0349 858 0 Hy El en 144

HYDRAULICS
ELECTRICS
TECHNICAL DATA
CL
CLAA AS TTARGO
ARGO C Series
08/2003 349858.0
The machines in this handbook are designed essentially for agricultural and associated applications. This is
their intended use.
Any modifications made to the machine without prior written approval from CLAAS or if the machine is used in
any way contrary to the intended use or if the machine is not properly driven or maintained then the Company
will not accept any liability whatsoever for any damage or injury (whether direct or consequential).
The method of operation and maintenance specified in this handbook should be strictly adhered to.
For your parts requirements, it is essential that only genuine CLAAS parts are fitted. Any resultant damage
from non-genuine parts will invalidate your machine warranty.
CLAAS operates a policy of continuous improvement to its products and reserve the right to change specifica-
tions and equipment without notice. Therefore some information within this handbook may differ from your
machine.
This manual is designed to service machines:
from Serial No. 50600011

up to Serial No. 50600251.
CONTENTS
INTRODUCTION
General
Machine identification
Health and Safety
SAFETY WARNINGS
SECTION 1
HYDRAULICS
Description and Operation 1.1
Description 1.1
General 1.1
Dumping (dissipation) of hydraulic pressure 1.1
To dump brake system pressure 1.1
To dump a system pressure 1.1
Hydraulic Circuit (machines up to 50600162) 1.2
Hydraulic Circuit (machines from 50600163) 1.4
Hydraulic tank 1.6
Hydraulic pump 1.7
Auxilliary hydraulic pump 1.7
Cooler bypass valve 1.7
Fan motor 1.8
Pressure relief valve 1.8
Fan reverse motor 1.8
Pressure filter 1.9
Steering and accumulator charge valve (STAC) 1.9
Accumulator 1.13
Pressure switch 1.13
Brake pressure servo valve 1.13
Transmission inching 1.14
Pressure switch (brake light) 1.15
Front axle 1.15
Steering cylinder (front) 1.15
Rear axle 1.15
Steering cylinder (rear) 1.15
Steering valve 1.16
Steering selector valve 1.17
Control valve 1.19
Inlet section/Relief valve 1.20
Lift/Lower section 1.21
Crowd/Dump section 1.22
Extension section 1.23
1st service/2nd service section 1.24
End plate 1.24
Lift cylinder 1.25
Load control valve 1.25
Extension cylinder 1.26
Compensator cylinder 1.27
Autohitch cylinder 1.27
Crowd cylinder 1.28
Changeover valve 1.29
1st service couplings 1.29
Manifold 1.30
Trailer brake coupling 1.30
Tap 1.30
CONTENTS
SECTION 1
HYDRAULICS
Description and Operation
Description (continued)
Trailer brake valve 1.31
Trailer tipping connection 1.31
2nd service couplings 1.31
Hydrostatic drive pump 1.32
Hydrostatic drive motor 1.33
Operation 1.34
Hydrostatic pump 1.36
Hydrostatic motor 1.37
Control valve 1.38
Relief valves 1.38
System pressure checks 1.39
Maintenance 1.41
Torque tightening 1.41
Hydraulic level 1.43
Hydraulic tank 1.44
Removal 1.44
Installation 1.45
Hydraulic pump 1.46
Removal 1.46
Installation 1.47
Auxilliary hydraulic pump 1.48
Removal 1.48
Installation 1.48
Fan motor 1.49
Removal 1.49
Installation 1.49
Fan reverse valve 1.50
Removal 1.50
Installation 1.50
Hydraulic filter 1.51
Removal 1.51
Installation 1.51
Brake system bleeding 1.52
General 1.52
Single brake valve (MICO) 1.53
Removal 1.53
Installation 1.53
Servicing - dismantling 1.54
Servicing - assembly 1.55
Trailer brake valve 1.56
Removal 1.56
Installation 1.56
Diverter valve 1.59
Removal 1.59
Installation 1.59
Manifold 1.60
Removal 1.60
Installation 1.60
Hydrostatic pump 1.61
Removal 1.61
Installation 1.62
CONTENTS
SECTION 1
HYDRAULICS
Maintenance (continued)
Multifunction valves 1.63
Removal 1.63
Installation 1.63
Hydrostatic motor 1.64
Removal 1.64
Installation 1.64
Purge relief valve 1.66
Removal 1.66
Installation 1.66
Hydrostatic system - pressure test/adjust 1.67
Charge pressure 1.67
Drive loop pressure (forward) 1.68
Drive loop pressure (reverse) 1.69
Adjusting motor case pressure 1.70
Travel speed - check/adjust 1.71
Control valve - check/adjust 1.72
Oil cooler (Machines up to S/No.50600162) 1.73
Removal 1.73
Installation 1.73
Oil cooler (Machines from S/No.50600163) 1.74
Removal 1.74
Installation 1.74
STAC valve 1.75
Removal 1.75
Installation 1.75
Accumulator (Machines up to S/No.50600162) 1.76
Removal 1.76
Installation 1.76
Accumulator (Machines from S/No.50600163) 1.77
Removal 1.77
Installation 1.77
Load control valve - lift cylider 1.78
Removal 1.78
Installation 1.78
Load control valve - crowd cylider 1.79
Removal 1.79
Installation 1.79
Load control valve - extension cylider 1.80
Removal 1.80
Installation 1.80
Control valve 1.81
Removal 1.81
Installation 1.81
Spool sections - general 1.83
Spool section - dismantling 1.83
Spool sections - assembly 1.84
Electrically controlled valves - dismantling 1.85
Electrically controlled valves - assembly 1.85
Inlet section - general 1.87
Inlet section - dismantling 1.87
Inlet section - assembly 1.87
CONTENTS
SECTION 1
HYDRAULICS
Maintenance (continued)
Steering 1.88
Description 1.88
Operation 1.88
Checking the steering system 1.91
Steering valve assembly 1.92
Removal 1.92
Installation 1.92
Dismantling 1.94
Assembly 1.94
Lift cylinder 1.94
Removal 1.94
Installation 1.95
Crowd cylinder 1.96
Removal 1.96
Installation 1.96
Compensator cylinder 1.97
Removal 1.97
Installation 1.97
Extension cylinder 1.99
Removal 1.99
Installation 1.101
Cylinder servicing 1.101
Servicing 1.101
Dismantling 1.101
Assembly 1.102
Autohitch cylinder 1.104
Removal 1.104
Installation 1.104
SECTION 2
ELECTRICS
Circuit diagrams
Key to circuit diagrams 2.1
Starting / Charging / Power distribution 2.5
Hydraulic Control 2.6
Wipers / Horn / Work Lamps 2.7
Head lamps / Side Lamps / Fog Lamps 2.8
Stop Lamps / Reverse Alarm / Turn Hazard Lamps / Radio / Steering Sensor 2.9
Heater / Air Conditioning / Interior Lamps / Instrumemts 2.10
Transmission Control 2.11
Chassis loom 2.12
Engine Loom 2.13
Cab Loom 2.14
Engine loom 2.13
Longitudinal stability indicator 2.15
Description 2.15
Sensor 2.16
Display Module 2.17
Testing and adjustment 2.19
Troubleshooting 2.19
Visual inspection 2.19
System check 2.20
Error indications from the display module 2.21
Sensor - test 2.21
CONTENTS
SECTION 2
ELECTRICS (continued)
General 2.21
Procedure to test the operation of the sensor 2.22
Procedure to install a sensor 2.23
Procedure to replace the display module 2.24
Calibration 2.25
Calibration procedure 2.25
Resetting the zero point 2.27
Testing load sensor function 2.28
Functional test of load sensor indicator 2.28
Procedure 2.29
Main instrument panel 2.30
Description 2.30
Removal 2.30
Installation 2.30
Functional description 2.31
Control joystick 2.32
Removal 2.32
Installation 2.32
Starter 2.33
Removal 2.33
Installation 2.33
Fusebox and relays 2.34
Description 2.34
Removal 2.35
Installation 2.35
Alternator 2.36
Alternator drive belt check 2.36
Removal 2.37
Installation 2.37
Transmission Control (SUSMIC) 2.38
S1X Mobile Computer 2.38
Removal 2.38
Installation 2.38
FNR switch assembly 2.39
Removal 2.39
Installation 2.39
Inch pedal sensor (brake pedal) 2.39
Removal 2.39
Installation 2.40
Mode switch 2.40
Removal 2.40
Installation 2.40
Speed sensor 2.41
Removal 2.41
Installation 2.41
CONTENTS
SECTION 3
TECHNICAL DATA
Dimensions 3.1
Weight 3.1
Machine speed 3.2
Carriage 3.2
Cycle time 3.2
Engine 3.3
Cooling 3.3
Transmission 3.3
Tyres 3.3
Hydraulics 3.4
Electrics 3.4
Capacities 3.4
INTRODUCTION
General
The contents of this Repair Manual, although correct at the time of publication, may be subject to alteration by
the manufacturer without notice.
This manual assumes that maintenance personnel have a sound knowledge of workshop practices and
safety procedures associated with the repairs of this type of machine. This manual is designed to assist with
the more specialised information required for removal and strip-down of major components.
It is recommended that the relevant part of this Repair Manual is studied carefully before proceeding with any
maintenance.
Machine identification
To make sure that the correct parts are obtained, always quote the machine Serial Number when ordering
parts.
Health and Safety
To prevent injury to personnel and damage to equipment and machinery, care must be taken to operate in a
safe manner. Read the Safety Warnings that follow and always work in a safe manner and obey the relevant
Warnings.
Throughout this manual and on the machine there are safety notes. Each note starts with a single word. The
meaning of these single words is as follows:
Identifies a hazard exists. If proper precautions are not taken, it is highly probable that the
operator (or others) could be killed or seriously injured.
Identifies a reminder of safety practices. Failure to observe these safety practices could result
in injury to the operator (or others) or damage to the machine.
In general these notes are used to indicate that the procedures being described in the manual must be
followed to avoid serious injury or death to yourself or others. The notes are also used to protect the machine
from unsafe maintenance practices.
SAFETY WARNINGS
Always wear correct fitting protective clothing. Loose or baggy clothing can be extremely
dangerous when operating or maintaining a machine.
Where possible, only work on or close to engines or machinery when they are stopped. If this
is not practical, remember to keep tools, test equipment and all parts of your body well away
from moving parts.
Avoid contact with exhaust pipes and exhaust manifolds when the engine is running; these
can be very hot.
Many liquids used on this machine are harmful if taken internally or splashed into the eyes. In
the event of accidentally swallowing oil, diesel fuel, anti-freeze, battery acid etc., DO NOT
induce vomiting, but OBTAIN QUALIFIED MEDICAL ASSISTANCE IMMEDIATELY.
Always obtain advice before mixing oils; some are incompatible.
Never run an engine in an enclosed space unless an exhaust extraction system is used.
Always Disconnect battery cables before using an external charger to prevent damage to
electrical system components.
Always Disconnect battery cables before working on the electrical system to prevent injury
caused by electric shock.
When it is necessary to work on the electrical system with power on, for fault diagnosis,
always have a safety man in attendance
Any dust found on the machine or produced during work on the machine should be removed
by extraction, not by blowing. Dust waste should be dampened, placed in a sealed container
and marked for safe disposal.
Always dump pressure from the hydraulic system before carrying out any maintenance or
adjustment (refer to page 1.1).
Never leave the machine unattended with pressure in the system.
Fine jets of hydraulic fluid at high pressure can penetrate the skin. Do not use your fingers to
check for hydraulic fluid leaks. Do not put your face close to suspected leaks. If hydraulic fluid
penetrates your skin OBTAIN QUALIFIED MEDICAL ASSISTANCE IMMEDIATELY.
Never allow unqualified personnel to attempt to remove or replace any part of the machine.
Always use the correct lifting equipment to remove large or heavy components.
Never attempt to lift or hold up the machine using the lash-down points.
SECTION 1
HYDRAULICS
HYDRAULICS 1.1
DESCRIPTION AND OPERATION
DESCRIPTION Dumping (dissipation) of hydraulic
pressure
General
The main hydraulic circuit supplies the power for boom
Always dump all hydraulic pressure
manipulation, attachments, brakes and steering.
from the system before servicing any
hydraulic component.
The auxiliary hydraulic circuit supplies the fan motor
and the hydrostatic transmission.
Ensure there is sufficient space and
headroom around machine before
A hydraulic oil reservoir supplies the main and auxiliary operating any hydraulic control.
hydraulic pumps. A header tank with a filter breather
cap supplies oil to the main hydraulic tank.
To dump brake system pressure
An oil cooler is fitted in the outlet from the hydrostatic
transmission circuit. 1. Stop the engine.
The main pump is driven from the engine. Pressurised 2. Make sure the machine is parked on firm and
oil from the pump is directed to the control valve. The level ground and chock the wheels.
Steering and Accumulator Charge (STAC) valve feeds
steering and brakes. Excess oil is to the control section 3. Turn the ignition switch to position (1).
of each boom service.
4. Set the parking brake switch, if necessary, to the
The main pump is of fixed displacement. The steering parking brake applied position.
service supplies a load-sensing signal, hydraulically, to
the STAC valve so as to provide the optimum supply of 5. Press the brake pedal repeatedly until the brake
oil. charge warning lamp illuminates.
The auxiliary pump is driven by the timing case gears 6. Press the brake pedal a further twenty times to
and supplies pressurised oil to the engine cooling fan ensure that residual pressure in the brake system is
motor. A low-pressure filter in the auxiliary system, fully dissipated.
installed between the fan motor and the transmission
hydrostatic drive pump constantly filters the hydraulic 7. Turn the ignition switch to off.
fluid. The filter includes a blockage indicator which
operates a warning light in the cab when servicing is
required. To dump a system pressure
NOTE: This procedure applies to all machine hydraulic
The hydrostatic drive pump for the transmission motor
systems, except brakes.
is driven by the engine crankshaft. The supply is from
the auxiliary system through the filter. 1. Stop the engine.
2. Make sure the machine is parked on firm and

level ground and chock the wheels.
3. Turn the ignition switch to position ‘I’.
3. Operate the applicable system until all hydraulic

pressure has been dissipated.
4. Turn the ignition switch to off.

1.2 HYDRAULICS
HYDRAULIC CIRCUIT (up to MachineS/No.50600162)
HYDRAULICS 1.3
Key to hydraulic circuits -
(up to MachineS/No.50600162)
1. Hydraulic tank 56. Pressure relief valve, 30 bar

2. Hydraulic pump, main 57. Proportional pressure reducing valves
3. Hydraulic pump, auxiliary (fwd & rear)
4. Header tank 58. Multifunction valve
5. Filter 59. Bypass valves
6. Cooler bypass valve 60. Pressure limiter, 480 bar
7. Fan motor 61. Relief valve, 530 bar
8. Pressure relief valve 62. Multifunction valve
9. Filter with Bypass 63. Check valve
10. Steering & Accumulator Charge (STAC) valve 64. Relief valve, 40 - 50 bar
11. Regulator, 190 bar 65. Control valve pump
12. Accumulator charge valve 66. Hydrostatic drive motor, comprising
13. Orifice 67. Control valve motor
14. Filter 68. Loop flushing valve, 2 - 3 bar
15. Priority valve 69. Purge relief valve, 16 bar
16. Accumulator 70. Brake pressure defeat valve
17. Pressure switch, 116 bar 71. Pressure compensator override, 180 bar
18. Brake pressure servo valve 72. Oil cooler
19. Pressure switch, 5 bar 73. Test point 1 (STAC main circuit)
20. Front axle 74. Test point 2 (STAC Brake pressure 160 bar)
21. Control valve, steering - Danfoss OSPF 75. Test point 3 (Hydrostatic drive pressure M1)
22. Steering control valve spool 76. Test point 4 (Hydrostatic drive pressure M2)
23. Shock valve, 225 - 245 bar 77. Test point 5 (Hydrostatic drive pressure M3)
24. Steering selector valve - attached to OSPF valve
25. Pressure relief valve, 175 bar
26. Non-return valve
27. Steering cylinder (rear axle)
28. Steering cylinder (front axle)
29. Main control valve, comprising
30. Inlet section/Pressure relief valve, 240 bar
31. Lift/lower section
32. Crowd/dump section
33. Shock valve, 210 - 125 bar
34. Extension/retract section
35. 1st auxiliary section
36. 2nd auxiliary section
37. End plate
39. Lift cylinder
40. Load control valve
41. Crowd cylinder
43. Compensator cylinder
44. Extension cylinder
46. Changeover valve
47. Quick coupler
48. Manifold
49. Quick coupler (Trailer tipping)
50. Cylinder, auto-hitch
51. Tap
52. Trailer brake valve
53. Quick coupler (Trailer braking)
54. Quick coupler
55. Hydrostatic drive pump, comprising
1.4 HYDRAULICS
HYDRAULIC CIRCUIT (from MachineS/No.50600163)
HYDRAULICS 1.5
Key to hydraulic circuits -

(from MachineS/No.50600163)
1. Hydraulic tank 56. Pressure relief valve, 30 bar

2. Hydraulic pump, main 57. Proportional pressure reducing valves
3. Hydraulic pump, auxiliary (fwd & rear)
4. Header tank 58. Multifunction valve
5. Filter 59. Bypass valves
6. Cooler bypass valve 60. Pressure limiter, 480 bar
7. Fan motor 61. Relief valve, 530 bar
8. Pressure relief valve, 90 bar 62. Multifunction valve
9. Filter with Bypass 63. Check valve
10. Steering & Accumulator Charge (STAC) valve 64. Relief valve, 40 - 50 bar
11. Regulator, 190 bar 65. Control valve pump
12. Accumulator charge valve 66. Hydrostatic drive motor, comprising
13. Orifice 67. Control valve motor
14. Filter 68. Loop flushing valve, 2 - 3 bar
15. Priority valve 69. Purge relief valve, 16 bar
16. Accumulator 70. Brake pressure defeat valve
17. Pressure switch, 116 bar 71. Pressure compensator override, 180 bar
18. Brake pressure servo valve 72. Oil cooler
19. Pressure switch, 5 bar 73. Test point 1 (STAC main circuit)
20. Front axle 74. Test point 2 (STAC Brake pressure 160 bar)
21. Control valve, steering - Danfoss OSPF 75. Test point 3 (Hydrostatic drive pressure M1)
22. Steering control valve spool 76. Test point 4 (Hydrostatic drive pressure M2)
23. Shock valve, 225 - 245 bar 77. Test point 5 (Hydrostatic drive pressure M3)
24. Steering selector valve - attached to OSPF valve 78. Fan reverse valve.
25. Pressure relief valve, 175 bar
27. Steering cylinder (rear axle)
28. Steering cylinder (front axle)
29. Main control valve, comprising
30. Inlet section/Pressure relief valve, 240 bar
31. Lift/lower section
32. Crowd/dump section
33. Shock valve, 210 - 125 bar
34. Extension/retract section
35. 1st auxiliary section
36. 2nd auxiliary section
37. End plate
39. Lift cylinder
41. Crowd cylinder
43. Compensator cylinder
44. Extension cylinder
46. Changeover valve
47. Quick coupler
48. Manifold
49. Quick coupler (Trailer tipping)
50. Cylinder, auto-hitch
51. Tap
52. Trailer brake valve
53. Quick coupler (Trailer braking)
54. Quick coupler
55. Hydrostatic drive pump, comprising
1.6 HYDRAULICS
Hydraulic tank (1)
A single hydraulic tank feeds the main and auxiliary

systems of the machine. A header tank, fitted with a
filler cap/filter, feeds the main tank. A dipstick in the
filler cap of the header tank is used to check system
contents.
Specifications:
Capacity:
Nominal (tank) 55 litres
Total (system oil) 80 litres
1. Return hose from fan motor

2. Spare (blanked) 11. Drain plug
3. Return hose from oil cooler 12. Drain plug
4. Return hose from control valve 13. Hose clip
5. Filler hose (from header tank) 14. Suction hose – Auxiliary pump
6. Return hose from brakes 15. Suction hose – Main pump
7. Return hose from steering
8. Return hose from transmission
9. Return hose from STAC
10. Hydraulic tank
HYDRAULICS 1.7
Hydraulic Pump (2)
The fixed displacement, main Hydraulic pump supplies

pressurised oil to the Steering and Accumulator (STAC)
valve, for the operation of the brakes, steering and to the
main control valve, via the STAC valve, for the services.
Specifications
Pressure (P) 250 bar (3481psi)
Capacity (flow) 80 l/min @ 2400 rpm
Auxiliary Hydraulic Pump (3)

The fixed displacement, auxiliary hydraulic pump supplies
pressurised oil to the fan motor. The return oil from the
fan motor is constantly filtered through the filter (9) and
returned to tank through the hydrostatic drive motor (55).
Specifications:
Pressure 160 bar (2321 psi)
Flow 191 l/min @ 2400 rpm
Cooler bypass valve (6)
The cooler bypass valve is fitted in the return line

between the hydrostatic drive pump and the hydraulic
tank. This valve diverts fluid to return whilst the engine is
being started and offloads the build-up of pressure until
pump pressure overcomes the spring in the cooler
bypass valve, when it will close.
1.8 HYDRAULICS
Fan motor (7)
NOTE: Fitted to machines up to S/No.50600162 only)
The fan motor (7) is hydraulically operated from the

auxiliary circuit. The fan is secured to the drive shaft
with a woodruff key and a nut. A cartridge pressure
relief valve (8) is attached to the fan motor.
Specifications
Pressure relief valve 160 bar (2321 psi)
Pressure relief valve (8)

1. Fan motor (7)
NOTE: Fitted to machines up to S/No.50600162 only) 2. Pressure relief valve (8)
3. Pressure - auxiliary pump
4. Return to tank
The cartridge pressure relief valve (8) is attached to the
5. To pressure filter
fan motor and relieves pressure to the return side of the
motor.
Specifications
Operating pressure 160 bar (2321 psi)
Fan reverse motor (7)

NOTE: Fitted to machines from S/No.50600163 only)
This type of fan motor is hydraulically operated from the

auxiliary circuit and is fitted as part of the Reverse Fan
engine cooling system. The fan is secured to the drive
shaft with a woodruff key, nut and tab washer.
1. To pressure filter
2. Fan motor (7)
3. Pressure - auxiliary pump
4. Return to tank
HYDRAULICS 1.9
Pressure filter (9)

The pressure filter is installed in the return line from
the hydrostatic motor. When the filter becomes
blocked a filter blockage warning light in the cab
illuminates and a bypass Non-Return Valve (NRV)
will open at 3.5 bar (50 psi).
When the warning light is illuminated

NO filtration is taking place. Always
change the filter IMMEDIATELY,
Specifications
Filtration 10 micron (µ)
1 Filter bowl
2 Filter media
3 Bypass valve
4 Pressure switch
Steering and Accumulator Charge (STAC)

valve (10)
The STAC valve provides priority oil flow for the load
sensing steering and to charge the brake accumulator
for full power braking. The valve contains a 190 bar
Regulator (11), an Accumulator Charge Valve (12), two
filters (13 & 14) and a Priority Valve (15).
1.10 HYDRAULICS
1.13 The steering and accumulator charge valve

provides oil flow, on demand and with equal priority,
to both the steering and the accumulator charging
system. While providing steering and braking oil flow,
excess oil flow is also available for the attachments.
When the accumulator is fully charged, the valve

functions as a load-sense priority valve and supplies
flow to the steering system in response to the load
sense signal. If the steering pressure rises above the
accumulator pressure then the accumulator is
charged up to the higher steer pressure. If the
accumulator pressure falls to the preset cut-in level,
the valve closes the load sense line and supplies a
fixed flow to charge the accumulator until a preset
cut-out pressure is reached.
Steering is available while the charging occurs. When

the charging is completed, the load sense line
reopens and the valve reverts to the load sense
steering operation.
At start up, if the accumulator is discharged, the

accumulator charge valve (12) is closed due to the
action of the spring. The priority valve (15) is held to
the left by its spring. Pump flow is directed to port
(P), and into (P1) through the check valve C, and into
the accumulator (16) and brakes. Since (12) is
closed, no flow passes through the pilot lines so that
the pressure downstream of orifice (13) is applied via
(13a) and (L1) to the left hand end of the priority valve
(15) and the pressure upstream of (13) is applied via
(P1) and (P) to the right hand end of (15). The flow
through (13) creates a pressure drop such that the
pressure on the right hand end of the priority valve
(15) is greater than that on the left. If the pump output
is high enough the pressure difference on each end of
the valve will be sufficient to overcome the spring load
and the valve will move to the left and spill some flow
(excess flow) to the control valve (29) and then to the
various hydraulic systems. The flow rate to the
accumulator (16) is therefore controlled by orifice (13)
and the spring loads. As flow passes into the
accumulator (16) its pressure will rise, as will the
pressure at P1, until the accumulator charge valve
(12) opens.
Up to this point the pressure on each side of the

piston (B) at the accumulator charge valve (12) has
been virtually the same. However, when (12) opens
the pressure to the left of the piston (B) becomes
less than the pressure to the right because of
pressure drop across orifice (13a) and (13b).
HYDRAULICS 1.11
If, while the accumulator is charging, the steering Key to STAC valve schematic:
wheel is turned some flow will be bled off at (P2) A. Pressure sensing line
which would reduce the flow through orifice (13). The
B. Accumulator charge valve piston
priority valve (15) will move to re-establish the design
flow through orifice (13) and provide flow to (P2). C. Check valve
L1. Passage
When the accumulator charge valve (12) is open the L2. Passage
load sense line to the steering control valve (OSPF) P. Passage
(21) can function as a normal dynamic load sense P1. Passage
system. The maximum pressure in the priority line (P)
P2. Passage
is determined by the regulator valve (11), which must
be set higher than the accumulator charge valve (12), Port to hydraulic tank (1)
or by the relief valve (25) in the steering control valve Supply port from hydraulic pump (2)
(OSPF) (21). The pressure can therefore rise above Steering and Accumulator Charge (STAC) valve (10)
the maximum setting of the accumulator charge valve
Regulator valve, 190 bar (11)
(12) if the steering loads are sufficient and the
accumulator (16) pressure will rise accordingly. The Accumulator charge valve (12)
accumulator (16) therefore operates at a minimum Orifice (13)
pressure, which is set either by the cut-in pressure of Load sensing orifice (13a)
the accumulator charge valve (12) and a maximum
Orifice (13b)
level which is set by it's cut-in pressure, or by the
steering pressure. Both the accumulator (16) and the Filter (14)
steering control valve (OSPF) (21) must be capable of Priority valve (15)
working at the same maximum pressure. Accumulator (16)
Port to control valve steering (OSPF) (22)
The spilled or excess flow (EF) can be used to Port for load sensing pressure relief valve (25)
operate other services at a pressure independent of
Port to main control valve (excess flow) (29)
the steering or brake pressures, within the limitations
of the pump. Port to brake valves (52)
Test point 1 (73) for supply pressure
Test point 2 (74) for braking system
STAC valve - Schematic

1.12 HYDRAULICS
Port to hydraulic tank (1)

Supply port from hydraulic pump (2)
Steering and Accumulator Charge (STAC) valve (10)
Port to control valve steering (OSPF) (22)
Port to main control valve (excess flow) (29)
Port to brake valves (52)
Test point 1 (73) for supply pressure
Test point 2 (74) for braking system
HYDRAULICS 1.13
Accumulator (16)
The nitrogen charged accumulator provides hydraulic
pressure for efficient operation of the brakes under all
pump load conditions. The accumulator is fitted on the
left, front side of the chassis.
Specifications
Pre-charge pressure 41 bar (595 psi)

Oil capacity 0.75 litre
Pressure switch (17)

The pressure switch illuminates a warning light in the
cab when brake pressure drops to below 116 bar.
The pressure switch is fitted at the outlet of the brake
accumulator (16).
Specification
Operating pressure 116 bar (1682 psi) falling
Brake pressure servo valve (18)
The valve operation is proportional to brake pedal

movement. When the brake pedal is pressed, the
valve allows pressure in the accumulator to apply the
brakes. When the brake pedal is released, the valve
closes the pressure line from the accumulator and
diverts brake pressure from the brake units to tank
to release the brakes.
Operation
With no force applied to the brake pedal, the valve is

in the neutral position and hydraulic system pressure
at the pressure port is blocked by the spool, the
brake pressure port is open to tank through the tank
port.
Initial application of the brake pedal moves the spool

into a position where all the ports are closed and
brake pressure has not been applied. Further
movement of the pedal moves the spool beyond the
closed position and allows pressurised fluid to flow to P Pressure
the brake port. When pedal movement is stopped, T Tank
the pressure at each end of the spool balances and A To brake
fluid flow stops. If further pressure is applied to the
brake pedal the spool will allow more fluid to pass to
the brakes until the spool balances again. Maximum
brake pressure is achieved when the brake pedal is
fully depressed and the piston is bottomed in the
housing.
1.14 HYDRAULICS
When the brake pedal is released, the spool moves

to close the pressure port and gradually open the
tank port to allow brake pressure to return to tank.
Specification
Brake pressure at A 44 bar (638 psi)
Transmission inching
A potentiometer on the brake pedal measures the

position of the brake pedal and controls the
deswashing of the transmission pump which prevents
overloading of the system and reduces brake disc
wear.
HYDRAULICS 1.15
Pressure switch (brake light) (19)
When the brake pedal is depressed the pressure

switch operates and illuminates the brake stoplights
at the rear light clusters.
Specification
Operating pressure 5 bar (72 psi) rising
Front axle (20)

The front axle contains double reduction bevel and
planetary hub reduction gears and a limited slip
differential. Braking is by inboard multi-disc units. The
parking brake is is operated by a separate park brake
pedal, when the pedal is pushed fully forward and
latches, the parking brake is applied. To release the
parking brake the rear end of the brake lever is pressed.
The outboard wheel hubs are steerable, operated by a

hydraulically operated steering cylinder (28), attached
to the axle. The rear steering cylinder is a double acting
hydraulic cylinder, supplied with pressure operating oil
from the Steering Control Valve (21). The two cylinder
rams have a ball joint end fitting, which connect to the
swivel hubs for the road wheels.
Steering cylinder (front) (28) 1. Front axle (20)

Specification 2. Front steering cylinder (28).
Stroke (lock to lock) 200 mm

Bore 85 mm
Rear axle
The rear axle contains double reduction bevel and
planetary hub reduction gears and a limited slip
differential.
The outboard wheel hubs are steerable, operated by a

steering cylinder (27) attached to the axle. The
construction and operation of the rear steering
cylinder is similar to the front steering cylinder.
Steering cylinder (rear) (27)
Specification
Stroke (lock to lock) 200 mm

Bore 85 mm
1. Rear axle
2. Rear steering cylinder (27).
1.16 HYDRAULICS
Steering valve (21)
When the steering valve is in neutral, oil passes

freely from the load sensing line to the STAC valve.
As the steering wheel is turned, the rotary valve
proportionally directs oil flow from the STAC valve to
the steering selector valve. The load sensing line is
not fully closed until the rotary valve is fully open.
When the steering input is stopped, the rotor
passages close and steering stops then the system
returns to the load-sensing mode. The valve contains
a spool valve (22) a PRV (25), two shock valves (23)
and a non-return valve (26).
Specification
Type OSPF250LS
PRV 170-175 bar (2466-2538 psi)
Shock valve 225-245 bar (3263-3553 psi)
STEERING - OSPF NEUTRAL

HYDRAULICS 1.17
STEERING - OSPF RIGHT TURN
Steering selector valve (22)

The steering selector valve is solenoid operated and
diverts oil to the respective ports of the steering
cylinders. Three modes of steering are available by
selecting the steering mode switch in the cab to give;
two-wheel steer (front wheels); four-wheel steer or
‘crab’ steer.
The machine must always be stationary

before changing steering modes.
C1 To rear cylinder
C2 To rear cylinder
C4 To front cylinder
T Return to tank
P Pressure from STAC valve (10)
24 Steering selector valve
1.18 HYDRAULICS
O OSPF250 valve (21)
A Adapter
E Steering selector valve (24)
LS From STAC valve (10)

HYDRAULICS 1.19
Control valve (29)

The control valve consists of up to five individual spool
valves, with common pressure and return lines, linked
together by an inlet cover and an end plate. The inlet
cover contains a pressure relief valve. The spools,
inlet cover and end plate are secured together with tie
bolts.
The individual components of the valve are described

in items 30 to 37.
Key to control valve

NOTE: Numbers in bold type refer to identification
numbers on main hydraulic schematic.
1 Inlet section/Relief valve, 240 bar (30) (10) 2nd auxiliary system connections
2 Lift/lower section (31) (11) Lift cylinder connections
3 1st auxiliary section (35) (12) Shock valves, 210 - 125 bar (33)
4 Crowd/dump section (32) (13) Crowd/Compensator cylinder connections
5 Shock valves, 210 - 125 bar (33) (14) 1st auxiliary system connections
6 Boom lift/lower section (34) (15) Extension cylinder connections
7 Non-return valve (38) (16) STAC valve connection
8 2nd auxiliary section (36) (17) Hydraulic tank connection
9 End plate (37)
1.20 HYDRAULICS
Inlet section/Relief valve (30)
Function
The inlet section provides for ultimate system
protection and the provision of main system pressure
for the operation of the spools. If the delivery
pressure exceeds 240 bar, the pressure relief valve
opens to return fluid from the spools to the hydraulic
tank.
P. Inlet from STAC valve P

T. Return to hydraulic tank T
V. Pressure relief valve V
HYDRAULICS 1.21
Lift/lower section (31)
Function
Lift service is fully proportional and operated
mechanically to provide oil flow to the lift circuit.
When the spool is moved from the neutral position, oil

at system pressure is delivered to the consumer
(service). The oil at the consumer meets a resistance
(i.e. to move the piston) and the pressure overcomes
this force and operates the service.
The spool is operated by oil pressure delivered by the

command of the joystick and is fully proportional.
In neutral the spool is ‘half-motored’, connecting port

B to the T line. A Port A - connection to service
B Port B - connection to service
T Return to tank
P Pressure
C Controller, proportional
(31) Lift section
(38) Check valve
1.22 HYDRAULICS
Crowd/dump section (32)
Function
Crowd service is fully proportional and operated
mechanically to provide oil flow to the crowd circuit.
When the spool is moved from the neutral position,

oil at system pressure is delivered to the consumer
The spool is operated by pilot oil pressure delivered

by the command of the joystick and is fully
proportional
In neutral the spool is closed’, neither of the

consumer ports A or B are connected to the T line.
This enables self-levelling operation from the
compensator cylinder.
To protect the circuit, shock valves are provided in

both A and B ports.
A Port A - connection to service

T Return to tank
P Pressure
(32) Crowd/dump section
(33) Shock and anti-cavitation valve-Port A (125 bar)
(33) Shock and anti-cavitation valve-Port B (210 bar)
(38) Check valve
HYDRAULICS 1.23
Extension section (34)
Function
Extension service is fully proportional and operated
electrically to provide oil flow to the extension circuit.

the resistance and operates the service.

electrical actuator under the command of the joystick
and is fully proportional.
In neutral the spool is ‘half-motored’, connecting port B Port B - connection to service
B to the T line. T Return to tank
P Pressure
(34) Extension section
(38) Check valve
1.24 HYDRAULICS
1st service (35)/2nd service (36) section
Function
1st service/2nd service is non-proportional and operated
electrically to provide oil flow to the 1st service/2nd
service circuit.


electrical actuator under the command of the
joystick.
These sections, although electrically controlled, are T Return to tank
non-proportional. Operation of the buttons on the P Pressure
joystick operate these sections as an on-off switch. C Controller, non-proportional
(35) 1st servive section
In neutral the spool is closed, neither of the (36) 2nd service section
consumer ports A and B are connected to the T line. (38) Check valve
End plate (37)
Function
The end plate provides a common link for the spool
pressure and return lines.
HYDRAULICS 1.25
Lift cylinder (39)

The lift cylinder is fitted below and forward of the
extension boom. The lift cylinder is supplied with
operating pressure oil from the lift section (31) and a load
control valve (40).
Specification
Type C40
Stroke 802 mm
Bore 115 mm
Type C50
Stroke 802 mm
Bore 115 mm
The load control valve is factory set

and should never be dismantled or
adjusted except for resealing.
Load control valve (40)

The load control valve for the lift cylinder is fitted in
the pressure oil supply lines, between the lift section
(31) and the lift extension cylinder (39). The valve
prevents any load movement in the event of hose
bursts or leakage. If the valve is defective, a complete
new cartridge must be fitted.
Key to Load Control Valve
1. Pilot pressure
2. Supply pressure
3. Pressure relief
4. To rod side
5. To full bore side
HYDRAULICS 1.26
Extension cylinder (44)

The boom extension cylinder is fitted inside the boom of
the machine and is supplied with operating pressure oil
from a load control valve (45) and the extension section
(34).
Specification:
Type C40 Stroke 1775 mm

Bore 70 mm
Type C50 Stroke 2025 mm

Bore 70 mm

The load control valve for the extension cylinder is fitted

between the extension cylinder (44) and the extension
section (34). The valve prevents any load movement in
the event of hose bursts or leakage. If the valve is
defective, a complete new cartridge must be fitted.
1. Pilot pressure
2. Supply pressure
3. Pressure relief
4. To rod side
1.27 HYDRAULICS
Compensator cylinder (43)

The compensator extension cylinder is fitted below and
to the rear of the extension boom and is connected to
the crowd/compensator section (32).
Specification
Stroke 355 mm
Bore 90 mm
Autohitch cylinder (50)

The autohitch cylinder, if fitted, is located on the rear of
the machine and is used to automatically connect and
lift a trailer onto the machine. The pressure oil supplies
to the autohitch cylinder are from the autohitch manifold
(48).
Specification
Stroke 300 mm
Bore 50 mm
HYDRAULICS 1.28
Crowd cylinder (41)

The crowd cylinder is fitted inside the head of the boom
and controls the operation of the head attachments. The
crowd cylinder is supplied with operating pressure oil
from the crowd/compensator section (32) and a load
control valve (42).
Specification:
Stroke 305 mm
Bore 125 mm

The load control valve for the crowd cylinder is fitted

between the crowd cylinder (41) and the crowd/
compensator section (32). The valve prevents any load
movement in the event of hose bursts or leakage. If the
valve is defective, a complete new cartridge must be
fitted.
1. Pilot pressure
2. Supply pressure
3. Pressure relief
4. To rod side
1.29 HYDRAULICS
Changeover valve (optional) (46)

The changeover valve is solenoid operated and
selected by a rocker switch in the cab. When
selected, the valve diverts oil from the 1st auxiliary
service to the rear of the machine where it can be
utilized to operate trailer tipping or autohitch.
Specification:
Solenoid operating voltage 12VDC
A1 Pressure from control valve

A2 Return to control valve
B1 Pressure to 1st service (front)
B2 Return from 1st service (front)
C1 Pressure to rear service/autohitch
C2 Return from rear service/autohitch
1st service couplings (47)
The 1st service couplings (not illustrated) are used to

attach hydraulic services to the front of the machine.
Specification:
Coupling type Quick-release

HYDRAULICS 1.30
Manifold (48)
The manifold is downstream of the diverter valve and
is used to deliver oil to the autohitch or trailer tipping
services.
(1) Tipping QR connector (if fitted)

(2) Hitch return hose
(3) Mounting
(4) Manifold (48)
(5) Tap adapter
(6) Bolt
(7) Washer
(8) Nut
(9) Washer
(10) Return hose (to diverter valve)
(11) Pressure hose (from diverter valve)
(12) Hitch pressure hose
Trailer brake coupling (49)
Specification:
Coupling type Quick release
Tap (51)
The tap is used to convert the dual acting service for
the autohitch to single acting service for trailer tipping
1.31 HYDRAULICS
Trailer brake valve (optional) (52)

When a trailer brake is connected to the trailer brake
coupling and brakes are applied, the porting of the
valve applies proportional pressure to the trailer
brake. When the brakes are released, the valve
returns fluid to the reservoir.
Trailer tipping connection (optional) (53)
Specification:
2nd service couplings (54)

The 2nd service couplings are used to attach a
second hydraulic attachment to the front of the
machine
Specification:

HYDRAULICS 1.32
Hydrostatic drive pump (55)
Function
The hydrostatic drive pump is driven by the engine

crankshaft and provides pressurised oil to operate the
transmission drive motor.
Specifications:
Charge pressure 30 bar (435 psi)

Pressure relief valve (56) 30 bar (435 psi)
Pressure limiter (60) 480 bar (6960 psi)
Relief valve (61) 530 bar (7685 psi)
Relief valve (64) 40 - 50 bar (580 - 725 psi)
(56) Pressure relief valve, 30 bar (65) Control valve pump

(57) Proportional pressure reducing valves (75) Test point 3
(fwd and rear) (76) Test point 4
(58) Multifunction valve (77) Test point 5
(59) Bypass valves
(60) Pressure limiters, 480 bar
(61) Relief valves, 530 bar
(62) Multifunction valve
(63) Check valves
(64) Relief valves, 40 - 50 bar
1.33 HYDRAULICS
Hydrostatic drive motor (66)
Function
The hydrostatic drive motor is driven by the
hydrostatic drive pump and provides drive to the
machine axles through the drop down box. The
hydraulic oil is circulated through an oil cooler to the
reservoir from an outlet on the motor.
Specifications:

Loop flushing valve (68) 2 - 3 bar (29 - 44 psi)
Purge relief valve (70) 16 bar (232 psi)
Pressure compensator override (71)180 bar (2610 psi)
(67) Control valve motor

(68) Loop flushing valve, 2 - 3 bar
(69) Purge relief valve, 16 bar
(70) Brake pressure defeat valve
(71) Pressure compensator override, 180 bar
HYDRAULICS 1.34
OPERATION
Transmission
The transmission is operated hydraulically using a

hydrostatic drive pump, mounted on the crankshaft
output shaft. This pump drives the hydrostatic drive
motor and provides drive to the machine axles
through the drop down box.
The operator can control the transmission using the

following controls
· Accelerator pedal
· Brake pedal
· Direction control lever
· Speed limiter twist grip
· Progressive/Aggressive mode switch
· Parking brake
The accelerator pedal function is straightforward. The

further the pedal is pushed down, the faster the
machine wants to go.
The brake pedal is an inching pedal. This consists of

a potentiometer on the pedal that measures the
position of the pedal and transmits this to the
Hydrostatic electronic unit (Susmic). The Susmic will
deswash the Hydrostatic pump i.e. the transmission
is slowly put back into neutral. For the first part of the
brake pedal travel there is no actual braking on the
axles, only the pump being deswashed. The next
stage of brake pedal travel is an overlap period, which
includes the pump being further deswashed and the
brakes starting to be applied. The final stage is when
brake pedal travel puts the transmission fully in
neutral and fully applies the brakes. This set up
makes sure that the engine RPM can be high to give
full hydraulic flow while the machine moves forward
slowly rather than at full speed. It further prevents the
brakes having to work against the transmission.
The direction control lever controls the direction of

machine movement i.e. when the lever is moved
forward the machine moves forwards. When the lever
is moved backwards, the machine moves in reverse.
For safety reasons, the lever must be lifted up from
the neutral position to enable it to be moved to the
forward or reverse selection.
1.35 HYDRAULICS
The speed limiter is the twist grip fitted to the

direction control lever and controls the Hydrostatic
motor. The speed limiter limits the maximum speed
(independent from the individual country road
regulatory maximum speeds) to 8 km/hr. This is a
useful feature when the machine is working in
confined spaces. While the operator still has full
engine RPM available for efficient hydraulic operation,
the machine will only reach a maximum speed of 8
km/hr without the operator having to operate the
inching pedal.
The Aggressive/Progressive mode switch changes

the characteristics of the Hydrostatic pump and
therefore transmission behaviour as follows:
Progressive mode – gives good resolution at low to

medium engine speeds, i.e. for a large
movement of the accelerator pedal there is a
small increase in machine speed, allowing
accurate control over the machine (e.g.
placement work).
Also gives good anti-stall characteristics at

medium to high engine speeds i.e. for a small
drop in engine speed there is a large speed
reduction and an increase in tractive effort and
therefore the engine does not stall when the
machine movement is blocked (e.g. heavy duty
rehandling).
Aggressive mode – gives a sharp speed increase with

a small amount of accelerator pedal movement
gives a quick accelerating machine with a very
responsive behaviour (e.g. rehandling and rapid
shuttling work).
NOTE: The driving behaviour is different only in the

engine speed range of approximately 900 to 2000
RPM. Outside that range the Aggressive and
Progressive characteristics are identical and
consequently the machine will reach the same final
speed.
When applying the parking brake, the Hydrostatic

pump is put into neutral and therefore the
transmission is in neutral. This is to prevent the
machine burning the brake discs.
HYDRAULICS 1.36
Hydrostatic pump
The drive shaft (14) of the pump is driven by the

engine and is connected to the pump rotor (8) and
charge pump (6). During rotation, high pressure oil
(5) moves the rods (10), arranged radially around the
the drive shaft, against the slides (12). The slides are
in contact with the pump swash plate (2).
The SUSMIC control module monitors the speed of

the engine with a speed sensor and uses this data to
control a solenoid valve (11). This solenoid valve
operates the servo-valve (11), which then positions
the servo-ram (9). The servo ram (9) controls the
swash plate (2), according to the direction of travel
and speed. The rods (10) will move axially to force oil
from the rotor cylinder, after which the rods (10) are
moved back by the charge pressure on the 'falling'
side of the swash plate (2). Oil fills the low pressure
side of the inclined swash plate (8) and is then forced
out when the swash plate (8) rotates to the high
pressure side. The rotating and inclined swash plate
(8) pumps oil from the cylinder, dependant on
rotational speed and the angle on inclination created
by the rods (10). The swash plate is returned to the
neutral position by the return springs (4) and
alignment of the neutral position is achieved with the
eccentric sscrews (3).
The control base (7) seperates the low pressure side

of the pump from the high pressure side.
1. Shaft sealing ring
The cylindrical rotor is sealed against the control 2. Swash plate
base (7) by spring pressure. 3. Neutral position adjusting srews
4. Return spring
5. High pressure
6. Charge pump (not fitted - external pump)
7. Control base
8. Cylidrical rotor
9. Servo-ram
10. Rod
11. Servo-valve
12. Slide
13. Bearing
14. Drive shaft.
1.37 HYDRAULICS
Hydrostatic motor
The output shaft from the hydrostatic motor is The range of movement for the valve segment (V) is
connected to the transmission gearbox on the front between 6 and 32 degrees, which provides a motor
axle. Rotational drive from the motor is produced by output ratio of between maximum and a minimum (5
hydraulic control and operation of the motor. to 1).
The output shaft is fitted into two taper roller bearings A constant pressure regulator (78) assists in the
(E) and is connected to the driving cylinder by a control of output speed and torque from the motor, for
synchronization joint (D). Hydraulically operated rods a particular charge pressure.
(K) are fitted into the drive cylinder and have sphreical
heads, which engage into pressed bearings on the The 12V DC solenoid valve (78A), which is fitted to
rear face of the output shaft. The cylinder head is the constant pressure regulator (78), will hold the
able to rotate on the bearing plate (L) of the valve output of the motor to maximum for as long as it is
segment (V), which is positioned in a location slot by powered. This allows the lower speed range of 8 km/h
the hydraulically operated control rod. to be achieved.
A constant pressure regfulator (78) moves the control 78. Constant pressure regulator
rod to position the valve segment (V). The angular 78A. Soloenoid valve (speed range 0-8 km/h or
position of the valve segment (V) will cause the rods
0-20 (32) km/h)
(K) to hydraulically drive the output shaft at greater or
lesser speed and torque, dependent on the angular S. Setting of swash angle
displacement of the valve segment (V). The hydraulic V. Valve segment
controller (78) will maintain minimum motor output for L. Bearing plate
as long as the charge pressure remains below the E. Taper roller bearing
control pressure of 180 bar. If the pressure increases D. Synchronisation joint
above 180 bar, the valve segment (10) is re-positioned
to increase the output of the motor. K. Rod
76. Purge pressure relief valve
HYDRAULICS 1.38
Control Valve
NOTE: Identification numbers in bold type after an
item refers to the number in the main hydraulic
schematic illustration.
Hydraulic fluid reaches the control valve inlet section

from the main pump. Spools are closed-centre, dead
headed into a pressure adjustment spool. When a
spool is actuated, pressure is directed to the service
with return flow diverted to tank.
If the control/spool is not released when the spool

reaches the end of its travel, the fluid builds up
pressure.
It is important that the relief valves

are not allowed to remain open for
more than a few seconds, otherwise
extreme fluid temperatures will result
and cause damage to the hydraulic
seals and reduce the life of the
hydraulic fluid.
The speed of operation of the services is related to
the amount of spool movement.
If external pressure is generated by accidental

contact with buildings or road surfaces, etc, the
System is protected by installation of relief valves.
Relief valves
Relief valves are fitted to the control valve to control
system pressure and the carriage/crowd service
pressure.
The boom extend/retract, lift/lower and all auxiliary

pressures are protected by the main system relief
valve in the inlet section of the control valve and is set
to operate at 240 bar (3480 psi).
Do not adjust the factory set relief

valves in the crowd spool.
The crowd spool contains two relief valves, one for the
crowd forward or dump set at 125 bar (1812 psi) and
one for the crowd back set at 210 bar (3045 psi).
Relief valves are factory set and cannot be adjusted.

The pressure setting is stamped on the valve, the
spring colours do not relate to the pressure rating of
the valve.
1.39 HYDRAULICS
System pressure checks
NOTE: Only check hydraulic pressure when oil is at

normal working temperature (60 ± 4°C) and with
engine at fast idle (1800 rpm).
Five test points are available as follows:
Test point 1 (STAC) (73) - main circuit
This test point is taken from the main circuit supply

to the Steering and Accumulator Charge (STAC) valve
(10). Test point 1 (73) is located on the side of the
STAC valve body.
1. Connect a pressure gauge to test point 1 (73).
2. Start the engine.
3. Operate the steering system over the full range.
NOTE: The pressure gauge will indicate the circuit

pressure supplied from the main hydraulic pump.
4. Read the pressure gauge indications.
5. Check pressure and make sure that when the

steering is operated to its limits, the maximum
pressure of 240 bar is maintained and the pump is
offloaded.
6. Stop the engine and remove the pressure gauge.
Test point 2 (STAC brake pressure) (74)
Test point 2 (74) is located on the regulated output

from the STAC valve to the braking system. STAC valve (10)
Test point 1 (73)
1. Connect a pressure gauge to test point 2 (74). Test point 2 (74)
3. Operate the brake system fully.
4. Read the pressure gauge indications.
5. Check the pressure gauge indications show re-

charging pressure as 138 bar +/- 5 bar and stops at
160 bar +/- 5 bar.
6. Stop the engine and remove the pressure gauge.

HYDRAULICS 1.40
Test point 3, 4 & 5 (Hydrostatic drive pressure)
NOTE: Test points 3, 4 and 5 are located on the

Hydrostatic Drive Pump (55).
1. Jack the machine off the ground.
6. Engage gear. The pressure gauges will show the

pressure of the oil supply to the Hydrostatic Drive
Pump (55).
75 Test point 3 (75) (max 30 bar charge pressure)
7. Read the pressure gauges.
76 Test point 4 (76)
77 Test point 5 (77)
8. Check pressure are:
Test point 3 - 480 bar +/- 10 bar 56 Hydrostatic drive pump (55)
Test point 4 - 480 bar +/- 10 bar
Test point 5 - 30 bar +/- 2.5 bar.
9. Disengage gear and stop the engine.
10. Remove the pressure gauges from test points 3,

4 and 5 on the Hydrostatic pump.
11. Lower the machine from the jacks.

HYDRAULICS 1.41
MAINTENANCE
Torque tightening
Where torque tightening figures are not given in the

procedures, use the torque tightening settings in the
following tables related to that fitting. The figures relate
to thread sizes and are applicable to steel only and have
a tolerance of 10%.
Male Union Adaptors

Tube O/D Thread Torque Nm
Series
6L G1/8A 18
6S G1/4A 55
8L G1/4A 35
8S G1/4A 55
10L G1/4A 35
10S G3/8A 80
12L G3/8A 70
12S G3/8A 80
15L G1/2A 90
16S G1/2A 115
18L G1/2A 90
20S G3/4A 180
22L G3/4A 180
25S G1A 310
28L G1A 310
30S G1 1/4A 450
35L G1 1/4A 450
38S G1 1/2A 540
42L G1 1/2A 540
6L M 10x1 18
6S M 12x1.5 35
8L M 12x1.5 25
8S M 14x1.5 55
10L M 14x1.5 45
10S M 16x1.5 70
12L M 16x1.5 55
12S M 18x1.5 90
15L M 18x1.5 70
16S M 22x1.5 135
18L M 22x1.5 125
20S M 27x2 180
22L M 26x1.5 180
25S M 33x2 310
28L M 33x2 310
30S M 42x2 450
35L M 42x2 450
38S M 48x2 540
42L M 48x2 540
1.42 HYDRAULICS
DKO Fittings
Wrench Torque
Tube Dim:
Size Nm
10L (10x1.5) 19M 45
12L (12x1.5) 22M 51
15L (15x1.5) 27M 74
18L (18x2.0) 32M 70
22L (22x2.0 or 2.5) 36M 135
28L (22x2.0 or 2.5) 41M 166
Walform Fittings
Wrench Torque
Tube Dim:
Siz e Nm
10L (10x1.5) 19M 50
12L (12x1.5) 22M 70
15L (15x1.5) 27M 100
18L (18x2.0) 32M 180
22L (22x2.0 or 2.5) 36M 230
28L (22x2.0 or 2.5) 41M 330
Controlled Final Assembly Fittings
Wrench Torque
Tube Dim:
Siz e Nm
10L (10x1.5) 19M 50
12L (12x1.5) 22M 70
15L (15x1.5) 27M 100
18L (18x2.0) 32M 115
22L (22x2.0 or 2.5) 36M 230
28L (22x2.0 or 2.5) 41M 330
Flexible Hoses
Wrench Torque
Tube Dim:
Siz e Nm
10L (10x1.5) 19M 45
12L (12x1.5) 22M 51
15L (15x1.5) 27M 74
18L (18x2.0) 32M 70
22L (22x2.0 or 2.5) 36M 135
28L (22x2.0 or 2.5) 41M 166
HYDRAULICS 1.43
HYDRAULICLEVEL
Fine jets of hydraulic fluid at high

pressure can penetrate the skin. Do
not use your fingers to check for
hydraulic fluid leaks. Do not put our
face close to suspected leaks. If
hydaulic fluid penetrates your skin
seek mecical help immediately.
Check
1. Place the machine on level ground.
2. Make sure all hydraulic cylinders are fully closed.
3. Stop the engine and apply the parking brake.
4. Open the engine pod cover.
NOTE: Wait for two minutes before checking

hydraulic fluid level.
5. Clean filler cap and remove.
6. Make sure fluid level is between the high and low

marks on the dipstick.
7. Top up as necessary using clean hydraulic fluid of

the correct specification. 1. Header tank
2. Filler cap
8. Refit the filler cap. 3. Dipstick
9. Close engine pod cover.

1.44 HYDRAULICS
HYDRAULIC TANK (1)
Removal
NOTE The removal and installation of the hydraulic

tank achieved by raising the boom and lifting the
tank through this space. However, it is much easier
to remove the hydraulic tank with the engine
removed.
1. Raise the boom and fit the boom safety stop.
2. Stop the engine, apply the parking brake and

disconnect the battery.
3. Refer to page 1.1 and dump hydraulic pressure.
NOTE The hydraulic tank contains 55 litres (12 gal)

of fluid.
4. Remove the drain plug (11) and drain the hydraulic

fluid into a suitable container. Do not reuse the
hydraulic fluid unless it can be specially filtered and
tested.
5. Remove the hose clips (13) from the suction

hoses (14) and (15) of the main and auxiliary pumps.
Remove the hoses (14)and (15) from the hydraulic
tank (10).
NOTE Make a note of all hose positions to aid

assembly.
6. Remove the hoses (1) to (9) from the hydraulic

tank (10).
7. Support the hydraulic tank and remove the nuts,

bolts and washers that attach the hydraulic tank to
the chassis. Remove the tank from machine.
8. Fit blanks to all openings on the tank and hoses

on the machine to prevent the ingress of dirt.
HYDRAULICS 1.45
Installation
1. Installation is the reverse of removal.
2. Use new hose clips.
3. Replenish the hydraulic tank before engine is started.
4. Purge the hydraulic system by starting the engine

and operating all services to fully extend and retract
cylinders several times.
5. Refer to Page 1.51 and check the hydraulic level and

replenish if necessary.
1. Return hose from fan motor 11. Drain plug

2. Spare (blanked) 12. Drain plug
3. Return hose from oil cooler 13. Hose clip
4. Return hose from control valve 14. Suction hose – Auxiliary pump
5. Filler hose (from header tank) 15. Suction hose – Main pump
6. Return hose from brakes
7. Return hose from steering
8. Return hose from transmission
9. Return hose from STAC
10. Hydraulic tank
1.46 HYDRAULICS
MAIN HYDRAULIC PUMP (2)
Removal
NOTE The main hydraulic pump (2) is located in the

engine compartment, attached to the left side of the
timing case. Remove components as necessary to get
access to the pump.
1. Stop the engine, apply the parking brake.
2. Refer to Page 1.1 and dump hydraulic pressure.
3. Disconnect the battery.
4. Make sure the pump (2) is free from dirt to avoid

contamination of the hydraulic system.
5. Remove the four cap screws (4), washers (3) from

clamps (6) and the remove the inlet pipe (5) from the (1) Outlet pipe
pump (2). Remove and discard the O-seal (7). (2) Hydraulic pump
(3) Washer
(4) Cap screw
6. Remove the outlet pipe (1) from the pump (2).
(5) Inlet pipe
(6) Clamp
7. Remove the cap screws (15) and washers (14) (7) O-ring
securing the pump (2) to the timing case (8) and remove (8) Timing case
the pump (2). Remove and discard the gasket (9).
8. Fit blanks to all openings on the pump (2) and pipes

(5) and (1), to prevent the ingress of dirt.
9. When a new pump is to be installed, remove the nut

(10) and washer (11) securing the drive gear (12) to the
pump shaft. Remove the drive gear (12) and woodruff key
(13) from the shaft.
(9) Gasket (13) Woodruff key

(10) Nut (14) Washer
(11) Washer (15) Bolt
(12) Gear
HYDRAULICS 1.47
Installation
When fitting a new hydraulic pump, it is

vital that the case of the pump is filled
with oil before the pump is fitted.
2. Fill the pump with 0.25 litre (0.44 pt) of oil, through
the outlet connection on the pump.
3. Use a new O-ring (7) when assembling the inlet

hose, lightly lubricated with clean hydraulic oil.
4. Use new washers (3) on the cap screws (2) when

assembling the inlet hose (5).
5. Use a new gasket (9) when assembling the pump

to the timing case.
7. Refer to Page 1.43 and replenish the hydraulic

tank before the engine is started.
1.48 HYDRAULICS
AUXILIARY HYDRAULIC PUMP (3)
Removal
NOTE The auxiliary hydraulic pump is located in the

engine compartment, attached to the right side of the
timing case. Remove components as necessary to get
access to the pump.
1. Stop the engine, apply the parking brake.
4. Make sure the auxiliary pump is free from dirt to avoid

5. Remove the inlet hose from the pump.
6. Remove the outlet hose from the pump.
7. Remove the two cap screws and washers

securing the pump to the timing case and remove the
pump. Discard the gasket.
8. Fit blanks to all openings on the pump and hoses

to prevent the ingress of dirt.
10. When a new pump is to be installed, remove the

nut and tab washer securing the drive gear to the
pump shaft. Remove the drive gear and woodruff key
from the shaft.
Installation
2. Use a new gasket between the pump and timing

case when installing the pump.
4. Refer to page 1.43 and check the hydraulic level

and replenish if necessary before the engine is
started.

6. Refer to Page 1.43 and check the hydraulic level

and replenish if necessary.
HYDRAULICS 1.49
FAN MOTOR (7)
Removal
NOTE: The fan motor is located forward of the engine
oil cooler/radiator assembly. Remove components as
necessary to get access to the motor.
1. Apply full left-hand lock to rear wheels.
5. Slide out the oil cooler and remove the service

cover over the radiator and oil cooler.
6. Make sure the motor (1) is free from dirt to avoid

7. Disconnect the three hydraulic hoses from the fan

motor (1). Blank the hydraulic hoses and the motor.
8. Remove the nut (8) and washer (9) securing the fan
(7) and flange (6) to the pump (1). Remove the fan (1)
and flange (7) assembly for access.
9. Remove the four cap screws (2), washers (3) and

(4) and the nuts (5) securing the pump (1) to the
mounting bracket (10). Remove the pump (1). (1) Fan motor
(2) Cap head screw
10. Fit blanks to all openings on the pump (1) and
hoses to prevent the ingress of dirt. (3) Washer
(4) Washer
11. Remove woodruff key (11) from the pump shaft.
(5) Nut
(6) Flange
Installation
(7) Fan
1. Installation is the reverse of removal. (8) Nut
2. Make sure the woodruff key (11) is fitted to the (9) Washer
pump shaft and it is aligned with the keyway of the (10) Mounting bracket
flange (6).
(11) Woodruff key.
3. Refer to Page 1.43 and replenish the hydraulic tank
before the engine is started.


if necessary.
1.50 HYDRAULICS
FAN REVERSE VALVE (78)
NOTE: From Machines S/No.50600162 only.
Removal
1. Stop the engine and chock the machine, apply the
parking brake.
2. Refer to page 1.1 and dump hydraulic pressure

then disconnect the battery.
3. Open engine cover to gain access to fan reverse

valve.
4. Disconnect the electrical connectors to the fan

reverse valve solenoid and the temperture switch.
5. Disconnect the four hydraulic hoses from the fan

reverse valve and blank the valve connections and
open hoses.
6. Remove the three bolts and washers that attach

the fan reverse valve to the structure. Remove the fan
reverse valve from the machine.
Installation
1. Installation is the reverse of the above procedure.
2. Refer to page 1.43, check the hydraulic level and

replenish if necessary before the engine is started.

and operating the fan reverse system and all services.
Fully extend and retract cylinders several times.
4. Refer to Page 1.43. Check the hydraulic level and

HYDRAULICS 1.51
HYDRAULIC FILTER (9)
Removal
NOTE: The hydraulic filter is fitted in the engine

compartment.
1. Remove components as necessary to get access

to the filter.
4. Make sure the filter (7) is free from dirt to avoid

5. Remove the indicator lead (4) from the indicator

switch on the hydraulic filter (7).
6. Remove the inlet pipe (1) and outlet hose (6) from
the filter (7) and fit blanks to the hoses and filter.
7. Remove the four bolts (2) and washers (3) securing

the filter (7) to the mounting bracket (5) and remove
the filter (7).
8. Fit blanks to all openings on the filter (7) and

hoses to prevent the ingress of dirt.
Installation
(1) Inlet pipe
1. Installation is the reverse of removal. (2) Bolt (Qty 4)
(3) Washer (Qty 4)
2. Refer to the service manual and fit a new filter (4) Indicator lead
element. (5) Mounting bracket
(6) Outlet hose
3. Refer to Page 1.43 and replenish the hydraulic tank (7) Hydraulic filter (9)

5. Refer to Page 1.43 and check the hydraulic level.

Replenish if necessary.
1.52 HYDRAULICS
BRAKE SYSTEM BLEEDING
General
Bleed the brake system after a brake system
component change and when air in the system is
suspected. Air in the system will not allow the brakes
to release properly and may cause damage.
1. Start the engine and allow the accumulator to fully

charge.
2. Stop the engine.
3. Slowly apply and release brakes until they will not

apply, waiting for one minute between applications.
Repeat this operation three times.
4. Start the engine and allow the accumulator to fully

charge then stop the engine. Operate the engine as
necessary to maintain accumulator at working
pressure throughout the bleeding procedure.
5. Attach a bleed tube to the bleed screw on the

brake unit nearest to the brake valve (front right) and
put the bleed tube into a suitable container. Carefully
open bleed screw, apply brakes until all air is bled
out of line then close bleed screw and remove bleed
tube. Bleed the other brake units and the trailer brake
valve in the order that follows:
1. Front left
2. Trailer brake valve (if fitted)
6. Release brake pressure for at least one minute.
7. Apply brakes, hold pedal down for ten seconds

then release pressure for one minute. Repeat this
operation two more times.
8. Bleed the brakes one more time.
9. Check the system components and brake lines for

leaks.
10. Test the operation of the brakes.

HYDRAULICS 1.53
SINGLE BRAKE VALVE (MICO) (18)

Removal tank before the engine is started.
NOTE: The brake valve is fitted forward of the cab. 4. Bleed the brake system (refer to Page 1.52) and
Remove the front cover and any components as test the brakes.
necessary to get access to the brake valve.
1. Stop the engine and chock the machine, apply the and operating all services to fully extend and retract
parking brake. cylinders several times.
2. Refer to page 1.1 and dump hydraulic pressure 6. Refer to Page 1.43, check the hydraulic level and
then disconnect the battery. replenish if necessary.
3. Make sure brake valve is free from dirt to avoid

4. Position a suitable container under the valve to

collect any oil spillage during removal.
5. Make sure the hoses are identified before removal

to help installation.
6. Remove the system pressure hose (2) from brake

valve connector ‘P’.
7. Remove the return hose (3) from brake valve

connector ‘T’.
8. Remove the service hose (4) from brake valve

connector ‘A’. Take care not to lose the orifice
located in the fitting.
9. Remove the two attachment bolts (5) securing the

brake valve (1) to the mounting bracket (6) and
remove the brake valve.
10. Fit blanks to all openings on the brake valve and

hoses to prevent the ingress of dirt.
1. Brake valve (10)
2. Pressure hose ‘P’
Installation
3. Return hose ‘T’
4. Service hose ‘A’
5. Bolt
6. Bracket
2. Make sure that the spool of the brake valve is fully
out. If necessary, adjust the brake pedal adjustment
cap-screw inside the cab until the spool of the brake Torque tighten the components as follows:
valve is fully out. Then torque tighten the cap-screw
lock nut to 25-27 Nm (18-20 lbf/ft.). Bolt (5) – 25-27 Nm (18-20 lbf/ft.)
1.54 HYDRAULICS
SINGLE BRAKE VALVE (MICO) (18) -

Servicing
Servicing is normally restricted to the replacement of

seals. When the bore of the cylinder or the piston is
scored, the brake valve must be replaced. 9. Remove O-ring (8*) and cup (10*) (note orientation)
from spacer (11). Remove O-ring (8*) and O-rings (6*)
from sleeve (7).
Dismantling
1. Make sure all the blanks are secure in the ports

then clean any dirt off the assembly before
dismantling.
2. Remove boot (20*) from piston (19).
3. Remove piston (19), springs (15**), (16), (17) and

shims (14) from housing bore.
NOTE: Some models also use a 6.35 mm (0.25 in.)

spacer with shims. Note the number of shims
removed from housing.
4. Examine bearing (18) for wear or damage, only

remove if necessary.
NOTE: Excessive wear on bearing (18) and piston

(19) require replacement.
5. Remove retainer assembly (13) from housing bore

(a ball bearing is pressed into the retainer).
6. Loosen nut (1) and remove end plug (4) from

housing. Remove spring (5), nut (1), washer (2) and
O-ring (3*) from end plug (4). 1. Nut 11. Spacer
2. Washer 12. Housing
7. Use a wooden dowel to remove spacer (11), sleeve 3*. O-ring 13. Retainer assembly
(7) and spool (9) assembly from housing bore. 4. End plug 14. Shim(s)
5. Spring 15.** Spring
NOTE: Take care not to scratch or mark sleeve (7) or 6*. O-ring 16. Spring
housing bore.Sleeve (7) and spool (9) are a matched
pair and must not be mixed with other parts. 7. Sleeve 17. Spring
Excessive wear on sleeve or spool will require 8*. O-ring 18. Bearing
replacement.
9. Spool 19. Piston
10.* Cup 20*. Boot
8. Separate spacer (11) and spool (9) from sleeve (7).
* Included in repair kit

NOTE: Take care not to damage cup or O-ring
grooves or bore. ** Not used in all models
HYDRAULICS 1.55
SINGLE BRAKE VALVE (MICO) (18) -

Assembly
Use a repair kit when assembling the valve, the repair

kit contains a new cup, boot and O-rings.
Before assembly, lightly lubricate the parts from the

repair kit and the spool and sleeve with clean
hydraulic oil.
Make sure all parts are clean before assembly.
1. Install a new cup (10*) in spacer (11) and one new

O-ring (8*) on spacer (11). Note direction of cup.
2. Install two new O-rings (6*) on large diameter end

of sleeve (7) and new O-ring (8*) on small end of
sleeve (7).
3. Carefully install spool (9) into sleeve (7). Note

direction of spool.
4. Install sleeve (7) and spool (9) assembly into

housing bore using a wooden dowel. Note direction of
assembly. Install spring (5) into housing bore.
5. Install end plug (4) and torque load to 10.9-20.3

Nm (96-180 lbf/in.) to seat sleeves. Then loosen end
plug ¼ turn and torque load to 1.1-6.0 Nm (10-60 lbf/
in.). Install new O-ring (3), washer (2) and nut (1). 1. Nut 11. Spacer
Hold the end plug (4) with a wrench and torque load 2. Washer 12. Housing
nut to 68.1-81.4 Nm (50-60 lbf/ft.).
3*. O-ring 13. Retainer assembly
4. End plug 14. Shim(s)
6. Install retainer assembly (13) in housing.
5. Spring 15**. Spring
NOTE: Depress retainer (13) until it bottoms on 6*. O-ring 16. Spring
spacer (11). Spool (9) and retainer (13) should return 7. Sleeve 17. Spring
when released. If the spool and retainer do not return 8*. O-ring 18. Bearing
when released, the bore of sleeve (7) may be
damaged. 9. Spool 19. Piston
10*. Cup 20*. Boot
7. Install shim(s) (14), springs (15**), (16) and (17)
and piston (19) in housing bore. * Included in repair kit
** Not used in all models
NOTE: Not all models use spring (15**). Some
models also use a 6.35 mm (0.25 in.) spacer with
shims. Make sure the same number of shims and the
spacer, that were removed during dismantling, are
installed.
8. Install new boot (20*) on housing.
9. Test the brake pressure at service hose A on

brake valve. Pressure can be adjusted by adding or
removing shims (14) to retainer assembly (13).
1.56 HYDRAULICS
TRAILER BRAKE VALVE (52)
Removal
NOTE: On machines up to S/No.50600162, the trailer
brake valve is fitted on the forward surface of the rear
service plate. Remove the rear cover from the boom
and the rear service plate, if necessary, to get
access to the valve.
NOTE: On machines from S/No.50600163 (and when
fitted as an option kit), the trailer brake valve is fitted
on a gusset plate in front of the forward left engine
and transmission mounting to the rear of the front
wheel. Remove the right front wheel, if necessary, to
get access to the valve.
1. Stop the engine, apply the parking brake, chock

the wheels and disconnect the battery.
3. Make sure valve (5) is free from dirt to avoid

4. Identify and label the hydraulic hoses.

(1) Service hose
6. Disconnect the service hoses (1), pilot hose (3), (2) Pressure hose
pressure hose (2) and return hose (4) from the valve (3) Pilot hose
(5) and blank open connections on valve and hoses. (4) Return hose
Tie hoses clear of valve (5).
(5) Trailer brake valve (52)
(6) Bleed point
7. Remove the two hexagon headed screws (7) and
(7) Hexagon headed screw
washers (8) securing the valve (5) to the machine
structure. Remove the valve (5) from the machine. (8) Washer
Installation

3. Refer to Page 1.52 and bleed the brake system

and test the brakes.

5. Refer to Page 1.43, check the hydraulic level and

HYDRAULICS 1.57
Servicing
seals. When the bore of the housing or the cylinder is
scored, the valve must be replaced.
Dismantling
dismantling.
2. Remove cap screws (17) securing base (16) to

housing (11).
3. Remove sleeve (15), spool (13) and ball (12).

Separate spool (13) from sleeve (15).
NOTE: Take care not to scratch or damage sleeve (7)

or housing (11) bore. The sleeve (7) and spool (9) are
a matched pair and must not be mixed with other
parts. Excessive wear on sleeve or spool will require
replacement.
4. Remove O-rings (14*) from sleeve (15).
5. Loosen nut (1) and remove end plug (4) from

housing (11) bore. Remove spring (5), nut (1), washer
(2) and O-ring (3*) from end plug (4).
6. Use a wooden dowel to remove spacer (10), sleeve

(7) and spool (9) assembly from housing (11) bore.
7. Separate spacer (10) and spool (9) from sleeve (7).
8. Remove O-rings (6*) and (8*) from sleeve (7).
NOTE: Take care not to damage O-ring grooves or

sleeve.
1. Nut 10. Spacer

2. Washer 11. Housing
3*. O-ring 12. Ball
4. End plug 13. Spool
5. Spring 14*. O-ring
6*. O-ring 15. Sleeve
7. Sleeve 16. Base
8*. O-ring 17. Cap screw
9. Spool
* Included in repair kit
HYDRAULICS 1.58
Assembly
NOTE: Use a repair kit when assembling the valve,

the repair kit contains new O-rings.
1. Before assembly, lightly lubricate the parts from

the repair kit and the spools and sleeves with clean
hydraulic oil.
2. Make sure all parts are clean before assembly.
3. Install new O-rings (6) on large diameter end of

sleeve (7) and a new O-rings (8) on smaller diameter
end of sleeve (7).
4. Carefully install spool (9) into sleeve (11). Note

direction of spool.
5. Install spacer (10) into housing (11) bore through

end plug (4) end of housing. Note direction of spacer.
6. Carefully install sleeve (7) and spool (9) assembly

into housing (11) bore using a wooden dowel. Note
direction of assembly.
7. Install spring (5) into housing (11) bore.
8. Install end plug (4) and torque load to 10.9-20.3

Nm (96-180 lbf/in.) to seat sleeve. Then loosen end
plug ¼ turn and torque load to 1.1-6.0 Nm (10-60 lbf/
in.).
9. Install new O-ring (3), washer (2) and nut (1). Hold
the end plug (4) with a wrench and torque load nut to
68.1-81.4 Nm (50-60 lbf/ft.).
10. Install new O-rings (14) on sleeve (15). Carefully

insert spool (13) into sleeve (15).
11. Install ball (12) on top of spool (9), already in

housing. Install sleeve (15) assembly in housing (11)
bore.
12. Carefully install base (16) over sleeve (15) while

aligning cap screws (17) with holes in housing (11).
13. Test the brake pressure at connector A on trailer

brake valve. Pressure can be adjusted by adding or
removing shims (17) to retainer assembly (16).
Torque load cap screws to 29.8 33.9 Nm
(22-25 lbf/ft.).
1.59 HYDRAULICS
DIVERTOR VALVE (46)
Removal
NOTE: The diverter valve (9) is fitted forward of the
rear service plate. Remove the rear cover from the
boom and the rear service plate, if necessary to get
access to the valve.
1. Stop the engine, apply the parking brake, chock

the wheels and disconnect the battery.
3. Make sure the divertor valve (9) is free from dirt to

avoid contamination of the hydraulic system.

6. Disconnect the hoses (1) and (4) to (8) from the

divertor valve (9) and blank open connections on the
valve and hoses. Tie hoses clear of valve.
6. Remove the two hexagonal headed screws (3) and (1) Return hose from manifold
washers (2) securing the valve (9) to the rear service (2) Washer
plate. Remove the divertor valve (9) from the machine. (3) Hex head screw
(4) Pressure hose to manifold
(5) 1st service pressure hose
Installation (6) 1st service return hose
(7) Pressure hose from control valve
1. Installation is the reverse of the above procedure. (8) Return hose to control valve
(9) Diverter valve (46)


HYDRAULICS 1.60
MANIFOLD (57)
Removal
NOTE: A manifold is fitted forward of the rear service
plate. Remove the rear cover from the boom and the
rear service plate, if necessary to get access to the
valve.

3. Make sure the manifold is free from dirt to avoid

5. Position a suitable container under the manifold to

6. Disconnect the hoses (1), (2) and (5) from the

manifold (6) and blank open connections on manifold
and hoses. Tie hoses clear of manifold.
(1) Return hose (to diverter valve)
7. Remove the pipe (3) from the manifold (6) and (2) Pressure hose (from diverter valve)
adapter on rear service plate, blank open connections (3) Hitch pressure hose
on manifold (6) and pipe (3). (4) Tipping QR connector (if fitted)
(5) Hitch return hose
(6) Manifold (48)
8. Disconnect the tap adapter (7) from the manifold
(7) Tap adapter
(6) and blank open connections.
(8) Washer
(9) Bolt
9. Remove the trailer tipping QR connector (4) (if (10) Nut
fitted). (11) Washer
10. Remove the two hexagonal headed bolts (9), four

washers (8) and (11) and two nuts (10) securing the
manifold (6) to the rear service plate. Remove the
valve (6) from the machine.
Installation



HYDRAULICS 1.61
HYDROSTATIC PUMP (55)
Removal 17. Carefully withdraw the pump from the adapter

plate until the drive hub is clear. Remove the pump
parking brake. from the machine.
2. Raise the boom and fit the boom safety stop to the Note: If the pump is to be replaced, do the step that
boom cylinder. follows.
18. Remove the cap screw and circlip from the drive
3. Refer to page 1.1 and dump hydraulic pressure hub on the pump drive shaft and remove the drive
then disconnect the battery. hub.
4. Remove the under engine guard, where applicable.
Note: Step 5 is applicable from Machines

S/No.5060013.
5. Lower the subframe containing the accumulator
and fan reverse valve.
6. Remove the battery.
7. Remove the washer bottle and tubing.
8. Disconnect harnesses and hoses.
9. Drain the hydraulic header tank and remove from

its frame.
10. Remove the air cleaner assembly.
11. Remove the bolts, nuts and washers that attach

the battery support subframe to the machine.
Remove the battery support subframe.
12. Remove the bolts, nuts and washers that attach

the engine hood, side door and rear engine cover.
Remove the engine hood, side door and rear engine
cover.
13. Mark the position then disconnect the

connections to the forward and reverse solenoids on
the hydrostatic pump.
14. Mark the position and then disconnect all hoses

connected to the hydrostatic pump.
The Hydrostatic Pump is heavy.

Make sure it is fully supported during
the removal procecedure.
16. Support the pump and remove the four bolts and
washers that attach the pump to the adapter plate.
1.62 HYDRAULICS
Installation
1. Installation is the reverse of the above procedure,

except the boom safety stop must be removed only
after hydraulic pressure has been established.
2. Make sure all hoses, electrical and mechanical

connectors are connected to the correct service.
3. Discard used sealing rings. Make sure new

sealing rings are fitted.
4. Tighten the four mounting bolts.


6. Make sure there are no hydraulic leaks.

8. Refer to Page 1.67 and test the hydrostatic

system.
HYDRAULICS 1.63
MULTI-FUNCTION VALVES (58) (62)
Removal
parking brake.
2. Raise the boom and fit the boom safety stop to the
boom cylinder.

4. Refer to Page 1.61 and gain access to the

hydrostatic pump (2).
5. Remove the multi-function valves (1) from the

hydrostatic pump (2).
Installation
1 Mutli-function valve (58 and 62)
1. Installation is the reverse of the above procedure,
2 Hydrostatic pump (55)
except the boom safety stop must be removed only
after hydraulic pressure has been established.

3. Torque the multi-function valve to:

Frame size 030 to 100 - 89 Nm (66 lbf ft)
Frame size 130 to 250 - 210 Nm (155 lbf ft)




system.
1.64 HYDRAULICS
HYDROSTATIC MOTOR (66)
Removal
1. Stop the engine and chock the machine, apply the 16. Remove the bolts (4) and washers (5) that attach
parking brake. the retaining clamps (3) and hoses (2) to the
hydrostatic motor (8).
2. Raise the boom and install the saftey cylinder
lock. 17. Remove the two hoses (2) from the hydrostatic
motor (8).
then disconnect the battery. The Hydrostatic Motor weighs
approximately 43 kg (106 lbs).
Take care when you move the
4. Drain the hydraulic oil tanks of hydraulic fluid. motor.
The drive shaft weighs approximately 18. Attach a suitable sling and hoist to support the
14 kg (31 lbs). Take care when weight of the hydrostatic motor (8).
supporting and moving the drive shaft.
19. Remove the four bolts that attach the hydrostatic
5. Position a suitable floor jack near to the front axle motor (8) to the front axle. Operate the hoist to
to support the drive shaft. Operate the floor jack to seperate the motor (8) from the front axle. Remove
support the weight of the drive shaft. the hydrostatic motor (8) from the machine.
Installation
6. Remove the bolts that attach the drive shaft to the
front axle. Operate the floor jack to lower the drive 1. Installation is the reverse of the above procedure.
shaft to the floor.
2. Clean and examine all components. Replace any
7. Note the position of the cable strap that secures damaged or worn components.
the hydraulic hose at connection (7) to the brake
cable. Cut and remove the cable strap. 3. Make sure all hoses, electrical and mechanical
connectors are connected to the correct service.
8. Disconnect the hydraulic hose at connection (7)
from the hydrostatic motor (8). 4. Discard used sealing rings and cable straps.
Make sure new sealing rings are fitted.
9. Disconnect the hydraulic hoses (1) and (6) from
the hydrostatic motor (8). 5. Refer to Page 1.43 and replenish the hydraulic
10. Disconnect the electrical connector from the

hydrostatic motor. and operating all services to fully extend and retract
11. Disconnect the three electrical connectors in the
electrical harness above the hydrostatic motor. 7. Make sure there are no hydraulic leaks.
12. Disconnect the hydraulic hose (12) from the T- 8. Refer to Page 1.43 and check the hydraulic level
piece connector (11) on the hydrostatic motor (8). and replenish if necessary.
13. Loosen the elbow connector (10) on the 9. Refer to Page 1.67 and test the hydrostatic
hydrostatic motor (8). system.
15. Disconnect the T-piece (11) from the hydrostatic

motor (8). Move the T-piece (11), with hose (9)
attached, away from the hydrostatic motor (8).
HYDRAULICS 1.65
1. Hose
2. Hoses
3. Hose clamps
4. Bolts
5. Washers
6. Hose
7. Hose connection
8. Hydrostatic motor (66)
9. Hose
10. Elbow connector
11. T-piece connector
12. Hose
1.66 HYDRAULICS
PURGE RELIEF VALVE (69)
Removal
parking brake.

3. Gain access to the hydrostatic motor (1), which is

located on the front axle.
4. Locate the purge relief valve (2) and mark the

position of the plug, lock nut and endcap.
5. Loosen the locknut and unscrew and remove the

purge relief valve assembly (2) from the motor (1).
Installation

3. Align the valve plug, lock nut and endcap to the

marks made at Step 4, during removal.
4. Torque the purge reliaf valve (2) to 52 Nm (38 lbf ft)

6. Purge the hydraulic system by starting the engine 1 Hydrostatic motor (66
cylinders several times. 2 Purge relief valve (69)


system.
HYDRAULICS 1.67
HYDROSTATIC STSTEM - PRESSURE TEST
AND ADJUST
Charge Pressure
1. Park the machine on firm and level ground. 14. Turn the battery back to it's original position and
refit the battery clamp.
2. Fully retract and lower the boom.
3. Set the transmission control to the NEUTRAL

position and engage the parking brake.
4. Make sure the machine is run to the normal

operating temperature of approximately 60 deg C
(140 deg F) then stop the engine.
5. Gain access to the battery and remove the battery

clamp. Turn the battery through 90 degrees to get
better access to the test point.
6. Remove the dust cover from test point M3a (1) on

the hydrostatic pump (3) and install a suitable
pressure gauge.
7. Start the engine and set the speed to low idle.
8. Check the pressure reading on the pressure gauge

is 30.3 bar +/- 2 bar.
Note: Do Steps 9 to 12 only if the charge pressure

requires adjustment.
1 Test point M3a

9. Repeat Steps 1 to 8.
2 Charge pressure adjuster
Note: During Step 10, one turn of the adjuster alters
the charge pressure by 3.5 bar.
10. Loosen the locknut on the charge pressure

adjuster (2). Turn the screw adjuster in a clockwise
direction to increase the pressure or counter-
clockwise to decrease the poressure.
11. Check the pressure reading on the pressure

gauge is 30.3 bar +/- 2 bar.
12. Tighten the locknut on the charge pressure

adjuster (2).
13. Stop the engine and remove the pressure gauge

from the test point M3a (1). Refit the dust cap.
1.68 HYDRAULICS
Drive loop pressures (forward)

1. Park the machine on firm and level ground. 14. Press the service brake control until the
maximum operational position is reached.
15. Check the readings on the two pressure gauges.
The pressure (HP) on test point 3 (3) should increase
3. Set the transmission control to the NEUTRAL to 480 bar. The pressure (LP) on test point 4 (2)
position and engage the parking brake. should be a minimum of 14 bar.
4. Make sure the machine is run to the normal 16. Release the service brake control and move the
operating temperature of approximately 60 deg C transmission control to the NEUTRAL postion.
17. Apply the parking brake.
5. Raise the machine on stands to clear the tyres of
the ground. 18. Stop the engine and remove the items fitted at
Step 9. Refit the dust caps to test points 3 (3) and 4
6. Lower the guard for the sump. (2).
7. Disconnect the electrical harness from the 14. Reconnect the elecrical harness to the
potentiometer on the cabin foot brake assembly. potentiometer on the cab foot brake assembly. Turn
the battery back to it's original position and refit the
battery clamp. Raise and secure the guard for the
8. Gain access to the battery and remove the battery sump.
better access to the test point.
15. Remove the stands, installed at Step 5 and lower
the machine to the ground.
9. Remove the dust cover from test point 3 (3) and 4
(2) on the hydrostatic pump (1) and install the items
listed at Step 8.
10. Start the engine and set the speed to low idle
speed.
Note: During Step 11, the difference between the

readings on the two pressure gauges should not be
greater than 7 bar.
11. Check the pressure readings on the two pressure

gauges are 30 bar +/- 2 bar.
12. Release the parking brake and set the engine

speed to upper idle speed for 15 seconds.
13. Move the tranmission control to the FORWARD

position.

2 Test point 4 (76)
3 Test point 3 (75)
HYDRAULICS 1.69
13. Press the service brake control until the

Drive loop pressures (reverse)
maximum operational position is reached.
1. Park the machine on firm and level ground.
14. Check the readings on the two pressure gauges.
2. Fully retract and lower the boom. The pressure (HP) on test point 3 (3) should increase
to 480 bar. The pressure (LP) on test point 4 (2)
should be a minimum of 14 bar.
15. Release the service brake control and move the
transmission control to the NEUTRAL postion.
4. Make sure the machine is run to the normal
operating temperature of approximately 60 deg C 16. Apply the parking brake.
17. Stop the engine and remove the items fitted at

5. Raise the machine on stands to clear the tyres of Step 8. Refit the dust caps to test points 3 (3) and 4
the ground. (2).
6. Disconnect the electrical harness from the 18. Reconnect the elecrical harness to the
potentiometer on the cabin foot brake assembly. potentiometer on the cab foot brake assembly. Turn
the battery back to it's original position and refit the
battery clamp.
7. Gain access to the battery and remove the battery
better access to the test point. 19. Remove the stands, installed at Step 5 and lower
the machine to the ground.
8. Remove the dust cover from test point 3 (3) and 4
(2) on the hydrostatic pump (1) and install the items
listed at Step 7.
9. Start the engine and set the speed to upper idle

speed.
Note: During Step 10, the difference between the

readings on the two pressure gauges should not be
greater than 7 bar.
10. Check the pressure readings on the two pressure

gauges are 30 bar +/- 2 bar.
11. Release the parking brake and set the engine

speed to upper idle speed for 15 seconds.
12. Move the tranmission control to the REVERSE

position.

2 Test point 4 (76)
3 Test point 3 (75)
1.70 HYDRAULICS
Adjusting the Motor Case Pressure
Note: The motor case pressure is controlled by the

purge relief valve, which is located in the hydrostatic
motor. The operating pressure for the valve is factory set.
If the motor pressures are not correct, the relief valve will
need to be examined for defects.

parking brake.

3. Refer to Page 1.65 and remove the relief valve

assembly from the hydrostatic motor.
4. Remove the end cap that retains the valve

assembly in the valve body.
5. Remove the valve and spring from the valve body.
6. Examine the valve components and replace any

that are damaged or worn.
Installation
2. Refer to Page 1.66 and install the relief valve

assembly to the hydrostatic motor.
HYDRAULICS 1.71
Travel Speed - Check and Adjust


4. Gain access to the hydrostatic motor. Remove

and discard the protective cap from the adjusting
screw.
5. Measure the length of the exposed thread on the

adjusting screw.
Note: Typical settings for thread length against

speed range are:
- 1.8 cm (0.7 in.) for 20 km/h (12 mph)

- 2.8 cm (1.1 in.) for 32 km/h (20 mph).
6. Make sure the exposed thread on the adjusting

screw is correct for the speed range required.
Note: Do Steps 7 to 9 only if speed adjustment is

necessary.
7. Loosen the locknut on the adjusting screw and

turn the adusting screw in a clockwise direction to
the limit of the minimum displacement of the motor.
Note: One complete turn of the adjusting screw will

change the displacement of the motor by 3.1 cc/Rev
(0.19 in. 3/Rev). An increase in diplacement will
decrease shaft speed, a decrease in displacement
will increase shaft speed.
8. Turn the adjusting screw in a counter-clockwise

direction until the required exposed thread length is
reached.
9. Torque the locknut to 86 Nm (63 lbf ft).
10. Install a new protective cap to the adjusting

screw.
1.72 HYDRAULICS
Control Valve (motor displacement) - Check

and Adjust
1. Park the machine on firm and level ground. 16. The correct position is reached when the
pressure gauge indicates a maximum pressure of
2. Fully retract and lower the boom. 180 to 200 bar.
3. Set the transmission control to the NEUTRAL 17. Tighten the locknut on the adjuster.
18. Release the service brake control and set the
4. Make sure the machine is run to the normal transmission control to the NEUTRAL position.
operating temperature of approximately 60 deg C
(140 deg F) then stop the engine. 19. Stop the engine and apply the parking brake.
5. Raise the machine on stands to clear the tyres of 20. Reconnect the electrical harness to the foot
the ground. brake.
6. Disconnect the electrical harness from the 21. Remove the pressure gauge from the test point
potentiometer on the cabin foot brake assembly. and refit the test point point plug.
7. Gain access to the hydrostatic motor and remove 22. Remove the stands installed at Step 5 and lower
the plug from the test point. the machine to the ground.
8. Install a suitable pressure gauge to the test point.
9. Start the engine and set the speed to idle speed.
10. Release the parking brake.
11. Operate the foot brake control until the maximum

operational position is reached.
12. Move the tranmission control to the FORWARD

position.
13. Make sure the transmission control is set to

HIGH SPEED.
14. Increase the engine speed slowly and check the

reading on the pressure gauge. As the engine speed
increases the pressure gauge should indicate a
maximum pressure of 180 to 200 bar and then return
to zero.
Note: Do Steps 15 to 17 only if adjustment is

necessary.
15. Loosen the locknut and turn the adjusting screw

in a clockwise direction to increase the pressure
HYDRAULICS 1.73
OIL COOLER (72)

(For Machines up to S/No.50600162 only)
Removal

4. If necessary, remove the right rear wheel to gain

access to the oil cooler.
5. Unlatch and pull the oil cooler assembly (2) out

and clear of the cooler housing (6).
6. Remove the six nuts and washers that attach the

closure plate (3) to the two support brackets (1).
Remove the closure plate (3).
7. Remove the six nuts and washers that attach the

two support brackets (1) to the oil cooler assembly
(2). Remove the two support brackets (1).
8. Disconnect the two hoses (4) and (5) from the oil 1 Support brackets
cooler assembly (2). 2 Oil cooler assembly (72)
3 Closure plate
9. Remove the oil cooler assembly (2) from the 4 Hose
machine.
5 Hose
6 Cooler housing
Installation
2. Make sure the two hoses (4) and (5) are connected
to the correct service.


cylinders several times. Make sure the oil cooler
operates correctly.

1.74 HYDRAULICS
OIL COOLER (72)

(For Machines from S/No.50600163 only)
Removal
3. Apply full and left wheel lock.

5. Lift the two latches (1) that secure the grill (2) in
position.
6. Remove the access panel (5) to gain access to

the oil cooler assembly (3).
7. Disconnect the two hoses (4) from the oil cooler

assembly.
8. Remove the two peg screws, nuts and washers

that attach the top of the oil cooler (3) assembly to
the structure.
9. Remove the oil cooler assembly (3) from the

machine.
Installation
2. Make sure the two hoses (4) are connected to the

correct service.

1 Latches
4. Purge the hydraulic system by starting the engine 2 Grill
and operating all services to fully extend and retract 3 Oil cooler assembly (72)
cylinders several times. Make sure the oil cooler
4 Hose (Qty 2)
operates correctly.
5 Access panel

HYDRAULICS 1.75
STAC VALVE (10)
Removal

4. Remove the battery (1).
5. Remove the engine cover and stay.
6. Remove the washer bottle (2) from insiside the

battery mounting tray (3).
7. Remove the battery mounting tray (3).
8. Note the connection of all hoses to the STAC valve

(6). Disconnect all hoses from the STAC valve (6).
9. Remove the four bolts (4) and washers (5) that

attach the STAC valve (6) to the structure.
10. Remove the STAC valve (6) from the machine.
Installation
2. Make sure all hoses are connected to the correct

service.


cylinders several times. Make sure the brake and
steering systems operate correctly.

1 Battery
2 Washer bottle
3 Battery mounting tray
4 Bolt
5 Washer
6 STAC valve (10)
1.76 HYDRAULICS
ACCUMULATOR (16)
(For Machines up to S/No.50600162 only)
Removal

4. Gain access to the accumulator , which is located

behind the support bracket over the front axle.
5. Disconnect the electrical connector to the

pressure switch.
5. Note the position of the two hoses connected to

the accumulator. Disconnect and remove the two
hoses, Tee piece and hose union from the neck of
the accumulator.
6. Remove the nut that attaches the accumulator to

the support bracket.
7. Remove the accumulator from the machine.
Installation
2. Make sure the two hoses are connected to the

correct service.


cylinders several times. Make sure the brake system
operate correctly.

HYDRAULICS 1.77
ACCUMULATOR (16)
(For Machines from S/No.50600163 only)
Removal

4. Open engine cover to gain access to the

accumulator (1), which is near the fan reverse valve.
5. Disconnect the electrical connector to the 1 Accumulator (16)

pressure switch (6). 2 Support bracket
3 Nut
5. Note the position of the two hoses (4) and (7) 4 Hose
connected to the accumulator (1). Disconnect and 5 T-piece
remove the two hoses (4) and (7), T-piece (5) and
hose union (8) from the neck of the accumulator (1). 6 Pressure switch
7 Hose
6. Remove the nut (3) that attaches the accumulator 8 Hose union
(1) to the support bracket (2).
7. Remove the accumulator (1) from the machine.
Installation


cylinders several times. Make sure the brake system
operate correctly.

1.78 HYDRAULICS
LOAD CONTROL VALVE (40) - LIFT CYLINDER
Removal
2. Fully extend the boom.
3. Fit the boom stop to the boom.

5. Note the position of the two hoses (1) and (3)

connected to the lift cylinder (4). Disconnect and
remove the two hoses (1) and (3).
1 Hose
2 Load control valve (40)
6. Remove the load control valve (2) from the lift
cylinder (4). 3 Hose
4 Lift cylinder
Installation



HYDRAULICS 1.79
LOAD CONTROL VALVE (42) - CROWD

CYLINDER
Removal
2. Fully extend and lower the boom.
4. Make sure equipment attached to the crowd

cylinder is fully supported.

1 Hose
2 Load control valve (42)
connected to the crowd cylinder (4). Disconnect and
remove the two hoses (1) and (3). 3 Hose
4 Crowd cylinder
7. Remove the load control valve (2) from the crowd
cylider (4).
Installation



1.80 HYDRAULICS
LOAD CONTROL VALVE (45) - EXTENSION

CYLINDER
Removal
2. Fully extend and lower the boom.
4. Make sure equipment attached to the crowd

cylinder is fully supported.


1 Hose
connected to the extension cylinder (4). Disconnect
and remove the two hoses (1) and (3). 2 Load control valve (45)
3 Hose
7. Remove the load control valve (2) from the 4 Extension cylinder
extension cylinder (4).
Installation



HYDRAULICS 1.81
CONTROL VALVE (29)
Removal
1. Operate the steering and apply full left hand lock to
the rear wheels.

4. Remove the rear left hand wheel for access to the

control valve.
5. Make sure control valve is free from dirt to avoid

6. Identify and label the electrical connections (1).

Disconnect the electrical connections (1) and fit 1 Electrical connections
blanks to the connections (1). 2 Mechanical connections
3 Hose connections
7. Identify and label the mechanical connections (2)
on the valve. Disconnect the mechanical connections
(2) to the valve.

9. Identify and label the hose connections (3).

Disconnect all hoses from the control valve and blank
open connections (3) on valve and associated hoses.
Tie hoses clear of valve.
10. Remove the bolts securing the valve to the

mounting plate. Remove the valve from the machine.
Installation
2. Make sure all hoses and electrical connectors are

connected to the correct service.
3. Make sure all mechanical connectors are




1.82 HYDRAULICS
Servicing
seals, cleaning of ancillary valves and replacement of
preset assemblies.
Dismantling
dismantling.
2. Label all sections and make a note of the order

that the components are assembled.
3. Stand the control valve on its end with the end

plate section (4) uppermost.
4. Remove the nuts (2) and washers (3) from the tie
bolts(1) and remove the PVP section. Remove the
other sections of the valve, one at a time.
5. Remove and discard the inter-section O-ring seals.
6. Examine the self-locating grooves for burrs, nicks

or other damage.
7. Burrs may be removed by careful honing with a

very fine grade stone. Any cut damage to a groove 1 Tie-bolt
requires that section to be replaced. 2 Nut
3 Washer
Assembly 4 End plate section (37)
1. Use new O-rings when assembling the valve,

lightly lubricated with clean hydraulic oil.
2. Before assembly, the section mating surfaces

should be cleaned and lightly lubricated with clean
hydraulic oil.
3. Assemble the sections onto the tie-bolts in the

correct order, as noted during dismantling. Make sure
that the identity marks align and the O-ring seals are
located in the grooves.
Take care when tightening the tie-bolts to

avoid distorting the sections and possible
binding of the spools and/or seal leakage.
4. Fit the washers (3) and nuts (2) to the tie-bolts (1)
and tighten finger tight.
5. Tighten the tie-bolt nuts (2) progressively in

rotation and torque load to 25 Nm (18 lbf/ft.).
HYDRAULICS 1.83
Spool sections
General
Two types of spool are fitted to the valve,
mechanically controlled and electrically controlled.
The crowd and lift sections are mechanically

controlled. They are of the same construction but the
lift section does not have relief valves.
The extend and auxiliary sections are electrically

controlled and are of the same construction.
The main components of a section are the main body

and spool assembly. These components are modular,
allowing combination to be matched to service
requirements.
Mechanically controlled valves
Dismantling
NOTE: Dismantling and assembly of the spool
section describes the section with relief valves fitted.
Disregard relief valve information for relevant sections.
1. Remove the cap screws (28) and washer (27)

securing end plate (26) to the main body (23) and
remove plate.
2. Remove the screws (14) and washer (15) securing

end cover(16) to the main body (23) and remove end
cover.
NOTE: Dismantling of the spool section is not

necessary when the fault is external leakage only.
3. Unscrew the securing bolt (17) from the spool (11)

and remove the two spring retainers (18) and (21),
spacer (19), spring (20) and plate (22).
4. Carefully slide spool (11) out of main body (23).
5. Remove O-rings (12) and (24) and wiper rings (13)

and (25) from each side of the main body (23).
6. Unscrew the relief valves (1) and (10) and remove

the O-rings (2) and (9).
7. Unscrew the check valve (5) and remove the spring

(6) and seat (7).
8. Remove O-ring seal kit (4) from the main body(23).
9. Clean the relief valves (1) and (10) in an approved

solvent and dry using an air jet, do not use cloths or
paper wipes.
1.84 HYDRAULICS
10. Clean the spool and housing in an approved Assembly

paper wipes. 1. Assemble the spool section in the reverse order to
dismantling. Take care not to damage the spool or
11. Examine the main body and spool for wear, burrs, main body when installing the spool.
blocked grooves or other damage. If any damage or
wear is found, the main body (23) or spool (11) must 2. Use new O-rings during assembly.
be replaced.
NOTE: If a pressure reducing valve is replaced, make

sure the correct rated valve is fitted.
12. Examine the pressure relief valves for damage or

wear. If any damage or wear is found, the valve must
be replaced as a unit
1 Relief valve 15 Washer

2 O-ring - Relief valve 16 End cover
3 O-ring - Relief valve 17 Securing bolt
4 Seal kit 18 Spring retainer
5 Check valve 19 Spacer
6 Spring 20 Spring12.
7 Valve seat 21 Spring retainer
8 O-ring – relief valve 22 Plate
9 O-ring – relief valve 23 Main body
10 Relief valve 24 O-ring
11 Spool 25 Wiper ring
12 O-ring 26 End plate
13 Wiper ring 27 Washer
14 Screw 28 Cap screw
HYDRAULICS 1.85
Electrically controlled valves
Dismantling
1. Remove the covers (1) and (10) and O-ring seals
(2) and (11) from the actuators (3) and (12) on each
side of the main body (9).
2. Remove the screws (20) and (13) and retainers (19)

and (14). Remove the actuators (23) and (12) from
each side of the main body (9).
3. Remove the operating rods (18) and (5) from each

actuator.
NOTE: Dismantling of the spool section is not

necessary when the fault is external leakage only.
4. Carefully slide spool (8) out of main body (9).
5. Remove O-ring (17) from each side of the main

body (9).
6. Unscrew the check valve (5) and remove the spring

(6) and seat (7).
7. Remove O-ring seal kit (4) from the main body (9).
8. Clean the spool (8) and housing (5) in an approved

paper wipes.
9 Clean the check valve (5) in an approved solvent

and dry using an air jet, do not use cloths or paper
wipes.
10. Examine the main body (9) and spool (8) for wear,
burrs, blocked grooves or other damage. If any
damage or wear is found, the main body (9) or spool
(8) must be replaced.
Assembly
1. Assemble the spool section in the reverse order to
dismantling. Take care not to damage the spool or
main body when installing the spool.
2. Use new O-rings during assembly.

1.86 HYDRAULICS
1 Cover 11 O-ring
2 O-ring 12 Actuator
3 Actuator 13 Screw
4 Seal kit 14 Retainer
5 Check valve 15 Operating rod
6 Spring 16 O-ring
7 Valve seat 17 O-ring
8 Spool 18 Operating rod
9 Main body 19 Retainer
10 Cover 20 Screw
HYDRAULICS 1.87
Inlet section (30)
General
The inlet section consists of the main body with main
pressure and return to tank connections and a
pressure relief valve. Dismantling and assembly of the
section is limited to these components.
Dismantling
1. Remove the pressure relief valve (3) from the main
body (4), complete with O-ring seals (1) and (2).
2. Clean the main body (4) in an approved solvent and

dry using an air jet, do not use cloths or paper wipes.
3. Examine the main body (4) for wear, burrs,

blocked grooves or other damage. If any damage or
wear is found, the main body (4) must be replaced.
4. Examine the pressure relief valve (3) for damage or

wear. If any damage or wear is found, the relief valve
(3) must be replaced.
Assembly
1. Assemble the inlet section in the reverse order to
dismantling. Take care not to not to damage the main
body when installing the components.
1 O-ring
2 O-ring
3 Pressure relief valve
4 Main body
1.88 HYDRAULICS
STEERING
Description
The steering system is fully hydrostatic. This means

that the steering motion is transmitted hydraulically
with no mechanical linkage between the steering
wheel and the steered wheels. The hydraulic supply
is by a dynamic system working with a load-sensing
(LS) pump. Pump supply passes through a priority
valve and generates a load-sensing signal.
Operation
The OSPF steering unit interfaces the steering

control valve with an adapter. Depending on the
steering mode selected in the cab, (two-wheel steer/ C1 To rear cylinder
four-wheel steer/crab steer), the steering control valve
C2 To rear cylinder
directs oil to the selected steering cylinder when
input is made from the steering wheel. C4 To front cylinder
P LS - Pump
In the neutral position, oil is allowed to flow freely T Tank
from the priority valve through the steering control
valve to return (LS to T). As the steering wheel is
turned the spools of the valve rotate against each
other and proportionally direct oil to the selected
steering cylinder. Not until the rotary valve is fully
open is the LS connection to the tank fully closed.
A pressure relief valve is fitted in the control valve. If

the pressure rises above 175 bar (2537 psi), the PRV
will open and return excess pressure to tank.
Two shock valves are fitted in the control valve, to

protect the cylinders and hoses and are set at a
higher pressure than the PRV.
When hydraulic pressure fails, the vehicle can be

steered manually. The steering wheel, when turned,
drives the outer spool with the cross pin and the rotor
is turned by the cardan shaft which acts as a manual
pump to supply oil to the steering cylinder. In this
case the steering effort required will be increased
significantly.
Control Valve specification

Type OSPF250LS O OSPF 250 valve (21)
PRV 170-175 bar (2465-2537 psi) A Adapter
Shock valve 225-245 bar (3262-3552 psi) E Selector valve (24)
Displacement 250 cu.cm/rev
HYDRAULICS 1.89
LS LS – line
1.90 HYDRAULICS
1. Tank, hydraulic 23. Shock valve, 225 - 245 bar

2. Hydraulic pump, main 24. Steering selector valve - attached to OSPF
4. Header tank valve
5. Filter 25. Pressure relief valve 175 bar
10. Steering & Accumulator charge valve (STAC) 26. Non-return valve
11. Regulator 27. Steering cylinder (rear axle)
12. Accumulator charge valve 28. Steering cylinder (front axle)
13. Filter 73. Test point 1 (STAC Ls pressure)
14. Filter 74. Test point 2 (STAC Brake pressure)
15. Priority valve A. To front brakes
21. Control valve, steering - Danfoss OSPF B. To trailer brake
22. Steering control valve spool C. To control valve
HYDRAULICS 1.91
Checking the steering system
Steering cylinder (27 & 28)
1. Raise and securely support the front axle.
2. Turn steering fully to left.
3. Disconnnect hose from adapter on right hand end

of cylinder
4. Start the engine and operate steering wheel fully

left to apply maximum hydraulic pressure to cylinder.
Make sure no oil flows from open right hand
connection.
5. Stop engine, connect hose to right hand hose to

adapter and repeat above check on left hand side of
cylinder.
6. Repeat all above checks on rear axle steering

cylinder.
7. Start engine and bleed the hydraulic lines free of

air.
OSPF steering unit (21)
1. Start the engine and run until oil is at normal

operating temperature and any air is purged from
system.
2. Set engine at maximum rev/min, turn the steering

wheel until the steering stops make contact.
3. If the steering wheel can be turned, the rotor, spool

or shock valves are faulty and the steering unit must
be replaced.
Servicing
Servicing is normally limited to the replacement of the

three main components (steering unit, adapter and
steering valve) and the seals between these
components.
HYDRAULICS 1.92
Steering valve assembly
Removal

3. Remove the front cover from outside of the cab.
4. Make sure the steering valve assembly is free from

dirt to avoid contamination of the hydraulic system.
5. Identify and label the electrical connectors on the

steering valve. Disconnect the electrical connectors
and fit blanks to the connectors and valve.
6. Position a suitable container under the steering

valve assembly to collect any oil spillage during
removal.
7. Identify and label the hydraulic hoses. Disconnect

all hoses from the steering valve assembly and blank
open connections on valve and hoses. Tie hoses
clear of valve.
8. From inside the cab, remove the nut, washer, three

bolts and washers securing the valve to the steering
column. Remove the valve from the machine by
disconnecting the splined drive
Installation
2. Make sure all hoses and electrical connectors are



and operating the steering to fully extend and retract
front and rear steering cylinders several times.

6. Check the steering operates correctly in all

modes, (two-wheel steer, four-wheel steer and crab
steer).
1.93 HYDRAULICS
Dismantling
1. Remove the four cap head screws (7) attaching the

steering valve (5) to the adapter (2). Remove and
discard the O-ring seals (6).
2. Remove the two cap head screws (4) attaching the

adapter (3) to the steering unit (1). Remove and
discard the O-ring seals (2).
3. Examine the steering valve for damage to the block

or solenoids and electrical connectors. If any damage
is found, the valve must be replaced as a unit.
4. Examine the adapter for damage to the block. If

any damage is found, the adapter must be replaced.
5. Examine the steering unit for damage to the block.

If any damage is found, the unit must be replaced.
Assembly
1. Assemble the steering valve assembly in the

reverse order to dismantling. 1 Steering unit
2 O-ring
2. Use new O-rings during assembly. 3 Adapter
4 Cap head screw – M10 x 46
3. Tighten the screws progressively in rotation. 5 O-ring
6 Steering valve
7 Cap head screw – M5 x 45
HYDRAULICS 1.94
HYDRAULIC CYLINDERS
Lift cylinder (39)
Removal
1. Raise the boom to a suitable height and support

using lifting equipment or support stands.

The lift cylinder heavy. Make sure

that the cylider is fully supported
during the removal procedure.
4. Remove the engine bonnet.
5. Support the upper end of the cylinder (4). Remove

the bolt (2), and washer (3) securing the upper
attachment pin (1). Drive out the upper attachment
pin and lower the cylinder onto a suitable support.
6. Identify the hydraulic hoses to make sure they are

reconnected correctly. Disconnect the two hydraulic
hoses (8) from the cylinder (11), blank the cylinder
and open hoses.
Take care when removing the cylinder,

that it does not damage the adjacent
components.
7. Support the cylinder (11), remove the bolt (5) and

washer (6) securing lower attachment pin (7) to the
chassis (10) Drive out attachment pin and remove
cylinder (11) from machine. Remove spacers (9) from
each side of attachment pin.
I
1.95 HYDRAULICS
Installation

tank before engine is started.

and operating the service to fully extend and retract
cylinder several times.

1 Upper attachment pin 7 Lower attachment pin

2 Bolt 8 Hydraulic hoses
3 Washer 9 Spacer
4 Upper cylinder 10 Chassis
5 Bolt 11 Lift cylinder (39)
6 Washer
HYDRAULICS 1.96
Crowd cylinder (41)
Removal (3) Purge the hydraulic system by starting the engine

1. Extend the boom and rest the carriage on the cylinder several times.
ground.
(4) Refer to Page 1.43 and replenish the hydraulic tank
if necessary.

The crowd cylinder heavy. Make sure

that the cylinder is fully supported
during the removal procedure..
NOTE: Make a note of the position of the spacers

located on the lower cylinder attachment pin.
4. Remove the two bolts (8), washers (7), locking

plate (6) and washers (2) securing lower cylinder
attachment pin (10) to the lever (13). Drive out lower
attachment pin and remove the spacers (11) from
each side of cylinder eye end (12).
5. Remove the bolts (1) and washers (2) securing the

cover plate (14) to the front of the boom (3) and
remove cover plate.
6. Disconnect the two hydraulic hoses from the 1 Bolt

cylinder, blank the cylinder and open hoses. 2 Washer
3 Boom
7. Support the cylinder. Remove the bolt (9) and 4 Upper attachment pin
washer (5) retaining the upper attachment pin (4). 5 Washer
Drive out the upper attachment pin (4) and remove the 6 Locking plate
cylinder from the machine. 7 Washer (2 off)
8 Bolt (2 off)
Installation 9 Bolt
10 Lower attachment pin
1. Installation is the reverse of the above procedure. 11 Spacer (2 off)
12 Crowd cylinder (41)
13 Lever
2. Refer to Page 1.43 and replenish the hydraulic 14 Cover plate
1.97 HYDRAULICS
Compensator cylinder (43)
Removal
1. Raise the boom to a suitable height and support
using lifting equipment or support stands.

4. Remove the engine bonnet.
The compensator cylinder heavy.

Make sure that the cylider is fully
supported during the removal
procedure.
5. Support the upper end of the cylinder (1). Remove

the bolt (4) and washer (3) retaining the upper
attachment pin (2). Drive out the upper attachment
pin (2) and lower the cylinder onto the lift cylinder, if
fitted, or a suitable support.
6. Disconnect the two hydraulic hoses (9) and (10)

from the cylinder (11), blank the cylinder and open
hoses.
7. Support the cylinder and remove the bolt (5),

washer (6) and lower attachment pin (7) attaching the
cylinder (11) to the chassis.
Installation

before engine is started.


HYDRAULICS 1.98
1 Upper cylinder 7 Lower attachment pin

2 Upper attachment pin 8 Chassis
3 Washer 9 Hydraulic hose
4 Bolt 10. Hydraulic hose
5 Bolt 11. Compensator cylinder (43)
6 Washer
1.99 HYDRAULICS
Extension cylinder (44)
Removal
1. Lower the boom to the horizontal position and

extend the boom by 1.5 m (5 ft).

The extension cylinder heavy. Make

sure that the cylinder is fully
procedure.
4. Remove the rear cover from the boom pivot.
5. Remove the rear service plate.
6. Remove the oil cooler and radiator.
7. Disconnect the two hydraulic hoses (6) and (8)

from the cylinder (7), blank the cylinder and open
hoses.
8. Remove the two circlips (11) retaining the forward

attachment pin (12) to the inner boom (9). Drive out
the forward attachment pin (12).
NOTE: Make a note of the position of the spigot

mounting clamps located on each side of the rear
cylinder attachment pin.
9. Remove the two bolts (5) and washers (4), on each

spigot mounting clamp (3), securing the cylinder rear
attachment spigot to the outer boom (10).
10. Remove the two nuts (2) securing the plate (1) to
the cylinder (7).
1 Plate
2 Nut
11. Remove the cylinder (7) rearwards from the boom. 3 Spigot mounting clamp (2 off)
4 Washer (8 off)
12. Remove the spigot mounting clamps (3) from the 5 Bolt (4 off)
cylinder spigots. 6 Extension cylinder hose
7 Extension cylinder (44)
8 Extension cylinder hose
9 Inner boom
10 Outer boom
11 Circlip (2 off)
12 Forward attachment pin
HYDRAULICS 1.100
Installation


and operating the extension, crowd and auxiliary
services to fully extend and retract cylinders several
times.

1.101 HYDRAULICS
Lift, crowd, compensator and extension

cylinder (39, 41, 43, & 44)
Servicing
The lift, crowd, compensator and extension cylinders

are of the same internal construction; the only
difference is the size. External differences consist of
end fittings and piping to the cylinder.
The hydraulic cylinders are heavy.

Take care when handling cylinders,
to avoid damage to components and
injury to personnel.
The dismantling and assembly procedure is based on

the extension cylinder. The procedures for all other
cylinders are similar.
Dismantling
1. Clean the exterior of the cylinder with a suitable

solvent and dry with compressed air. Do not use
cloths or paper towels to dry component.
2. Drain the cylinder of as much hydraulic fluid as

possible, into a suitable container, before
dismantling.
3. Support the cylinder on ‘V’ blocks and make sure

that when the piston is removed the components are
not damaged.
If compressed air is used to extend

the piston assembly, the gland nut
(13) must not be removed. Release
all pressure before the gland nut is
removed.
4. When the piston assembly is difficult to extend, a

compressed air supply may be used to pressurise
the cylinder. Use only the minimum pressure
necessary to extend piston.
5. Using a suitable spanner, unscrew the gland

assembly (18) from the cylinder (1).
6. Withdraw the piston rod (19) complete with piston

assembly (9) from the cylinder (1). If necessary, fit a
suitable size pin through the eye-end of the piston rod
and carefully tap with a soft-faced hammer to remove
piston rod.
HYDRAULICS 1.102
7. Remove the grub screw (4) from the piston (8) and
unscrew and remove the piston (8) from the piston rod
(19).
8. Remove and discard all seals and O-rings (3), (5),

(6) and (10) from the piston (8).
9. Remove and discard all seals and O-rings (10),

(11), (12), (14), (16) and (17) from the gland nut (13).

and should not be dismantled or
10. If the load control valve (2) is faulty, remove by

unscrewing. A new control valve (2) must be fitted.
Assembly
1. Assemble the hydraulic cylinder in the reverse

order to dismantling.
2. Use new O-rings, seals and spacers during

assembly.
3. Make sure all old Loctite is removed from the

threads of the piston, piston rod and grub screw
before assembly. Apply Loctite sealant to threads of
piston rod and securely screw piston to piston rod
before fitting grub screw.
4. Lubricate O-rings, seals and spacers with clean

hydraulic oil before and during assembly.
5. Torque tighten the components in accordance with

the Table on the following page.
1.103 HYDRAULICS
Component
Item
Gland nut Piston Grub screw Load control valve
Extension cylinder 720-770 Nm 2000 Nm 18 Nm 100 Nm

(530-568 lbf/in.) (1474 lbf/in.) (13 lbf/in.) (74 lbf/in.)
Compensator 650 Nm 1500 Nm 12 Nm

-
cylinder (480 lbf/in.) (1105 lbf/in.) (9 lbf/in.)
950 Nm 2000 Nm 18 Nm 85 Nm
Crowd cylinder
(700 lbf/in.) (1474 lbf/in.) (13 lbf/in.) (63 lbf/in.)
950 Nm 2000 Nm 18 Nm 85 Nm
Lift cylinder
(700 lbf/in.) (1474 lbf/in.) (13 lbf/in.) (63 lbf/in.)
1 Cylinder 11 Seal
2 Load control valve 12 Seal
3 Seal 13 Gland nut
4 Grub screw 14 Seal
5 Seal 15 Seal
6 Seal 16 O-ring (not fitted to extension)
7 O ring 17 Seal
8 Piston 18 Gland assembly
9 Piston assembly 19 Piston rod
10 Seal
HYDRAULICS 1.104
Autohitch cylinder (50)
Removal


hoses (2) from the cylinder (4), blank the cylinder
connections and open hoses.
The autohitch cylinder heavy. Make

sure that the cylinder is fully
procedure.
4. Support the auto-hitch assembly and remove the

bolts (5), washers (6) and (12) and nuts (11) securing
assembly to mounting plate (10). Slide assembly
rearwards and remove from machine.
5. Remove the lock nut (7), nut (8)and washer (9)

securing the cylinder lower attachment to the lower
1 Drawbar pin
hook channel (3). Remove the drawbar pin (1)
2 Hydraulic hose
securing the cylinder to the channel. Remove the
3 Lower hook channel
cylinder from the lower hook channel (3).
4 Auto-hitch cylinder
5 Bolt
Installation
6 Washer
7 Lock nut
1. Installation is the reverse of the above procedure. 8 Nut
9 Washer
2. Refer to Page 1.43 and replenish the hydraulic tank 10 Mounting plate
before engine is started. 11 Nut
12 Washer
and operating the auto-hitch service to fully extend and
retract cylinder several times.

HYDRAULICS 1.105
Steering cylinder (15 & 19)
Removal

hoses from the cylinder (2) and blank the cylinder
connections and open hoses.
3. Remove the adapter (1) from the cylinder (2) to

allow cylinder to slide through locating bracket.
4. Loosen the track rod end securing nut (7) on each

track rod (8) and using a suitable removal tool;
disconnect track rod ends from axle.
5. Loosen the ball joint lock nut (6) on the inboard

end of each track rod (8) and remove the track rods
from ball joint (5). Remove the ball joint from each end
of the piston rod (4).
6. Remove the three screws (3), securing cylinder to

axle and slide cylinder out of brackets.
7. Fit a blank to the open cylinder connection.
Installation


and operating the steering to fully extend and retract
4. Refer to Page 1.56 and check the hydraulic level 1 Adapter

and replenish if necessary. 2 Cylinder (27 & 28)
3 Cylinder retaing screw (3 off)
Refer to the axle section and adjust the tracking and
on the rear axle, the operation of the steering position 4 Piston rod
switch. 5 Ball joint
6 Ball joint lock nut
5.
6. Torque tighten the components as follows: 7 Track rod lock nut
8 Track rod
Cylinder retaining screws (3) - 120 Nm (88 lbf/ft.)
Ball joint (5) - 300 Nm (220 lbf/ft.)
Ball joint lock nut (6) - 250 Nm (184 lbf/ft.)
Track rod loc nut (7) - 220 Nm (162 lbf/ft.).
1.106 HYDRAULICS
Dismantling
1. Clean the exterior of the cylinder with a suitable
solvent and dry with compressed air. Do not use
cloths or paper towels to dry component.
2. Drain as much hydraulic fluid as possible from the

cylinder into a suitable container before dismantling.
3. Support cylinder on ‘V’ blocks; make sure that

when the piston is removed the components are not
damaged.
4. Remove the circlip (10) from the gland assembly

(2). Push the gland assembly into the cylinder (7)
and remove the snap ring (1).
5. Remove the gland assembly (2) from the cylinder

(7) by pressing the piston rod (3) complete with gland
assembly from the cylinder (7). If necessary, carefully 1. Snap ring
tap the piston rod with a soft-faced hammer. 2. Gland assembly
3. Piston rod
6. Remove the gland assembly (2) from the piston rod 4. Magnetic band
(3). Remove the O-ring (9), piston rod seal (11) and 5. Wiper ring
wiper ring (12) from the gland assembly (2).
6. Seal
7. Cylinder
7. Remove the O-rings (8) and magnetic band (4)
8. O-ring
from the piston rod (3).
9. O-ring
10. Circlip
8. Remove the wiper ring (5) and piston rod seal (6)
from the cylinder (7). 11. Seal
12. Wiper ring
Assembly
1. Assemble the steering cylinder in the reverse order
to dismantling.
2. Use new seals and wiper rings during assembly.
3. Lubricate seals and wiper rings with clean

hydraulic oil before and during assembly.
SECTION 2
ELECTRICS
ELECTRICS 2.1
Circuit Diagrams Key

Item Description Sheet No. Notes
F1 Rear Wiper Fuse 3

F2 Work Lights Fuse 3
F3 Roading Fuse 2
F4 Turn/Radio Fuse 5
F5 Heater/Fuel Gauge Fuse 6
F6 Hydraulic Control Fuse 2
F7 SLI Fuse 2
F8 Fog Lamp Fuse 4
F9 Rear Work Lamp Fuse 3
F10 Front Work Lamp Fuse 3
F11 Fuel Sol Fuse 1
F12 Stop Lamps/Steer Sensor Fuse 5
F13 RH Side Lamp Fuse 4
F14 LH Side Lamp Fuse 4
F15 RH Mainbeam Fuse 4
F16 LH Mainbeam Fuse 4
F17 RH Dip Beam Fuse 4
F18 LH Dip Beam Fuse 4
F19 Hazard Warning Fuse 5
F20 Transmission Control (Susmic) Fuse 7
F21 Int Lamps Fuse 6
F22 Front Wiper Fuse 3
F23 Horn Fuse 3
F24 Ignition Fuse (Air Conditioning Fuse
behind roof liner - Machines up to
S/No.50600083) 6
F25 Boom W/Lights in-line Fuse 3
F26 Side W/Lights in-line Fuse (LH) 3
F27 Side W/Lights in-line Fuse (RH) 6
F28 Fan Reverse in-line Switch 3
R1 Boom Work Lamps Relay 1
R2 Ignition Relay 5
R3 Turn/Hazard Signal Unit -
R4 Not Allocated 3
R5 Front Work Lamps Relay 3
R6 Rear Work Lamps Relay 3
R7 Side Work Lamps Relay 4
R8 Headlamp Relay 1
R9 Neutral Start Relay 2
R10 Aux1 Disable Relay 2
R11 Hydraulic Disable Relay 1
R12 Starter Solenoid Relay 3
R13 Side Lamp Relay 6
R14 A/C Fan Relay -
R15 Not Allocated -
R16 Cold Start Relay 1
1 Alternator 1
2 Battery Disconnect Switch 1
3 Battery 1
4 Starter Solenoid 1
5 Starter Motor -
6 Not Allocated 1, 6
7 Ignition Switch -
8 Ignition Relay -
9 Not Allocated 6, 7
10 Park Brake Switch
2.2 ELECTRICS
Circuit Diagrams Key (continued)
11 Cold Start Advance Sol 1

12 Fuel Solenoid 1
13 Mode Switch 7
14 FNR Selector Switch 7
15 Susmic 7
16 Speed Sensor 7
17 Inch Pedal 7
18 Trans Sol Rev 7
19 Trans Sol Fwd 7
20 Motor Displacement Solenoid 7
21 SLI Display 2
22 Steer Arm Switch 2
23 Steer Sol Rear Axle 2
24 Steer Sol Front Axle 2
25 Not Allocated -
26 Roading Switch 2
27 Aux 1A Switch 2
28 Aux 1B Switch 2
29 Extend Switch 2
30 Retract Switch 2
31 Aux 2A Switch 2
32 Aux 2B Switch 2
33 Aux 1A Sol 2
34 Aux 1B Sol 2
35 Extend Sol 2
36 Retract Sol 2
37 Aux 2A Sol 2
38 Aux 2B Sol 2
39 Diverter Sol 2
40 Rear Hydraulic Service Switch 2
41 Horn Switch 3
42 Front Wash/Wipe Switch 3
43 Rear Wash/Wipe Switch 3
44 Horn 3
45 Front Wash Motor 3
46 Front Wiper Motor 3
47 Rear Wash Motor 3
48 Rear Wiper Motor 3
49 Boom Work Lamps Switch (option) 3
50 Side Work Lamps Switch (option) 3
51 Rear Work Lamps Switch 3
52 Front Work Lamps Switch 3
53 LH Boom Work Lamp 3
54 RH Boom Work Lamp 3
55 RH Side Work Lamp 3
56 LH Side Work Lamp 3
57 Roof Beacon Lamp (Ext Din) -
58 RH Rear Work Lamp 3
59 LH Rear Work Lamp 3
60 RH Front Work Lamp 3
61 LH Front Work Lamp 3
62 Light Switch 4
63 Side Lamp RH Front 4
64 Side Lamp RH Rear 4
ELECTRICS 2.3
65 RH Boom Side Lamp 4

66 LH Boom Side Lamp 4
67 No. Plate Lamp 4
68 Side Lamp LH Rear 4
69 Side Lamp LH Front 4
70 Fog Light Switch 4
71 RH Rear Fog Lamp 4
72 LH Rear Fog Lamp 4
73 Main/Dip Switch 4
74 LH Dip Beam 4
75 RH Dip Beam 4
76 RH Main Beam 4
77 LH Main Beam 4
78 Stop Lamp Switch 5
79 LH Stop Lamp 5
80 RH Stop Lamp 5
81 RH Rev Lamp 5
82 LH Rev Lamp 5
83 Reverse Alarm 5
84 Front Steer Warning Lamp 5
85 Rear Steer Warning Lamp 5
86 Front Steer Sensor 5
87 Rear Steer Sensor 5
88 Radio (option) 5
89 LH Speaker 5
90 RH Speaker 5
91 Hazard Switch 5
92 Not Allocated 5
93 Turn Signal Switch 5
94 LH Boom Turn Lamp (option) 5
95 LH Rear Turn Lamp 5
96 LH Front Turn Lamp 5
97 RH Front Turn Lamp 5
98 RH Rear Turn Lamp 5
99 RH Boom Turn Lamp (option) 5
100 Beacon Dim Switch 6
101 Beacon (option) 6
102 Interior Lamp Switch 6
103 Interior Lamp 6
104 AC/Heater Switch 6
105 Heater Blower 6
106 Air Con Switch 6
107 Air Con Thermostat 6
108 Air Con Clutch 6
109 A/C Condensor Unit 6
110 A/C Breaker 6
111 Condensor Fans 6
112 Low Pressure Switch 6
113 High Pressure Switch 6
114 Fuel Sender 6
115 Instrument Pack 6
116 Main Beam W/L 6
117 RH Turn W/L 6
118 LH Turn W/L 6
2.4 ELECTRICS
119 Trailer Turn W/L 6

120 Side W/L 6
121 Front Work Lamps W/L 6
122 Rear Work Lamps W/L 6
123 Park Brake W/L 6
124 Fuel Gauge 6
125 Tacho 6
126 Engine Temp Gauge 6
127 Alternator W/L 6
128 Oil Pressure W/L 6
129 Air Filter W/L 6
130 Hydraulic Filter W/L 6
131 Brake Pressure W/L 6
132 Eng Temp Gauge 6
133 Oil Pressure Switch 6
134 Air Filter Switch 6
135 Hydraulic Filter Switch 6
136 Low Brake Pressure Switch 6
137 Not Allocated -
138 Not Allocated -
139 Not Allocated -
140 Not Allocated -
141 Not Allocated -
142 Not Allocated -
143 Not Allocated -
144 Not Allocated -
145 Not Allocated -
146 Not Allocated -
147 Not Allocated -
148 Not Allocated -
149 Not Allocated -
150 Not Allocated -
151 Not Allocated -
152 Not Allocated -
153 Not Allocated -
154 Not Allocated -
155 SLI Strain Gauge 2
156 Not Allocated 1
157 Fan Reverse Switch 6
158 Temp Switch 6
159 Fan Reverse Solenoid 6
160 Hydraulic Temp W/L 6
ELECTRICS ( SHEET 1) 2.5
STARTING / CHARGING / POWER DISTRIBUTION (All Machines)
HYDRAULIC CONTROL (All Machines)
WIPERS / HORN / WORK LAMPS (All Machines)
HEAD LAMPS / SIDE LAMPS / FOG LAMPS (All Machines)
STOP LAMPS / REVERSE ALARM / TURN - HAZARD LAMPS / RADIO / STEERING SENSOR (All Machines)
HEATER / AIR CONDITIONING / INTERIOR LAMPS / INSTRUMENTS (All Machines)
TRANSMISSION CONTROL (All Machines)
ELECTRICS 2.12
CHASSIS LOOM
2.13 ELECTRICS
ENGINE LOOM
ELECTRICS 2.14
CAB LOOM
2.15 ELECTRICS
LONGITUDINAL STABILITY INDICATOR
Description
The Longitudinal Stability Indicator (LSI) monitors the

forward stability of the machine. The LSI provides
audible and visual signals in order to alert the
operator to the condition of a loaded machine.
The main components of the LSI are a sensor (2)

and a display module (1). The sensor is mounted on
the rear axle and the display module is located
inside the cab on the cab right side console. An
intermediate harness (3) connects to the display
module connector (5) and the sensor. The
intermediate harness is routed from the space
between the rear of the cab and the hydraulic control
valve through the cab to the instrument panel. The
LSI is powered by the machines electrical system
and power is supplied to the display module through
a connector (4). The following Table 1 shows the
power supply required to operate the LSI.
ELECTRICS 2.16
The LSI is activated when the engine start switch is Pow er Supply
turned to the ON position. The sensor sends
Nominal Voltage 12 Volts DC
electrical signals to the display module which then
provide the operator with audible and visual signals. Voltage Range 10.5 Volts to 15.5 Volts
The display module attempts to simulate the load Current 100mA to 300mA (1)
chart for the machine.
(1) The current will depend on the load that is indicated on the
display module.
The electrical signal that is sent from the sensor to
the display module is proportional to the strain that is
applied to the sensor. The sensor is subject to the
same strains that are applied to the rear axle. These
strains depend on the weight of the load that is
carried on the work tool and the amount of boom
extension.
SENSOR
Specifications
S en so r
Length 60mm (2.4 inch)
Physical size Width 60mm (2.4 inch)
Height 25mm (1 inch)
Temperature range Min -25°C (-13°F)
(storage) Max 75°C (167°F)
Temperature range Min -5°C (23°F)
(operating) Max 75°C (167°F)
Min 0%
Humidity
Max 100%
The sensor is a sealed unit with a wiring harness

and plug attached.
The sensor (2) is bonded and secured by three bolts

(6) to the top of the rear axle.
The type of sensor installed on the machine is

known as a strain sensor or strain gauge. The strain
sensor measures the change in electrical resistance
that results from the amount of strain (stretch) that is
applied to the wires in the sensor. Factors that affect
the amount of strain applied to the sensor are listed
below.
1. The weight of the load that is carried on the

work tool.
2. The amount of boom extension.
3. The angle of the boom.
As the electrical resistance in the sensor changes, a

change in voltage is measured by the display
module. As more strain is applied to the sensor, a
greater change in voltage is measured.
2.17 ELECTRICS
DISPLAY MODULE
Specification
Display Module
Length 120mm (4.72 inch)
Physical size Width 110mm (4.3 inch)
Height 30mm (1.2 inch)
Temperature range Min -25°C (-13°F)
(storage) Max 75°C (167°F)
Temperature range Min 0°C (32°F)
(operating) Max 50°C (122°F)
10% (No Moisture
Min
Condensation)
Humidity
90% (No Moisture
Max
Condensation)
The display module (1) is mounted in the cab side

console on the right side of the cab. The display
module provides audible and visual signals in order
to alert the operator to the forward stability of the
machine.
A harness with two connectors is attached to the

display module. The 4-way connector (5) is used to
connect the display module via an intermediate
wiring harness (3), that is routed through the cab, to
the harness on the sensor (2) fitted to the rear axle.
The second connector (4), a 2-way version, is used
to connect to the main electrical system of the
machine to provide power to the LSI.
The display module measures the load from the

sensor by changes in voltage. This is then
calculated as a percentage value of the maximum
load. Indicators are then illuminated on the panel of
the display module according to the percentage
value. The display module has eleven indicators.
ELECTRICS 2.18
The display module indicators and switches are

listed below. The indicators and mute switch are
located on the front of the display module.
Green indicator (7) shows that the LSI is

receiving power and is powered up.
NOTE: The single green indicator does not indicate

correct operation or guarantee calibration.
Green indicator (8) is a 50% load indicator.
Green indicator (11) is a 70 % load indicator.
Green indicator (12) is a 75% loads indicator.
Amber indicators (14) and (15) are 75% load

indicators.
Red indicators (16) and (17) are 100% load

indicators.
Switch (18) marked

! initiates a self-
diagnostic routine test for the display module
and is also used to mute the alarm audible
warning. It is also used for setting a zero
point when calibrating the display module.
The following push buttons are located on the side of

the display module.
Push button (19) is labelled “CAL”. This is an

on/off switch for the calibration mode.
Push button (20) is labelled ”Span” and push

button (21) is labelled “Span+%”. These push
buttons are used in the calibration mode to
obtain the calibration point for setting the
indicators.
When the engine start switch is turned to the ON

position, for the first two to three seconds, all
indicators will be illuminated and the audible alarm
will sound. This indicates that the display module is
performing an internal self-check. When the display
module has completed its internal self-check all
indicators except indicator (7) will be extinguished
and the audible alarm will cease. Indicator (7) will
remain illuminated at all times that the system is
powered up. Any error signals displayed in the first
30 seconds after power up should be disregarded.
2.19 ELECTRICS
When the load on the machine increases from 50%

to 80% green indicators (8), (9), (10), (11), (12) and
(13) illuminate progressively. When one or two
green indicators are illuminated the lift operation is
within the machine stability. When all the green
indicators are illuminated the lift operation is still
within the machines capability but extra caution is
necessary.
When the amber indicators (14) and (15) illuminate

the audible alarm sounds intermittently. This
indicates that the limit for the longitudinal stability of
the machine has been reached. Extra caution is
necessary. Do not increase the outreach of the
load.
When red indicators (16) and (17) are illuminated

and the audible alarm sounds continuously, the limit
for the longitudinal stability of the machine has been
exceeded. When this condition occurs, do not
proceed with the lift operation. To restore
longitudinal stability to the machine the following
steps must be carried out in this sequence.
1. Retract the boom (if boom is extended).

2. Lower boom (if boom is elevated).
TESTING AND ADJUSTMENT
Troubleshooting
Machine preparation for troubleshooting.
NOTE: Full rear wheel steering onto the axle stops

can give a false reading on the display module.
The machine must be prepared correctly before

attempting any troubleshooting on the system. Use
the following procedure to prepare the machine.
1. Park the machine on level ground.
2. Engage the parking brake.
3. Retract the boom.
4. Lower the coupler and the work tool to the

ground.
5. Stop the engine.
Visual inspection
Carry out a visual inspection of the main system

components before attempting any instrument
checks on the system. Use the following procedure
to inspect the system.
ELECTRICS 2.20
1. Inspect the display module for damage or

loose mounting.
2. Inspect the sensor on the rear axle for

loose attachment bolts.
3. Inspect the sensor on the rear axle for

secure bonding and signs of corrosion at the
bonded surface.
4. Inspect the wiring harness, that connects

the system components together, look for cuts
or other damage.
System Check
NOTE: Disregard any error indications displayed

during the first 30 seconds after power up.
1. Turn the engine start switch to the ON

position. All the indicators will be illuminated
for two to three seconds and the audible
alarm will sound. This indicates that the LSI is
performing an internal self-check. On
completion of self-check all indicators except
indicator (7) will be extinguished and the
audible alarm will cease.
NOTE: If self-check is performed with a load on the

boom, more than one indicator will remain
illuminated.
2. Refer to the appropriate load chart. Pick up

a load that is heavy enough to tip the machine
when the boom is fully extended and raise the
coupler 150 mm (6 in.) above the ground.
NOTE: Keep the coupler 150 mm (6 in.) above the

ground.
3. Extend the boom in stages and observe the

indicators on the display module. As the
boom is extended indicators (8) through (13)
on the display module must illuminate
progressively.
4. Continue to extend the boom. As the boom

approaches the point of instability, amber
indicators (14) and (15) must be illuminated
and the audible alarm sounds at
approximately half second intervals.
5. Continue to extend the boom. As the boom

extends past the point of instability, red
indicators (16) and (17) illuminate and the
audible alarm sounds continuously.
6. Retract the boom.

2.21 ELECTRICS
7. Press and hold ! switch (18). All

indicators must illuminate and the audible
alarm must sound. When the ! switch

(18) is released the display module should
return to normal operation.
NOTE: If the system does not behave as expected

there may be a fault or the system could require
calibration. Refer to section headed “Calibration”.
Error indications from the display module
• If none of the indicators are illuminated the display

module may not be receiving power. Alternatively an
internal protection device may have operated due to
a fault in the system. Unplug the power
connector(4) for the display module and check the
power supply. If there is power to the module and
the fault persists install a new display module. Refer
to section headed “Display module - Replace” for the
procedure.
• If indicator (7) is flashing quickly and indicator (10)

and (11) are illuminated, the output from the sensor
may be negative. The output from the sensor may
be more than 100% of the load range. If so the
system requires calibration. Refer to section headed
“Calibration”.
• If indicators (8), (9), (10), (11), (12) and (13) flash

slowly there is a fault in the display module. Replace
the display module. Refer to section headed
“Display module - Replace” for the procedure.
• If all the indicators are flashing slowly except

indicator (7), which is flashing quickly, the sensor
may be damaged or disconnected. Check the
connection to the sensor. Check the operation of the
sensor using a spare sensor. If necessary replace
the damaged sensor and calibrate the system.
Refer to sections headed “Sensor Test” and
“Calibration” for the procedure.
• If the audible alarm sounds continuously and the

machine is not overloaded the display module is not
calibrated correctly. Also if all the indicators are
illuminated and the machine is not overloaded the
display module is not calibrated correctly. Refer to
section headed “Calibration” for the procedure.
Sensor - Test
General
The sensor is bonded to the centre of the rear axle

of the machine. Problems that are associated with
the sensor are usually due to a break in the electrical
circuit or failure of the adhesive that bonds the
sensor to the rear axle.
ELECTRICS 2.22
A break in the electrical circuit usually results in all

the indicators on the display module flashing slowly
except indicator (7) which will flash quickly. The
audible alarm will also sound intermittently.
A failure of the adhesive that bonds the sensor to the

rear axle usually results in no readout or erratic
readout from the display module.
Procedure to test the operation of the

sensor
1. Park machine on level ground.
2. Engage parking brake
3. Fully retracted boom.
4. Fully lower boom.
5. If fitted, remove work tool from coupler.
6. Ensure wheels are set to straight ahead.
7. Stop the engine.
8. Turn engine start switch to ON position.

The display module in the cab will perform a
self-check.
On completion of self-check only green
indicator (7) should be illuminated.
If indicators (8) to (17) are flashing slowly and

indicator (7) is flashing quickly the sensor may be
damaged or disconnected.
(a) Check the two connections to the sensor.

One of the connectors is located behind
instrument panel (22). The other connection
is located between the rear of the cab and the
hydraulic control valve. This connects the
harness for the sensor to the intermediate
harness which is routed through the cab.
(b) Test the operation of the sensor by

substituting a spare sensor. If necessary
replace the sensor. Refer to “Procedure to
install sensor”.
If indicator (7) is flashing quickly and indicators (10)

and (11) are illuminated, the output from the sensor
may be negative. (The output of the sensor may be
more than 100% of the load range). Refer to
“Calibration procedure” and calibrate the system.
If the display module does not comply with any of the

previous steps in this procedure, the problem may
not be with the sensor. Refer to “Testing and
Adjustment - System Check” for further information.
2.23 ELECTRICS
Procedure to install a sensor
The sensor has three pads which are bonded and

bolted to the rear axle.
NOTES: (1) When bolted to the rear axle the

elements of the sensor must not be twisted or
stretched. If the elements are twisted or stretched
an offset will be applied to the sensor.
(2) When bonding sensor to rear axle
ensure matting surfaces are free from dirt, grease
and any other contamination. A poor bond will affect
the performance of the system.
Adhesive (154-8875) and activator (154-8876) are

required to install the sensor to the rear axle.
The procedure to install the sensor is as follows.
1. Disconnect the connector that attaches the

sensor to the intermediate harness. Remove
any cable straps that secure the sensor
harness.
2. Remove the three bolts that secure the

sensor to the rear axle and remove the
sensor.
3. Thoroughly clean the surface area on the

rear axle where the sensor is to be mounted.
All traces of adhesive must be removed.
Remove all traces of paint and corrosion. Use
a suitable cleaning agent to remove the main
debris and degrease the surface.
4. Ensure the area is thoroughly degreased

and dry with a suitable clean cloth.
5. Prepare the new sensor for fitting. Remove

any protective coating and thoroughly clean
the mating surface of the sensor.
6. Hold the sensor to the axle and check the

alignment of the three bolt holes. Loosely
install the three bolts and check that the
sensor is not pre-stressed by the bolts.
7. Remove the bolts and sensor.
8. Ensure the area is still clean and apply a

thin film of activator (154-8876) to the surface
area of the axle where the sensor is to be
mounted.
9. Apply a thin film of adhesive (154-8875) to

the mounting surface of the sensor.
ELECTRICS 2.24
10.Install the sensor onto the axle and secure

with the three bolts. Tighten the three bolts in
the following sequence.
(i) Tighten each bolt finger tight.
(ii) Tighten each bolt to a torque setting of

10 Nm (7.5lbf/ft.).
(iii) Tighten each bolt to a torque setting of

20 Nm (14.75lbf/ft.).
(iv) Tighten each bolts to a torque setting

of 30 Nm (22lbf/ft.).
11.Connect the sensor harness to the

intermediate harness. If necessary secure
with cable straps.
12.Allow a minimum of four hours for the

adhesive to cure. Refer to the instructions for
the specific adhesive.
13.When adhesive is thoroughly cured, refer

to “Calibration procedure” and calibrate
system.
Procedure to replace the Display Module
The display module cannot be repaired. If faulty it

must be replaced with a new part.
The procedure to install a new display module is as

follows.
1. Remove the two screws (23) that secure

the display module (1) to the cab side console
on the right side of the cab.
2. Remove the instrument panel (22).
3. Use the hole for the instrument panel in

order to locate connector (4) for the power
supply and connector (5) for the sensor.
Trace the harness from the display module in
order to identify the connectors.
4. Disconnect connectors (4) and (5).
5. Remove the display module, with attached

harness and connectors, from the cab side
console.
6. Install a new display module into the cab

side console. Connect the harness to the
power supply and to the sensor with
connectors (4) and (5).
7. Reinstall the instrument panel.

2.25 ELECTRICS
8. Install two screws (23) in order to secure

the display module to cab side console.
9. Refer to “Calibration procedure” and

calibrate system.
Calibration
When a new sensor has been installed, or when a

new display module has been installed, the LSI
system must be calibrated.
When the system is calibrated, a zero point for the

load is first set. The zero point is set when the boom
coupler has no load fitted and the boom is lowered
and fully retracted. A load is then fitted to the boom
coupler and the 100% calibration point is set. Push
buttons (19), (20) and (21) on the display module are
used to set the calibration points.
Calibration procedure
Use the following procedure to set the zero and

100% calibration points:
Before proceeding with the calibration set up, ensure

the following conditions are met:
1. The machine is parked on level ground.
2. Wheels are steered to the straight ahead

position.
3. The boom is fully retracted.
4. The bottom of the coupler is 150 mm (6in.)

above the ground.
5. A work tool is not installed on the coupler.
6. The engine is running and the parking

brake is applied.
The calibration procedure is as follows:
1. Remove the display module (1) from the

cab side console in order to gain access to
the push buttons (19), (20) and (21) that are
required to calibrate the LSI. Refer to
“Procedure to replace the display module” for
further information.
2. Briefly press the push button (19) marked

“CAL” and release. This action will put the
display module in the calibrate mode. Green
indicator (7) and red indicator (16) should start
to flash quickly.
ELECTRICS 2.26
NOTE: If the display module is in the calibrate mode

and push button (19) is pressed, the display module
will return to the normal operate mode.
3. Wait approximately 15 seconds. Briefly
press the push button (18) marked !

and release. This will store the current load
as the zero calibration point. Green indicator
(7) must illuminate for two to three seconds.
Also the audible alarm must sound once to
indicate that the correct zero calibration point
has been set. The display module should
then revert to the calibration mode. The green
indicator (7) and the red indicator (16) must
flash quickly.
NOTE: When the zero calibration point is set, the

100% calibration point is set to a low value. This will
cause the audible alarm to sound continuously if the
100% calibration point is not set in the following
steps of this procedure.
4. Pick up an appropriate work tool. The work

tool must be of the type that will allow a load
heavy enough to tip the machine forward.
5. Refer to the appropriate load chart. Pick up

a load.
NOTE: The load must be heavy enough to just tip

the machine when the boom is fully extended in
order to obtain the correct calibration.
6. Extend the boom. Keep the bottom of the

coupler 150 mm (6in.) above the ground.
Continue to extend the boom until the
machine tips forward. The rear wheels must
be just off the ground.
7. Wait approximately 15 seconds until the

machine is not rocking.
NOTE: The machine must not be rocking or

vibrating.
8. Press the push button (21) marked

“SPAN+%” and release. A value of 100% is
then set. This is calculated from the current
load which is assumed to be 110%. Only the
red indicator (17) must illuminate for
approximately two to three seconds. Also the
audible alarm must sound three times. After
these warnings the display module should
revert to the calibrate mode. Green indicator
(7) and red indicator (16) must flash.
2.27 ELECTRICS
9. Press the push button (19) marked “CAL”

and release. The action will return the display
module to the normal operating mode. Green
indicator (7) and red indicator (16) will stop
flashing. If 100% load is still applied, all
indicators will illuminate and the audible alarm
will sound. Calibration of the system is now
complete.
10. Retract the boom. The rear wheels will

come back into contact with the ground.
Leave the load in place on the work tool.
11. Carefully extend and retract the boom

whilst observing the display module. Ensure
that the display module gives the readings that
are expected. Refer to “Description - Display
module”.
12. Set down the load and disengage from the

work tool.
13. Retract the boom. Lower the work tool to

the ground and stop the engine. Turn engine
start switch to OFF position.
Resetting the zero point
If it is necessary to readjust the zero point without

resetting the 100% calibration point, perform the
following procedure.
Before proceeding with the calibration set up ensure

the following conditions are met:
1. The machine is parked on level ground.
2. Wheels are steered to the straight ahead

position.
3. The boom is fully retracted.
4. The bottom of the coupler is 150 mm (6 in.)

above the ground.
5. A work tool is not installed on the coupler.
6. The engine is running and the parking

brake is applied.
The calibration procedure is as follows:
1. Remove the display module (1) from the

cab side console in order to gain access to
the push buttons (19), (20) and (21) that are
required to calibrate the LSI. Refer to
“Procedure to replace the display module” for
further information.
ELECTRICS 2.28
2. Ensure the display module is in the normal

operating mode.
3. Press the push button (20) marked “SPAN”

and hold pressed. Only the green indicator
(7) must flash.
4. At the same time press the ! button

(18) on the display module. Green indicator
(7) must illuminate continuously for two to
three seconds and the audible alarm must
sound once. Green indicator (7) must then
start to flash again. The zero setting has now
been reset, but the 100% calibration point has
remained unchanged.
5. Stop the engine. Turn engine start switch to

the OFF position.
Testing Load Sensor Function

Functional test of Load Sensor Indicator
Switch on ignition.
Switch on the road travel switch on and ensure the

bottom light of the indicator comes on.
Press test switch (2) on the load indicator (1), ensure

all lights come on and buzzer is heard.
1 Longitudinal stability indicator A Load sensor connector A

2 Test switch A1 Machine harness connector
3 Load Sensor (155) A2 Load sensor cable connector
2.29 ELECTRICS
Procedure Carry out the following tests:
Drive the machine for approximately 15 minutes so - Test the reading when the machine is not
that axle reaches normal operating temperature. loaded
- Test the reading when the machine is at
Stop the machine in the following condition: maximum permissible weight (test weight)
- The reading should be approximately 1.5 -
- On straight and level ground 2.0 mV less at maximum permissible
- With all wheels straight ahead weight than when not loaded.
- Ensure parking brake released
- With the boom pivot point and the carriage NOTE: The reading can indicate a negative value.
pivot point at the same height
- With the boom fully retracted
- Ensure forks and front attachments
removed.
Disconnect load sensor electrical connector (A) on
rear axle.
Using a multimeter set to mV and test probes Part

No. 365 747.0, connect test probes to pins 3 and 4
of connector (A2).
Green cable (pin 3) = + signal voltage

Yellow cable (pin 4) = - signal voltage
Switch on the ignition and the main hydraulic switch.
1 Longitudinal stability indicator A Load sensor connector A

2 Test switch A1 Machine harness connector
3 Load Sensor (155) A2 Load sensor cable connector
ELECTRICS 2.30
MAIN INSTRUMENT PANEL
Description
1. Tachometer 11. Not Used

2. Hour meter 12. Battery charge indicator light
3. Fuel gauge 13. Hydraulic filter blockage warning light
4. Engine coolant temperature gauge 14 Headlight main beam warning light
5. Direction indicator light (left) 15. Direction indicator light (right)
6. Engine oil pressure light 16. Trailer turn indicator light
7. Spare 17. Road light indicator light (where used)
8. Air cleaner filter blockage light 18. Front work lights indicator light (where used)
9. Parking brake warning light 19. Rear work lights indicator light (where used)
10. Not Used 20. Hydraulic oil temperature warning lamp.
(Machines S/No.50600163 to 50600251
The main instrument panel is located in the cab to only)
the right of the steering wheel.
Removal
The panel is located in facia by snap conectors. Hold

bezel of panel with fingertips and pull out of facia.
Installation
Align panel and push into facia.

2.31 ELECTRICS
Ident
Description Operation
N o.
1. Tachometer Measures engi ne rpm - Low i dle 975

Measures engi ne rpm - Off load 2450.
2. Hours meter Measures machi ne usage whi lst engi ne i s runni ng.
3. Fuel gauge A s the fuel tank i s an i rregular shape the quanti ty of fuel regi stered
by the gauge between E mpty and 1/2 i s greater than the quanti ty
between 1/2 and Full.
4. Engine coolant temperature gauge Measures coolant temperature at the thermostat housi ng. A s the
gauge i s not annotated an approxi mate gui de i s that normal
operati ng temperature shows the needle i n a verti cal posi ti on on
the gauge.
5. Direction indicator light (left) Illuminates when the left turn signal is given.
6. Engine oil pressure light Illuminates on initial start up and then only if the engine oil pressure
drops below a preset level.
7. Spare
8. Air cleaner filter blockage light Illuminates when the pressure differential between the clean air and
that in the inlet manifold exceeds a preset level. This indicates an
obstruction in the air cleaner.
9. Parking brake warning light Illuminates when the parking brake is applied .
10. Not Used
11. Not Used I
12. Battery charge indicator light Illuminates on initial start up or when a charging fault is present.
13. Hydraulic filter blockage warning Illuminates on start up and then only when the bypass valve in the
light hydraulic filter is opening.
14. Headlight main beam warning light Illuminates when full beam headlamp is in use.
15. Direction indicator light (right) Illuminates when the right turn signal is given.
16. Trailer turn indicator light Illuminates only when the trailer socket is connected and the trailer
turn signal lamps are functioning and when the 4-way hazard warning
lamps are operated even without a trailer.
17. Road light indicator light Illuminates when roadlights are switched on. Does not indicate correct
function.
18. Front work lights indicator light Illuminates when worklights are switched on. Only operates when
roadlights are on. Does not indicate correct function.
19. Rear work lights indicator light Illuminates when worklights are switched on. Only operates when
roadlights are on. Does not indicate correct function.
20. Hydraulic oil temperature warning Illuminates if the temperature of the hydraulic oil is excessive.
lamp (Machines S/No.50600163 to 50600251 only)
ELECTRICS 2.32
CONTROL JOYSTICK
The control joystick (7) is mounted to a fixed bracket

on the right hand side of the operators seat.
The joystick controls the lift and crowd functions by

bowden cables. The extension and auxiliary
hydraulic services are operated by push buttons on
the joystick. These push buttons connect a 12 volt
signal to the solenoids which operate the erlated
section of the main hydraulic control valve.
Removal
Disconnect the vehicle battery.
Remove boom function lever (1).
Remove self-tapping screws (2) securing shroud (3)

and lift shroud for access to mechanism.
Remove bolts (4), washers and nuts securing

mechanism to supotr frame.
Disconnect bowden cables (5).
Disconnect electrical connector (6) and remove

joystick from shroud.
Installation
Installation is the reverse of the above procedure.
Test operation of joystick and adjust bowden cables

as necessary.
2.33 ELECTRICS
STARTER
The starter motor (1) is a pre-engaged heavy duty

type located, on the left hand side of the engine.
Removal
Disconnect machine’s battery.
When working under the engine

ensure electrics isolated and
machine securely chocked.
Always fit the boom safety stop when
the boom is in the raised position.
Remove the sump protection guard from beneath

machine.
Remove the mesh panel from the inside of the

engine pod adjacent to the boom.
Disconnect starter motor electrical cables.
Remove starter motor attachment bolts and remove

starter motor from engine.
Installation
Installation is the reverse of the above procedure.

ELECTRICS 2.34
FUSEBOX AND RELAYS
Description
The fuse and relay box (1) is located below the facia
mounted switches and radio (if fitted) on the left
hand side of the cab. Where it is attached to the cab
front by four screws (2) and washers (3).
Removal
To remove the Fuse and Relay box carry out the

Disconnect machines battery.
Remove the four screws (2) and washers (3) holding

the fuse box to the cab front.
Carefully ease fuse box into cab to gain access to

electrical connectors.
Disconnect electrical connectors from rear of fuse

box. Ensure connections are labelled to aid correct
connection.
Transfer serviceable fuses and relays from old fuse

box to replacement item.
Installation
Connect electrical connections on rear of fuse box.
Position fuse box on mounting studs and insert four

screws (2) and washers (3). Carefully tighten
screws ensuring no cables become trapped .
Replace fuses and relays as required.
Carry out checks on all systems using the fuse box.

2.35 ELECTRICS
Fuses
F1 7.5 Amp -
Rear wiper F13 5 Amp -
Right hand side light
F2 7.5 Amp -
Working lights F14 5 Amp -
Left hand side light
F3 10 Amp -
Road switch F15 7.5 Amp -
Right hand main beam
F4 10 Amp -
Direction indicators/Radio F16 7.5 Amp -
Left hand main beam
F5 25 Amp -
Heater F17 7.5 Amp -
Right hand dip beam
F6 5 Amp -
Hydraulic controls F18 7.5 Amp -
Left hand dip beam
F7 3 Amp -
Safe load indicator F19 10 Amp -
Hazard warning light
F8 10 Amp -
Rear fog lights F20 10 Amp -
Transmission controls
F9 15 Amp -
Rear working lights F21 10 Amp -
Interior light/Beacon/Din socket
F10 7.5 Amp -
Front working lights F22 15 Amp -
Steering column multifunction
F11 10 Amp -
Engine run/Fuel sender/Brake low switch
pressure light F23 10 Amp - Headlight flash
F12 10 Amp - Stop lights/Steering sensor/ F24 7.5 Amp - Instrument panel
Transmission dump light
Relays
R1 Boom working lights

R2 Ignition
R3 Direction indicators
R5 Front working lights
R6 Rear working lights
R7 Side working lights
R8 Headlights
ELECTRICS 2.36
ALTERNATOR
The alternator is capable of producing the total

electrical power requirements of the machine. It is
fitted on the left of the engine and belt driven from
the crankshaft pulley. The alternator contains an
integral voltage regulator.
The following precautions must be taken to avoid

damage to the alternator and voltage regulator.
1 Do not disconnect the battery while the

engine is running. This will cause a voltage
surge in the alternator charge system which
will damage the diodes and/or transistors.
2 Do not short any connections to ground.
3 Do not check the current flow using “spark

contact”.
4 Always disconnect the battery ground

terminal before removing the alternator.
5 Always disconnect the battery ground

terminal when charging the battery in the
vehicle using a battery charger.
Alternator drive belt check
To ensure maximum life from the drive belt it is

recommended that the drive belt be checked at
regular intervals, as detailed in the Operator’s
Manual, for wear, damage and tension. Visually
check the belt for signs of wear or damage and
replace as necessary.
Check the belt tension as follows.(For best results a

‘Fenner’ or similar belt tension gauge should be
used).
Fit the gauge at the centre of the longest free length

and check the tension in accordance with the
manufactures instructions.
If no gauge is available, press the belt with the

thumb at the centre of the longest free length using a
force of 45N. The resultant belt deflection should be
10mm.
If the belt tension has to be adjusted carry out the

following steps.
Loosen the pivot fasteners of the alternator (1) and

the adjustment bar (2). Adjust the alternator to give
the correct tension and tighten the fasteners.
Recheck the belt tension.

2.37 ELECTRICS
NOTE: New belts should be re-checked after the

first 20 hours of use.
Removal
In the event that the alternator has to be removed

from the vehicle, carry out the following steps.
Disconnect the battery.
Disconnect the alternator electrical connections.
Loosen the alternator pivot fasteners (1) and the

alternator adjustment bar fastener (2).
Release the belt tension and remove the belt.
Remove the adjustment bar fastener (2) from the

alternator and remove the pivot fasteners (1).(Make
a note of the position of the washers and distance
pieces to ensure correct assembly).
Remove the alternator.
Installation
Place the alternator in position and assemble loosely

the alternator pivot fasteners and adjustment bar
fastener. (Ensure that the washers and distance
pieces removed earlier are refitted correctly).
Fit the drive belt and move the alternator so that the
drive belt tension is correct. (See Alternator Drive
Belt Check).
Tighten the pivot and adjustment bar fasteners and

recheck the drive belt tension.
Reconnect the alternator electrical connections.
Reconnect the battery.

ELECTRICS 2.38
TRANSMISSION CONTROL (SUSMIC)

Description
The Transmission control is a NFPE (Non-Feedback

Proportional Electric) system consisting of an S1X
mobile computer (1), located behind the front fascia,
below the instrument panel. The operation is
controlled by the FNR switch (2) located on the left
of the steering column. The remainder of the
system comprises an ‘inch pedal sensor’(3) which is
part of the brake pedal (4), a ‘mode switch’(5)
located on the cab side console, a ‘speed sensor’
(21) located at the right hand rear of the engine on
the flywheel housing and forward and reverse
solenoids located in the hydrostatic drive pump. 1. S1X mobile computer
2. FNR switch
S1X Mobile Computer. 3. Inch pedal sensor
4. Brake pedal
Removal 5. Mode switch
To remove the S1X Mobile computer (1) carry out

the following procedure.
Disconnect the machines battery.
Gain access to the computer by removing the

necessary interior trim.
Disconnect electrical connector (6) from bottom of

computer.
Loosen, but do not remove the right hand securing

bolt (7) and washer (8).
Support computer and remove the left hand securing

bolt (9) and washer (10), slide computer to left to
clear right hand securing bolt and remove.
6. Electrical connector
7. Bolt
Installation
8. Washer
9. Bolt
With electrical connector on computer facing
10. Washer
downwards, slide the slotted locating lug (11) on the
11. Locating lug
right hand side of the computer under the bolt (7)
and washer (8), ensuring that the washer is between
the bolt head and the mounting lug.
Align bolt hole in left hand mounting lug with hole in

dash board and insert bolt (9) and washer (10) and
tighten.
Tighten right hand bolt.
Connect electrical connector to computer.
Reconnect machines battery. Carry out test of

system.
On completion of test refit cab trim.

2.39 ELECTRICS
FNR switch assembly
Removal
To remove the FNR switch assembly (2) carry out

the following procedure.
Remove the two socket head screws (12) that

secure the FNR switch assembly (2) to the multi-
function switch (13)
Disconnect electrical connector (14) from steering

column loom.
Remove FNR switch assembly. 12. Socket head screw

13. Multi-function switch
Installation
Connect electrical connector (14) to steering column

loom.
Position FNR switch assembly (2) onto steering

column and align with multi-function switch (13).
Insert two socket head screws (12) and tighten.
Reconnect machines battery.
Carry out test of Transmission control system using

procedure laid down in Operator’s Manual.
Inch Pedal Sensor (Brake pedal)
Removal
NOTE: If the pedal is replaced as a complete unit no

special tools are required. If the sensor only is
replaced, special tools are required to reset it.
To remove the Inch Pedal sensor (3) from the brake

pedal (4) carry out the following procedure.
Gain access to sensor (3) located on left hand side

of brake pedal pivot. 15. Electrical connector
16. Electrical socket
Disconnect electrical connector (15) from electrical 17. Bolt
socket (16) on top of sensor. 18. Spacer
Remove securing bolts (17) holding sensor to spacer

(18).
Remove sensor.
ELECTRICS 2.40
Installation.
Position sensor (3) on spacer (18) and align bolt

holes in sensor with bolt holes in spacer.
Insert securing bolts (17) and tighten.
Connect electrical connector (15) to electrical socket

(16) on top of sensor.
Reconnect the machines battery.
Set the sensor to the peda using the special tool.
Mode switch
Removal
To remove the mode switch (5) carry out the

Disconnect the machines battery.
Carefully prise mode switch (5) from cab side

console (19) being careful not to strain electrical
connector (20) on the rear of the switch.
Remove electrical connector (20) from rear of switch

and remove switch.
Installation
19. Cab side console
Connect electrical connector (20) to rear of mode 20. Electrical connector
switch (5).
Ensure mode switch (5) is correct way up and insert

into cab side console (19).
Push mode switch (5) firmly into cab side console

(19) until retaining lugs on switch locate with
console.
Reconnect machines battery.
Carry out test of Transmission control system using

2.41 ELECTRICS
Speed Sensor
Removal
To remove the speed sensor (21) carry out the

Disconnect electrical connector (22) from main

wiring loom.
Loosen lock nut (23), unscrew and withdraw speed

sensor (21) from adapter (24) on the flywheel
housing (25).
Installation
Measure the depth from the flywheel housing to the

teeth of the flywheel ring gear using a suitable depth
gauge.
Screw lock nut (23) onto speed sensor (21) ensuring

that there is sufficient thread free to allow sensor to
seat correctly in adapter (24).
Insert sensor (21) into adapter (24) to give a

clearance of 2 mm between the sensor and the
flywheel ring gear. Tighten lock nut (23) to lock
21. Speed sensor
sensor (21) in position.
23. Lock nut
Fit adapter to flywheel housing.
24. Adapter
25. Flywheel housing
Connect electrical connector (22) to main wiring
loom.
Connect machines battery.
Carry out test of transmission control system using

SECTION 3
TECHNICAL DATA
TECHNICAL DATA 3.1
C 40 C 50
Dimensions
A Length to front of carriage mm 3650 3850
B Length front to rear wheels mm 3342 3368
C Overall width over tyres mm 1800 1900
D Track width mm 1464 1564
E Height over cab on std tyres mm 1960 2130
F Interior cab width mm 845 845
G Wheelbase mm 2300 2300
H Ground clearance mm 320 400
I Turning radius on std tyres mm 2999 3100
J Overall bobywork width mm 1800 1800
Weight (unladen) kg 5000 5500

3.2 TECHNICAL DATA
C 40 C 50
Machine speed (km/hr)
Forward Low 8 8
Forward High 30 30
Carriage
Max crowd forward fully lowered - 50 50

degrees below horizontal
Max crowd back fully lowered - 14 14

degrees behind vertical
Max crowd forward fully raised - 15 15

degrees above horizontal
Max crowd backward fully raised - 79 79

degrees beyond vertical
Total carriage rotation - degrees 154 154
Max distance between forks - mm 1200 1200
Cycle time
Lift se c 6.0 6.0
Lower se c 4.5 4.5

Extend se c 4.9 5.7
Retract se c 3.4 4.3

Crowd forward (dump) se c 2.2 2.2
Crowd backward se c 2.7 2.7

TECHNICAL DATA 3.3
C 40 C 50
Engine
Perkins 1004.42 (diesel) kW (PS) 64 (86) 64 (86)
Max speed rpm 2200 2200
Net output Nm (rpm) 300 (1400) 300 (1400)
Cooling
Thermostat - opens °C 70 - 80 70 - 80
Thermostat - fully open °C 90 - 95 90 - 95
Transmission
Drive type 4WD 4WD
Transmission type Hydrostatic Hydrostatic
Max road speed km/hr 32, 25 or 20 32, 25 or 20
Tyres
Cross Ply, Agri 10.5 - 20 N/A
Cross Ply, Agri 12.5 - 20 12.5 - 20
Radial Ply, Ind 275 R 20 N/A
Radial Ply, Ind 335 R 20 335 R 20
Radial Ply, Agri N/A 375 R 20

3.4 TECHNICAL DATA
C 40 C 50
Hydraulics
Pump type Gear Gear
Primary system max. pressure bar 240 240

Primary system max flow l/min 80 @ 2200 rpm 80 @ 2200 rpm
Secondary system max. pressure bar 150 150
Secondary system max flow l/min 35 35
Electrics
Battery capacity Amp/hr 110 110
Alternator output Amp 65 65
Capacities
Hydraulic system litre 25 25
Hydraulic tank litre 70 70

Fuel tank litre 85 85
Engine oil litre 8.5 8.5
Engine coolant litre 28.5 28.5
Transmission transfer box litre 0.7 0.7
Axle - front litre 7.0 7.0

Axle - rear litre 7.0 7.0
Axle - final drive (each) litre 0.8 0.8
Screen wash litre 2.0 2.0
Brakes
Foot brake Servo (front axle) Servo (front axle)
Parking brake Front axle Front axle

Paul Dodd
Field Service Manager
Following the policy of Caterpillar to improve their products as technical developments continue, Caterpillar
reserve the right to make alterations which may not necessarily correspond to text and illustrations contained
in this publication, and without incurring obligation to alter any machines previously delivered.
Reproduction or translation of this publication, in whole or part, is not permitted without the written consent of
Caterpillar.
All rights under the provision of the Copyright Act are reserved.
349859.0
08/2003

0349 858 0 Hy El en 144

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HYDRAULICS

This manual is designed to service machines:

from Serial No. 50600011

Health and Safety

Always obtain advice before mixing oils; some are incompatible.

Never leave the machine unattended with pressure in the system.

2. Make sure the machine is parked on firm and

3. Turn the ignition switch to position ‘I’.

3. Operate the applicable system until all hydraulic

4. Turn the ignition switch to off.

1. Hydraulic tank 56. Pressure relief valve, 30 bar

Key to hydraulic circuits -

1. Hydraulic tank 56. Pressure relief valve, 30 bar

Hydraulic tank (1)

A single hydraulic tank feeds the main and auxiliary

1. Return hose from fan motor

Hydraulic Pump (2)

The fixed displacement, main Hydraulic pump supplies

Auxiliary Hydraulic Pump (3)

Cooler bypass valve (6)

The cooler bypass valve is fitted in the return line

Fan motor (7)

NOTE: Fitted to machines up to S/No.50600162 only)

The fan motor (7) is hydraulically operated from the

Pressure relief valve 160 bar (2321 psi)

Pressure relief valve (8)

Operating pressure 160 bar (2321 psi)

Fan reverse motor (7)

This type of fan motor is hydraulically operated from the

Pressure filter (9)

When the warning light is illuminated

Filtration 10 micron (µ)

Steering and Accumulator Charge (STAC)

1.13 The steering and accumulator charge valve

When the accumulator is fully charged, the valve

Steering is available while the charging occurs. When

At start up, if the accumulator is discharged, the

Up to this point the pressure on each side of the

STAC valve - Schematic

Port to hydraulic tank (1)

Pre-charge pressure 41 bar (595 psi)

Pressure switch (17)

Operating pressure 116 bar (1682 psi) falling

Brake pressure servo valve (18)

The valve operation is proportional to brake pedal

With no force applied to the brake pedal, the valve is

Initial application of the brake pedal moves the spool

When the brake pedal is released, the spool moves

Brake pressure at A 44 bar (638 psi)

A potentiometer on the brake pedal measures the

Pressure switch (brake light) (19)

When the brake pedal is depressed the pressure

Front axle (20)

The outboard wheel hubs are steerable, operated by a

Steering cylinder (front) (28) 1. Front axle (20)

Stroke (lock to lock) 200 mm

The outboard wheel hubs are steerable, operated by a

Steering cylinder (rear) (27)

Stroke (lock to lock) 200 mm

Steering valve (21)

When the steering valve is in neutral, oil passes

STEERING - OSPF NEUTRAL