HL750 3

WHEEL LOADER HYUNDAI HL750-3
HL750-3 Service Manual Open index screen
CONTENTS
Foreword
SECTION 1 GENERAL
Group 1 Safety Hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Group 2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Group 3 Operational checkout record sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
SECTION 2 ENGINE
Group 1 Structure and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
SECTION 3 POWER TRAIN SYSTEM

Group 1 Structure and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Group 2 Operational checks and troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Group 3 Tests and adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
Group 4 Disassembly and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
SECTION 4 BRAKE SYSTEM

SECTION 5 STEERING SYSTEM

SECTION 6 WORK EQUIPMENT

SECTION 7 ELECTRICAL SYSTEM

Group 1 Component location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Group 2 Electrical circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Group 3 Monitoring system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
Group 4 Electrical component specification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33
Group 5 Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-42
Group 6 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-59
FOREWORD
1. STRUCTURE
This service manual has been prepared as an aid to improve the quality of repairs by giving the
serviceman an accurate understanding of the product and by showing him the correct way to perform
repairs and make judgements. Make sure you understand the contents of this manual and use it to
full effect at every opportunity.
This service manual mainly contains the necessary technical information for operations performed in
a service workshop.
For ease of understanding, the manual is divided into the following sections.
Structure and function

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Unexpected machine movement can cause
serious injury.
Before performing any work on the wheel loader,
attach aųDo Not OperateŴtag on the right side
controller lever. WARN
DO
NOT
OPERATE
USE HANDHOLDS AND STEPS

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Make certain all parts are reinstalled correctly if the
roll-over protective structure(ROPS) is loosened or
removed for any reason. Tighten mounting bolts
to proper torque.
The protection offered by ROPS will be impaired if
ROPS is subjected to structural damage, is
involved in an overturn incident, or is in any way
altered by welding, bending, drilling, or cutting. A
damaged ROPS should be replaced, not reused.
1-9
GROUP 2 SPECIFICATIONS
1. MAJOR COMPONENT
Tooth Bucket Tire Head light Hydraulic tank Air cleaner Radiator
Main control valve Boom cylinder Main pump Precleaner Battery Rear combination lamp
Bucket link Bell crank Bucket cylinder Cab Engine Muffler Counterweight
Boom Front axle Steering cylinder Step Transmission Rear axle Fuel tank Step
1-10
2. SPECIFICATIONS
1) WITHOUT TOOTH AND CUTTING EDGE TYPE BUCKET
B
F
J
I
5025
H
3741
3015
K
40
C
50
5900 50
D
E 1698
A
Description Unit Specification

Operating weight kg(lb) 12645(27819)
Struck 1.9(2.5)
Bucket capacity m3(yd3)
Heaped 2.2(2.9)
Overall length A 6885(22' 7")
Overall width B 2600( 8' 6")
Overall height C 3300(10' 10")
Ground clearance D 412( 1' 4")
Wheelbase E mm(ft-in) 2900( 9' 6")
Tread F 1930( 6' 4")
Dump clearance at 45 G 2828( 9' 3")
Dump reach H 942( 3' 1")
Width over tires I 2460( 8' 1")
Dump angle J 45
Degree ( )
Roll back angle(Carry position) K 46.3
Lift(With load) 6.4
Cycle time Dump(With load) sec 1.2
Lower(Empty) 3.2
Maximum travel speed km/hr(mph) 39(24.3)
Braking distance 12(39' 4")
m(ft-in)
Minimum turning radius 5.9(19' 4")
Gradability Degree ( ) 30
First gear 6.2(3.8)
Second gear 13.0(8.1)
Forward
Third gear 26.0(16.3)
Travel speed Fourth gear km/hr(mph) 39.0(24.3)
First gear 6.2(3.8)
Reverse Second gear 13.0(8.1)
1-11
2) BOLT-ON CUTTING EDGE TYPE BUCKET
B
F
J
I
5025
H
3741
3015
K
G
40
C
50
5925 50
D
E 1698
A

Struck 2.0(2.6)
Heaped 2.3(3.0)
Tread F 1930( 6' 4")
Dump angle J 45
Degree ( )
Lift(With load) 6.4
Lower(Empty) 3.2
m(ft-in)
Minimum turning radius 5.9(19' 4")
First gear 6.2(3.8)
Forward
First gear 6.2(3.8)
1-12
3) WITH TOOTH TYPE BUCKET
B
F
J
I
5025
H
3741
3015
K
40
C
50
5980 50
D
E 1698
A

Struck 1.9(2.5)
Heaped 2.2(2.9)
Tread F 1930( 6' 4")
Dump angle J 45
Degree ( )
Lift(With load) 6.4
Lower(Empty) 3.2
m(ft-in)
Minimum turning radius 6(19' 8")
First gear 6.2(3.8)
Forward
First gear 6.2(3.8)
1-13
3. WEIGHT
HL750
Item
kg lb
Front frame assembly 1055 2326
Rear frame assembly 1400 3086
Front fender 54 119
Rear fender 30 66
Counterweight 410 904
Cab 580 1279
Engine assembly 424 935
Transmission 316 697
Drive shaft(T/M to F/D Front) 23 51
Drive shaft(T/M to F/D, Rear) 18 40
Front axle(Include differential) 702 1548
Rear axle(Include differential) 715 1576
Tire 1277 2815
Hydraulic tank 153 337
Fuel tank 212 467
Main pump assembly 22 49
Main control valve 34 75
Boom 828 1825
Bell crank 240 529
Bucket link 46 101
2.3m bucket, with bolt on cutting edge
3
1100 2425
2.2m3 bucket, with tooth 1030 2271
2.2m bucket, without tooth and cutting edge
3
940 2072
Boom cylinder assembly 218 481
Bucket cylinder assembly 124 273
Steering cylinder assembly 41 90
Air tank 13 29
Seat 40 88
Battery 44 97
1-14
4. SPECIFICATION FOR MAJOR COMPONENTS
1) ENGINE
Item Specification
Model Cummins B5.9-C

Type 4-cycle turbocharged diesel engine
Cooling method Water cooling
Number of cylinders and arrangement 6 cylinders, in-line
Firing order 1-5-3-6-2-4
Combustion chamber type Direct injection type
Cylinder bore stroke 102 120mm(4.02" 4.72")
Piston displacement 5880cc(352.8cu in)
Compression ratio 17.5 : 1
Rated gross horse power 150ps at 2200rpm
Maximum gross torque at 1600rpm 61kgf m(441lbf ft)
Engine oil quantity 16.4 (4.3 U.S. gal)
Dry weight 400kg(881.8lb)
High idling speed 2370 50rpm
Low idling speed 950 50rpm
Rated fuel consumption 172g/ps hr
Starting motor Delco Remy 37MT(24V)
Alternator DAC HC60(24V-60AMP)
Battery 2 12V 160Ah
2) MAIN PUMP
Item Specification
Type Fixed displacement tandem gear pump

Capacity 2 41.0cc/rev
Maximum operating pressure 210kg/cm2(3000psi)
Rated oil quantity 2 91 / min (24.0 U.S. gpm/20.0 U.K. gpm)
Rated speed 2300rpm
1-15
3) BRAKE PUMP
Item Specification
Type Fixed displacement tandem gear pump

Capacity 8.4cc/rev
Maximum operating pressure 150kg/cm2(2130psi)
Rated oil quantity 18 / min (4.75U.S. gpm/4.0U.K. gpm)
4) MAIN CONTROL VALVE
Item Specification
Type 2 spool
Operating method Hydraulic pilot assist
Main relief valve pressure 210kg/cm2(3000psi)
Overload relief valve pressure 230~250kg/cm2(3270~3560psi)
5) REMOTE CONTROL VALVE
Item Specification
Type Pressure reducing type

Minimum 5.8kg/cm2(82.5psi)
Operating
Maximum 30kg/cm2(427psi)
Single operation stroke Lever 75mm(3.0in)
6) CYLINDER
Item Specification
Boom cylinder Bore dia Rod dia Stroke 140 75 695mm

Bucket cylinder Bore dia Rod dia Stroke 150 80 475mm
Steering cylinder Bore dia Rod dia Stroke 70 40 430mm
1-16
7) DYNAMIC POWER TRANSMISSION DEVICES
Item Specification
Model Clark HR 24423

Torque converter
Type Single-stage, single-phase
Type Semi-automatic power shift
Transmission Gear shift Forward fourth gear, reverse third gear
Adjustment Electrical single lever type, kick-down system
Drive devices 4-wheel drive
Axle Front Front fixed location
Rear Oscillation 26 of center pin-loaded
Wheels Tires 20.5-25, 16PR(L3)
Travel Four-wheel, wet-disc type, full hydraulic
Brakes Spring applied, hydraulic released drum
Parking
brake on T/M output shaft.
Type Full hydraulic, articulated
Steering
Steering angle 40 to both right and left angle, respectively
1-17
5. TIGHTENING TORQUE OF MAJOR COMPONENT
No. Items Size kg m lb ft
1 Engine mounting bolt, nut M10 1.5 6.9 1.4 50 10

Engine
2 Radiator mounting bolt, nut M12 1.75 12.3 2.5 89 18
3 Main pump housing mounting bolt 1/2-13UNC 19.6 2.9 142 21
4 Main control valve mounting socket bolt M10 1.5 6.9 1.4 50 10
5 Orbitrol valve mounting bolt M10 1.5 5 1 36 7.2
6 Priority valve mounting bolt M 8 1.25 2.5 0.5 18 3.6
7 Hydraulic Brake valve mounting bolt M 8 1.25 2.5 0.5 18 3.6
8 system Cut off valve mounting bolt M 8 1.25 2.5 0.5 18 3.6
9 Cushion valve mounting bolt M8 1.25 2.5 0.5 18 3.6
10 Fuel tank mounting bolt M20 2.5 57.9 8.7 419 63
11 Hydraulic oil tank mounting bolt M16 2.0 29.7 4.5 215 32.5
12 Air tank mounting bolt M16 2.0 29.7 4.5 215 32.5
13 Transmission mounting bolt 3/4-10UNC 45 7.3 325 52.8
14 Front axle mounting bolt M20 2.5 57.9 8.7 419 63
Power train
15 Rear axle support mounting bolt, nut M27 2.0 135 15 976 108
system
16 Tire mounting nut M22 1.5 60 2 434 15
17 Drive shaft joint mounting bolt, nut 3/8-24UNF 6 0.8 43 5.8
18 Counterweight mounting bolt M30 3.0 199 29.9 1439 216
19 Operator's seat mounting bolt M 8 1.25 3.4 0.8 25 5
Others
ROPS Cab mounting bolt(12EA) 1-14UNS 86 620
20
ROPS Cab mounting bolt(4EA) 1 1/4-12UNF
1-18
6. TORQUE CHART
Use following table for unspecified torque.
1) BOLT AND NUT
(1) Coarse thread
8T 10T
Bolt size
kg m lb ft kg m lb ft
M 6 1.0 0.85 ~ 1.25 6.15 ~ 9.04 1.14 ~ 1.74 8.2 ~ 12.6
M 8 1.25 2.0 ~ 3.0 14.5 ~ 21.7 2.73 ~ 4.12 19.7 ~ 29.8
M10 1.5 4.0 ~ 6.0 28.9 ~ 43.4 5.5 ~ 8.3 39.8 ~ 60
M12 1.75 7.4 ~ 11.2 53.5 ~ 79.5 9.8 ~ 15.8 71 ~ 114
M14 2.0 12.2 ~ 16.6 88.2 ~ 120 16.7 ~ 22.5 121 ~ 167
M16 2.0 18.6 ~ 25.2 135 ~ 182 25.2 ~ 34.2 182 ~ 247
M18 2.5 25.8 ~ 35.0 187 ~ 253 35.1 ~ 47.5 254 ~ 343
M20 2.5 36.2 ~ 49.0 262 ~ 354 49.2 ~ 66.6 356 ~ 482
M22 2.5 48.3 ~ 63.3 350 ~ 457 65.8 ~ 98.0 476 ~ 709
M24 3.0 62.5 ~ 84.5 452 ~ 611 85.0 ~ 115 615 ~ 832
M30 3.5 124 ~ 168 898 ~ 1214 169 ~ 229 1223 ~ 1655
174 ~ 236 1261 ~ 1703 250 ~ 310 1808 ~ 2242
(2) Fine thread

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

1/4" 19 3 21.7
3/8" 22 4 28.9
1/2" 27 5 36.2
3/4" 36 12 86.8
1" 14 101
3) FITTING
Thread size Width across flat mm kg m lb ft

1/4" 19 4 28.9
3/8" 22 5 36.2
1/2" 27 6 43.4
3/4" 36 13 94.0
1" 41 15 109
1-20
7. RECOMMENDED LUBRICANTS
Use only oils listed below or equivalent.
Do not mix different brand oil.
Ambient temperature C( F)
Capacity
Service point Kind of fluid
(U.S. gal) -20 -10 0 10 20 30 40
(-4) (14) (32) (50) (68) (86) (104)
SAE 30
SAE 10W
Engine
Engine oil 16.4(4.3)
oil pan
SAE 10W-30
SAE 15W-40
Torque converter
Oil 25(6.6) DEXRON
Transmission
Front : 39(10.3)
Axle Gear oil Rear : 39(10.3) SAE 80W-90LSD/APIGL-5
Tank: ISO VG 32
108(28.8)
Hydraulic tank Hydraulic oil ISO VG 46
System:
150(39.6) ISO VG 68
ASTM D975 NO. 1

Fuel tank Diesel fuel 203(53.6)
ASTM D975 NO. 2
NLGI NO. 1
Fitting
Grease As required
(Grease nipple)
NLGI NO. 2
Mixture of
antifreeze
Radiator 44(11.6) Ethylene glycol base permanent type
and water
50 : 50
1-21
GROUP 3 OPERATIONAL CHECKOUT RECORD SHEET
şOwner 9
şDate 9
şHours 9
şSerial No. 9
şTechnician 9
Ɠ Use this sheet to record operational

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

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

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

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

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

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

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

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

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

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

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

Front axle Front drive shaft Rear drive shaft Rear axle
The power train consists of the following components:

Transmission
Front and rear drive shafts
Front and rear axles
Engine power is transmitted to the transmission through the torque converter.
The transmission is a hydraulically engaged four speed forward, three speed reverse countershaft type
power shift transmission. A drum type parking brake is located on the front of the transmission output
shaft.
The transmission outputs through universal joints to two drive shaft assemblies. The front drive shaft is
a telescoping shaft which drives the front axle. The front axle is mounted directly to the loader frame.
The front axle is equipped with limited slip differential.
The rear axle is mounted on an oscillating pivot. The rear axle is equipped with limited slip differential.
The torque transmitted to front axle and rear axle is increased by the pinion gear and ring gear of
differential. It then passes from the differential to the sun gear shaft(axle shaft of final drive).
The torque of the sun gear is increased by a planetary mechanism and is transmitted through the
planetary hub to the wheel.
3-1
HYDRAULIC SCHEMATIC
1-2-3
Declutch
To transmission
lube
Cooler
FR
From master
cylinder Charging
Filter pump
assembly
Vent
Converter Clutch
safety valve regulator
Torque
converter Removable
screen
Oil sump
3-2
HYDRAULIC CIRCUIT
Modulation Modulation
valve FWD. valve REV.
Torque REV.
converter Clutch
regulator valve
FWD.LO
Hose B
A FWD H/4
Converter
safety
valve
Cooler C 2
D
1
Filter E
3
Hose Pump
Lubrication
Suction screen
Air breather
Oil sump
Forward Reverse Neutral

1 2 3 4 1 2 3 1 2 3
B X X X
C X
A X X X X
E X X X X X X
D X X X
X : Solenoid activated
3-3
2. TORQUE CONVERTER
Stator
Input side Output side
Turbine Impeller
Torque converter is a stemless transmitting system to transmit engine power by means of hydraulic
force. As usual, this system(torque converter) is consisting of three elements(impeller wheel, turbine
wheel, stator wheel).... the impeller wheel connected to input shaft, the turbine wheel connected to
output shaft and the stator wheel(guide bland) fixed to the housing.
The above impeller wheel and turbine wheel face each other and also, the stator wheel is located
between these two elements. These three elements are enclosed in the oil filled housing.
As the impeller wheel is turned by the engine, centrifugal force causes oil to strike the turbine wheel at
high velocity and forces it to turn.
The stator is provided to change the direction of oil flow after it has gone through the turbine wheel and
send it back to the impeller wheel. At that time, reaction torque is caused and this is added to the
torque of turbine wheel. As a result, the output torque is increased to several times of engine torque.
The output torque becomes the largest when the output shaft is stopped(the torque of output shaft at
that time is called the stalling torque). When the load on the output side decreases, the reaction torque
also decreases and, in contrast with this, the output speed increases.
As explained the above, the torque converter has the working to change output torque automatically in
accordance with strength of load.
Besides, transmitting of torque is done by oil and that results it is possible to slip between the engine
side(output side) and at the same time, mechanical shock can be absorbed.
3-4
3. TRANSMISSION
1) TYPICAL CROSS SECTION
Fwd
Rev 2nd 1st
4th 3rd
3-5
2) TRANSMISSION LAYOUT
B A
F
H
N
G L
K
A Torque converter F Reverse clutch K 3rd clutch

B Charge pump assembly G 1st clutch L 4th clutch
C Pump drive idler gear H 2nd clutch M Output shaft
D Pump drive gear J Idler shaft N Control valve assembly
E Forward clutch
3-6
3) OPERATION OF TRANSMISSION
(1) Forward
① Forward 1st
In 1st forward, FWD clutch and 1st clutch are engaged.
FWD clutch and 1st clutch are actuated by the hydraulic pressure applied to the clutch piston.
Input
Fwd
Rev 2nd 1st
4th 3rd
Idler
Output
3-7
② Forward 2nd
In 2nd forward, FWD clutch and 2nd clutch are engaged.
FWD clutch and 2nd clutch are actuated by the hydraulic pressure applied to the clutch piston.
Input
Fwd
Rev 2nd 1st
4th 3rd
Idler
Output
3-8
③ Forward 3rd
In 3rd forward,FWD clutch and 3rd clutch are engaged.
FWD clutch and 3rd clutch are actuated by the hydraulic pressure applied to the clutch piston.
Input
Fwd
Rev 2nd 1st
4th 3rd
Idler
Output
3-9
④ Forward 4th
In 4th forward, 4th clutch and 3rd clutch are engaged.
4th clutch and 3rd clutch are actuated by the hydraulic pressure applied to the clutch piston.
Input
Fwd
Rev 2nd 1st
4th 3rd
Idler
Output
3-10
(2) Reverse
① Reverse 1st
In 1st reverse, REV clutch and 1st clutch are engaged.
REV clutch and 1st clutch are actuated by the hydraulic pressure applied to the clutch piston.
Input
Fwd
Rev 2nd 1st
4th 3rd
Idler
Output
3-11
② Reverse 2nd
In 2nd reverse, REV clutch and 2nd clutch are engaged.
REV clutch and 2nd clutch are actuated by the hydraulic pressure applied to the clutch piston.
Input
Fwd
Rev 2nd 1st
4th 3rd
Idler
Output
3-12
③ Reverse 3rd
In 3rd reverse, REV clutch and 3rd clutch are engaged.
REV clutch and 3rd clutch are actuated by the hydraulic pressure applied to the clutch piston.
Input
Fwd
Rev 2nd 1st
4th 3rd
Idler
Output
3-13
4) ELECTRIC SOLENOID CONTROL
Direction & Solenoids Clutches

speed energized pressurized
Forward 1st V X Y Forward & 1st

Forward 2nd V X Forward & 2nd
Forward 3rd V Forward & 3rd 2P
Forward 4th V Z 4th & 3rd
Reverse 1st W X Y Reverse & 1st R.C RP 2C
Reverse 2nd W X Reverse & 2nd

1P
Reverse 3rd W Reverse & 3rd
FHP
Pilot and clutch pressure check points
V Z Y
1P 1st pilot Fwd 4th 1st
2P 2nd pilot
2C 2nd clutch
4P(FHP) 4th clutch
W X
RP reverse pilot Rev 2nd
RC reverse clutch
・Energized Inlet
Pilot
pressure
Vent
・De-energized
Vent
3-14
5) EGS FUNCTIONAL DESCRIPTION
(1) Definition of terms
① Selecting UP :
Rotate the shift lever away from the driver. This movement is spring returned.
② Selecting DOWN :
Rotate the shift lever towards the driver. This movement is spring returned.
③ Selecting FORWARD :
Push the shift lever away from the driver. The forward position is a stable shift lever position.
④ Selecting REVERSE :
Pull the shift lever towards the driver. The reverse position is a stable shift lever position.
⑤ Selecting NEUTRAL :
Place the shift lever in the center position. The neutral position is a stable shift lever position.
⑥ Selecting DECLUTCH :
Connect input wire 14 to ground.
⑦ Requesting KICK DOWN :
Push the kick down button mounted on the top of the shift lever.
(2) Display arrangement
1 2 3 4 5 6 7 8
N T F N R EGS
Lamps 1-4 : Indicate the selected lever position / direction(color).

Indicate the selected transmission gear / direction(color).
Lamp N : ON if the transmission is placed in neutral.
Lamp T : Used in self diagnostic modes and for fault signalling.
Lamp S/8 : Used to indicate "standstill" or a possible speed sensor problem.
During the initialization phase after power up, both the N and T lamp are ON. Also when the
EGS controller is malfunctioning both lamps are ON or blink simultaneously.
※ All lamps can have different functions in the diagnostic modes.
3-15
(3) Connector pin designations
Below table lists the function of each EGS connector pin.
Pin Function
1 Battery plus
2 Battery ground
3 Neutral start solenoid(on in neutral)
4 CV solenoid 1
5 CV solenoid 2
6 CV forward solenoid
7 CV reverse solenoid
8 Warning lamp
9 Not used
10 Speed sensor input HOT
11 Speed sensor input GND
12 Speedometer output
13 CV forward HI/LO(splitter) solenoid
14 Declutch input
15 Not used(internally connected with kick down button)
CV : control valve
(4) Selftest functions

The EGS has special circuitry to help verifying its operation.
Three selftest modes are built into the EGS control programs :
・ INPUT TEST
・ SPEED SENSOR TEST + LAMP TEST
・ OUTPUT TEST
① Selftest mode invocation
Below table lists what conditions must be satisfied during POWER UP to get into a specific
selftest mode.
Leaving the selftest mode is done by switching OFF the power of the EGS.
Selftest mode To enter mode
Input test FWD & UP

Speed sensor test REV & UP
Output test FWD & DOWN
② Selftest operation
Selftest operation is described in Electrical system, SECTION 2.
3-16
(5) Functional description
① Selftest of NEUTRAL
At power up, regardless of the shift lever position, the EGS selects neutral. All transmission
outputs are switched off. The neutral start output is switched on only if the shift lever is placed in
the neutral position.
Neutral is selected by moving the shift lever to the center stable position.
Alternatively, neutral can be selected by connecting EGS input wire 14 to ground.(See declutch
feature).
② EGS in NEUTRAL
While in neutral, lamp N is ON.

In order to leave neutral you must make sure EGS input wires 14 is not grounded.
FORWARD is selected by moving the shift lever to the forward position.
REVERSE is selected by moving the shift lever to the reverse position.
At startup, no outputs are activated. When forward or reverse is selected, but the vehicle speed
is too high(above 1000 rpm), neutral remains selected and the warning lamp is switched on. If
the vehicle speed is low(below 800 rpm), the selected direction is engaged in 2nd gear. If vehicle
speed is between these 2 values, neutral 2nd is selected for 1 second in order to slow down the
machine before the direction is engaged.
If the sensor indicates standstill, the S-led lights up GREEN.
③ EGS in FORWARD
In forward, lamps 1-4 light up GREEN indicating the selected lever position.
Upon selection of forward from neutral, 2nd gear forward is selected. However, if before neutral
was selected, 1st gear was obtained due to a shift lever downshift, 1st gear will be engaged.
An UPSHIFT is made by moving the shift lever to the UP position and then returning it to the
center position(spring returned).
Holding the lever in the UP position, gives subsequent upshifts 1.5 seconds spaced in time.
When the speed sensor indicates standstill (S-led on), only 1st and 2nd gear can be selected.
If the sensor fails when driving in a gear higher than 2nd, the gear remains engaged.
Downshifts will be granted, upshifts will be ignored if the gear exceeds or equals 2nd gear.
A DOWNSHIFT is made by moving the shift lever to the DOWN position and then returning it to
the center position(spring returned).
Holding the lever in the DOWN position, gives subsequent downshift 1.5 seconds spaced in
time.
3-17
④ EGS in REVERSE
In reverse, lamps 1-3 light up ORANGE indicating the selected lever position.
Upon selection of reverse from neutral, 2nd gear reverse is selected. However, if before neutral
was selected, 1st gear was obtained due to a shift lever downshift, 1st gear will be engaged.
An UPSHIFT is made by moving the shift lever to the UP position and then returning it to the
center position(spring returned).
Holding the lever in the UP position, gives subsequent upshifts 1.5 seconds spaced in time.
When the speed sensor indicates standstill(S-led on), only 1st and 2nd gear can be selected.
If the sensor fails when driving in a gear higher than 2nd, the gear remains engaged.
Downshifts will be granted, upshifts will be ignored if the gear exceeds or equals 2nd gear.
A DOWNSHIFT is made by moving the shift lever to the DOWN position and then returning it to
the centre position(spring returned).
Holding the lever in the DOWN position, gives subsequent downshift 1.5 seconds spaced in
time.
⑤ Quick shifts
When repeatedly pushing shift lever to the UP or DOWN position and back to the center
position(hold it more than 0.1 second UP/DOWN), the selected lever position alters faster than
when holding the lever to get sequential shifts.
The transmission however creeps towards the selected lever position one gear at a time with
1.5 second interval between shifts.
This is indicated by a blinking lamp indicating the engaged transmission gear position.
⑥ Downshift protection
When a downshift is requested, but the vehicle is driving too fast and danger for overspeeding
exists, the request is stored, but not executed. The warning lamp switches on, indicating the
driver he has to slow down in order to get the requested shift.
The fact that the downshift is not granted is also displayed on the EGS. The led corresponding
to the current gear is blinking, the led corresponding to the requested gear is on.
3-18
⑦ Direction changes
If while driving in one direction, the opposite direction is elected, depending on the vehicle speed
and the gear the transmission is currently in, a different direction change action is made.
The new gear after a direction change is 2nd gear, except if 1st gear was obtained due to a shift
lever downshift. In this case, 1st gear will be selected after the direction change. This gear is
referred to as the fwd-rev gear.
If the current gear does not exceed the fwd-rev gear, fwd-rev gear and the new direction is
engaged if the vehicle speed is not too high. If the vehicle speed is too high, the old direction
remains engaged.
If the current gear exceeds the fwd-rev gear, a check is made on the modulation speed.
(This speed is the maximum speed at which a direction change is acceptable)
In this application, the maximum speed is 11.7km/h. If the modulation speed is not exceeded,
the new direction is engaged(same gear for maximum deceleration), followed by a downshift to
the fwd-rev gear after a small delay.
If the modulation speed is exceeded, the EGS will make successive downshifts until one of the
previous conditions is met.
After the direction clutch engagement, eventual upshifts are delayed for 3 seconds, in order to
make sure that the modulation time completely elapsed before the upshift occurs.
※ If the transmission is in 2nd gear and a direction change is requested, but the vehicle
speed exceeds the modulation index, a downshift is made to 1st gear. This will cause
hard braking. As soon as the vehicle speed drops below the modulation index, the
direction is inverted and 2nd gear is selected.
⑧ Declutch function
When wire 14(brake pedal switch) is connected to ground, the transmission is put in neutral
when the vehicle speed is below 5km/h and the transmission is in first or 2nd gear. When the
brake pedal is released, or when the vehicle speed increases and exceed this limit, normally the
shift lever selected direction is reengaged. An exception to this is described in point ⑩.
Automatic shifting in neutral.
⑨ Kick down function

The kick down is only functional when driving in 2nd gear.
If the kick down is pressed, a downshift to first gear is made if no risk for overspeeding the
transmission exists.
If a direction change is requested, 2nd gear is selected.
If in first gear, the vehicle speed exceeds 5km/h, an automatic upshift to 2nd gear is made.
3-19
⑩ Automatic shifting in neutral
In order to prevent transmission overspeeding while driving in neutral, the EGS automatically
shifts to a gear position that suits best the current vehicle speed.
If the shift lever is placed in the same direction it was in before neutral was selected, the direction
clutch is engaged in the gear the EGS shifted to in neutral.
If the shift lever is placed in the opposite direction to what it was in before neutral was selected, a
reversal procedure is engaged as described in ⑦ Direction changes.
However, if the vehicle after being stopped is again driving(neutral being selected all the time),
the vehicle must slow down(speed < 1000 rpm) in order to get drive again.
⑪ Speedometer output
Output wire 12 generates pulses for controlling the speedometer. The amount of pulses is
26.27 pulses per km/h. See wiring diagram for installation of speedometer.
⑫ Warning lamp
Output wire 8 is activated to indicate the driver has to slow down in order to get the requested
situation.
Some situation where this lamp is switched on :
to indicate downshift protection during a direction change sequence EGS drives too fast during
startup.
3-20
4. AXLE
1) OPERATION
・ The power from the engine passes through torque converter, transmission and drive shafts, and is
then sent to the front and rear axles.
・ Inside the axles, the power passes from the bevel pinion to the bevel gear and is sent at right
angles. At the same time, the speed is reduced and passes through the both differentials to the
axle shafts. The power of the axle shafts is further reduced by planetary-gear-type final drives and
is sent to the wheels.
(1) Front axle
3 2
1 Final drive 2 Front differential 3 Front axle
(2) Rear axle
3
2
1 Final drive 2 Rear differential 3 Rear axle
3-21
2) SECTION OF FRONT DIFFERENTIAL
A A
1
5
1 Bevel pinion 3 Sun gears 5 Side gear(differential)

2 Bevel gear 4 Shaft
3-22
3) SECTION OF REAR DIFFERENTIAL
A A
1
5
1 Bevel pinion 3 Sun gears 5 Side gear(differential)

2 Bevel gear 4 Shaft
3-23
4) DIFFERENTIAL
(1) Description
When the machine makes a turn, the
outside wheel must rotate faster than the
inside wheel. A differential is a device
which continuously transmits power to the
right and left wheels while allowing them
to turn a different speeds, during a turn.
The power from the drive shaft passes
through bevel pinion and is transmitted to
the bevel gear. The bevel gear changes
the direction of the motive force by 90°,
and at the same time reduces the speed.
It then transmits the motive force through
the differential to the axle gear shaft.
(2) When driving straight forward

When the machine is being driven Pinion
straight and the right and left wheels are Side gear Side gear
rotating at the same speed, so the sun
gear inside the differential assembly do
not rotate, therefore the power is equally
transmitted to the left and right axle gear
shaft.
Pinion
(3) When turning

When turning, the rotating speed of the Swing
left and right wheels is different, so the Pinion
pinion gear and side gear inside the Side gear Side gear
differential assembly rotate in accordance
with the difference between the rotating
speed of the left and right wheels.
The power of the carrier is then
transmitted to the axle gear shafts.
Pinion Ring gear
3-24
4) TORQUE PROPORTIONING DIFFERENTIAL
(1) Function
① Because of the nature of their work, 4-
wheel-drive loaders have to work in
places where the road surface is bad.
In such places, if the tires slip, the ability
to work as a loader is reduced, and also
the life of the tire is reduced.
The torque proportioning differential is
installed to overcome this problem.
In structure it resembles the differential of
an automobile, but the differential pinion
gear has an odd number of teeth.
Because of the difference in the
resistance from the road surface, the
position of meshing of the pinion gear
and side gear changes, and this
changes the traction of the left and right
tires.
(2) Operation
① When travelling straight(equal Spider rotating
direction
resistance from road surface to left
and right tires)
Under this condition, the distances
involving the engaging points between
right and left side gears and pinion-a and FL FR
a b
b-are equal and the pinion is balanced Engaging Engaging
point point
as FL×b=FR×a. Thus, FL=FR, and
the right and left side gears are driven
with the same force. Left side gear Pinion Right side gear
3-25
② When travelling on soft ground
(resistance from road surface to left
and right tires is different)
If the road resistance to the left wheel is
smaller, the left side gear tends to rotate Spider rotating
forward, and this rotation changes the direction
engaging points between the side gears
and pinion. As a result, the distances
involving the engaging points becomes
a>b. The pinion now is balanced as FL Small road FL
Large road
FR
×b=FR×a, where FL>FR. The right resistance a b resistance
side gear is driven with a greater force Engaging Engaging
point point
than the left side gear. The torque can
be increased by up to about 30% for Left side gear Right side gear
either side gear. Pinion
The pinion therefore does not run idle
and driving power is transmitted to both
side gears until the difference between
road resistance to the right and left
wheels reaches about 30%.
3-26
6) FINAL DRIVE(front & rear)
1 Axle shaft 2 Planetary gear 3 Rear gear

4 Sun gear
(1) To gain a large drive force, the final drive uses a planetary gear system to reduce the speed and
send drive force to the tires.
(2) The power transmitted from the differential through axle shaft(1) to sun gear(4) is transmitted to
planetary gear(2). The planetary gear rotates around the inside of a fixed ring gear(3) and in this
way transmits rotation at a reduced speed to the planetary carrier.
This power is then sent to the wheels which are installed to the planetary carriers.
3-27
5. TIRE AND WHEEL
1) The tire acts to absorb the shock from the ground surface to the machine, and at the same time
they must rotate in contact with the ground to gain the power which drives the machine.
2) Various types of tires are available to suit the purpose. Therefore it is very important to select the
correct tires for the type of work and bucket capacity.
1 Wheel rim 2 Tire 3 O-ring

4 Lock ring 5 Side ring 6 Valve assembly
3-28
GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING
1. POWER TRAIN OPERATIONAL CHECKS

This procedure is designed so that the mechanic can make a quick check of the system using a
minimum amount of diagnostic equipment. If you need additional information, read structure and
function, Group 1.
A location will be required which is level and has adequate space to complete the checks.
The engine and all other major components must be at operating temperature for some checks.
Locate system check in the left column and read completely, following the sequence from left to right.
Read each check completely before performing.
At the end of each check, if no problem is found(OK), that check is complete or an additional check is
needed. If problem is indicated(NOT OK), you will be given repair required and group location.
If verification is needed, you will be given next best source of information:
Chapter 2. Troubleshooting
Group 3. Tests and adjustments
3-29
Transmission oil must be at operating temperature for these checks.
Item Description Service action

Transmission oil warm-up Start engine. Apply service brakes. OK
procedure Check completed.
C H
Move transmission selector lever to
3rd speed.
Move transmission control lever to
forward "F" position.
Increase engine speed to high idle
for 30 seconds.
neutral "N" position and run for 15
seconds.
Repeat procedure until transmission
temperature gauge arrow points to
bar above dial.
Transmission selector Move selector lever to each position. OK

lever check. Check completed.
LOOK : Lever must align with gear
Engine OFF.
indicator in each position. NOT OK
Repair or replace switch.
NOTE : Indicator position changes
slightly as steering column is tilted.
FEEL : Lever must move freely
through all positions.
Transmission noise Run engine at approximately 1600 OK

check rpm. Check completed.
Engine running.
Drive unit with transmission in each NOT OK
forward and reverse speed. Go to transmission makes
excessive noise chapter 2 in
LISTEN : Transmission must not
this group.
make excessive noise in any range.
Engine rpm must not "lug down" as
unit is shifted between gears.
3-30
Transmission "quick Release park brake and shift to 2nd OK

shift" check forward. Check completed.
Engine running.
Drive machine at approximately NOT OK
P 1600rpm and press boom control Check connector at base of
lever switch once. control valve.
LOOK/FEEL : Transmission must
shift to and remain in 1st gear.
Press boom control lever switch
once.
shift back to 2nd gear.
Shift to (4th) gear and press boom
control lever switch once.
not shift down.
NOTE : If boom lever switch is
pressed twice, transmission will shift
down the immediately back to 2nd.
Forward, reverse and 4th Park unit on level surface. OK
speed clutch pack drag Check completed.
check. Apply service brakes.
NOT OK
Transmission must Move transmission control lever to
If unit moves, repair
be warmed up for neutral.
transmission.
this check.
Engine running. Move speed selector lever to 1st.
P
Release park brake and service
brakes.
Run engine at low idle.
LOOK : Unit must not move in either
direction.
3-31
1st, 2nd, and 3rd speed Stop unit on a level, hard surfaced OK
clutch pack drag check area. Check completed.
Engine running.
Run engine at low idle. NOT OK
Repair transmission.
Release park and service brakes.
Put transmission in 1st forward, 2nd
forward, and then 3rd forward.
Note machine movement.
LOOK : Machine must roll ahead in
each gear.
NOTE : If machine rolls ahead in
one gear but not the other two, drag
is indicated in that clutch pack.
Transmission pressure, Run engine at low idle. OK

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

modulation check 1600rpm. Check completed.
Engine running.
Put transmission in 1st forward, shift NOT OK
several times from forward to Go to unit shifts too fast,
reverse and reverse to forward. chapter 2 in this group.
Repeat check in 2nd gear.
LOOK : Unit must slow down and
change direction smoothly.
3-32
Torque converter check Start engine. Apply service brakes. OK

Check completed.
Move transmission selector lever to
3rd speed. NOT OK
If stall rpm are too low or too
Move transmission control lever to high, problem may be
forward "F" position. engine power or torque
Increase engine speed to high idle, converter.
observe engine rpm and record If stall rpm is too high, it
lowest rpm reading. could be too powerful
engine or clutch slipping.
LOOK : Torque converter stall rpm
must be within the following range.
(2300~2440rpm)
neutral "N" position and run for 15
seconds.
3-33
2. TROUBLESHOOTING
1) TRANSMISSION
Diagnose malfunction charts are arranged from most probable and simplest to verify, to least
likely, more difficult to verify. Remember the following steps when troubleshooting a problem :
Step 1. Operational check out procedure(see group 3 in section 1.)
Step 2. Operational checks(see group 2.)
Step 3. Troubleshooting(see group 2.)
Step 4. Tests and / or adjustments(see group 3.)
Problem Cause Remedy
Transmission slippage Low oil level Fill to proper level.

Wrong oil grade Change oil.
Low clutch pressure Refer to "low clutch pressure".
Leak in transmission control valve Remove valve and inspect gaskets.
or gasket
Low transmission pump flow due Do transmission pump flow test.
to worn pump Refer to "low charging pump flow".
Weak or broken pressure Do transmission system pressure test.
regulating valve spring
Low clutch pressure Low oil level Fill to proper level.
Clutch pressure regulating valve Clean valve spool and housing.
spool stuck open.
Faulty charging pump Replace pump.
Broken or worn clutch shaft or Replace sealing ring.
piston sealing ring
Modulator spool orifice blocked. Clean spool orifice.
Low charging pump flow Low oil level Fill to proper level.
Suction screen plugged Clean suction screen. Also, check the filter.
If suction screen is clogged pump may be noisy.
Air leaks at pump intake hose Tighten all connections or replace hose if necessary.
and connections or collapsed
hose
Defective oil pump Replace pump.
3-34
Machine will not move Applied park brake Check park brake fuse.
Check continuity to park brake switch.
No power to transmission Check transmission controller fuse.
controller.
Excessive leakage in Do transmission element leakage test using system
transmission element pressure.
Worn clutch disks Repair clutch pack.
Low or no transmission pressure See clutch pack pressure is low in this group.
Service brake will not release Do brake pedal operational check.
Do service and park system drag checks.
Failed torque converter Do torque converter stall test.
If engine pulldown is normal, torque converter is
good.
Broken shafts or gears Drain transmission to determine if large pieces of

metal contamination are present.
Broken drive shafts Inspect drive shafts and universal joints for external
damage. Repair.
Broken ring or pinion gear If drive shaft rotate with transmission in gear but
machine does not move, a differential failure is
indicated. Repair.
Machine does not engage Malfunctioning transmission Check solenoid valve.
in low gear control solenoid valve
Stuck spool in transmission Remove and inspect transmission control valve
control valve spools.
Stuck modulation valve Inspect modulation spool. Replace if necessary.
Noisy converter Worn oil pump Replace.

Worn or damaged bearings A complete disassembly will be necessary to
determine what bearing is faulty.
3-35
Transmission shifts too Low oil level(aeration of oil) Fill to proper level.
slow
Low transmission pressure Do transmission system pressure test.
Restricted transmission pump Remove and clean screen.
suction screen
Low transmission pump flow See low charging pump flow in this group.
Excessive transmission element Do transmission element leakage test using system
leakage pressure.
Stuck modulation valve Inspect modulation spool. Replace if necessary.
Restricted modulation orifice Remove orifice and inspect for contamination and /or
plugging.
Restricted oil passages between Remove control valve and inspect oil passage.
control valve and transmission
elements
Transmission shifts too Wrong transmission controller Check if transmission controller has been changed
fast
System pressure too high Do transmission system pressure test.
Stuck modulation valve Remove and inspect modulation valve.
Replace if necessary. Also remove end cover to
inspect modulation spool and control valve housing.
Replace if necessary.
Stuck or missing check valves Inspect transmission control valve.
Missing O-ring from end of Remove orifice and inspect port for O-ring.
modulation orifice
Broken piston return spring Disassemble and inspect clutch.
Machine "creeps" Warped disks and plates in Check transmission.

in neutral transmission
Machine runs only in 2nd Wrong transmission controller Check if transmission controller has been changed.
gear
3-36
Transmission hydraulic High oil level Transmission overfilled or hydraulic pump seal
system overheats leaking.
Low oil level Fill to proper level.
Wrong oil grade Change oil.
Park brake dragging Check for heat in park brake area.
Pinched, restricted or leaking lube Check cooler lines.
lines
Machine operated in too high Operate machine in correct gear range.
gear range
Malfunction in temperature gauge Install temperature sensor to verify temperature.
or sender
Restricted air flow through Check radiator whether restricted or not.
radiator
Failed oil cooler bypass valve(in Disassemble and inspect.
thermal bypass valve)
Low transmission pump output Refer to "low charging pump flow".
Worn oil sealing rings Remove, disassemble and rebuild converter
assembly.
Worn oil pump Replace.
Pump suction line taking air Check oil line connections and tighten securely.
Excessive transmission Worn parts or damaged in Remove transmission suction screen. Inspect for
noise(under load or no transmission metal particles.
load) Repair as necessary.
Low or no lube Check converter out and lube pressure.
Also check the pump flow.
Foaming oil Incorrect type of oil Change oil.
Air leak on suction side of pump Check oil pickup tube on side of transmission.
Oil ejected from dipstick Plugged breather Inspect breather on top of transmission. Replace.
Machine vibrates Low engine speed Check engine speed.
Failed universal joints on Check universal joints.
transmission drive shaft or
differential drive shafts
3-37
Machine lacks power and Engine high idle speed set too Check high idle adjustment.
acceleration low
Low engine RPM at converter Tune engine check governor.
stall
Low transmission pressure Refer to "low clutch pressure".
Failed torque converter Do torque converter stall speed test.
Low engine power Do engine power test.
Torque converter stall Aerated oil Put clear hose on thermal bypass outlet port.
RPM too high Run machine to check for bubbles in oil.
Clutch slippage Refer to "transmission slippage".
Leakage in torque converter seal Do converter-out pressure test.
Torque converter not transferring Replace torque converter.
power(bent fins, broken stator)
Torque converter stall Low engine power Do engine power test.

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

light comes on when
Cold oil Warm oil to specification.
shifting from forward to
reverse(all other gears Leak in reverse pack Do transmission pressure, pump flow, and leakage
OK) check.
3-38
2) DIFFERENTIAL / AXLE
Differential low on oil External leakage Inspect axle and differential for leaks.
Excessive differential Low oil level in differential Check oil. Remove drain plug and inspect for metal
and/or axle noise particles in differential case.
Disassemble and determine cause.
Dragging brakes Do brake check.
Failed pinion bearing Remove and inspect pinion.
Check to ensure pinion housing was indexed.
Incorrect gear mesh pattern Remove pinion gear housing and inspect ring and
between ring and pinion gear pinion gear.
Failed differential pinion gears Remove differential housing drain plug and inspect
and / or cross shafts for metal particles. Disassemble and inspect.
Failed axle bearing Do axle bearing adjustment check.
Mechanical failure in axle Remove differential. Inspect, repair.
planetary
Oil seeping from outer Excessive end play in axle Do axle bearing adjustment check.
axle seal
Worn outer bearing and/or cup Disassemble and inspect outer axle bearing, cup,
spacer, and seal. Replace, if necessary.
Overfilled differential oil Check differential oil return system for excessive
internal restriction.
Axle overheats Low differential oil Add oil.
Overfilled differential oil Adjust oil level properly.
Brake drag Check brake drag.
3) DRIVE LINE
Excessive drive line Yokes not in line on drive shafts Inspect. Align drive shaft yokes.
vibration or noise
Worn front drive line support Inspect, repair.
bearing
Bent drive shaft Inspect all drive shafts. Replace.
Loose yoke retaining nuts(drive Inspect. Replace.
shafts wobble at high speed)
Lack of lubrication Lubricate with proper grade of grease.
3-39
GROUP 3 TESTS AND ADJUSTMENTS
1. CLUTCH CUT-OFF PRESSURE SWITCH TEST

The setting pressure of the clutch cut-off
Brake valve
pressure switch should be suited with the
specification. The rated pressure is 25 kgf/cm2.
For the detailed method for pressure adjusting,
refer to page 4-27.
Clutch cut-off
pressure switch
3-40
3. TRANSMISSION PUMP PRESSURE AND FLOW TESTING
1) TEST PORT
B
A
M
N
Port Description
A Regulated clutch pressure snap

G J connector (pressure switch)
H B Modulated forward clutch pressure

C Reverse clutch pressure
C
D 2nd clutch pressure
F
E 3rd clutch pressure
F 1st clutch pressure
G Converter outlet temperature
H Converter outlet pressure
J Converter inlet pressure
K Port for lube oil from cooler
L Port for converter out oil to cooler
M Lube in pressure check point
N Forward high(4th) clutch pressure
3-41
2) TESTING
Before testing is carried out, ensure that the oil is at the correct level and at normal operating
temperature 180~ 200 F(80 ~ 95 C).
3) TORQUE CONVERTER STALL TEST
Mark the engine crankshaft pulley with chalk or reflective tape and check the maximum no-load
speed of the engine using a stroboscopic tachometer.
Raise the loader arms and set the machine against fixed obstruction. Apply the parking brake
firmly and the footbrake. Select forward 3th and, with the throttle fully open, check engine speed
which should be as shown in technical data. Torque converter stall speed is min. 2300rpm.
Do not apply the clutch cut off switch during this test as the clutch disconnect will be
activated and a false reading will result.
Repeat the above test whilst simultaneously operating the loader arm raise service to blow off the
main relief valve.
Engine speed should be as shown in technical data.
If engine speeds are appreciably below the stated figures, the engine is losing power and should be
serviced or overhauled. Where the engine speed does not change significantly from the governed
speed, check the transmission for clutch slippage or internal leakage. Above phenomenon is also
indicated an incorrect torque converter.
4) CLUTCH LEAKAGE TEST
Connect a flowmeter between the transmission and oil cooler. With the parking brake firmly
applied, test at 1800rpm transmission input direction spool in forward or reverse and range spool in
1st, 2nd or 3rd. Converter out flow should not exceed 2.5GPM(9.5lpm) less than charging pump
flow or a max difference of 1GPM(3.8lpm) between any two speeds. Record the flow rate. Repeat
the test for each clutch pair.
5) CLUTCH PRESSURE TEST
Connect a pressure gauge to the clutch pressure tapping point A. Run the engine at idling speed,
engage clutches in sequence(as in previous test) and note the gauge readings which should be as
shown in technical data. Clutch pressure should be in 17~20bar(240~280psi).
Clutch pressure should not vary by more than 0.34bar(5psi) from one another. Any clutch showing
a greater variation should be disassembled for servicing.
Note : Never use service brake while making clutch pressure checks.
Units having brake actuated declutching in forward and/or reverse will not give a true
reading.
Always use parking brake when making clutch pressure checks.
3-42
6) PUMP FLOW TEST
Stop the engine and remove transmission filter. Assemble flow test tool by locating adapter K
through center bore of body L and securing with adapter.
Screw body onto filter spigot on transmission and connect a flow meter N as shown.
Start the engine and run at 2000rpm. The flow meter will show the pump flow which should be as
shown in technical data. A low reading indicates a worn pump or blocked suction strainer.
M
L
Specifications
Oil temperature 180~200 F(80~ 95 C)
Pump flow(minimum) 17.5GPM
Low transmission pump flow can be caused by :
Low oil level.
Cold transmission oil.
Plugged suction screen.
Air leak in pump suction tube.
Pump mounting cap screws loosen.
Worn transmission pump.
3-43
2. CONTROL VALVE
1) STRUCTURE
11
1
2 12
8
13
4
14
9 15
5
16
17
6 20
10
21
7
22
18
23
24
36
3
35
37
25
26
27
45
19
28
34 29
44 33
32 30
43 31 31
38
42
39
40
41
1 Elbow 16 Spring 31 Solenoid coil

2 Tube assy 17 Shift spool 32 O-ring
3 Elbow 18 Pipe plug 33 O-ring
4 Valve plug 19 Gasket 34 O-ring
5 Shift spool 20 Plug 35 Control valve housing
6 Spring 21 Spool stop 36 Spool stop
7 Shift spool 22 Spool 37 Ground wire harness
8 Plug 23 Spring 38 Screw
9 Valve spool 24 Valve body 39 Receptacle & wire assy
10 Spring 25 Pipe plug 40 Lock washer
11 Plug & O-ring 26 Lock washer 41 Nut
12 Spring 27 Screw 42 Grommet
13 Shift spool 28 Lock washer 43 Dust cover
14 Spool stop 29 Screw 44 Dust cover seal
15 Roll pin & plug stop 30 Shuttle valve solenoid 45 Mounting stud
3-92
2) DISASSEMBLY AND ASSEMBLY
The numerical sequence shown on the 4 3
illustration is intended as a guide to
disassembling.
7
For assembly the sequence should be
reversed. 6
(1) When disassembly

Depress spool 22 to remove stop 21. 5 8
Renew oil seals when spools 5 and 13 2
are removed.
1
Depress spool 9 to remove stop 36.
(2) When assembly 9 10
Depress spool 9 to fit stop 36. 11 12
Take care not to cut lips of oil seals
when refitting spools 5 and 13.
Depress spool 22 to fit stop 21.
Refer to tightening sequence as shown
in the figure.
Torque settings
Item N m kgf m lbf ft

27, 29 31-33 3.2-3.4 23-25
3-93
3. AXLE
1) GENERAL INSTRUCTIONS
Before starting operations for disassembling, overhauling and reassembling the following points
should be borne in mind.
(1) Cleaning components
Never use gasoline, solvents or other inflammable fluids to clean components. Use
approved commercial solvents that are uninflammable and non-toxic.
Maximum cleanness is recommended when working on an assembly, consequently, all
components should be thoroughly cleaned before reassembly.
Ambient where operations are carried out should be dust free and as clean as possible.
Make sure that tools and equipment are at hand, particularly those listed and shown in this
manual. Components that have been misplaced may be cause of failures on assembly
operations as well as chips or foreign matters.
When overhauling the assembly we suggest to replace the following parts with new ones:
Seal rings
Gaskets
O-ring
Threaded rings with notched collar
Any component damaged during disassembly
In case of failure and breaking inside of assembly, all ducts and casings should be duly cleaned
up so as to remove all material left to prevent further damage after assembling components.
In order to heat bearings use proper heating plates, pipings or suitable ovens.
Never heat parts by using a torch. Oil bath, heated by a torch, may be used to warm up
components.
Lubricate all sections concerned when reassembling shafts, bearings, etc.
When mounting heat fitted components make sure of their proper position after they cooled off.
Lubricate O-ring seals before installing them in relevant seats to prevent kinking during assembly,
such a position would impair proper sealing.
3-94
(2) Assembling leakproof components
Use of proper sealing compounds is recommended when assembling matched parts to be sealed
against fluid leakages(Oil or water) and no sealing gasket is used.
Best results are reached, with said compounds, if matching surfaces are duly cleaned and
degreased prior a uniform coat is spread all over the contact area.
We suggests the following sealing compounds :
RHODORSIL CAF 1
LOCTITE PLASTIC GASKET
SILASTIC 732 RTV
Air breather
Oil inlet and level plug
Air breather
Oil drain plug
Use only genuine spare parts to warrant proper operations and prevent interchangeability
problems.
3-95
2) TIGHTENING TORQUES(Front and rear)
Torque
No. Item
kgf m lbf ft
1 Screws fixing sleeves to axle case 61.2 3.1 441.6 22.1
2 Screws securing bevel ring gear to differential case 33.7 1.7 243.2 12.2
3 Screws fixing differential half-cases 12.2 0.6 88.0 4.4
4 Screws securing differential caps 33.7 1.7 243.2 12.2
5 Screws securing differential to axle case 22.4 1.1 161.6 8.1
6 Screw securing pinion support 33.7 1.7 243.2 12.2
7 Screws fixing side gear carrier to wheel hub 7.1 0.4 51.2 2.6
8 Screws fixing side cover 3.6 0.2 26.0 1.3
9 Standard backlash of bevel gear set 0.20 ~ 0.28mm
3-96
3) DISASSEMBLING AND ASSEMBLING AXLE UNITS
Lift and handle all heavy components by using proper equipment.
Make sure that assemblies or components be held up by proper slings close to the unit to
be lifted.
Location of oil filling and draining plugs on axle casing and side final drives.
Final drive
Differential unit
Final drive
3
2
Oil drain
Drain oil from central section thru plug 2.
Drain oil from side final drives thru plug 3.
3-97
4) DISASSEMBLING SIDE FINAL DRIVES
40
(1) Remove final drive cover releasing the six screws(40).

Cover(1) is provided with three threaded holes for puller screws.
3-98
DISASSEMBLING SIDE FINAL DRIVES
46
12
10 9
5 11
6 10
9
4
3 46
2
39
1
38
42
16
14
17
15
18
41
19
20
7
40
44,45 43
37
36
35
21
34
22
33
23
24 5
25 6
32 7
26 31
110 9
27 28
10
29
11
30
12
(2) Remove O-ring seal(2).

(3) Pull out axle shaft backing plate(3) using puller screw.
(4) Undo screws(4) fixing side gear carrier(5) to wheel hub(31).
(5) Suitably support side gear carrier(5), pry it off to separate carrier from wheel hub(31).
(6) Pull out side gear carrier assy(5).
(7) Remove lockring(15) retaining sun gear(14) on wheel shaft(46).
(8) Pull out sun gear(14).
(9) Remove disk carrier hub(16) along with thrust washer(27) resting against wheel hub sleeve.
(10) Remove solid and lined disks(17,18) of brake.
(11) Remove wheel shaft(46).
(12) Pull out lockring(26), securing ring nut(25) and lock plates(24).
(13) Remove lock plates(24).
3-99
(14) Install the specific spring retainer. Spring retainer installed
Secured thru the three threaded holes of
22
disk pressure plates(21) - to compress
brake return spring(22) and allow ring nut
(25) removal.
(15) Unlock and turn out ring nut(25) from
sleeve(38).
A
(16) Remove pressure plate(21) along brake
return spring retainer.
25
21
A Spring retainer
21 Pressure plate
22 Return spring
25 Ring nut
3-100
46
12
10 9
5 11
6 10
9
4
3 46
2
39
1
38
42
16
14
17
15
18
41
19
20
7
40
44,45 43
37
36
35
21
34
22
33
23
24 5
25 6
32 7
26 31
110 9
27 28
10
29
11
30
12
(17) Suitably support wheel hub(31) and pull out ring gear unit(30) and relevant support(29).
(18) Pick up the six rods(19) located in relevant seats on ring gear support(29).
(19) Pry off lockring(20) from ring gear(30) by using a screwdriver.
(20) Disassemble ring gear support(29) from ring gear(30).
(21) Should replacement of outer wheel bearing(28) inner race be mandatory, old part can be removed
by a proper puller or by a remover that can be inserted in the specific holes of ring gear support
(29).
(22) Remove retainer of brake unit spring, disassemble spring(22), retaining cup(23) and pressure
plate(21).
(23) Remove brake actuating piston(34) from wheel hub sleeve(38) by compressed air thru brake oil
ducting.
(24) Remove and replace the two O-ring seals(33 and 35) in relevant seats on brake actuating piston.
(25) Pull out the complete wheel hub(31).
(26) Remove O-ring seal(41).
3-101
46
12
10 9
5 11
6 10
9
4
3 46
2
39
1
38
42
16
14
17
15
18
41
19
20
7
40
44,45 43
37
36
35
21
34
22
33
23
24 5
25 6
32 7
26 31
110 9
27 28
10
29
11
30
12
(27) Pry off from wheel hub(31), seal(37) and remove inner race with roller cage of inner wheel bearing
(36).
(28) Push out, by a proper remover, outer races of outer and inner wheel bearings(28 and 37) from
hub(31).
(29) Should sleeve(38) be damaged, it can be removed by undoing relevant fixing screws(43). At
reassembly, smear proper sealing compound on axle case joining flange and tighten screws with
a torque of : See tightening torque No.1
(30) Mark side gear pins(6) and various components for identification of original position at
reassembly.
(31) Arrange side gear carrier(5) on wooden blocks and push out pins(6) with a proper remover.
(32) Pick up all needle rollers(10,11).
(33) It is important to keep matched needle rollers and thrust washers(9) with relevant pin(6), this is
consequent to predetermined assembly tolerance limits.
(34) Remove side gears(12) and relevant thrust washers(9) no gear can be removed prior having
released all of them.
3-102
5) ASSEMBLING SIDE FINAL DRIVE
46
12
10 9
5 11
6 10
9
4
3 46
2
39
1
38
42
16
14
17
15
18
41
19
20
7
40
44,45 43
37
36
35
21
34
22
33
23
24 5
25 6
32 7
26 31
110 9
27 28
10
29
11
30
12
(1) Reinstall wheel hub(31), first fit outer races of wheel inner and outer bearings(36 and 28), make
sure they rest against relevant seats. Position inner race with roller cage of wheel inner side
bearing(36) before fitting lip seal(37).
(2) Refit O-ring seal(41).
(3) Support suitably wheel hub(31) during the assembling stage to prevent seal damages, then, fit
wheel inner bearing(36) in sleeve(38).
(4) Lubricate seals(33 and 35) on piston(34), insert it at travel end on wheel hub sleeve(38).
(5) Fit inner race of wheel outer bearing(28) on ring gear support(29), by heating equipment or proper
installer ; Then, mount support(29) in ring gear(30) and secure by lockring(20).
(6) Mount ring gear and support unit(30 and 29) on sleeve(38).
(7) Fit the six rods(19) in relevant seats on ring gear support(29).
(8) Install the spring retainer(Figure at page 3-100) and compress spring(22) with relevant retaining
cup(23) on pressure plate(21).
(9) Mount the pressure plate-spring assembly on ring gear support(29).
3-103
Determining the space available to form the brake disk pack
Record depth from seating surface of side

gear carrier on wheel hub to outer edge of A
ring gear, identify said value as A.
Record depth from ring gear outer edge to
brake pressure plate, identify said value
as B. Subtract the value recorded from B
value A recorded on previous step,
identify it a D.
i.e. : A - B = D
Record depth from disk reaction face to

outer edge of side gear carrier.
Value recorded as C should be subtracted
from value D previously recorded.
i.e. : C + D = X C
This is the space available to form the
brake disk pack.
Forming the disk pack

X
Computing thickness of disk pack(Solid +
lined ones) it is necessary to subtract the
clearance of 1mm for each brake disk plus
the total thickness of the lined disks from
the space available for the remaining
clearance with solid disks(Outer teeth) of
proper thickness with a tolerance of
0.25mm.
3-104
ASSEMBLING SIDE FINAL DRIVE
46
12
10 9
5 11
6 10
9
4
3 46
2
39
1
38
42
16
14
17
15
18
41
19
20
7
40
44,45 43
37
36
35
21
34
22
33
23
24 5
25 6
32 7
26 31
110 9
27 28
10
29
11
30
12
(10) Hand screw ring nut(25) on wheel hub sleeve(38).

(11) Tighten ring nut(25) by the proper wrench so as to reach the prescribed pre-load for wheel
bearings and corresponding to a revolving torque of 1.5-3.1kgf m(10.8-22.4lbf ft) checking
alignment for the lockplates(24).
To prevent wrong recording of torque values, it is advisable to seat bearing properly before checks
by revolving repeatedly the wheel hub.
(12) Remove spring retainer compressing brake actuator return spring.
Insert lockplates(24), securing ring nut(25) and fit lockring(26).
(13) Side gear carrier(5).
Arrange the three side gears(12) in proper carrier seat.
Two rows of needle rollers of the same selection class should be used for replacement in each
single side gear pin.
(14) Insert outer thrust washers(9), smear with grease pin lower portion(Head end) and position the
first row of needle rollers, fit spacer, smear with grease pin upper portion and position the second
row of needle rollers(10,11).
(15) Position outer thrust washers(9) of side gear on side gear carrier and aline holes.
(16) Insert and force fit complete pins(6) and avoid any bump or knock that could cause roller fall.
3-105
ASSEMBLING SIDE FINAL DRIVE
46
12
10 9
5 11
6 10
9
4
3 46
2
39
1
38
42
16
14
17
15
18
41
19
20
7
40
44,45 43
37
36
35
21
34
22
33
23
24 5
25 6
32 7
26 31
110 9
27 28
10
29
11
30
12
(17) Insert wheel shaft(46).

(18) Insert thrust washer(48).
(19) Mount disk carrier hub(16) on wheel shaft(46).
(20) Mount alternately solid disks and lined disks.
Insert a solid disk(Outer teeth) facing the pressure plate(27).
(21) Insert sun gear(14) and secure with lockring(15).
(22) Mount the side gear carrier assembly (5) on side gear unit and secure on wheel hub(31) locking
fixing screws(4) with a tightening torque of : See tightening torque No.7.
(23) Force fit wheel shaft backing plate(3).
(24) Mount O-ring seal(2) on edge.
(25) Rotate and aline pins (6) to allow mounting of cover(1) which act also as pin lock to prevent their
rotation.
(26) Fit side final drive cover(1).
(27) Smear fixing screws(40) with sealing compound, then, lock with a tightening torque of : See
tightening torque No.7.
3-106
6) DISASSEMBLING AND REASSEMBLING DIFFERENTIAL UNIT
(1) Disassembly
Unlock and undo screws(28) retaining differential unt then, remove it from axle case.
28
(2) Assembly
Clean throughly matching surfaces, apply selaling compund and mount differential unit on alxle
case, lock the screws(28) with a tightening torque of : See tightening torque No. 5.
3-107
7) DISASSEMBLING DIFFERENTIAL UNIT
11
G
A 6
1 9 5
B 8
7
3
2
2 12
3 13
10
30
19
29
6
5 9
8
28
22 14
D E 24
F 15 16 25
4 17
A 18
110 B C
C
D
120
E
F
130 23
G
26
20 27
21
(1) Hammer out spring pins(1) locking slotted rings(3) and release then.
Mark caps(B) to match parts at reassembly.
(2) Release fixing screws(A) and remove caps(B) and relevant threaded rings(3).
(3) Release and remove screws(22) securing support(12) of bearing(13) of bevel pinion shank.
(4) Remove support(12) of bevel pinion bearing by means of puller screws.
(5) Lift up differential unit from differential support(C), along with bearing support(12).
(6) Remove ring gear deflection plunger(20) and relevant counternut(21).
(7) Insert a screw in the seat of plunger(20) to react against unscrewing torque of pinion ring nut(27).
This screw should have a threaded length of 100mm, its tip should shaped so as not to be
damaged when contacting pinion teeth.
Make sure that screw be correctly engaged in pinion teeth.
(8) Straighten notches on pinion ring nut(27).
(9) Unlock and undo ring nut.
(10) Remove drive flange(23), washer and pinion ring nut, then, back up reaction screw.
3-108
DISASSEMBLING DIFFERENTIAL UNIT
11
G
A 6
1 9 5
B 8
7
3
2
2 12
3 13
10
30
19
29
6
5 9
8
28
22 14
D E 24
F 15 16 25
4 17
A 18
110 B C
C
D
120
E
F
130 23
G
26
20 27
21
(11) Pry off seal(25) from drive flange.

(12) Remove bevel pinion(E) from differential support(C), hammer pinion shank with a proper remover,
care not to damage threads.
(13) Pick up inner race of pinion shank bearing(24).
(14) Remove from differential support(C) outer races of outer and inner pinion bearings(24 and 16).
Pick up shims(17) for pinion axial position adjustment, spacer(18) and shim(19).
(15) Flatten notches retaining bearing(13) race on pinion(E) shank.
(16) Remove bearing(13) race from pinion(E) shank by a proper puller.
(17) Remove pinion underhead bearing (16) by a proper puller.
Mark differential half-cases(F and G) for reference at reassembly.
(18) Remove fixing screws(11) and separate half-cases(F and G).
Have a visual and dimensional check of wear on sun and side gears(6 and 8) relevant thrust
washers(5 and 9) and spider(7).
(19) Remove bearings(2) from half-cases(F and G) by a proper puller.
(20) Fit inner races of differential bearings(2) on half-cases(F and G).
3-109
DISASSEMBLING DIFFERENTIAL UNIT
11
G
A 6
1 9 5
B 8
7
3
2
2 12
3 13
10
30
19
29
6
5 9
8
28
22 14
D E 24
F 15 16 25
4 17
A 18
110 B C
C
D
120
E
F
130 23
G
26
20 27
21
This operation should be carried out by heating equipment or proper installer.

(21) Clamp ring gear(D) in a vise fitted with soft caps and remove screws(4) securing ring gear(D) to
case(F).
(22) Overhauling pinion bearing support(12).
(23) Remove split pin(10), washer(15) and pin(14).
(24) Remove bearing outer race from support(12) of pinion(E).
Check wear conditions of components, renew as required.
(25) Finally, press fit outer race of bearing(13) on support(12) of pinion(E).
(26) Finally, reassemble retaining washer(15), pin(14) and split pin(10) on support(12).
(27) Mount bevel ring gear(D) on case(F) lock relevant fixing screws(4) with a tightening torque of :
See tightening torque No.2.
Position differential components in relevant seats, then, join half-cases(F and G) matching
reference marked prior disassembly.
(28) Mount and lock half-cases fixing screws(11) with a tightening torque of : See tightening torque
No.3.
3-110
8) ASSEMBLING DIFFERENTIAL UNIT
Determining thickness of adjustment shims(Axial position of bevel pinion) : See clause 9 at page 3-114.
11
G
A 6
1 9 5
B 8
7
3
2
2 12
3 13
10
30
19
29
6
5 9
8
28
22 14
D E 24
F 15 16 25
4 17
A 18
110 B C
C
D
120
E
F
130 23
G
26
20 27
21
(1) Press fit inner race of inner(Underhead) bearing(16) on pinion by heating equipment or proper
installer.
(2) Position shim(17), computed as per clause 9 at page 3-114, in its seat and press fit outer races of
inner(Underhead) and outer bearings(16 and 24) of pinion.
(3) Fit spacer(18) on pinion along with shims(19) for bearing pre-load adjustment; Then, mount inner
race of pinion outer bearing(24).
To facilitate proper pre-load computation, it is advisable to mount as many shims as required to
warrant a pinion end play and not a pre-load(That could be excessive) on bearings.
(4) Fit drive flange(23) on pinion(E), position the specific reaction screw and tighten nut(27) with a
torque of 58.2 - 64.3kgf m(420 - 464lbf ft).
(5) Back up reaction screw from pinion.
Check pinion end play by means of a dial gauge; Then, disassemble parts and change shims so
as to eliminate all end play and reach the intended pre-load.
Reassemble components, check that proper pre-load of bearing be corresponding to a revolving
torque(No seal installed) of 0.2-0.4kgf m(1.4-2.9lbf ft).
(6) As the prescribed pre-load of bearings as been reached remove drive flange(23) and fit lip seal
(25) in relevant seat.
3-111
ASSEMBLING DIFFERENTIAL UNIT
11
G
A 6
1 9 5
B 8
7
3
2
2 12
3 13
10
30
19
29
6
5 9
8
28
22 14
D E 24
F 15 16 25
4 17
A 18
110 B C
C
D
120
E
F
130 23
G
26
20 27
21
(7) Remount drive flange again and tighten a specified above.

(8) Remove definitively, reaction screw from differential support.
(9) Position differential assembly with ring gear on supportC).
(10) Insert support(12) of bearing(13) while differential is lowered and tighten fixing screw(22) with a
torque of : See tightening torque No.6.
(11) Insert ring nut(3) and adjust temporarily backlash.
(12) Mount caps(B), minding not to invert position and lock screws(A) fixing support to differential with
a torque of : See tightening torque No.4.
Check differential end play by a dial gauge.
Screw in a ring nut so as to have a notch alined against the slot of lock plate and actuate the
opposite nut up to eliminate end play.
As such a condition has been reached go on with bearing pre-load by screwing in ring nut further
one more notch.
3-112
ASSEMBLING DIFFERENTIAL UNIT
11
G
A 6
1 9 5
B 8
7
3
2
2 12
3 13
10
30
19
29
6
5 9
8
28
22 14
D E 24
F 15 16 25
4 17
A 18
110 B C
C
D
120
E
F
130 23
G
26
20 27
21
(13) Position a dial gauge perpendicular the

ring gear(D) tooth(See figure) and check
that, with pinion steady, backlash be of :
See tightening torque No.9, otherwise
rotate both ring nuts(3), displacing them of
a same number of notches and nearing
ring gear to pinion if backlash is excessive
and moving away on the contrary.
Brush red lead on some ring gear teeth,
rotate to mesh pinion and ring gear
repeatedly so as to make evident tooth
contact. Proper and correct tooth contact
marks are visible on a new bevel gear set
as a result of an optimum contact
approached on the tester, consequently, a
proper axial position of pinion against ring
gear will emphasize remarking of previous
tester contact marking.
(14) Fit spring pins(1) to lock differential ring nuts.
(15) Make two lock notches on pinion nut collar(27).
Apply sealing compound to bevel ring gear deflection plunger(20), then, screw in up to contact ;
Turn back by about 90 degree to leave the required clearance and lock counternut holding
plunger steady.
3-113
9) DETERMINING THICKNESS OF ADJUSTMENT SHIMS
X
A A
S B+D
(1) Some dimensions should be recorded before starting reassembly of bevel pinion to determine
thickness of spacer to be fitted between inner(Underhead) pinion bearing and backing of relevant
seat in differential support.
Record dimension from ring gear axis to seat of inner(Underhead) pinion bearing(That will be
identified as A).
Example : In our case A = 206.6mm
(2) A number X prefixed by symbol is marked on bevel pinion face.
Said value, expressed in tenth of millimeter, indicate the deviation from the theoretical distance
from pinion underhead to ring gear axis :
i.e. : + 1 = 0.1mm
Consequently, the true distance(Identified as B) will be :
B = 168.5 Deviation
In our case : B = 168.5 + 0.1 = 184.1mm
(3) Measure thickness of pinion head bearing and identify as D.
Example : In our case D = 34.15mm
(4) Compute thickness of shim S for proper axial position of bevel pinion :
S = A - (B + D)
Example : In our case S = 206.6 - (168.6 + 34.15) = 3.85mm
(5) Increase by 0.05mm the computed thickness value to compensate subsequent bearing pre-load.
Round off to the nearest tenth of millimeter to the computed thickness value :
i.e. : 4.02 Rounded off = 4mm
3.88 Rounded off = 3.9mm
3-114
SECTION 4 BRAKE SYSTEM
1. OUTLINE
Ɠ The brakes are operated by a pressure compensated, closed center hydraulic system.
Flow is supplied by a fixed displacement, gear type brake pump.
BRAKE SYSTEM
The fixed displacement brake pump supplies flow to the cut-off valve for service brake circuit and
park brake circuits. It flows to four accumulator. The accumulator has a gas precharge and an
inlet check valve to maintain a pressurized volume of oil for reserve brake applications.
Oil through the accumulator flows to the brake valves. The brake valve is a closed center design,
dual circuit operated by a pedal.
The front and rear brakes will operate simultaneously with only one brake pedal depressed.
The differential contains annular brake piston and double sided disk.
Brake pump flow also goes to the parking brake solenoid valve.
The brake system contains the following components:
şBrake pump
şParking brake solenoid valve
şCut-off valve
şBrake valve
şAccumulators
şParking brake cylinder
şPressure switches
4-1
FULL POWER HYDRAULIC BRAKE
SYSTEM
ADVANTAGES - The full power hydraulic Response time
brake system has several advantages over Full power brake actuation VS
Air/Hydraulic brake actuation
traditional brake actuation systems. These
systems are capable of supplying fluid to a 1000
range of very small and large volume
service brakes with actuation that is faster 900
than air brake systems. Figure represents 800
a time comparison between a typical Brake pressure
700 (Full power)
air/hydraulic and full power hydraulic brake
Brake torque(lbşin)
actuation system. 600
Brake pressure
Full power systems can supply significantly 500 (Air/hydraulic)
higher brake pressures with relatively low Brake torque
400
reactive pedal forces. The reactive pedal (Air/hydraulic)
force felt by the operator will be proportional 300
Brake torque
to the brake line pressure being generated. 200 (Full power)
This is referred to as brake pressure
modulation. 100
Another key design feature of full power
0 1 2 3 4
systems is the ability to control maximum
brake line pressure. In addition, because Time(Seconds)
these systems operate with hydraulic oil,
filtration can be utilized to provide long
component life and low maintenance
operation.
Because these systems are closed center,
by using a properly sized accumulator,
emergency power-off braking that is
identical to power-on braking can be
achieved. These systems can be either
dedicated, where the brake system pump
supplies only the demands of the brake
system or non-dedicated, where the pump
supplies the demands of the brake system
as well as some secondary down stream
hydraulic devise.
Another important note is that all seals
within these system must be compatible
with the fluid medium being used.
4-2
2. HYDRAULIC CIRCUIT
Front
34
Rear
21
19 17
20
8 2.1 2.1 2.5 2.2
5.1 1.1 5.2 1.2
A B
16
P T
15 15 15
23 22 21 A 1st pump
7
15 B 2nd pump
27 C Brake pump
28 Steering system
18 1
MCV
Return line
RCV Lever
5
22
1 C B A
Return line
23
28
24
25 26 27
1 Pump assy 18 Pressure switch 24 Hydraulic tank

7 Cut off valve 19 Pressure switch 25 Return filter
8 Brake valve 20 Pressure switch 26 Bypass valve
15 Accumulator 21 Parking brake cylinder 27 Oil cooler(Option)
16 Solenoid valve 22 Line filter 28 Check valve(Option)
17 Pressure switch 23 Air breather 34 Axle
4-3
1) SERVICE BRAKE RELEASED
Front
34
Rear
21
19 17
20
8 2.1 2.1 2.5 2.2
5.1 1.1 5.2 1.2
A B
16
P T
15 15 15
23 22 21 A 1st pump
7
15 B 2nd pump
27
C Brake pump
28 Steering system
18 1
MCV
Return line
RCV Lever
5
22
1 C B A
Return line
23
28
24
25 26 27
When the pedal of brake valve(8) is released, the operating force is eliminated by the force of the
spring, and the spool is returned.
When the spool removes up, the exhaust port is opened and the hydraulic oil in the piston of axles
return to the tank(24).
Therefore, the service brake is kept released.
4-4
2) SERVICE BRAKE OPERATED
Front
34
Rear
21
19 17
20
8 2.1 2.1 2.5 2.2
5.1 1.1 5.2 1.2
A B
16
P T
15 15 15
23 22 21 A 1st pump
7
15 B 2nd pump
27
C Brake pump
28 Steering system
18 1
MCV
Return line
RCV Lever
5
22
1 C B A
Return line
23
28
24
25 26 27
When the pedal of brake valve(8) is depressed, the operating force overcomes the force of the
spring, and is transmitted to the spool. When the spool moves down, the inlet port is opened, and
at the same time the hydraulic oil controlled the pressure level by the cut-off valve(7) enters the
piston in the front and rear axles. Therefore, the service brake is applied.
4-5
3) PARKING BRAKE RELEASED
Front
34
Rear
21
19 17
20
8 2.1 2.1 2.5 2.2
5.1 1.1 5.2 1.2
A B
16
P T
15 15 15
23 22 21 A 1st pump
7
15 B 2nd pump
27
C Brake pump
28 Steering system
18 1
MCV
Return line
RCV Lever
5
22
C B A
1
Return line
23
28
24
25 26 27
When the parking brake switch is pushed, the solenoid valve(16) is energized and the hydraulic oil
controlled the pressure level by the cut-off valve(7) enters the parking cylinder(21). It overcomes
the force of the spring and pushes the piston rod. This releases the brake.
Therefore, the hydraulic oil pressure is applied to the parking cylinder(21) through the solenoid
valve(16) and the parking brake is kept released.
4-6
4) PARKING BRAKE OPERATED
Front
34
Rear
21
19 17
20
8 2.1 2.1 2.5 2.2
5.1 1.1 5.2 1.2
A B
16
P T
15 15 15
23 22 21 A 1st pump
7
15 B 2nd pump
27
C Brake pump
28 Steering system
18 1
MCV
Return line
RCV Lever
5
22
1 C B A
Return line
23
28
24
25 26 27
When the parking brake switch is pushed once more, the solenoid valve(16) is deenergized and the
valve open the exhaust port.
At the same time, the hydraulic oil in the parking cylinder(21) return to the tank through the solenoid
valve(16). When the piston rod is returned by the force of the spring, the parking brake is applied.
4-7
3. BRAKE PUMP
1) STRUCTURE
31
20
21
22
24
27
32 25
33 23
22
21
20
23 19
28
35
36
26 24
29
30
19 Spacer plate 25 Driven gear 31 Cover

20 O-ring 26 Drive gear 32 Washer
21 Back up seal 27 Rear body 33 Bolt
22 Seal element 28 O-ring 35 Dowel
23 Bushing 29 Coupling 36 O-ring
24 Bushing 30 Cap screw
Brake pump used for the brake of this machine is pressure loaded type gear pump. This gear pump
have a maximum delivery pressure of 150kg/cm2(2130psi).
The pressure loaded type gear pump is designed so that the clearance between the gear and the side
plate can be automatically adjusted according to the delivery pressure. Therefore, the oil leakage from
the side plate is less than that in the case of the fixed side plate type under a high discharge pressure.
Consequently, no significant reduction of the pump delivery occurs, even when the pump is operated
under pressure.
4-8
2) PRINCIPLE OF OPERATION
(1) Mechanism for delivering oil

The drawing at right shows the
operational principle of an external gear
pump in which two gears are rotating in
mesh.
The oil entering through the suction port is
trapped in the space between two gear Suction Discharge
teeth, and is delivered to the discharge
port as the gear rotates.
Except for the oil at the bottom of the gear
teeth, the oil trapped between the gear
teeth, is prevented from returning to the
suction side with the gears in mesh.
Since the gears are constantly delivering
oil, the oil delivered to the discharge port
is forced out of the port.
The amount of discharge increases with
the speed of rotation of the gear.
If there is no resistance in the oil passage
into which the discharged oil flows, the oil
merely flows through the passage,
producing no increase in pressure.
If however, the oil passage is blocked with
something like a hydraulic cylinder, there
will be no other place for the oil to flow, so
the oil pressure will rise. But the pressure
which rises in this way will never go
higher, once the hydraulic cylinder piston
starts moving because of the oil pressure.
As described earlier, the pump produces
the oil flow, but not the oil pressure. We
can therefore conclude that pressure is a
consequence of load.
In other words, the pressure depends on
a counterpart.
4-9
(2) Internal oil leakage
Oil leaks from a place under higher
pressure to a place under lower pressure,
provided that a gap or a clearance exists
in between.
In the gear pump, small clearances are
provided between the gear and the case
and between the gear and the side plate
to allow the oil to leak out and to serve as
a lubricant so that the pump will be
e
protected from seizure and binding. charg
Dis
The drawing at right shows how the
leaked oil flows in the pump. As such,
there is always oil leakage in the pump
from the discharge side(Under higher
pressure) to the suction side. The
n
delivery of the pump is reduced by an ctio
Su
amount equal to the pump discharge.
In addition, the delivery of the pump will
also decrease as the amount of oil
leakage increases because of expanded
radial clearance resulting from the wear of
pump parts, the lower oil viscosity
resulting from increases in the oil
temperature, and the initial use of low
viscosity oil.
4-10
(3) Forces acting on the gear
The gear, whose outer surface is
subjected to oil pressure, receives forces
jointing towards its center.
Due to the action of the delivery pressure,
the oil pressure in higher on the delivery
side of the pump, and due to suction
pressure, is lower on the suction side. In
the intermediate section, the pressure will
gradually lower as the position moves
from the delivery side to the suction side. Drive gear
This phenomenon is shown in the
drawing at right.
In addition, the gears in mesh will receive Suction Discharge
interacting forces. side side
These forces pushing the gears toward
the suction side are received by the
bearings. Since the gears are pressed Driven gear
toward the suction side by these forces,
the radial clearance becomes smaller on
the suction side in the case. In some
pumps, the clearance may become zero, Pressure distribution
thus allowing the gear teeth and the case
to come into light contact.
For this reason, an excessive increase in
the delivery pressure must be avoided,
since it will produce a large force which
will act on the gears, placing an overload
on the bearings, and resulting in a
shortened service life of the bearing or
interference of the gear with the case.
4-11
(4) "Trapping" phenomenon of the oil
When a gear pump is rotating with the
gears in mesh as shown in the drawing at
right, in some instances two sets of gear
Delivery Suction side
teeth are in mesh while in other instances side
only one set of the gear teeth is in mesh.
When two sets of the teeth are in mesh
simultaneously, the oil in the space Trapping starts
between the meshed gear teeth will be
trapped inside-the front and rear exits will The space
reaches the
be completely shut. minimum
This is called the "trapping" phenomenon
of oil.
The space in which the oil is trapped Trapping ends
moves from the suction side to the
delivery side as the gears rotate. The
volume of the space gradually decreases
from the start of trapping until the space
reaches the center section, and then
gradually increases after leaving the
center section until the end of trapping. Fixed side plate type
Since the oil itself is non-shrinkable, a
reduction of the volume of space will
greatly increase the oil pressure, unless
Side plate
some plosion in made to relieve oil
pressure. The high pressure oil will
cause the pump to make noise and
vibrate.
To prevent this, relief notches are Relief notch
provided on the side plates to release the
oil to the delivery side.
As shown in the drawing at right, the relief
notches are provided in such a way that Pressure loaded type Bushing
the oil can be relieved from the tapping
space to the delivery side when the
volume of the space is reduced.
Relief notches are also provided on the
suction side to prevent the formation of a
vacuum in the space by allowing the oil to
enter the space from the suction side
when the space is reduced.
4-12
4. BRAKE VALVE
1) STRUCTURE
13,15
11
12
7
8,9
10,14
37
6
5
3 2
1
4 17
19 36
20 18
24
21
23
25
27 28
26 30
29
31
32
33
34
35
1 Base plate 13 Rivet 27 Ring

2 Bushing 14 Pin 28 Spool
3 Nut 15 Pedal cover 29 Retainer
4 Screw 17 Guide pin 30 Spring
5 Piston 18 Spring 31 Spool
6 Bellows 19 Washer 32 Spring
7 Pin 20 Cap 33 Snap ring
8 Bracket 21 Spring 34 Washer
9 Bracket 23 Cap 35 Plug
10 Retaining ring 24 Ball 36 Bolt
11 Plate 25 Spring 37 Bolt
12 Pedal 26 Housing
4-13
2) OPERATION
Set of springs
Upper spool
51
24 21
11
Lower spool
52
25 22
12
Leading edges
24
51
11 21
25
52
12 22
4-14
(1) Purpose
The purpose of the brake valve is to sensitively increase and decrease the braking pressure when
the brake pedal is actuated.
(2) Ready position
When the braking system is ready for operation, its accumulator pressure acts directly on ports
(11, 12) of the brake valve. A connection is established between ports(21, 22) and ports(51, 52)
so that the wheel brakes ports(21, 22) are pressureless via the returns ports(51, 52).
(3) Partial braking
When the brake valve is actuated, an amount of hydraulic pressure is output as a ratio of the foot
force applied.
The spring assembly(21) beneath base plate(1) is designed in such a way that the braking
pressure changes depending on the angle. In the lower braking pressure range, the machine
can be slowed sensitively.
When the braking process is commenced, the upper spool(28) is mechanically actuated via
spring assembly(21), and the lower spool(31) is actuated hydraulically by spool(28). As spools
(28 and 31) move downward, they will first close returns(51, 52) via the control edges, thus
establishing a connection between accumulator ports(11, 12) and ports(21, 22) for the wheel
brake cylinders. The foot force applied now determines the output braking pressure. The
control spools(28 and 31) are held in the control position by the force applied(Spring assembly)
above the spools and the hydraulic pressure below the spool(Balance of forces).
After output of the braking pressure, spools(28 and 31) are in a partial braking position, causing
ports(11, 12) and(51, 52) to close and holding the pressure in ports(21, 22).
(4) Full braking position
When pedal(12) is fully actuated, end end position of the brakes is reached and a connection
established between accumulator ports(11, 12) and brake cylinder ports(21, 22). Returns (51,
52) are closed at this point.
When the braking process is ended, a connection is once again established between brake
cylinder ports(21, 22) and return ports(51, 52), closing accumulator ports(11, 12).
The arrangement of spools in the valve ensures that even if one braking circuit fails the other
remains fully operational. This is achieved by means of the mechanical actuation of both spools
and requires slightly more pedal travel.
(5) Limiting the braking pressure
Pedal restriction screw(37) on base plate(1) below pedal(12) is used to limit the braking pressure.
(6) Failure of a circuit
In the event of the lower circuit failing, the upper circuit will remain operational. Spring assembly
(21) will mechanically actuate spool(28). In the event of the upper circuit failing, the lower circuit
will remain operational since the lower spool(31) is mechanically actuated by spring assembly(21)
and spool(28).
(7) Installation requirements
Return lines(51, 52) must be connected directly to the tank.
The connecting lines must be installed is such a way as to permit proper bleeding.
4-15
(8) Maintenance of the brake valve
No special maintenance beyond the legal requirements is necessary.
When using high-pressure cleaners on the machine, please make sure that the water jet is not
aimed directly at the brake valve(To prevent damaging the bellows).
For safety reasons the whole of the brake valve must be replaced if parts other than those
listed above are damaged.
(9) Repair work
When working on the braking system, always make sure that there is absolutely no
pressure in the system. Even when the engine is switched off there will be some
residual pressure in the system.
Ɠ When doing repair work, make sure your environment is very clean.
Immediately close all open ports on the components and on pipes using plugs.
(10) Replacing the pedal cover
Pedal cover(15) is simply pulled of by hand. The new pedal cover is pushed over pedal(12) and
tightened manually. Fasten the bellows with the strap retainers.
(11) Replacing the complete actuating mechanism
Carefully clamp the unit vertically in a fixture. The actuating mechanism can be removed by
taking out the four screws(36) below base plate(1). Make sure that spring assembly (21) does
not fall out. When installing the new actuating mechanism, make sure that spring assembly (21)
is fitted in the right order. Tighten the four screws(36).
(12) Replacing the bellows
To change bellows(6) it is advisable to remove pedal(12). For this purpose, loosen retaining ring
(10) and knock out pin(14) using a mandrill. When knocking out the bolt, make sure that the
mandrill is applied to the side of the bolt without a knurl. Remove pedal(12) and bellows(6).
Now fit the new bellows(6) and proceed in reverse order as described above. The upper portion
of bellows(6) is fastened to piston(5), its lower portion to base plate(1) secure the bellows using
clamps.
(13) Replacing the grooved ring
Carefully clamp the unit vertically in a fixture. Unscrew plug(35) and pull spool(28 and 31) out
downwards. Check the spools for damage. If they are found to be damaged, the whole brake
valve needs to be replaced(Pairs of spools and housings are matched in manufacturing).
If the spools are not damaged in any way, remove the whole actuating mechanism as described
above. Remove spring assembly(21) and grooved ring(27) and put in a new greased grooved
ring with its lips pointing downwards. Install both the spring assembly as shown in the drawing,
and the pedal. Put in spring(30), followed by spool(31), using a slight turning motion if possible.
Insert spring(32) and close the unit with screw plug(35).
Check return ports(51, 52) to see if there is a gap of approx 2mm between the lower edged of the
hole and the control edge of spool(28). If this is not the case, take out screw plug(35) once more
and change the setting by removing or adding distance washers(19) in the upper spring plate.
Replace the screw plug and once again check the distance between the lower edge of the hole at
ports(51, 52) and the control edge of spool(28).
4-16
5. CUT-OFF VALVE
1) STRUCTURE
1 35 37 36 38 30 3 2 5 6 4 34 7
31
32
23
33
21
16 15 14 20 21
VIEW A
1 Housing 15 Washer 33 Spool

2 Spool 16 Screw plug 34 Nut
3 O-ring 20 Shuttle valve 35 Ball
4 Back up ring 21 Retaining ring 36 Spring
5 Cap 23 Spring 37 Washer
6 Spring 30 Screw 38 Plug
7 Pipe 31 Ball
14 Return valve 32 Plug
4-17
2) OPERATION
E1 E2
27
G
F 21 22 23
5
28
27
28
1
1
5
21
Item Spec
22 Cut-in pressure 120+10kgf/cm2
Cut-off pressure 150-10kgf/cm2
Flow rate 45ֻ/min
23 Flow rate to the brake circuits 3+1ֻ/min
Max pressure at port 5 Max 200kgf/cm2
Temperature of medium -30 ~ +80Ş
C
Ambient temperature -30 ~ +80Ş
C
VIEW A Medium Mineral oil
M12ź1.5 2.9Ź0.31kgşm
Torque M16ź1.5 4.1Ź0.51kgşm
M18ź1.5 5.1Ź0.51kgşm
4-18
(1) Purpose
The purpose of the cut-off valve is to control the pressure level in the accumulators.
The cut-off valve must keep the pressure level of the brake accumulators between 120 kgf/cm2
(1710psi) and 150kgf/cm2(2130psi). This is obtained by a switching mechanism which pressurizes
the braking system again to approx 150 kgf/cm2, only if the pressure has dropped to less than
120kgf/cm2.
(2) Ready position
When the braking system is ready for operation(i.e. the accumulators are charged) the pump
stream is present at port 1 of the cut-off valve. A connection is established between ports 1 and 5
so that the pump stream is, with a small difference in pressures, returned directly to the reservoir.
The rear of main spool(33) is pressureless. The pressure within the braking system will hold
control spool(2) in its locked position(E1) in which the rear of main spool(33) is directly connected
to return 5 via hole(G). Check valve(14) in the hole to port 27 secures the accumulator pressure
of the operating accumulator. This is available as an additional braking volume for the braking
system, preventing excessively frequent actuation of the cut-off valve in the event of a leakage.
Shuttle valves(20) additionally secure each braking circuit against pressure looses in the event of
a broken pipe.
(3) Charging process
As the accumulator pressure falls to the preset value, control spool(2) will, through the force of
spring assembly(6), overcome its locked position(E1) and move to another locked position(E2).
Via orifice(F) and oil stream flows to the rear of main spool(33). The pressure building up at the
rear of main spool(33) and the pressure present below main spool(33) put main spool(33) in a
floating position, permitting a partial stream to continue to reach port 5 and the remaining stream
to flow to ports(21, 22, 23) via check valve(14) until the pressure within the braking system is
approx 150kgf/cm2. Control spool(2) will then once again move to locked position(E1) in which a
connection is established between ports 1 and 5. The whole of the pump stream once again
flows to the reservoir via port 5. Check valve(14) again secures the accumulator pressures.
The connecting line must be installed in such a way as to permit proper bleeding. The double
check valve can be mounted in any position.
(5) Maintenance of the cut-off valve
(6) Repair work
pressure in the system. Even when the engine is switched off there will be some residual
pressure in the system.
Ɠ When doing repair wok, make sure your environment is very clean.
Ɠ For safety reasons the whole of the cut-off valve must be replaced if damaged.
4-19
6. PARKING BRAKE CYLINDER
1) STRUCTURE
1
Item Spec
A
Operating pressure Max 150kgf/cm2
Stroke 80Ź3mm
Release pressure 80+4kgf/cm2
Threaded port M16ź1.5
Weight 8.0kg
Operating temperature range -40 ~ 80Ş
C
B Medium Mineral oil
G Output force at 0mm stroke 3.0kN

Output force at 80mm stroke 5.0kN
E
F H Piston rod deflection 3Şon all sides
D Emergency release facility Yes
Yoke Yes
C Bellows Yes
1 Port C Piston rod F Arrow

A Hydraulic portion D Quick release facility G Clamp
B Spring E Bellows H Clamp
2) OPERATION
(1) Purpose
The spring brake cylinder serves to generate the braking force for the wheel brake in parking
braking systems.
(2) Ready position
In the driving condition, the pressure from the parking brake solenoid valve is acting directly on
port 1 of the spring brake cylinder. The parking brake is released.
(3) Braking position
When the parking brake solenoid valve is actuated, the hydraulic pressure is reduced as a
function of the parking brake solenoid valve.
As the pressure in the hydraulic portion(A) of the spring brake cylinder is reduced, the force of the
releasing compression spring(B) makes piston rod(C) retract in the direction of the cylinder's axis,
thus actuating the wheel brake. The spring brake cylinder's maximum brake force is reached
when the pressure falls to zero.
4-20
(4) Quick release facility
This cylinder is available with a quick-release facility.
This permits, in the event of the pressure in the hydraulic portion(A) failing, the wheel brake to be
released by applying a blow in the direction of the arrow(F), using a hammer, thus severing the
frictional connection established between compression spring(B) and piston rod(C) and actuating
the quick-release facility(D).
As the pressure in the hydraulic portion(A) builds up again, the connection between compression
spring(B) and piston rod(C) is established once more and the spring brake cylinder is fully
operative again.
The connecting lines must be installed in such a way as to permit proper bleeding. The cylinder
should be mounted at a slight angle, its piston rod pointing downwards.
(6) Maintenance of the spring brake cylinder
No maintenance beyond the legal requirements is necessary.
(7) Repair work
pressure in the system. Even when the engine is switched off there will be some residual
pressure in the system.
Ɠ For safety reasons the whole of the spring brake cylinder must be replaced if parts other
than those listed above are damaged.
(8) Replacing the bellows
Remove clamp(H) from the bellows, replace as necessary when fitting the new bellows. Pull off
the faulty bellows(E), push on new bellows and fasten with clamp(H).
The enclosed portion of the cylinder is spring-loaded.
4-21
7. BRAKE ACCUMULATOR
1) STRUCTURE
81L1-0004
Item
(Item15)
Diameter 121mm
Mounting height 155mm
Nominal volume 0.75m3
Priming pressure 50kgf/cm2
Operating medium Oil
B
Operating pressure Max 180kgf/cm2
Thread M18ź1.5
A Operating temperature range -30 ~ 80Ş
C
C
Priming gas Nitrogen
A Fluid portion C Diaphragm

B Gas portion D Valve disk
2) OPERATION
(1) Purpose
Fluids are practically incompressible and are thus incapable of accumulating pressure energy. In
hydropneumatic accumulators, the compressibility of a gas is utilized to accumulate fluid. The
compressible medium used in the accumulators is nitrogen.
In braking systems, the purpose of the accumulators is to store the energy supplied by the
hydraulic pump. They are also used as an energy reserve when the pump is not working, as a
compensator for any losses through leakage, and as oscillation dampers.
(2) Operation
The accumulator consists of a fluid portion(A) and a gas portion(B) with a diaphragm(C) as a gas-
tight dividing element. The fluid portion(A) is connected to the hydraulic circuit, causing the
diaphragm accumulator to be filled and the gas volume to be compressed as the pressure rises.
When the pressure falls, the compressed gas volume will expand, thus displacing the
accumulated pressure fluid into the circuit.
The diaphragm bottom contains a valve disk(D) which, if the diaphragm accumulator is
completely empty, closes the hydraulic outlet, thus preventing damage to the diaphragm.
The accumulators can be fitted in the hydraulic circuit, directly on a component or in blocks on
suitable consoles.
They should be fitted in as cool a location as possible.
Installation can be in any position.
4-22
(4) Maintenance of the accumulator
The accumulator should be checked annually. It should be replaced if the initial gas
pressure has fallen by more than 30%(Please refer to Performance testing and
checking of the accumulator).
(5) Disposal of the accumulator
Before the accumulator is scrapped, its gas filling pressure must be reduced. For this
purpose, drill a hole through gas chamber(B) using a drill approx 3mm in diameter. The
gas chamber is located on the side opposite the threaded port above the welding seam
around the center of the accumulator.
Ɠ Wear safety goggles when doing this job.
(6) Performance testing and checking of the accumulator
The accumulator is gradually pressurized via the test pump; Until the initial gas pressure is
reached, the hydraulic pressure in the accumulator will rise abruptly. This is apparent
from gauge M. If the initial gas pressure is more than 30% below the prescribed value,
the accumulator needs to be replaced. If the measuring process needs to be repeated,
wait for intervals of 3 minutes between the individual tests. Any accumulator whose initial
gas pressure is insufficient must be scrapped following the instructions under Disposal of
the accumulator.
The amount of initial gas pressure can also be checked from the machine. Start the
machine's engine. The pump will now supply oil to the accumulators. Until the initial gas
pressure is reached, the hydraulic pressure in the accumulator will rise abruptly. This is
apparent from the gauge in the cab. If the initial gas pressure is more than 30% below the
prescribed value, that initial pressure lies outside the permissible range for at least one of
the accumulators fitted in the machine. This accumulator can be traced only by using the
method described above, i.e. all accumulators have to be individually tested. The
accumulator whose initial gas pressure is insufficient must be replaced and scrapped
following the instruction under Disposal of the accumulator.
Accumulator M
A Safety valve
4-23
(7) Repair work
pressure in the system. Even when the engine in switched off there will be some
For safety reasons the accumulators need to be replaced as a whole if damaged.
4-24
8. PRESSURE SWITCHES
1) STRUCTURE
şNormally closed
H1
şNormally open
H2
ş Technical data
H1 H2 Adjusting range Adjusting pressure Voltage
Item Type Medium G
mm mm kg/cm2 kg/cm2 V
Parking NC Oil M12ź1.5 55 9 20 ~ 50 21 Ź 2 Max 42

Charging NC Oil M12ź1.5 55 9 50 ~ 150 100 Ź 10 Max 42
Brake stop NO Oil M12ź1 43 9 3~6 3~6 Max 42
Clutch cut-off NO Oil PF 1/4 55 9 20 ~ 50 24 Ź 2 Max 42
NC : Normally closed NO : Normally open
4-25
2) OPERATION
(1) Purpose
The pressure switches are used to visually or audibly warn the driver of the pressure within the
system.
(2) Make contact / circuit closer
The pressure switch can be fitted in the braking system or directly on one of its components.
The system pressure acts on an absorption area within the switch, making an electrical contact as
the pressure on that area is increased. The resulting current is used to activate a warning facility,
for instance.
(3) Break contact / circuit breaker
The pressure switch can be fitted in the braking system or directly on one of its components.
The system pressure acts on a absorption area within the switch, breaking an electrical contact
as the pressure on that area is increased. The current is now broken, e.g. to deactivate a
warning facility.
No special measures need to be taken.
(5) Maintenance of the pressure switch
When using high-pressure cleaners on the machine, please make sure that the water jet is not
directed at the pressure switch(Corrosion of contacts).
(6) Repair work
pressure in the system. Even when the engine is switched off there will be some
Ɠ For safety reasons the pressure switch needs to be replaced as a whole if damaged.
4-26
(7) Adjusting and testing pressure switch
The adjusting screw located between the two contact plugs can be set to the desired value within
a certain range. For adjusting range, please refer to the table Technical data on the previous
page.
After making the adjustment, the adjusting screw should be secured using wax or a similar
material.
(,)
(+) Screw
4-27
9. PARKING BRAKE
1) STRUCTURE
4
1
1 Parking brake drum 4 Lever 6 Spring

2 Parking brake cylinder 5 Rod 7 Piston rod
2) OPERATION
(1) The parking brake is drum type and is installed on the transmission.
(2) The force of the spring(6) inside the parking brake actuator(2) is used to apply the brake
mechanically; It is released by hydraulic pressure.
(3) The parking brake cylinder mounting bracket is fixed to the transmission housing. The drum is
installed to the output shaft of the transmission.
4-28
(4) Brake operated
When the parking brake switch is pushed
for parking, the solenoid valve is actuated
and the valve open the exhaust port.
2
At the same time, the hydraulic oil in the
parking brake actuator(2) return to the
tank. When the piston rod(7) is returned 6
by the force of the spring(6), the parking
brake is applied.
(5) Brake released

When the parking brake switch is pushed
once more, the solenoid valve is actuated
and the hydraulic oil controlled the
pressure level by the cut-off valve enters 2
the parking cylinder(2). It overcomes the
force of the spring(6) and pushes the 6
piston rod(7).
This releases the parking brake.
Therefore, the hydraulic oil pressure is
applied to the parking brake actuator(2) 7
and the parking brake is kept released.
4-29
1. OPERATIONAL CHECKS
This procedure is designed so the mechanic can make a quick check of the system using a minimum
amount of diagnostic equipment. If you need additional information, read Structure and function,
Group 1.
Chapter 2 : Troubleshooting
Group 3 : Tests and adjustments
4-30
ƓHydraulic oil must be at operating temperature for these checks(Refer to page 6-51).
Parking brake capacity Start engine. OK

check 20 30 Check completed.
20 Fasten seat belt.
Seat belt must be worn 10
10
40
NOT OK
while doing this check to 5 0 mph
30
Release parking brake and put
0
km/h 50
Inspect parking brake. Go
prevent possible injury transmission in 2nd gear forward.
to group 3.
when machine stops
Drive machine at 8 km/hr and
suddenly.
switch parking brake ON.
LOOK/FEEL : Machine must
come to a stop within 2 meters(6
feet) when parking brake is
engaged at 8 km/hr.
Transmission must shift to neutral.
Parking brake Turn parking brake to ON. OK

transmission lockout Check completed.
Place transmission in 1st forward.
check
NOT OK
Engine running. Slowly increase engine speed to
Go to transmission control
high idle.
circuit in section 3.
LOOK : Machine must not move.
4-31
Service brake pump Stop engine. OK

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

check Check completed.
Apply service brakes, release park
Engine running.
brake and put transmission in 2nd NOT OK
forward. Check brake pressure in
group 3.
Increase engine speed to high
idle. IF OK
Inspect brake disk, see
LOOK : Machine may not move
group 3.
or move at a very slow speed.
Repeat check three times to
ensure accurate results.
4-32
Brake accumulator Start and run engine for 30 OK

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

ON STAR
T
Stop engine.
F
OF
NOT OK
Wait 2 minutes.
If brake leakage is
Turn key switch to ON and wait 5 indicated with brakes
seconds. released, check leakage
at accumulator inlet check
LOOK : Brake oil pressure
valve and brake valve. If
warning lamp must not come on
brake leakage is indicated
within 2 minutes after stopping
with brakes applied, check
engine.
for leakage at brake valve
and brake pistons.
Check individual
component leakage.
4-33
Service brake pedal Slowly depress brake pedal. OK

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

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

position. Check completed.
Release parking brake. NOT OK
Adjust clutch cut-off
Run engine at half speed in 1st
switch, see group 3.
forward.
Firmly depress brake pedal.
FEEL : Transmission must
disengage when brake pedal is
depressed at 30% of pedal stroke.
NOTE : Clutch cut-off pressure
switch can be adjusted to operator
preference to match your loading
needs.
4-34
2. TROUBLESHOOTING
1) SERVICE BRAKE
Diagnose malfunction charts are arranged from most probable and simplest to verify, to least likely,
more difficult to verify. Remember the following steps when troubleshooting a problem :
Step 1. Operational check out procedure(See section 1)
Step 2. Operational checks(In this group)
Step 3. Troubleshooting
Step 4. Tests and adjustments(See group 3)
Poor or no brakes Brake accumulator charge low. Do brake accumulator check.

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

Clutch cut-off switch out of Adjust switch.
adjustment.
Brake valve malfunction. Disassemble and inspect.
Low oil level. Check oil level.
Brakes drag Brake pedal not returning Inspect floor mat and pedal.
properly.
Debris holding valve partially Do brake valve pressure test.
open in brake valve.
Warped brake disk. Inspect brake disk.
Stuck brake piston. Repair.
Brakes lock up Brake valve malfunction. Clean or replace brake valve.
4-35
Brakes chatter Air in brake system. Do brake bleed procedure.

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

light will not go out or pressure warning switch.
stays on excessively
Brake accumulator pressure Recharge accumulator.
long after start-up
too low.
Low brake pump standby Do brake pump standby pressure test.
pressure setting.
Leakage in pressure reducing Do pressure reducing valve manifold leakage
manifold block. test.
Leakage in brake system. Do brake system components leakage tests.
Worn brake pump. Do brake pump flow test.
Leakage in parking brake Do parking brake pressure test.
solenoid.
4-36
2) PARKING BRAKE MALFUNCTIONS
Brake will not hold Pads not adjusted correctly. Adjust parking brake.
Malfunctioning parking brake Inspect and replace.
solenoid.
Worn brake disk and / or brake Disassemble, inspect, repair.
pads.
Brake piston hangs up in bore. Remove and inspect. Repair.
Brake disk overheats Pads out of adjustment. Adjust parking brake.

Brake not released. Release parking brake.
Disassemble, inspect brake.
Repair if necessary.
Inspect for loosen or broken lines between brake
pressure switch and indicator on dash.
Parking brake indicator Faulty wiring or switch. Inspect for loose or broken lines between brake
in monitor does not pressure switch and indicator on dash.
come on when brake Inspect for a faulty indicator on dash. Replace if
applied necessary.
Brake will not apply Pads out of adjustment. Adjust parking brake.
Malfunctioning wiring, switch, Check electric circuit.
or solenoid.
Restriction between brake Remove hose and inspect. Replace.
valve and brake.
4-37
1. PARKING BRAKE PERFORMANCE

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

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

Remove axle housing and inspect for wear of
brake disks.
Replace brake disks if oil grooves of facing
material are no longer visible.
4-38
3. HYDRAULIC BRAKE BLEEDING PROCEDURE
Escaping fluid under pressure can
penetrate the skin causing serious injury. B
Avoid the hazard by relieving pressure
before disconnecting hydraulic or other
lines. Tighten all connections before
applying pressure.
Search for leaks with a piece of
cardboard. Protect hands and body from
high pressure fluids.
Ɠ If an accident occurs, see a doctor
immediately. Any fluid injected into the
skin must be surgically removed within a
few hours or gangrene may result.
Doctors unfamiliar with this type of injury
A
should reference a knowledgeable
medical source.
Two people are required to bleed brake
system oil, one to operate brake valve and
other to open and close bleed screws.
1) Install frame locking bar. Engage parking
brake.
2) Put a clear plastic tube on bleed screw(B)
to route low to hydraulic reservoir filler tube
or container(A).
3) Start engine and run at low idle.
4) Push and hold brake pedal down until
brake bleeding procedure is complete. Frame locking bar
Ɠ If bubbles continue for more than 2
minutes, stop bleeding procedure.
Check for and correct problem, then
continue.
5) Open on bleed screw on differential and
axle assembly until hydraulic oil starts to
flow. Close bleed screw when oil is free of
air. Release brake pedal.
6) Repeat steps 1-5 for each bleed screw.
7) Push either brake pedal and hold down.
8) Check hydraulic oil level.
4-39
GROUP 4 DISASSEMBLY AND ASSEMBLY
1. BRAKE PUMP
1) STRUCTURE
31
20
21
22
24
27
32 25
33 23
22
21
20
23 19
28
35
36
26 24
29
30
19 Spacer plate 25 Drive gear 31 Cover

20 O-ring 26 Drive gear 32 Washer
21 Back up seal 27 Rear body 33 Bolt
22 Seal element 28 O-ring 35 Dowel
23 Bushing 29 Coupling 36 O-ring
24 Bushing 30 Cap screw
4-40
2) GENERAL
(1) Introduction
Each unit comprises an end cover, body housing, the bush/gear assembly and a mounting flange
bolted together. The gear/bush assembly consists of a pair of meshing gears supported by plain
bearings in the bushes. The drive gear journal extends through the mounting flange to form the
drive shaft. A lip type shaft seal and O-rings provide external sealing whilst special lobe seals and
backing rings are used internally.
(2) Routine maintenance
No maintenance is necessary other than periodic checks for tightness of the mounting bolts and
visual examination for oil leakage. The unit should be kept externally clean, especially in the area
of the shaft seals as dirt can accelerate seal wear and cause leakage.
The unit must be operated only with clean oil and the system manufacturer's directions for
periodic renewal of system oil filter elements must be strictly observed.
(3) Field servicing
Seal kits and spare parts are available to enable units to be serviced.
4-41
3) DISASSEMBLY
31
20
21
22
24
27
32 25
33 23
22
21
20
23 19
28
35
36
26 24
29
30
Ɠ Before disassembling ensure that the unit itself, bench and tools are thoroughly clean.
(1) Lightly mark the end cover(31), body(27) and spacer plate(19) to ensure reassembly in the
correct position.
(2) Remove the bolts(18) and separate the brake pump unit from the main pump using a soft faced
hammer.
(3) Remove splined coupling(29) and O-rings(28) sealing the internal passages between the pump
sections.
(4) Remove the spacer plate(19) from the body(27), free from spacer plate from location dowel(35)
using a soft faced hammer.
(5) Remove the backup seal(21), the seal element(22) and the body O-ring(20).
(6) Remove the end cover(31) from the body(27).
(7) Remove the backup seal(21), the seal element(22) and the body O-ring(20).
Ɠ Before removing the internal components each bushing(23, 24) must be marked to denote its
location within the body. On the plain area of the bush away from the seal location, lightly mark.
(8) With the unit laying on its side grasp hold of the drive shaft(26) and pull it squarely out of the body
(27) bringing the bushing(23, 24) with it.
(9) Remove the driven gear(25) and the two remaining bushing(23, 24).
4-42
4) INSPECTION AND REPAIR
(1) Assessment
Each components should be thoroughly cleaned, carefully examined and assessed for suitability
re-use. Below is a guide for inspecting the various components.
(2) Body
‫ ڸ‬Inspect the body bore cut-in where both gears wipe into the body.
‫ ڹ‬The body can only be re-used if the cut-in is bright and polished in appearance and the depth
does not exceed 0.15mm(0.006").
‫ ں‬The body should be replaced if the surface is scored, has a matt appearance or shows signs that
the tip of the gears have dug in and torn away the surface material.
‫ ڻ‬The body should be inspected to ensure that there is no superficial damage which may
adversely effect performance or sealing. Pay particular attention to the port threads and body O-
ring seal recesses.
(3) Spacer plate and end cover
‫ ڸ‬The inner surfaces should be inspected to ensure that there is no unusual wear or scoring in the
regions where the body O-rings and backing rings contact, which result in external leakage.
‫ ڹ‬Check the shaft seal recess for scoring or damage that could result in oil leakage around the
outer diameter of the shaft seal. Replacement shaft seals can be refitted with Loctite hydraulic
sealant to overcome slight damage in this area.
(4) Bushing
‫ ڸ‬The side faces which abut the gears should be perfectly flat showing no sign of scoring.
Characteristically there are bright polished areas on this surface caused by loading against the
gear side faces, which is often more pronounced on the low pressure side. The bush should be
replaced if there is any general scoring or fine scoring with a matt appearance or tearing of the
surface material. Often there is a witness where the tips of the opposing gears have wiped an
overlap reassembling a half moon shape. There must be no noticeable wear step as it is critical
that the bush side face is completely flat to the gear side face.
‫ ڹ‬The bearing liners are acceptable providing that they are not scored or show other damage.
The general outside area of the bush should not show any prominent signs of wear.
(5) Gears
‫ ڸ‬The gear side faces should be examined for bruising or scoring. Often operation on
contaminated fluid shows scoring between the root of the gear and the journal undercut, which
leaves a wear step. If a wear step can be felt, coincidental with the root diameter, by drawing a
sharp pointed tool across the surface from the undercut outwards towards the tip of the gear,
then the gear is unserviceable.
‫ ڹ‬The gear teeth should then be carefully examined to ensure that there are no signs of bruising or
‫ ں‬pitting.
The journal bearing surfaces should be completely free from scoring or bruising. The surface
‫ ڻ‬should appear highly polished and smooth to touch.
Examine the area where the shaft seal lips run on the drive shaft, this shows up as a polished
‫ ڼ‬ring or rings. If a noticeable groove can be felt or there is scoring the shaft should be replaced.
Provided the drive shaft is not damaged from the drive-coupling and the gears have not been
harmed as described above, then the gears can be re-used. If, however, the gears are
‫ ڽ‬damaged they must be replaced as a matched pair.
As a matter of good practice, when pumps have been disassembled, all the seals should be
replaced. It is most important that only the genuine seals are used.
4-43
5) ASSEMBLY
31
20
21
22
24
27
32 25
33 23
22
21
20
23 19
28
35
36
26 24
29
30
Ɠ Ensure that all parts are perfectly clean and lightly lubricate the bushes and gears with hydraulic
oil(Ensure body O-ring recess and end faces remain free from oil). This will assist with their
assembly when they are later fitted into the body.
(1) Refit the cover drive shaft bushing(23) and cover driven bushing(24) into the undowelled end of
the body(27) from where they were removed.
(2) Place the end cover(31) against the body(27) and then stand the assembly on the cover so that
the hollow dowels are uppermost, i.e. the bushing should be at the bottom with the bushings
against the cover.
(3) Fit the drive shaft(26) and driven gear(11) back into their original positions in the body(27).
(4) Refit the separate plate drive shaft bushing(24) and the separate plate driven bushing(23) into
their original bores.
(5) Fit the new body O-ring(20).
(6) Fit the new seal element(22) and backup seal(21) to the bushing.
(7) Fit the dowel(35) to the body(27).
(8) Carefully refit the spacer plate(19) to the body(27). If the spacer plate(19) is not fitted squarely
the backup seal(21) may become misplaced and trapped, resulting in internal damage if the unit
is run in this condition.
4-44
ASSEMBLY
31
20
21
22
24
27
32 25
33 23
22
21
20
23 19
28
35
36
26 24
29
30
(9) Fit O-rings(28, 36) and coupling(29) to the spacer plate(19).

(10) Holding the whole unit together carefully turn it over, making sure it is supported on the spacer
plate(19) not the shaft.
(11) Slide off the end over and fit seals as in (5) and (6) above.
(12) Fit the end cover(31), taking care not to dislodge the backup seal(21) and bolt(33) the unit
together. Tighten the bolts to the torque figures stated below.
şTightening torque : 5.0Ź0.3kgfşm(36.2Ź2.2lbfşft)
Ɠ Pour a small amount of oil into a port and check that the shaft can be rotated without undue force
using a smooth jawed hand wrench hooked around the shaft or a suitable half coupling locked
against the key.
4-45
9) RUNNING-IN
Pressure gauge
Test unit Variable

Microbic restrictor
filter
Flow
meter
Relief valve
Strainer
Tank
(1) A unit which has been re-assembled with either new gears, bushes or body, must be carefully
run-in before it is subjected to full working conditions.
(2) Ideally this should be done on a test rig(See figure) where pressure can be gradually applied and
any wipings from the body cut-in arrested by filters.
(3) It is recommended that the unit is run-in at 1500rpm, initially, at zero pressure for one minute then
in stages with the pressure increased by 500psi every minute, until maximum rated pressure has
been attained. Frequently check the system temperature, ensuring that it does not exceed the
maximum permissible figure of 80Ɓ C. If the temperature exceeds the system or unit specification
the test must be delayed and operated off-load until acceptable temperatures are obtained.
4-46
SECTION 5 STEERING SYSTEM
1. OUTLINE
The steering system of this machine consists of a fixed-displacement pump supplying a load sensing
steering system and an open center loader system.
The components of the steering system are :
şSteering pump(1st pump)
şSteering valve
şPriority valve
şCushion valve
şSteering cylinders
The steering pump, the first pump of main pump, draws hydraulic oil from the hydraulic tank.
Outlet flow from the pump flows to the priority valve. The priority valve preferentially supplies flow, on
demand, to the steering valve. When the machine is steered, the steering valve routes flow to the
steering cylinders to articulate the machine.
When the machine is not being steered, or if pump flow is greater than steering flow, the priority valve
supplies flow to the loader system.
That is, output flow from the steering pump enters into the second pump of main pump for the
operation of the attachment.
5-1
LH RH
L R
H E A 1st pump
B 2nd pump
C Brake pump
G
MCV
T LS P
RCV lever
30
Return line
Return line
33
LS CF EF
4 21MPa
T
D
P
Brake system
C B A
1
Return line
31 30 23
LS P EF
28
29 21MPa
24
25 26
27
32
A
1 Pump assy 24 Hydraulic tank 29 Emergency pump(Option)

4 Priority valve 25 Return filter 30 Check valve(Option)
5 Steering valve 26 Bypass valve 31 Check valve(Option)
6 Cushion valve 27 Oil cooler(Option) 32 Pressure switch(Option)
9 Steering cylinder 28 Check valve(Option) 33 Pressure switch(Option)
23 Air breather
5-2
1) NEUTRAL
LH RH
L R
5
H A 1st pump
E
B 2nd pump
C Brake pump
T LS P MCV
Return line
LS CF
4 21MPa
EF
T
D
P
RCV lever
Brake system
1 C B A
Return line
Return line
23
28
24
25 26 27
ş The steering wheel is not being operated so control spool(G) does not move.
ş The oil from the steering pump(A) enters port P of the priority valve and the inlet pressure oil moves
the spool(D) to the left.
ş Oil flow into LS port to the hydraulic tank(24) through orifice and return filter.
ş So, the pump flow is routed to the loader system(Main control valve) through the EF port.
5-3
2) LEFT TURN
LH RH
L R
5
H A 1st pump
E
B 2nd pump
C Brake pump
G
T LS P MCV
Return line
LS CF
4 21MPa
EF
T
D
P
RCV lever
Brake system
1 C B A
Return line
Return line
23
28
24
25 26 27
ş When the steering wheel(E) is turned to the left, the spool(G) within the steering unit(5) connected
with steering column turns in left hand direction.
ş At this time, the oil discharged from the steering pump flows into the spool(G) of the steering unit(5)
through the spool(D) of priority valve and flows into the gerotor(H).
ş Oil flow from the gerotor flows back into the spool(G) where it is directed out the left work port(L) to
the respective chamber of the steering cylinders(9).
ş Oil returned from left and right cylinder returns to hydraulic tank through the spool of the steering unit.
ş When the above operation is completed, the machine turns to the left.
5-4
3) RIGHT TURN
LH RH
L R
5
H
E A 1st pump
B 2nd pump
C Brake pump
G
T LS P MCV
Return line
LS CF
4 21MPa
EF
T
D
P
RCV lever
Brake system
1 C B A
Return line
Return line
23
28
24
25 26 27
ş When the steering wheel(E) is turned to the right, the spool(G) within the steering unit(5) connected
with steering column turns in right hand direction.
ş At this time, the oil discharged from the steering pump flows into the spool(G) of the steering unit(5)
through the spool(D) of priority valve and flows into the gerotor(H).
ş Oil flow from the gerotor flows back into the spool(G) where it is directed out the right workport to the
respective chamber of the steering cylinders(9).
ş Oil returned from left and right cylinder returns to hydraulic tank through the spool of the steering unit.
ş When the above operation is completed, the machine turns to the right.
5-5
3. PRIORITY VALVE
1) STRUCTURE
20 19 6 1 19 18
4 3 5 11 10 9
2 8 14 17 13 16 12 15
1 Housing 8 Body sub assy 15 O-ring

2 Spool assy 9 Body 16 Guide
3 Spool 10 Ring 17 Holder
4 Orifice 11 Screen 18 Plug
5 Orifice 12 Screen 19 O-ring
6 Control spring 13 Spring 20 Plug
7 Relief cartridge 14 Ball
5-6
2) OPERATION
(1) Neutral
C
CF EF 3 9 EF CF LS
LS D
LOADER ACTUATED
P
C
The priority valve is a pressure control valve that maintains priority pressure to the closed center
steering valve. With the steering valve in neutral, flow through is blocked and all flow through the
priority valve is directed out the EF port to the main control valve.
With the engine off, the spool(3) is pushed to the left(Viewed from sectional drawing) by the spring(9).
The passage to the EF port is blocked while the passage to the CF port is open.
When the machine is first started, all pump flow is routed to the steering valve which blocks the flow.
With the flow blocked, the pressure increases.
Steering inlet pressure is supplied through the pilot orifice to the left end of the spool. This causes the
priority valve spool to shift to the right against the spring and open the EF port.
As long as the steering valve is in neutral, just enough pressure is maintained at the steering valve to
keep the priority valve spool shifted to the right.
The operating pressure in the loader system has no effect on the operation of the priority valve. With
the loader actuated in relief(D) the priority valve will not shift until the machine is steered.
Flow through the priority valve spool passes from the CF port through the orifice(C) and into the LS port.
It flows through the steering valve LS passage which is routed to return when the steering valve is in
neutral. This provides a warm-up circuit for the steering valve to prevent binding of the steering valve
due to oil temperature extremes.
The priority valve has a test port located on the side of the valve section to test P port pressure.
5-7
(2) Midturn
C
CF EF 3 9
EF CF LS
FULL STEER RATED

P
17 C
When the machine is steered, load sensing pressure from the steering valve flows through the orifices
LS port in the priority valve. Load sensing pressure plus spring(9) force move the spool to the against
the pilot pressure on the right end of the spool. This restricts flow to the loader through the EF port
while the CF port is opened to the steering valve.
The load sensing circuit is control circuit that routes steering workport pressure to the spring side of the
priority valve spool. It allows the priority valve spool to sense the pressure that is required to steer the
unit under varying conditions.
During normal steering conditions, oil is entered into the load sensing circuit through an orifice in the
steering valve. When steering at the full steer rate(D), the orifice opens to an unrestricted passage. At
low engine speed, the spool will shift to the full left position, directing all flow to the steering valve. At
high idle, the steering system can use about one-half of the pump flow. Therefore, the excess oil flows
to the main control valve.
The load-sensing circuit receives the majority of its flow from the load sensing orifice in the steering
valve. Some flow is also supplied from the CF port through orifice(C) in the priority valve spool.
5-8
(3) Full turn
C
CF EF 3 9
EF CF LS
LS
P
17
When the machine is steered to a full turn, the frames bottom against the steering stops. To limit
steering system pressure, a relief system is built into the priority valve assembly.
When the frames bottom is stoped, the pressure in the steering cylinders increases. This pressure is
sensed at the LS port. When the pressure in the LS port increases enough to push poppet(3) off its
seat, oil in the load sensing circuit flows to return through the T port. Load sensing pressure is limited to
the pressure setting of the relief valve.
Pressure to the steering valve(Pilot pressure), which is sensed at the left end of the priority valve
spool(3), continues to increase until it can move the spool to the right against the load sensing pressure
plus spring force. At this time, all oil flows out of the EF port to the loader control valve.
If the loader attachment is being operated while steering, the loader function will slow until the machine
reaches the steering stops. At that time, the loader cycle speed will increase until the machine is
steered again.
5-9
4. STEERING VALVE
1) STRUCTURE
21 17 18 19 20 22 23
25
24
14
SECTION B-B DETAIL D SECTION C-C
15 16 12 3
B B
C
B B C
C
A D C
13 11 10 7 8 9 6 5 4 2 1
SECTION A-A
1 Cap screw 10 Pin 18 Compression spring

2 End cap 11 Centering spring 19 Plug
3 O-ring 12 Needle bearing 20 O-ring
4 Gerotor 13 Bearing race 21 Valve seat
5 Spacer plate 14 O-ring 22 Ball
6 Drive 15 Dust seal 23 Roll pin
7 Housing 16 Retaining ring 24 Backing ring
8 Sleeve 17 Poppet 25 Seal
9 Spool
5-10
2) OPERATION
A NEUTRAL
B
D Load sense port to priority valve
4 Gerotor
System pressure oil

Spool 9 G Return
Work pressure oil
J 8
G Trapped oil
Steering shaft Sleeve F
Return
From priority valve Return pressure oil
The steering valve consists of a spool(9) inside a sleeve(8) within a housing. When steering wheel is
not moving, the valve is in the neutral(A) position. In neutral, the spool and sleeve are aligned so that
oil flow through the valve is blocked. The steering cylinder(B) are held stationary by trapped oil in the
left and right workports.
When the steering valve is turned to the right, the spool rotates relative to the sleeve, and opens
passages which allow pump flow through the spool and sleeve assembly. Oil flows to the gerotor(4)
causing the gerotor gear to rotate. Oil flow from the gerotor flows back into the valve where it is
directed out the right workport to the respective ends of the steering cylinders.
A bypass orifice is machined into the spool and sleeve assembly. It is a variable orifice that introduces
a small leak into the pressure side of the steering valve. Its purpose is to dampen the initial pressure
surge when the steering wheel is partially turned. When the steering wheel is fully turned, the leak is
closed off.
Return oil flows back in through the left workport through the spool and sleeve assembly to return. The
load sensing orifice is located between the sleeve and the gerotor. This orifice feeds the load sensing
circuit between the steering valve and the priority valve through the LS port.
When the rotation of the steering wheel stops, the gerotor gear continues to move, turning the sleeve,
until the sleeve stops the flow to the gerotor. At this point, the valve is back in the neutral position and
will remain there until the steering wheel is moved again.
The valve has a variable steering which is proportional to the speed the steering wheel is rotated. A
variable orifice bypasses oil around the gerotor. Turning the steering wheel slowly takes approximately
seven turn(Variable orifice small) lock to lock versus four turns(Variable orifice large) when turning the
steering wheel quickly.
5-11
5. CUSHION VALVE
1) STRUCTURE
B A
B A
13
16 15 5 14 1 2 3 6 7 5 4
17 8 13 12 11 10 9
SECTION B-B SECTION A-A
1 Housing 7 Back ring 13 Plug

2 Poppet 8 Orifice 14 Plug
3 Spring 9 Plug 15 Spring
4 Valve seat 10 O-ring 16 Poppet
5 O-ring 11 Spring 17 Plug
6 O-ring 12 Spool
5-12
2) OPERATION
L R
B A
B A
16 2 3
Check valve Pilot valve

section section
Main valve
section
SECTION B-B
8 12 11 9
SECTION A-A
The cushion valve is a valve that eliminates steering jerk motion. It makes a higher pressurized oil to
flow into another line in order to prevent the shock on steering system.
The pressure by rapid supplied pressurized oil from R port is higher than the spring(3) force, so it press
and open the poppet(2). Then the oil flows to the central groove of the spool(12), and flows to L port
through the poppet of the check valve(16) on L port side.
At this time, this pressurized oil flows to the pressure area of the plug(9) through the orifice(8), and this
force is higher than the spring(11) force plus the oil pressure on L port side, so the spool(12) is shifted to
the right. The flow of the supplied oil to L port side through the poppet(2) from R port side is trapped.
The flow of this instant oil makes the function of the cushion. After this operation, the normal steering
operation is not affected because this valve is not operated any longer.
Also, for the response of the pressure when the operation is slow as a cushion effect is not required, the
spool(12) is closed before the poppet(2) is opened, so this valve is not operated.
5-13
6. STEERING CYLINDER
1) STRUCTURE
7,8 11 3 5,6 9,10 4 1 2 13,14 15 16 12 17
22,23 20,21 19 18 22,23
1 Tube assy 9 O-ring 17 Nylon nut

2 Rod assy 10 Back up ring 18 Pipe assy
3 Gland 11 O-ring 19 U-bolt
4 Bushing 12 Piston 20 Nut
5 Rod seal 13 O-ring 21 Spring washer
6 Back up ring 14 Back up ring 22 Spherical bearing
7 Dust wiper 15 Piston seal 23 Retaining ring
8 Snap ring 16 Wear ring
5-14
2) OPERATION
7 5 3 2 15 16 12 17
This machine use to cross connected cylinder for steering operation.

The steering cylinder use a gland(3) to remove piston and sealed seals. Dust wiper(7) located on the in
side of the gland protects cylinder inner parts from dust. The piston(12) is fastened to the rod(2) by a
nut(17).
The piston uses a single wear ring(16) with a piston seal(15) to seal between the piston and tube. The
gland seals against the tube with two O-rings. The rod is sealed against the gland with a rod seal(5).
5-15
This procedure is designed so the service man can make a quick check of the steering system using
a minimum amount of diagnostic equipment. If you need additional information, prefer to structure
and function in group 1.
Locate system check in the left column and read completely, following this sequence from left to right.
If verification is needed, you will be given next best source of information :
5-16
ƓHydraulic oil must be at operating temperature for these checks(Refer to page 6-51).
Steering valve check Run engine at low idle. OK

Check completed.
A
Turn steering wheel until frames are
at maximum right(A) and then left(B)
NOT OK
positions.
Go to next check.
B LOOK : Frames must move
smoothly in both directions.
When steering wheel is stopped,
frames must stop.
FEEL : Excessive effort must not be
required to turn steering wheel.
NOTE : It is normal for steering to
drift from stops when steering wheel
is released.
Steering system leakage Turn steering wheel rapidly until OK
check Left Right frames are against stops. Check completed.
Heat hydraulic oil to
operating temperature. Hold approximately 2kg on steering NOT OK
Run engine at high idle. wheel. Do steering system leakage
test in group 3 to isolate the
Count steering wheel revolutions for leakage.
1 minute.
Repeat test in opposite direction.
LOOK : Steering wheel should
rotate less than 6rpm.
NOTE : Use good judgment;
Excessive steering wheel rpm does
not mean steering will be affected.
Priority valve low Park machine on a hard surface. OK

pressure check Check completed.
Hold brake pedal down.
NOT OK
Run engine at high idle.
Do priority valve pressure
Steer machine to the right and left test in group 3.
as far as possible.
LOOK : Machine must turn at least
half way to the right and left stops.
5-17
Priority valve high Steer to steering stop and release OK

pressure check wheel. Check completed.
Roll bucket back and hold over relief NOT OK
and observe engine rpm. Priority pressure is set too
high. Do priority valve
Turn wheel to steering stop and pressure test in group 3.
hold, observe engine rpm.
LOOK : Steering stall engine rpm
must be higher than hydraulic stall
rpm.
5-18
2. TROUBLESHOOTING
Ɠ Diagnose malfunction charts are arranged from most probable and simplest to verify, to least likely,
more difficult to verify. Remember the following steps when troubleshooting a problem :
Step 1. Operational check out procedure(See group 3 in section 1)
No steering Low oil level. Add recommended oil.

Restricted suction line. Check.
Failed hydraulic pump. Remove and inspect return filter for metal
pump particles.
Failed main hydraulic pump drive. Remove main hydraulic pump and inspect
drive gear.
Stuck priority valve spool. Remove and inspect priority valve spool.
Broken priority valve spring. Remove and inspect spring.
Relief valve in priority valve stuck open. Do priority valve relief cartridge leakage
test in group 3.
Failed hydraulic lines. Check.
Slow or hard steering Too much friction in the mechanical parts of Lubricate bearings and joints of frame or
the machine. cylinders or repair if necessary.
Cold oil. Check steering column installation.
Low priority valve pressure setting. Warm the hydraulic oil.
Do priority valve pressure test in group 3.
Clean or replace cartridge in bottom of
priority valve.
Worn hydraulic pump. Do hydraulic pump performance check.
Sticking priority valve spool. Remove and inspect.
Broken priority valve spring. Remove and inspect.
Pinched or restricted LS line. Inspect line. Do priority valve LS port
flow test in group 5.
Low system relief valve setting. Test and adjust if necessary.
Low overload relief valves setting. Test and adjust if necessary.
5-19
Constant steering to Air in system. Check for foamy oil.

maintain straight travel
Leakage in steering system. Do steering system leakage check.
Worn steering(Orbitrol) valve. Do steering valve neutral leakage test in
group 3.
Leaf spring without spring force or broken. Replace leaf springs.
Spring in overload relief valve broken. Replace overload relief valve.
Gear wheel set worn. Replace gear wheel set.
Cylinder seized or piston seals worn. Replace defects parts.
Slow steering wheel Leakage in steering system. Do steering system leakage check.
movement will not cause
any frame movement Worn steering valve gerotor. Do steering leakage check.
Steering wheel can be Leakage in steering system. Do steering system leakage check.
turned with frames
against steering stop
Steering wheel turns with Broken steering column or splined of Remove and inspect.
no resistance and causes steering valve.
no frame movement
Lack of oil in steering valve. Start engine and check steering operation.
Leakage in steering system. Do steering system leakage test in group 3.
Erratic steering Air in oil. Check for foamy oil.

Low oil level. Add recommended oil.
Sticking priority valve spool. Remove and inspect spool.
Loose cylinder piston. Remove rod to inspect piston.
Damaged steering valve. Remove and inspect.
Spongy or soft steering Air in oil. Check for foamy oil.

Low oil level. Add recommended oil.
Free play at steering Loose steering wheel nut. Tighten.
wheel
Worn or damaged splines on steering Inspect.
column or valve.
Steering valve binding or Binding in steering column or misalignment Inspect.
steering wheel does not of column.
immediately return to
neutral when released High return pressure. Check for a pinched or damaged return
line.
Contamination in steering valve. Inspect hydraulic filter for contamination.
Repair cause of contamination. Flush
hydraulic system.
5-20
Steering valve locks up Large particles of contamination in steering Inspect hydraulic filter for contamination.
valve. Repair cause of contamination. Flush
hydraulic system.
ƕ Thermal shock Do priority valve LS port flow test in
group 5. This oil flow provides a warm -up
flow to steering valve when not using the
steering.
Worn or damaged steering valve. Repair or replace valve.
Abrupt steering wheel Improperly timed gerotor gear in steering Time gerotor gear.
oscillation valve.
Steering wheel turns by Lines connected to wrong port. Reconnect lines.
itself
Worn or damaged steering valve. Repair or replace valve.
Vibration in steering High priority valve setting. Do priority valve pressure test in group 3.
system or hoses jump
Neutral position of Steering column and steering unit out of Align the steering column with steering unit.
steering wheel cannot be line. Adjust the play and, if necessary, shorten
obtained, i.e. there is a the splines journal.
tendency towards
Too little or no play between steering Contact the nearest service shop.
"motoring"
column and steering unit input shaft.
Pinching between inner and outer spools. Replace leaf springs.
"Motoring" effect. Leaf springs are stuck or broken and have Clean steering unit or contact the nearest
The steering wheel can therefore reduced spring force. service shop.
turn on its own
Inner and outer spools pinch, possibly due Reduce return pressure.
to dirt.
Return pressure in connection with the
reaction between differential cylinder and
steering unit too high.
Backlash Cardan shaft fork worn or broken. Replace cardan shaft.
Leaf springs without spring force or broken. Replace leaf springs.
Worn splines on the steering column. Replace steering column.
Jerky steering LS port orifice missing. Inspect orifice.

Orifice in top end of priority valve spool Disassemble and inspect.
missing.
ƕ Thermal stock is caused by a large temperature differential(Approx 30Ş C, 50ŞF) between the steering valve and
hydraulic oil. If the steering is not operated for a long period of time and the orifice in the bottom of the priority
valve spool is plugged, the steering valve may bind up when the steering is operated if the hydraulic oil is hot
enough.
5-21
"Shimmy" effect Air in the steering cylinder. Bleed cylinder.

The steered wheels
vibrate Find and remove the reason for air
(Rough tread on tires gives collection.
vibrations.) Mechanical connections or wheel bearings Replace worn parts.
worn.
High priority valve setting pressure. Set pressure as regular value.
Steering wheel can be Oil is needed in the tank. Fill with clean oil and bleed the system.
turned the whole time
Steering cylinder worn. Replace or repair cylinder.
without the steered
wheels moving Gear wheel set worn. Replace gear wheel set.
Spacer across cardan shaft forgotten. Install spacer.
Steering wheel can be One or both anticavitation valves are leaky Clean or replace defect or missing valves.
turned slowly in one or or are missing in overload relief valves.
both directions without
the steered wheels One or both overload relief valves are leaky. Clean or replace.
turning
Steering is too slow and Insufficient oil supply to steering unit, pump Replace pump or increase number of
heavy when trying to turn defective or number of revolutions too low. revolutions.
quickly
Relief valve setting too low. Adjust valve to correct setting.
Relief valve sticking owing to dirt. Clean the valve.
Spool in priority valve sticking owing to dirt.. Clean the valve, check that spool moves
easily without spring.
Too weak spring in priority valve. Replace spring by a stronger.
"Kick back" in steering Fault in the system. Contact authorized man or shop.
wheel from system
Kicks from wheels
Heavy kick-back in Wrong setting of cardan shaft and gear- Correct setting as shown in service
steering wheel in both wheel set. manual.
directions
Turning the steering Hydraulic hoses for the steering cylinders Connect lines to correct ports.
wheel activates the have been switched around.
steered wheels opposite
Hard point when starting Spring force in priority valve too weak. Replace spring by a stronger.
to turn the steering wheel
Air in LS and / or P line. Bleed LS and P line.
Clogged orifices in LS or P side in priority Clean orifices in spool and in connecting
valve. plugs for LS and P.
Oil is too thick(Cold). Let machine run until oil is warm.
Too little steering force Pump pressure too low. Correct pump pressure.
5-22
1. HYDRAULIC OIL CLEAN UP PROCEDURE USING PORTABLE FILTER CADDY

Ɠ Service equipment and tool
şPortable filter caddy
şTwo 4000mm ź 3/4" 100R1 Hoses
şQuick disconnect fittings
şDischarge wand
şConnectors
Ɠ Brake system and steering system use
oil from hydraulic reservoir. Flush all
lines in the brake and steering system.
Disassemble and clean major
components for brake and steering
system.
Brake and steering components may fail
if brake steering system is not cleaned
after hydraulic reservoir contamination.
1) If hydraulic system is contaminated due to a

major component failure, remove and
disassemble steering cylinders to clean
debris from cylinders.
2) Install a new return filter element. Inspect
filter before installing new element.
Ɠ For a failure that creates a lot of debris,
remove access cover from reservoir.
Drain and clean reservoir of fill the
specified oil to reservoir through upper
cover.
3) To minimize oil loss, pull a vacuum in
reservoir using a vacuum pump. Connect
filter caddy suction line to drain port at
bottom of reservoir using connector. Check
to be sure debris has not closed drain port.
4) Put filter caddy discharge line into reservoir
filler hole so end is as far away from drain
port as possible to obtain a thorough
cleaning of oil.
5-23
5) Start the filter caddy. Check to be sure oil
is flowing through the filters.
Operate filter caddy approximately 10
minutes so oil in reservoir is circulated
through filter a minimum of four times.
Ɠ Filtering time for reservoir is 0.089
minute ź number of liters(0.33 minute
źnumber of gallons).
Ɠ Reservoir capacity : 108ֻ(29U.S. gal)
Leave filter caddy operating for the next
steps.
6) Start the engine and run it at high idle.
Ɠ For the most effective results, cleaning
procedure must start with the smallest
capacity circuit then proceed to the next
largest capacity circuit.
7) Operate all functions, one at a time, through
a complete cycle in the following order:
Clam, steering, bucket, and boom. Also
include all auxiliary hydraulic functions.
Repeat procedure until the total system
capacity has circulated through filter caddy
seven times, approximately 30 minutes.
Each function must go through a minimum
of three complete cycles for a through
cleaning for oil.
Ɠ Filtering time for complete hydraulic
system is 0.158 minute ź number of
liters(0.6 minute ź number of gallons).
Complete hydraulic system capacity is
approx 150ֻ(40U.S. gal). Filtering time
for machines with auxiliary hydraulic
functions must be increased because
system capacity is larger.
8) Stop the engine. Remove the filter caddy.
9) Install a new return filter element.

10) Check oil level in reservoir ; Add oil if
necessary.
5-24
2. TEST TOOLS
1) CLAMP-ON ELECTRONIC TACHOMETER

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

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

The display monitor tachometer is accurate
enough for test work.
20 30
10 20
40
10
5 30
0 mph
0 50
km/h
5-25
3. STEERING SYSTEM RESTRICTION TEST
ş SPECIFICATION
Oil temperature 65Ź6Ş C(150Ź10Ş F)
Engine speed High idle
Maximum pressure 2.0Mpa(20bar, 285psi)
at steering valve
ş GAUGE AND TOOL
Gauge 0~7.0Mpa(0~70bar, 0~1000psi) 1EA
A
şThis test will check for restrictions in the
steering system which can cause overheating
of hydraulic oil.
T
1) Install temperature reader.(See

temperature reader installation procedure in
this group.)
2) Heat hydraulic oil to specifications.(See
hydraulic oil warm up procedure at page
6-51.)
3) Connect fitting(A) and gauge to steering
valve.
Do not operate steering or loader
functions or test gauge may be
damaged.
4) Run engine at specification and read
pressure gauges.
If pressure is more than specification at the
steering valve, inspect priority valve for a
stuck spool. Make sure orifice plugs are
installed in ends of priority valve spool.
Check for plugged orifice in priority valve LS
port.
5-26
4. STEERING VALVE LEAKAGE TEST
ş SPECIFICATION
Oil temperature 40Ź6Ş C(100Ź10ŞF)
Maximum leakage 7.5ֻ/ min(2gpm)
ş GAUGE AND TOOL
Temperature reader
Measuring container(Approx 20ֻ)
Stop watch
1) Install frame locking bar to prevent machine

from turning.
A
this group.) B
6-51.)
4) Disconnect return hose(A) from fitting.
Install cap fitting(B).
5) Run engine at specifications. Rotate
steering wheel against locking bar using
approximately 1.2kgşm of force.
Measure oil flow from return hose for 1
minute.
6) Leakage is greater than specifications,
repair or replace steering valve.
5-27
5. PRIORITY VALVE PRESSURE TEST
ş SPECIFICATION
Relief pressure 20.5~21.5Mpa
(205~215bar, 3200~3300psi)
ş GAUGE AND TOOL
Gauge 0~35.0Mpa(0~350bar, 0~5000psi)
Temperature reader
1) Connect test fitting and gauge to test port

on priority valve.
2) Install temperature reader.(See temperature
installation procedure in this group.)
3) Install frame locking bar.
6-51.)
5) Run engine at specifications and turn
steering wheel rapidly hold approximately
22N(5lb force) pressure on wheel with
frames locked.
Ɠ If steering wheel is turned slowly, it will
continue to with the frames locked.
This will give an incorrect pressure
reading.
If steering wheel continues to turn
rapidly with the frames locked, steering
system leakage is indicated.
6) Read pressure gauge. This is the priority
valve relief pressure.
7) If pressure in not to specification, remove
elbow and connector from bottom of priority
valve. Turn adjusting screw in relief
cartridge using a hex head wrench to adjust
pressure.
If pressure cannot be adjusted to
specification, disassemble and inspect
priority valve.
5-28
6. PRIORITY VALVE "LS" PORT FLOW TEST
ş SPECIFICATION
Oil temperature 40Ź6Ş C(100Ź10Ş
F)
Engine speed Low idle
LS port flow(Approx) 1ֻ/min(0.2gpm)
ş GAUGE AND TOOL
Temperature reader
Measuring container
Stop watch A
Priority valve LS port flow test will check for a
plugged or missing orifice in the bottom of
the priority valve spool. A plugged orifice
will block warm up flow to the steering valve B
which can cause thermal shock.(See for an
explanation of thermal shock.)
A missing orifice can cause the pump to be

loaded to high pressure at all times causing
overheating.

this group.)
6-51.)
3) Disconnect line from LS port and install
plug(A).
4) Connect line(B) to priority valve.
5) Start engine and run at specification.
6) Measure flow from LS port for 1 minute.
If flow is low, low steering system neutral
pressure or a plugged orifice in bottom
priority valve spool is indicated.
If flow is high, remove priority valve spool
and inspect for a missing orifice.
Do hydraulic system restriction test in this
group.
5-29
7. PRIORITY VALVE RELIEF CARTRIDGE
LEAKAGE TEST
ş SPECIFICATION
Maximum leakage1mֻ/min(16 drops per min)
ş GAUGE AND TOOL
Temperature reader
Measuring container
Stop watch

reader installation procedure in this group.) B

hydraulic oil warm up procedure at page A
6-51.)
3) Disconnect line(A) from T port on priority
valve. Install plug(B) in line.
4) Start engine and run at specification.
5) Measure oil leakage from T port.
6) If leakage is more than specification,
disassemble and inspect cartridge for
damage or debris.
5-30
1. PRIORITY VALVE
1) STRUCTURE
20 19 6 1 19 18
4 3 5 11 9 10
2 8 14 17 13 16 12 15
1 Housing 8 Body sub assy 15 O-ring

2 Spool assy 9 Body 16 Guide
3 Spool 10 Ring 17 Holder
4 Orifice 11 Screen 18 Plug
5 Orifice 12 Screw 19 O-ring
6 Control spring 13 Spring 20 Plug
7 Relief cartridge 14 Ball
2) TOOLS
şTorque wrench(5kgfşm)
şHex socket wrench(1")
şHex socket wrench(7/8")
şHex wrench (7/32")
şPincette
şGrease
5-31
3) DISASSEMBLY
Ɠ Cleanliness is the primary means of
assuring satisfactory the priority valve life.
Select clean place.
Before removing the piping, clean the
surrounding area of valve ports.
(1) Fix the housing(1) in a vise with copper or

lead sheets.
Do not over tighten jaws. CF EF
(2) Loosen plug(18) for LS port.
(3) Remove spring (6).
CF EF
(4) Remove spool assy(2).
CF EF
5-32
(5) Remove plug(20) and separate O-ring
(19) and plug(18, 20) individually.
Ɠ Can't remove the orifice(4) and orifice(5)
CF EF
from spool(3), because the orifices were
locked at the spool.
(6) Remove the relief valve cartridge

assembly(7) from the housing(1).
CF EF
(7) Secure the hexagon head of the relief in a

vise and loosen the screw(12) from relief
valve with hexagon wrench.
(8) Remove the O-ring(15).

(9) Remove the guide(16), spring(13), holder
(17) and ball(14), in that order.
(10) Do not remove the screen(11) and ring
(10) because that parts were locked the
relief valve.
5-33
4) ASSEMBLY
Ɠ Clean all metal parts in clean solvent and
blow dry with air and correct any damage,
burrs and rust.
Ɠ Do not wipe dry with cloth or paper towel.
Ɠ Replace seals such as O-ring with new
ones as a rule and coat with grease.
(1) Assembly the relief valve cartridge(7).

‫ ڸ‬Insert the O-ring(15) onto the housing(1).
‫ ڹ‬Assemble the guide(16), spring(13),
holder(17) and ball(14) and insert this
sub assembly to the housing(1).
‫ ں‬Tighten the screw(12) by using hexagon

wrench.
Ɠ Steering valve setting pressure of priority
valve is adjustable by the screw(12).
ş1 turn Ƒ 70kgf/cm2
(2) Fix the housing(1) in a vise.

CF EF
Ɠ Do not over tighten jaws.
(3) Insert the relief valve cartridge(7) into the
housing(1) and tighten the valve
assembly.
şTighten torque : 2.1kgfşm(15.2lbşft)
5-34
(4) Insert the spool(2) in the housing(1).
Ɠ Secure the spool(2) remain in their correct
direction as the illustration. CF EF
Ɠ Secure the spool(2) to move smoothly by

finger.
CF EF
(5) Insert the spring(6) into the housing(1).
CF EF
(6) Install the O-ring(19) onto plug(18, 20) and

install the plug(18, 20) into the housing(1).
şTighten torque : 4.5kgfşm(32.5lbşft) CF EF
This completes assembly.
5-35
5) TROUBLESHOOTING
Steering wheel 1. Relief valve is clogged with dirt. Disassembly, clean and reassembly.
is heavy
2. Spool is stuck. Disassembly, clean and reassembly or
replace.
3. Orifice of plug and spool is clogged. Disassembly, clean and reassembly.
(Steering wheel a. Pump is faulty. Check pump.
is heavy at
engine low idle)
(Steering speed b. Control pressure is low. Reset control pressure.

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

2. O-ring is damaged. Replace.
5-36
2. STEERING VALVE
1) STRUCTURE
13
16
12
13
14
25 15
24
6 21 17
18 20
19
10 8
1
9
11
2
3
4
3
23 22 5
3
1 Cap screw 10 Pin 18 Compression spring

2 End cap 11 Centering spring 19 Plug
3 O-ring 12 Needle bearing 20 O-ring
4 Gerotor 13 Bearing race 21 Valve seat
5 Spacer plate 14 O-ring 22 Ball
6 Drive 15 Dust seal 23 Roll pin
7 Housing 16 Retaining ring 24 Backing ring
8 Sleeve 17 Poppet 25 Seal
9 Spool
2) TOOLS
ş13mm Socket
şTorque wrench(4kgfşm)
ş15/16" Hexagon key
şSmall blade screwdriver
şSoda straws(2EA)
5-37
3) DISASSEMBLY
Ɠ Cleanliness is extremely important when
repairing a hydraulic steering control unit.
Work in a clean area. Before disconnecting
the hydraulic lines, clean the port area of
the steering control unit. Before
disassembly, drain the oil, then plug the
ports and thoroughly clean the exterior of
the steering control unit. During repairs,
always protect machined surfaces.
Ɠ Mount steering control unit in vise
(0.5-0.75in)
horizontally for breaking loose seven cap
13-19mm
screws. Use this mounting position for final
torque of reassembled unit.
Ɠ Steering control units with anti-cavitation

valves require special handling in both
disassembly and reassembly. Ball valves
(2) can end up in a cavity in the housing Roll Pin
were they are not supposed to be. These
Check ball
unit must be disassembled and
reassembled in the vertical position ; Anti-cavitation valves
(Located under these
Removal of anti-cavitation valves is outlined two cap screw)
13-19mm
in step (8). (0.5-0.75in)
Ɠ After cap screws have been loosened,
mount steering control unit in the vise
vertically for disassembly and reassembly.
Ɠ Illustrations have been created from the
exploded parts drawing, and do not relate End can
top view
the parts correctly as seen by the service
person.
5-38
(1) Remove the 7 cap screws(1), end cap(2),
Cap screw
O-ring(3), gerotor(4), O-ring(3), spacer O-ring
plate (5) and O-ring(3).
End cap
Gerotor
Spacer plate
Housing
(2) Engage tool with splined end of spool.
Housing vertically mounted
Housing
Tool
Gerotor star
Splined drive
(3) Protect gerotor star and hand with shop

towel - Hold gerotor star and splined drive Gerotor star
and splined
from turning. drive engaged
Tool
5-39
(4) Twist tool to compress centering spring
radially CW or CCW, decreasing the coil Gerotor
star
diameter of the centering spring allowing it Centering spring
to be removed along with the spool and
sleeve(Ball checks if applicable), drive, Tool
pin, bearing race(2), retaining ring, and

needle thrust bearing.(Bearing races, Hidden pin
(See note)
retaining ring, and needle thrust bearing,
not shown on drawing(Right). Centering
spring shown compressed.)
Ɠ Hidden pin
If tension on this pin is released before
these parts are fully disengaged and the
pin is not horizontal, the pin can drop and
lockup can occur like a deadbolt.
Positioning unit vertically is a safe option
and is required if the unit has anti-
cavitation valves.
(5) With drive held stationary and centering

spring compressed, carefully push these
assembled parts out of housing.
Tool
Spool, sleeve, drive,

pin, bearing race, retaining
ring, needle thrust bearing
and second bearing race
(6) Remove the thrust bearing race and

needle thrust bearing. Gerotor star
Splined drive
Needle thrust bearing
Housing
Tool
Spool, sleeve, drive,
pin, bearing race
and retaining ring
Bearing race
5-40
(7) Remove the retaining ring, bearing race,
centering spring, pin, drive, spool, sleeve.
Drive Sleeve Centering spring Bearing race

Retaining
ring
Spool
Pin
Bearing race
Retaining ring
Centering
spring free
position
Sleeve
Drive
Pin
Spool
5-41
Anti cavitation valves
(8) Insert two soda straws, one in each of two
threaded holes, as a safety measure for Port face Guide tool
removal of two small ball check valves (Soda straw)
and roll pins(Correct threaded holes
identified in illustration right). Remove
housing from vise, tilt the housing and Top view
bring the port face upward. Continue Anti-cavitation valve-
turning the housing until the roll pins and Insert soda straw(2),
one into each of these
ball checks slide through the straws from two threaded holes
the meter(Gerotor) end of the housing.
Soda straw
Meter(Gerotor) end
Port face
Roll pin
Meter Check ball

(Gerotor) Port face
end
Check ball
Roll pin
Roll pin
Tilt housing
Soda straw
(9) Remove the shaft seal. These three

parts may or may not still be in the
Backup washer
housing. These parts include O-ring, seal Seal ring
ring, and backup washer. O-ring
Housing
(10) Using a small blade screwdriver, carefully
pry the dust seal from the housing.
Ɠ Do not damage the dust seal seat.
Seal(3 Piece)
Dust seal
5-42
4) ASSEMBLY
Ɠ Check all mating surfaces. Replace any
parts that have scratches or burrs to lessen
the chance of leakage. Wash all metal
parts in clean solvent. Blow them dry with
pressurized air. Do not wipe parts dry with
paper towels or cloth. Lint in a hydraulic
system will cause damage.
Ɠ Always use new seals when reassembling
hydraulic steering control units.
Ɠ During reassembly lubricate the new seals
with a petroleum jelly like Vaseline. Also
lubricate machined surfaces with clean
hydraulic fluid. Housing Dust seal
(1) Lubricate and install the dust seal ; See

drawing(Right) for correct seal orientation.
Anti cavitation valves

(2) Installing the anti-cavitation ball checks
seems simple enough ; However, a word
of caution : Use a soda straw as a guide
tool. Drop the straw into the hole to the
bottom of bore, then drop ball through
straw. Pull straw and use the same
procedure in second ball seat. Check
each bore with small light to make sure Check ball
each ball is in the correct place. Add roll
pin in each bore. Roll pin
Guide tool
(Soda straw)
Port face
Anti-cavitation
valves
5-43
(3) Apply a light coating of clean hydraulic
fluid to the spool and slide it into the
sleeve along with the ball checks if Sleeve
applicable.
(4) Install the drive and pin. Drive
(5) Install the centering spring. Position one

Pin
end of spring in slotted end of spool and
Spool
sleeve, and compress the spring radially
(CCW) to engage free end of spring.
Sleeve
(6) Install the bearing race and retaining ring
onto spool. Spool
Centering
Drive spring free
position
Pin
Install centering
spring as shown
(1st load position)
Bearing race Retaining ring
Drive Sleeve Centering spring Bearing race
Retaining
ring
Spool
Pin
5-44
Ɠ Apply a light coating of petroleum jelly to
the inside diameter of the previously
mounted dust seal in the housing.
Ɠ Apply a light coating of petroleum jelly to
the needle thrust bearing, second bearing
race, and three part shaft seal. Position
each part onto the spool as shown in
enlarged section drawing below. The
needle thrust bearing goes between the
two bearing races and must be centered
around retaining ring.
Ɠ Apply a light coating of clean hydraulic
fluid to the spool and sleeve assembly and
slide it into the housing ; See steps (7)-
(12).
Ɠ Do not damage the dust or shaft seals.

O-ring
Seal ring
Backup washer Housing with dust seal
Gerotor star
Splined drive
Spool sleeve, drive,

pin, bearing race and
retaining ring
Bearing race Tool
Seal(3 Piece)
Sleeve Centering spring

Bearing race
Drive
Spool
Seal(3 Piece) Seal ring

Pin
Backup washer
Retaining ring O-ring

(Must be centeredaround retaining ring.
Use petroleum jelly to hold parts in place.)
5-45
(7) Protect gerotor star and hand with shop
towel - Hold gerotor star and splined end
of drive to keep it from turning.
(8) Insert tool through housing ; Engage with
splined end of spool assembled inside of Housing vertically mounted
sleeve along with ball checks(If
applicable), centering spring, drive, pin, Housing
bearing race, retaining ring, needle thrust Gerotor star
bearing, second bearing race, shaft seals
and backup washer. Twist tool to
compress spring coils radially CW or
CCW.
Ɠ If by some chance this unit is in the
horizontal position keep pin nearly
horizontal. If tension on this pin is
Spool, sleeve,drive,
released before these parts are fully pin, bearing race, retaining
engaged and the pin is not horizontal, the ring,needle thrust bearing
and second bearing race Tool
pin can drop and lockup can occur like a
deadbolt.
(9) Keep centering spring compressed, and

carefully insert these assembled parts into
Centering spring
housing. Do not force.(Bearing races,
retaining ring, needle thrust bearing, shaft
seals and backup washer not shown on Tool
drawing at right. Centering spring shown
compressed.)
(10) Release centering spring tension.
Tool
5-46
(11) Remove gerotor star.
(12) Remove tool.
Tool
Gerotor Star
(13) Lubricate and install a new O-ring seal in

the groove in the housing.
(14) Install the wear plate O-ring groove up
and align the holes in the wear plate with Cap screw
threaded holes in the housing. O-ring

the groove in the wear plate.
(16) Install the gerotor and align the screw
End cap
holes.
Gerotor
the groove in the gerotor ring. Spacer plate
(18) Install the end cap and 7 cap screws.
Housing
Pretighten the cap screws, in a criss-cross
pattern, to 1.7kgfşm(12.3lbfşft), finally in a
criss-cross pattern, tighten cap screws to
3.4kgfşm(24.6lbfşft).
5-47
3. CUSHION VALVE
1) STRUCTURE
4
75 14
6
13 2
5
15
1
16
10
11
3
2 13
6
7
5
4 16 17
15
5
14
12
11
10
9
1 Housing 7 Back up ring 13 Plug

2 Poppet 8 Orifice 14 Plug
3 Spring 9 Plug 15 Spring
4 Valve seat 10 O-ring 16 Poppet
5 O-ring 11 Spring 17 Plug
6 O-ring 12 Spool
2) TOOLS
şTorque wrench(5 ~ 20kgfşm)
şHexagon wrench(5, 6, 8mm)
şSpanner(36mm) or socket
ş Pincette
şGrease and seal tape
5-48
3) DISASSEMBLY
Ɠ Cleanliness is extremely important when
repairing a cushion valve.
Ɠ Clamp valve in vise. Use protective
material on vise jaws.
Ɠ Do not over tighten jaws.
(1) Pilot valve part

‫ ڸ‬Remove seat valve(4).
‫ ڹ‬Remove O-ring(5, 6) and back up ring(7)

from seat valve(4).
‫ ں‬Remove poppet(2).
5-49
‫ ڻ‬Remove spring(3).
(2) Main valve part

‫ ڸ‬Remove plug(9).
‫ ڹ‬Remove spring(11).
‫ ں‬Remove spool(12).
5-50
‫ ڻ‬Remove O-ring(10) from plug(9).
‫ ڼ‬Remove plug(13).
‫ ڽ‬Remove orifice(8).
(3) Check valve part

‫ ڸ‬Remove plug(14).
5-51
‫ ڹ‬Remove spring(15).
‫ ں‬Remove poppet(16).
‫ ڻ‬Remove plug(13, 17).
5-52
4) ASSEMBLY
Ɠ Clean all metal parts in clean solvent and
blow dry with air and correct any damage,
burrs and rust.
Ɠ Do not wipe dry with cloth or paper towel.
Ɠ Replace seal such as O-ring with new ones
as a rule and coat with grease.
(1) Check valve part

‫ ڸ‬Insert poppet(16), spring(15).
‫ ڹ‬Install O-ring(5) on plug(14) and install

this plug assembly into housing(1).
şTighten torque : 6.0kgfşm(43lbşft)
(2) Pilot valve part

‫ ڸ‬Insert O-ring(5, 6), back up ring(7) into
valve seat(4).
5-53
‫ ڹ‬Insert spring(3) and poppet(2) into
housing(1).
‫ ں‬Install valve seat(4) into housing(1).

şTighten torque : 6.0kgfşm(43lbşft)
(3) Main valve part

‫ ڸ‬Insert orifice(8) into housing(1).
‫ ڹ‬Insert spool(12) into housing(1).

Spool(12) should rotate smoothly in
housing(1) with finger tip force.
5-54
‫ ں‬Insert O-ring(10) onto each plug(9).
‫ ڻ‬Insert spring(11), plug(9) into housing(1).

şTighten torque : 14kgfşm(101lbşft)
‫ ڼ‬Insert plug(13) into housing(1).

‫ ڽ‬Insert plug(17) into housing(1).

5-55
5) TROUBLESHOOTING
Steering cylinder 1. Check valve seat side is clogged Disassembly, clean and reassembly.
reaction is bad with dirt.
(Wheel slip is
2. Main valve spool is stuck. Disassembly, clean or replace.
large)
3. Orifice is clogged with dirt. Disassembly, clean and reassembly.
Non cushion 1. Main valve speed is stuck. Disassembly, clean or replace.

effect or less
2. Pilot valve poppet is stuck. Disassembly, clean or replace.
Leakage 1. Loosen the plug. Apply seal tape and retighten specified
torque.
2. Damage of O-ring. Replace.
5-56
4. STEERING CYLINDER
1) STRUCTURE
7,8 11 3 5,6 9,10 4 1 2 13,14 15 16 12 17
22,23 20,21 18 22,23

19
1 Tube assy 9 O-ring 17 Nylon nut

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

Torque
Part name Item Size
kgfşm lbfşft
Gland 3 M72 ź 2 60Ź10 434Ź72
Nylon nut 17 M24 ź 2 75Ź7.5 542Ź54
Nut(Pipe assy) 18 M22 ź 1.5 30Ź3 217Ź22
Nut 20 M10 ź 1.5 8Ź0.8 58Ź6
5-58
3) DISASSEMBLY
(1) Remove cylinder head and piston rod
‫ ڸ‬Hold the clevis section of the tube in a
vise.
Ɠ Use mouth pieces so as not to damage
the machined surface of the cylinder
tube. Do not make use of the outside
piping as a locking means.
‫ ڹ‬Pull out piston rod(2) about 200mm

'7.1in(-Because the piston rod is rather
heavy, finish extending it with air pressure
200mm
after the oil draining operation.
‫ ں‬Loosen and remove the gland(3).

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

assembly together from cylinder tube(1).
Ɠ Since the piston rod assembly is heavy
Lift
in this case, lift the tip of the piston rod(2)
with a crane or some means and draw it
out. However, when piston rod(2) has
been drawn out to approximately two
thirds of its length, lift it in its center to Full straight Oil pan
draw it completely. sideways
5-59
Note that the plated surface of piston
rod(2) is to be lifted. For this reason, do
not use a wire sling and others that may
damage it, but use a strong cloth belt or
a rope.
‫ ڼ‬Place the removed piston rod assembly

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

‫ ڸ‬Remove the piston nut(17). 14 13 15 16 12 17
‫ ڹ‬Remove piston assembly(12), back up
ring(14) and O-ring(13).
‫ ں‬Remove the gland(3) assembly from

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

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

dust wiper(7) to the bottom of the hole of (Straight down)
dust wiper. Metal
At this time, press a pad metal to the 7
metal ring of dust seal.
‫ ں‬Fit snap ring(8) to the stop face.
‫ ڻ‬Fit back up ring(6) and rod seal(5) to

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

Therefore, confirm it before fitting them. Push bar
Ɠ Fitting rod seal(5) up side down may
damage its lip. Therefore check the
correct direction that is shown in fig.
5
5-62
‫ ڼ‬Fit back up ring(10) to gland (3).
Ɠ Put the backup ring in the warm water of 4
30~50Ş C.
9
‫ ڽ‬Fit O-ring(9) to gland(3). 10
3
11
(2) Assemble piston assembly

Ɠ Check for scratches or rough surfaces.
12
If found smooth with an oil stone.
‫ ڸ‬Coat the outer face of piston(12) with
hydraulic oil.
‫ ڹ‬Fit piston seal(15) to piston

Ɠ Put the piston seal in the warm water of 15
60~100Ş C for more than 5 minutes.
Ɠ After assembling the piston seal, press its
outer diameter to fit in.
‫ ں‬Fit wear ring(16) to piston(12).

‫ ڻ‬Fit back up ring(14) and O-ring(13) to 14 13 16 12
piston(12).
5-63
(3) Install piston and gland
Gland assembly
‫ ڸ‬Fix the piston rod assembly to the work
Piston rod
bench.
‫ ڹ‬Apply hydraulic oil to the outer surface of
piston rod(2), the inner surface of piston
and gland.
‫ ں‬Insert gland assembly to piston rod(2).
‫ ڻ‬Fit piston assembly to piston rod.

Piston assembly
Piston rod
‫ ڼ‬Tighten piston nut(17) to piston rod(2).

2 17
şTightening torque : 75Ź7.5kgfşm
(542Ź54lbfşft)
5-64
(4) Overall assemble Fix with a bar
‫ ڸ‬Place a V-block on a rigid work bench.
Mount the cylinder tube assembly(1) on it
and fix the assembly by passing a bar Lift
through the clevis pin hole to lock the
assembly.
‫ ڹ‬Insert the piston rod assembly in to the Straight
cylinder tube assembly, while lifting and
moving the piston rod assembly with a Apply liquid packing
crane.
Ɠ Be careful not to damage piston seal by
thread of cylinder tube.
‫ ں‬Match the bolts holes in the cylinder
head flange to the tapped holes in the
Tube
cylinder tube assembly and tighten
socket bolts to a specified torque. Piston rod
Ɠ Refer to the table of tightening torque.
Wrench
Gland
5-65
SECTION 6 WORK EQUIPMENT
1. HYDRAULIC SYSTEM OUTLINE

The loader hydraulic system is a pilot operated, open center system which is supplied with flow from
the fixed displacement main hydraulic pump.
The pilot control system is a low pressure, closed center hydraulic system which is supplied with flow
from the first(Steering) pump.
The loader system components are :
şMain pump
şMain control valve
şBucket cylinder
şBoom cylinders
şPilot supply unit
şRemote control valve(Pilot control valve)
şSafety valve
The pilot supply unit consists of the pressure reducing valve, relief valve and accumulator.
Flow from the main hydraulic pump not used by the steering system leaves the priority valve EF port.
It flows to the inlet port plate of a mono block type main control valve.
The main control valve is a tandem version spool type, open center valve which routes flow to the
boom, bucket or auxiliary cylinders(Not shown) when the respective spools are shifted.
Flow from the steering pump(The first pump) is routed to the pilot supply unit where the steering
pump outlet pressure is reduced to pilot circuit pressure. The pilot supply unit flow to the remote
control valve.
The remote control valve routed flow to either end of each spool valve section in the main control
valve to control spool stroke.
A accumulator mounted on pilot supply unit supplies a secondary pressure source to operated
remote control valve so the boom can be lowered if the engine is off.
The return circuit for the main hydraulic system have return filter inside the hydraulic tank. The return
filter uses a filter element and a bypass valve. The bypass valve is located in the upside of filter.
6-1
10 11
LH RH
3 T P
B.D/F B.U IN OUT
2
T
B3 a3(L)
A3 5 1 3 4 2
FLOATING RIDE
b3
25MPa
T
BOOM DOWN BOOM UP
a2 b2
14
P
B1 23MPa
23MPa
A1
DUMP ROLL BACK
a1 b1
F2
P
13
21MPa
F1
U
Priority EF port
T
12
3MPa
P1 P2
Steering system
Brake system
1 C B A
Return line
23
28 A 1st pump
24 B 2nd pump
25 26 27 C Brake pump
1 Main pump 12 Pilot supply unit 25 Return filter

2 Main control valve 13 Line filter 26 Bypass valve
3 Remote control valve 14 Safety valve 27 Oil cooler(Option)
10 Bucket cylinder 23 Air breather 28 Check valve(Option)
11 Boom cylinder 24 Hydraulic tank
6-2
1) WHEN THE RCV LEVER IS IN THE RAISE POSITION
10 11
LH RH
3 T P
B.D/F B.U IN OUT
2
T
B3 a3(L)
A3 5 1 3 4 2
FLOATING RIDE
b3
25MPa
T
BOOM DOWN BOOM UP
a2 b2
14
P
B1 23MPa
23MPa
A1
DUMP ROLL BACK
a1 b1
F2
P
21MPa
13
F1
U
Priority EF port
T
12
3MPa
P1 P2
Steering system
Brake system
1 C B A
Return line
23
28 A 1st pump
24 B 2nd pump
ş When the RCV lever(3) is pulled back, the boom spool on the second block is moved to raise
position by pilot oil pressure from port 3 of RCV.
ş The oil from main pump(1) flows into main control valve(2) and then goes to the large chamber of
boom cylinder (11) by pushing the load check valve of the boom spool through center bypass circuit
of the bucket spool.
ş The oil from the small chamber of boom cylinder(11) returns to hydraulic oil tank(24) through the
boom spool at the same time.
ş When this happens, the boom goes up.
6-3
2) WHEN THE RCV LEVER IS IN THE LOWER POSITION
10 11
LH RH
Anti cavitation valve
3 T P
B.D/F B.U IN OUT
2
T
B3 a3(L)
A3 5 1 3 4 2
FLOATING RIDE
b3
25MPa
T
BOOM DOWN BOOM UP
a2 b2
14
P
B1 23MPa
23MPa
A1
DUMP ROLL BACK
a1 b1
F2
P
13
21MPa
F1
U
Priority EF port
T
12
3MPa
P1 P2
Steering system
Brake system
1 C B A
Return line
23
28 A 1st pump
24 B 2nd pump
ş When the RCV lever(3) is pushed forward, the boom spool on the second block is moved to lower
position by pilot pressure from port 5 of RCV.
ş The oil from main pump(1) flows into main control valve and then goes to small chamber of boom
cylinder(11) by pushing the load check valve of the boom spool through center bypass circuit of the
bucket spool.
ş The oil returned from large chamber of boom cylinder(11) returns to hydraulic tank(24) through the
boom spool at the same time.
ş When the lowering speed of boom is faster, the return oil from the large chamber of boom cylinder
combines with the oil from the pump through the anti cavitation valve, and flows into the small
chamber of the cylinder.
This prevents cylinder cavitation by the negative pressure when the pump flow cannot match the
boom down speed.
6-4
3) WHEN THE RCV LEVER IS IN THE FLOAT POSITION
10 11
LH RH
5th control valve
3 T P
B.D/F B.U IN OUT
2
T
B3 a3(L)
A3 5 1 3 4 2
FLOATING RIDE
b3
25MPa
T
BOOM DOWN BOOM UP
a2 b2
14
P
B1 23MPa
23MPa
A1
DUMP ROLL BACK
a1 b1
F2
P
13
21MPa
F1
U
Priority EF port
T
12
3MPa
P1 P2
Steering system
Brake system
1 B A
Return line
23
28 A 1st pump
24 B 2nd pump
ş When the RCV lever(3) is pushed further forward from the lower position, the boom down pilot
port(5) is connected with tank port(T) by shift of 5th control valve. Thus, the boom spool is return
to neutral position and the boom float spool is moved to float position by pilot oil pressure from port
1 of RCV.
ş The work ports(A3), (B3) and the small chamber and the large chamber are connected to the
return passage, so the boom will be lowered due to it's own weight.
ş In this condition, when the bucket is in contact with the ground, it can be move up and down in
accordance with the shape of the ground.
6-5
4) WHEN THE RCV LEVER IS IN THE DUMP POSITION
10 11
LH RH
3 T P
B.D/F B.U IN OUT
2
T
B3 a3(L)
A3 5 1 3 4 2
FLOATING RIDE
b3
25MPa
T
BOOM DOWN BOOM UP
a2 b2
14
P
B1 23MPa
23MPa
A1
DUMP ROLL BACK
a1 b1
F2
P
13
21MPa
F1
U
Priority EF port
T
12
3MPa
P1 P2
Steering system
Brake system
1 C B A
Return line
23
28 A 1st pump
24 B 2nd pump
ş If the RCV lever(3) is pushed right, the bucket spool on the first block is moved to dump position by
pilot oil pressure from port 2 of RCV.
ş The oil from main pump(1) flows into main control valve(2) and then goes to the small chamber of
bucket cylinder(10) by pushing the load check valve of the bucket spool.
ş The oil at the large chamber of bucket cylinder(10) returns to hydraulic tank(24) through the bucket
spool.
ş When this happens, the bucket is dumped.
ş When the dumping speed of bucket is faster, the oil returned from the large chamber of bucket
cylinder combines with the oil from the pump, and flows into the small chamber of the cylinder.
bucket dump speed.
6-6
5) WHEN THE RCV LEVER IS IN THE ROLL BACK(retract) POSITION
10 11
LH RH
3 T P
B.D/F B.U IN OUT
2
T
B3 a3(L)
A3 5 1 3 4 2
FLOATING RIDE
b3
25MPa
T
BOOM DOWN BOOM UP
a2 b2
14
P
B1 23MPa
23MPa
A1
DUMP ROLL BACK
a1 b1
F2
P
13
21MPa
F1
U
Priority EF port
T
12
3MPa
P1 P2
Steering system
Brake system
1 C B A
Return line
23
28 A 1st pump
24 B 2nd pump
ş If the RCV lever(3) is pulled left, the bucket spool on the first block is moved to roll back position by
pilot oil pressure from port 4 of RCV.
ş The oil from main pump(1) flows into main control valve(2) and then goes to the large chamber of
bucket cylinder by pushing the load check valve of the bucket spool.
ş The oil at the chamber of bucket cylinder(10) returns to hydraulic tank(24) through the bucket spool.
ş When this happens, the bucket roll back.
ş When the rolling speed of bucket is faster, the return oil from the small chamber of bucket cylinder
combines with the oil from the pump, and flows into the large chamber of the cylinder.
bucket rolling speed.
6-7
6) WHEN THE RCV LEVER IS IN THE HOLD POSITION
10 11
LH RH
3 T P
B.D/F B.U IN OUT
2
T
B3 a3(L)
A3 5 1 3 4 2
FLOATING RIDE
b3
25MPa
T
BOOM DOWN BOOM UP
a2 b2
14
P
B1 23MPa
23MPa
A1
DUMP ROLL BACK
a1 b1
F2
P
13
21MPa
F1
U
Priority EF port
T
12
3MPa
P1 P2
Steering system
Brake system
1 C B A
Return line
23
28 A 1st pump
24 B 2nd pump
ş The oil from main pump(1) flows into main control valve(2).
ş In this time, the bucket spool, the boom spool and the boom float spool are in neutral position, then
the oil supplied to main control valve(2) returns into hydraulic tank(24) through center bypass circuit
of each spool.
ş In this condition, each cylinder keeps the neutral position, so the boom and the bucket is holded.
6-8
3. MAIN PUMP OPERATION
1) STRUCTURE
16
5
6
7
14
7
6
5 13
4
18
17 15 12
11 10
6
7
34 8
7
6
5
4
3
9
1
1 Shaft seal 8 Driven gear 14 Driven gear

2 Circlip 9 Drive gear 15 Drive shaft
3 Flange 10 Front body 16 Cover
4 O-ring 11 Splined coupling 17 Washer
5 Seal 12 O-ring 18 Stud assy
6 Seal 13 Center body 34 Dowel
7 Balance plate
6-9
2) OPERATION
9 3 5,6 4 10 5,6 13 5,6 14 4 5,6
1,2 Bushing 7 8 7 7 15 7 16
The main hydraulic pump is a fixed displacement gear type pump. The pump is drive at engine
speed by the transmission. The pump shafts are supported by bushings in the flange assembly(3),
front body(10), rear body(13) and cover(16).
As the drive gear(9) and shaft(15) turns the idler gears(8, 14), the gear teeth come out of mesh.
Oil flows from the hydraulic tank through the inlet into the cavity between the gear teeth. As the
gears continue to rotate, the oil becomes trapped between the gear teeth and the balance
plates(7).
The trapped oil is then carried to the pump outlet. Oil is forced out the outlet to supply the hydraulic
function. As the gears re-mesh, they form a seal to prevent oil from flowing between the gears and
back to the inlet.
The pump uses outlet pressure oil to load the balance plates(7) against the gear faces. This
controls internal leakage to maintain pump displacement.
Outlet pressure fills the area bounded by the seals(5, 6) to force the pressure plate against the high
pressure area or the gear faces. Pump shaft lubrication is achieved by routing outlet pressure oil
into the area between the gear shafts and the bushings. The oil is collected at the end of the
shafts in the hollow areas in the port and flange plates and routed back to return.
6-10
4. REMOTE CONTROL VALVE
1) STRUCTURE (1/3)
1.10
1.8
1.2A
1.17 1.3A
1.18
1.19
1.10
1.12 1.4
1.1 1.6 1.1
1.9
1.5
1.7
1.21 1.24
1.19
1.18
1.17
1.13
1.12
1.11
1.14
1.20
1.16
1.23
1.15
1.1 Half handle 1.9 Screw 1.17 Screw

1.2A Insulation cap 1.10 Self locking nut 1.18 Lock washer
1.3A Pusher 1.11 Screw 1.19 Belleville washer
1.4 Rocker arm 1.12 Washer 1.20 Fitting clamp
1.5 Spacer 1.13 Hollow lever 1.21 Thimble
1.6 Spacer 1.14 Nut 1.23 Complete handle
1.7 Contact switch 1.15 Nut 1.24 Cable
1.8 Spacer 1.16 Bellows
6-11
STRUCTURE (2/3)
2.25
2.24
2.7
C C
A C 2.1
2.8
2.2A 2.23
2.9 B
C
2.10 2.22
2.3
2.11
2.21
2.12 2.20
2.13
C C
A C 2.4
A C 2.5
2.14 2.19
2.15 2.15
2.16 2.16
2.15
2.6
2.17
2.18
2.1 Bracket 2.8 Counter nut 2.17 Connector blade

2.2A Shim 2.9 Nut 2.18 Junction box
2.2B Shim 2.10 Press screw 2.19 Complete solenoid
2.2C Shim 2.11 Plunger 2.20 Spring ring
2.3 Joint 2.12 Circlip 2.21 Armature
2.4 Flange 2.13 Shim 2.22 Joint
2.5 Plug 2.14 Plunger guide 2.23 Friction washer
2.6 Electric bracket 2.15 O-ring 2.24 Friction washer
6-12
STRUCTURE (3/3)
C C
A C
2.37 2.37
2.38
2.38 2.38 2.38
2.39 2.39
2.40 2.40
2.41 2.41
2.4A 2.4A
2.4B 2.4B
2.4C 2.4C
2.43 2.43
3.8
3.7 2.44
3.9 3.6
2.45
3.12
3.10 3.13
3.11
3.2
3.14
3.15 3.3
3.16
3.5,3.17 3.4
4.1A
4.1B 3.1
2.37 Complete plunger 2.45 Spring 3.10 Nut

2.38 1/2 Washer 3.1 Plug 3.11 Screw
2.39 Spring retainer 3.2 O-ring 3.12 Plate
2.40 Spring 3.3 Intermediate plate 3.13 O-ring
2.41 Spring 3.4 Screw 3.14 Piston
2.4A Shim 3.5 Housing 3.15 Spring
2.4B Shim 3.6 Plug 3.16 Washer
2.4C Shim 3.7 Identification plate 3.17 Housing
2.43 Spool 3.8 Pin 4.1A Spool
2.44 Socket 3.9 Screw 4.2A Spool
6-13
2) OPERATION
5 1
5 T 1
3
4 P
14 5 2
15
T 1
5
SECTION X-X
Electromagnetic lock
T P 9
10
22bar
11
5
5 1 34 2 4
3
7
(1) Hydraulic functional principle 2
Pilot devices with end position locks operate as
direct operated pressure reducing valves.
T 8
X P X
They basically comprise control lever(1), four
pressure reducing valves, housing(6) and locks. 6
Each pressure reducing valve comprises control
spool(2), control spring(3), return spring(4) and
push rod(5). Port 4 Port 2
At rest control lever(1) is held in its neutral position
by return springs(4). Ports(1, 2, 3, 4) are
connected to tank port T via bore(8).
When control lever(1) is deflected push rod(5) is pressed against return spring(4) and control
spring(3).
Control spring(3) initially moves control spool(2) downwards and closes the connection between
the relevant port and tank port T. At the same time the relevant port is connected to port P via
bore(8). The closed loop control phase starts, as soon as control spool(2) finds its balance
between the force from control spring(3) and the force, which results from the hydraulic pressure
in the relevant port(port 1, 2, 3 or 4).
Due to the interaction between control spool(2) and control spring(3) the pressure in the relevant
port is proportional to the stroke of push rod(5) and hence to the position of control lever(1).
This closed loop pressure control dependent on the position of the control lever and the
characteristics of the control spring permits the proportional hydraulic control of the main
directional valve.
Rubber sleeve(9) protects the mechanical components in the housing from contamination.
6-14
(2) End position lock
Only those control ports, for which it is necessary to hold the control lever in a deflected position
are equipped with end position locks.
Electromagnetic lock
An additional spring(7) under push rod(5) warns, due to the increase in force which is required to
keep this spring compressed, that the stroke of push rod(5) and control lever(1) is nearly at its
end.
Once this point has been exceeded ring(10) is placed in contact with solenoid armature(11).
If the solenoid is energized, control lever(1) is held in its end position by means of the
electromagnetic force.
The lock is released automatically when the solenoid is deenergized.
(3) Fifth control port
This remote control valve is equipped with a fifth control port, which is used to control the boom
floating function. This function may be operated by moving spool(14) against spring(15) under
the influence of the pressure acting in port 1.
As soon as this pressure reaches 22bar, control port 5 is connected with T.
6-15
5. MAIN CONTROL VALVE
1) STRUCTURE
11 Housing 79.1 O-ring 90 Compression spring

13 Short cover 80 Port relief valve 91 Compression spring
18 Long cover 80.1 Lock nut seal 92 Compression spring
40 Spool 80.2 Piston seal 98 Compression spring
41 Spool 80.3 O-ring 99 Bleed screw
45 Spring retainer 80.4 O-ring 104 Snap ring
54 Bleed screw 82 Main relief valve 107 Seal ring
56 Locking screw 82.1 O-ring 124 O-ring
57 Cone 82.2 O-ring 300 Plate
59 Locking screw 82.3 Thrust ring 301 Bolt
78 Locking screw 82.4 O-ring 302 O-ring
79 Check valve 88 compression spring 303 Locking screw
6-16
STRUCTURE
Port Port name Port size
P From main pump SAE 6000psi 3/4"

T To hydraulic tank SAE 6000psi 1"
A1, B1 To bucket cylinder port SAE 6000psi 3/4"
A3, B3 To boom cylinder port SAE 6000psi 3/4"
a1, b1 Bucket pilot port PF 1/4
a2, a3, b2, b3 Boom pilot port PF 1/4
6-17
2) BOOM SECTION OPERATION
(1) Spool in neutral
T
a3(L)
B3
A3
FLOATING RIDE
b3
B2 25Mpa
A2
BOOM DOWN BOOM UP
a2 b2
A3 B3
a2 b2
Plug Overload relief valve

Built-in check valve Low pressure passage
If the remote control valve is not operated, the oil supplied from the pump port passes through the
neutral passage to the low pressure passage at the outlet section, and then returns to the tank port.
6-18
(2) Boom raise position
T
a3(L)
B3
A3
FLOATING RIDE
b3
B2 25Mpa
A2
BOOM UP
a2 b2
A3 B3
a2 b2
When the pilot pressure from remote control valve is supplied to the pilot port(b2), the spool moves to
the left and the neutral passage is closed.
The oil supplied from the pump pushes up the load check valve(1) and flow into boom cylinder port(B3).
The pump pressure reaches proportionally the load of cylinder and fine control finished by shut off of the
neutral passage.
The return oil from cylinder port(A3) flows into the tank via the low pressure passage.
6-19
(3) Boom lower position
Anti cavitation valve

(See section drawing
of the third block
at page 6-21)
When the pilot pressure from remote control valve is supplied to the pilot port(a2), the spool moves to
the right and the neutral passage is closed.
The oil supplied from the pump pushes up the load check valve(2) and flow into boom cylinder port(A3).
neutral passage.
The return oil from cylinder port(B3) flows into the tank via the low pressure passage.
When the lowering speed of boom is faster, the return oil from the large chamber of boom cylinder
combines with the oil from the pump through the anti cavitation valve, and flows into the small chamber
of cylinder. This prevents cylinder cavitation by the negative pressure when the pump flow cannot
match the boom lowering speed.
6-20
(4) Boom float position
If the operator overrides the additional spring(7) in the RCV lower position, the pilot pressure from
remote control valve rises further and then the boom float spool is pushed to the end position, opening
up the neutral passage to tank and simultaneously(A3), (B3) ‫ آ‬T.
Parallel the boom down spool will be released to neutral, became of moving spool in the remote control
valve at 22bar(Refer to page 6-14).
In float position the boom drops quickly due to its own weight.
When the bucket touches the ground and the wheeled loader is moving, the bucket raised or lowered
following the unevenness of the ground due to the (A3), (B3) ‫ آ‬T connecting.
6-21
3) BUCKET SECTION OPERATION
(1) Spool in neutral
B1 23Mpa
A1 23Mpa
DUMP ROLL BACK
a1 b1
21Mpa
A1 B1
a1 b1
Overload relief valve Overload relief valve

Built-in check valve Low pressure passage
If the remote control valve is not operated, the oil supplied from the pump port passage through the
neutral passage to the low pressure passage at the outlet section, and then return to the tank port.
6-22
(2) Retract(roll back) position
B1 23Mpa
A1 23Mpa
ROLL BACK
a1 b1
21Mpa
A1 B1
a1 b1
When the pilot pressure from remote control valve is supplied to the pilot port(b1), the spool moves to
the left and the neutral passage is closed.
The oil supplied from the pump pushes up the load check valve(1) and flow into boom cylinder port(B1).
neutral passage.
The return oil from cylinder port(A1) flows into the tank via the low pressure passage.
6-23
(3) Dump position
B1 23Mpa
A1 23Mpa
DUMP ROLL BACK
a1 b1
21Mpa
A1 B1
a1 b1
When the pilot pressure from remote control valve is supplied to the pilot port(a1), the spool moves to
the right and the neutral passage is closed.
The oil supplied from the pump pushes up the load check valve(2) and flow into boom cylinder port(A1).
neutral passage.
The return oil from cylinder port(B1) flows into the tank via the low pressure passage.
6-24
3) MAIN RELIEF VALVE
ş The main relief valve is installed at the inlet of Main poppet(A) Valve seat
Pilot poppet(C)
the main control valve. When the oil goes
Z
above the set pressure, the relief valve
drains the oil to the tank.
In this way, it sets the maximum pressure in
the hydraulic circuit and protects the circuit. P
T Y
ş The valve poppet(C) is connected via the
D1
throttle drillings(D1) and (D2) with the P port. D2 Pressure spring(F) Adjustment
If static pressure increases above the set screw(E)
pressure value, the valve poppet(C) opens
and allows oil to flow freely to tank(Y). This P
oil generates a pressure drop in the spring
chamber of the main poppet, the closing
force of the spring(Z) is cancelled, and the T
main poppet(A) opens to allow the pump
flow to flow to tank(T).
Damped opening and closing is obtained by
the throttled volumetric change. P
ş The set pressure can be varied by changing T Y
the tension of pressure spring(F). To
change the set pressure, remove cap nut,
loosen lock nut and turn adjustments
screw(E) and follows.
P
T Y
6-25
4) OVERLOAD RELIEF VALVE
ş The overload relief valve(Combined relief/ Annular passage
anticavition valve) is in the boom cylinder and
Valve body(1)
bucket cylinder circuit in the main control Main poppet(2)
Pilot poppet(3)
valve.
If shock causes any abnormally high
pressure in the cylinder when the main AB
valves is at neutral, the overload relief valve
releases the abnormal pressure and protects
the cylinder from damage.
T
ş During normal operation, the poppet(2) is Pressure spring(4)
positioned against the body(1) to seal the A1 A3 A2 Main poppet spring
workport(A) oil from the return(T) passage.
ş As the circuit pressure approach the relief A,B
pressure setting, the pressure forces the pilot
poppet(3) off its seat and allows oil to flow
freely via the annular passage to tank.
This oil generates a pressure drop in the
T
spring chamber of the main poppet(2), the
closing force of the spring(4) is cancelled.
The main poppet(2) opens to allow flow from
P to T.
ş If cavitation in the workport occurs, the oil
pressure in the workport drop below return
pressure. AB
Tank line return pressure oil works against
the shoulder(A3) of the poppet to force it
open against the spring and the workport
T
pressure at (A2)-(A1).
A,B
6-26
6. PILOT OIL SUPPLY UNIT
1) STRUCTURE
1 20 2 18 19 14 13 12 11 10 15 17 16
P1
3 4 5 6 7 8 9
P2
Port Size
3MPa
P1, P2 3/4" UNF U
4.5MPa
U, T 9/16" UND
P1 T
CIRCUIT DIAGRAM
1 Accumulator 8 Plug 15 Plug

2 Connector 9 Nut 16 Shuttle valve
3 O-ring 10 Plug 17 Housing
4 Spring 11 Seal 18 O-ring
5 Valve 12 Spring 19 Plug
6 Valve 13 Spring retainer 20 Washer
7 Spring 14 Spool
6-27
(2) OPERATION
1 20 2 18 19 14 13 12 11 10 17 16
P1
T
U
3 4 5 6 7 8 9
Pilot oil supply unit are a combination of valves which reduce the pressure of medium and high pressure
circuits in order to supply remote control valve with a low pressure supply of oil. They basically consist
of the accumulator(1), the housing(17), a shuttle valve(16), a direct operated pressure relief valve(6) and
a check valve(5).
Fluid flows from the high pressure via the shuttle valve(16) through port P1 into the unit and then to the
secondary circuit. The pressure is reduced to the required level by means of spool(14) and passes via
the check valve(5) into the accumulator(1) thus ensuring though port U greater control power and-when
necessary-emergency operation should the main circuit be switched off or become defective.
Pressure relief valve(6) protects the pilot circuit should the spool(14) fail to operate. Check valve(5)
prevents the accumulator emptying into the primary circuit.
Accumulator satisfies short term peak power demands and is a source of emergency power should the
main circuit pressure fail.
6-28
7. SAFETY VALVE UNIT
1) STRUCTURE
The safety valve locks or permits pilot oil flew to the main control valve operation.
P
12
T
13
6
2
9,10 5
7
11 4
P 14
1
T
1 Body 6 Handle 11 Spring plunger

2 Retainer 7 Spring ring 12 Knob
3 Adjust stem 8 O-ring 13 Socket set screw
4 Housing 9 O-ring 14 Spring pin
5 Clutch ring 10 Back up ring
6-29
8. BOOM AND BUCKET CYLINDER
The boom cylinders are two unit and the bucket cylinder is one unit. They use a bolt on rod guide.
The piston(12) threads on to the rod(2) and is retained by a nut(17) and set screw(18).
The piston seals against the tube(1) with piston seal(14). Two wear rings(15) are located on each
side of the piston seal.
The gland(3, the rod guide) seals against the tube with an O-ring(10). The cylinder thread seals
against the rod with a lip type buffer ring(7) and a rod seal(5). A dust wiper(8) cleans the rod when it
is retracted.
1) BOOM CYLINDER
8,9 5,6 3 7 4 10,11 21 2 1 26 24,25 2013,14 12 15 16 18 17 23,24 22
19 27,28
1 Tube assy 11 Back up ring 21 Pipe assy

2 Rod assy 12 Piston 22 O-ring
3 Gland 13 O-ring 23 Bolt
4 Bushing 14 Back up ring 24 Spring washer
5 Rod seal 15 Piston seal 25 Bolt
6 Back up ring 16 Wear ring 26 Band
7 Buffer ring 17 Piston nut 27 Bushing
8 Dust wiper 18 Screw 28 Dust seal
9 Snap ring 19 Bolt
10 O-ring 20 Pipe assy
6-30
2) BUCKET CYLINDER
29,30 8,9 5,6 3 7 4 10,11 20 2 1 28 23,25 26,27 21 13,1412 15 16 18 17 23,24 22
19 29,30

6 Back up ring 16 Wear ring 26 U-bolt
7 Buffer ring 17 Piston nut 27 Nut
8 Dust wiper 18 Screw 28 Bracket
9 Snap ring 19 Bolt 29 Bushing
10 O-ring 20 Pipe assy 30 Dust seal
6-31
9. HYDRAULIC OIL TANK
1) STRUCTURE
ş The oil from the hydraulic tank is sent from the pump through control valve to the cylinders.
In the return circuit, the oil from various parts merges.
ş A part of oil is cooled in the oil cooler, passes through the hydraulic filter and returns to the
hydraulic tank(1).
ş If the hydraulic return oil filter becomes clogged, return filter bypass valve(3) acts to allow the oil to
return directly to the hydraulic tank(1). This prevents damage to the hydraulic filter(2). The
bypass valve(3) is also actuated when negative pressure is generated in the circuit.
13,16
9
5 10 4 6
14,17
1
18,19 7,11
VIEW A
14,17 8,11 12,15
1 Hydraulic tank 8 Cover 15 Spring washer

2 Element 9 Plate 16 Hardened washer
3 Bypass valve 10 Plate 17 Hardened washer
4 Air breather 11 O-ring 18 Overheat switch
5 Spring 12 Bolt 19 O-ring
6 Sight gauge 13 Bolt
7 Cover 14 Bolt
6-32
2) RETURN OIL FILTER BYPASS VALVE
(1) When the filter is clogged
Bypass valve(1) is opened and the oil
returns directly to the tank without passing 1
through the filter.
Bypass valve set pressure : 1.36kg/cm2
(19.3psi)
From MCV
6-33
3) AIR BREATHER
The air breather is equipped with the
capacity to perform three functions
simultaneously-as an air filter, breathing
valve, and as a lubrication opening.
(1) Preventing negative pressure inside
the tank
The tank is a pressurized sealed type, so
negative pressure is formed inside the
hydraulic tank when the oil level drops
during operations. When this happens, 4
the difference in pressure between the
tank and the outside atmospheric 1
pressure opens the poppet in the
breather, and air from the outside is let 2
into the tank or prevent negative pressure.
3
(2) Preventing excessive pressure inside
the tank
When the hydraulic cylinder is being used,
the oil level in the hydraulic system
increases and as temperature rises. If
the hydraulic pressure rises above the set
pressure, breather is actuated to release
the hydraulic pressure inside the tank. 1 Body 3 Strainer
(3) Specification 2 Element 4 Cap
Description Spec
Exhaust side setting pressure 0.5kg/cm2(7.1 psi)

Intake side setting pressure 0.05kg/cm2(0.7psi)
Element 10ҏm
Filtration rating
Strainer 40ҏm
6-34
10. ACCUMULATOR
The accumulator is installed at the pilot oil 1
supply unit. When the boom is left the 2
raised position, and the control levers are
operated with the engine stopped the
pressure of the compressed nitrogen gas
inside the accumulator sends pilot pressure 3
to the control valve to actuate it and allow 4
the boom and bucket to come down under 5
their own weight.
Type of gas Nitrogen gas(N2)
Volume of gas 0.75ֻ(0.2 U.S.gal)
Charging pressure of gas 16kg/cm2(228psi)
1 Screw plug
Max actuating pressure 30kg/cm2(427psi)
2 Sealing ring
3 Diaphragm
4 Closure button
5 Steel pressure vessel
6-35
This procedure is designed so the mechanic can make a quick check of the system using a minimum
amount of diagnostic equipment. If you need additional information, read Structure and function,
Group 1.
6-36
Ɠ Hydraulic oil must be at operating temperature for these checks(Refer to page 6-51).
Hydraulic system warm- Hold a hydraulic function over OK

up procedure relief to heat oil.(Don't keep relief Check completed.
Run engine at high idle. condition over 5 seconds at a
Refer to page 6-51. time)
Periodically cycle all hydraulic
functions to distribute warm oil.
Repeat procedure until oil is at
operating temperature.
FEEL : Hydraulic tank must be
uncomfortable to hold your hand
against.
(Approximately 45 ~55Ş
C)
Hydraulic pump With bucket flat on ground, OK
performance check actuate boom raise. Time how Check completed.
Heat hydraulic oil to long it takes to raise boom to full
NOT OK
operating temperature. height.
Go to priority valve high
LOOK : Boom must raise to full pressure check at page
height in less than 7 seconds. 5-28.
IF OK
Do steering system
leakage check at page
5-27.
IF OK
Do main hydraulic pump
flow test at page 6-52.
Control valve lift check With bucket partially dumped, OK
Run machine at low idle. lower boom to raise front of Check complete.
machine.
NOT OK
Slowly move boom control Repair lift checks in main
lever(RCV lever) to boom lower control valve at page 6-
position. 53.
Slowly move bucket control lever
to bucket dump position.
LOOK : Boom must not raise
before moving down.
Bucket must not rollback before
dumping.
6-37
Bucket rollback circuit Position bucket at a 45Şangle OK

relief valve check against an immovable object. Check complete.
Engage transmission in 3rd speed NOT OK
forward. Replace boom lower
check valve.
LOOK : Bucket angle must not
change.
Bucket dump circuit Raise front of machine which OK
relief valve low pressure bucket at 45Şangle. Go to next check.
check
Backdrag with bucket while NOT OK
observing bucket angle. Do loader system and
circuit relief valve test at
LOOK : Bucket must not rollback
page 6-53.
Pilot control valve float With the bucket partially dumped, OK
check lower boom to raise front of Check complete.
Run engine at low idle. machine.
NOT OK
Push control lever to the float
Do pilot control valve
detent position and release lever.
pressure test in group 3.
LOOK : Front of machine lower to
the ground and valve must remain
in float position when lever is
released.
Boom cylinder and Set the boom and bucket OK
bucket cylinder drift horizontal, then stop the engine. Check complete.
check
Stop the engine, wait for 5 NOT OK
minutes, then start measuring. Go to next check.
B
Measure the amount the lift and
dump cylinder rods retract during
15 minutes.(Unloaded bucket)
A
A : Retraction of boom cylinder
rod
B : Retraction of bucket cylinder
rod
Boom cylinder must drift less than
40mm
Bucket cylinder must drift less
than 40mm
6-38
Boom cylinder leakage Dump bucket until teeth or cutting OK

check edge is perpendicular to the Drift is approximately the
Heat hydraulic oil to ground. same between first and
operating temperature. Raise boom until cutting edge is second measurement.
about 1m(3ft) above ground. Repair main control valve
Stop engine. Measure drift from or circuit relief valve.
tooth or cutting edge to ground for
NOT OK
1 minute.
If drift is considerably less
Wait 10 minutes. on second measurement,
Measure drift from tooth or cutting repair cylinder.
edge to ground for 1 minute.
LOOK : Compare the drift rate
between the first measurement
and the second measurement.
Bucket cylinder leakage Raise bucket about 1m(3ft) off OK
check ground with bucket level. Drift is approximately the
Heat hydraulic oil to Stop engine. Place a support same between first and
operating temperature. under boom. second measurement.
Measure drift from tooth or cutting Repair main control valve
edge to ground for 1 minute. or circuit relief valve at
Wait 10 minutes. page 6-53.
Measure drift from tooth or cutting NOT OK
edge to ground for 1 minute. Drift is considerably less
on second measurement.
LOOK : Compare the drift rates
between the first measurement Repair cylinder.
and the second measurement.
Check valve of safety Put bucket level and position OK
valve leakage check about 1.2m(4ft) above ground. Check complete.
Heat hydraulic oil to Place a piece of tape on cylinder NOT OK
operating temperature. rod at least 51mm(2in) from rod Check or replace safety
guide. valve.
Run engine at low idle in safety-
release position.
LOOK : Bucket must not drift up.
Pilot control valve Stop engine. Turn key switch to OK
(RCV lever) check OFF position. Check completed.
Move control lever to all positions
and then release. NOT OK
Repair pilot control valve.
LOOK : Lever must return to
neutral when released from all
positions.
6-39
Bucket leveler Position bucket fully dumped just OK

(Positioner) check above ground level. Check complete.
Move control lever to bucket NOT OK
leveler detent position and Do bucket leveler checks
release. in group 3.
LOOK : Bucket must rollback to
the level position and control lever
must return to neutral.
If bucket is in a rolled back
position when key is turned ON,
control lever must be returned to
neutral manually if placed in the
bucket leveler detent position.
After bucket is dumped once,
bucket leveler will work normally.
Boom height kickout Position bucket flat on ground. OK
check Check complete.
Move control lever to boom raise
detent position and release. NOT OK
Do boom height kickout
LOOK : Boom must raise to the
check in group 3.
set height and stop.
Control lever must return to
neutral.
Cycle time check Function Operating condition Maximum cycle time
Boom raise Bucket flat on ground to full height. 6.9sec
Boom lower(Float) Full height to level ground. 3.8sec
Bucket dump Boom at full height. 1.5sec
Bucket rollback Boom at full height. 2.0sec
Steering(No. of Frame stop to frame stop. 3.0sec(5.75 turns)
turns)
OK
Check complete.
NOT OK
Go to slow hydraulic
functions in group 3.
6-40
Ɠ MEASURING BOOM AND BUCKET CYCLE TIME
1. MEASUREMENT CONDITION
şCoolant temperature : Inside operating range
şSteering position : Neutral
şHydraulic temperature : 45~55Ş C
şBucket : Unloaded
şEngine speed : High idling
2. MEASURING TOOL
şStop watch(1 EA)
3. MEASURING PROCEDURE
Lifting time of boom
1) LIFTING TIME OF BOOM
Set the bucket near the maximum tilt back
position and at the lowest position on the
ground. Raise the bucket and measure
the time taken for bucket to reach the
maximum height of the boom.
2) LOWERING TIME OF BOOM

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

Raise the boom to the maximum height and Dumping time of bucket
measure the time taken for the bucket to Rollback time of bucket
move from the maximum tilt back position
to the maximum dump position
4) ROLL BACK TIME OF BUCKET
Raise the boom to the maximum height and
measure the time taken for the bucket to
reach the maximum tilt back position.
6-41
2. TROUBLESHOOTING
Ɠ Diagnose malfunction charts are arranged from most probable and simplest to verify, to
least likely, more difficult to verify. Remember the following steps when troubleshooting a
problem :
Step 1. Operational check out procedure(See section 1)

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

functions
Cold oil. Warm oil up.
Slow engine speed. Adjust engine speed control linkage.
Check high idle speed.
Suction line air leak. Check for foamy oil.
Low oil supply. Add recommended oil.
Wrong oil viscosity. Use recommended oil.
Oil leaking past cylinders or control Check cylinder drift in group 2.
valve.
Blocked or damaged line. Inspect lines.
Faulty or misadjusted pilot oil supply Do pilot oil supply unit pressure test in
unit. group 3.
Faulty pilot control valve(RCV). Do pilot control valve(RCV) pressure
test in group 3.
Binding main control valve spool. Inspect valve.
Faulty priority valve. Check priority valve specification.
6-42
No steering or hydraulic Low oil level. Add recommended oil.
function
Failed hydraulic pump. Remove and inspect return filter for
metal pump particles.
Failed main hydraulic pump drive. Remove main hydraulic pump and
inspect drive gear.
No hydraulic functions Failed hydraulic pump. Remove and inspect return filter for
steering normal metal pump particles, or replace the
pump.
Failed line filter. Remove and inspect line filter for RCV.
Faulty safety valve. Safety valve leakage test or ON, OFF
function test.
Stuck open port relief valve. Replace relief valve.
Boom float function Low pilot control pressure. Do pressure reducing valve pressure
does not work test in group 3.
Faulty pilot control valve(RCV). Replace relief valve.
Main control valve spool binding in Do pressure reducing valve pressure
bore. test in group 3.
One hydraulic function Faulty pilot control valve(RCV). Do pilot control valve pressure test.
does not work
Inspect and repair valve.
Stuck open port relief valve. Replace relief valve.
Oil leaking past cylinder packings. Do boom and bucket cylinder leakage
test in group 3.
Blockage in oil lines or valve. Inspect lines for damage.
Disconnect and inspect lines for internal
blockage.
Main control valve spool stuck in bore. Inspect and repair valve.
Low hydraulic power Leakage within work circuit. Do cylinder drift check in group 2.
Low system relief valve(Main relief Do loader system and port relief valve
valve) setting. pressure test in group 3.
Low port relief valve setting. Do loader system and port relief valve
pressure test in group 3.
Faulty or misadjusted pilot oil supply Do pilot oil supply unit pressure test in
unit . group 3.
Leaking system relief valve. Remove and inspect valve.
Worn hydraulic pump. Do hydraulic pump performance check
in group 2.
Faulty pilot control valve(RCV). Do pilot control valve(RCV) pressure
test in group 3.
6-43
Function drifts down Leaking cylinders. Do cylinder leakage checks in group 2.

Leaking seals in circuit relief valve(Port Inspect seals. Replace relief valve.
relief valve) or valve stuck open.
Leaking loader control valve. Repair or replace valve section.
Boom drifts up Leakage in boom down spool. Remove and inspect boom down spool.
Boom down does not Safety valve not operated. Operate valve.
work
Stuck pilot control valve. Inspect.
Engine off.
Faulty line filter. Remove and inspect filter.
Accumulation not operated. Inspect.
Main control valve spool stuck. Inspect and repair valve.
Oil overheats Low oil viscosity in hot weather. Use recommended oil.
Excessive load. Reduce load.
Holding hydraulic system over relief. Reduce load.
Leakage in work circuit. Do boom and bucket cylinder leakage
test in group 3.
Plugged fins in oil cooler. Inspect and clean oil cooler.
Internally plugged oil cooler. Do hydraulic oil cooler restriction test in
group 3.
Incorrect system or circuit relief valve Do loader system and circuit relief valve
setting. pressure test in group 3.
Restriction in oil lines or main control Inspect for dented or kinked lines.
valve. Do hydraulic system restriction test in
group 3.
Pinched or restricted priority valve LS Run engine at low idle. Steer machine
back and forth. If engine load
line.
decreases while steering, a restricted
LS line or priority valve malfunction is
indicated.
Do priority valve LS port flow test in
group 3.
Malfunctioning priority valve. Do hydraulic system restriction test in
group 3.
Leaking system main relief valve. Remove and inspect valve and seals.
Worn hydraulic pump(Internal leakage). Do hydraulic pump performance check
in group 2.
Function drops before Stuck open lift check valve. Do control valve lift check in group 2.
raising when valve is
activated
6-44
Hydraulic oil foams Low oil level. Add recommended oil.

Wrong oil. Change to recommended oil.
Water in oil. Change oil.
Loose or faulty suction lines(Air leak in Tighten or install new lines.
system).
Remote control valve Leaking plunger seals. Remove, inspect and replace plunger
(RCV) leaking seals.
6-45
Ɠ Followings are general precautions for maintenance of the hydraulic system and
equipment.
1) Every structure has its limit of strength and durability. The relief valve is installed to limit the
pressure on the hydraulic equipment and protect various parts of the wheel loader from possible
damage. Therefore, never change the preset pressure of the relief valve unless absolutely
necessary.
2) Since the hydraulic equipment is built with precision, the presence of only the slightest amount of
dust and / or other particles in the hydraulic circuit might cause wear and/or damage, resulting in
unstable functions and/or damage, resulting in unstable functions and/or unexpected accidents.
Therefore, always keep hydraulic oil clean. Periodically, check the filter in the return circuit and
replace the element as necessary.
3) Extract about 200cc of hydraulic oil from the tank as a sample every 6 months. If possible, have it
analyzed by a specialist to confirm that the oil can still be used. Never extract the oil for sampling
until the oil temperature has become the normal operating temperature. Since the replacement
period varies depending on operating conditions, refer to Operator's manual and change oil.
4) Should the equipment get damaged due to the presence of metal particles and/or foreign matter in
the circuit drain out the hydraulic oil and carry out flushing. Also, replace the filter element and
clean the hydraulic tank. Change the hydraulic oil entirely.
5) When checking the filter, if found metal particles in the element, drain out the hydraulic oil entirely,
flush the whole circuit, and then fill with new oil. The presence of metal particles may indicate
internal damage to the equipment. In such a case, check carefully before flushing, and repair or
replace as required.
6) To add and/or change the hydraulic oil, always use recommended oil.(Refer to the list of
recommended oils and lubricants at page 1-21, Recommended lubricants.) Never mix oil of
different makes of kinds.
7) To change the hydraulic oil, use a clean vessel and funnel for pouring it into the tank. Never use
cloth because it might cause the presence of lint in the circuit.
8) When removing the hydraulic equipment, be sure to put plugs or caps on hoses, tube lines and
ports. Also, enter mating marks for later identification.
9) Disassemble and/or assemble the hydraulic equipment only in a clean place free of dust. When
disassembling, be careful about the interchangeability of parts, and clean the disassembled parts
with pure and clean mineral cleansing oil. Clean the internal passages as well. After the parts
have dried, wipe them off with a clean lint-free cloth.
10) When overhauling the hydraulic equipment replace all O-rings, backup rings, etc. with new ones.
Assemble O-rings with grease or vaseline applied.
11) After installing the equipment, add more hydraulic oil to make up for that lost during disassembly.
12) Tighten joints correctly. Loose joints will cause the hydraulic oil to leak. If the oil leaks, the tank oil
level drops and air gets sucked in, so the pump will break down. Also loose joints in suction lines
will take air in and might cause abnormal noise, malfunction or damage to pumps.
6-46
1. HYDRAULIC OIL CLEAN UP PROCEDURE USING PORTABLE FILTER CADDY

Ɠ Service equipment and tool
şPortable filter caddy
şTwo 4000mm ź 1in 100R1 Hoses
şQuick disconnect fittings.
şDischarge wand
şVarious size fittings.
Ɠ Brake system uses oil from hydraulic
reservoir. Flush all lines in the brake,
pilot, steering system and cut off
system. Disassemble and clean major
components for brake and steering
system. Remove and clean pilot caps
from main control valve.
Brake and steering components may fail
if brake and steering system is not
cleaned after hydraulic reservoir
contamination.
1) If hydraulic system is contaminated due to a
major component failure, remove and
disassemble steering cylinders to clean
debris from cylinders.
2) Install a new return filter element. Inspect
filter housing before installing new element.
Ɠ For a failure that creates a lot of debris,
remove access cover from reservoir.
Drain and clean reservoir of fill the
specified oil to reservoir through upper
cover.
3) To minimize oil loss, pull a vacuum in
reservoir using a vacuum pump. Connect
filter caddy suction line to drain port at
bottom of reservoir using connector. Check
to be sure debris has not closed drain port.
4) Put filter caddy discharge line into reservoir
filler hole so end is as far away from drain
port as possible to obtain a thorough
cleaning of oil.
6 -47
5) Start the filter caddy. Check to be sure oil is
flowing through the filters.
Operate filter caddy approximately 10
minutes so oil in reservoir is circulated
through filter a minimum of four times.
Ɠ Reservoir capacity : 199ֻ(52.6U.S. gal)
Leave filter caddy operation for the next
steps.
6) Start the engine and run it at high idle.
Ɠ For the most effective results, cleaning
procedure must start with the smallest
capacity circuit then proceed to the next
largest capacity circuit.
7) Operate all functions, one at a time, through
a complete cycle in the following order:
Clam, steering, bucket, and boom. Also
include all auxiliary hydraulic functions.
Repeat procedure until the total system
capacity has circulated through filter caddy
seven times, approximately 30 minutes.
Each function must go through a minimum
of three complete cycles for a through
cleaning for oil.
Ɠ Filtering time for machines with auxiliary
hydraulic functions must be increased
because system capacity is larger.
8) Stop the engine. Remove the filter caddy.
9) Install a new return filter element.
10) Check oil level in reservoir; Add oil if
necessary.
6 -48
2. BOOM HEIGHT KICKOUT ADJUSTMENT
1) Lift the boom up to a desired height, set the
boom control lever at hold, then stop the Boom
engine.
Bolt
Be careful lest work equipment fall
down. Proximate
switch
Put the hydraulic safety lock lever in the
LOCK position.
Plate
2) Loosen bolts then tighten them after

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

between the plate and the probe of the
proximate switch are 3Ź1mm.
Nut
Proximate switch
2Ź0ll Plate
4) Start the engine. Position the bucket on

the ground. Then lift the bucket to a Neutral
desired height by using the control lever Detent position
2
2
R
and release the hand.

Confirm the lever automatically returns to
the neutral position and the boom(The
bucket) stop at the adjusted position.
6 -49
3. TEST TOOLS
1) CLAMP-ON ELECTRONIC TACHOMETER
INSTALLATION
şService equipment and tools
Tachometer
A : Clamp on tachometer.
Remove paint using emery cloth and B
connect to a straight section of injection D
line within 100mm(4in) of pump. Finger C
tighten only-do not over tighten.
B : Black clip(-). Connect to main frame.
C : Red clip(+). Connect to transducer. A
D : Tachometer readout. Install cable.
2) DIGITAL THERMOMETER INSTALLATION

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

The display monitor tachometer is accurate
enough for test work.
20 30
10 20
40
10
5 30
0 mph
0 50
km/h
6 -50
4. HYDRAULIC OIL WARM UP PROCEDURE
1) Install temperature reader(See
this group).
2) Run engine at high idle.
3) Hold a hydraulic function over relief to heat
the oil.
4) Periodically cycle all hydraulic functions to
distribute warm oil.
5) Heat oil to test specification(Approx 50Ɓ
C).
6 -51
5. MAIN HYDRAULIC PUMP FLOW TEST
ş SPECIFICATION
Oil temperature 65Ź6ƁC(150Ź10Ɓ F)
Engine speed 2300Ź25rpm
Test pressure 210Ź5bar(3000psi)
Maximum pump flow 137ֻ/min(36gpm)
ş FLOW METER GAUGE AND TOOL
Gauge 0~35MPa(0~350bar, 0~5000psi)
To MCV
Temperature reader
1) Make test connections.
this group.)
hydraulic oil warm up procedure in this
group.)
4) Run engine at test specifications.
5) Close flow meter loading valve to increase
pressure to test specifications.
6) Read flow meter.
7) If flow is below specifications, check suction
line and suction pressure for abnormality
before removing pump.
6 -52
6. LOADER SYSTEM AND PORT RELIEF
VALVE PRESSURE TEST
ş SPECIFICATION
D
Oil temperature(45~55Ɓ
C)
Relief valve Engine speed Relief pressure
210Ź5kg/cm2
System(M) High
(3000Ź70psi)
Boom 250Ź5kg/cm2
Low
raise(U) (3560Ź70psi)
Bucket 230Ź5kg/cm2
Low
rollback(R) (3270Ź70psi)
Bucket 230Ź5kg/cm2
Low M R U
dump(D) (3270Ź70psi)
ş Gauge and tool

D : Bucket dump relief valve
M : System(Main) relief valve A
R : Bucket rollback relief valve
U : Boom raise relief valve
Block(Rear frame mounting)
1) Install pressure gauge to block(A) in pump
delivery line.
this group.)
group.) To MCV
4) To check the system relief valve(M), run

engine at high idle. Lower boom to
bottomed position.
Slowly activate boom down function while
watching pressure gauge. If pressure is not
to specification, loosen lock nut on system
relief valve(M) and adjust to specification.
6 -53
Ɠ Do not adjust the system relief valve
above 260kg/cm2 (3700psi). Damage to
the pump will result from excessive
pressure settings.
5) To check the bucket dump, bucket rollback,
and boom raise, adjust the system relief
valve to 260kg/cm2 (3700psi).
Run engine to maintain 800 ~ 850rpm when
hydraulic function is activated over relief.
Activate the function to be checked with the
cylinder bottomed. Read the pressure
gauge.
If pressure is not to specification cycle relief
valve over relief 10 times to flush.
Read pressure gauge again. Turn screw
to adjust valve to specification.
Ɠ Do not work machine with system relief
adjusted above specification or
structural damage may occur.
6) Adjust system relief valve to specification.
6 -54
7. HYDRAULIC SYSTEM RESTRICTION TEST
ş SPECIFICATION
Oil temperature 65Ź6Ɓ C(150Ź10Ɓ F)
Maximum pressure at steering(Orbitrol)
valve 2MPa(20bar, 285psi)
Maximum pressure at main control valve A
1MPa(10bar, 145psi)
ş GAUGE AND TOOL
Gauge 0~7MPa(0~70bar, 0~1000psi) 2EA
T
This test will check for restrictions in the
hydraulic system which can cause
overheating of hydraulic oil.
reader installation procedure in this group.)
group.)
3) Connect fitting(A) and gauge to steering
valve.
4) Connect fitting and gauge to main control
valve.
Do not operate steering or loader
functions or test gauge may be
damaged. T port
5) Run engine at specification and read
pressure gauges.
P
main control valve, check for a kinked,
dented or obstructed hydraulic line. Check
main control valve for a binding spool.
Main control valve
block, inspect neutral condition of the
steering valve and priority valve for a stuck
spool. Make sure orifice plugs are installed
in ends of priority valve spool.
Check for plugged orifice in priority valve LS
port and dynamic signal orifice on the spool
of priority valve.
6 -55
8. LOADER CYLINDER DRIFT TEST
A
ş SPECIFICATION
Oil temperature 40Ź6Ɓ
C(100Ź10Ɓ
F)
Boom horizontal
Bucket horizontal
Bucket unloaded
B
Item Standard value
Retraction of boom
40mm A : Retraction of bucket cylinder rod
cylinder rod
B : Retraction of boom cylinder rod
Retraction of bucket
40mm
cylinder rod
ş GAUGE AND TOOL

Stop watch
Temperature reader
Put the safety lock lever in the lock
position.
Do not go under the work equipment.
1) Set the boom and bucket horizontal, then
stop the engine.
2) Stop the engine, wait for 5 minutes, then
start measuring.
3) Measure the amount the boom and bucket
cylinder rods retract during 15 minutes.
6 -56
9. BOOM AND BUCKET CYLINDER LEAKAGE
TEST
ş SPECIFICATION
Oil temperature 40Ź6Ɓ C(100Ź10Ɓ
F)
Maximum leakage 15 ֹ/min(1/2 oz/min)
ş GAUGE AND TOOL
Temperature reader
Stop watch
Measuring container
1) Fasten temperature sensor to head end
port of cylinder to be tested. Cover sensor
with a shop towel.
group.)
Never work under raised equipment
unless it is supported with a hoist or
support stands.
3) Full extend the cylinder to be tested. If
testing the boom cylinders, restrain boom in
the fully raised position using a hoist or a
stand.
Ɠ Check cylinders for leakage in the fully
extended position only. In the retracted
position contacts the end of the cylinder
and seals off piston seal leakage.
4) Remove and plug cylinder rod end hose or
line.
5) Run engine at low idle. Activate control
lever to extend cylinder for 1 minute over
relief while measuring leakage for open
port.
If leakage is within specification, excessive
cylinder drift is caused by leakage in the
main control valve or circuit relief valve.
6 -57
10. PILOT CONTROL VALVE PRESSURE TEST
ş SPECIFICATION
Begin metering 1/4" of lever travel
Pressure in detent :
Boom float detent 2.2MPa(22bar)
Pressure at feel positionƕ:
Boom power down 19~22bar
Boom raise 19~22bar
Bucket rollback 19~22bar
Bucket dump 19~22bar
ş GAUGE AND TOOL
ƕ As the control lever is moved from neutral,
the pilot pressure will suddenly jump up to
approximately 5.8bar at 1/4in travel. The
pressure should then increase smoothly to
the specification at the FEEL position(or 3/4
lever travel), and then jump up about 270-
330psi as the lever is moved into detent. A
This test will determine if adequate pilot
pressure is available to move the loader
control valve spools.
Ɠ The FEEL position is when lever is
Remote block
moved to feel the ramp of the detent
before lever passes into detent position.
1) Lower boom to ground.
2) Connect gauge to the pilot pressure port(A)
of function to be checked.
this group.)
4) Heat hydraulic oil to specification.(See
group.)
6 -58
5) Run engine at specification. Activate
function to be checked and record pressure
reading.
Ɠ If boom raise or bucket rollback FEEL
positions are not operation due to boom
or bucket position, plug boom float
detent wires into bucket leveler solenoid
or boom height kickout solenoid. This
will provide a feel position on the
control lever.
6 -59
11. PILOT OIL SUPPLY UNIT PRESSURE TEST
ş SPECIFICATION
Engine speed Low idle and stop
A
Pilot pressure setting 30~35bar(430~500psi)
Relief valve setting pressure
45bar(640psi) Remote block
Accumulator precharging pressure
16bar(230psi)
ş GAUGE AND TOOL
The pilot supply unit consist of the pressure
reducing valve, the relief valve and an
accumulator. This regulates pressure to
the pilot control circuit.
1) Connect gauge to test port(A) on the block.
this group.)
3) Heat hydraulic oil to specification.(See
group.)
4) Run engine at low idle for 1 minute and
stop engine, wait for 5 minutes. Then start
measuring.
5) If pressure in not within specifications,
replace valve. The valve is staked and
should not be adjusted.
6 -60
12. CYCLE TIME TEST
ş SPECIFICATION
Oil temperature 65Ź6Ɓ C(150Ź10Ɓ
F)
Function Operating conditions Maximum cycle time(Seconds)
Boom raise Bucket flat on ground to full height 6.9

Boom lower(Float) Full height to ground level 3.8
Bucket dump Boom at full height 1.5
Bucket rollback Boom at full height 2.0
Steering(Number of turns) Frame stop to stop 3.0(5.75 turns)
Hydraulic pump performance cycle time.
Function Operating conditions Maximum cycle time(Seconds)

Bucket flat on ground to full height
Boom raise 12.2
while holding steering over relief
6 -61
13. HYDRAULIC OIL FILTER INSPECTION
PROCEDURE
1
1) Lower the bucket to the ground, stop the 2
engine, move the control lever back and
forth several times, and clean all over the
3
upper surface of the hydraulic oil tank.
4
2) Remove the bolts(1) and take out the filter
case cover(3) and O-ring(4). 5
3) Remove the spring(5) and bypass valve(6).
6
4) Remove the filter element(7) from the tank.
5) Check the element and the filter case
bottom for debris. Excessive amounts of
7
brass and steel particles can indicate a
failed hydraulic pump or a pump failure in
process. A rubber type of material can
indicated cylinder packing or other packing
failure.
Ɠ The hydraulic oil filter in the filter case of
the hydraulic oil tank should be
replaced every 250 operating hours(For
the first replacement, at 50 hours) or
more often. When the filter element is
replaced, please keep as follows.
(1) Clean the inside of the filter case.
(2) Place new element in the proper positions
inside the filter case.
(3) Install the bypass valve and spring.
Make sure the element stand upright, and
check for complete contact of the element
bottom with the filter case bottom.
(4) Install the O-ring and filter case covers.
Tighten them with bolt. Replace the O-
ring with new one if damaged.
6 -62
1. MAIN PUMP
1) STRUCTURE
16
5
6
7
14
7
6
5 13
4
18
17 15 12
11 10
6
7
34 8
7
6
5
4
3
9
1
1 Shaft seal 8 Driven gear 14 Driven gear

2 Circlip 9 Drive gear 15 Drive shaft
3 Flange 10 Front body 16 Cover
4 O-ring 11 Splined coupling 17 Washer
5 Seal 12 O-ring 18 Stud assy
6 Seal 13 Center body 34 Dowel
7 Balance plate
6 -63
2) GENERAL INSTRUCTION
(1) Cleanliness
‫ ڸ‬Cleanliness is the primary means of assuring satisfactory hydraulic pump life. Components
such as flanges and covers are best cleaned in soap and hot water, then air dried. Gears
should be washed in solvent, air dried, and oiled immediately.
Certain cleaning solvents are flammable. Do not allow sources of ignition in the area
when using cleaning solvents.
‫ ڹ‬Protect all exposed surfaces and open cavities from damage and foreign material.
Ɠ Gear journals and gear faces are super finished. Take care not to touch these surfaces
after oil and solvent have been removed.
(2) Lubrication of moving parts
During assembly, all running surfaces(Bushing and spacer plate) must be lightly lubricated with a
clean oil or aerosol lubricant.
(3) Tools required for assembly
‫ ڸ‬Torque wrench(0-20kgfşm, 0-150lbfşft)
‫ ڹ‬Open end wrenches
‫ ں‬Seal installation tools(Inner and outer)
‫ ڻ‬Shaft bullet(Seal protector)
‫ ڼ‬Installation plate
6 -64
3) DISASSEMBLY
16
5
6
7
14
7
6
5 13
4
18
17 15 12
11 10
6
7
34 8
7
6
5
4
3
9
1
Ɠ Prior to starting work ensure that the pump and the working area are thoroughly clean and free
from sources of contamination.
(1) Mark end cover(16), rear body(13), front body(10) and mounting flange(3) to ensure correct
assembly.
(2) On parallel shafted pumps remove key(20) and circlip(19).
(3) Remove the 4 bolts(18) serrated washers(17) clamping the units together, separate the pumps by
removing the rear unit from the location dowels in the body - use a soft faced hammer.
(4) Remove splined coupling(11) and discard O-ring(12) sealing the internal passages between the
pump sections.
(5) Disassemble rear pump by removing the end cover(16) from the body(13), free cover front
location spigot using a soft faced hammer.
(6) Remove drive shaft(15) from its bore by pushing it out from the connection hole in the rear face,
this will also remove balance plate(7).
Ɠ Note position of gear and balance plate for correct reassembly.
(7) Remove driven gear(8) and lower balance plate(7).
6 -65
DISASSEMBLY
16
5
6
7
14
7
6
5 13
4
18
17 15 12
11 10
6
7
34 8
7
6
5
4
3
9
1
(8) Discard O-ring(4) from end cover, seal(6) and seal energizer(5) from balance plates.
(9) Disassemble front pump by separating flange(3) from its location spigot in body(10) - use soft
faced hammer.
(10) Remove shaft seal(1) from flange(3). Flanges have two shaft seals fitted back to back and the
outer shaft seal must be removed first to gain access to retaining circlip(2).
(11) Remove circlip(2) and inner shaft seal(1) take care to ensure that the seal recess is not damaged
as this could result in leakage.
(12) Grasp drive shaft(9) and remove it with balance plate(7), finally remove driven gear(8) and lower
balance plate(7).
Ɠ Note their positions for correct assembly.
(13) Remove and discard O-ring(4) in flange recess and seal(6) and seal energizer(5) from balance
plates.
(14) Clean off all loctite sealant from flange/ body and end cover/body interfaces.
6 -66
4) INSPECTION AND REPAIR
(1) Assessment
Each components should be thoroughly cleaned, carefully examined and assessed for suitability
re-use. Below is a guide for inspecting the various components.
(2) Body
‫ ڸ‬Inspect the body bore cut-in where both gears wipe into the body.
‫ ڹ‬The body can only be re-used if the cut-in is bright and polished in appearance and the depth
does not exceed 0.15mm(0.006").
‫ ں‬The body should be replaced if the surface is scored, has a matt appearance or shows signs that
the tip of the gears have dug in and torn away the surface material.
‫ ڻ‬The body should be inspected to ensure that there is no superficial damage which may adversely
effect performance or sealing. Pay particular attention to the port threads and body O-ring seal
recesses.
(3) Mounting flange and end cover
‫ ڸ‬The inner surfaces should be inspected to ensure that there is no unusual wear or scoring in the
regions where the body O-rings and backing rings contact, which result in external leakage.
‫ ڹ‬Check the shaft seal recess for scoring or damage that could result in oil leakage around the
outer diameter of the shaft seal. Replacement shaft seals can be refitted with Loctite hydraulic
sealant to overcome slight damage in this area.
(4) Balance plate
‫ ڸ‬The side faces which abut the gears should be perfectly flat showing no sign of scoring.
Characteristically there are bright polished areas on this surface caused by loading against the
gear side faces, which is often more pronounced on the low pressure side. The balance plate
should be replaced if there is any general scoring or fine scoring with a matt appearance or
tearing of the surface material. Often there is a witness where the tips of the opposing gears
have wiped an overlap reassembling a half moon shape. There must be no noticeable wear
step as it is critical that the balance plate side face is completely flat to the gear side face.
‫ ڹ‬The bearing liners are acceptable providing that they are not scored or show other damage. The
general outside area of the balance plate should not show any prominent signs of wear.
(5) Gears
‫ ڸ‬The gear side faces should be examined for bruising or scoring. Often operation on
contaminated fluid shows scoring between the root of the gear and the journal undercut, which
leaves a wear step. If a wear step can be felt, coincidental with the root diameter, by drawing a
sharp pointed tool across the surface from the undercut outwards towards the tip of the gear,
then the gear is unserviceable.
‫ ڹ‬The gear teeth should then be carefully examined to ensure that there are no signs of bruising or pitting.
‫ ں‬The journal bearing surfaces should be completely free from scoring or bruising. The surface
should appear highly polished and smooth to touch.
‫ ڻ‬Examine the area where the shaft seal lips run on the drive shaft, this shows up as a polished
ring or rings. If a noticeable groove can be felt or there is scoring the shaft should be replaced.
‫ ڼ‬Provided the drive shaft is not damaged from the drive-coupling and the gears have not been
harmed as described above, then the gears can be re-used. If, however, the gears are
damaged they must be replaced as a matched pair.
‫ ڽ‬As a matter of good practice, when pumps have been disassembled, all the seals should be
replaced. It is most important that only the genuine seals are used.
6 -67
3) ASSEMBLY
16
5
6
7
14
7
6
5 13
4
18
17 15 12
11 10
6
7
34 8
7
6
5
4
3
9
1
Ɠ Prior to assembly all parts must be perfectly clean and lubricated with clean hydraulic oil.
Ɠ Renew all seals using clean hydraulic oil as a lubricant.
(1) Front pump
‫ ڸ‬Fit inner shaft seal(1) into the recess in the mounting flange, with the garter spring facing into the
pump, refit circlip(2) into its groove.
Fit outer shaft seal with garter spring facing uppermost. Coat lips of seals with a high melting
point grease.
Ɠ If the seal recess has been scored, then seal outside diameter can be coated with loctite
hydraulic sealant to prevent leakage.
‫ ڹ‬Stand pump body on its rear face, fit seal(6) and seal energizer(5) to the groove in the balance
plate. Carefully feed the balance plate into the body bores. Ensure that the seals remain in
position and that the two small holes through the balance plate are to the low pressure side of the
unit, i.e. side with large 4 bolt port pattern.
‫ ں‬Insert drive shaft(9) and driven gear(8) into their original bores.
‫ ڻ‬Replace top balance plate with small holes to low pressure side of the unit, fit seal(6) and seal
energizer(5) to grooves in balance plate.
‫ ڼ‬Fit O-ring(4) to groove in mounting flange and apply a small amount of loctite sealant to the body
lower face, i.e. outboard of oval spigot. This sealant is to prevent moisture entering this area
preventing corrosion.
‫ ڽ‬Carefully feed mounting flange over the drive shaft, ensure flange is in its original position-4mm
hole in rear face of flange must be to the low pressure side of the unit. Tap flange on to its
location spigot with a soft faced hammer.
6 -68
16
5
6
7
14
7
6
5 13
4
18
17 15 12
11 10
6
7
34 8
7
6
5
4
3
9
1
(2) Rear pump

‫ ڸ‬Support front pump on the mounting flange-not the drive shaft-fit O-rings(12) into the grooves
around connection passages in the rear face, replace splined coupling(11).
‫ ڹ‬Fit rear pump body to front pump ensuring that it locates on the dowels and the through holes
line up.
‫ ں‬Fit seal(6) and seal energizer(5) to grooves in balance plate(7) and carefully feed into body
bores. Ensure seals remain in position and that the two small holes through the balance plate
are to the low pressure side, i.e. the side without a port.
‫ ڻ‬Fit drive gear(15) ensuring that it locates in the splined coupling(11), fit driven gear(14).
‫ ڼ‬Replace upper balance plate in its original position, i.e. with 2 small holes to low pressure side, fit
seal(6) and seal energizer(5) to groove in plate.
‫ ڽ‬Fit O-ring(4) to groove in end cover, apply a small amount of loctite sealant to lower face of body,
i.e. outboard of oval spigot.
‫ ھ‬Fit end cover in its original position, washer(17) and through bolts(18).
Tightening torque : 9.5Ź0.5kgfşm(68.7Ź6.3lbfşft)
‫ ڿ‬Pour a small amount of clean hydraulic oil into ports and check that the unit rotates without
undue force. If excessive force it required then seals in balance plates are possibly trapped and
the unit should be disassembled and reassembled correctly.
6 -69
6) RUNNING-IN
Pressure gauge
Test unit Variable

Micronic restrictor
filter
Flow
meter
Relief valve
Strainer
Tank
(1) A unit which has been reassembled with either new gears, balance plate or body, must be
carefully run-in before it is subjected to full working conditions.
(2) Ideally this should be done on a test rig(See figure) where pressure can be gradually applied and
any wipings from the body cut-in arrested by filters.
(3) It is recommended that the unit is run-in at 1500rpm, initially, at zero pressure for one minute then
in stages with the pressure increased by 500psi every minute, until maximum rated pressure has
been attained. Frequently check the system temperature, ensuring that it does not exceed the
maximum permissible figure of 80Ɓ C. If the temperature exceeds the system or unit specification
the test must be delayed and operated off-load until acceptable temperatures are obtained.
6 -70
2. BOOM AND BUCKET CYLINDER
1) BOOM CYLINDER
8,9 5,6 3 7 4 10,11 21 2 1 26 24,25 2013,14 12 15 16 18 17 23,24 22
19 27,28

6 Back up ring 16 Wear ring 26 Band
7 Buffer ring 17 Piston nut 27 Bushing
8 Dust wiper 18 Screw 28 Dust seal
9 Snap ring 19 Bolt
10 O-ring 20 Pipe assy
6 -71
2) BUCKET CYLINDER
29,30 8,9 5,6 3 7 4 10,11 20 2 1 28 23,25 26,27 21 13,1412 15 16 18 17 23,24 22
19 29,30

6 Back up ring 16 Wear ring 26 U-bolt
7 Buffer ring 17 Piston nut 27 Nut
8 Dust wiper 18 Screw 28 Bracket
9 Snap ring 19 Bolt 29 Bushing
10 O-ring 20 Pipe assy 30 Dust seal
6 -72
2) TOOLS AND TIGHTENING TORQUE
(1) Tools
Tool name Remark
B
Allen wrench 12
Spanner 17
(-) Driver Small and large sizes

Torque wrench Capable of tightening with the specified torques
(2) Tightening torque

Torque
Part name Item Size
kgfşm lbfşft
Bucket cylinder 19 M14 ź 2 15Ź1.5 108Ź11
Socket head bolt
Boom cylinder 19 M14 ź 2 15Ź1.5 108Ź11
Bucket cylinder 22 M10 ź 1.5 4.5Ź0.5 33Ź3.6
Hex head screw
Boom cylinder 23 M10 ź 1.5 4.5Ź0.5 33Ź3.6
Bucket cylinder 17 M64 ź 3 150Ź15 1085Ź109
Piston nut
Boom cylinder 17 M64 ź 3 150Ź15 1085Ź109
Bucket cylinder 12 M64 ź 3 100Ź10 723Ź72
Piston
Boom cylinder 12 M64 ź 3 100Ź10 723Ź72
Bucket cylinder 18 M10 ź 1.5 4.5Ź0.5 33Ź3.6
Set screw
Boom cylinder 18 M10 ź 1.5 4.5Ź0.5 33Ź3.6
6 -73
3) DISASSEMBLY
(1) Remove gland and piston rod
‫ ڸ‬Hold the clevis section of the tube in a
Ɠ vise. Use mouth pieces so as not to
damage the machined surface of the
cylinder tube. Do not make use of the
outside piping as a locking means.
‫ ڹ‬Pull out piston rod(2) about 200mm

(7.1in). Because the piston rod is rather
200ll
heavy, finish extending it with air pressure
after the oil draining operation.
‫ ں‬Loosen and remove socket bolts(19) of

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

assembly together from cylinder tube(1). Lift
Ɠ Since the piston rod assembly is heavy in
this case, lift the tip of the piston rod(2)
with a crane or some means and draw it
out. However, when piston rod(2) has
been drawn out to approximately two Oil pan
thirds of its length, lift it in its center to Full straight
sideways
draw it completely.
6 -74
Ɠ Note that the plated surface of piston
rod(2) is to be lifted. For this reason, do
not use a wire sling and others that may
damage it, but use a strong cloth belt
or a rope.
‫ ڼ‬Place the removed piston rod assembly

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

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

rod(2). Lift with a crane
Plastic
Ɠ If is too heavy to move, move it by hammer 3 2
striking the flanged part of gland(3) with a
plastic hammer. Full straight
Ɠ Pull it straight with gland assembly lifted
with a crane.
Exercise care so as not to damage the
lip of rod bushing(4) and packing(5, 6, 7,
8, 9) by the threads of piston rod(2).
6 -75
(3) Disassemble the piston assembly
‫ ڸ‬Remove wear ring(16) and piston seal 16 15 16
(15).
damage the grooves.
(4) Disassemble gland assembly

‫ ڸ‬Remove back up ring(11) and O-ring(10). 8,9 5,6 7 11 10 4
‫ ڹ‬Remove snap ring(9) and dust wiper(8).
‫ ں‬Remove back up ring(6), rod seal(5) and
buffer ring(7).
damage the grooves.
Ɠ Do not remove seal and ring, if does not
damaged.
6 -76
4) ASSEMBLY
‫ ڸ‬Coat the inner face of gland(3) with
hydraulic oil.
‫ ڹ‬Coat dust wiper(8) with grease and fit

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

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

Therefore, confirm it before fitting them.
Push bar
Ɠ Fitting rod seal(5) up side down may
damage its lip. Therefore check the
correct direction that is shown in fig.
5
6 -77
‫ ڼ‬Fit back up ring(11) to gland(3).
Ɠ Put the backup ring in the warm water of
30}50Ş C.
‫ ڽ‬Fit O-ring(10) to gland(3). 11
10

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

Ɠ Put the piston seal in the warm water of 15
60}100Ş Cfor more than 5 minutes.
Ɠ After assembling the piston seal, press its
outer diameter to fit in.
‫ ں‬Fit wear rings(16) to piston(12).

‫ ڻ‬Fit back up rings(14) and O-ring(13) to 14 13 16 16
piston(12).
6 -78
(3) Install piston and gland
Gland assembly
‫ ڸ‬Fix the piston rod assembly to the work
bench. Piston rod
‫ ڹ‬Apply hydraulic oil to the outer surface of
piston rod(2), the inner surface of piston
and gland.
‫ ں‬Insert gland assembly to piston rod(2).
‫ ڼ‬Fit pistion assembly to piston rod.

şTightening torque : 100Ź10kgfşm Piston assembly
(723Ź72lbfşft) Piston rod
‫ ڼ‬Tighten piston nut(16) and screw(17) to

piston rod(2). 2 18 17
şTightening torque
Item kgfşm lbfşft
17 150 Ź 15 1085 Ź 109

18 4.5 Ź 0.5 33 Ź 3.6
6 -79
(4) Overall assemble
‫ ڸ‬Place a V-block on a rigid work bench. Fix with a bar
Mount the cylinder tube assembly(1) on it Lift
and fix the assembly by passing a bar
through the clevis hole to lock the
assembly. Straight
‫ ڹ‬Insert the piston rod assembly in to the
cylinder tube assembly, while lifting and
moving the piston rod assembly with a Apply liquid packing
crane.
Ɠ Be careful not to damage piston seal by
thread of cylinder tube.
‫ ں‬Match the bolts holes in the cylinder head
flange to the tapped holes in the cylinder
tube assembly and tighten socket bolt. Piston rod
şTightening torque : 15Ź1.5kgfşm Tube
(108Ź11lbfşft) Hexagon
socket wrench
Gland
6 -80
SECTION 7 ELECTRICAL SYSTEM
GROUP 1 COMPONENT LOCATION
1. LOCATION 1
8 14
1 9 15
2 10 16
3 11
12
4
2
2
13
R
5
6
17
18
19
20
7 21
22
23
1 Multi function switch 9 Beacon switch(Option) 17 Rear wiper/washer switch

2 Starting switch 10 Work lamp switch 18 Air conditioner switch
3 Horn button 11 Main light switch 19 Hazard switch
4 Cluster 12 Clutch cut off switch 20 Aircon & heater switch
5 EGS lever 13 Parking brake switch 21 Check unit
6 Kick down switch 14 Cold start switch(Option) 22 Relay board
7 Service meter 15 EGS prolix switch 23 Fuse box
8 Emergency steering pilot lamp(Option) 16 Buzzer stop switch
7-1
2. LOCATION 2
10 9 8 14 1 2 4 3
13 12 11 5 7 6 15
1 Alternator 6 Coolant temp sendor 11 Front combination lamp

2 Light 7 T/M temp sendor 12 Light
3 Rear combination lamp 8 Clutch oil pressure switch 13 Air horn
4 Battery 9 Relay board 14 Engine oil pressure switch
5 Overheat switch 10 Proximate switch 15 Back up buzzer
7-2
GROUP 2 ELECTRICAL CIRCUIT
7-3
CAB SIDE TRANSMISSION HARNESS FRONT SIDE
FRAME SIDE
GAUGE SIDE
7-4
1. ILLUMINATION CIRCUIT
1) OPERATING FLOW
Fuse box (No.20) Illumination switch [CS-39(1)] Switch ON, 1st step
[CS-39(7)] Hazard and illumination switch indicator lamp ON
[CS-39(5)] Fuse box(11) I/conn [CN-3(6)] RH Combi clearance lamp ON [CL-16(4)]
I/conn [CN-8(1)] LH Head lamp ON [CL-3(4)]
I/conn [CN-7(14)] All cluster guage lamp ON
Fuse box(12) I/conn [CN-3(8)] I/conn [CN-10(1)] No. plate lamp
ON [CL-21(2)]
LH Combi clearance lamp ON [CL-15(4)]
I/conn [CN-8(13)] RH Head lamp ON [CL-4(4)]
2) CHECK POINT
Engine Key switch Check point Voltage
‫ ڸ‬- GND (Switch input)

‫ ڹ‬- GND (Switch output)
OFF ON 20~25V
‫ ں‬- GND (To light)
‫ ڻ‬- GND (To gauge lamp)
Ɠ GND : Ground
7-5
ILLUMINATION CIRCUIT
FUSE BOX
2
LH HEAD LIGHT
3
RH HEAD LIGHT
ILL & HEAD LAMP SW NUMBERPLATE LAMP
3 RH COMBI
LH COMBI
SPEED METER
T/M TEMP
HAZARD SW
WATER TEMP
VOLT METER
4
FUEL METER
7-6
2. HEAD LIGHT CIRCUIT
1) OPERATING FLOW
Fuse box(No.19) Head light switch [CS-39(4)] Light switch ON, 2nd step [CS-39(2)]
Multi function switch [CS-11(8)]
Multi function switch MIDDLE [CS-11(7)] I/conn [CN-8(3)] LH Head light low beam
ON [CL-3(1)]
RH Head light low beam
ON [CL-4(1)]
Multi function switch DOWN [CS-11(6)] I/conn [CN-8(2)] LH Head light high beam
ON [CL-3(2)]
RH Head light high beam
ON [CL-4(2)]
I/conn [CN-7(3)] Cluster high beam pilot
lamp ON [CL-41(2)]
2) CHECK POINT

‫ ں‬- GND (Multi function input)
‫ ڻ‬- GND (Multi function output)
OFF ON 20~25V
‫ ڼ‬- GND (Multi function output)
‫ ڽ‬- GND (Low beam)
‫ ھ‬- GND (High beam)
‫ ڿ‬- GND (Passing B+)
Ɠ GND : Ground
7-7
HEAD LIGHT CIRCUIT
FUSE BOX
1 LH HEAD LIGHT
RH HEAD LIGHT
ILL & HEAD LAMP SW

8
2
HI BEAM PILOT LAMP
4
3
5 6
MULTI FUNCTION SW EARTH
7-8
3. WORK LIGHT SWITCH
1) OPERATING FLOW
Fuse box(No.17) Work light switch [CS-21(5)] Work light switch ON [CS-21(1)]
I/conn [CN-5(4)] LH Front work lamp ON [CL-6(2)]
RH Front work lamp ON [CL-5(2)]
Work light switch [CS-21(6)] Work light switch ON [CS-21(2)]
I/conn [CN-3(4)] I/conn [CN-10(2)] LH Rear work lamp
ON [CL-22(2)]
RH Rear work lamp
ON [CL-23(2)]
Work lamp switch indicator lamp ON
2) CHECK POINT

OFF ON 20~25V
‫ ں‬- GND (Front work light)
‫ ڻ‬- GND (Rear work light)
Ɠ GND : Ground
7-9
WORK LIGHT SWITCH
FUSE BOX
1 1
FRONT WORK
LIGHT,LH
FRONT WORK
LIGHT,RH
3
WORK LAMP
2
2
REAR WORK
LIGHT,LH
REAR WORK
LIGHT,RH
7-10
4. STARTING CIRCUIT
1) OPERATING FLOW
Battery(+) terminal Battery relay(M8, B+ terminal) Fusible link [CN-60(1)]
I/conn [CN-1(1)] Fuse box (No.13) Start switch [CS-2(1)]
Ɠ The EGS lever is neutral position. It is necessary condition before the starting.
The EGS has an output signal which is activated whenever the shift lever is in the neutral position.
This signal can be used to control a relay and prevent engine from starting whenever the shift lever is
not in the neutral position.
(1) When start key switch is in ON position
Start switch ON Start switch [CS-2(2)] I/conn [CN-2(1)] Battery relay [CR-1]
Battery relay operating(All power is supplied with the electric component)
Start switch [CS-2(3)] Fuse box [No.4] I/conn [CN-2(8)]
I/conn [CN-4(8)] Engine stop solenoid [CN-79]
(2) When start key switch is in START position
Start switch START [CS-2(5)] Start safety relay [CR-5(2)] Start safety relay [CR-5(4)]
I/conn [CN-3(3)] I/conn [CN-4(5)] Start relay [CR-23(2)]
Starter(Terminal B+ and S connector of start motor)
2) CHECK POINT
‫ ڸ‬- GND (Battery B+)

‫ ڹ‬- GND (Fusible link)
‫ ں‬- GND (Start key B+)
‫ ڻ‬- GND (Start key BR terminal)
‫ ڼ‬- GND (I/conn CN-2(1))
Running ON 20~25V
‫ ڽ‬- GND (Start key R2 terminal)
‫ ھ‬- GND (Start safety relay output)
‫ ڿ‬- GND (Check unit)
‫ ۀ‬- GND (Start key IG terminal)
‫ ہ‬- GND (Engine stop solenoid)
Ɠ GND : Ground
7-11
STARTING CIRCUIT
CHECK UNIT
EGS
FUSE BOX
PROLIX SW
SAFETY RY 7
60R 60R 60B 60B
MASTER SW
BATT RY
NEUTRAL RY
2
STARTER
5
START RY
4
9
6 3
START SWITCH ENG STOP SOL

EMER TRAVEL
SWITCH 10
7-12
5. ENGINE STOP CIRCUIT
1) OPERATING FLOW
Start key OFF [CS-2(3)] Fuse box (No.4) I/conn [CN-2(8)] I/conn [CN-4(8)]
Engine stop solenoid OFF [CN-79]
2) CHECK POINT
‫ ۀ‬- GND (Start key IG terminal)

OFF OFF 0V
‫ ہ‬- GND (Engine stop solenoid)
Ɠ GND : Ground
3) WIRING DIAGRAM - See page 7-12.
7-13
6. CHARGING CIRCUIT
When the starter is activated and the engine is started, the operator releases the key switch to the
ON position.
Charging current generated by operating alternator flows into the battery through the battery
relay(CR-1).
The current also flows from alternator to each electrical component and controller through the fuse
box.
1) OPERATING FLOW
(1) Warning flow
Altermator [CN-74(I)] I/conn [CN-4(4)] I/conn [CN-2(2)] Check unit [CN-58(2)ơ(18)]
I/conn [CN-6(1)] Cluster charge warning lamp ON [CL-46(1), Below 24V]
JT-27(4)ơ(10) Volt meter [CN-104(B)]
(2) Charging flow
Alternator Starter [CN-45(B+)] Battery relay [CR-1]
Battery(+) terminal Charging
I/conn [CN-60(1),(2)] I/conn [CN-1(1),(2)] Fuse box
2) CHECK POINT
‫ ڸ‬- GND (Battery)

‫ ڹ‬- GND (Battery relay)
‫ ں‬- GND (ALT B)
Running ON 20~28V
‫ ڻ‬- GND (ALT I)
‫ ڼ‬- GND (Check unit)
‫ ڽ‬- GND (Fuse box)
Engine Key switch Check point Resistance
Running ON ‫ ھ‬- GND (Cluster) ſ‫װ‬

Ɠ GND : Ground
7-14
CHARGING CIRCUIT
FUSE BOX
CHECK UNIT
CHARGE
2 1
60R 60R 60B 60B
7 BATT RY
MASTER SW
6
VOLT METER
STARTER
ALTERNATOR
7-15
7. ELECTRIC PARKING, DECLUTCH CIRCUIT
1) OPERATING FLOW
(1) Parking OFF
Fuse box (No.6) Parking switch OFF [CS-17(6)‫(آ‬8)] Parking solenoid ON(Activated)
Parking brake released(By hydraulic pressure)
(2) Parking ON
Fuse box (No.6) Parking switch ON Parking solenoid [CN-71] OFF
Parking brake applied [By spring force]
[CS-17(6)‫(آ‬2)] Parking switch indicator lamp ON
[CS-17(5)‫(آ‬1)] I/conn [CN-15(4)]
EGS [CN-111(14)] T/M declutch
Declutch ON
(3) Fuse box (No.6) Clutch cut-off switch ON Clutch cut-off switch [CS-42(6)‫(آ‬2)]
Clutch cut-off switch indicator lamp ON
Clutch cut-off switch [CS-42(5) ‫(آ‬1)]
Service brake applied
Service brake pressure switch ON [CD-5]
I/conn [CN-15(4)] Declutch
Clutch oil pressure switch
2) CHECK POINT
‫ ڸ‬- GND (Parking switch input)

‫ ڹ‬- GND (Parking switch output)
‫ ں‬- GND (Parking switch input)
Running ON ‫ ڻ‬- GND (Parking switch output) 20~25V
‫ ڼ‬- GND (Parking solenoid)
‫ ڽ‬- GND (Press switch clutch cut-off)
‫ ھ‬- GND (Declutch input signal)
Ɠ GND : Ground
7-16
ELECTRIC PARKING, DECLUTCH CIRCUIT
EGS
CHECK UNIT FUSE BOX
PROLIX SW
NEUTRAL RY
7
2 1 3
PARKING SW
4 5
6
CLUTCH CUT-OFF SW
PARK SOL
CLUTCH EMER TRAVEL

CUT-OFF SWITCH
7-17
8. WIPER AND WASHER CIRCUIT
1) OPERATING FLOW
Fuse box (No.7) Wiper relay [CR-4(1)‫(آ‬3)] Front wiper motor [CN-21(P)]
Front relay 2 [CR-26(2), (3)]
Multi function switch [CS-12(6)]
Rear wiper & washer switch [CS-3(1)]
Rear wiper motor [CN-102(P)]
(1) Front washer switch ON
‫ ڸ‬Washer switch ON [CS-12(6)‫(آ‬2)] Washer tank [CN-22(2)] Washer operating
Check unit [CN-58(21)‫(آ‬15)] Wiper relay 2
[CR-26(2)‫(آ‬4)] Wiper motor [CN-21(Lo)]
Wiper motor operating(Low)
(2) Front wiper switch ON
‫ ڸ‬INT position
Wiper switch ON [CS-12(6)‫(آ‬1)] Check unit [CN-58(10)‫(آ‬15)] Wiper relay
[CR-26(2)‫(آ‬4)] Wiper motor [CN-21(Lo)] Wiper motor intermittently operating
‫ ڹ‬Lo position
Wiper switch ON [CS-12(6)‫(آ‬4)] Wiper motor [CN-21(Lo)] Wiper motor operating (Low)
‫ ں‬Hi position
Wiper switch ON [CS-12(6)‫(آ‬3)] Wiper relay [CR-4(1)‫(آ‬4)] Wiper motor [CN-21(Hi)]
Wiper motor operating(High)
(3) Auto-parking(When switch OFF)
Wiper motor [CN-21(Lo)] OFF Fuse box (No.7) Wiper relay [CR-4(4)‫(آ‬3)]
Wiper relay 2 [CR-26(3)] Wiper motor [CN-21(P)‫(آ‬S)] Wiper motor stop
(4) Rear wiper and washer switch
‫ ڸ‬Wiper switch ON(1st step)
Wiper switch ON [CS-3(1)‫(آ‬6)] Wiper motor operating
Rear wiper and washer switch indicator lamp ON
‫ ڹ‬Washer switch ON(2nd step)
Washer switch ON [CS-3(1)‫(آ‬3)] Rear washer tank [CN-103(2)] Washer operating
2) CHECK POINT

‫ ڸ‬- GND (Front wiper power input)
‫ ڹ‬- GND (Rear wiper power input)
‫ ں‬- GND (Wiper relay power input)
‫ ڻ‬- GND (Front wiper motor Lo power input)
‫ ڼ‬- GND (Front wiper motor High power input)
Stop ON 20~25V
‫ ڽ‬- GND (Wiper relay power input)
‫ ھ‬- GND (Front washer power output)
‫ ڿ‬- GND (Rear washer power output)
‫ ۀ‬- GND (Front wiper motor power output)
‫ ہ‬- GND (Rear wiper motor power output)
Ɠ GND : Ground
7-18
WIPER AND WASHER CIRCUIT
CHECK UNIT FUSE BOX
REAR WIPER
WIPER RY2
3
WIPER RY
9 5
1 7 4
10 8
2
F/WASHER
R/WASHER
FRONT WIPER
REAR WIPER & WASHER SW
MULTIFUNCTION SWITCH
7-19
MONITORING CIRCUIT
CHECK UNIT
BRAKE OIL
T/M TEMP
A/CIEANER FILTER
ENGINE OIL
WATER TEMP
OVER HEAT
HYD TEMP
PARKING FUEL METER
FUEL SENDER
T/M OIL TEMP
ENG OIL PRESS

HYD TEMP
PARK PS BRAKE
OIL PS
OVER HEAT SW
AIR FILTER
WATER TEMP
7-20
HAZARD, TURN AND ROTARY CIRCUIT
COMBI LAMP RH
ROTARY LAMP
COMBI LAMP LH
FUES BOX
FLASHER UNIT
RH TURN LAMP,RR
LH TURN LAMP,RR
LH TURN LAMP,FR
RH TURN LAMP,FR
EARTH
HAZARD SW BEACON LAMP SW MULTI FUNCTION SWITCH
7-21
3. MONITORING SYSTEM
1. CLUSTER
The gauges panel consists of gauges and monitors as shown below, to warn the operator in case of
abnormal machine operation or conditions for the appropriate operation and inspection.
ş Gauges : Indicate operating status of the machine.
ş Warning lamp : Indicate abnormality of the machine.
ş Pilot lamp : Indicate operating status of the machine.
Ɠ The monitor installed on this machine does not entirely guarantee the condition of the
machine.
Daily inspection should be performed according to chapter 6, Maintenance.
Engine oil pressure warning lamp T/M oil pressure warning lamp
Overheat warning lamp Hyd oil temp warning lamp
Battery charging warning lamp Brake fail warning lamp
Left turning pilot lamp Right turning pilot lamp
High beam pilot lamp Parking brake pilot lamp
20 30
20 P
10
40
10
5 30
0 mph
0 50
km/h
E F
WATER FUEL
TRANS BATT
T/M oil temperature gauge Battery volt meter

Engine coolant temperature gauge Speedometer
Air cleaner warning lamp Fuel gauge
1) SPEEDOMETER
(1) Specification
30
20 Input(Hz) Input pulse
10 20
40
10
5 0 mph
30 Vpp = 20V MIN
0
km/h 50 1km = 26.2Hz
GND 1.8V MAX
(2) Indicated standard
Standard(km/h) 0 20 40
+4.8 +4.8
Allowable(km/h) 0
0 0
7-22
2) FUEL GAUGE
(1) This gauge indicates the amount of fuel in the fuel tank.
Red White
(2) Fill the fuel when the red range illuminates.
E F
(3) The gauge indicates continuously the current fuel amount
FUEL
even after turn OFF the starting switch. This does not mean
that the gauge is out of order.
Ɠ If the gauge illuminates the red range even though the
machine is on the normal condition, check the electric
device as that can be caused by the poor connection of
electricity or sensor.
Fuel quantity Tolerance Resistance(‫)װ‬ Zone
E +0.7, -0.7 240 Red

F +2.0, -2.0 33.5 White
3) ENGINE COOLANT TEMPERATURE GAUGE

(1) This indicates the temperature of coolant.
Green Red şGreen range : 37-105Ş C(99-221Ş F)
şRed range : 105Ş C(221ŞF) Above
(2) The green range illuminates when operating.
WATER
(3) Keep idling engine at low speed until the green range
illuminates, before operation of machine.
(4) When the red range illuminates, turn OFF the engine, check
the radiator and engine.
Temperature(Ş
C) Tolerance Resistance(‫)װ‬ Zone
37 +11.7, -13.9 533.2 Green
105 +1.7, -1.8 73.3 Red
7-23
4) TRANSMISSION OIL TEMPERATURE GAUGE
(1) This range indicates the temperature of transmission oil.
Green Red şGreen range : 37-120Ş C(99-248ŞF)
şRed range : 120Ş C(248ŞF) Above
(2) The green range indicates when operating.
TRANS
(3) Keep idling engine at low speed until the green range
indicates, before operation of machine.
(4) If the indicator is in the red range, it means the transmission is
overheated. Be careful that the indicator does not move into
the red range.
Temperature(Ş
C) Tolerance Resistance(‫)װ‬ Zone
37 +13.9, -16.7 767.7 Green
120 +2.8, -2.8 65.4 Red
5) BATTERY VOLT METER

(1) This gauge indicates the voltage in the charging system when
White Green Red the engine is running.
(2) If the indicator is below 24V(White range), it means that the
electricity is being discharged. If the indicator is above
BATT
30V(Red range), an unusually high voltage may damage the

alternator. Check the charging system in both cases.
Temperature(Ş
C) Tolerance Input voltage(V) Zone
24 +0.50, -0.50 24 Green
30 +0.25, -0.25 30 Red
6) DIRECTION PILOT LAMP

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

(1) This lamp works when the illuminating direction is upward.
(2) This lamp comes ON when the dimmer switch is operated,
e.g., when passing another vehicle.
7-24
8) PARKING BRAKE PILOT LAMP
(1) When the parking brake is actuated, the lamp lights ON.
Ɠ Check the lamp is OFF before driving.
9) BRAKE FAIL WARNING LAMP

(1) The lamp lights ON when the oil pressure of service brake
drops below the normal range.
(2) When the lamp is ON, stop the engine and check for its
cause.
Ɠ Do not operate until any problems are corrected.
10) TRANSMISSION OIL PRESSURE WARNING LAMP

(1) The lamp lights ON when the oil pressure of the
transmission drops.
(2) When the lamp is ON, stop the engine and check the
transmission system.
11) AIR CLEANER WARNING LAMP

(1) This lamp operates by the vacuum caused inside when the
filter of air cleaner is clogged.
(2) Check the filter and clean or replace it when the lamp
operates.
12) BATTERY CHARGING WARNING LAMP

(1) This lamp is ON when key ON, it is turned OFF after starting
the engine.
(2) Check the battery charging circuit when this lamp comes ON,
during engine operation.
7-25
13) ENGINE OIL PRESSURE WARNING LAMP
(1) If lamp comes ON during engine operation, shut OFF
engine immediately. Check oil level.
14) OVERHEAT WARNING LAMP

(1) This lamp is turned ON when the temperature of cooling water
is over the normal temperature (110Ş
C, 230Ş
F).
(2) Check the cooling system when the lamp is ON.
15) HYDRAULIC OIL TEMP WARNING LAMP

(1) This warning lamp operates and the buzzer sounds when the
temperature of hydraulic oil is over 105Ş
C(221Ş
F).
(2) Check the hydraulic oil level when the lamp is turned ON.
(3) Check for debris between oil cooler and radiator.
7-26
2. SWITCHES
Emergency steering pilot lamp(Option) Cold start switch(Option)

Beacon switch(Option) Prolix switch
Work lamp switch Buzzer stop switch
Main light switch
Clutch cut off switch
Parking brake switch
2
2
R
Switch panel
Rear wiper and washer switch
Multi function switch Air conditioner switch
Starting switch Hazard switch
Horn button
Kick down switch
Override switch
1) STARTING SWITCH
(1) There are three positions, OFF, ON and START.
ON STAR
T
(2) OFF : None of electrical circuits activate.
F
OF
(3) ON : All the systems of machine operate.

(4) START : Use when operating the engine.
Release key immediately after starting.
7-27
2) OVERRIDE SWITCH
(1) This switch is for an emergency in case the EGS(Electronic Gear
Selection) is inoperative.
Forward
(2) The machine can travel with forward 2th or backward 2th at EGS
prolix switch ON.
N
Backward
3) HAZARD SWITCH
(1) Use for parking, or roading machine.
Ɠ If the switch is left ON for a long time, the battery may be
discharged.
(2) The below indicator lamp is turned ON when operating this switch.
4) CLUTCH CUT OFF SWITCH

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

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

(1) This switch turns ON the working lamps located on the cab and
radiator door.
8) AIR CONDITIONER SWITCH

(1) This switch use to operates the air conditioner.
(2) Refer to the air conditioner and heater for detail operation.
9) REAR WIPER AND WASHER SWITCH

(1) The switch use to operates the rear wiper and washer by two step.
şFirst step : The rear wiper operates.
şSecond step : The washer liquid is sprayed and the rear wiper is
operated only while pressing. If release the switch,
return to the first step position.
7-29
10) BUZZER STOP SWITCH
(1) The red lamp on the cluster lights ON and the buzzer sounds when
the machine has a problem.
In this case, if the switch is pressed, the buzzer will be stopped. Be
sure to check machine for problems.
(2) Wait until the lamp is turned OFF, if the red lamp lights ON after the
buzzer stopped.
If not, stop engine and check the system which the lamp is ON.
11) COLD START SWITCH(Option)

(1) This switch is used for starting the engine in cold weather.
If pressed, starting aid fluid is injected for easier engine starting.
12) CAB LAMP SWITCH

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

(1) The kick-down button is pushed, gear selection will instantly changes
Kick down switch from F2(R2) to F1(R1).
(2) If the button is pushed or machine speed reaches up to 6km/hr, the
gear selection will automatically change to F2(R2).
7-30
14) EMERGENCY STEERING PILOT LAMP(Option)
Primary
Primary
(1) Primary
Emergency
Emergency If the oil pressure in the steering pump drops, the lamp will light up. If
this lamp flashes during operation, the action alarm should sound.
Ɠ If the lamp lights up, immediately pull the machine to a safe
place and stop the machine.
(2) Emergency
This lamp will flash if the oil pressure in the emergency steering
pump drops. The lamp notifies the operator that if the steering
system also failed at this time, there is no emergency steering
system for backup.
Ɠ Immediately pull the machine to a convenient stop and stop the
engine.
Ɠ This machine is equipped with ground driven emergency
steering pump. It is normal for the lamp to flash after 5
seconds when the machine is stopped.
15) MULTI FUNCTION SWITCH

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

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

(1) This switch turns ON the rotary light on the cab.
18) EGS PROLIX SWITCH

(1) When the EGS is inoperative, press this switch at starting switch is
OFF.
(2) Start engine with starting switch when keep override switch is Neutral
position.
7-32
GROUP 4 ELECTRICAL COMPONENT SPECIFICATION
Part name Symbol Specifications Check
Ɠ Check specific gravity

12V ź 80Ah 1.280 Over : Over charged
Battery
(2EA) 1.280 ~ 1.250 : Normal
1.250 Below : Recharging
Rated load : Ɠ Check coil resistance

24V Normal : About 50‫װ‬
Battery relay
100A(Continuity) Ɠ Check contact
CR-1 1000A Normal : ſ‫װ‬
(30 Seconds)
Ɠ Check disconnection
2 Normal : 0‫װ‬
Fusible link 1 24V 60A (Connect ring terminal and
CN-60 check resistance between
terminal 1 and 2)
Ɠ Check contact
1.25BW
1.25GY
1.25LW
1.25LB
OFF : ſ‫(װ‬For each terminal)

ON : 0‫(װ‬For terminal 1-3)
CS-2
6 5 4 3 2 1
Start key -
ST ſ‫(װ‬For terminal 1-5)
ACC
OFF START : 0‫(װ‬For terminal 1-3
HT
C R2 R1 IG BR B OFF and 1-5)
Pa
Ɠ Check contact
Pressure switch N.C TYPE
CD-3 CD-26 Normal : 0‫(װ‬Close)
CD-25 CD-39
Pa
Ɠ Check contact
Pressure switch N.O TYPE
Normal : ſ‫(װ‬Open)
CD-4 CD-11
CD-5 CD-40
7-33
Pa 0.5kg/cm2 Ɠ Check contact

Pressure switch
(For engine oil) (N.C TYPE) Normal : 0‫(װ‬Close)
CD-18
T Ɠ Check resistance
Coolant temp - Normal : ſ‫װ‬
sensor
225Ş
F Over : 0‫װ‬
CD-9
Ş
C
Coolant Ɠ Check resistance
-
temp sensor 192Ź13.5‫ װ‬at 73.9Ş
C
CD-8
Pa Pressure :
Air cleaner Ɠ Check contact
635mmH2O
pressure switch Normal : ſ‫װ‬
CD-10 (N.O TYPE)
2 Ɠ Check LED lamp

Parking
1 24V 1.2A Ɠ Check Resistance
solenoid
About 24‫װ‬
CN-71
1 Ɠ Check resistance
Reed switch :
Fuel sender 2 Full : About 30‫װ‬
Magnetic type
CD-2 Low level : About 300‫װ‬
7-34
Transmission Ş
C
Ɠ Check resistance
oil temperature 1/2 P.T.F
137.2Ź14.5‫ װ‬at 87.8Ş
C
sender
CD-29
1 2 1
Ɠ Check resistance
2
Normal : About 200‫װ‬
Relay 3
24V 20A (For terminal 1-3)
(4pin) 4 4 3
: ſ‫װ‬
CR-2 CR-26 AC RY1
(For terminal 2-4)
CR-5 AC RY2
Ɠ Check resistance
1
2
3 4 6 Normal : About 160‫װ‬
4 (For terminal 2-6)
Relay 6 24V 20A : 0‫װ‬
(5pin) 3 1 2
(For terminal 1-3)
CR-4 CR-38 : ſ‫װ‬
CR-35
(For terminal 1-3)
1 B
Proximate 2 S
switch 24V 400mA -
3 E
CN-100 CN-101
T Ɠ Check resistance
Hydraulic
- Normal : ſ‫װ‬
temperature
CD-1 105Ş
C Over : 0‫װ‬
Ɠ Check contact
Normal : 1.12‫װ‬
2 Lo 1 (For terminal 2-4)
Air conditioner 4 Hi 2
: 2.07‫װ‬
-
resistor 3 ML 3
4 (For terminal 3-4)
1 MH
: 3.17‫װ‬
(For terminal 4-1)
7-35
Ɠ Check resistance
Speaker 4‫ װ‬20W
Normal : 50‫װ‬
CN-23(LH)
CN-24(RH)
10 9 8 7 6 5 4 3 2 1
10 6 5 Ɠ Check contact
OFF : ſ‫װ‬
Switch 24V 8A (For terminal 1-5, 2-6)
9 8 2 7 1
(Locking type)
CS-17 CS-41 CS-50 : 0‫װ‬
CS-21 CS-42 CS-54 (For terminal 5-7, 6-8)
CS-23
10 9 8 7 6 5 4 3 2 1
Switch 10 4 1 Ɠ Check contact

(Non-locking 24V 8A OFF : ſ‫װ‬
type) 9 2 75 (For terminal 2-4, 1-7)
CS-3 CS-39
Work lamp
Work lamp, 1
24V 70W
Room lamp, 2 Ɠ Check disconnection
Number plate Number plate lamp Normal : A few‫װ‬
CL-1 CL-6 CL-22
lamp CL-5 CL-21 CL-23 Room lamp
24V 10W
M 24V 70W Ɠ Check disconnection

Beacon lamp
(H1 TYPE) Normal : A few‫װ‬
CL-7
Ɠ Check operation
Hour meter h -
Supply power(24V) to
terminal No.2 and contact
CN-48 terminal No.1 and ground
7-36
Ɠ Check operation
22-28V 2A Supply power(24V) to each
Horn
110dB terminal and connect ground
CN-20 CN-25
Pa 1
Ɠ Check contact
Receiver dryer 2 24V 2.5A
Normal : ſ‫װ‬
CN-29
1 S.L+
2 ACC
3 N.C
4 S.R+ Ɠ Check resistance
5 N.C
Cassette radio 6 S.L- 24V 20W+20W Power ON : 4‫װ‬+4‫װ‬
7 B+
8 S.R- (For terminal 1-6, 4-8)
9 N.C
CN-27
24V 0.5A
Back up buzzer -
110dB
CN-65
M 1
Ɠ Check contact
Washer pump 2 24V 2.5A Normal : 26.4 ‫װ‬
CN-103 CN-22 (For terminal 1-2)
P
S
24V 1.5A
Hi
Wiper motor 2-speed -
E M Lo
Auto parking
CN-102 CN-21
7-37
3
2
Cigar lighter 1 24V 5A -
CL-2
Ɠ Check contact
Ether 24V 15A
CN-78
Engine stop Ɠ Check resistance

24V
solenoid Normal : 15-25‫װ‬
CN-79
B+ G
3~ Ɠ Check voltage
Alternator I 20V 60A
GND Normal : 24-28V
CN-74
B+
M
Delco Remy
Starter Ɠ Operating or not
M 28MT 24V
CN-45
1
Air conditioner Ɠ Check contact
2 24V 79W
compressor Normal : 13.4‫װ‬
CN-28
7-38
2 Ɠ Check contact
Start relay 1 24V 200A
CR-23
M 1 24V 9A
Blower -
2 2900Ź150rpm
1 GND
2 24 5 36
COM
3 MH Ɠ Check resistance
Blower switch 4 LOW - Normal : 0‫(װ‬For terminal 1-2,
5 ML
6 HI
1 3, 4, 5, 6)
CS-58
M+ 1
Mode actuator S+ 2
M
and M- 3 DC Servo motor
-
temperature FS 4 9-16V 300mA Max
actuator S- 5
NC 6
R 2 Ɠ Check resistance
Intake actuator M 12V
F 1 Normal : 2.0‫װ‬
Working
temperature of
1
Thermostat contact point -
2
A/C ON : 4.5Ş C
A/C OFF : 1.5ŞC
7-39
3 E
G 24V
2 B
Flasher unit 85 ~ 190 C/M -
1 L
50dB
CR-11
1 Lo
24V 75W/70W
2 Hi
(H4 TYPE) Ɠ Check disconnection
Head lamp 3 E
4 C
24V 4W Normal : A few‫װ‬
(T4W)
CL-3 CL-4
4 C
24V 5W
3 T
(R5W)
Combi lamp 2 E -
1 S 2ź24V 21W
(P21W)
CL-15 CL-16
1
24V 21W
Turn lamp 2 -
(P21W)
CL-24 CL-25
1 m
Transmission rp Ɠ Internal resistance
2 -
speed sensor 1480‫װ‬Ź7.5%
CD-27
Continuous
Capacity :
Master switch 180Amp -
Push in capacity :
1000Amp
7-40
2
24V 200mA
Warning buzzer 1 -
90Ź5dB(ֻm)
CN-26
M 1
Air conditioner
2 24V -
fan
CN-83
Ether switch
and buzzer Ɠ Check contact
stop switch 24V 8A OFF : ſ‫װ‬
(Rocker switch (For terminal 1-5, 2-6)
push button)
CS-30 CS-34
Ɠ Check contact
OFF : ſ‫װ‬
Prolix switch
24V 8A (For terminal 1-5, 2-6)
(Locking type)
: 0‫װ‬
(For terminal 5-7, 6-8)
CS-7
Ɠ Check contact
Emergency Change over OFF : ſ‫װ‬
travel switch switch (For terminal 5-4, 5-6
1-2, 2-3)
CS-43
Ɠ Check contact
Normal : 80~90‫װ‬
(For terminal 1-5, 2-6
Joy stick lever -
3-7, )
: ſ‫װ‬
CN-144
(For terminal 4-8)
7-41
GROUP 5 CONNECTORS
1. CONNECTOR DESTINATION
Connector No. of Connector part No.
Type Destination
number pin Female Male
CN-1 58 2 I/conn(Frame harness-Main harness) S813-030200 S813-130200
CN-2 SWP 12 I/conn(Frame harness-Main harness) S814-012000 S814-112000
CN-5 SWP 8 I/conn(Cab harness-Main harness) S814-008000 S814-108000
CN-6 SWP 12 I/conn(Gauge harness-Main harness) S814-012000 S814-112000
CN-8 SWP 14 I/conn(Front harness-Main harness) S814-014000 S814-114000
CN-9 SWP 8 I/conn(T/M check harness-Main harness) S814-008000 S814-108000
CN-10 SWP 4 I/conn(Cowl harness-Frame harness) S814-004000 S814-104000
CN-11 SWP 6 I/conn(Frame harness-Gauge harness) S814-006000 S814-106000
CN-13 Fasten 8 I/conn(Main harness-AC AVA Assy) S810-008202
CN-15 - 12 I/conn(Main harness-T/M harness) S814-012000 S814-112000
CN-20 - 1 Horn S819-010122
CN-21 - 1 Front wiper motor 2-250129-2
CN-22 - 2 Front washer tank S814-002000
CN-23 Shur 1 Speaker(LH) S822-014000 S822-114004
CN-24 Shur 1 Speaker(RH) S822-014000 S822-114004
CN-25 - 1 Horn S819-010122
CN-26 Fasten 2 Warning buzzer S810-002202
CN-27 PA 9 Cassette and radio S811-009003
CN-28 - 2 Compressor(Air conditioner) 0297-3407
CN-29 - 2 Receiver drier 21L7-12000
CN-30 PA 13 Air conditioner controller S811-013002
CN-36 - 20 Fuse box 21L7-00230
CN-45 Ring term - Starter S820-414000
CN-48 - 1 Hour meter S819-010112
CN-58 - 36 Check unit 344111-1
CN-60 58 2 Fusible link S813-130200
CN-65 Shur 1 Back up buzzer S822-014000
CN-71 J 2 Parking solenoid S816-002001
CN-74 Ring term - Alternator S820-406000
CN-78 Shur 2 Ether S822-014000
CN-79 Ring term 3 Fuel cut off solenoid S818-020311
CN-83 - 2 Air conditioner fan PH805-02028
CN-100 J 3 Boom kick out S816-003001
CN-101 J 3 Bucket leveler S816-003001
7-42
Type Destination
CN-102 - 1 Rear wiper motor 2-250129-2
CN-103 - 2 Rear washer tank S814-002000
CN-104 Ring term - Volt meter S821-105000
CN-107 Ring term - Fuel gauge S821-105000
CN-111 Buchse socket 35 Control unit 6029-199-004
CN-112 Buchse socket 6 Transmission WG/PW 6029-199-018
CN-117 Ring term - Water temp S821-105000
CN-119 Ring term - Transmission temp S821-105000
CN-127 Ring term - Speed meter S821-105000
CN-144 Fasten 8 Joy stick S810-008202
Relay
CR-1 Ring term - Battery relay S820-104000
CR-2 Fasten 4 Horn relay S810-004202
CR-4 Fasten 6 Wiper relay S810-006202
CR-5 Fasten 4 Safety relay S810-004202
CR-11 Fasten 3 Flasher unit S810-003702
CR-23 J 2 Start relay S816-002003
CR-26 Fasten 4 Wiper relay 2 S810-004202
CR-30 Fasten 4 Back up relay S810-004202
CR-35 Fasten 6 Ride control relay S810-006202
CR-38 Fasten 6 Neutral relay S810-006202
Switch
CS-2 SWP 6 Start key switch S814-006000
CS-3 SWF 10 Rear wiper switch 593757
CS-5 Shur 1 Horn switch S822-014000
CS-7 SWF 10 Prolix switch 593757
CS-11 SWP 8 Multi function switch S814-008000
CS-12 SWP 6 Multi function switch S814-006000
CS-17 SWF 10 Parking switch 593757
CS-21 SWF 10 Work lamp switch 593757
CS-23 SWF 10 Beacon switch 593757
CS-30 SWF 10 Ether 593757
CS-34 SWF 10 Buzzer stop switch 593757
CS-39 SWF 10 Illumination and head lamp switch 593757
CS-41 SWF 10 Hazard switch 593757
CS-42 SWF 10 Clutch cut off switch 593757
CS-43 Fasten 6 Emergency travel switch S810-006202
CS-50 SWF 10 Ride control 593757
CS-54 SWF 10 Air conditioner switch 593757
CS-58 Fasten 6 Blower switch S810-006202
7-43
Type Destination
Light
CL-1 - 2 Room lamp MG610392
CL-2 Fasten 3 Cigar lighter S810-003202
CL-3 SWP 4 Head light(LH) S814-004000
CL-4 SWP 4 Head light(RH) S814-004000
CL-5 SWP 2 Work light(LH) S814-002000
CL-6 SWP 2 Work light(RH) S814-002000
CL-7 Fasten 1 Beacon lamp S810-001202
CL-15 SWP 4 Combi lamp(RR, LH) S814-004000
CL-16 SWP 4 Combi lamp(RR, RH) S814-004000
CL-21 SWP 2 Numberplate lamp S814-002000
CL-22 SWP 2 Work light(LH) S814-002000
CL-23 SWP 2 Work light(RH) S814-002000
CL-24 SWP 2 Turn lamp(LH) S814-002000
CL-25 SWP 2 Turn lamp(RH) S814-002000
CL-41 SWF 2 Hi beam lamp(Dash board) 913328
CL-42 SWF 2 Turn lamp(LH, Dash board) 913328
CL-43 SWF 2 Turn lamp(RH, Dash board) 913328
CL-44 SWF 2 Parking lamp(Dash board) 913328
CL-45 SWF 2 Brake fail lamp(Dash board) 913328
CL-46 SWF 2 Charge lamp(Dash board) 913328
CL-47 SWF 2 Hydraulic oil lamp(Dash board) 913328
CL-48 SWF 2 Over heat lamp(Dash board) 913328
CL-49 SWF 2 Engine oil lamp(Dash board) 913328
CL-50 SWF 2 Air cleaner lamp(Dash board) 913328
CL-51 SWF 2 Transmission oil lamp(Dash board) 913328
CL-52 SWF 2 Glow lamp(Dash board) 913328
CL-53 SWF 2 Steering pressure lamp 913328
CL-54 SWF 2 Steering pump pressure lamp 913328
Sensor, sender
CD-1 - 1 Hyduaulic oil temp sendor 1-150656 S820-105000
CD-2 SWP 2 Fuel sendor S814-002000
CD-3 - 1 Brake fail pressure switch S819-010112
CD-4 - 1 Stop lamp pressure switch S819-010112 S820-105000
CD-5 - 1 Clutch cut off pressure switch S819-010112
CD-8 Ring term - Water temp sendor
CD-9 - 1 Over heat switch 21EA-50150
CD-10 Ring term 2 Air cleaner switch S814-002000
CD-18 Ring term - Engine oil pressure switch
CD-25 - 2 Transmission oil pressure switch S819-010122
7-44
Type Destination
CD-26 - 1 Parking pressure switch S819-010112
CD-27 Rund stecker 2 Turbine speed sendor 6029-199-002
CD-29 Ring term - Transmission temp sendor S820-106000
CD-39 - 2 Steering pressure switch S819-010122
CD-40 - 2 Steering pump pressure switch S819-010122
7-45
2. CONNECTION TABLE FOR CONNECTORS
1) 58-L TYPE CONNECTOR
No. of
pin Receptacle connector(Female) Plug connector(Male)
1 1
S813-030100 S813-130100
1 2 1 2
S813-030200 S813-130200
7-46
2) PA TYPE CONNECTOR
No. of
2 5 1 3
1 3 2 5
S811-005002 S811-105002
3 7 1 4
1 4 3 7
S811-007002 S811-107002
4 9
1 5
1 5
4 9
S811-009002 S811-109002
5 11 1 6
11
1 6 5 11
S811-011002 S811-111002
7-47
No. of
6 13 1 7
13
1 7 6 13
S811-013002 S811-113002
8 17 1 9
17
1 9 8 17
S811-017002 S811-117002
10 21 1 11
21
1 11 10 21
S811-021002 S811-121002
7-48
3) 58-X TYPE CONNECTOR
No. of
1 1
S813-060100 S813-160100
2 1
1 2
S813-060200 S813-160200
7-49
4) J TYPE CONNECTOR
No. of
Receptacle connector(Female) Plug connector(Male)
pin
1 1
2 2
S816-002001 S816-102001
2 3 1
3 1 2
S816-003001 S816-103001
7-50
5) SWP TYPE CONNECTOR
No. of
1 1
S814-001000 S814-101000
2 1
1 2
S814-002000 S814-102000
3 1
2 1 2 3
S814-003000 S814-103000
2 4
1 3
1 3 2 4
S814-004000 S814-104000
7-51
No. of
3 6 1 4
3 6
1 4
S814-006000 S814-106000
4 8
1 5
1 5 4 8
S814-008000 S814-108000
4 12 1 9
12
4 12
1 9
S814-012000 S814-112000
3 14 1 11
14
1 3 14
11
S814-014000 S814-114000
7-52
6) CN TYPE CONNECTOR
No. of
1 1
S810-001202 S810-101202
2 2
1 1
S810-002202 S810-102202
3 2
1 2 1 3
S810-003202 S810-103202
2 4 1 4
1 3 2 3
S810-004202 S810-104202
7-53
No. of
3 6 1 4
1 4 3 6
S810-006202 S810-106202
4 8 1 5
1 5 4 8
S810-008202 S810-108202
7-54
7) BS TYPE CONNECTOR
No. of
2 1
1 2
S812-002001 S812-102001
1 3 1 2
2 3
S812-003001 S812-103001
2 4 1 3
1 3 2 4
S812-004001 S812-104001
3 6 1 4
1 4 3 6
S812-006001 S812-106001
7-55
8) LC TYPE CONNECTOR
No. of
5 10
10
1 6
S815-010000
6 12
12
1 7
S815-012000
8 16
16
1 9
S815-016000
9 18
18
1 10
S815-018000
7-56
No. of
12 24
24
1 13
S815-024000
7-57
9) 375 FASTEN TYPE CONNECTOR
No. of
Receptacle connector(Female) Plug connector(Male)
pin
1 2 1 2
S810-002402 S810-102402
7-58
GROUP 6 TROUBLESHOOTING
1. WHEN STARTING SWITCH IS TURNED ON, CLUSTER LAMP DOES NOT LIGHT UP
şBefore carrying out below procedure, check all the related connectors are properly inserted and the
fuse No.2 is not blown out and ON/OFF of bulb.
şAfter checking, connect the disconnected connectors again immediately unless otherwise specified.
Cause Remedy
YES
Defective cluster Replace
YES Check voltage
between CN-58
(1) and chassis
Disconnection in Repair or replace
NO
wiring harness or (After clean)
Check voltage poor contact
between CN-7(4) between
and chassis
CN-58(1) and
fuse No.2

NO
poor contact
between CN-7(4)
and CN-36(2)
CLUSTER
FUSE
4
No.2
CN-7
CN-58
Check voltage
YES 20 ~ 30V
NO 0V
7-59
2. WHEN COOLANT OVERHEAT LAMP LIGHTS UP(Engine is started)
şBefore carrying out below procedure, check all the related connectors are properly inserted.
Cause Remedy
YES
Coolant overheat Check engine
(105Ş
CŹ2Ş C) system
YES
Defective Replace
Check resistance
YES overheat switch
between CN-4
Does display go (10) and chassis
off when Disconnection in Repair or replace
Starting switch : OFF NO
disconnect CD-9 wiring harness or (After clean)
Check resistance
and connector? YES poor contact
between CN-2(4)
Starting switch : ON between CD-9
Engine : start
and chassis
and CN-2(4)
Starting switch : OFF
Check resistance Disconnection in Repair or replace

NO
between CN-6(4) wiring harness or (After clean)
NO
and chassis poor contact
between CN-6(4)
Before checking, and CN-2(4)
disconnect CD-9

NO
CLUSTER OVERHEAT SWITCH

T
4 4 10
CN-6 CN-2 CN-4 CD-9
CHECK UNIT
24
CN-58
Check resistance
YES MAX 1‫װ‬
NO MIN 1M‫װ‬
7-60
3. WHEN AIR CLEANER LAMP LIGHTS UP(Engine is started)
Cause Remedy
YES
Defective air Repair air cleaner
cleaner or air or replace air
cleaner switch cleaner switch
Does display go YES
off when Disconnection in Repair or replace
disconnect CD-10 wiring harness or (After clean)
and connector? poor contact
Starting switch : ON between CN-3(5)
Engine : start Check resistance
between CN-3(5) and CD-10
NO
and chassis
YES
Before checking, wiring harness or (After clean)
disconnect CD-10 Check resistance poor contact CN-3
between CN-6(6)
NO (5) and CN-6(6)
and chassis
NO
CLUSTER
AIR CLEANER SWITCH
6 5 Pa
CN-6 CN-3
CD-10
CHECK UNIT
36
CN-58
Check resistance
YES MAX 1‫װ‬
NO MIN 1M‫װ‬
7-61
4. WHEN ENGINE OIL PRESSURE LAMP LIGHTS UP(Engine is started)
Cause Remedy
YES
Engine oil leakage, Check engine oil
or defective switch level or replace
switch
YES
Does display go
off when wiring harness or (After clean)
disconnect CD-18 Check resistance poor contact
YES
and connector? between CN-4(9) between CN-4(9) -
Starting switch : ON and chassis CD-18
Engine : start
Disconnection in Replace
Check resistance NO
wiring harness or
between CN-6(5)
NO
and chassis poor contact
between CN-6(5) -
Starting switch : OFF CN-2(5)- CN-4(9)
Before checking,
disconnect CD-18
NO
ENGINE OIL PRESSURE SWITCH

CLUSTER
5 5 9 Pa
CN-6 CN-2 CN-4 CD-18
CHECK UNIT
23
CN-58
Check resistance
YES MAX 1‫װ‬
NO MIN 1M‫װ‬
7-62
5. WHEN HYDRAULIC OIL TEMPERATURE LAMP LIGHTS UP(Engine is started)
Cause Remedy
YES
High temperature Check hydraulic
of hydraulic oil or oil temperature
defective switch (105Ş CŹ2Ş C),
Does display go hydraulic cooling
off when or replace switch
disconnect CD-1
and connector? YES
Starting switch : ON
Engine : start
Check resistance poor contact
between CN-6(8) between CN-6(8)
NO
and chassis and CD-1
Before checking, Defective cluster Replace
disconnect CD-1 NO
HYDRAULIC OIL
CLUSTER TEMPERATURE SWITCH
T
8
CN-6 CD-1
CHECK UNIT
12
CN-58
Check resistance
YES MAX 1‫װ‬
NO MIN 1M‫װ‬
7-63
6. WHEN TORQUE CONVERTER OIL TEMPERATURE GAUGE DOES NOT OPERATE
(Check torque converter oil temperature lamp ON/OFF)
Cause Remedy
YES
YES
between CN-7 wiring harness or (After clean)
(10) and chassis poor contact
between CN-
Starting switch : ON Check resistance
7(10) and CN-9(6)
Engine : start between CN-9(6)
See : TABLE NO
and chassis YES
Starting switch : OFF wiring harness or (After clean)
See : TABLE
between CD-29 between CN-9(6)
NO
and chassis and CD-29
See : TABLE Defective sender Replace
NO
TRANS
TRANSMISSION OIL
CLUSTER TEMPERATURE SENDER
Ş
C
10 6
CN-7 CN-9 CD-29
Check resistance
YES MAX 1‫װ‬
NO MIN 1M‫װ‬
Check table
Temperature
50Ş
C 92Ş
C 120Ş
C 130Ş
C
Item
Unit resistance(‫)װ‬ 168.7 (34) 19.5 12.4
Tolerance 0Ş~ -10Ş (-) Ź3Ş +10Ş~ 0Ş
Angle -30Ş -8Ş +27Ş +30Ş
7-64
7. WHEN COOLANT TEMPERATURE GAUGE DOES NOT OPERATE
(Check coolant temperature lamp ON/OFF)
Cause Remedy
YES
YES
Check resistance wiring harness or (After clean)
between CN-7 poor contact
(11) and chassis
between CN-7
Starting switch : ON (11) and CN-2(3)
Engine : start Check resistance
See : TABLE between CN-2(3) YES
NO Disconnection in Repair or replace
and chassis
Before checking, poor contact
disconnect connector between CN-2(3)
See : TABLE
Check resistance and CN-4(12)
between CN-4
NO
(12) and chassis YES
Starting switch : OFF wiring harness or (After clean)
See : TABLE
between CD-8 between CN-4
NO
and chassis (12) and CD-8
See : TABLE Coolant overheat Check coolant
NO
TRANS
or defective temperature or
sender replace
CLUSTER WATER TEMPERATURE SENDER
11 Ş
C
3 12
CN-7 CN-2 CN-4 CD-8
Check resistance
YES MAX 1‫װ‬
NO MIN 1M‫װ‬
Check table
Temperature
(40Ş
C) 91Ş
C 105Ş
C 120Ş
C
Item
Unit resistance(‫)װ‬ 222 (41.3) 28 19.2
Tolerance Ź5Ş (-) Ź4.5 (-)
Angle -30Ş 0Ş +13Ş +30Ş
7-65
8. WHEN FUEL GAUGE DOES NOT OPERATE(Check warning lamp ON/OFF)
Cause Remedy
YES
YES
between CN-7 wiring harness or (After clean)
Starting switch : OFF between CN-7
See : TABLE (12) and CN-2(7)
Check resistance
between CN-2(7)
NO YES
and chassis Disconnection in Repair or replace
See : TABLE wiring harness or (After clean)
poor contact
Check resistance between CD-2(1)
between CD-2(2) and CN-2(7)
NO
and chassis
YES
See : TABLE Check circuit Repair or replace
Check resistance
between CD-2(2) (After clean)
between CD-2(2)
and chassis
NO and CD-2(1) with
chassis
See : TABLE Defective sensor Replace
NO
E F
FUEL
FUEL SENDER
CLUSTER
1
12 7 2
CD-2
CN-7 CN-2
Check resistance
YES MAX 1‫װ‬
NO MIN 1M‫װ‬
Check table
Temperature
Empty (1/2) Full
Item
Unit resistance(‫)װ‬ 95 (32.5) 7
Tolerance Ź2.5Ş Ź5Ş Ź2.5Ş
Angle -30Ş 0Ş +30Ş
7-66
9. WHEN GAUGES OF FUEL, HYDRAULIC OIL AND COOLANT INDICATE HIGH OR FULL
Cause Remedy
YES Defective cluster Replace
Check resistance
between CN-7
(13) and chassis
Starting switch : ON NO
Voltage : 20~30v
poor contact
between CN-7
(13) and chassis
CLUSTER
13
CN-7
Check resistance
YES MAX 1‫װ‬
NO MIN 1M‫װ‬
7-67
10. WHEN BATTERY LAMP LIGHTS UP(Engine is started)
Cause Remedy
YES
Check voltage Defective cluster Replace
YES
between CN-6(1)
and chassis Disconnection in Repair or replace
NO
poor contact
between CN-6(1)
and CN-58(18)
YES
Defective check Replace
Check voltage
YES unit
between CN-58
(2) and chassis
Voltage : 27.5~30V
NO
poor contact
Check voltage Check voltage between CN-58(2)
YES
between between CN-2(2) and CN-2(2)
alternator terminal and chassis
YES
"I" and chassis Voltage : 26~30V Disconnection in Repair or replace
Voltage : 26~30V wiring harness or (After clean)
between CN-4(4) between CN-4(4)
NO
and chassis and CN-2(2)

NO
poor contact
between CN-4(4)
and alternator
terminal " H "
Defective alternator Replace

NO
CLUSTER CHECK UNIT
1 18
CN-6
2
CN-58
ALTERNATOR
2 4 "I" TERMINAL
Check valtage
CN-2 CN-4
YES 20 ~ 30V
NO 0V
7-68
11. WHEN PARKING SOLENOID DOES NOT WORK
fuse No.6 is not blown out.
Cause Remedy
YES
Defective parking Replace
brake solenoid
Check voltage YES

between CN-71 Disconnection in Repair or replace
(2) and chassis wiring harness or (After clean)
poor contact
Parking switch : ON-OFF
Check voltage between CS-17(8)
Voltage : 20~30V NO between CS-17 and CN-71(2)
(8) and chassis
YES
Parking switch : OFF Defective parking Replace
Voltage : 20~30V Check voltage switch
between CS-17
NO
(6) and chassis
NO
poor contact
between CS-17(6)
and CN-36(6)
PARKING SWITCH
8
FUSE
6
No.6
CS-17
CN-71
2
2
1
PARKING SOLENOID
7-69
12. TRANSMISSION IS NOT RETURNED TO NEUTRAL WHEN PARKING BRAKE IS APPLIED
fuse No.1(Transmission controller) and No.6 are not blown out.
Cause Remedy
YES
Defective T/M Replace
Check voltage
YES controller
between EN-111
(14) and chassis
Voltage : 20~30V NO
poor contact
Check voltage between CS-17(6)
between CN-15 and fuse No.6
(1) and chassis
YES
Starting switch : ON Disconnection in Repair or replace
Parking switch : ON wiring harness or (After clean)
Prolix switch : OFF
Voltage : 20~30V poor contact
Check voltage
between CN-15
between CS-17
NO (4) and CS-17(1)
(1) and chassis
Voltage : 20~30V YES
Parking switch : ON Check voltage Defective switch Replace
between CS-17
NO
(5) and chassis Disconnection in Repair or replace
NO
poor contact
between CS-17(5)
and fuse No.6
4
PROLIX SWITCH
FUSE
CN-15
4
No.1
5
8
CS-7
PARKING SWITCH
FUSE
6
No.6
5
1
CS-17
7-70
13. MACHINE DOES NOT TRAVEL
fuse No.1(Transmission controller) is not blown out.
şWiring diagram : See page 7-17.
Cause Remedy
YES
poor contact
Is there continuity
YES between CS-42(5)
between CN-15
(4) and chassis? - CS-42(1) -CD-5 -
CN-15(4)
Disconnect parking
switch connector
Clutch cut-off switch Defective parking Repair or replace
:OFF NO
Is voltage switch or (After clean)
YES between CN-15 disconnection
(4) and chassis
wiring harness or
20-30V?
poor contact
Parking switch : OFF between CN-15
Is there continuity (4) and CS-17(1)
YES
between CN-15 (2)
and chassis?
‫ڞ‬
NO
Is voltage between Disconnection in Repair or replace

NO
CN-15(1) and wiring harness or (After clean)
chassis 20-30V? poor contact
Starting switch : ON between CN-15
(2) and chassis

NO
poor contact
between CN-15
(1) and fuse No.1
YES
Defective T/M Replace
Is problem controller(EGS)
‫ڞ‬ removed when
EN-111 is YES
replaced? Is problem Defective T/M Replace
removed when harness
NO T/M harness is
replaced?
Check solenoid Repair or replace
NO
(After clean)
7-71
14. WHEN STARTING SWITCH IS TURNED ON, HEAD LAMP DOES NOT LIGHTS UP
FUSE BOX
fuse No.19 is not blown out and ON/OFF of bulb.
Cause Remedy
YES
Defective bulb Replace
Check voltage
YES
between CL-3(1) -
(3) and CL-4(1) -(3)
Voltage : 20~30V Disconnection in Repair or replace
NO
Starting switch : ON wiring harness or (After clean)
Head lamp switch : ON
YES between CN-8(3)
between CN-8(3)-
and (6) CL-3(1), 4(1) and
Voltage : 20~30V CL-3(3), 4(3)- CN-36
Starting switch : ON CN-8(6) LH HEAD LIGHT
Head lamp switch : ON
Disconnection in Repair or replace ILL & HEAD LAMP SW

NO
wiring harness or (After clean) CL-3
Check voltage RH HEAD LIGHT
poor contact
between CS-11
between CN-8(3)
(7) and chassis
and CS-11(7)
Starting switch : ON CL-4
Head lamp switch :
YES
ON-OFF Defective Replace CS-39
multifunction switch
Check voltage
YES
between CS-11 Disconnection in Repair or replace
NO HI BEAM PILOT LAMP
(8) and chassis wiring harness or (After clean)
Voltage : 20~30V poor contact
Starting switch : ON Check voltage between CS-11(8) CL-41
between CS-39 and CS-39(2)
NO
(2) and chassis
CN-8
YES Defective head Replace switch
Check voltage lamp switch
between CS-39 EARTH
NO
(4) and chassis
CS-11
NO
poor contact
between CS-39(4)
and fuse No.19
MULTI FUNCTION SW CN-7 JT-28
7-72
15. WHEN STARTING SWITCH IS TURNED ON, WIPER MOTOR DOES NOT OPERATE
şAfter checking, connect the disconnected connectors again immediately unless otherwise specified. FUSE BOX
CHECK UNIT
Cause Remedy
YES
CN-58
Check voltage Defective front Replace
YES between front wiper motor
wiper motor and
chassis Poor connection of Replace
Check voltage Voltage : 20~30V
NO
YES chassis
between CN-20 Starting switch : ON
Wiper switch : 1st
(Lo) and chassis
Voltage : 20~30V
Starting switch : ON Disconnection in Repair or replace
Check voltage Wiper switch : 1st NO
YES wiring harness or (After clean)
between CS-12
CN-36
between CS-12(4)
Voltage : 20~30V WIPER RELAY2
and CN-21(Lo)
Check voltage
Wiper switch : OFF
CS-12(6) Defective wiper Replace
NO
switch CR-26
Voltage : 20~30V
Wiper switch : 1st Disconnection in Repair or replace
NO WIPER RELAY
poor contact
between CS-12(6)
and fuse No.7
CR-4
CS-12
CS-11
CS-5
CN-21
FRONT WIPER
MULTI FUNCTION SWITCH
7-73
16. WHEN STARTING SWITCH ON DOES NOT OPERATE
FUSE BOX
şBefore carrying out below procedure, check all the related connectors are properly inserted and and
the fuse No.15 is not blown out.
Cause Remedy
YES
Defective cable Repair or replace
Check voltage (After clean)
YES assembly
between CN-60(2)
and chassis
Short circuit or Replace
Voltage : 20~30V NO
Check voltage defect of fusible
YES
between CR-1 link or defective
(M4) and chassis
battery relay
Voltage : 20~30V
NO
Check voltage wiring harness or
YES between CS-2
(1)[and CS-2(2)] poor contact
and chassis between CS-2(2) -
Voltage : 20~30V CN-36
CN-2(1)-CR-1
(M4)
Check voltage NO MASTER SW
wiring harness or BATT RY
and specific 60R 60R 60B 60B
gravity of battery poor contact
between fuse No.
Specific gravity : MIN 1.28
Voltage : MIN 24V 13 and CS-2(1) or CR-1
defect of start
TO STARTER
switch
CN-1
CN-60
Battery capacity Repair or replace
NO
too low (After clean)
DO-2
CN-2
CS-2
START SWITCH
7-74
17. WHEN STARTING SWITCH IS TURNED ON, WORK LAMP DOES NOT LIGHTS UP
şBefore carrying out below procedure, check all the related connectors are properly inserted, and the
FUSE BOX
Cause Remedy
YES
Check voltage Defective lamp Replace
YES between each
lamp(2) and
chassis Disconnection in Repair or replace
NO
Check voltage Voltage : 20~30V wiring harness or (After clean)
YES Starting switch : ON poor contact
between CS-21
(2) and chassis between CN-10(2)
and CS-21(2)
Voltage : 20~30V
Check voltage Defective work Replace switch
NO
between CS-21 lamp switch
(6) and chassis YES
Starting switch : ON CN-36
between CS--21(6)
between fuse No.
NO and fuse No.16
16 and chassis FRONT WORK LIGHT,LH
Voltage : 20~30V WORK LAMP SW
Starting switch : ON Short circuit of fuse Replace CN-5 CL-6
NO
FRONT WORK LIGHT,RH
CL-5
CS-21
CN-10
CN-3 REAR WORK LIGHT,LH
CL-22
REAR WORK LIGHT,RH
CL-23
7-75
18. WHEN ENGINE DOES NOT START
EGS
şCheck supply of the power at engine stop solenoid while starting switch is ON. FUSE BOX
şAfter checking, connect the disconnected connectors again immediately unless other wise specified.
şCheck forward reverse switch at neutral position.
CN-111
Cause Remedy
YES
Defective battery Check engine
system charge or
replace (After
checking specific
gravity of battery)
YES
Check voltage Defective magnet Replace
Check operation YES between starter of start motor
of start motor magnet coil and
CN-15
chassis Defective start Replace
Starting switch : Start NO
Starting switch : Start relay
YES CN-36
‫ڞ‬
Check operation SAFETY RY
Check voltage
NO of starter relay YES STARTER
between CR-5(4) TO BATT
and chassis
Starting switch : Start
Starting switch : OFF NO CR-5
wiring harness or
CN-45
Check operation poor contact START RY
of start safety between CN-3(3)
NO
relay and CR-5(4)
Check switch : Neutral YES CR-23
Defective relay Replace
Check voltage ENG STOP SOL
between CR-5(3)
NO
and chassis
Starting switch : OFF NO
‫ڟ‬ CN-79
YES
Defective start Replace
Check voltage relay
‫ڞ‬ between CR-23
(2) and chassis
Voltage : 20~30V NO
Starting switch : ON wiring harness or
poor contact
between CN-3(3)-
CR-23(2)
CN-2
CS-2
YES
wiring harness or CN-4
‫ڟ‬ between CN-15 between CN-15(3) START SWITCH
(2) and chassis and CR-5(3)
Starting switch : OFF CN-3
Defective EGS Replace
NO
7-76

HL750 3

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WHEEL LOADER HYUNDAI HL750-3

HL750-3 Service Manual Open index screen

SECTION 3 POWER TRAIN SYSTEM

SECTION 4 BRAKE SYSTEM

SECTION 5 STEERING SYSTEM

SECTION 6 WORK EQUIPMENT

SECTION 7 ELECTRICAL SYSTEM

Structure and function

2. Convert 550mm into inches.

Millimeters to inches ‫ڟ‬

0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

Kilogram to Pound 1kg = 2.2046lb

0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84

0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378

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

0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980

7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1

14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0

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

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

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

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

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

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

FOLLOW SAFE PROCEDURE

WEAR PROTECTIVE CLOTHING

WARN OTHERS OF SERVICE WORK

USE HANDHOLDS AND STEPS

WORK IN CLEAN AREA

PROTECT AGAINST FLYING DEBRIS

PROTECT AGAINST NOISE

SUPPORT MACHINE PROPERLY

SERVICE COOLING SYSTEM SAFELY

HANDLE FLUIDS SAFELY-AVOID FIRES

BEWARE OF EXHAUST FUMES

REMOVE PAINT BEFORE WELDING OR

SERVICE MACHINE SAFELY

STAY CLEAR OF MOVING PARTS

AVOID HEATING NEAR PRESSURIZED FLUID

PREVENT BATTERY EXPLOSIONS

USE TOOLS PROPERLY

USE PROPER LIFTING EQUIPMENT

DISPOSE OF FLUIDS PROPERLY

LIVE WITH SAFETY

KEEP ROPS INSTALLED PROPERLY

Description Unit Specification

Description Unit Specification

Description Unit Specification

Model Cummins B5.9-C

Type Fixed displacement tandem gear pump

Type Fixed displacement tandem gear pump

4) MAIN CONTROL VALVE

5) REMOTE CONTROL VALVE

Type Pressure reducing type

Boom cylinder Bore dia Rod dia Stroke 140 75 695mm

Model Clark HR 24423

1 Engine mounting bolt, nut M10 1.5 6.9 1.4 50 10

(2) Fine thread

Thread size Width across flat mm kg m lb ft

Thread size Width across flat mm kg m lb ft

ASTM D975 NO. 1

Ɠ Use this sheet to record operational