CHAPTER 8

HYDRAULIC SYSTEM

1. STRUCTURE
1.1 HYDRAULIC SYSTEM DIAGRAM
(1) Transmission Case
(2) Hydraulic Filter
(3) Gear Pump
(4) Steering Unit
(5) Steering Cylinder
(6) Primary Valve Assembly
(7) Shuttle Cover
(8) PTO Clutch Control Valve
(9) Joystick Control Valve
C34-WOO May. 2005
HYDRAULIC SYSTEM
C34W801A
(10) Horizontal Control Valve
(11) Horizontal Control Cylinder
(12) Hydraulic Cylinder
(13) Remote Hydraulic Valve
(14) MLS Valve
(15) Attenuator
(16) Oil Cooler
(17) PTO Clutch Assembly
8-3
CHAPTER 8 DK651/751/801/901

1.2 HYDRAULIC CIRCUIT

C34W802A

(1) Transmission Case (9) Joystick Control Valve

(2) Hydraulic Filter
(3) Gear Pump
(4) Steering Unit
(5) Steering Cylinder
(6) Primary Valve Assembly
(7) Shuttle Cover
(8) PTO Clutch Control Valve
(10) Horizontal Control Valve
(11) Horizontal Control Cylinder
(12) Hydraulic Cylinder
(13) Remote Hydraulic Valve
(14) MLS Valve
(15) Attenuator
(16) Oil Cooler

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 HYDRAULIC SYSTEM

1.3 OIL FILTER

The oil filter is located in the gear pump suction line. A

permanent magnet, serving as a magnet filter, is in-
serted in the element. The filter for the hydraulic eleva-
tion system contains vacuum sensor and temperature
sensor to detect the clogging.

C34W803A

(1) Hydraulic Filter (3) Temperature Sensor

(2) Filter Bracket (4) Vacuum Sensor

C34-WOO May. 2005 8-5

CHAPTER 8 DK651/751/801/901

1.4 HYDRAULIC PUMP

The hydraulic pump (1) provides constant oil flow to DK651

operate the steering wheel and hydraulic cylinder. The
hydraulic pump assembly consists of two pumps hav-
ing different displacements.
(cc/rev)
Model DK651 DK751 DK801 DK901
Capacity 1 14.4 20.8 ← ←
2 11.1 14.4 ← ←

DK751/801/901

C34W804A

(1) Hydraulic Pump

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 HYDRAULIC SYSTEM

1.5 POWER STEERING SYSTEM

C34W805A

(1) Transmission Case (4) Steering Unit

(2) Hydraulic Filter (5) Steering Cylinder
(3) Hydraulic Pump

The Load Reaction front oil-pressured power steering The steering cylinder adopts a double rod system so
is standard for DK651/DK751/801/901 models. Only that there is no difference in rotation rate either to the
its steering unit is connected to the steering cylinder left or right when cornering is needed.
through the oil hydraulic hose.

C34-WOO May. 2005 8-7

CHAPTER 8 DK651/751/801/901

A. POWER STEERING UNIT

The power steering unit consists of the steering valve
(2) and the flow control valve with relief valve (1).

Model DK651 DK751/801/901

Capacity 96 cc/rev 120 cc/rev
Relief pressure 140 kgf/cm2
137.2 bar
1991.2 psi

C34W806A

(1) Relief Valve (2) Steering Valve

B. STEERING CYLINDER

C34W807A

Cylinder O.D.(A) Cylinder I.D.(B) Rod O.D. (C) Stroke (D)

DK651 φ 65 mm (φ 2.559 in.) φ 55 mm ( φ 2.165 in.) φ 45 mm (φ 1.772 in.) 224 mm (8.819 in.)
DK751/801/
φ 70 mm (φ 2.756 in.) φ 60 mm ( φ 2.362 in.) φ 50 mm (φ 1.969 in.) 724 mm (28.504 in.)
901

8-8 C34-WOO May. 2005

 HYDRAULIC SYSTEM

1.6 PTO CLUTCH SYSTEM

Classification DK651 DK751 DK801 DK901

Solenoid Maximum capacity ( /min) 25 ← ← ←
valve Rated capacity ( /min) 7.1 ← ← ←
Modulating 2
Relief pressure (kgf/cm ) 16 ~ 18 ← ← ←
valve Capacity ( /min) 7 ← ← ←

C34W808A

(1) Solenoid Valve

(2) Modulating Valve

By turning the PTO switch to “ON” the PTO clutch first

applies oil pressure through the primary valve to the
clutch and transfers torque to the PTO shaft. And, when
the height adjusting lever is engaged into the lift
position, PTO torque is automatically disconnected by
the attached-working-tool lift sensor.

C34-WOO May. 2005 8-9

CHAPTER 8 DK651/751/801/901
1.7 JOYSTICK VALVE
The double-spool remote valve also contains a
springloaded detent mechanism to provide a float po-
sition for loader operation. In float position, fluid is free
to flow between piston and rod sides or the loader lift
cylinder allowing the elevating arms to float over un-
even terrain.
The double-spool remote control valve contains check
valves located in the valve spool passages. The check
valves function to hold the loader lift and bucket cylin-
ders in a fixed position while the valve is being initially
operated to prevent dropping the load.
8-10
C34W809A
In operation, the check valve is retained on its seat by
spring force plus the back side pressure of fluid con-
tained in the loader cylinder. During initial spool
movement, pump-pressurized fluid fills the passage
to the check valve, and the remaining pump fluid flows
to the sump through the open center passage.
With continued spool movement, the open center pas-
sage closes.
Pump pressure increases on the force of the check
valve, overcoming the backside pressure, and causes
the check valve to open. Pump fluid flow then flows to
the cylinder.
This action prevents any backflow out of the cylinder
and provides a smooth-lifting action of the loader.
C34-WOO May. 2005
 HYDRAULIC SYSTEM

1.8 HORIZONTAL CONTROL SYSTEM

C34W810A

(1) Control Switch (3) Sensor

(2) Control Valve (4) Cylinder

The rotary type horizontal control system is adopted.

The relief pressure is between 170 ~ 175 kg/cm² (166.
7 ~ 171.6 bar, 2417.9 ~ 2489.0 psi). This horizontal
control system is easily operated with the lift control
switch attached to the lever guard on the right side of
the driver’s seat. In addition, another lift control switch
is attached to the right fender so that the controlling
system can be operated from the outside of the tractor.

C34-WOO May. 2005 8-11

CHAPTER 8 DK651/751/801/901

1.9 HYDRAULIC LIFT CYLINDER SYSTEM

C34W811A

(1) MSL Valve (3) Remote Valve (Single)

(2) Remote Valve (4) Hydraulic Cylinder

Hydraulic lift system to raise the implement connected

to the 3 point link provides three applications of posi-
tion control, draft control and mixed control by the
control valve and the linkage installed on the hydraulic
cylinder body.
Since main control valve is available to control oil flow-
ing in and out of the hydraulic cylinder so to control the
implement up and down at a constant speed regard-
less of the implement load, high work performance
can be achieved without impact while raised or
lowered. Several implements can be attached at a time
for their applications owing to the outlet valve (however,
detent float double acting valve, detent float double act-
ing valve) of the exterior oil pressure equipped on the
rear of the power lift body.

8-12 C34-WOO May. 2005

 HYDRAULIC SYSTEM

A. TOP LINK BRACKET DEVICE

C34W812A

(1) Plate (9) Bolt (17) Pin

(2) Roller (10) Bolt (18) Spring
(3) Flange (11) Nut (19) O-ring
(4) Tie Rod (12) Nut (20) Pin
(5) Cover (13) Lock Washer (21) Pin
(6) Crank (14) Lock Washer (22) Bushing
(7) Top Link Bracket (15) Spring Peaks (23) Grease Nipple
(8) Tie Rod (16) Pin

If an impact is applied on the implement, cover (5) and

spring (18) absorb the impact with the top link while
connected to the linkage by plate (1) and tie rod (8) to
raise the implement. And oil flowing line is changed by
the linkage of the control valve at this moment.

C34-WOO May. 2005 8-13

CHAPTER 8 DK651/751/801/901

2. TROUBLESHOOTING

2.1 POWER STEERING SYSTEM

Symptom Probable Cause Action

Steering wheel is heavy to 1. Orbitrol unit
operate. • Deflected center from the • Correct (caused if the tightening
column. bolt with orbitrol is loosened free).
• Abrasion due to dust on spool or • Replace
sleeve.
• Excessive tightening torque of • Tighten at the torque as speci-
bolts (7 places) on end cover. fied evenly.
2. Pump
• Incapable drive. • Repair
• Worn out or in error. • Replace
• Defectively rated. • Reset pressure and oil amount.
3. Relief valve
• In error (defective operation). • Replace
• Low pressure set. • Reset
No returning to neutral position 1. Orbitrol unit
even if hand is off steering • Abrasion due to dust on spool or • Replace
wheel or turning as it pleases sleeve.
• Deflected center from the • Correct
column.
Defective or incapable operation 1. Orbitrol unit
of the cylinder against the • Air flowed in the gerotor, inlet or • Bleed air
turning of steering wheel engagement parts due to long
term unemployed.
2. Cylinder
• Air flowed in. • Bleed air
• Piston seal damaged. • Replace
Steering wheel turns reversibly 1. Orbitrol unit
• Improper adjustment of valve • Correct
timing (when dismantling and
reassembling).
2. Pipe
• Improper piping of port 4. • Correct
Oil leakage 1. Oil seal worn out
1. Shaft area(circumference of • Contaminated delivering oil. • Replace operating fluid
spline in spool) 1. Damaged O-ring
2. Assembled area (among • Damaged during disassembly/ • Replace
housing, spacer plate, gerotor reassembly
and end cover)

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2.2 HYDRAULIC LIFT CYLINDER SYSTEM
Trouble
Hydraulic cylinder rises irregu-
larly
Hydraulic cylinder doesn’t
operate
Elevating arm is positioned at
STOP and there is periodic
vibration with motor ON: load not
decreased with motor OFF.
When working in the adjusted
draft stage, working machine
responds too sensitively.
Adjusted draft doesn’t operate
and hydraulic cylinder moves up
and down as the operation of
position lever.
Hydraulic cylinder starts to rise
but stops as soon as load
applied (Relief valve not
obstructed).
Hydraulic cylinder not fallen in
entire range.
Hydraulic cylinder not fallen.
Rising capacity not conform with
specification
Hydraulic cylinder supports the
load, but there is vibration
periodically: load decreased
with motor OFF.
The implement responses very
sensitively when running it after
adjusting
C34-WOO May. 2005
Probable Cause
• Lack in tank (mission case) oil
• Intake filter clogged
• Intake line mixed with air
• Sticking of control pision.
• Limit switch control of position
lever faulty
• Draft control lever control faulty
• Position lever control faultly
• Inside connection control faulty
• Power transmission tie rod (7)
faulty
• Position lever control faulty
• Sensitivity control faulty
• Sticking of OUTLET valve
• Poor sealing of MLS valve
• Relief valve and safety valve
control faulty
• Bad pump efficiency
• Bad efficiency of MLS valve
• Piston gasket worn
• Valve sensitivity faulty
• Relief valve fault
• Lowering control valve faulty
• Poor adjustment due to the
sensitivity of MLS valve
HYDRAULIC SYSTEM
Remedy
• Fill in oil to adequate level.
• Clean or replace filter.
• Check intake pipe, O-ring, and
bolt for looseness.
• Disassemble MLS valve, adjust
and clean the piston
• Adjust control position and limit
the operation range of upper
part.
• Adjust draft control.
• Adjust position lever.
• Disassemble hydraulic cylinder.
• Adjust draft control.
• Adjust position lever.
• Adjust sensitivity.
• Disassemble MLS valve and
clean OUTLET value.
• Disassemble MLS valve and
clean OUTLET valve.
• Disassemble MLS valve and
replace inside seal ring.
• Replace gasket
• Adjust sensitivity or replace
valve.
• Disassemble and repair MLS
valve
• Adjust sensitivity
8-15
CHAPTER 8 DK651/751/801/901

3. INSPECTION, DIASSEMBLY AND REPAIR

3.1 HYDRAULIC FILTER

A. CHECKING
As for the hydraulic filter (1), the oil filter shall be re-
placed if its alarm lamp on the instrument panel is
turned on to avoid damages on the hydraulic system.
And the hydraulic filter also shall be replaced every
service term of 200 hours.

C34W813A

(1) Hydraulic Filter

3.2 HYDRAULIC PUMP

A. CHECKING DK651 DK751/801/901

Check the displacement of hydraulic pump
1st Pump
1. Set a Flow-meter to the 1st hydraulic pump (2) for
elevation.
2. Start the engine and set the conditions as below.
3. Keep the engine speed at 2200 rpm and measure
the displacement of hydraulic pump (2).
4. If the displacement is less than allowable limit,
check the hydraulic filter for clogged and the pipes
for tightening. Then, check the oil level and mea-
sure the displacement again.
C34W814A
5. If the problem still exists, replace the hydraulic
pump (2). (below 90%)
(1) Steering Pipe
Without load: Max. 45.7 LPM
(2) Hydraulic Pipe

Test Conditions

Engine speed 2200 rpm

Transmission oil temperature 45 ~ 55°C
Pressure 140 kgf/cm2
137.2 bar
1991.2 psi
Flux max. 45.7 /min

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 HYDRAULIC SYSTEM

2nd Pump
1. Check the displacement as same manner with 1st
pump.
Without load: more than 28.5 LPM

Test Conditions

Engine speed 2200 rpm

Transmission oil temperature 45 ~ 55°C
Pressure 180 ~ 185 kgf/cm2
176.5 ~ 181.4 bar
2560.1 ~ 2631.3 psi
Flux max. 28.5 /min

B. REMOVING HYDRAULIC PUMP DK651 DK751/801/901

1. Open the bonnet.
2. Remove the side cover.
3. Unscrew the bolts and remove the hydraulic pipe
(1) and steering pipe (2).
4. Unscrew the bolts and remove the inlet pipe (3).
5. Unscrew the bolts and remove the hydraulic pump
(4).

(When assembling)
• Installing the steering pipe.
Regardless of nut sizes of the bite-type connecting
pipe, to properly fasten the nut, rotate the nut to the C34W815A
following degrees after the point of drastic increase
of torque from tightening the nut on the connecting (1) Steering Pipe (3) Inlet Pipe
pipe. (2) Hydraulic Pipe (4) Hydraulic Pump
- Min. tightening angle: 1/6 turns
- Max. tightening angle: 1/3 turns
• Check the O-ring for damage.

C34-WOO May. 2005 8-17

CHAPTER 8 DK651/751/801/901

3.3 STEERING SYSTEM

A. CHECKING
Relief Pressure Check
1. Open the bonnet
2. Remove the side cover.
3. Remove the blocking plate (LH).
4. Disconnect the steering hose (1), install the adapter
and reconnect the steering hose.
5. Start the engine and set the conditions as below.
6. Turn the steering wheel completely and measure
the pressure when the relief valve starts to operate.
7. If the measured value exceeds the allowable limits,
replace the steering unit.
C34W817A

Test Conditions (1) Steering Hose

Engine speed 2,200 rpm
Transmission oil temperature 45 ~ 55 °C
Oil pressure 140 kgf/cm2
137.2 bar
1991.2 bar

Item Tightening torque

Steering hose 24.5 N·m
2.5 kgf·m
18.0 lbf·ft

B. REMOVAL
Steering Unit
1. Unscrew the bolts and remove the instrument panel
cover (1).
2. Unscrew the bolts, disconnect the harness
connector, and remove the instrument panel as-
sembly (2).

C34W818A

(1) Instrument Panel Cover

(2) Instrument Panel Assembly

8-18 C34-WOO May. 2005

 HYDRAULIC SYSTEM

3. Remove the return spring (1).

4. Remove the snap pin and the tilt rod (2).
5. Remove the steering cover (3).
6. Remove the steering hoses (L, R, T, P) (4).
7. Unscrew the bolts (5) and remove the steering
assembly.

C34W819A

8. Remove the snap ring (6) and the steering wheel

assembly (7).
9. Unscrew the bolts (8) and remove the steering guide
(9).

C34W821A

(When reassembling) (1) Return spring

Apply the grease when installing the steering unit and (2) Tilt Rod
steering shaft. (3) Steering Cover
Be cautious of the installing direction of steering hoses. (4) Steering Hose L, R, T, P
• Steering hose P: A red tag attachment (5) Bolt
• Steering hose R: A white tag attachment (6) Snap Ring
• Steering hose L: A yellow tag attachment (7) Steering Wheel Assembly
• Steering hose T: A blue tag attachment (8) Bolt
Item Tightening torque (9) Steering Guide
Steering guide 44.1 N·m
4.5 kgf·m
32.5 lbf·ft
Steering hose nipple 49.0 N·m
5 kgf·m
36.1 lbf·ft
Steering hose (L, R) 24.5 N·m
2.5 kgf·m
18.0 lbf·ft
Steering hose (P, T) 34.3 N·m
3.5 kgf·m
25.3 lbf·ft

C34-WOO May. 2005 8-19

CHAPTER 8 DK651/751/801/901

Steering Cylinder

C34W823A

(1) Bolt (8) Bolt

(2) Cylinder Cover (RH) (9) Cylinder Support Pin
(3) Cylinder Cover (LH) (10) Spacer
(4) Split Pin (11) Steering Cylinder
(5) Nut (12) Steering Cylinder
(6) Spacer (13) Rod End
(7) Support Pin (14) Rod End

1. Remove the bolts (1)and the cylinder cover (2,3). (When reassembling)
2. Pull out the split pin (4), ubscrew the nuts (5), and Apply the sealant (Loctite #271 or quivalent) when in-
remove the ball joint assembly (13) from the front stalling the ball joint to steering cylinder.
axle case.
3. Unscrew the bolts (8) and remove the cylinder sup- Item Tightening torque
port pin (9) with steering cylinder (11,12). Ball joint 166.7 ~ 196.1 N·m
4. Disconnect the steering hoses. 17 ~ 20 kgf·m
122.9 ~ 144.6 lbf·ft

8-20 C34-WOO May. 2005

 HYDRAULIC SYSTEM

3.4 PTO CLUTCH

A. CHECKING
Relief Pressure Check
1. Remove the seat assembly (1).
2. Remove the rubber mat under the seat (2). (DK751/
801/901)
3. Remove the seat support plate.
4. Remove the oil level inspection plug (4) in the PTO
clutch modulator valve (3).
5. Install the pressure tester (special tool).
6. Start the engine and set the conditions as below.
7. Turn on the PTO switch and measure the pressure.
8. If the measured value exceeds the allowable limits,
C34W824A
replace the modulating valve (3).

Engine speed 2500 rpm

Transmission oil temperature 45 ~ 55°C
Relief valve setting pressure 16 ~ 18 kgf/cm 2
15.7 ~ 17.7 bar
227.6 ~ 256.0 psi

Test Conditions
(When reassembling)
Wrap the teflon tape or apply the sealant (Loctite #572)
on the thread of oil inpection plug.

Item Tightening torque

Oil inspection plug N·m C34W825A

kgf·m (1) Seat Assembly

lbf·ft (2) Rubber Mat
(3) PTO Clutch Modulating Valve
(4) Oil Inspection Plug

C34-WOO May. 2005 8-21

CHAPTER 8 DK651/751/801/901

B. REMOVAL
1. Remove the seat assembly (1).
2. Remove the rubber mat under the seat (2). (DK751/
801/901)
3. Remove the seat support plate.
4. Remove the PTO hydraulic pipe 3 (3).
5. Disconnect the harness connector (4).
6. Unscrew the bolts (5) and remove the PTO sole-
noid valve (6).
7. Unscrew the bolts (7) and nuts (8) and remove the
modulating valve (9).

C34W826A

(When reassembling)
Apply the grease on the O-ring.
Be careful not to damage the modulator valve.

Item Tightening torque

Solenoid Valve 5.8 ~ 7.8 N·m
0.6 ~ 0.8 kgf·m
4.3 ~ 5.7 lbf·ft

Installing the PTO Hydraulic Pipe 3

Regardless of nut sizes of the bite-type connecting
pipe, to properly fasten the nut, rotate the nut to the C34W827A
following degrees after the point of drastic increase of
torque from tightening the nut on the connecting pipe. (1) Seat Assembly (6) PTO Solenoid
• Min. tightening angle: 1/6 turns (2) Rubber Mat (7) Bolt
• Max. tightening angle: 1/3 turns (3) PTO Hydraulic Pipe 3 (8) Nut
(4) Connector (9) Modulator Valve
(5) Bolt

8-22 C34-WOO May. 2005

 HYDRAULIC SYSTEM

3.5 HORIZONTAL CONTROL SYSTEM

A. CHECKING
Relief Pressure Check
1. Disconnect the hydraulic hose RL2 (2) of the hori-
zontal control cylinder (1).
2. Install the inspection adapter to the cylinder and
connect the hydraulic hose RL2.
3. Start the engine and set the conditions as below.
4. Operate the lift cylinder and measure the pressure.
5. If the measured value is out of the specified range,
check the tightening torques and components
conditions, and replace if necessary.

Test Conditions C34W828A

Engine speed 2200 rpm (1) Horizontal Control Cylinder

Transmission oil temperature 45 ~ 55°C (2) Hydraulic Hose RL2
2
Relief valve setting pressure 170 ~ 175 kgf/cm
166.7 ~ 171.6 bar
2,418 ~ 2,489 psi

Item Tightening torque

Hydraulic hose RL2 24.5 N·m
2.5 kgf·m
18.0 lbf·ft

C34-WOO May. 2005 8-23

CHAPTER 8 DK651/751/801/901

Horizontal Control Setting (When Installing

New Cable)
1. Turn on the automatic horizontal switch (1) and set
the horizontal control dial (2) to the center position.
2. Install the sensor cable (3) to the bracket (4) as
shown in figure.
3. Install the cable wire to the lever (5).
4. Install the cable to the lift cylinder bracket (6) so that
the screw is located at center position.
5. Connect the cable wire to the lift cylinder pin (7).
6. Start the engine and move up and down the exter-
nal horizontal control switch.
7. Tighten the nut at the point where the length of cyl- C34W829A
inder is not changed anymore when operating the
switch.

Item Factory Spec.

Setting length of 84 ± 1 mm
cylinder rod (A) (3.307 ± 0.039 in.)

8. After adjustment of lift cylinder, adjust the length of

left lift rod so that each distance from ground to lower
link at both sides is same.

Item Factory Spec.

Step difference between ± 5 mm
left and right lower links (± 0.197 in.)
(B)
C34W830A

C34W831A

(1) Automatic Horizontal Switch

(2) Automatic Horizontal Dial
(3) Sensor Cable
(4) Bracket
(5) Lever
(6) Lift Cylinder Bracket
(7) Lift Cylinder Pin

8-24 C34-WOO May. 2005

 HYDRAULIC SYSTEM

B. REMOVING
1. Remove the seat assembly (1).
2. Remove the rubber mat under the seat (2). (DK751/
801/901)
3. Remove the seat support plate.
4. Remove the horizontal control sensor cable (3).
5. Disconnect the two harness connectors (4).
6. Set the lower link (5).
7. Unscrew the joint bolt and remove the hydraulic
pipes (J1, J2) (6, 7).
8. Remove the hydraulic pipes (RL1, RL2) (8) and
the return hose (9).
9. Unscrew the bolt (10) and remove the horizontal C34W832A

control valve (11).

10. Pull out the pin and remove the lift cylinder (12).

(When assembling)
Set the horizontal control after installation.

Item Tightening torque

Joint bolt 39.2 ~ 44.1 N·m
4.0 ~ 4.5 kgf·m
28.9 ~ 32.5 lbf·ft
Hydraulic hose (RL1, 24.5 N·m
RL2) and return hose 2.5 kgf·m
18.0 lbf·ft
C34W833A

C34W834A

(1) Seat Assembly (8) Hydraulic Hose

(2) Rubber Mat (RL1, RL2)
(3) Horizontal Control (9) Return Hose
Sensor Cable (10) Bolt
(4) Connector (11) Horizontal Control
(5) Lower Link Valve
(6) Hydraulic Pipe (J1) (12) Lift Cylinder
(7) Hydraulic Pipe (J2)

C34-WOO May. 2005 8-25

CHAPTER 8 DK651/751/801/901

3.6 HYDRAULIC LIFT SYSTEM

A. REMOVING HYDRAULIC LIFT CYLINDER

Draining Coolant

CAUTION
• Never remove the radiator cap when the engine
is hot.
• Relieve any excess pressure before removing the
cap completely.

1. Stop the engine and let cool down.

2. Open the bonnect and remove the radiator drain
cock (2) and radiator cap (1) to drain the coolant.
C34W835A
3. After all coolant is drained, close the drain plug.

Coolant DK651 9.1

capacity (2.4 U.S.gal.)
DK751/801/ 18.5
901 (4.8U.S.gal.)

(Filling)
• Fill coolant fully into the radiator, and fill it up the
point between “Full” and “Low” mark on the coolant
recovery tank (3).

C34W836A

(1) Radiator Cap (2) Drain Cock

(3) Coolant Recovery Tank

Removing Bonnet
1. Open the bonnet (1) and disconnect the battery
negative cable.
2. Remove the both side covers (LH, RH) (2).
3. Remove the bonnet wiring harness (3).
4. Unscrew the bolts and remove the bonnet support
1 (4) and 2 (5).
5. Unscrew the nuts and remove the bonnet.

NOTE:
• When disconnecting the battery cables, disconnect
the negative (-) cable first, when connecting, (+)
cable first. C34W837A

(1) Bonet (4) Bonet Support 1

(2) Side cover (LH, RH) (5) Bonet Support 2
(3) Bonet Wiring Harness

8-26 C34-WOO May. 2005

 HYDRAULIC SYSTEM

Removing Muffler Pipe DK651

1. Remove the nut (1) and washer from the muffler
support.
2. Unscrew the bolts from the muffler (2) and remove
the muffler pipe (3).
3. Unscrew the bolts and remove the muffler cover 2 (4).
4. Remove the snap pin, plain washer, head pin and
bonnet support cylinder (5).
5. Unscrew the nuts and bolts and remove the muffler
(2).

(1) Nut (4) Heat Shield

(2) Muffler (5) Bonnet Support Cylinder
(3) Muffler Pipe DK751/801/901

C34W838A

Removing Bonnet Support DK651

1. Unscrew the bolts and separate the right shield
plate (1) from the bonnet support (5).
2. Unscrew the bolts and separate the guide plate (3)
from the left shield plate (2).
3. Remove the air bleeder hose (4) from the fuel tank.
4. Unscrew the bolts and remove the fuse box (6) from
the shield plate.
5. Unscrew the bolts and separate the left shield plate
(2) from the bonnet support (5).
6. Unscrew the bolts and remove the bonnet support (5).

(1) Shield Plate (RH) (4) Air Bleeder Hose C34W839A

(2) Shield Plate (LH) (5) Bonnet Support DK751/801/901

(3) Guide Plate (6) Fuse Box

C34W840A

C34-WOO May. 2005 8-27

CHAPTER 8 DK651/751/801/901

F. REMOVING HYDRAULIC PIPES AND DK651

HEATER HOSES
1. Unscrew the bolts and remove the brake oil reser-
voir (1). Drain the brake oil completely.
2. Remove the steering hose (2) (T).
3. Remove the brake hoses (3) (LH, RH).
4. Remove the steering hoses (4) (LH, RH).
5. Remove the clutch hose (5).
6. Remove the steering hose (6) (P) behind the left
fuel tank.
7. Release the pipe band and remove the heater hose
(7).
8. Remove the accelerator pedal wire cable (8).

Item Tightening torque

Clutch and brake hose 19.6 ~ 23.5 N·m
2.0 ~ 2.4 kgf·m
14.4 ~ 17.3 lbf·ft
Steering L, R 24.5 N·m
hose 2.5 kgf·m
18 lbf·ft
P, T 34.3 N·m
3.5 kgf·m
25.3 lbf·ft
Pipe bend 9.8 N·m
C34W844A
1 kgf·m
7.2 lbf·ft
DK751/801/901

(When reassembling)
• Locate the pipe band before tightening.
- Pipe band may interfere with the bolts.
- Hose Types:
Steering hose P: A red tag attachment
Steering hose R: A white tag attachment
Steering hose L: A yellow tag attachment
Steering hose T: A blue tag attachment
• Bleed the air form the systems (Clutch: page 3-18,
Brake: page 6-9).

(1) Brake Oil Reservoir (5) Clutch Hose

(2) Steering Hose T (6) Steering Hose P
(3) Brake Hose (7) Heater Hose
(4) Steering Hose L, R (8) Accelerator Wire Cable

C34W845A

8-28 C34-WOO May. 2005

 HYDRAULIC SYSTEM

Removing Cabin
1. Unscrew the bolts and remove the seat assembly
(1).
2. Remove the rubber mat (2).

C34W848A

(1) Seat Assembly (2) Rubber Mat

3. Remove the grips of front wheel drive lever (2) and

the PTO lever (1) and the flexible rubber cover (5)
and the steel plate (4).
4. Remove the grip of shuttle lever (3) and flexible rub-
ber cover (5).

C34W849A

(1) PTO Lever

(2) Front Wheel Drive Lever
(3) Shuttle Lever
(4) Steel Plate
(5) Flexible Rubber Cover

5. Unscrew the bolts and slide up the flexible rubber

cover (1) to remove the main shift lever (2) and the
range shift lever (3).
6. Release the lever guide (4), disconnect the harness
connector (5) of lateral control switch (6), and re-
move the steel plate (7). (if equipped)

C34W850A

(1) Flexible Rubber Cover

(2) Main Shift Lever (5) Connector
(3) Auxiliary Shift Lever (6) Lateral Control Switch
(4) Lever Guide (7) Plate
C34-WOO May. 2005 8-29
CHAPTER 8 DK651/751/801/901

7. Open the inspection window and disconnect the har-

ness connectors.

C34W851A

8. Support the transmission with a removing jack (1),

remove the rear tires, and install the safety stands
(2) under the rear axle housing.

C34W852A

9. Open the left inspection window and disengage the

parking brake cable (3) from the brake cam lever.

C34W853A

8-30 C34-WOO May. 2005

 HYDRAULIC SYSTEM

10. Open the right inspection window. Disengage the

MSL lever (4) joint, remote valve lever rod, rear
differential lever rod, position control lever (6) con-
necting rod, draft control lever connecting rod, front
differential cable (7) and harness connector (8)
(parking brake and position control micro switch).
11. Remove the A/C valve (9) under the left side of
cabin.
12. Bind the cabin with a nylon rope.
13. Carefully raise the cabin with a hoist wile pulling
out the joystick lever. Remove the cabin
completely.

Item Tightening torque

Rear tire M18 (7T) 274.5 ~ 318.7 N·m
28 ~ 32.5 kgf·m
202.5 ~ 235 lbf·ft
Cabin M16 (7T) 196.1 ~ 144.6 N·m
mounting 20 ~ 23 kgf·m
bolt/nut
225.5 ~ 166.3 lbf·ft
A/C valve 24.5 ~ 34.3 N·m
2.5 ~ 3.5 kgf·m
18 ~ 25.3 lbf·ft

C34W854A

(1) Removing Jack

(2) Safety Stand
(3) Parking Brake Cable
(4) MLS Lever
(5) Rear Differential Lever
(6) Position Control Lever
(7) Front Differential Cable
(8) Harness Connector
(9) A/C Valve

C34-WOO May. 2005 8-31

CHAPTER 8 DK651/751/801/901

Removing 3-point Link

1. Disengage the lift cylinder (4) from the lower link
(1).
2. Remove the horizontal control wire (2).
3. Remove the hydraulic hoses (RL1, RL2) (3).
4. Remove the lift cylinder (4).
5. Remove the lower link (1).

(When assembling)
Item Tightening torque
Hydraulic hose 24.5 N·m
2.5 kgf·m C34W855A

18.0 lbf·ft
(1) Lower Link
Reset the horizontal control position (Refer to page 8-24). (2) Horizontal Control Wire
(3) Hydraulic Hose (RL1, RL2)
(4) Elevating Cylinder

Removing Hydraulic Lift Cylinder

1. Unscrew the bolts (1) and remove the hydraulic
pipes (A, B, C, D).
2. Remove the hydraulic pipes (VA, VB) (2).
3. Unscrew the bolts and socket support assembly
and lowering control valve (3).
4. Unscrew the nuts and remove the remote valve as-
sembly (4).
5. Remove the return hose and the hydraulic pipes
(J1, J2) (5, 6).
6. Unscrew the bolts and remove the horizontal con-
trol valve (7).
7. Unscrew the bolts and remove the hydraulic lift cyl- C34W856A
inder (8).
(When reassembling) (1) Eye Bolt
• Check all O-rings for damage. (2) Hydraulic Pipe (VA, VB)

• Apply liquid gasket (Threebond 1208D or equivalent) (3) Lowering Control Valve
to mating surface of the hydraulic cylinder and trans- (4) Reciprocating Valve Assembly
mission housing. (5) Hydraulic Pipe (J1)
Installing the hydraulic pipe (6) Hydraulic Pipe (J2)
Bite Regardless of nut sizes of the bite-type connect- (7) Lateral Control Valve
ing pipe, to properly fasten the nut, rotate the nut to the (8) Hydraulic Lift Cylinder
following degrees after the point of drastic increase of
torque from tightening the nut on the connecting pipe.
- Min. tightening angle: 1/6 turns
- Max. tightening angle: 1/3 turns

Item Tightening torque

Hydraulic bolt 34.3 ~ 39.2 N·m
3.5 ~ 4.0 kgf·m
25.3 ~ 28.9 lbf·ft
Hydraulic lift M12 (7T) 77.4 ~ 90.2 N·m
cylinder mount- 7.9 ~ 9.2 kgf·m
ing bolt
57.1 ~ 66.5 lbf·ft

8-32 C34-WOO May. 2005

 HYDRAULIC SYSTEM

B. DISASSEMBLING HYDRAULIC LIFT CYLIN-

DER
Hydraulic Lift Control Lever
1. Remove the screw (1) from the internal link in cylin-
der assembly.
2. Unscrew the bolts (2) and remove the relevant parts
as an assembly.

C34W857A

(1) Screw (13) Flange

(2) Bolt (14) Clutch Hub
(3) Spring Washer (15) Spring
(4) Gasket (16) Bolt
(5) Support (17) Spring Washer
(6) Pitman Arm (18) Bolt
(7) Clutch (19) Shaft
(8) Spring (20) Clutch
(9) Bolt (21) Control Lever
(10) Clutch Hub (22) Snap Ring
(11) O-ring (21) Screw
(12) Snap Ring

Control Valve (MLS Valve)

1. Unscrew the control valve mounting bolts (1).
2. Remove the control valve (2).

(When assembling)
• Be careful not to damage O-ring.

Item Tightening torque

Mounting bolt 23.6 ~ 27.4 N·m
2.4 ~ 2.8 kgf·m
17.4 ~ 20.2 lbf·ft

C34W858A

(1) Bolt
(2) Control Valve Assembly
(3) Power Lift Body (Hydraulic Cylinder Block)

C34-WOO May. 2005 8-33

CHAPTER 8 DK651/751/801/901

Lifting Arm, Hydraulic Cylinder And Hydrau-

lic Arm Shaft
1. Remove the cylinder mounting screws (13, 16) and
the crank mounting screw (6).
2. Remove the snap ring (1). Remove the hydraulic
arm shaft and the lifting arm while tapping them
with a urethan hammer.
3. Remove the hydraulic cylinder (14), piston (11), con-
necting rod (10) and crank (7).

(When reassembling)
1. Carefully insert the seal (12) onto the piston (11).
2. Apply the transmission oil to the cylinder, and then C34W859A
install the piston (11).
3. Apply the grease to the bottom of piston (11) con- (1) Snap Ring (9) Pin
tacting to connecting rod (10). (2) Elevating Arm (LH) (10) Connecting Rod
4. Align the holes of shaft (8) and crank (7). (A, B) (3) Elevating Arm (RH) (11) Piston
5. Apply the grease to the right and left bushings of (4) Washer (12) Seal
power lift body.
(5) Seal (13) Screw
(6) Screw (14) Cylinder
(7) Crank (15) O-ring
(8) Shaft (16) Screw

Bushings
1. Remove the bushings (1, 2).

(When reassembling)
• Apply the transmission oil to the hydraulic cylinder
boss and bushings.

C34W860A

(1) Bush (2) Bush

8-34 C34-WOO May. 2005

 HYDRAULIC SYSTEM

Top Link Bracket

C34W861A

(1) Plate (7) Top Link Bracket (13) Lock Washer (19) O-ring
(2) Roller (8) Tie Rod (14) Lock Washer (20) Pin
(3) Closing Flange (9) Bolt (15) Spring Fix (21) Pin
(4) Spring (10) Bolt (16) Pin (22) Bushing
(5) Tie Rod (11) Nut (17) Pin (23) Grease Nipple
(6) Crank (12) Nut (18) Spring Fix

1. Remove the socket support and coupler socket as-

sembly before disassembling the top link bracket
assembly.
2. Remove the bolt (9), lock washer (13), Tie rod (8)
and plate (1).
3. Remove the nut (12).
4. Remove the spring pin (20) and pin (16).
5. Remove the top link bracket (7).

CAUTION
• Be careful not to drop top link bracket (7) to the
ground when removing pin (16).

C34-WOO May. 2005 8-35

CHAPTER 8 DK651/751/801/901

C. CONTROL (MLS) VALVE DISASSEMBLY,

ASSEMBLY AND INSPECTION
1. Remove the control valve from the housing
(Hydraulic cylinder).
2. Remove the O-rings (1) from outside of the body.

C34W862A

(1) O-ring

3. Remove the rubber cover (3) from the speed control

shaft (4).
4. Remove the three socket head cap (5) screws (2)
securing to the body (1) of the rockshaft control
valve.

C34W863A

(1) Control Valve Body

(2) Socket Head Cap Screws
(3) Rubber Cover
(4) Speed Control Shaft
(5) Head Cap

5. Remove the spool valve (1) from the head end of

body (3).
6. Remove the speed control valve (2) from head end
of the body (3).

C34W864A

(1) Spool Valve (3) Body

(2) Speed Control Valve

8-36 C34-WOO May. 2005

 HYDRAULIC SYSTEM

CAUTION
• Valves are composed of matched components
(spools, springs, body, etc.). If any component
shows wear, the entire valve must be replaced.
• Orientation of balancing passage in one end of
the spool is very important. This balancing pas-
sage must be assembled facing towards the cap
of spool valve.

7. Inspect the components for wear. Replace as

required.

C34W865A

(1) Pilot Spool (6) Pin

(2) Spring (7) Valve
(3) Valve (8) Seat Valve
(4) Plug (9) Spring
(5) Lever Ass’y (10) Valve

8. Screw a bolt into the valve located under the speed

control valve (1) and remove the valve (4).
9. Remove the spring (2) and ball under valve.
10. Inspect components for wear paying special at-
tention to valve and seats. Replace as required.

IMPORTANT
• The e nd plate is under tension from valve
springs. Do not remove the socket head cap
screws securing the end plate to the body with-
out retaining the head as indicated in the story.
Do not disturb the set screw with the lock nut!
C34W866A
Removing this screw will change internal relief
pressures!
(1) Valve (4) O-ring
(2) Spring (5) Body
(3) Pilot Spool

C34-WOO May. 2005 8-37

CHAPTER 8 DK651/751/801/901

11. Remove the center socket head cap screw (2).

Secure one of the socket head cap screw (2) that
were used to secure head to body (4) (longer than
plate screw) in center hole.
12. Place the valve, head end down, on a level sur-
face to reduce the chance of loosing internal
components.
13. Back off all three screws evenly until two outside
screws disengage from threads in the body. At
this point the spring tension will be relieved to a
safe level. Unscrew the center screw and remove.

C34W867A

(1) End Plate

(2) Socket Head Cap Screws
(3) Set Screw Lock Nut (4) Body

14. Remove the end plate (2), spring (1) and valve
spool (7) as a unit.
15. Note the location of spacers (4), plug, piston (3)
and spring followers (5).

C34W868A

(1) Spring (5) Spring Followers

(2) End Plate (6) Valve Seat
(3) Piston (7) Control Spool
(4) Spacers

16. Compress the spring (3) until it is free of spring

pocket (2). Remove the spring (3) and valve spool
from end plate (1).

C34W869A

(1) End Plate (3) Spring

(2) Spring Pocket (4) Control Spool

8-38 C34-WOO May. 2005

 HYDRAULIC SYSTEM

17. Remove the spacers (2).

18. Remove the spring follower (1) and spring (3) from
body.

C34W870A

(1) Spring Follower (3) Spring

(2) Spacers

19. Use magnet to remove the ball from body. Also

remove the ball seat if it did not come out with the
spring.

C34W871A

20. Remove the valve seat (2) from the body.

C34W872A

(1) O-ring (2) Valve Seat

C34-WOO May. 2005 8-39

CHAPTER 8 DK651/751/801/901

21. Remove the pilot valve (1) from body.

C34W873A

(1) Pilot Valve

22. Remove the piston (1) and the piston spring (3)
from the body.
23. Inspect the O-ring (2) on the piston (1). Replace it
if damaged.

C34W874A

(1) Piston (3) Spring

(2) O-ring

C34W875A

(1) Spring

8-40 C34-WOO May. 2005

 HYDRAULIC SYSTEM

24. Remove the spool (1) from body.

C34W876A

(1) Spool

25. Remove the orifice screw (1) from side of the body.
26. Make sure the hole in the orifice screw is not
plugged or damaged.

IMPORTANT
• DO NOT attempt to remove balls used to black
drill passages in body.

27. Clean body and components in suitable solvent.

Carefully blow out all passages in the body with
compressed air.
28. Inspect the body and all components for wear of
damage. Pay special attention to be sure that the C34W877A
ports and small passages are clean and open.
Replace as required. (1) Orifice Screw

CAUTION
• Individual components of speed control valve
are not serviceable. If the body and/or compo-
nents are worn or damaged the entire speed con-
trol valve must be replaced as a unit.

(Assembly)

CAUTION
• Assembly is carried out in reverse order of
disassembly.
• Lubricate all components liberally with hydrau-
lic fluid during assembly.
• Always install new O-rings when reassembling
components.

C34-WOO May. 2005 8-41

CHAPTER 8 DK651/751/801/901

• Make sure that the balancing passage (2) in the

spool (1) is facing the cap (4) of the spool valve.

C34W878A

(1) Spool (3) Body

(2) Balancing Passage (4) Cap

• Make sure that flat (2) on speed control valve lines

up with flat (2) on the inside of the cover (1).

C34W879A

(1) Cover (3) Flat

(2) Flat

• Secure the head (3) to the body (2) with socket

head cap screws (1).
• Replace the rubber cover (5) on the speed control
shaft (4).

C34W880A

(1) Socket Head Cap Screws

(2) Body
(3) Head
(4) Speed Control Shaft
(5) Rubber Cover

8-42 C34-WOO May. 2005

 HYDRAULIC SYSTEM

D. CHECK AND ADJUSTMENT

a . Hydraulic Cylinder Bore

1. Check the cylinder’s inside surface for scratchs or
damage.
2. Using a cylinder gauge, measure the cylinder I.D.
3. If the measured value exceeds the allowable limits,
replace the hydraulic cylinder block.

Item Factory spec.

Cylinder Reference φ 110 ~ φ 110.054 mm
I.D. (A) dimension φ 4.330 ~ φ 4.333 in.
Allowable φ 110.150 mm C34W881A
limit φ 4.337 in.

b. Clearance Relationship Between Hydraulic

Arm Shaft and Bush
1. Using a O.D. micrometer, measure the hydraulic
arm O.D.
2. Using a I.D. micrometer, measure the bush I.D. and
then calculate the clearance.
3. If the calculated clearance exceeds the allowable
limits, replace the bush.

Item Factory spec.

Hydraulic Right Reference 0.125 ~ 0.230 mm
arm shaft allowable 0.00492 ~ 0.00906 in.
O.D.
Allowable 0.50 mm
C34W882A
limit 0.0197 in.
Left Reference 0.125 ~ 0.220 mm
dimension 0.00492 ~ 0.00866 in.
Allowable 0.50 mm
limit 0.0197 in.

Item Factory spec.

Hydraulic Right (A) 49.970 ~ 49.940 mm
arm shaft 1.96732 ~ 1.96614 in.
O.D.
Left (B) 44.975 ~ 44.950 mm
1.77066 ~ 1.76968 in.

Item Factory spec.

Bush I.D. Right (A1) 50.075 ~ 50.115 mm
(After 1.97145 ~ 1.97303 in.
assembled)
Left (B1) 45.075 ~ 45.115 mm
1.77460 ~ 1.77618 in.

C34-WOO May. 2005 8-43

CHAPTER 8 DK651/751/801/901

c. Reaction Spring Assembly Reference Dimen-

sion

Item Factory spec.

Reaction Reference 50 mm
spring dimension 1.9685 in.
assembly
initlal
length (L)

C34W883A

(1) Spring (3) Nut

(2) Hex. Bolt

d. Dimensional Setting of Position Control Bolt

1. When assembling the control valve (MLS valve)
into power lift body, “A” dimension will be 112
mm (4.409 in.).
2. If adjusting the control bolt (1), loosen nut (2) and
then tighten-lock nut (2).

Item Factory spec.

Reference “A” Setting 112 mm
dimension length 4.4094 in.
“B” Setting 50.5 mm
length 1.9881 in.

C34W884A

(1) Control Bolt

(2) Nut

8-44 C34-WOO May. 2005

 HYDRAULIC SYSTEM

e . Lever Position Setting

• Adjustment of Position Control Lever
The position control lever can be adjusted with a small
load applied to the elevating arm.
1. Loosen the position control shaft (3), and lever tight-
ening bolt (4).
2. Using a 13 mm (0.512 in.) spanner, rotate the posi-
tion control shaft (3) counterclockwise until the el-
evating arm has stopped to climb by the inside hy-
draulic limit. Because of safety, the area, although
the elevating arm is at it’s maximum angle, will never
contact the hydraulic limit switch.
3. Elevate the lever up and down two or three times.
C34W885A
Check it for operation and make sure it is located at
the same position that you set it at.
(1) Position Control Lever
(2) Draft Control Lever
(3) Position Control Shaft
(4) Hex. Bolt
(5) Lifting Arm

[A] Hydraulic Lifting Arm at End of Stroke

[E] Back Stop
[F] Back Stop

• Draft Control Lever (If equipped)

1. Lower the elevating arm, loosen the lock nut (1)
and push backward.
2. Disengage the lock bolt (4).
3. Adjust the length of the feedback rod (2).

Item Factory spec.

Reference Length of 135 mm
dimension feedback rod 5.3149 in.
(L)

4. With minimum rpm, lower the position control lever

(6) to the stopper (8), and then slowly raise the Draft
control lever (5) toward the stopper (7) so that the C34W886A
elevating arm might be raised.
5. Decrease and adjust the length (L) of feedback rod (1) Nut
gradually one rotation a time, until the rod smooth (2) Feedback Rod
lowers. (3) Position Control Shaft
6. After a completion of the adjustment, tighten the nut (4) Hex. Bolt
(1) and lock bolt (4).
(5) Draft Control Lever
(Ref.) (6) Position Control Lever
When raised to max. using the Draft control lever, height (7) Stopper
(H) will be higher between 15 and 20 mm (0.591 ~ 0.787 (8) Stopper
in.) than the max, using the position control lever.

C34-WOO May. 2005 8-45

CHAPTER 8 DK651/751/801/901

f. Sensibility Adjustment
Position the rockshaft lifting arms, with a weight applied,
so that they reach about half their angular movement
range.
In this way the Control Valve is positioned in its neutral
phase.
Loosen nut “A” and turn the embedded hexagonal
screw “B” in a counter direction until the lifting arms
start swaying continuously.
With a slow movement stop the movement of the arms
by rotating screw “B” in a clockwise direction.
When the arms remain blocked in their position, which
can be controlled with the relevant instrument posi-
tioned on the end of the lifting arm, rotate(clockwise) C34W887A
the screw “B” for 1/2~3/4 of a turn max. Llock the posi-
tion with the self-locking nut “A”. (A) Nut (B) Screw
In this way the Control Valve is sensitivity adjusted.

8-46 C34-WOO May. 2005