R 5A
E18 0.85 LW
B AD4 27
11 5A
ILL.F/R,R/L
C AD5 12 28
X2
13
14 CN-36
F21 3.0 W
CN-13
BATTERY MASTER SW
BATT RY
R4 B G
F23C 1.25 L R1
G79 1.25 B
R3
R2 CS-0
CR-1
F22 5.0 R
1
2 2
F21 3.0 W
1 1
CN-1 CN-60
F23B 1.25 L
2
EF20A 1.25 RW
1
2
DO-3 STARTER
F23A 1.25 L
2 B+
G78 1.25 B
1 B
1 DO-2 M
2 F23 1.25 L M
2
5 F12 1.25 V
EF20 0.85 RW
3 1 CN-45
EF20 1.25 RW
4 DO-1 START RY
5
G11 1.25 B
6 1
E05 1.25 R
7 2
9 4 8 9 CR-23
E18 0.85 LW E18 1.25 LW
10
F12 0.85 V
9
3
M04B 1.25 Or
6 11
M01 1.25 WOr

10 1
M43 1.25 R
1
11 12 2 2 CN-92
E18 0.85 LW
12 13 A VEHICLE KEY SW INPUT
5
4
1
6
2
3
3 3
CS-2
14 B BATT. 24V
13 4 4 C BATT. 24V
B 14 15 D BATT. 24V
1
0, I 5 5
15 M BATT. 24V
CN-12 6 6 S BATT. 24V
CN-3 7 7 E BATT. GROUND
H 0 I II
8 8 F BATT. GROUND
6
5
3
2
C ST ACC BR
H H BATT. GROUND
9 9
P BATT. GROUND
START SWITCH 10 10 W BATT. GROUND
E05 0.85 R E05 1.25 R
11 11 N FAN CLUTCH
12 12 J FUEL WARMER
CN-4 ECM
CN-2
7607EL06
7-14
6. ELECTRIC PARKING, DECLUTCH CIRCUIT
1) OPERATING FLOW
(1) Parking OFF
Fuse box (No.8) Parking switch OFF [CS-17(6) (8)] Parking solenoid ON (Activated)
Parking brake released (By hydraulic pressure)
(2) Parking ON
Fuse box (No.8) Parking switch ON Parking solenoid [CN-71] OFF
Parking brake applied [By spring force]
[CS-17(5) (7)] T/M control unit [CN-52(21)]
T/M declutch
(3) Declutch ON
Fuse box (No.8) Clutch cut-off switch ON Clutch cut-off switch [CS-42(5) (1)]
Controller [CN-58(10) (29)] Service brake applied Service brake pressure switch
ON [CD-5] T/M control unit [CN-52(66)] Declutch
2) CHECK POINT
ཛ - GND (Parking switch input)

ཛྷ - GND (Parking switch output)
ཝ - GND (Parking switch input)
Running ON ཞ - GND (Parking switch output) 20~25V
ཟ - GND (Parking solenoid)
འ - GND (Pressure switch clutch cut-off)
ଖ GND : Ground
7-15
ELECTRIC PARKING, DECLUTCH CIRCUIT
CONTROL UNIT CONTROLLER
SERIAL-L
TACHO +
SERIAL-H
WIPER RY
WASH SIG
BRAKE PS
SAFETY RY
PREHEATER
PARKING SIG
NEUTRAL SIG
STEERING RY
BUZZER STOP
FUEL SENSOR
AUTO SEL.SW
WIPER INT SIG
RIDE CONT. ON
EF1
ED10
VGS
ED11
VPE2
VPE1
ED5
ED2
ED9
ED6
ED3
ED7
CANF-T
CANF-L
CANF-H
STEERING P/P PS
RIDE CONT. AUTO
CLUTCH CUT-OFF PS
CLUTCH CUT-OFF SW
36 35 34 33 32 31 30 29 28 11 10 9 8 7 6 5 4 3 2 1
64
65
66
67
68
19
20
21
22
23
25
26
27
28
29
CN-52 CN-58
M26 0.85 Gr
T26 0.85 YW
M34 0.85 ROr
M31 0.85 GrW
T36 0.85 WOr

FUSE BOX[CN-36(2)]
9 10 10
9
4 8
2 C05C 0.85 R
7
7 1 6
5 5
4
3
2
M17 1.25 OrW
II I 0
1
ILL & HEAD LAMP SW : ON(1st step) FUSE BOX
BEACON LAMP 20A
1
ILL.LAMP 10A
4 2 1 2
HEAD LAMP 20A
3
PARKING SW BACK/STOP LAMP 10A
G17 0.85 B 4
HORN/CONVERTER 30A
9 10 10 C05K 0.85 R 5
9 AIR-CON/HEATER 20A
M44 0.85 L 6
8 CIGAR 20A
8 T26 0.85 YW 7
6 7
2 M09E 0.85 W M09 0.85 W SWITCH 10A
6 8
7 M09F 1.25 W F/R WIPER 20A
5 5 9
1
4 CN-36
3
2
1
CS-17
3
CLUTCH CUT-OFF SW
G09 0.85 B
9 10 10 C05J 0.85R
9
8
8
6 7
2
6
7 M09C 0.85 W 6
5 5 5
1
G27 0.85 B
T36 0.85 WOr
4
M26 0.85 Gr
M34 0.85 ROr
M44 0.85 L
G28 0.85 B
3
1
1
2
2
M31 0.85 GrW
CD-5
CD-26
1 1 2
CS-42
Pa
Pa
CN-71
PARK PARK PS CLUTCH

SOLENOID CUT-OFF
7407EL08
7-16
7. WIPER AND WASHER CIRCUIT
1) OPERATING FLOW
Fuse box (No.9) Wiper relay [CR-4(30) (87a)] I/conn [CN-13(9)]
Front wiper motor [CN-21(1)]
Wiper relay Lo [CR-26(86), (87)]
I/conn [CN-7(8)] Multi function switch [CS-12(6)]
Rear wiper & washer switch [CS-3(1)]
Rear wiper motor [CN-102(1)]
(1) Front washer switch ON
ཛ Washer switch ON [CS-12(6) (2)] Washer tank [CN-22(2)] Washer operating
Controller [CN-58(5) (33)] Front wiper relay Lo
[CR-26(87) (30)] I/conn [CN-13(13)]
Front wiper motor [CN-21(5)] Wiper motor operating(Low)
(2) Front wiper switch ON
ཛ INT position
Wiper switch ON [CS-12(6) (1)] I/conn [CN-7(13)] Controller [CN-58(8) (33)]
Wiper relay Lo [CR-26(87) (30)] I/conn [CN-13(13)] Front wiper motor [CN-21(5)]
Front wiper motor intermittently operating
ཛྷ Lo position
Wiper switch ON [CS-12(6) (4)] Wiper relay Lo [CR-26(87a) (30)] I/conn [CN-13(13)]
Front wiper motor [CN-21(5)] Front wiper motor operating (Low)
ཝ Hi position
Wiper switch ON [CS-12(6) (3)] Wiper relay Hi [CR-4(30) (87)] I/conn [CN-13(12)]
Front wiper motor [CN-21(4)] Front wiper motor operating(High)
(3) Auto-parking(When switch OFF)
Switch OFF Fuse box (No.9) Wiper relay Hi [CR-4(30) (87a)] I/conn [CN-13(9)]
Front wiper motor [CN-21(1) (2)] Multi function switch [CS-12(5) (4)]
Wiper relay Lo [CR-26(87a) (30)] I/conn [CN-13(13)] Front wiper motor [CN-21(5)]
Wiper motor stop
(4) Rear wiper and washer switch
ཛ Wiper switch ON(1st step)
Wiper switch ON [CS-3(1) (6)] Rear wiper motor [CN-102(5)] Rear wiper motor operating
ཛྷ Washer switch ON(2nd step)
Washer switch ON [CS-3(1) (3)] Rear washer tank [CN-103(2)] Washer operating
7-17
2) CHECK POINT

ཛ - GND (Front wiper switch power input)
ཛྷ - GND (Rear wiper switch power input)
ཝ - GND (Wiper relay power input)
ཞ - GND (Front wiper motor Lo power input)
ཟ - GND (Front wiper motor High power input)
Stop ON 20~25V
འ - GND (Wiper relay power input)
ཡ - GND (Front washer power output)
ར - GND (Rear washer power output)
ལ - GND (Front wiper motor power output)
ཤ - GND (Rear wiper motor power output)
ଖ GND : Ground
7-18
WIPER AND WASHER CIRCUIT
CS-3
G11 0.85 B
REAR WIPER & WASHER SW
9 10 10
9
M54 0.85 W
3 8
7 6 5 Lo M
8
REAR WIPER
M55 0.85 Or M55 0.85 Or
6 6 5 4 Hi
1 4
5 G55 1.25 B
10
M54 0.85 W 3 1B
4
0,I
M56 0.85 L 2 2Pf

3 M14B 1.25 L
1 3E
II I 0
2 CN-102
M14C 1.25 L
1
8
2
CONTROLLER
36 NEUTRAL SIG
35 SAFETY RY
34 PREHEATER
M22 0.85 Gr
33 WIPER RY
FRONT WASHER
32 STEERING RY
31 SERIAL-H
CN-22
G54 1.25 B 30 SERIAL-L
M 1
M27B 0.85 R 29 CLUTCH CUT-OFF PS
2 28 FUEL SENSOR
27 HYD TEMP SENDER
26 COOLANT SIG
CN-103
REAR WASHER
G53 1.25 B 25 ALT LEVEL

M 1
M56A 0.85 L 24 REMOTE FAN(-)
2
23 REMOTE FAN(+)
22 GND
21 BUZZER
20 SPEEDMETER SIG.
19 CAN-L
18 CAN-H
17 AUTO SEL.TCU
16 TAHCO -
15 STEERING PS
14 ENG OIL PS
13 AIR FILTER
12 IG 24V
11 AUTO SEL.SW
10 CLUTCH CUT-OFF SW
8 M30 0.85 Y
9 TACHO +
Hi 7 8 WIPER INT SIG
F Lo
6 7 RIDE CONT. ON
L 6 RIDE CONT. AUTO
O 5 M27 0.85 R
R 4
5 WASH SIG
5B 4 BUZZER STOP
7-19
B+ 3
3 STEERING P/P PS
CN-58
2 2 PARKING SIG
1 1 BRAKE PS
CS-11
8 WB
7 Y Lo W6
Hi
2 BW L
BWG 4
3 BG C
R
II
1
I
9
0
J 0 6
G 5
CS-12 7
II BVi 3 M14D 1.25 L
6 8
I L 4
5 9
M39 0.85 G
4 10
J BY 1 M38 0.85 Br
3 11
C RW 6 M27A 0.85 R
2 12
W Gr 2 M30 0.85 Y
1 13
14
HO Y CN-7
CS-5
7
M14 1.25 L
M40 0.85 VOr
1
FUSE BOX
2
F/R WIPER
HEAD LAMP
ILL.LAMP
BEACON LAMP
BACK/STOP LAMP
SWITCH
CIGAR
HORN/CONVERTER
WORK LAMP
AIR-CON/HEATER
3
4
5
6
7
CN-21 8
FRONT WIPER
M45C 0.85 W
3E 1 9
2Pf 2 10 G51 1.25 B
10A
10A
10A
30A
20A
11
20A
30A
20A
3
20A
20A
1B
M49 0.85 G
CN-36
4 12
M46 0.85 R
10
4 Hi
2
1
7
3
9
4
6
5 13
M45B 0.85 W
M14A 1.25 L
M45A 0.85 W
M22 0.85 Gr
M38 0.85 Br
M
M45 0.85 W
5 Lo 6
M39 0.85 G
M49 0.85 G
14
G25 1.25 B
M46 0.85 R
CN-13
5
6
4
CR-26
CR-4
87a
85
87
86
30
87a
85
87
86
30
WIPER RY LO
WIPER RY HI
87a 87 85
87a 87 85
30 86
30 86
7607EL09
HAZARD, TURN AND ROTARY CIRCUIT
COMBI LAMP LH
1 4 C 1
RF52C 0.85 L F52 1.25 L
2 3 T 2
G75 1.25 B
3 2 E 3
4 1 S ROTARY LAMP
4
CL-15 C08 1.25 GY
5 5 FUSE BOX
G13 1.25 B
6 6 C07 1.25 G BEACON LAMP 20A
1
7 7 CL-7 ILL. LAMP 10A
8 8 2
HEAD LAMP 20A
9 COMBI LAMP RH 9 3
BACK/STOP LAMP 10A
10 4 C 10 4
RF50C 0.85 Or F50 1.25 Or HORN/CONVERTER 30A
11 3 T 11
G74 1.25 B 5
12 2 E 12 AIR-CON/HEATER 20A
6
13 1 S
13 CIGAR 20A
14 CL-16 7
14 SWITCH 10A
CN-3 8
15 F/R WIPER 20A
CN-5 9
WORK LAMP 30A
10
OPTION 10A
11
CASSETTE/BUZZER 5A
12
PREHEATER 30A
13
TURN LAMP 20A
14
RADIO/ROOM LAMP 5A
15
START KEY 30A
FLASHER UNIT 16
M42C 1.25 BrW TCU 10A
1 L 17
M11 1.25 R ECM 10A
2 B G 18
G62 1.25 B CLUSTER 10A
3 E 19
CR-11 AC & HEATER 10A
20
CN-36
CLUSTER
20 TX-PC
19 GND
17 ILL.
1 16 T/M ERROR
9
8
7
6
5
4
3
2
1
15 SERIAL-L
14
13
12
11
10
2 14
CN-7
RF50A 0.85 Or SERIAL-H
3 12 GND
RF52A 0.85 L 11
4 GND
10 RX-PC
5 9 FWE
6 8 N.C
7 7 WORK LAMP
RF50A 0.5 Or 6 HIGH BEAM
8
5 RH TURN
9 4 LH.TURN
10 RF52A 0.5 L 3 24V PER.
11 2 24V IG
1 24V IG
12 1 CN-51
CN-12 2
3
4
RF52B 0.85 L
RF50B 0.85 Or
M42 1.25 BrW
5 LH TURN,FR
G03 1.25 B
6 1
6
5
4
3
2
1
8
7
6
5
4
3
2
1
R52 1.25 L
CS-5
CS-12
CS-11
7 2
8 CL-24
W6 9
L 4
G 5
Y
10 RH TURN,FR
Gr 2
BY 1
RW 6
BVi 3
BWG 4
RF52D 0.85 L G13 1.25 B

11 1
RF50 0.85 Or R50 1.25 Or
I
G10 0.85 B
M42B 1.25 BrW
M42A 1.25 BrW
RF50D 0.85 Or
RF52 0.85 L
II
G23 1.25 B
C08A 1.25 GY
C07 1.25 G
J
C08B 1.25 GY
12 2
C
W
C
HO
Hi
I
0
J 0
II
CN-10 CL-25
Lo
9
8
7
6
5
4
3
2
1
9
8
7
6
5
4
3
2
1
Hi
CS-41
CS-23
B+
6
6
5
10 10
L
R
10 10
O
L
R
8 WB
2 BW
3 BG
5B
7 Y Lo
9
8
2
7
1
9
8
2
7
1
HAZARD SWITCH BEACON LAMP SWITCH MULTI FUNCTION SWITCH
7407EL11
7-20
3. MONITORING SYSTEM
1. CLUSTER
The gauges panel consists of gauges and monitors as shown below, to warn the operator in case
of abnormal machine operation or conditions for the appropriate operation and inspection.
Â Gauges : Indicate operating status of the machine.
Â Warning lamp : Indicate abnormality of the machine.
Â Pilot lamp : Indicate operating status of the machine.
ö 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.
ö When the monitor provides a warning immediately check the problem, and perform the
required action.
ÿCluster [ Machine serial no. ; HL740-7(-#0974),HL740TM-7(-#0348) ]
Warning lamp High beam pilot lamp

Work light pilot lamp Right turning pilot lamp
Left turning pilot lamp Parking brake warning lamp
Preheater warning lamp Hyd oil temp warning lamp
Brake fail warning lamp Clutch cut off pilot lamp
Steering warning lamp Battery charging warning lamp
(Emergency) Fuel low level warning lamp
Steering warning lamp Seat belt warning lamp
(Primary)
Air cleaner warning lamp
Engine overheat
warning lamp T/M error warning lamp
Engine oil pressure
warning lamp
20 30
10 10 20 40 M MENU
Menu switch
0 0 30
50 BACK Back switch
mph
Km/h
NEXT Next switch
SE
E
C
L
Select switch
Hyd oil temp gauge

T/M oil temperature gauge LCD display
Battery volt meter Speedometer
Engine coolant temperature gauge Fuel gauge
77073CD02
7-21
ÿCluster [ Machine serial no. ; HL740-7(#0975-),HL740TM-7(#0349-) ]
Warning lamp High beam pilot lamp

Work light pilot lamp Right turning pilot lamp
Left turning pilot lamp Parking brake warning lamp
Preheater warning lamp Hyd oil temp warning lamp
Brake fail warning lamp Clutch cut off pilot lamp
Steering warning lamp Battery charging warning lamp
(Emergency) Fuel low level warning lamp
Steering warning lamp Seat belt warning lamp
(Primary)
Air cleaner warning lamp
Engine overheat
warning lamp T/M error warning lamp
Engine oil pressure
warning lamp
LCD
mph
Km/h
Select(Enter) key
Right
Hyd oil temp gauge Escape key
T/M oil temperature gauge Main/Menu key
Battery volt meter Speedometer
Engine coolant temperature gauge Fuel gauge
77073CD02-1
1) SPEEDOMETER
(1) The speedometer displays the speed of machine in mph and
km/h.
77073CD03
7-22
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.
ö If the gauge indicates below E point even though the
machine is on the normal condition, check the electric device
77073CD04 as that can be caused by the poor connection of electricity or
sensor.
3) ENGINE COOLANT TEMPERATURE GAUGE

(1) This indicates the temperature of coolant.
Red
ÂRed range : Above 104ÁC (219ÁF )
(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 the
range 77073CD05 radiator and engine.
4) TRANSMISSION OIL TEMPERATURE GAUGE

(1) This range indicates the temperature of transmission oil.
Red
operating range.
Operating
(3) If the indicator is in the red range, it means the transmission is
range 77073CD06 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
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.
Check the charging system in both cases.
77073CD07
7-23
6) HYD OIL TEMPERATURE GAUGE
(1) This range indicates the temperature of hydraulic oil.
Red
operating range.
Operating
(3) If the indicator is in the red range, reduce the load on the system.
range 77073CD08 If the gauge stays in the red range, stop the machine and check
the cause of the problem.
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) WORK LIGHT PILOT LAMP

(1) This lamp lights ON when work lamp switch is pressed.
77073CD11
10) 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
7-24
11) PARKING BRAKE WARNING LAMP
(1) When the parking brake is actuated, the lamp lights ON.
ö Check the lamp is OFF before driving.
77073CD13
12) PREHEATER WARNING LAMP

(1) This lamp lights ON when start switch is turned clockwise to the
ON position. Light will turn off after approximately 15~45
seconds, depending on engine temperature, indicating that
preheating is completed.
(2) When the lamp goes out the operator should start cranking the
77073CD14 engine.
13) CLUTCH CUT OFF PILOT LAMP

(1) When the clutch cut off switch is pressed, the lamp lights ON.
77073CD65
14) 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.
ö Do not operate until any problems are corrected.
77073CD16
15) ENGINE OVERHEAT WARNING LAMP

(1) This lamp is turned ON when the temperature of cooling water is
over the normal temperature(104ÁC, 219ÁF)
(2) Check the cooling system when the lamp is ON.
77073CD17
7-25
16) ENGINE OIL PRESSURE WARNING LAMP
(1) This lamp is comes ON after starting the engine because of the
low oil pressure.
(2) If the lamp comes ON during engine operation, shut OFF engine
immediately. Check oil level.
77073CD18
17) 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.
ö Consult a HYUNDAI dealer to investigate the cause.
77073CD19
ö Do not operate until the cause has been corrected.
18) 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
19) HYD OIL TEMPERATURE WARNING LAMP

(1) This warning lamp operates and the buzzer sounds when the
temperature of hydraulic oil is over 105ÁC(221ÁF).
(2) Check the hydraulic oil level when the lamp is turned ON.
(3) Check for debris between oil cooler and radiator.
77073CD21
20) 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
7-26
21) FUEL LOW LEVEL WARNING LAMP
(1) Fill the fuel immediately when the lamp is turned ON.
77073CD23
22) SEAT BELT WARNING LAMP

(1) This lamp lights ON for the first five seconds after starting the
machine.
77073CD24
23) STEERING WARNING LAMP(Option)

(1) Primary
If the oil pressure in the steering pump drops, the lamp will light
up. If this lamp flashes during operation, the action alarm
should sound.
ö If the lamp lights up, immediately pull the machine to a safe
place and stop the machine.
77073CD66
(2) Emergency
This lamp will flash if the oil pressure in the emergency steering
pump drops. The lamp notifies the operator that if the steering
system also failed at this time, there is no emergency steering
system for backup.
77073CD15
ö Immediately pull the machine to a convenient stop and
stop the engine.
ö This machine is equipped with ground driven emergency
steering pump. It is normal for the lamp to flash after 5
seconds when the machine is stopped.
7-27
24) LCD [ Machine serial no. ; HL740-7(-#0974),HL740TM-7(-#0348) ]
Cluster 1( ) LCD
1
2( ) MENU
M 2 - Display main menu
MENU
- Return to the normal display

BACK
3
3( ) BACK
4
NEXT
Return to the previous menu
5
SELECT
4( ) NEXT
5( ) SELECT
77073CD72
(1) Normal display
TYPE 1 TYPE 2
1
c
a e 3
2 d
b
6 4
5
77073CD73
Forward, reverse, neutral LCD type 1, Display during AEB mode

F, R, N Forward, reverse, neutral LCD type 2, Display during AEB mode
1
1, 2, 3, 4 Actual gear -
P Parking brake mode active -
a Wiper motor intermittently operating -
2 When operating intermittently, it
b -
shows an operating time interval.
c, d Up and down shifting c : Forward, d : Reverse
3 Automatic mode
e Pre-selected gear -
HOUR
4 Hour meter Display the total operation hours of the machine

COOLANT
5 C Engine coolant temperature Display in accordance with selected items
AUT Ride control mode active Ride control switch AUTO position,see page7-36-4
6 ON Ride control mode active Ride control switch ON position, see page7-36-4
(Option)
OFF Ride control mode turn off Ride control switch MIDDLE position,see page7-36-4
ö Both type1 and type2 are LCD modes and they can be changed each other by operator’s selection.
7-28
(2) Display map
Normal Main menu Sub menu Activate item

Press MENU Press ACCESSORY Press ACCESSORY
M
ACCESSORY JOB TIMER JOB TIMER
CLOCK STOP WATCH ON
USER ODOMETER OFF
ADJUSTMENT LIGHT CONT
DIAGNOSTICS RESET
Previous Press Previous Press Previous Press

menu menu menu
77073CD74

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

Light control -
ÂBrightness control : , .
Clock ÂWhen 12H or 24H is selected, the current
Â , : input, : setting.
PM
Clock ON/OFF Â : Clock display ON or OFF.
1
ÂAlarm setting. It is possible to set 3 alarms.
Alarm 2
ÂStop alarming : or buzzer stop switch.
3
User
ÂRaise the idle rpm to 1200rpm automatically
Alternate idle -
to warm up the engine.
Mode 1 ÂAutomatic travelling speed is applied from 1st
Auto 1/2
Mode 2 ÂAutomatic travelling speed is applied from
Mode 1 ÂPress button once : Shift down, press button
Quick
shift Mode 2 ÂPress button every time : Shift to lower gear
(Down) respectively. -
Auto ÂON : Transmission auto condition.
Select ÂOFF : Transmission semi-auto condition.
Aux-sw
Clutch ÂON : Clutch cut-off is activated. -
Cut-off ÂOFF : Clutch cut-off is cancelled.
7-29
Main group Sub group Meaning Display on LCD display
Adjustment Unit ÂChoose between metric and inch unit display.
TOTAL-DIS TOTAL-DIS
Km Mile
Wiper ÂWhen using the intermittent function of wiper

ÂRegulate idle rpm.
Alternate RPM ÂPress , : Adjust idle rpm increments -
Pulse ÂPress : Modification. -

ÂIt controls the disk interval of the transmission,
AEB -
automatically.
ÂEnglish : Display in English.
ENG/KOR -
ÂKorean : Display in Korean.
ÂType 1 : Indicate with the symbol.
Display 1/2 ÂType 2 : Indicate with a letter. ,
Diagnostics Fault ÂError code display.
-
Code ÂRefer to page 7-31.
Machine ÂHydraulic temperature and battery voltage HYD BATT-VOLT
Monitor display. C V
ÂPress : Display ON or OFF.
Fault ÂError code display.
-
Code ÂConsult a Hyundai dealer to error code.
Engine
ÂEngine coolant temperature display. COOLANT
Monitor C

ÂConsult a Hyundai dealer to error code. -
Transmis- Code
sion Transmission oil temperature display. OIL TEMP
Monitor ÂPress : Display ON or OFF. F
(3) Machine fault code

Press ö To go out from fault explanation window,

press button.
030 Er : 030 (Press , to go out to first menu.)
050 ö No error will be indicated in case that
025 there’s no fault.
046
Fuel level sensor open
or short to power
77073CD60
7-30

Electrical 012 Alternator voltage low Below 5V
system 013 Alternator voltage high Above 36V
014 Buzzer circuit open or short to ground
Engine 031 Fuel level sensor short to ground
system 034 Cooling fan driving valve open or short to ground
T/M system
7-31
LCD [ Machine serial no. ; HL740-7(#0975-),HL740TM-7(#0349-) ]
1 LCD
2( ) Right
1
3( ) Select(Enter)
2 4( ) Escape
3 Return to the previous menu
4 5( ) Main, Menu
5 - Display menu
7707A3CD04-1
- Return to the main display
(1) Main display
2
TYPE 1 TYPE 2
1
4
c
a
3 e 5
b
d
7
6
8 9
7707A3CD10-1

Job timer, Odometer, Hydraulic temperature, Battery
1 Job Time 1.26h Monitoring information
voltage, Coolant temperature, T/M oil temperature.
2 AUTO
State information Ride state(option), Warming up
a When operating intermittently, it shows an operating time interval
3 Wiper display
b Wiper motor intermittently operating
Forward, reverse, neutral LCD type 1
F, R, N Forward, reverse, neutral LCD type 2
4 Actual gear display
1, 2, 3, 4 Actual gear
P Parking brake mode active
c, d Up and down shifting c: Forward, d: Reverse
5 Select gear display Automatic mode
e Pre-selected gear
Fault
6 71 Fault code display Fault code state display
7 0 RPM Engine rpm display Now engine rpm state display
8 11.0Hr Hour meter display Hour meter state display
9 PM 12:05 Timer & alarm display Now time & alarm state display
ö Both type1 and type2 are LCD modes and they can be changed each other by operator’s selection.
(Adjustment/Display, see page 7-34)
7-32
(2) Display map
Main Menu Sub menu Activate item
7707A3CD11-1

Accessory ÂMeasure the various job time.
Job timer Job Time 1.26h
ÂPress : Display ON, OFF or RESET
ÂMeasures time in seconds.
Stop watch -
ÂPress : Start. Press again : Stop.
Latest ÂDistance until recent times. Latest 20.5 Km

Odometer
Total ÂTotal distance. Total 30.5 Km
ÂControl of LCD display luminosity.

Light control -
ÂBrightness control : .
Clock ÂWhen 12H or 24H is selected, the current
Â : input, : setting. PM 22:05
Clock ON/OFF Â : Clock display ON or OFF.
1
ÂAlarm setting. It is possible to set 3 alarms.
Alarm 2
ÂStop alarming :
3
User ON
Alternate ÂRaise the idle rpm to 1200rpm automatically
idle to warm up the engine. -
OFF
Mode 1 ÂAutomatic travelling speed is applied from 1st
Auto
select Mode 2 ÂAutomatic travelling speed is applied from
Mode 1 ÂPress button once : Shift down, press button
Quick
shift Mode 2 ÂPress button every time : Shift to lower gear
(Down only) respectively. -
Auto ÂON : Transmission auto condition.
select ÂOFF : Transmission semi-auto condition.
Aux-sw
Clutch ÂON : Clutch cut-off is activated. -
cut-off ÂOFF : Clutch cut-off is cancelled.
7-33
Adjustment MKS Total 50.7 Km
Unit ÂChoose between metric and inch unit display.
ENG Total 31.5 Mile
Wiper ÂWhen using the intermittent function of wiper
ÂRegulate idle rpm.
Alternate RPM ÂPress : Adjust idle rpm increments -
Pulse ÂPress : Modification. -

ÂIt controls the disk interval of the transmission,
AEB automatically.
ÂIt is set at the factory, so there's no need to
Model -
change.
ÂEnglish : Display in English.
ENG/KOR -
ÂKorean : Display in Korean.
ÂType 1 : Indicate with the symbol.
Display 1/2 ÂType 2 : Indicate with a letter. ,
Diagnostics Fault ÂError code display.

-
code ÂRefer to page 7-35.
Machine ÂHydraulic temperature and battery voltage HYD temp 100.6 C
Monitor display. Bat Volt 27.5 V
Fault ÂError code display. -
code ÂConsult a Hyundai dealer to error code.
Engine
ÂEngine coolant temperature display.
Monitor Coolant Temp 57.6 C

-
Transmis- code ÂConsult a Hyundai dealer to error code.
sion Transmission oil temperature display.
Monitor ÂPress : Display ON or OFF.
Oil Temp 37.6 C
Version ÂDisplay the controller(MCU) and cluster version. -
7-34
(3) Machine fault code
3 's FAULT 71
34 71 72 TCU Communication Error
7707A3CD36-1
ö To go out from fault explanation window, press button.

(Press , to go out to main.)
ö No error will be indicated in case that there’s no fault.

Electrical 012 Alternator voltage low Below 5V
system 013 Alternator voltage high Above 36V
014 Buzzer circuit open or short to ground
Engine 031 Fuel level sensor short to ground
system 034 Cooling fan driving valve open or short to ground
T/M system
7-35
(4) Transmission warning
Symbol Meaning Remarks
LF, LR Limp home gear -

F/R/ / flashing Direction F or R selected while turbine
speed is too high, CAUTION gear will -
engage if turbine speed drops
฀฀ Oil temperature too low, no gear available Warm up engine / transmission
WS Warning sump temperature Changes between actual gear/direction
while driving, in neutral only displayed if no
fault is detected
WT Warning torque converter temperature Changes between actual gear/direction
fault is detected
WE Warning high engine speed Changes between actual gear/direction
fault is detected
7-36
2. SWITCHES
Beacon switch(option)
Buzzer stop switch
Work lamp switch Auto select switch

Main light switch Clutch cut off switch
Parking brake switch Ride control switch(option)
Front
Hazard switch Rear wiper/washer switch
LH SIDE
A
Kick down switch
Horn button
Multi function switch
Kick down switch
74073CD03
1) STARTING SWITCH
(1) There are three positions, OFF, ON and START.
Â (OFF) : None of electrical circuits activate.
Â (ON) : All the systems of machine operate.
Â (START) : Use when starting the engine.
Release key immediately after starting.
ö Key must be in the ON position with engine running maintain
77073CD41
electrical and hydraulic function and prevent serious machine
damage.
7-36-1
2) HAZARD SWITCH
(1) Use for parking, or roading machine.
OFF
ö If the switch is left ON for a long time, the battery may be
ON
discharged.
77073CD42
3) CLUTCH CUT OFF SWITCH

(1) This switch is pressed, it will cut off the clutch when brake operates.
ö Be careful not to use this switch when driving on a slope.
(2) When the switch failure occurs, it will be able to operate a clutch off
function from LCD.
ö Refer to page 7-33.
77073CD43
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.
ö When operating the gear selector lever, be sure to release the
parking brake. If the machine is operated with the parking
brake engaged, the brake will overheat and may cause the
brake system to go out of order.
77073CD44
5) MAIN LIGHT SWITCH

(1) This switch use to operates the clearance lamp and head light by
two step.
ÂFirst step : Clearance lamp and cluster illumination lamp comes
ON. Also, all indicator lamp of switches come ON.
ÂSecond step : Head light comes ON.
77073CD45
6) WORK LAMP SWITCH

(1) This switch use to operates the front and rear work lamps by two
step.
ÂFirst step : Front work lamp located on the cab comes ON.
ÂSecond step : Rear work lamp located on the cab comes ON.
77073CD46
7-36-2
7) REAR WIPER AND WASHER SWITCH
(1) The switch use to operates the rear wiper and washer by two step.
ÂFirst step : The rear wiper operates.
ÂSecond 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
8) 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
77073CD48 buzzer stopped.
If not, stop engine and check the system which the lamp is ON.
9) AUTO SELECT SWITCH

(1) Manual mode(Η)
Press the top of the switch for the manual mode of the autoshift
function. The operator selects the desired speed and the desired
direction in the manual mode with the gear selector lever.
(2) Automatic mode(Θ)
77073CD49 Press the bottom of the switch for the autoshift function in the
automatic mode. Press the bottom of the switch prior to shifting the
transmission into forward or reverse in order to activate the autoshift
function.
ö The operator can select two kinds of auto matic modes.
(1st Ĉ 4th, 2nd Ĉ 4th)
ö When the switch failure occurs, it will be able to operate a auto
select function from LCD.
ö Refer to page 7-33.
10) BEACON SWITCH (Option)

(1) This switch turns ON the rotary light on the cab.
77073CD50
7-36-3
11) 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 9.5km/h. The automatic ride control automatically
shuts off during low speed 8km/h travel mode.
77073CD51
(2) ON position
Push in the bottom of the ride control switch in order to turn on the
system for ride control regardless speed. The ride control will
smooth the ride of the machine during travel.
77073CD51-1
(3) MIDDLE position

Push the ride control switch to the middle position in order to turn off
the system for the ride control.
77073CD51-2
12) HORN BUTTON

(1) If you press the button on the top of the multifunction switch, the
Horn button
horn will sound.
73033CD28A
13) CAB LAMP SWITCH

(1) This switch turns ON the cab room lamp.
73033CD24
7-36-4
14) KICK DOWN SWITCH
Kick down switch (1) Manual mode
It is effective 2nd speed to 1st speed only and recover to 2nd speed
quickly when push the switch one more time.
(2) Automatic mode
Η Mode 1(Down/Up)
It shifts down quickly from current gear to one step lower speed by
74073CD11
pushing the switch and recover to original speed quickly when push
the switch one more time.
Θ Mode 2(Down)
It shifts down from current gear to one step lower speed when push
the switch everytime.
ö Refer to page 7-29,33.
15) MULTI FUNCTION SWITCH

O J Ɇ ɇ (1) Front wiper and washer switch
Η When the switch is in J position, the wiper moves intermittently.
Θ When placed in Ɇ or ɇ position, the wiper moves continuously.
Ι If you push the grip of the lever, washer liquid will be sprayed and
the wiper will be activated 2-3 times.
73033CD29
ö 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

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

Η This switch is used to warn or signal the turning direction of the
machine to other vehicles or equipment.
Θ Push the lever up for turning left, pull the lever down for turning
Right turning right.
73033CD31
7-36-5
GROUP 4 ELECTRICAL COMPONENT SPECIFICATION
Part name Symbol Specifications Check
ଖ Check specific gravity

12V Ý 100Ah 1.280 over : Over charged
Battery
(2EA) 1.280 ~ 1.250 : Normal
1.250 below : Recharging
Rated load : ଖ Check coil resistance

24V Normal : About 50˟
Battery relay 100A(Continuity) ଖ Check contact
1000A(30seconds) Normal : ˳˟
CR-1
ଖ Check disconnection
2 Normal : 0˟
Fusible link 1 24V 60A (Connect ring terminal and
CN-60 check resistance between
terminal 1 and 2)
H BR ACC ST C
ଖ Check contact
23 56
H 0 I II 4 OFF : ˳˟ (For each
terminal)
0, I
Start key 1
B - ON : 0˟ (For terminal 1-3)
1 2 3 4 5 6 ˳˟ (For terminal 1-5)
START : 0˟ (For terminal 1-3
CS-2
and 1-5)
1
Pa
2 ଖ Check contact
Pressure switch N.C TYPE Normal : 0˟ (CLOSE)
CD-3 CD-26
CD-39 CD-41
1
ଖ Check contact
Pressure switch 2 Pa N.O TYPE
Normal : ˳˟ (OPEN)
CD-4 CD-40
CD-5 CD-52
7-37
1 ଖ Check resistance
Solenoid valve 2 24V 1A Normal : 15~25˟
(For terminal 1-2)
CN-137
Pa Pressure :
Air cleaner ଖ Check contact
pressure switch 635mmH2O
Normal : ˳˟
(N.O TYPE)
CD-10
2 ଖ Check LED lamp

Parking
1 24V 1.2A ଖ Check Resistance
solenoid
About 24˟
CN-71
CN-71 CN-136
1
ଖ Check resistance
Reed switch :
Fuel sender 2 Full : About 30˟
Magnetic type
CD-2 Low level : About 300˟
1 2 1
2 ଖ Check resistance
3 Normal : About 200˟
Relay 4 4 3 24V 20A (For terminal 1-3)
(4pin)
AC RY(H1)
CR-2 ACAC
CR-26 RY(M2)
RY1 : ˳˟
CR-35
CR-5 CR-42
CR-30CR-3
AC RY2 (For terminal 2-4)
CR-6 CR-7 CR-46
CR-2 CR-30
30
86
87a 87 85 Normal : About 160˟
87 (For terminal 2-6)
Relay 85 24V 20A : 0˟
(5pin) 87a 30 86
(For terminal 1-3)
CR-4 CR-5 CR-26 : ˳˟
CR-40 CR-41
(For terminal 1-3)
7-38
1 B
3 E
Proximate
4 S 24V 400mA
switch
CN-100 CN-101
1 T ଖ Check resistance
Hydraulic
2 Normal : ˳˟
temperature
105°C over : 0˟
CD-1
ଖ Check contact
1 Lo 1
MH 3 Normal
2
Aircon resistor 3 ML 2 1.12˟ : (For terminal 2-4)
4 Hi 4 2.07˟ : (For terminal 3-4)
3.17˟ : (For terminal 4-1)
1
Speaker 2 4˟ 20W
Normal : 50˟
CN-23(LH)
CN-24(RH)
10 9 8 7 6 5 4 3 2 1
10 6 5
ଖ Check contact
OFF : ˳˟
Switch
24V 8A (for terminal 1-5, 2-6)
(Locking type) 9 8 2 7 1
: 0˟
CS-17 CS-23
CS-23 CS-34
CS-42
CS-41 CS-42
CS-21 CS-41 CS-51
CS-54 (for terminal 5-7, 6-8)
CS-50
10 9 8 7 6 5 4 3 2 1
Switch 10 4 1 ଖ Check contact

(Non-locking 24V 8A OFF : ˳˟
type) 9 2 75 (for terminal 2-4, 1-7)
CS-3
CS-3 CS-20
CS-34CS-39
CS-39
7-39
1
Work lamp
2
Work lamp, 24V 70W
Room lamp, CL-1
CL-1 CL-6
CL-6 CL-22
CL-22 ଖ Check disconnection
Number plate lamp
Number plate CL-5
CL-5 CL-21
CL-21CL-23
CL-23 Normal : A few˟
CL-24 CL-25 CL-30 Room lamp
lamp
CL-32 CL-33 CL-35 24V 10W
CL-36
M 24V 70W ଖ Check disconnection

Beacon lamp
(H1 TYPE) Normal : A few˟
CL-7
24V A
24V
GND B
DC/DC ଖ24V (A-B)
12V 12V C 12V 3A
Converter 12V (B-C)
CN-138
ଖ Check operation
22-28V 2A
Horn Supply power(24V) to each
110dB
CN-20 CN-25 terminal and connect ground
2 PA
1 ଖ Check contact
Receiver dryer 24V 2.5A
Normal : ˳˟
CN-29
1 S.L+
2 ACC
3 N.C
4 S.R+ ଖ Check resistance
5 N.C
Cassette radio 6 S.L- 24V 20W+20W Power ON : 4˟ +4˟
7 B+
8 S.R- (for terminal 1-6, 4-8)
9 N.C
CN-27
7-40
24V 0.5A
Back up buzzer -
110dB
CN-65
M 1 ଖ Check contact
Washer pump 2 24V 2.5A Normal : 26.4 ˟
(for terminal 1-2)
CN-103 CN-22
1 2 3 4 5 6
24V 1.5A
Hi
Wiper motor E M Lo
2-speed -
Auto parking
CN-102 CN-21
B
A
Cigar lighter 24V 5A -
1
CL-2
B+ G
3
I ଖ Check voltage
Alternator U 24V 70A
GND Normal : 24~28V
CN-74
M
Nippandenso
Starter 228000-7902 ଖ Operating or not
B+ M 24V
CN-45
7-41
1
Aircon ଖ Check contact
24V 79W
compressor Normal : 13.4˟
CN-28
2 ଖ Check contact
Start relay 1 24V 200A
Normal : 11.3˟
CR-23
M 1 24V 9A
Blower -
2 2900· 150rpm
1 Normal : 0 ˟
1°C OFF
Duct sensor (for terminal 1-2),
2 4°C ON
the atmosphere temp:
over 4°C
Door switch 24V 2W
Normal : About 5M˟
CS-1 CS-55
3 E
G 24V
2 B
Flasher unit 85 ~ 190 C/M -
1 L
50dB
CR-11
7-42
1 Lo
2 Hi 24V 75W/70W
(H4 TYPE) ଖ Check disconnection
Head lamp 3 E
24V 4W Normal : A few ȳ
4 C (T4W)
CL-3 CL-4
4 C
24V 5W
3 T
(R5W)
Combi lamp 2 E -
1 S
2Ý 24V 21W
(P21W)
CL-15 CL-16
1
24V 21W
Turn lamp 2 -
(P21W)
CL-24 CL-25
Continuous
capacity :
Master switch 180Amp -
Push in capacity :
1000Amp
2
24V 200mA
Warning buzzer 1 -
90· 5dB(˜ m)
CN-26
1 ଖ Check contact
5 BL- BL+ 1
2
6 BK- BK+ 2 Normal : 80~90˟
3
7 FL- FL+ 3
4 (For terminal 1-5, 2-6
Joy stick lever -
5 3-7, )
6
4 8
7 : ˳˟
8 CN-114 (For terminal 4-8)
7-43
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-2 AMP 15 I/conn(Frame harness-Main harness) 2-85262-1 368301-1
CN-3 AMP 15 I/conn(Main harness-Frame harness) 2-85262-1 368301-1
CN-4 SWP 12 I/conn(Frame harness-Engine harness) S816-012002 S816-112002
CN-5 AMP 15 I/conn(Main harness-Cab harness) 2-85262-1 368301-1
CN-6 AMP 15 I/conn(Main harness-Frame harness) 2-85262-1 368301-1
CN-7 AMP 14 I/conn(Cab front harness-main harness) S814-014000 S814-114000
CN-8 SWP 12 I/conn(Main harness-Front harness) S816-012002 S816-112002
CN-10 SWP 12 I/conn(Front harness-Main harness) S816-012002 S816-112002
CN-11 DEUTSCH 8 I/conn(Main harness-Aircon harness) DT06-8S -
CN-12 AMP 15 I/conn(Frame harness-Engine harness) 2-85262-1 368301-1
CN-14 AMP 15 I/conn(Frame harness-Main harness) 2-85262-1 368301-1
CN-19 AMP 12 I/conn(Cab front harness-main harness) S814-012000 S814-112000
CN-20 Molex 2 Horn 36825-0211 -
CN-21 HW090 6 Front wiper motor
sealed 6189-01330 -
CN-22 SWP 2 Front washer tank S814-002000 -
CN-23 YAZAK1 2 Speaker(LH) 7123-1520 -
CN-24 YAZAK1 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 - 1 Comp(Air-con) NMWP01F-B -
CN-29 KET 2 Receiver drier MG640795 -
CN-45 Ring term - Starter S820-414000 -
CN-51 AMP 20 Cluster 174047-2 -
CN-52 AMP 68 T/M Control unit 962175 -
CN-53 - 6 Diagnostic - 1-408705-0
CN-58 Econo seal
III 36 Controller 344111-1 -
CN-60 58 2 Fusible link - S813-130200
CN-65 J 2 Back up buzzer DT06-2S -
CN-71 J 2 Parking solenoid DT06-2S -
CN-74 Ring term - Alternator S820-105000 -
CN-75 AMP 2 Fan clutch 85202-1 -
CN-83 KET 2 Aircon fan MG651092 -
7-44
Type Destination
CN-93 - 50 ECM DRC26-50S-05 -
CN-96 PACKARD 2 Fuel heater 1530-0027 -
CN-100 Autonics - Boom kick out 21L6-20020 -
CN-101 Autonics - Bucket leveler 21L6-20020 -
HW090
CN-102 sealed 6 Rear wiper motor 6189-01330 -
CN-103 SWP 2 Rear washer tank S814-002000 -
CN-110 - 2 Joystick 1-480698-0 -
CN-111 - 8 Joystick S814-002000 -
CN-112 - 16 Gear box 21L7-60290 1201-0974
CN-114 - 6 Joystick 1-480704-0 -
CN-121 PACKARD 4 Gear shift lever 1201-0974 -
CN-122 PACKARD 4 Gear shift lever - 1201-5797
CN-136 - 2 Ride control valve DT06-2S-P012 -
CN-137 - 2 Ride control solenoid DT06-2S-P012 DT04-2P
CN-138 DEUTSCH 3 DC/DC Converter DT06-3S -
CN-139 DEUTSCH 2 12V socket - DT04-2P
CN-144 J 6 Pedal S816-006002 -
Relay -
CR-1 Ring term - Battery relay S820-104000 -
CR-2 250 4 Horn relay S810-004202 -
CR-3 250 4 Front work lamp relay S810-004202 -
CR-4 250 6 Wiper relay S810-006202 -
CR-5 250 2 Safety relay S810-006202 -
CR-6 250 4 Rear work lamp relay S810-004202 -
CR-7 250 4 Aircon relay S810-004202 -
CR-11 250 3 Flasher unit S810-003702 -
CR-23 J 2 Start relay - S814-102001
CR-24 - 1 Preheater relay S822-014000
CR-30 250 4 Back-up relay S810-004202 -
CR-35 250 4 Ride control relay S810-004202 -
CR-42 250 4 Preheater relay S810-004202 -
CR-46 250 4 Fuel warmer relay S810-004202 -
Switch -
CS-1 - 1 Door switch S822-014004 -
CS-2 SWP 6 Start key switch S814-006000 -
CS-3 SWF 10 Rear wiper switch 593757 -
CS-5 Shur 1 Horn switch S822-014000 -
7-45
Type Destination
CS-11 SWP 8 Multi function switch S814-008000 -
CS-12 SWP 6 Multi function switch S814-006000 -
CS-17 SWF 10 Parking switch 593757 -
CS-20 SWF 10 Work lamp switch 593757 -
CS-22 SWF 10 Beacon lamp switch 593757 -
CS-23 SWF 10 Beacon switch 593757 -
CS-34 SWF 10 Buzzer stop switch 593757 -
CS-39 SWF 10 Main light switch 593757 -
CS-41 SWF 10 Hazard switch 593757 -
CS-42 SWF 10 Clutch cut off switch 593757 -
CS-50 SWF 10 Ride control switch 593757 -
CS-51 SWF 10 Auto/manual switch 593757 -
CS-52 SWF 10 Attachment lock switch 593757 -
CS-53 SWF 10 Attachment unlock switch 593757 -
CS-55 - 1 Door switch S822-014004 -
Light
CL-1 - 2 Room lamp MG610392 -
CL-2 250 3 Cigar lighter S810-001202 -
CL-3 SWP 4 Head light(LH) S814-004000 -
CL-4 SWP 4 Head light(RH) S814-004000 -
CL-5 DEUTSCH 2 Work light(LH) - DT06-2S
CL-6 DEUTSCH 2 Work light(RH) - DT06-2S
CL-7 250 1 Beacon lamp S810-001202 -
CL-15 SWP 4 Combi lamp(RR, LH) S814-004000 -
CL-16 SWP 4 Combi lamp(RR, RH) S814-004000 -
CL-21 - 1 Numberplate lamp 170183-2 -
CL-22 DEUTSCH 2 Work light(LH) - DT06-2S
CL-23 DEUTSCH 2 Work light(RH) - DT06-2S
CL-24 SWP 2 Turn lamp(LH) S814-002000 -
CL-25 SWP 2 Turn lamp(RH) S814-002000 -
Sensor, sender
CD-1 AMP 2 Hydraulic oil temp sendor 85202-1 -
CD-2 SWP 2 Fuel sendor S814-002000 -
CD-3 Rubber cap - Brake fail pressure switch 21EA-003100 -
CD-4 Rubber cap - Stop lamp pressure switch 21EA-003100 -
CD-5 Rubber cap - Clutch cut off pressure switch 21EA-003100 -
CD-10 Ring term 2 Air cleaner switch S820-105000 -
7-46
Type Destination
CD-15 AMP 2 Converter sensor 85202-1 -
CD-17 AMP 2 Engine pick-up sensor 85202-1 -
CD-26 Rubber cap - Parking pressure switch 21EA-003100 -
CD-27 AMP 2 Turbine pick up sensor 85202-1 -
CD-35 PACKARD 2 Fuel filter sensor 1204-0753 -
CD-39 Rubber cap - Steering pressure switch 21EA-00310 -
CD-40 Rubber cap 2 Steering pump pressure switch 21EA-00310 -
CD-50 AMP 2 Gear chain sensor 85202-1 -
CD-51 - 3 Output speed sensor 282087 -
CD-52 AMP 2 Oil filter 282080 -
7-47
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
7-48
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
7-49
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
10 21 1 11
21
1 11 10 21
S811-021002 S811-121002
7-50
3) J TYPE CONNECTOR
No. of
pin
1 1
2 2
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
6 3 1 8 5 2
8 5 2 6 3 1
S816-008001 S816-108001
7-51
4) SWP TYPE CONNECTOR
No. of
pin
1 1
S814-001000 S814-101000
2 1
1 2
S814-002000 S814-102000
3 1
2 1 23
S814-003000 S814-103000
2 4 1 3
1 3 2 4
S814-004000 S814-104000
7-52
No. of
pin
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
7-53
5) CN TYPE CONNECTOR
No. of
pin
1 1
S810-001202 S810-101202
2 2
1 1
S810-002202 S810-102202
3 2
1 2 1 3
S810-003202 S810-103202
2 4 1 4
1 3 2 3
S810-004202 S810-104202
7-54
No. of
pin
3 6 1 4
1 4 3 6
S810-006202 S810-106202
4 8 1 5
1 5 4 8
S810-008202 S810-108202
7-55
6) ITT SWF CONNECTOR
No. of
pin Receptacle connector(Female) Plug connector(Male)
2
10
1 10
9
SWF593757
7) HW090 SEALED CONNECTOR

No. of
6 3
4
6
6189-0133
8) MWP02F-B CONNECTOR
No. of
2 1
2
PH805-02028
7-56
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
pin
85202-1
11) AMP 040 MULTILOCK CONNECTOR

No. of
pin
12
1 6
7 12
174045-2
7-57
12) KET 090 WP CONNECTORS
No. of
pin
2 1
MG640795
13) ITT SWF CONNECTOR

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

No. of
pin
1
1
NMWP01F-B
7-58
15) DEUTSCH DT CONNECTORS
No. of
pin
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
6 1 1 6
4 3 3 4
DT06-6S DT04-6P
7-59
No. of
pin
4 5 5 4
1 8 8 1
DT06-8S DT04-8P
6 7 7 6
12
1 12 12 1
DT06-12S DT04-12P
7-60
GROUP 6 TROUBLESHOOTING
1. WHEN STARTING SWITCH IS TURNED ON, CLUSTER LAMP DOES NOT LIGHT UP
½ Before carrying out below procedure, check all the related connectors are properly inserted and the
fuse No.26 is not blown out and ON/OFF of bulb.
½ After checking, connect the disconnected connectors again immediately unless otherwise specified.
Cause Remedy
YES
Defective cluster Replace
Check voltage
YES
between CN-51
(1, 2) and chassis
NO Disconnection in Repair or replace

wiring harness or (After clean)
Check voltage
poor contact
between CN-12
(1) and chassis between
CN-51(1, 2) and
CN-12(1)
NO
Disconnection in Repair or replace
poor contact
between CN-12(1)
and fuse No.26
CLUSTER
1
FUSE
2 1
No.26
CN-51
CN-12
Check voltage
YES 20 ~ 30V
NO 0V 7607EL14
7-61
2. WHEN BATTERY LAMP LIGHTS UP(Engine is started)
½ Before carrying out below procedure, check all the related connectors are properly inserted.
Cause Remedy
YES
Defective controller Replace
Check voltage
YES
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-3(4)
(25) and CN-3(4)
and chassis
YES
Voltage : 26~30V Disconnection in Repair or replace
Check voltage poor contact
between CN-4(8) between CN-4(8)
NO
Check voltage and chassis and CN-3(4)
between
alternator terminal Disconnection in Repair or replace
"I" and chassis NO
Voltage : 26~30V poor contact
Starting switch : ON
between CN-4(8)
and alternator
terminal " I "
Defective alternator Replace

NO
CONTROLLER
ALTERNATOR
25 4 8 " I " TERMINAL
CN-3 CN-4
CN-58
Check valtage
YES 20 ~ 30V
NO 0V 7707EL23
7-62
3. WHEN PARKING SOLENOID DOES NOT WORK
fuse No.8 is not blown out.
Cause Remedy
YES
Defective parking Replace
Check voltage brake solenoid
between CN-71
(2) and chassis YES
Defective parking
Check voltage
Starting switch : ON switch
Parking switch : ON-OFF NO
between CS-17
Voltage : 20~30V (6) and chassis
Disconnection in
Voltage : 20~30V NO
wiring harness or
poor contact
between CS-17(6)
and Fuse No.8
PARKING SWITCH PARKING SOLENOID

8 2
1
5
CN-71
6
CS-17 FUSE
No.8
7407EL24
7-63
4. TRANSMISSION IS NOT RETURNED TO NEUTRAL WHEN PARKING BRAKE IS APPLIED
fuse No.17(T/M controller) and No.8 are not blown out.
Cause Remedy
YES
Defective T/M Replace
control unit
Check voltage YES

between CN-52
(21) and chassis
poor contact
Starting switch : ON Check voltage between CN-52
Parking switch : ON between CS-17
Voltage : 20~30V NO (21) and CS-17(7)
(7) and chassis
YES
Voltage : 20~30V Defective switch Replace
Parking switch : ON Check voltage
between CS-17
NO
(5) and chassis
NO
Voltage : 20~30V wiring harness or (After clean)
poor contact
between CS-17(5)
and fuse No.8
PARKING SWITCH
FUSE
6
5 No.8
7
CS-17 T/M CONTROL UNIT
21
CN-52
Check resistance
YES MAX 1˟
NO MIN 1M˟
7407EL25
7-64
5. MACHINE DOES NOT TRAVEL
fuse No.17(Transmission control unit) is not blown out.
½ Wiring diagram : See page 7-16.
Cause Remedy
YES
Defective clutch Replace
cut-off switch
Check resistance
YES
between CD-5
and chassis
NO Is there continuity Defective T/M Replace

between CN-52 NO
(66) and chassis? control unit
NO
Defective T/M Replace
Is voltage between
control unit
CN-52(21) and
chassis 20-28V? YES
Defective parking Replace
Parking switch : OFF
switch
Clutch cut-off Is there continuity
switch : ON between CS-17(7)
YES
and chassis?
Disconnection Repair or replace

NO
poor contact
between CN-52
(21) and CS-17(7)
Check resistance
YES MAX 1˟
NO MIN 1M˟
7-65
6. WHEN STARTING SWITCH IS TURNED ON, WIPER MOTOR DOES NOT OPERATE
fuse No.9 is not blown out.
½ After checking, connect the disconnected connectors again immediately unless otherwise specified. CONTROLLER
GND
CAN-L
CAN-H
IG 24V
BUZZER
SERIAL-L
TAHCO -
TACHO +
SERIAL-H
WIPER RY
WASH SIG
ALT LEVEL
BRAKE PS
SAFETY RY
AIR FILTER
ENG OIL PS
PREHEATER
FUSE BOX
PARKING SIG
NEUTRAL SIG
STEERING RY
COOLANT SIG
STEERING PS
BUZZER STOP
FUEL SENSOR
AUTO SEL.SW
AUTO SEL.TCU
WIPER INT SIG
BEACON LAMP 20A
REMOTE FAN(-)
RIDE CONT. ON
REMOTE FAN(+)
1
STEERING P/P PS
RIDE CONT. AUTO

Cause Remedy
CLUTCH CUT-OFF PS
SPEEDMETER SIG.
CLUTCH CUT-OFF SW
ILL.LAMP 10A
HYD TEMP SENDER

2
YES HEAD LAMP 20A
1
2
3
8
4
5
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
Defective front Replace 3
Check voltage BACK/STOP LAMP 10A
CN-58 4
YES between front wiper motor HORN/CONVERTER 30A
5
wiper motor and AIR-CON/HEATER 20A
6
20A
M30 0.85 Y
CIGAR
M27 0.85 R
chassis 7
M22 0.85 Gr
Poor connection of Replace
NO SWITCH 10A
Check voltage Voltage : 20~30V chassis 8
YES M14 1.25 L F/R WIPER 20A
between CN-21(5) Starting switch : ON 9
WORK LAMP 30A
Wiper switch : 1st 10
and chassis
CN-36
Voltage : 20~30V WIPER RY LO

Starting switch : ON Disconnection in Repair or replace M46 0.85 R
30
Check voltage Wiper switch : 1st NO M45A 0.85 W 87a 87 85
86
YES between CS-12 wiring harness or (After clean) M45 0.85 W
87
M22 0.85 Gr
(4), CN-7(10) and poor contact 85
M39 0.85 G
87a 30 86
chassis between CN-7(10) CR-26
Voltage : 20~30V and CN-21(5),
Wiper switch : OFF CN-13(5)
WIPER RY HI
M14A 1.25 L
30
Defective wiper Repair or replace M38 0.85 Br 87a 87 85
NO 86
M49 0.85 G
switch or (After clean) 87
G25 1.25 B
85
disconnection in M45B 0.85 W 30 86
Check voltage 87a
wiring harness or CR-4
CS-12(6)
poor contact
Voltage : 20~30V between CS-12(4)
Starting switch : ON and CN-7(10).
Wiper switch : 1st
YES
M14D 1.25 L
M39 0.85 G
M38 0.85 Br
M27A 0.85 R
M30 0.85 Y

Check voltage poor contact
between CN-7(8) between CS-7(8)
6
7
9
8
NO
10
11
12
13
14
CN-7
and chassis. and fuse No.9

M46 0.85 R
G51 1.25 B
M49 0.85 G
M45C 0.85 W
Discomection in Repair or replace

NO
6
5
4
3
2
1
8
7
6
5
4
3
2
1

CS-5
CS-11
CS-12
1
2
3
4
5
6
7
8
9
10
11
12
13
14
poor contact
CN-13
W6
L 4
between CS-12(6)
G 5
Y
Gr 2
BY 1
RW 6
BVi 3
M40 0.85 VOr

BWG 4
and CN-7(8).
I
II
J
C
W
C
HO
Hi
1
2
3
5
I
4
6
0
J 0
II
Lo
CN-21
Hi
B+
3E
F
2Pf
1B
4 Hi
5 Lo
L
R
O
L
R
M
8 WB
2 BW
3 BG
5B
7 Y Lo
FRONT WIPER
7607EL12
7-66
7. WHEN STARTING SWITCH "ON" DOES NOT OPERATE
½ Before carrying out below procedure, check all the related connectors are properly inserted and and
the fuse No.16 is not blown out.
Cause Remedy
FUSE BOX
YES
Defective cable Repair or replace 14
RADIO/ROOM LAMP 5A
Check voltage 15
assembly (After clean) M04 1.25 Or START KEY 30A
YES 16
between CN-60(2) TCU 10A
17
and chassis ECM 10A
18
CLUSTER 10A
Short circuit or Replace 19
Voltage : 20~30V NO AC & HEATER 10A
20
Check voltage defect of fusible SPARE 10A
YES 21
between CR-1 ECM 5A
link or defective 22
RCV 10A
(R1) and chassis 23
battery relay CONTROLLER 10A
24
Voltage : 20~30V TCU 10A
25
CLUSTER 10A
26
Disconnection in Replace ILL,F/L,R/R 5A
27
NO ILL.F/R,R/L 5A
Check voltage 28
wiring harness or
YES between CS-2 CN-36
poor contact F21 3.0 W
(1)[and CS-2(2)]
and chassis BATTERY MASTER SW
between CS-2(2) - BATT RY
Voltage : 20~30V R4 B G
CN-3(6)-CR-1 F23C 1.25 L R1
G79 1.25 B R3 TO STARTER

(R1) R2 CS-0
CR-1
F22 5.0 R
2 2
F21 3.0 W
Disconnection in Replace 1 1
Check voltage NO CN-1 CN-60
wiring harness or
and specific
gravity of battery poor contact
between fuse No.
Specific gravity : MIN 1.28
Voltage : MIN 24V 16 and CS-2(1) or
1
2 F23 1.25 L 2
defect of start
3 F12 1.25 V
1
switch 4 DO-1
5
6
Battery capacity Repair or replace 7
NO 8
too low (After clean) 9
F12 0.85 V
10
M04B 1.25 Or
11
12
5
4
1
6
2
3
CS-2
13
B 14
1
0, I
15
CN-3
H 0 I II
4
6
5
3
2
H
C ST ACC BR
START SWITCH
7707EL27
7-67
8. WHEN STARTING SWITCH IS TURNED ON, WORK LAMP DOES NOT LIGHTS UP
½ Before carrying out below procedure, check all the related connectors are properly inserted, and the
fuse No.10 is not blown out. FUSE BOX
BEACON LAMP 20A
½ After checking, connect the disconnected connectors again immediately unless otherwise specified. 1
2
HEAD LAMP 20A
3
BACK/STOP LAMP 10A
4
HORN/CONVERTER 30A
5
AIR-CON/HEATER 20A
6
Cause Remedy CIGAR 20A
7
YES SWITCH 10A
8
Defective lamp Replace F/R WIPER 20A
Check voltage 9
M10 1.25 Gr WORK LAMP 30A
10
YES between each
OPTION 10A
11
lamp and chassis
Disconnection in Repair or replace CN-36
NO OPT
Voltage : 20~30V wiring harness or (After clean)
Starting switch : ON FRONT WORK LAMP
poor contact C03D 1.25 Or
Check voltage 2
YES G15 1.25 B
between CL-6(2), 1
between CN-5(2), CL-36
(4) and chassis CL-5(2), CL-22(2), FRONT WORK LAMP
C03C 1.25 Or
CL-23(2) and CN- 2
G14 1.25 B
1
Voltage : 20~30V 5(4), CN-5(2). CL-35
Starting switch : ON 1
2 FRONT WORK
Check voltage Disconnection in Repair or replace FR WORK LAMP RY 3 LAMP,LH
C03 1.25 Or C03 1.25 Or C03A 1.25 Or
YES between CR-3(4), NO 3 4 4 4 2
wiring harness or (After clean) M51 0.85 W G11 1.25 B
3 5 G01 1.25 B 1
CR-6(4) and M10A 1.25 Gr 6 CL-6
poor contact 2
G21 1.25 B 7
chassis 1 2 1 FRONT WORK
between CN-5(4) - 8
CR-3 LAMP,RH
Voltage : 20~30V 9 C03B 1.25 Or
CR-3(4) and CN- 2
10 G12 1.25 B
Starting switch : ON 11 1
5(2) - CR-6(4) 12 CL-5
OPT
Check voltage 13 REAR WORK LAMP
14 C04C 1.25 Br
between CR- Defective work Replace relay 15 2
NO G16 1.25 B
1
3(2), CR-6(2) and lamp relay CN-5
CL-32
chassis REAR WORK LAMP
RR WORK LAMP RY C04D 1.25 Br
YES 2
Voltage : 20~30V C04 1.25 Br G17 1.25 B
Disconnection in Repair or replace 3 4 4 1
Starting switch : ON M52 0.85 L
wiring harness or (After clean) 3 CL-33
M10B 1.25 Gr
2
poor contact G22 1.25 B REAR WORK
Check voltage 1 2 1 LAMP,LH
between CR-3(2), CR-6 G24 1.25 B
1
between fuse No. C04B 1.25 Br
NO CR-6(2) and fuse 2
10 and chassis WORK LAMP SW CL-22
No.10 G13 0.85 B
9 10 10 C05F 0.85 R
Voltage : 20~30V 9
4 8 REAR WORK
Starting switch : ON 2 M59 0.85 Y LAMP,RH
Short circuit of fuse Replace 7 G25 1.25 B
NO 1
7 1 6 C04A 1.25 Br
M51 0.85 W 2
5 5
C05G 0.85 R CL-23
4
3
2 M52 0.85 L CLUSTER
C05H 0.85 R
II I 0
1 20 TX-PC
19 GND
CS-20
17 ILL.
16 T/M ERROR
CS-39
15 SERIAL-L
9 10 10 14 SERIAL-H
9 12 12 GND
4 8
11 11 GND
2 C05C 0.85 R 10 RX-PC
7 10 9 FWE
7 1 6 9
5 M59 0.5 Y 8 N.C
5 7 WORK LAMP
8
4 7 6 HIGH BEAM
3 6 5 RH TURN
2 4 LH.TURN
M17 1.25 OrW 5
II I 0
1 3 24V PER.
4 2 24V IG
ILL & HEAD LAMP SW : ON(1st step) 3 1 24V IG
2 CN-51
1
CN-12
7407EL28
7-68
9. WHEN ENGINE DOES NOT START
½ Check supply of the power at engine stop solenoid while starting switch is ON. CONTROL UNIT
½ Before carrying out below procedure, check all the related connectors are properly inserted.
½ After checking, connect the disconnected connectors again immediately unless other wise specified.
½ Check forward reverse switch at neutral position.
VMGA2
AIP6
AIP4
AIP1
VPI
EF4
VPE2
ED1
ED5
ED2
ED9
ED6
ADM5
45
46
51
55
56
57
62
63
64
65
66
67
68
FUSE BOX
Cause Remedy CN-52 14
VM OUTPUT SIGNAL K A
RADIO/ROOM LAMP 5A
YES VP F B N D B 15
1 2 3 4 1 2 3 4 1 2 3 4 C START KEY 30A
Defective battery Check engine ED 16
T37 0.85 W
AD1 B1 D TCU 10A
system charge or AD2 B2 17
CN-121 ECM 10A
AD3 B3 18
replace (after AD4 V CLUSTER 10A
19
AD5 R A 1 AC & HEATER 10A
checking specific B
SAFETY RY 20
AD6 AS 2 M43 1.25 R
30 SPARE 10A
gravity of battery) AD7 C 3 21
T37C 0.85 W 85 ECM 5A
YES A AD3 D 4 86 87a 87
E05 0.85 R 22
Defective magnet Replace
M01 1.25 WOr
Check voltage B AD2

CN-122 5 87 RCV 10A
Check operation M21 0.85 L 23
YES between starter of start motor C AD1 6 85 CONTROLLER 10A
D AD7(KD) 7 24
of start motor magnet coil and X1 8
87a 30 86 TCU 10A
25
A ED1(VP) 9 CR-5 CLUSTER 10A
chassis Defective start Replace 26
Starting switch : start NO D AD6 10 ILL,F/L,R/R 5A
Starting switch : start B AD4 27
relay 11 5A
ILL.F/R,R/L
C AD5 12 28
X2
13
YES 14 CN-36
ཁ
CN-13
Check operation Check voltage
NO of starter relay YES
between CR-5
(87) and chassis
Starting switch : start
Disconnection in Replace
Starting switch : OFF NO
wiring harness or
Check operation poor contact
of start safety between CN-2(11)
NO
relay and CR-5(87)
Check switch : neutral YES
Defective relay Replace
Check voltage
between CR-5 STARTER
NO TO BATT
(86) and chassis B+
ག
Starting switch : OFF NO
M
YES CN-45
Defective start Replace
Check voltage relay START RY
G15 1.25 B
ཁ between CR-23 1 1
M43 1.25 R
F12 0.85 V
M01 1.25 WOr
E05 1.25 R
M04B 1.25 Or
2 2
(2) and chassis CR-23
5
4
1
6
2
3
3
CS-2
Disconnection in Repair or replace 4

Voltage : 20~30V NO B
1
Starting switch : ON wiring harness or 0, I 5 1

6 2
poor contact
7 3
between CN-2(11) H 0 I II
8 4
4
6
5
3
2
H
-CN-4(7)-CR-23(2) C ST ACC BR 9 5
START SWITCH 10 6
E05 0.85 R
YES 11 7
Disconnection in Repair or replace 12 8
wiring harness or CN-2 9
10
Check voltage poor contact 11
ག between CN-13 between CN-13(4) 12
(4) and chassis and CR-5(86) CN-4
Starting switch : OFF

Defective DW-3 Replace 7707EL29
NO
7-69

Manual de Serviço Hyundai Hl740-7

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Manual de Serviço Hyundai Hl740-7

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HL740 (TM) -7 manual de serviço Página 1 de 1

RODA DE CARREGADOR HL740 (TM) -7

Group 1 Safety Hints 1-1

FOLLOW SAFE PROCEDURE

WEAR PROTECTIVE CLOTHING

WARN OTHERS OF SERVICE WORK

USE HANDHOLDS AND STEPS

WORK IN CLEAN AREA

PROTECT AGAINST FLYING DEBRIS

PROTECT AGAINST NOISE

SUPPORT MACHINE PROPERLY

SERVICE COOLING SYSTEM SAFELY

HANDLE FLUIDS SAFELY-AVOID FIRES

BEWARE OF EXHAUST FUMES

REMOVE PAINT BEFORE WELDING OR

SERVICE MACHINE SAFELY

STAY CLEAR OF MOVING PARTS

AVOID HEATING NEAR PRESSURIZED FLUID

PREVENT BATTERY EXPLOSIONS

USE TOOLS PROPERLY

USE PROPER LIFTING EQUIPMENT

DISPOSE OF FLUIDS PROPERLY

LIVE WITH SAFETY

KEEP ROPS INSTALLED PROPERLY

Bucket Tire Hydraulic tank Radiator

Boom Main control valve Cab Air cleaner Counterweight

Bucket Tire Hydraulic tank Radiator Counterweight

Boom cylinder Main control valve Cab Air cleaner Battery

Description Unit Specification

Description Unit Specification

Description Unit Specification

Description Unit Specification

Description Unit Specification

Model Cummins QSB5.9-C

3) FAN AND BRAKE PUMP

4) MAIN CONTROL VALVE

5) REMOTE CONTROL VALVE

Type Joystick(or with aux lever)

1 Engine mounting bolt(2EA) M20Ý 2.5 57.9· 8.7 419· 62.9

(2) Fine thread

Thread size(PF) Width across flat(mm) kgf½ m lbf½ ft

3) PIPE AND HOSE(ORFS TYPE)

Thread size(UNF) Width across flat(mm) kgf½ m lbf½ ft

13/16-16" 24 4.4 32.5

Thread size(PF) Width across flat(mm) kgf½ m lbf½ ft

Torque converter SAE 10W-30

ASTM D975 NO. 1

1. Monitor indicator and gauge checks(Engine OFF)

½ Hourmeter and gauge check

2. Transmission, axle and engine linkages, neutral start

½ Transmission control lever and neutral

3. Monitor indicator and gauge checks(Engine running)

½ Monitor display and alternator output checks

½ Park brake capacity check

½ Transmission oil warm up procedure

6. Hydraulic system checks

½ Hydraulic system warm up procedure

½ Steering valve check

½ Operating lights check

9. Cab components and vandal protection checks

½ Cab door latch check

Group 1 Structure and Function 2-1

Front lift bracket

Starting motor Lube oil filter