Hyundai SL760

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

Group 2 Specifications ----------------------------------------------------------------------------------------------------- 1-10
Group 3 Operational Checkout Record Sheet --------------------------------------------------------------- 1-20
SECTION 2 POWER
POWER TRAIN SYSTEM
Group 1 Structure and Function -------------------------------------------------------------------------------------- 2-1

Group 2 Transmission ------------------------------------------------------------------------------------------------------ 2-2
Group 3 Axle --------------------------------------------------------------------------------------------------------------------- 2-23
SECTION 3 BRAKE SYSTEM
Group 1 Structure ------------------------------------------------------------------------------------------------------------- 3-1

Group 2 Air Brake Circuit ------------------------------------------------------------------------------------------------- 3-2
Group 3 Components specification and function ---------------------------------------------------------- 3-3
SECTION 4 STEERING SYSTEM
Group 1 Hydraulic Circuit ------------------------------------------------------------------------------------------------- 4-1

Group 3 Operational Checks and Troubleshooting ------------------------------------------------------- 4-14
Group 4 Test and Adjustments ---------------------------------------------------------------------------------------- 4-20
SECTION 5 WORK EQUIPMENT
Group 1 Hydraulic Circuit ------------------------------------------------------------------------------------------------- 5-1

Group 4 Test and Adjustments ---------------------------------------------------------------------------------------- 5-31
SECTION 6 ELECTRICAL SYSTEM
Group 1 Component Location ----------------------------------------------------------------------------------------- 6-1

Group 2 Electrical Circuit ------------------------------------------------------------------------------------------------- 6-3
Group 3 Monitoring System --------------------------------------------------------------------------------------------- 6-4
Group 4 Connector ----------------------------------------------------------------------------------------------------------- 6-13
0-9
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 group explains the order to be followed when removing, installing, disassembling or assembling
each component, as well as precautions to be taken for these operations.
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Contact your Hyundai distributor for the latest information.
0-1
2. HOW TO READ THE SERVICE MANUAL
Distribution and updating Revised edition mark (①②③…)
Any additions, amendments or other changes When a manual is revised, an edition mark is
will be sent to HYUNDAI distributors. recorded on the bottom outside corner of the
Get the most up-to-date information before you pages.
start any work.
Revisions
Filing method Revised pages are shown at the list of revised
1. See the page number on the bottom of the pages on the between the contents page and
page. section 1 page.
File the pages in correct order.
2. Following examples shows how to read the Symbols
page number. So that the shop manual can be of ample
Example 1 practical use, important places for safety and
3-3 quality are marked with the following symbols.
Section number (3. Power train
system)
Consecutive page number for Symbol Item Remarks
each section.
Special safety precautions are
3. Additional pages : Additional pages are necessary when performing the
indicated by a hyphen(-) and number after the work.
Safety
page number. File as in the example. Extra special safety precautions
10 - 4 are necessary when performing
10 - 4 - 1 the work because it is under
Added pages internal pressure.
10 - 4 - 2
10 - 5 Special technical precautions or
※ Caution
other precautions for preserving
standards are necessary when
performing the work.
0-2
3. CONVERSION TABLE
Method of using the Conversion Table
The Conversion Table in this section is provided to enable simple conversion of figures. For details of
the method of using the Conversion Table, see the example given below.
Example
1. Method of using the Conversion Table to convert from millimeters to inches
Convert 55 mm into inches.
(1) Locate the number 50 in the vertical column at the left side, take this as ⓐ, then draw a horizontal
line from ⓐ.
(2) Locate the number 5in the row across the top, take this as ⓑ, then draw a perpendicular line
down from ⓑ.
(3) Take the point where the two lines cross as ⓒ. This point ⓒ gives the value when converting
from millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Group 2 Specifications -----------------------------------------------------------------------------------------------------1-10
Group 3 Operational Checkout Record Sheet ---------------------------------------------------------------1-20
SECTION 1 GENERAL
GROUP 1 SAFETY HINTS
FOLLOW SAFE PROCEDURE

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

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

Unexpected machine movement can cause
serious injury.
Before performing any work on the wheel load-
er, attach a 「Do Do Not Operate
Operate」 tag on the
right side controller lever.
850K1SH03E
USE HANDHOLDS AND STEPS

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Make certain all parts are reinstalled correctly if
the roll-over protective structure (ROPS) is
loosened or removed for any reason. Tighten
mounting bolts to proper torque.
The protection offered by ROPS will be
impaired if ROPS is subjected to structural
damage, is involved in an overturn incident, or is
in any way altered by welding, bending, drilling,
or cutting. A damaged ROPS should be 73031GE22
replaced, not reused.
1-9
GROUP 2 SPECIFICATION
1. MAJOR COMPONENT
Bucket Tire Head light Hydraulic tank Air cleaner Raidator
Boom Boom cylinder Main control valve Battery Counterweight
Bell crank Bucket cylinder Cab Main pump Precleaner Muffler Engine
Bucket link Front axle Steering cylinder Transmission Rear axle Fuel tank
850K2SE01E
1-10
2. SPECIFICATIONS
1) WITH BOLT-ON CUTTING
B CUTTING EDGE TYPE BUCKET
F
I
5540
J
H
4220
C
K
40
G
57
655 50
D
0
E 2025
A
850K2SE03E
Description Unit Specification

Operating weight kg (lb) 17100 (37700)
Struck 2.7 (3.5)
Bucket capacity m3 (yd3)
Heaped 3.1 (4.1)
Overall length A 8000 (26' 3")
Overall width B 2900 (9' 6")
Overall height C 3480 (11' 5")
Ground clearance D 430 (1' 5")
Wheelbase E mm (ft-in) 3300 (10' 10")
Tread F 2200 (7' 3")
Dump clearance at 45˚ G 3135 (10' 3")
Dump reach (full lift) H 1025 (3' 4")
Width over tires I 2770 (9' 1")
Dump angle J 45
degree (˚)
Roll back angle (carry position) K 47
Lift (with load) 5.8
Cycle time Dump (with load) sec 1.1
Lower (empty) 3.7
Maximum travel speed km/hr (mph) 38.6 (24.1)
Braking distance 12.5 (41' 0")
m (ft-in)
Minimum turning radius (center of outside tire) 5.75 (18' 10")
Gradeability degree (˚) 30
First gear 10.8 (6.7)
Forward
Travel speed Second gear km/hr (mph) 38.6 (24.1)
Reverse First gear 14.8 (9.2)
1-11
2) WITH TOOTH TYPE BUCKET
B
F
I
5660
J
H
4220
C
K
G
57
662 50
D
0
E 2025
A
850K2SE04E
Description Unit Specification

Operating weight kg (lb) 17100 (37700)
Struck 2.6 (3.4)
Bucket capacity m3 (yd3)
Heaped 3.0 (3.9)
Overall length A 8150 (26' 9")
Overall width B 2950 (9' 8")
Overall height C 3480 (11' 5")
Ground clearance D 430 (1' 5")
Wheelbase E mm (ft-in) 3300 (10' 10")
Tread F 2200 (7' 3")
Dump clearance at 45˚ G 3015 (9' 11")
Dump reach (full lift) H 1120 (3' 8")
Width over tires I 2770 (9' 1")
Dump angle J 45
degree (˚)
Roll back angle (carry position) K 47
Lift (with load) 5.8
Cycle time Dump (with load) sec 1.1
Lower (empty) 3.7
Maximum travel speed km/hr (mph) 38.6 (24.1)
Braking distance 12.5 (41' 0")
m (ft-in)
Minimum turning radius (center of outside tire) 5.75 (18' 10")
Gradeability degree (˚) 30
First gear 10.8 (6.7)
Forward
Travel speed Second gear km/hr (mph) 38.6 (24.1)
Reverse First gear 14.8 (9.2)
1-12
3. SPECIFICATION FOR MAJOR COMPONENTS
1) ENGINE
Item Specification
Model Weichai Power WD10G220E2
Type 4-cycle turbocharged diesel engine.
Control type Mechanical control
Cooling method Water cooling
Number of cylinders and arrangement 6 cylinders, in-line
Firing order 1-5-3-6-2-4
Combustion chamber type Direct injection type
Cylinder bore × stroke 126×130 mm (5.0"×5.1")
Piston displacement 9726 cc (594 cu in)
Compression ratio 17 : 1
Rated gross horse power 162 kW / 2200 rpm
Maximum gross torque at 1400rpm 860 N·m
Engine oil quantity 24ℓ(6.3 U.S. gal)
Dry weight 1000 kg (2000 lb)
High idling speed 2400±50 rpm
Low idling speed 750±50 rpm
Rated fuel consumption (at rated) 225 g/kW·hr
Starting motor 24 V-8.1 kW
Alternator 24 V-55 Amp
Battery 2×12 V×120 Ah
1-13
2) MAIN PUMP
Item Specification
Type Fixed displacement gear pump
Capacity 151.1 cc/rev
Maximum operating pressure 190 kgf/cm2 (2700 psi)
Rated oil quantity 332ℓ/min (87.7 U.S.gpm)
Rated speed 2200 rpm
3) STEERING PUMP
Item Specification
Type Fixed displacement gear pump
Capacity 80 cc/rev
Maximum operating pressure 160 kgf/cm2 (2280 psi)
Rated oil quantity 151ℓ/min (39.9 U.S.gpm)
Rated speed 2200 rpm
4) MAIN CONTROL VALVE

Item Specification
Type 2 spool
Operating method Mechanical control
Main relief valve set pressure 190 kgf/cm2 (2700 psi)
Overload relief valve set pressure (bucket in) 200 kgf/cm2 (2840 psi)
5) CYLINDER
Item Specification
Boom cylinder Bore dia×Rod dia×Stroke Ø160×Ø 80×820 mm
Bucket cylinder Bore dia×Rod dia×Stroke Ø180×Ø100×545 mm
Steering cylinder Bore dia×Rod dia×Stroke Ø 90×Ø 50×440 mm
1-14
6) DYNAMIC POWER TRANSMISSION DEVICES
Item Specification
Model ZL50
Converter Double-stage, Double-phase
Type
Transmission Transmission Mechanical, hydraulic
Gear shift Forward second gear, reverse first gear
Control Mechanical single lever type
Drive devices 4-wheel drive
Axle Front Front fixed location
Rear Oscillation±12˚ of center pin-loaded
Wheels Tires 23.5-25, 16PR (L3)
Travel Four-wheel, dry-disc type, pneumatic
Brakes
Parking Drum type brake on transmission, pneumatic
Type Hydraulic, articulated
Steering
Steering angle 40˚ to both right and left angle, respectively
1-15
4. TIGHTENING TORQUE OF MAJOR COMPONENT
Torque
No. Descriptions Bolt size
kgf·m lbf·ft
1 Engine mounting bolt (2EA) M24×3.0 100 ± 15 723 ± 108
2 Engine mounting bolt (bracket) M12×1.75 10.7 ± 1.6 77.4 ± 11.6
Engine
3 Radiator mounting bolt M16×2.0 29.7 ± 4.5 215 ± 32.5
4 Fuel tank mounting bolt M16×2.0 29.7 ± 4.5 215 ± 32.5
5 Main pump housing mounting bolt M12×1.75 12.8 ± 3.0 92.6 ± 21.7
6 Main control valve mounting bolt M12×1.75 12.8 ± 3.0 92.6 ± 21.7
7 Steering unit mounting bolt M10×1.5 6.9 ± 1.4 49.9 ± 10.1
Hydraulic
8 Steering valve mounting bolt M10×1.5 6.9 ± 1.4 49.9 ± 10.1
system
9 Brake valve mounting bolt M8×1.25 2.5 ± 0.5 18.1 ± 3.6
10 Control lever mounting bolt M10×1.5 6.9 ± 1.4 49.9 ± 10.1
11 Hydraulic oil tank mounting bolt M16×2.0 29.7 ± 4.5 215 ± 32.5
12 Transmission mounting bolt M24×3.0 100 ± 15 723 ± 108
13 Transmission mounting bolt (bracket) M18×2.5 32.7 ± 4.9 237 ± 35.4
14 Power Torque converter housing mounting bolt M12×1.75 10.7 ± 1.6 77.4 ± 11.6
15 train Front axle mounting bolt, nut M30×2.0 200 ± 15 1447 ± 108
16 Tire mounting nut M20×1.5 79 ± 2.0 571 ± 14.5
17 Drive shaft joint mounting bolt, nut 1/2-20UNF 15.5 ± 0.5 112 ± 3.6
18 Counterweight mounting bolt M30×2.0 199 ± 29.9 1439 ± 216
19 Others Operator seat mounting bolt M8×1.25 3.4 ± 0.8 24.5 ± 5.8
20 Cab mounting bolt (4EA) M27×3.0 70 ± 10 506 ± 72.3
1-16
5. 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
M30×3.0 124 ~ 168 898 ~ 1214 169 ~ 229 1223 ~ 1655
M36×4.0 174 ~ 236 1261 ~ 1703 250 ~ 310 1808 ~ 2242
(2) Fine thread

8T 10T
Bolt size
kg·m lb·ft kg·m lb·ft
M 8×1.0 2.17 ~ 3.37 15.7 ~ 24.3 3.04 ~ 4.44 22.0 ~ 32.0
M10×1.25 4.46 ~ 6.66 32.3~48.2 5.93 ~ 8.93 42.9 ~ 64.6
M12×1.25 7.78 ~ 11.58 76.3 ~ 83.7 10.6 ~ 16.0 76.6 ~ 115
M14×1.5 13.3 ~ 18.1 96.2 ~ 130 17.9 ~ 24.1 130 ~ 174
M16×1.5 19.9 ~ 26.9 144 ~ 194 26.6 ~ 36.0 193 ~ 260
M18×1.5 28.6 ~ 43.6 207 ~ 315 38.4 ~ 52.0 278 ~ 376
M20×1.5 40.0 ~ 54.0 289 ~ 390 53.4 ~ 72.2 386 ~ 522
M22×1.5 52.7 ~ 71.3 381 ~ 515 70.7 ~ 95.7 512 ~ 692
M24×2.0 67.9 ~ 91.9 491 ~ 664 90.9 ~ 123 658 ~ 890
M30×2.0 137 ~ 185 990 ~ 1338 182 ~ 248 1314 ~ 1795
M36×3.0 192 ~ 260 1389 ~ 1879 262 ~ 354 1893 ~ 2561
1-17
2) PIPE AND HOSE (FLARE type)
Thread size (PF) Width across flat (mm) kgf·m lbf·ft
1/4" 19 4 28.9
3/8" 22 5 36.2
1/2" 27 9.5 68.7
3/4" 36 18 130
1" 41 21 152
1-1/4" 50 35 253
3) PIPE AND HOSE (ORFS type)

Thread size (UNF) Width across flat (mm) kgf·m lbf·ft
9/16-18 19 4 28.9
11/16-16 22 5 36.2
13/16-16 27 9.5 68.7
1-3/16-12 36 18 130
1-7/16-12 41 21 152
1-11/16-12 50 35 253
4) FITTING
Thread size Width across flat (mm) kgf·m lbf·ft
1/4" 19 4 28.9
3/8" 22 5 36.2
1/2" 27 9.5 68.7
3/4" 36 18 130
1" 41 21 152
1-1/4" 50 35 253
1-18
6. RECOMMENDED LUBRICANTS
Use only oils listed below or equivalent.
Do not mix different brand oil.
Ambient temperature˚C(˚F)
Capacity
Service point Kind of fluid -20 -10 0 10 20 30 40
ℓ (U.S. gal)
(-4) (14) (32) (50) (68) (86) (104)
SAE 30
SAE 10W
Engine oil pan Engine oil 20 (5.3)
SAE 10W-30
SAE 15W-40
Transmission Gear oil 50 (13.2) ATF DEXRON Ⅲ
SAE 80W-90
Front : 28 (7.4)
Axle Gear oil
Rear : 28 (7.4)
SAE 85W-90
ISO VG 32
Tank :
150 (39.6)
Hydraulic tank Hydraulic oil ISO VG 46
System :
260 (68.7)
ISO VG 68
ASTM D975 NO.1

Fuel tank Diesel fuel 280 (74)
ASTM D975 NO.2
NLGI NO.1
Fitting
Grease As required
(grease nipple) NLGI NO.2
Mixture of
antifreeze Ethylene glycol base permanent type
Radiator 44 (11.6)
and water
50 : 50
·SAE : Society of Automotive Engineers ·NLGI : National Lubricating Grease Institute

·API : American Petroleum Institute ·ASTM : American Society of Testing and Material
·ISO : International Organization for Standardization ·ATF : Auto Transmission Fluid
1-19
GROUP 3 OPERATIONAL CHECKOUT RECORD SHEET
·Owner :
·Date :
·Hours :
·Serial No. :
·Technician :
※ Use this sheet to record operational

checkout results.
Perform the operational check before
installing any test equipment. 850K1CH01
OK NOT
Item Comments
OK
1. Cluster indicator and gauge checks (engine OFF)
· Gauge check □ □
· Battery check □ □
· Cluster indicator circuit check □ □
· Cluster turn signals and warning indicator check □ □
2. Transmission checks
· Transmission control lever and neutral □ □
3. Cluster indicator and gauge checks (engine running)
· Cluster display and alternator output checks □ □

· Transmission temperature gauge check □ □
· Transmission oil pressure gauge check □ □
· Brake air pressure gauge check □ □
· Engine coolant temperature gauge check □ □
1-20
4. Brake system and clutch cut off checks
· Park brake capacity check □ □

· Park brake transmission lockout check □ □
· Service brake capacity check □ □
· Brake system leakage check □ □
· Service brake pedal check □ □
· Service and park brake system drag check □ □
· Clutch cut off check □ □
5. Driving checks
·Transmission noise check □ □

·1st and 2nd speed clutch pack drag check □ □
·Transmission pressure, pump flow and leakage check □ □
·Torque converter check □ □
·Engine power check □ □
6. Hydraulic system checks
·Hydraulic system warm up procedure □ □

·Hydraulic pump performance check □ □
·Control lever boom float check □ □
·Bucket rollback circuit relief valve check □ □
·Bucket dump circuit relief
Low pressure check □ □
High pressure check □ □
·Boom and bucket cylinder drift check □ □
7. Steering system checks
·Steering unit check □ □

·Steering system leakage check □ □
1-21
8. Accessory checks
·Operating lights check □ □

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

·Cab door hold, open latch check □ □
·Cab door release button check □ □
·Cab door lock check □ □
·Cab door window check □ □
·Cab window latch check □ □
·Seat and seat belt check □ □
·Air intake filter door check □ □
·Engine side panels check □ □
·Radiator cap access door check □ □
·Frame locking bar check □ □
·Service decal check □ □
1-22
SECTION 2 POWER TRAIN SYSYTEM

Group 2 Transmission ------------------------------------------------------------------------------------------------------- 2-2
Group 3 Axle ---------------------------------------------------------------------------------------------------------------------- 2-23
SECTION 2 POWER TRAIN SYSYTEM
GROUP 1 STRUCTURE AND FUNCTION
1. POWER TRAIN COMPONENT OVERVIEW
Transmission Engine
Front axle
Front drive shaft Center drive shaft Rear drive shaft Rear axle
850KPT01E
The power train consists of the following components:

·Transmission
·Front, center 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 two speed forward, one speed reverse countershaft type
power shift transmission. A drum type parking brake is located on the transmission.
The transmission outputs through universal joints to three drive shaft assemblies. The front drive shaft
is a telescoping shaft which drives the front axle. The front axle is mounted directly to the loader frame.
The rear axle is mounted on an oscillating pivot.
The power transmitted to front axle and rear axle is reduced by the pinion gear and ring gear of
differential. It then passes from the differential to the sun gear shaft(Axle shaft) of final drive.
The power of the sun gear is reduced by a planetary mechanism and is transmitted through the
planetary hub to the wheel.
2-1
GROUP 2 TRANSMISSION
1. TECHNICAL DATA
Rated input power 154 kW
Rated input speed 2200 rpm
Torque converter mode Single-stage, two-phase, four-element
Torque ratio when zero speed 4±0.20
Transmission Type Two forward and one reverse gears,
power shift, planetary structure
Mechanical Gear Ratio; Gear I 2.155
Gear II 0.578
Reverse 1.577
I/O gear ratio of P.T.O P.T.O. 1 1.0
P.T.O. 2 1.167
Hydraulic oil pressure 1.10 ~ 1.40 MPa
Inlet oil pressure, torque converter 0.30 ~ 0.45 MPa
Outlet oil pressure, torque converter 0.20 ~ 0.30 MPa
Lubricating oil pressure 0.10 ~ 0.20 MPa
Max. permissible tempeture at outlet of torque converter 120˚C
2. STRUCTURAL PRINCIPLE
Hydraulic transmission consists of hydraulic torque converter and power-shifting mechanical
transmission. The transmission diagram is as shown as figure 3.
P.T.O. 1
Input
(engine)
Output Output
P.T.O. 2
Figure 3 Structural diagram of hydraulic transmission.
2-2
3. STRUCTURE
850KTM100
1 Working pump 14 Large overrunning clutch cam 26 Direct gear input shaft
2 Variable speed pump 15 Outer-ring gear, large over- 28 Direct gear cylinder
3 First-stage input gear running clutch 30 Direct gear piston
4 Input second-stage gear 16 Sun gear 31 Direct gear frictional plate
5 Shaft gear 17 Reverse planet wheel 32 Direct gear thrust plate
6 Guide pulley seat 18 Reverse pinion carrier 33 Reverse-gear I connection disc
7 Second-stage turbine 19 Gear I planet gear 34 Gear I pinion carrier
8 First-stage turbine 20 Reverse inner toothed annulus 35 Gear I cylinder
9 Guide pulley 21 Rear axle output shaft 36 Gear I piston
10 Pump pulley 22 Front back release sliding 37 Gear I inner toothed annulus
11 Transfer gear sleeve 38 Gear I frictional plate
12 Intermediate input shaft 23 Output gear, transmission 39 Reverse frictional plate
13 Large overrunning clutch 24 Front axle output shaft 40 Reverse piston
roller 25 Output gear
2-3
4. OUTSIDE VIEW
VIEW A
850KPT50
2-4
5. OPERATION
1) HYDRAULIC TORQUE CONVERTER
Torque converter is designed as single-stage, two-phase and four elements. Its construction is as
shown in figure 2 (page 2-3).
Torque converter consists mainly of pump pulley (10), first-stage turbine (8), second-stage turbine
(7) and guide pulley (9). The pump pulley connects to engine flywheel by a flexible steel board.
When the pump pulley turns, oil in torus is driven and has certain kinetic energy. Then the oil drives
the first- and second-stage turbines, and drives the transmission running. Since turbines’ torque
and speed would change by variation of load, the torque converter possesses the functions of
automatic torque- and speed-changing. The guide pulley is fixed on housing of torque converter by
a guide pulley seat (6).
When hydraulic transmission has a small load or high speed, the second-stage turbine works
individually; however, when the load increases and the speed decreases (at the moment the speed
of motor is basically unchanged), two turbines automatically work together.
2) MECHANICAL TRANSMISSION
Power of the second-stage turbine (7) is transferred to intermediate input shaft (12) via input
second-stage gear (4), and that of the first-stage turbine to input first-stage gear (3), then to outer-
ring gear of large overrunning clutch (15). When external load is comparatively small, speed of
intermediate input shaft (12) is higher than that of outer-ring gear of large overrunning clutch (15),
thus making large overrunning clutch roller (13) racing. At this time the second-stage turbine works
individually.
When external load is increasing, speed of intermediate input shaft (12) is caused to descend
gradually. If speed of the intermediate input shaft (12) is lower than that of outer-ring gear of large
overrunning clutch (15), the roller (13) is to be wedged. Power from the first-stage turbine is
transferred to large overrunning clutch cam (14) via the roller (13). Since the cam (14) and the
intermediate input shaft (12) are connected with bolts, the first- and the second-stage turbines work
together at the time. Mechanical transmission has two forward gears and one reverse gear.
Transmission route and power flow chart of each gear are as shown in figure 4, 5 and 6.
← Hydraulic oil
← Hydraulic oil
←
Hydraulic
oil
Figure 4 Power flow chart of forward gear I Figure 5 Power flow chart of forward gear II
2-5
At the bottom of the transmission, there is a front and rear axle release device (see to figure 2),
which can control single- or dual-axle drive. Pull the control rod outward for single-axle drive and
push inside for dual-axle drive. Generally, use single-axle drive in long-distance transport with
light load to reduce loss from power recycling; and use dual-axle drive when operating under
heavy load on slushy roads or crossing bridges.
Hydraulic oil →
Hydraulic oil →
Figure 6 Diagram of reverse gear power flow chart
3) HYDRAULIC SYSTEM
Safety valve
(0.3~0.45 MPa) Pressure reducing valve
(P=1.1~1.4 MPa)
(P=1.1~1.4 Mpa)
Small hole
Check valve
Bypass
valve Torque converter
Filter
Clutch lockup cutoff valve
Gear
Cooler pump Shift lever
Lubricant
Reverse gear
Gear I
Gear II
Neutral
pressure
regulator valve
(0.1~0.2 MPa)
Gear I
clutch
Main oil circuit (P main=1.1~1.4MPa)
Lubricant
removal circuit Gear shift oil way
Reverse Gear II Torque converter inlet circuit
gear clutch Torque converter outlet circuit
clutch Sump
Sump Valve spool, valve rod
Diagram of hydraulic system of hydraulic transmission 850KPT51
2-6
6. APPLICATION AND INSTALLATION
1) INSTALLATION AND CONNECTION
(1) Connection to engine
Surface of torque converter casing is directly connected to that of engine flywheel casing by
bolts. Through the connection between flexible steel board of converter and engine flywheel by
stud bolts and nuts, power is transferred. Head of centering shaft at front end of pump pulley
cover inserts flywheel centering hole as centering.
When installing, screw stud bolts into flywheel, open a chock on torque converter, lift the
transmission and make hole on flexible steel board and centering hole lining up, screw end-face
bolts and tighten the nuts through square holes at lower side of the chock, at last, cover the
chock.
※ Difference between the plane of flywheel casing and that of flywheel ≤0.50 mm.
(2) Connection to oil pump
Working oil pump and steering oil pump are directly mounted onto PTO1 and PTO2 of
transmission. (Shaft head length 60~65 mm, key connection useful length ≥40 mm).
※ Connection parameter must be correct.
(3) Installation on vehicle
Had better apply three- or four-point flexible supporting installation. There is each one V-block at
both sides of transmission for installation and it’s required to weld corresponding V-blocks on the
vehicle body, too. Between two V-blocks insert a rubber plate of 10~12 mm as elastic layer,
avoiding stress from vehicle chassis being transmitted to transmission housing directly.
(4) Selection and assembly of filter
Select filter meeting parameter as follows : Min. filter flow: 120ℓ/min
Filter accuracy not less than 150 mesh/inch. Use sintered filter as far as possible.
The installation height of filter and oil pipes must not be higher than that of the oil pipe connector
of housing.
(5) Selection and assembly of cooler
Calculate cooling capacity required on the basis of an ambient temperature 30, which should be
35~40% of the rated power of engine. Normal flow must be assured.
Cooler for transmission should be located at cool water end of the cooling system.
Diameter of oil pipe and thread connector for cooler and filter should be more than 20, and
when oil pipe exceeds 1m in length, the value increases by 20%.
※ The system maker is liable for correct installation.
2) APPLICATION REQUIREMENTS
(1) After installation of hydraulic transmission, fill in about AFT (DEXRON Ⅲ) from the oil hole.
Check the oil level again after 5min running from starting engine, which should reach the height
of oil-level plug. During checking, be sure to take safety measures to avoid vehicle moving or
rolling.
(2) Oil level should be checked before each shift operating.
(3) When the transmission works, the hydraulic oil pressure should be kept within 1.1~1.4 MPa. In
case of the value is lower than 1 MPa or higher than 1.6 MPa, stop and check to avoid damaging
the parts inside.
2-7
(4) The oil temperature should be lower than 120˚C. When it exceeds, keep the engine speed within
1200~1500 rpm and make the transmission at neutral, then the oil temperature should decrease
to a normal value in 2~3 min. If not, it shows there are problems in the system, which must be
resolved before operation.
(5) Reduce machine speed before transmission changing down. And stop before reversing.
(6) The shifting lever should be at neutral position when starting the engine.
(7) Stop when control by using the axle releasing device.
After installation of a new T/M, keep running in for twelve hours under a load less than 70%, four
hours for each of three gears. Check the oil temperature, oil pressure and the tightness of bolts.
After running in, clean the sump strainer of transmission and then renew oil.
3) MAINTENANCE
Maintenance is carried out after running for 50, 250, 1000 and 2000 hours.
(1) 50 hours maintenance : ① check oil level ② Inspect the control system.
(2) 250 hours maintenance : Clean filter and clean sump.
(3) 500 hours maintenance : Change oil.
(4) 1000 hours maintenance : Replace filter.
(5) 2000 hours maintenance : Dismantle and inspect the transmission and the torque converter,
replace easily-worn parts, regulate or replace parts when necessary.
2-8
7. MAIN FAILURES AND REMEDIES
Main Failures Remedies
The engine rotating, but machine can not run
1. Did not in any gears 1. Put into gear or check if it correct
2. Hydraulic oil level too low 2. Add oil
3. Brake rod of shift valve can not return 3. Dismantle and check the brake rod
4. Insufficient oil supply due to shifting oil pump 4. Replace oil pump or oil seals
damaged or oil seals broken
Insufficient driving force
1. Low oil pressure at inlet of torque converter 1. Check oil level; clean sump strainer and filter; check
the pressure regulating valve of torque converter
2. Clutch sliding 2. Inspect clutch oil pressure and piston oil seal
3. Insufficient engine speed 3. Inspect the engine
Variable speed oil pressure too low
1. Misalignment of reducing valve 1. Realignment
2. Obstructed oil filter 2. Clean oil filter
3. Damaged oil pump 3. Replace oil pump
4. Serious oil leakage in clutch oil seal 4. Replace oil seals
Oil temperature in torque converter too high
1. Oil level in transmission too low or too high 1. Fill oil acc. to specified
2. Clutch sliding 2. Check oil pressure of clutch
3. Long-time, heavy load operation 3. Stop to cool
Can not put into gear after emergent braking
1. Misalignment limit screws of air brake valve pedal 1. Realign the limit screws of pedal so that air brake
valve can return completely.
2. Choked piston of air brake valve. Return is 2. Clean and repair the piston
unavailable after release of brake.
3. Choked brake valve rod 3. Dismantle and check brake valve rod
2-9
8. DISASSEMBLY AND ASSEMBLY
1) DISASSEMBLY
(1) Use a M16 socket wrench to unscrew
6-M10×60 bolts on the interface
between oil pump and casing. Use a
copper bar to lightly knock on the outside
of oil pump and remove the oil pump.
850KTM01
(2) When assebmling, set a paper washer

on the surface of oil pump with grease,
set 6-M10×60 bolts and fasten up one
by one.
850KTM02
850KTM03
850KTM04
2-10
(3) Use a M16 socket wrench to fasten up
10-M10×70 and 1-M10×65 bolts on the
control valve.
850KTM05
(4) When assembling, set a paper washer

on the surface of casing with grease and
mount the control valve. First set a bolt,
then insert 10-M10×70 and 1-M10×65
bolts in sequence and fasten up. Be sure
that the bolts are fastened from inside to
outside not to have the water paper
broken.
850KTM06

26-M10×30 and 5-M10×70 jointing the
torque converter and transmission. Use
3-M10×70 art bolts to disassemble the
torque from the casing.
850KTM07
850KTM08
2-11
(6) Dismount the bearing seat and torque
converter respectively.
1 Bearing seat
1
850KTM09
850KTM10
(7) Disassemble the input first and second

g e a r s f r o m t h e t o r q u e c o nve r t e r
respectively.
1
1 Input first gear
2 Ball thrust bearing
3 Ball bearing (55×120×29)
2 3
850KTM11
4 Input second gear

5 Oil seal (45×53×5)
5
850KTM12
2-12
26-M10×30 and 5-M10×70 jointing the
torque converter and transmission. Use 1
3-M10×70 art bolts to disassemble the
torque from the casing.
1 Ball bearing (55×100×21) 2
2 Steering oil pump driving shaft
3 Steering oil pump drive gear
Flat key (14×35) 3
Ball bearing (50×90×20) 850KTM13
4 Ball bearing (60×95×18) 4

5 Gear shaft
6 Ball bearing (50×90×20)
5 6
850KTM14
(9) Disasemble biaxial assy.
850KTM15
850KTM16
2-13
(10) Put the transmission in level position
and use a M16 wrench to unscrew
8-M10×30 bolts of end cover. Set two
eye bolts into screw hole and remove the
end cover.
1 End cover
1
850KTM17
2 Casing
850KTM18
(11) Use two M12 eye bolts to sling the direct

gear assy out.
1 Direct gear assy
850KTM19

8-M14×40 bolts on the mid-cover to
remove it.
1 Mid-cover
1
850KTM20
2-14
(13) Remove the parts of the planetary gear
sets inside transmission, gear I cylinder
assy, 15 spring pins, springs, friction
discs (4 sets), gear I planet carrier,
isolator assy, friction discs (4 sets),
reverse gear planet carrier assy and
reverse gear piston in sequence.
850KTM21
850KTM22
(14) Remove 2 rings 130 at two sides of the

casing and knock out the output shaft
forward from the rear side.
850KTM23
850KTM24
2-15
2) ASSEMBLY
(1) Clean the transmission case, put it in
level position, and assemble the reverse
gear piston.
850KTM25
1 Reverse gear piston
1
850KTM26
(2) Assemble reverse planetary gear.
850KTM27
850KTM28
2-16
(3) Assemble 4 sets of reverse driven disc
and driving disc in sequence.
1 Reverse driving disc
2 Reverse driven disc
2
850KTM29
850KTM30
(4) Assemble friction disc isolator assy.

1 Friction disc isolator assy
850KTM31
850KTM32
2-17
(5) Assemble gear I planet gear carrier assy.
1 Pinion carrier
2 Reverse ring gear
2
850KTM33
850KTM34
(6) Assemble gear I ring gear and 4 sets of

driving disc and driven disc.
1 Gear I ring gear
1
850KTM35
2 Driven disc
3 Driving disc
3
850KTM36
2-18
(7) Insert 15 springs and spring pins, and put
the gear I cylinder body assy.
850KTM37
1 Gear I cylinder body
850KTM38
(8) Put the mid-cover and use a M22 socket

wrench to fasten up 8-M14M0 bolts on
the mid-cover.
1 Mid-cover
1
850KTM39
850KTM40
2-19
(9) Assemble direct gear assy, end cover,
and use a M16 wrench to fasten up 8-M
10×30 bolts.
1 Direct gear assy
1
850KTM41
850KTM42
(10) Assemble steering oil pump driving shaft

and gear shaft assy into the torque
converter.
850KTM43
1 Gear shaft
1
850KTM44
2-20
(11) Assemble the 1st/2nd stage gear input
and bearings into torque converter.
850KTM45
850KTM46
(12) Assemble the biaxial assy into the

transmission box.
850KTM47
850KTM48
2-21
(13) Joint the torque conver ter to the
transmission and set 2-A10×30 pin and
then use a M16 socket wrench to fasten
26-M10×30 and 5-M10×70 to combine
the torque converter with transmission
box.
850KTM49
850KTM50
(14) Assemble the control valve and oil pump.
850KTM51
850KTM52
2-22
GROUP 3 AXLE
1. OVERVIEW
1) FEATURES IN STRUCTURE
As the main part of chassis transmission system, driving axle has the functions of increasing the
torque from engine, distributing it to the left and right side driving wheels, and allowing the wheels
to have differential feature. In addition, driving axle also receives various forces from road and
chassis.
The axle is a two stage transmission device and consists mainly of driving axle housing assembly,
main reductor assembly, planetary reductor assembly and brake assembly. The first stage device is
main reductor assembly driven by gleason bevel gear, which is large in input torque, high in
efficiency, sand table in work.
The second stage device is planetary reductor assembly with planetary reduction driving structure
with four planetary wheels (NGW type) which is high in overall running rigidity and stable in output
speed.
2) PRINCIPLE
The inputting flange inputs the torque from engine, through the main reductor, the power will reach
planetary reductor system via differential axle. Then the power is driven to planetary carrier, it
makes the tire to move.
The work line is: engine torque→input flange→the main reductor→differential axle→planetary
reductor system→Tire. (figure 1, 2)
Tire Differential
Planetary axle
reductor
Main Input
reductor flange
Figure 1
2-23
Tire
Planetary Differential Axle

housing Main
reductor axle Flange
reductor
Figure 2
2-24
3) MAIN PERFORMANCE PARAMETERS
Model ZL50K (front and rear axle)
Max. Load 27000 kg
Assembling dimensions 2248 mm
Fixing dimensions with chassis (mm) 890×260×400
Resultant gear ratio 26.11
Speed Ratio Main speed ratio 5.286
Speed ratio of planetary reductor 4.9
Max. torque 520 kgf·m (3760 Ibf·ft)
Brake torque 1330 kgf·m (9625 Ibf·ft)
Oil pressure of braking 11 MPa
2-25
4) TROUBLESHOOTING
Names of
Problem Cause Remedy
the parts
The main re- Large noise The gaps of the gears are over- Adust the gaps of the gears.
ductor and sized.
the differen- The rolling bearing is abraded. Exchange the bearing.
tial gear Early-stage heat of the The lubrication is bad, no lubrica- Refuel to the normal oil level.
housing tion oil or excessive lubricating oil.
Periodical abnormal The gears are cut. Exchange the gears.
noise There are foreign bodies inside. Drain the oil to inspect.
The stening piece becomes loose. Fasten the fastening piece.
M a l f u n c t i o n o f t h e The cross axle is broken. Exchange the cross axle.
differential gear
Oil leakage The oil seal is aged and abraded. Exchange the oil seal.
The sealing glue becomes Scrap the used glue, and smear
ineffective. afresh.
The fastening piece becomes Fasten the fastening piece.
loose.
T h e w h e e l Non-rotation of the The semi-axle is twisted off. Exchange the semi-axel.
reductor wheel The differenrial system doesn't A d j u s t a n d ex c h a n g e t h e
work. differential system.
Abnormal noises The gears are cut. Exchange the gears.
There are foreign bodies. Drain the oil to inspect.
Early-stage heat of the The lubrication is bad, i.e, no Refuel the lubricating oil to the oil
housing lubr icating oil or excessive level.
lubricating oil.
Non-returning of the The sealing ring of the piston is Exchange the sealing ring.
friction plate aged and abraded.
The oil inlet nozzle beomes loose. Screw the oil inlet nozzle.
The casting of the grip is defective. Exchange or repair the breaking
grip.
2-26
5) STRUCTURE
(1) Front and rear axle
1 3
4
2 5
8
7
Axle housing oil level plug
9
10
11
12
850KAX110
1 Planetary reduction assy 7 Seal

2 Driving axle shell 8 Plug
3 Brake assy 9 Main reductor
4 Washer 10 Pin
5 Bolt 11 Washer
6 Deflation valve 12 Bolt
2-27
(2) Planetary reductor
1 2 3
4 5 6 7 8
9
10
11
12
13
14 15
16 17
18 19
14 20
21 22
23 24
25 24
26
27
28
29
30 31
32 33 34
35 36
37 38 39
850KAX111
1 Plug 14 Washer 27 Internal gear assy

2 Washer 15 Roller needle 28 Bearing
3 Bolt 16 Space bushing 29 Rim
4 Washer 17 Planetary gear 30 Washer
5 Cover 18 Steel ball 31 Nut
6 Snap ring 19 Planetary gear shaft 32 Bearing
7 Plug 20 Shaft 33 Seal spacer
8 Seal 21 Snap ring 34 Oil seal
9 Bolt 22 Sun gear 35 Oil seal
10 Bolt 23 Spacer 36 Gasket
11 Planetary gear carrier 24 Nut 37 Brake disk
12 Seal ring 25 Washer 38 Washer
13 Adjusting pin 26 Taper bushing 39 Bolt
2-28
(3) Main reductor
16
17
18
19
30
20 29
28
21 27
26
22 23 24 25
15
14
13 31
12
11 30
10 29
28
9 27
8
67 32
45
3
2
1 39
38
37
35
34
33
43 17
44 36 16
40
41
42
850KAX112
1 Lock nut 16 Adjusting nut 31 Iron wire

2 Washer 17 Bearing 32 Nut
3 O-ring 18 Differential bolt 33 Cage
4 Flange 19 Nut 34 Thrust washer
5 Bolt 20 Cage 35 Axle shaft gear
6 Washer 21 Driven bevel gear 36 Cage
7 Oil seal 22 Bolt 37 Bolt
8 Oil seal 23 Washer 38 Lock plate
9 Sealing gland 24 Crossing 39 Nut
10 Bearing 25 Bevel gear 40 Bearing
11 Bearing bushing 26 Bearing seat 41 Stop ring
12 Adjusting washer 27 Bolt 42 Bevel gear
13 Shaft bushing 28 Lock plate 43 Washer
14 Bearing 29 Washer 44 Bolt
15 Adjusting washer 30 Bolt
2-29
(4) Brake assembly
2
3
4
5
6 Oil entry
6
5
4
3
2
7
8
9
10
11
12
13
14
15
850KAX113
1 Exterior brake 6 Brake disk 11 Deflating valve

2 Piston 7 O-ring 12 Washer
3 Rectangular seal 8 Inner brake 13 Bolt
4 Dust case 9 Washer 14 Washer
5 Block ring 10 Connecting 15 Bolt pin
2-30
2. SPECIAL TOOL
The special tool is used to unfasten the main reductor lock nut.
13
25
Quenching
70
hardness 50HRD
25
18
8.5
+0.2
85 65 0
Unit : mm
850KAX104
2-31
3. DISASSEMBLY
1) Put the driving axle to disassemble on a
secure support. Have a wide working area
with good light, the ground being clean and
free from dust, and preventing from wind
that may carry dust.
※ Clean all surfaces of driving axle before
disassembly.
2) Remove the oil plugs at axle bottom and

two wheel sides to drain gear oil from axle
housing.
※ Use a clean container for containing gear
oil. Clean container allows easy estimation
of used oil. Worn off metal, distinct
deterioration or pollution of oil in the used
oil shows the condition of axle.
850KAX08
850KAX09
3) Removing brake caliper assembly. Use a

torque spanner to unscrew M20 bolts (4
bolts for each brake caliper) and remove
the brake caliper.
850KAX10
2-32
4) Removing each end cover at both sides of
axle. Use a torque spanner to unscrew
M12×1.25 bolt (8 bolts each side) and
then push off the end cover with bolt
through screw hole and remove it.
850KAX11
850KAX12
5) Pulling out the sun gear and differential

axle. Remove the adjusting pin from the
exterior end of differential axis and use a
spring outside caliper to remove retainer
ring at the same time and then remove the
sun gear.
850KAX13
850KAX14
2-33
6) Removing main reductor assembly. Use a
spanner to unscrew M16 bolts (total 14 pcs)
and push the assembly off the axle housing
with the bolt through screw hole, then move
out with a hoisting equipment or manpower.
※ Step 5) must be performed before removing
main reductor assembly. I.e, the differential
axle must be pulled out in advance,
otherwise it will catch axle shaft gear to
cause removal of main reductor 850KAX15
unavailable.
850KAX16
7) DISASSEMBLY AND INSPECTION OF MAIN REDUCTOR

(1) Fix the assembly on a rotary table.
(2) First remove the thrust bolt.
850KAX17
(3) Make the assembly’s larger side upward,

and remove wire, M12 bolts and lock
washers on the block.
850KAX18
2-34
(4) Remove bearing block and adjustment
nut.
※ Be mindful to make marking for the
bearing block, adjustment nut and case
for each side not to be confused when
reassembling.
(5) Remove the differential assembly.
※ Be careful not to be confused with bearing
outer race of two sides.
850KAX19
(6) Removing conical bearing. Unscrew

driven crown gear bolts and nuts, total 12
sets, then remove the crown gear (driven)
off the differential case.
850KAX20
850KAX21
2-35
(7) Turn the assembly over. First use a chisel
or a sharp object to strip the locking
por tion of lock nut and then use a
specialized tool to remove the lock nut.
For specialized tool, refer to page 2-18.
850KAX22
(8) Remove the washer and O-ring and

remove the flange.
850KAX23
(9) Remove the bolt on sealing gland and

then remove the sealing gland.
※ When removing sealing gland, be careful
not to scratch oil seal.
850KAX24
850KAX25
2-36
(10) Reassemble the flange and lock nut and
use a bolt to push whole the driving gear
off through the thread hole.
※ When removing a bearing block, be
careful not to make the adjusting washer
damaged or missing.
(11) Unfasten the lock nut and remove the
flange, bearing bushing, shaft bushing
and washer and so on in order.
※ When removing a bearing bushing, be 850KAX26
careful to keep the shaft bushing and
adjusting washer well.
※ Drive and driven gear form a pair and,
when anyone is damaged, whole the pair
should be replaced.
※ If three bearing inner rings to the drive
gear are damaged or worn, a pulling tool
can be used to pull out. Take care not to
make bearing installing surface on the
drive gear damaged.
850KAX27
8) DISASSEMBLY AND INSPECTION OF DIFFERENTIAL DEVICE

(1) Remove the bolts, nuts (8 sets) of
differential device and small differential
cage.
※ When removing small cage of differential
device, check if there is matching marks
on the holes of differential crossing of
large and small cage. If no, make marks.
850KAX28
(2) Remove differential crossing, bevel gear

and its washer, axle shaft gear and its
washer.
※ If a bearing at two sides of differential
device is damaged or worn severely,
forcible removal is available (use a chisel
to knock out).
Be careful not to have the bearing fitting
surface on the differential cage damaged.
850KAX29
2-37
9) DISASSEMBLY AND INSPECTION OF PLANETARY REDUCTOR
(1) Remove the bolts for rim.
850KAX30
(2) Push the planetary carrier off with bolt

through the thread hole (There are two
thread holes on a planetary carrier) and
O-ring on the hub.
850KAX31
(3) Remove the inner hexagon nut and lock

washer on final drive axle.
850KAX32
(4) Remove the taper bushing (Use a copper

bar to shock out).
850KAX33
2-38
(5) Pull the ring gear carrier out.
850KAX34
(6) Pull the hub and brake disc out (can be

removed as one body).
※ When pulling the hub and brake disc out,
be careful to keep balance as being hung
in the air not to make the spline on the
shaft to scratch oil seal.
850KAX35
(7) Remove the bolts from brake disc to

separate the brake disc from hub.
850KAX36
850KAX37
2-39
10) DISASSEMBLY AND INSPECTION OF PLANETARY CARRIER
(1) Place the planetary carrier on a platform,
with its large side upward. Use a pressing
machine or manpower to press the
planetary carrier out.
※ Take out the locking ball at the other side
as the planetary shaft is pushed out for
about 15mm or it might be lost.
850KAX38
(2) After removing four shafts, remove the

planetary gear and washer.
※ Be careful not make the needle, ring or
washer of planetary gear to fall down or
be lost.
850KAX39
4. CLEANING AND INSPECTION

1) Examine each element and fine surface and determine if there is over wear.
2) Before reassembly, each part should be cleaned with kerosene and blown dry.
3) Specially for the positions where there was a damaged part, such as the inside of axle housing,
main reductor or planetary carrier housing, the residue (iron and copper chippings) must be
removed.
4) All the oil sealing elements should be replaced and reuse is not permitted once removed.
2-40
5. REASSEMBLY
1) Reassembly of the driving axle should be
made in the reverse procedure of above
disassembly.
(1) Place the cleaned large and small
differential cages on a platform, set the
axle shaft gear washer in the large
differential cage, then fit the axle shaft
gear. Set the planetary bevel gear and
washer with ball face on to the four
journals of differential crossing, which is 850KAX40
then inserted into four corresponding

holes in the large differential cage.
Assemble another axle shaft gear, washer
and small differential cage.
※ When assembling small differential cage,
be careful to align the holes of differential
crossing of large and small differential
cage with the markings.
850KAX41
(2) After assembly of differential device, use

the bolts applied thread locking glue to
joint, and fasten up with M16×1.5 nuts.
Tightening torque should be 19.7~26.2
kgf·m (142~190 Ibf·ft).
850KAX42
(3) Assemble the driven spiral bevel gear

onto the flange of large differential cage,
use the bolts applied thread locking glue
to joint, and fasten up with M16×1.5 nuts.
Tightening torque should be 19.7~26.2
kgf·m (142~190 Ibf·ft).
850KAX43
2-41
(4) Use a specialized tool to push the
preheated bearing inner race into two
sides of differential device.
The gear backlash of axle shaft gear and
bevel gear is 0.18-0.23 mm and, after
assembly, the gears should facilely rotate
and has no deactivation.
850KAX44
2) REASSEMBLY OF DRIVE GEAR ASSEMBLY

(1) Push the bearing inner race onto the
journal of drive spiral bevel gear and then
fit the outer race. Then, fit the shaft
bushing and adjusting washer, assemble
the bearing bushing fitted with bearing,
bearing inner race, flange and main
reductor lock nut.
850KAX45
850KAX46
2-42
※ The lock nut should be only fastened up,
not locked with thread locking glue. Apply
a force of 35~40 kgf·m (253~289 Ibf·ft)
to the lock nut for main reductor and then
use a tension gauge to hook in the fitting
hole of bearing bushing and pull the
gauge in tangential direction. The torque
should be OK if the readings of the gauge
is within 1.32~1.97 kgf·m (2.91~4.34
Ibf·ft) as the bearing bushing starts to 850KAX47
turn.
(3) Take a bearing and push its inner race
into drive spiral bevel gear journal and
assemble a snap ring onto the outer ring.
850KAX48
3) REASSEMBLY OF MAIN REDUCTOR

(1) Fix the case of main reductor on a rotary
table with its small side upward, apply
sealant onto the adjusting washer and fit it
onto the small side, then assemble drive
gear assembly, and fasten up with two
M14×1.5×55 bolts with a torque of
12.6~16.8 kgf·m (91.1~122 Ibf·ft).
※ When assembling drive gear assembly,
be careful to make the oil passage hole
on bearing bushing aligning with that of
850KAX49
casing.
(2) Turn the case for 180˚ to make large side

upward and fit the differential assembly in.
850KAX50
2-43
(3) Fit the bearing block and adjustment nut.
Assuring a certain backlash between
drive and driven gears (apprx. 0.25-0.40 ),
fasten the adjustment nut at a side to the
extent that the driven gear can be turned
with difficulty and then turn the nut back
1/5~1/10 turn to keep the axial clearance
of bearing within 0.1~0.18, to secure a
certain pre-tight strength between two
tapered bearings. 850KAX51
(4) Precisely adjust the back lash between

drive and driven spiral bevel gears to be
within 0.25~0.40, its variable less than 0.1.
Be sure that, when the nut at one side is
turned back, the other side nut is fastened
for the same extent, to secure the pre-
tight strength as adjusted under above
item (figure 850KAX52).
(5) By marking test, the contact face should
be near to the small side along tooth 850KAX52
length, mesh mark ≥1/2 of tooth length,
and the contact face at the middle of gear
surface. Mesh mark should meet the
requirements of figure 850KAX55.
Otherwise, the number of adjusting
washer (shim) can be added or
subtracted, or loosen the nut at one side
and fasten that at other side for the equal
amount to make adjustment (figure
850KAX55).
After completing this step of adjustment,
850KAX53
be sure to inspect the back lash again as
d e s c r i b e d i n a b o v e s t e p. I f t h e
requirements as correct mesh mark and
back lash can not be met simultaneously,
the pair of drive & driven spiral bevel gear
or main reductor case must be replaced.
(6) Fasten up the bolts for main reductor with
torque of 75.5~89.7 kgf·m (546~649
Ibf·ft), lock the locking washer with
M10×20 bolts with torque of 4.6~6.0
k g f·m ( 3 3 . 3 ~ 4 3 . 4 I b f·f t ) ( f i g u r e
850KAX53). 850KAX54
(7) Fasten up the bolts for main reductors,

locking washer and bolt M10×20-8.8 and
bind with wire (figure 850KAX54).
2-44
※BACKLASH CHECK AND ADJUSTMENT
Contact position on driven gear

Driven spiral bevel face
gear
Forward Backward
Gear moving
Method of adjustment
direction
Drive face
Move the driven gear to get close to

drive gear. Move the drive gear
outward if the back lash is too small.
Driven face
Move the driven gear away from

Drive spiral bevel drive gear. Move the drive gear
gear
inward if the back lash is too large.
Move the drive gear to get close to

Drive face driven gear. Move the driven gear
outward if the back lash is too small.
Move the drive gear away from

driven gear. Move the driven gear
Driven face
inward if the back lash is too large.
Figure 850KAX55
(8) Clean the bore of seal gland, and apply a

certain amount of grease and push the oil
seal B80×100×10, FB80×100×10 into
seal gland in order. Then apply lithium
bisulfide grease into the gaps of two oil
seals.
※ For the order of two oil seals, FB type oil
seal should be at outside and the seals be
pressed level.
850KAX56
2-45
(9) Place case with its small side upward,
remove the flange and two M14 bolts,
apply sealant on the end surface of
bearing bushing, and fit up the seal gland
with oil seal, apply thread lock glue to
M12×1.5×55-10.9 and M14×1.5×55-
10.9, then assemble along with grower
washer, fasten diagonally.
850KAX57
Fastening torque for M12×1.5×55-10.9

should be 8.2~10.2 kgf·m (59.3~73.8
Ibf·ft), that for M14×1.5×55-10.9 be
12.6~16.8 kgf·m (91.1~122 Ibf·ft).
※ When fitting sealing gland, be careful not
to make the spline to scratch oil seal.
850KAX58
(10) Install the flange on to the spline of drive

spiral bevel gear, then fit the O-ring,
washer and lock nut, with fastening torque
to the lock nut at 76.5~81.6 kgf·m
(553~590 Ibf·ft) (lock up the lock nut after
checking there is no error in assembly).
※ Check if the surface of flange to contact
with oil seal is smooth and without cracks.
850KAX59
850KAX60
2-46
(11) Turn the bracket for 90˚, insert the thrust
bolt applied sealant, turn it into position,
and then turn back for 1/4 turn, and fit lock
washer and M27×22 nut, turn with
fastening torque at 45.9~54 kgf·m
(332~391 Ibf·ft) to lock up the lock
washer.
850KAX61
4) REASSEMBLY OF PLANETARY CARRIER ASSEMBLY

(1) After cleaning the bore of planetary gear,
apply a right amount of lithium grease,
and insert the selected needles and
space bushing of planetary gear into the
bore. Be careful that needles selection
should be matching, with the difference
between max. and min. diameter less than
0.003 mm.
850KAX62
(2) Fix planetary gear and washer.
850KAX63
(3) Push the planetary gear shaft into the

planetary carrier, put a ø3/8 steel ball in
the hemispherical hole to prevent the
planetary gear shaft to turn.
850KAX64
2-47
5) REASSEMBLY OF HUB ASSEMBLY
(1) Place the hub on a table with its small
side upward, apply a right amount of
grease on the inner surface of the bore of
hub and then push a bearing outer ring
into small side, put up the inner race, and
push the oil seal spacing bush into the
bore. Use a specialized tool to push oil
seal B150×180×15 and
FB150×180×15 into the bore of hub in
order. 850KAX65
850KAX66
(2) Assemble the brake disc and fasten with

brake disc bolts M20×1.5 and grower
washer with a torque at 51~60 kgf·m
(369~434 Ibf·ft).
(3) Tur n over the hub with brake disc
assembled with its large side upward,
apply a right amount of grease on the
inner surface of the bore on the large side
of hub, and push the outer ring of bearing
32026 in. 850KAX67
(4) Fit the O-ring onto the rabbet of ø384
hub.
850KAX68
2-48
6) REASSEMBLY OF AXLE
(1) Clean the axle housing assembly and put
it on a support, insert the preheated
gasket to wheel side supporting axle
thermally securing the end surface of
gasket to be perpendicular with axle
center and the parallelism with support is
controlled within 0.1 mm.
(2) Mount the hub assembly at the both sides
of axle.
※ When assembling hub and brake disc, 850KAX69
ke e p t h e m i n g o o d b a l a n c e a n d
suspending to prevent the oil seal from
being scratched by spline.
(3) Preheat the inner race of bearing and fit it
into the small side of ring carrier assembly
welded and align the female spline of ring
carrier with the spline of wheel side
supporting axle to assemble.
850KAX70
(4) Fit taper bushing.
850KAX71
2-49
(5) Turn the inner hexagon nut to the thread
onto the wheel side supporting axle (apply
thread lock glue on the thread of nut) and
fasten to give a certain pre-tight strength
to the bearing and turn the hub at the
same time to make two bearings into
correct positions. Apply a twisting force of
11.9~16.1 kgf·m (86.0~116 Ibf·ft) to the
rim bolts and at the time, just moving of
hub means the pre-tight strength of taper 850KAX72
bearing is OK. Put up a locked spacer and
make its claw to get in the locking groove
of nut and then fasten up the lock nut
(inner hexagon nut, locking glue applied
on the thread) at outside with a torque of
35.7~40.8 kgf·m (258~295 Ibf·ft) making
its locking claw to get in the locking groove
of outside nut.
850KAX73
(6) Assemble planetary carrier.
850KAX74
(7) Assemble rim bolts and nuts, and fasten

up with a torque spanner with a torque of
43.8~47.9 kgf·m (317~346 Ibf·ft).
※ Take care to check if the O-ring is fit up for
rim when fixing planetary carrier.
850KAX75
2-50
7) When mounting main reductor, first locate
three stop dowels on the mounting surface
of axle housing and apply a coat of silicone
adhesive uniformly between the main
reductor and axle housing and align the
main reductor to its mounting position to
assemble and fasten up with main reductor
bolts M14×1.5×35 with a torque of
1 2 . 6 ~ 1 6 . 8 kgf·m ( 9 1 . 1 ~ 1 2 2 Ibf·ft)
(M16×1.5×35 and 19.7~26.2kgf·m 850KAX76
(142~190 Ibf·ft).
850KAX77
8) Set the sun gear at the side of differential

axle with locating groove and set the snap
ring and push into axle housing securing
correct mesh between sun gear and the
planetary gear inside the planetary carrier.
After that two people can turn the wheel
side at two different sides in reverse
direction and smooth rotation should be
secured.
850KAX78
9) Select suitable adjusting pin and end cover

for the two sides of axle and secure a 1-2
mm clearing between the adjusting pin and
stop block after assembly. Apply some
silicone adhesive on the end cover and fix it
on the planetary carrier with M12×1.25
bolts wrapped with tape and fasten up with
a torque of 7.1~9.2 kgf·m (51.4~66.5
Ibf·ft).
850KAX79
2-51
10) Mount the brake caliper and fasten up with
brake caliper bolts with a torque of 51~59.1
kgf·m (369~427 Ibf·ft).
11) Insert the plug at the axle bottom and fix.
Supply oil into the axle housing (differential
gear) and wheel side (planetary gear).
·Oil amount
Front axle : 24ℓ(6.3 U.S. gal)
Rear axle : 24ℓ(6.3 U.S. gal)
Supply oil unit is it overflows from the oil
filler, then install the plug.
Recommended oil is SAE 85W-90.
2-52
6. GENERAL TROUBLES AND TROUBLESHOOTING
Since the loader features great torque and complex structure, failure to observe repair and working
standards may cause troubles. Followings are description of troubles, causes, symptoms and measures.
1) ABNORMAL NOISE FROM DRIVING AXLE
Complex noise is produced from driving axle and defective parts, incorrect assembly and
adjustment of main transmission system and excessive wear during using cause noise in travelling
and operation. Generally, noise increases by increase of vehicle speed.
(1) Noise due to inappropriate backlash between drive and driven gears.
① Symptoms and causes.
·Too much backlash between two gears causes arrhythmic gear knocking sound, clunking.
·Too little backlash causes gears to jam and overheat.
·Uneven backlash causes rhythmic rattle noise and further causes the driving axle to sway.
② Measures.
·Remove the main reductor and adjust the back lash between drive and driven gears.
(2) Noise due to improper fit of incorrect bearing clearance
① Symptom and cause.
·Too little clearance causes noise sounds like continued “M---!” and excessive clearance like
"Hara---Hara!"
② Measures.
·Remove main reductor and add or subtract washer/shim to readjust bearing clearance.
·Replace with new bearing, if damaged, and readjust the clearance.
(3) Periodic abnormal noise
·Gears are cut, or there are foreign objects inside sounding like clatter.
② Measures.
·Replace the damaged gear or clear the foreign objects.
(4) Abnormal noise in differential device
·When planetary gear and differential crossing are jammed, cracking sound is made, specially
as cornering.
·Poor mesh gears make complex noise such as sounding "M---" as machine travel in straight
line and plus clicking as cornering.
② Measures.
·Remove main reductor to replace differential crossing, or planetary gear and differential gear.
2) DRIVING AXLE HOUSING OVERHEAT
(1) Symptom and cause.
After a period of time of travelling or operation, touch the axle housing with hand and, when you
feel hot and can not sustain, the axle housing is determined overheat. Overheat of axle housing is
mainly due to too little bearing clearance, too little back lash of drive and driven gears, choked
deflection valve on the axle, or insufficient lubricant.
(2) Measures.
First check the deflection valve for being choked, and insufficient lubricant and, if no problem with
these factors, remove main reductor, and check and adjust bearing clearance or back lach
between drive and driven gears.
2-53
3) OIL LEAKS
Gear oil leaks at junction between main reductor and axle housing, junction between main
reductor flange and sealing gland, and inside planetary reductor. Oil leaks at junction between
main reductor and axle housing is mainly due to loose bolt or deteriorated sealant and that at
junction between main reductor flange and sealing gland and inside planetary reductor is
mainly due to aged and worn oil seal or O-ring.
(2) Measures.
Reapply sealant and fasten up bolts, replace sealing gland or O-ring.
4) WEAK DRIVING FORCE
Weak scraping and shearing force of loader under normal oil temperature of transmission.
One cause may be broken differential axis.
(2) Measures.
First determine which of the differential axle of front axle or rear axle is broken. Turn down the
bucket to make the front wheels to rise away from the ground and then change to reverse gear
and step on it gradually to observe whether the loader can travel or not. If the loader can not
travel and rear driving axle turns, the rear differential axle may be broken.
2-54
Group 1 Structure ------------------------------------------------------------------------------------------------------------- 3-1

Group 2 Air brake circuit --------------------------------------------------------------------------------------------------- 3-2
Group 3 Components specification and function ----------------------------------------------------------- 3-3
GROUP 1 STRUCTURE
3 6
1
7
T/M
9
8 11
5
Engine
4
2
10
850KBS01
1 Air brake valve 7 Clutch cut off lever

2 Air tank 8 Parking air pressure switch
3 Air booster 9 Front axle
4 Oil and water separator 10 Rear axle
5 Safety valve 11 Parking brake cylinder
6 Parking brake lever
3-1
GROUP 2 AIR BRAKE CIRCUIT
12
5
1 10
3
FRONT
2
3 AXLE
6
4
8 7
REAR
PARKING
OFF ON ON OFF
E/G
AIR COMPRESSOR
9
11
T/M clutch
850KBS05
1 Air brake valve 7 Clutch cut off lever

2 Air tank 8 Parking brake lever
3 Air booster 9 Parking air pressure switch
4 Oil and water separator 10 Brake lamp air pressure switch
5 Safety valve 11 Parking brake cylinder
6 Auto water drain 12 Pressure switch and sensor
3-2
GROUP 3 COMPONENTS SPECIFICATION AND FUNCTION
1. BRAKE VALVE
1) USE AND STRUCTURE
As a main device of foot brake, this unit adopts high technology and can be applied to single circuit
braking system of machines.
2) WORKING PRINCIPLE
When the brake pedal (2) is pressed, the rod (3) presses the equalizing spring (4) to produce a
pressure, which then pushes the piston (6) to move down to make intake valve (7) to open allowing
compressed air to flow from inlet to outlet port. When brake pedal (2) is released, return spring (5)
pushes the piston (6) to move up to make intake valve to return to original position to close air flow
between inlet and outlet. Remaining pressure at outlet is vented through exhaust port.
3) TECHNICAL DATA
(1) Operating air pressure : 784 kPa
(2) Working temperature : -30 ~ +80˚C
(3) Working medium : air
4) MOUNTING AND CONNECTION SIZE

(1) Connection screw : M22×1.5 (3EA)
(2) Mounting : 4-ø9
(3) Dimensions : 136×136×335
5) CORRECT USE AND MAINTENANCE

(1) Notes in using
① Before mounting, remove the plugs for inlet and outlet, and be sure to have the pedal and valve
body are securely assembled. Valve clearance should be adjusted properly with adjusting screw
(pressure of surplus for the roller to press the rod should be less than 0.5 mm) and fasten up the
nut.
② Insert M8 bolts through 4-ø9 holes to make secure assembly.
③ When connecting with piping, distinguish inlet port from outlet. Marking “1” means, inlet, “2”
means outlet and “3” exhaust port.
(2) Notes in Maintenance
① There should be water draining and filtering devices in air circuit to secure a clean air source.
Anti-rust process is required for the brake tubes and air cylinder.
② A space should be secured for freely moving of the pedal.
③ When replacing a wearing part, use a part same with the worn, the damaged fastening pieces
(such as stop ring, bolt) must also be replaced. All parts should be assembled in correct position
securely and no other part be damaged. After replacing, do not assemble to the machine before
completing test.
④ The moving part of air brake valve should be served grease. If the brake doesn’t grip properly or
grips weakly, check the wearing parts of air brake valve and braking system.
3-3
6) TROUBLESHOTTING
Trouble Cause Remedy
Air leaks under no work. Worn rubber. Replace rubber or assembly.
Air leaks under work. Worn rubber. Replace rubber or assembly.
Unsmooth exhaust. Seizing of piston. Replace the assembly.
Improper adjustment of pedal Adjust the adjusting screw manually to the
roller and rod. extent that pedal roller is just contacting the rod.
(Pressure of surplus for the roller to press the
rod should be less than 0.5 mm)
7) STRUCTURE AND MOUNTING SIZE
View A
Air outlet
Air
intlet
Air outlet
850KBS10
1 Bolt 4 Equalizing spring 7 Intake valve

2 Pedal 5 Spring
3 Rod 6 Piston
3-4
2. PARKING BRAKE CYLINDER
1) STRUCTURE
The unit is mainly applied for supporting localization and also for the emergency brake system of
other middle and small size loaders remodeled for the purpose.
Working principle of the unit is to make braking by exhaust. That is, when the pressure of the air
line reaches 390 kPa, or tube is broken, the manual control brake valve is triggered to cut off the
clutch and, at the same time, relieve the pressure inside the unit to cause the energy stored spring
to actuate emergency braking. When emergency situation occurs or stopping the vehicle on a
slope, the driver may press a button to make operation as above to stop machine firmly. This unit
provides safety with exhaust braking.
3) TECHNICAL DATA
(1) Rated operating air pressure : 784 kPa
(2) Opening pressure : 400 kPa
(3) Rod stroke : 60±1 mm
(4) Brake power : ≥5100N
(5) Weight : 7 kg
(1) Mount : 2-M16×38
(2) Air inlet : M12×1.25
5) CORRECT USE AND MAINTENANCE:
(1) Notes in Using
① Remove the thread protector plug before mounting operation.
② Fix 2-M16 bolts on the working frame and connect pin to brake arm.
③ Never try to disassemble the assembly by yourself. Use specialized equipment for disassembly
if repair is required.
(2) Notes in Maintenance
① There should be water draining and filtering devices in air circuit to secure a clean air source.
Anti- pollution and rust process is required for the brake tubes and air cylinder.
② When replacing a wearing part, use a part same with the worn, and the damaged fastening
pieces (such as stop ring, bolt) must also be replaced. All parts should be assembled in correct
position securely and no other part be damaged. After replacing, do not assemble to the
machine before completing test.
6) TROUBLESHOTTING
Air leaks at piston rod Worn O-ring.
Replace the wearing part or assembly.
Air leaks at cylinder Worn piston cup.
3-5
850KBS11
3-6
3. PARKING BRAKE LEVER
The unit is mainly applied for the emergency brake system of other middle and small size loaders
remodeled for the purpose.
Working principle of the unit is to make braking by exhaust. That is, when the pressure of the air
line reaches 240~310 kPa, or tube is broken, the manual control brake valve is triggered to cut off
the clutch and, at the same time, relieve the air pressure inside the energy stored spring brake
chamber to actuate emergency braking. When emergency situation occurs or stopping the vehicle
on a slope, the driver may press a button to make operation as above to stop vehicle firmly. This
unit provides safety with exhaust brake.
3) TECHNICAL DATA
(2) Protecting pressure : 240~310 kPa
(3) Weight : 0.34 kg
(1) M22×1.5
(2) Air inlet : PT1/8”
(3) Air outlet : 2-PT1/4”
(1) Notes in using
① Remove the thread protector plug before mounting operation.
② When mounting, unscrew the sealing nut of M22×1.5 thread, fit the mounting plate and then
recover the sealing nut and fasten up.
When connecting, discriminate each port. Marking “1” means, inlet, “2” means outlet and “3”
exhaust port.
(2) Notes in maintenance
① There should be water draining and filtering devices in piping to secure a clean air source. Anti-
pollution and rust process is required for the brake tubes and air cylinder.
② When replacing a wearing part, use a part same with the worn, the damaged fastening pieces
(such as stop ring, bolt) must also be replaced. All parts should be assembled in correct position
completing test.
③ The moving part of air brake valve should be served grease. If the brake doesn’t grip properly or
grips weakly, check the wearing parts of braking system and emergency brake valve.
3-7
6) TROUBLESHOTTING

Air leaks under no work Replace wearing part or assembly.
Worn rubber.
Air leaks under work Replace wearing part or assembly.
52
S=32
M22×1.5
(141)
PT1/8"
216
2-PT1/4"
369
Air inlet
Air outlet Air outlet
Air outlet
850KBS12
3-8
4. SAFETY RELIEF VALVE
Safety relief valve automatically drains condensate inside the air cylinder of brake line and manual
drainage is also available.
Safety relief valve is used to automatically drain condensate inside the air cylinder of brake line by
variation of air pressure (air pressure drops 0.03~0.1 MPa) and manual drainage is also available
after parking for fast drainage.
3) TECHNICAL DATA
(3) Weight : 0.1 kg
(1) M22×1.5
(2) Exhaust port down.
To connect air cylinder
Manual drainage button
Exhaust port
850KBS13
3-9
5. SAFETY VALVE
Safety valve is used to ensure that charge pressure of air brake line does not exceed 900 kPa.
Compressed air flows in through air inlet and, when the pressure at inlet exceeds 850 kPa, the
safety valve A is actuated for air relief to protect the air brake line.
3) TECHNICAL DATA
(1) Safety operating pressure : 850~900 kPa
Inlet M16×1.5 is connecting screw.
5) NOTES IN USING
Adjusting bolt of safety valve has been already set as delivery and user is not permitted to adjust or
remove the part as his/her wish.
6) TROUBLESHOOTING
Leaks at valve port Damaged rubber of safety valve stem Replace safety valve assy
assy.
Adjusting bolt
Air outlet
Air inlet
850KBS14
3-10
6. CLUTCH CUT OFF LEVER
Clutch cut-off lever is a manual operation valve for operating air brake element.
(1) After air under pressure flows in, change the lever from position I to II to open the valve and the
inlet and outlet are interconnected and have the same pressure.
(2) Change the lever from position II to I to close the valve and make the outlet and exhaust port
interconnected. Air is exhausted to atmosphere through outlet 3.
3) TECHNICAL DATA
(1) Rated operating pressure : 784 kPa
(3) Weight : 0.3 kg
4) MOUNTING AND CONNECTION SIZE:
(1) Mounting size : 2-M5
(2) Connection size : Inlet (M10×1), outlet (M10×1)
(3) Dimensions : 49×30.5×100
(1) Notes in using
① Before mounting, remove the protector plugs for inlet, outlet and exhaust port.
② Mount the unit on a plate.
① If severely worn wearing part or air leaks is found, immediately replace the wearing part.
② When replacing a wearing part, use a part same with the worn. All parts should be assembled in
correct position securely and no other part be damaged. After replacing, do not assemble to the
machine before completing test.
6) TROUBLESHOOTING
Leaks
eaks at exhaust port Polluted valve assy. Clean pipe line.
Damaged valve assy. Replace valve.
3-11
I cut off II open
Air
outlet
Air inlet
850KBS15
3-12
7.OIL AND WATER SEPARATOR
1) STRUCTURE
Oil and water separator combined valve is applicable to brake system. This device features
automatic control of working pressure in brake system and auto drainage of oil and water after
filtering. Since the unit has a built-in protector, safe pressures can be guaranteed.
Air under pressure from compressor flows into the valve through air inlet and water and impurities
can be filtered off through a strainer. After filtering, the compressed air reaches the outlet through
one-way valve to charge the cylinder. When the pressure inside cylinder reaches opening pressure,
air that enters into top head overcomes resistance of pressure spring to push control valve assy to
move upward to open the exhaust valve at the lower part to discharge the air along with filtered
impurities and water into atmosphere and compressor becomes idle state. When the pressure
inside air cylinder drops to exhaust stop value and the air inside cavity of top head can not
overcome the pressure spring, control valve moves down, and the exhaust valve moves up by the
action of spring to stop exhaust valve and air supply to cylinder is restarted.
3) TECHNICAL DATA
(1) Opeing pressure : 784±20 kPa
(2) Exhaust stop pressure : 685 ~ 750 kPa
(3) Working temperatures : -30 ~ +100˚C
(4) Weight : 1.8 kg
(1) Mounting size : 2-M8×40 double end stud
(2) Connection size : Inlet (M22×1.5), outlet (M22×1.5)
(3) Dimensions : 150.5×128.5×220
5) CORRECT USE AND M MAINTENANCE
AINTENANCE
(1) Notes in using
① Before mounting, remove the plugs for inlet and outlet.
② Mount the unit on the mount plate with outlet down.
③ Pressure regulator screw and safety valve have been set as delivery and user is not permitted to
adjust or remove by his/her self.
① The length of pipe from air compressor to combined valve should not be less than 2 m, aperture
not less than ø12 to ensure fully cooling of hot air and condensing moisture in air.
② If severely worn wearing part or air leaks is found, immediately replace the wearing part.
③ When replacing a wearing part, use a part same with the worn, the damaged fastening pieces
(such as bolt and nut) must also be replaced. All parts should be assembled in correct position
completing test.
3-13
6) TROUBLESHOOTING
Leaks
eaks at exhaust port. Polluted exhaust valve. Clean pipe line.
Damaged exhaust valve. Replace exhaust valve.
Leaks
eaks at top head vent Damaged diaphragm. Clean pipe line.
Damaged control piston O-ring. Replace control piston O-ring.
Air
outlet
Air inlet
850KBS16
3-14
Group 1 Hydraulic circuit -------------------------------------------------------------------------------------------------- 4-1

Group 2 Structure and function --------------------------------------------------------------------------------------- 4-5
Group 4 Tests and Adjustments -------------------------------------------------------------------------------------- 4-20
GROUP 1 HYDRAULIC CIRCUIT
1. STEERING CIRCUIT
LH RH
R L
8
MCV
P T LS
11 CF EF LS
7
9
13
P T
14
2
10
12
850K3HC33
2 Steering pump 9 Oil cooler 13 Air breather

6 Steering cylinder 10 Return filter 14 Hydraulic tank
7 Priority valve 11 Orifice fitting
8 Steering unit 12 Bypass valve
4-1
2. NEUTRAL
LH RH
R L
8
MCV
P T LS
11 CF EF LS
7
D
9
13
P T
14
2
10
12
850K3HC34
The steering wheel is not being operated so control spool (G) does not move.
The oil from the steering pump enters port P of priority valve and the inlet pressure oil moves the spool
(D) to the right.
The pump flow is returned to the tank through the EF port.
4-2
3. LEFT TURN
LH RH
R L
8
MCV
P T LS
11 CF EF LS
7
9 D
13
P T
14
2
10
12
850K3HC35
When the steering wheel is turned to the left, the spool (G) within the steering unit (8) connected with
steering colurm turns in left hand direction.
At this time, the oil discharged from the steering pump flows into the spool(G) of the steering unit (8)
through the spool (D) of priority valve (7) and flows into the gerotor(H).
Oil flow from the gerotor flows back into the spool (G) where it is directed out the left work port (L) to the
respective chamber of the steering cylinders (6).
Oil returned from left and right cylinder returns to hydraulic tank through the spool of the steering unit.
When the above operation is completed, the machine turns to the left.
4-3
4. RIGHT TURN
LH RH
R L
8
MCV
P T LS
11 CF EF LS
7
9 D
13
P T
14
2
10
12
850K3HC36
When the steering wheel is turned to the right, the spool (G) within the steering unit (8) connected with
steering colurmn turns in right hand direction.
At this time, the oil discharged from the steering pump flows into the spool (G) of the steering unit (8)
through the spool (D) of priority valve (7) and flows into the gerotor (H).
Oil flow from the gerotor flows back into the spool (G) where it is directed out the right work port (R) to
the respective chamber of the steering cylinders (6).
Oil returned from left and right cylinder returns to hydraulic tank through the spool of the steering unit.
When the above operation is completed, the machine turns to the right.
4-4
1. STEERING PUMP
18
17
16
15
13
20
19
14
5
6
12
5
6
7
11 8
9
6 10
10
9
8
7
6
4
3 2
2
1
850K4SP01
1 Snap ring 8 Back up seal 15 Name plate

2 Shaft seal 9 Seal 16 Rivet
3 Front cover 10 Wear plate 17 Nut
4 Snap ring 11 Drive gear 18 Stud bolt
5 Seal 12 Driven gear 19 Nut
6 Bushing 13 Gear housing 20 Bolt
7 Spacer 14 Rear cover
4-5
2. STEERING UNIT
1) STEERING GEAR
21
1 11
12
22
19
2 13
3 14
5 15
25
16
20
15
6 24
23
17
7
8
18
9
10
850KSE31
1 Centering spring 10 Bolt 19 Pin

2 Seal 11 Cap screw 20 Housing
3 Bearing 12 Washer 21 Spool
4 Seal 13 End cap 22 Sleeve
5 O-ring 14 Spacer 23 X-ring
6 O-ring 15 O-ring 24 Plug
7 O-ring 16 Gerotor 25 Orifice
8 Front cap 17 Drive
9 Spring washer 18 Plate
4-6
2) OVERLOAD VALVE
33
27
26 34
31 30
31
35
28
28
30
29 34
28
30
31 33
32
31
30
28
29
28
26
27
850KSE30
26 O-ring 30 Ball 34 Washer

27 Plug 31 Poppet 35 Body
28 O-ring 32 Spring
29 Spool 33 Ball retainer
4-7
(1) Overview
Overload valve is a combined valve for full hydraulic steering gear, and can be directly assembled
to four port flanges of steering valve body to become integrated one.
(2) Structure and Working Principle
Overload valve consists of a one-way valve and two-way buffer valve, which guarantee stable
steering performance, safety and reliability.
① Features:
Compact design, easy installation, space efficiency.
Flexible pressure regulation, no leaks.
Combined valve can simplify hydraulic system and has low costs.
② Structure
- One-way valve has a taper structure, consists of a valve seat, spool and spring and is fitted to
inside of oil inlet of valve body. This valve features light resistance and good sealing. High
pressure oil from hydraulic pump must pass through one-way valve to reach steering valve
body. This one-way valve is designed to prevent operation of hydraulic system from being
broken due to deflection of steering wheel because of return of oil to pump due to oil pressure
in cylinder being higher than operating oil pressure that is caused by obstruction to steering
wheel in special situations. One-way valve needs not adjustment in normal use, but reverse oil
leaks should be prevented.
- Two-way buffer valve includes two direct-acting overflow valves and consists of a spring, two
ball valve seats and two steel balls. This device is attached to the valve body to the each port of
two chambers of steering cylinder. The ports are connected to return port. The product features
simple structure and easy manufacture and repair, and functions as two safety valves to unload
and make oil returning when pressure in a chamber of cylinder increases as speedy steering or
vehicle travel encounters sudden variation in resistance to protect the oil circuit between
steering cylinder and steering gear, assuring safe and reliable steering. Opening pressure of
the valve is 5~6 MPa higher than operating pressure of steering gear.
(3) Installation and Requirements in Using
① Installation
Be sure to make correct connection of four ports, i.e., P, T, A and B when installing the valve
block on the flange at the steering gear side.
Be careful to keep clean junction surface of flange and prevent dirt from entering into the system.
Four O-rings in between valve block and steering gear flange should be laid flat, two screws
fastened at even fastening torque, 4.1 ~ 5.1 kgf·m (29.7 ~ 36.9 Ibf·ft). Be sure that valve block
is not twisted.
② Oil temperature range : -20 ~ 80˚C
Normal oil temperature : 30 ~ 60˚C
Hydraulic oil in high temperature for long time causes the oil to be prematurely deteriorated.
③ Oil selection: Viscosity index of 17~33cst at normal temperature and viscosity index of over 100
are suitable and ISO VG46 (ISO VG32, ISO VG68) oil is recommended.
④ Filtering : Maintain clean operating fluid and have filtering precision of system not less than 30
µm.
⑤ Pressure of two-way buffer valve is already set as delivery and, if adjustment is required, be
sure to make on a test bed.
4-8
(4) Troubleshooting
Trouble Cause Remedy
Vehicle travel is deflected, or Failed two-way buffer valve (steel ball Clean two-way buffer valve, replace
cylinder will not move (or is stuck by dirt or spring failed), failed spring or seal ring.
slowly) when turning wheel seal ring.
P r e s s u r e c o u l d n o t b e Broken spring. Replace spring.

regulated (increase or
Poor sealing at valve port causes valve Set the spool and seat, or replace part.
decrease)
constant open.
Valve spool is stuck due to burr or oil Remove, inspect and repair.
stain.
Unstable pressure, with Poor contact between valve spool and Set the valve spool and seat, or
frequent noise and vibration seat. replace part.
Poor spool motion. Check valve spool for being stuck by

dirt.
Bent or too weak spring. Replace spring.

Dirty oil, clogged damping hole Change fluid, dredge damping hole
Flow exceeds specified value. Replace with a larger flow valve.
4-9
3. PRIORITY VALVE
7
9
10
6
15
5
11
4 12
13
14
1
850KSE35
1 Plug 6 O-ring 11 Spring

2 O-ring 7 Valve block 12 Sleeve
3 Spool 8 Poppet seat 13 Adjust shim
4 Body 9 O-ring 14 Plug
5 Spring 10 Poppet 15 Spring
4-10
4. TROUBLESHOOTING FOR LOAD SENSING STEERING SYSTEM
The steering system consists of steering pump, steering unit (steering gear + overload valve) and
priority valve. Safety valve of steering system is attached to the priority valve.
1) HARD STEERING
STEERIN
(1) Hard and stiff steering :
Turn the steering wheel with engine off and then release immediately to check the wheel for
returning. If no, you have a stuck valve in steering column. You can unscrew the bolt connecting
steering rod and steering gear and add washer. The principle is that the structure of steering
column must guarantee no transmission of axial load to input shaft of steering gear. Assembly of
steering rod must ensure that the steering gear can return to neutral position after completion of
operation.
(2) Clogged orifice by dirt, stuck stem or deformed main spring of priority valve :
Clean the orifice and stem of priority valve.
(3) Safety valve pressure of steering system is on the low side :
Light steering while travelling normally and heavy steering while parked means low pressure of
safety valve (increase the pressure of safety valve properly).
(4) Decreased oil pump efficiency or lacking of oil supply :
Diagnosis is made by throttle position and hot or cold hydraulic fluid.
(5) Steering wheel will not move (fallen out steel ball or spool of one-way valve has, stuck input port,
or clogged oil way) :
Check the steel ball for existing, and the one-way spool at P port of valve block for fallen out and
caused the oil way blocked, and check the system tubing for normal flow.
(6) Premature opening of safety valve on the priority valve (stuck by impurities) :
Open the return way of safety valve on the priority valve to check the safety valve for premature
opening before steering to the dead point. If open, steering will be hard. Normally, the safety valve
should open after steering to the dead point and hydraulic fluid flowing out. In case of premature
opening, you need to clean the safety valve on the priority valve or replace the safety valve assy.
(7) Troubles such as worn hydraulic oil pump :
Repair or replace the oil pump.
2) STOPPING POINT
POINT IS NOT SENSED
(1) Two-way buffer valve pressure is on the low side :
Safety valve pressure can be increased to a proper value.
(2) Too high pressure value set for safety valve of steering system :
Pressure set for safety valve on the priority valve can be increased to a proper value.
(3) Return tube of priority valve is blocked :
Disassemble the return tube of safety valve and steer to the dead point. No returning oil means
blocked oil tube.
(4) Low pretightening force on the bolt at the end of steering gear :
Increase the pretightening force properly.
(5) Too much wheel play :
Replace the stator/rotator or grind the end surface of stator to decrease the play between the
rotator and stator.
4-11
3) NO SENSING OF STOPPING POINT ON ONE SIDE
(1) One cavity pressure of two-way buffer valve is too low :
Increase the two-way buffer valve pressure properly.
(2) Buffer valve port is clogged by dirt :
Clean the port of buffer valve.
4) STEERING WHEEL TURNS BY ITSELF

(1) Axially stuck steering gear and steering lever shaft :
Diagnose by referring to the first item of hard steering.
(2) Valve malfunction due to dirt in oil :
Clean the valve.
(3) Too hot oil causing malfunction of valve :
Clean the valve.
(4) Broken spring :
Replace the spring piece.
5) STEERING WHEEL SHIMMY

(1) Too low two-way buffer valve pressure:
Increase two-way buffer valve pressure properly.
(2) Weak or broken spring piece:
Broken spring piece and noncentering valve spool and sleeve. Replace spring piece.
6) STEERING PULL
(1) Weak or broken spring piece :
Weak or broken spring piece and noncentering valve spool and sleeve. Replace spring piece.
(2) Too low pressure in one cavity of two-way buffer valve :
Broken or deformed spring. Replace spring. Increase the pressure for two-way buffer valve.
7) WHEEL WON’T TURN, STEERING WHEEL DOES

(1) Lack of oil in oil tank :
Add oil in oil tank.
(2) Worn steering cylinder :
Replace steering cylinder.
(3) Too much play between stator and rotator due to wear :
Replace stator and rotator pair or grind the stator to decrease the play.
4-12
5. STEERING CYLINDER
7614SE150
1 Snap ring 9 O-ring 24 Bushing

2 Joint bearing 10 Piston seal 25 Tube assy
3 Dust wiper 11 Wear ring 26 Piston
4 O-ring 12 Screw 27 Cover
5 Rod seal 13 Name plate 28 Nut
6 Buffer ring 21 Piston rod 29 Plug
7 O-ring 22 Back up ring
8 Snap ring 23 Gland
4-13
GROUP 3 OPERATIONAL CHECKS AND TROUBLESHOOTING
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 2.
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 this 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 4 : Tests and adjustments
4-14
※Hydraulic oil must be at operating temperature for these checks.
Item Description Service action

Steering unit check Run engine at low idle. OK
Check completed.
A
Turn steering wheel until frames
are at maximum right (A) and NOT OK
B
then left (B) positions. Go to next check.
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 Right Turn steering wheel rapidly until OK
check frames are against stops. Check completed.
Heat hydraulic oil to oper- Left
Hold approximately 2kgf on NOT NOT OK
ating temperature.
steering wheel. Do steering system leak-
Run engine at high idle.
age test in group 4 to
Count steering wheel revolutions
isolate the leakage.
for 1 minute.
Repeat test in opposite direction.
LOOK : Steering wheel should
rotate less than 5rpm.
NOTE : Use good judgment;
Excessive steering wheel rpm
does not mean steering will be
affected.
Priority valve low press- Park machine on a hard surface. OK
ure check Check completed.
Hold brake pedal down.
NOT OK
Do steering system leak-
Steer machine to the right and age test in group 4 to
left as far as possible. isolate the leakage.
LOOK : Machine must turn at
least half way to the right and left
stops.
Priority valve high pres- Steer to steering stop and OK
sure check release wheel. Check completed.
Roll bucket back and hold over NOT OK O
relief and observe engine rpm. Do priority valve pressure
test.
Turn wheel to steering stop and
hold, observe engine rpm.
LOOK : Steering stall engine
rpm must be higher than hydrau-
lic stall rpm.
4-15
2. TROUBLESHOOTING
※ Diagnose malfunction charts are arranged from most probable and simplest to verify, to least
likely, more difficult to verify. Remember the following steps when troubleshooting a problem :
Step 1. Operational check out procedure (see group 3 in section 1)
Step 2. Operational checks (in this group)
Step 3. Troubleshooting
Step 4. Tests and adjustments (see group 4)

No steering Low oil level. Add recommended oil.
Restricted suction line. Check.
Failed hydraulic pump. Remove and inspect return filter for
metal pump particles.
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 relief cartridge leakage test.
Failed hydraulic lines. Check.
Slow or hard steering Too much friction in the mechanical Lubricate bearings and joints of frame
parts of the machine. or cylinders or repair if necessary.
Check steering column installation.
Cold oil. Warm the hydraulic oil.
Low priority valve pressure setting. Do priority valve pressure test.
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 4.
Low system relief valve setting. Test and adjust if necessary.
Low overload relief valves setting. Test and adjust if necessary.
4-16
Constant steer ing to Air in system. Check for foamy oil.
maintain straight travel
Leakage in steering system. Do steering system leakage check.
Worn steering unit. Do steering unit neutral leakage test in
group 4.
Leaf spring without spring force or Replace leaf springs.
broken.
Spring in overload relief valve broken. Replace overload relief valve.
Gear wheel set worn. Replace gear wheel set.
Cylinder seized or piston seals worn. Replace defects parts.
S l ow s t e e r i n g w h e e l Leakage in steering system. Do steering system leakage check.
movement will not cause
Worn steering unit gerotor. Do steering unit leakage check.
any frame movement
Steering wheel can be Leakage in steering system. Do steering system leakage check.
turned with frames
against steering stop
Steer ing wheel tur ns Broken steering column or splined of Remove and inspect.
with no resistance and steering unit.
causes no frame
Lack of oil in steering unit. Star t engine and check steering
movement
operation.
Leakage in steering system. Do steering system leakage test in
group 4.
Erratic steering Air in oil. Check for foamy oil.
Low oil level. Add recommended oil.
Sticking priority valve spool. Remove and inspect spool.
Loose cylinder piston. Remove rod to inspect piston.
Damaged steering unit. Remove and inspect.
Spongy or soft steering Air in oil. Check for foamy oil.
Low oil level. Add recommended oil.
Free play at steering Loose steering wheel nut. Tighten.
wheel
Worn or damaged splines on steering Inspect.
column or valve.
Steering unit binding or B i n d i n g i n s t e e r i n g c o l u m n o r Inspect.
steering wheel does not misalignment of column.
immediately return to
High return pressure. Check for a pinched or damaged return
neutral when released
line.
Contamination in steering unit. Inspect hydraulic filter for contamination.
Repair cause of contamination. Flush
hydraulic system.
4-17
Steering unit locks up Large particles of contamination in Inspect hydraulic filter for contamination.
steering unit. Repair cause of contamination. Flush
hydraulic system.
★ Thermal shock Do priority valve LS port flow test in
group 5. This oil flow provides a warm-
up flow to steering unit when not using
the steering.
Worn or damaged steering unit. Repair or replace steering unit.
Abrupt steering wheel Improperly timed gerotor gear in steering Time gerotor gear.
oscillation unit.
Steering wheel turns by Lines connected to wrong port. Reconnect lines.
itself
Worn or damaged steering unit. Repair or replace steering unit.
Vibration in steer ing High priority valve setting. Do priority valve pressure test.
system or hoses jump
Neutral position of Steering column and steering unit out of Align the steering column with steering
steering wheel cannot line. unit.
be obtained, i.e. there
Too little or no play between steering Adjust the play and, if necessary,
is a tendency towards
column and steering unit input shaft. shorten
"motoring"
the splines journal.
Pinching between inner and outer
spools. Contact the nearest service shop.
"Motoring" effect. Leaf springs are stuck or broken and Replace leaf springs.
The steering wheel can have therefore reduced spring force.
turn on its own
Inner and outer spools pinch, possibly Clean steering unit or contact the
due to dirt. nearest service shop.
Return pressure in connection with the Reduce return pressure.
reaction between differential cylinder
and
steering unit too high.
Backlash Cardan shaft fork worn or broken. Replace cardan shaft.
Leaf springs without spring force or Replace leaf springs.
broken.
Worn splines on the steering column. Replace steering column.
Jerky steering LS port orifice missing. Inspect orifice.
Orifice in top end of priority valve spool Disassemble and inspect.
missing.
★ Thermal shock is caused by a large temperature differential (Approx 30˚C, 50˚F) between the steering unit and
hydraulic oil. If the steering is not operated for a long period of time and the orifice in the bottom of the priority
valve spool is plugged, the steering unit may bind up when the steering is operated if the hydraulic oil is hot
enough.
4-18
"Shimmy" effect Air in the steering cylinder. Bleed cylinder.
The steered wheels Find and remove the reason for air
vibrate collection.
(Rough tread on tires
Mechanical connections or wheel Replace worn parts.
gives vibrations.)
bearings worn.
High priority valve setting pressure. Set pressure as regular value.
Steering wheel can be Oil is needed in the tank. Fill with clean oil and bleed the system.
turned the whole time
Steering cylinder worn. Replace or repair cylinder.
without the steered
wheels moving Gear wheel set worn. Replace gear wheel set.
Spacer across cardan shaft forgotten. Install spacer.
Steering wheel can be One or both anticavitation valves are Clean or replace defect or missing
turned slowly in one or leaky or are missing in overload relief valves.
both directions without the valves.
steered wheels turning
One or both overload relief valves are Clean or replace.
leaky.
Steering is too slow and Insufficient oil supply to steering unit, Replace pump or increase number of
heavy when trying to turn pump defective or number of revolutions revolutions.
quickly too low.
Relief valve setting too low. Adjust valve to correct setting.
Relief valve sticking owing to dirt. Clean the valve.
Spool in priority valve sticking owing to Clean the valve, check that spool moves
dirt. easily without spring.
Too weak spring in priority valve. Replace spring by a stronger.
"Kick back" in steering Fault in the system. Contact authorized man or shop.
wheel from system
Kicks from wheels
H e a v y k i c k - b a c k i n Wrong setting of cardan shaft and gear- Correct setting.
steering wheel in both wheel set.
directions
Turning the steering wheel Hydraulic hoses for the steering Connect lines to correct ports.
activates the steered cylinders have been switched around.
wheels opposite
Hard point when starting Spring force in priority valve too weak. Replace spring by a stronger.
to turn the steering wheel
Air in LS. Bleed LS line.
Clogged orifices in LS in priority valve. Clean orifices in spool and in connecting
plugs for LS.
Oil is too thick (cold). Let machine run until oil is warm.
Too little steering force Pump pressure too low. Correct pump pressure.
4-19
GROUP 4 TESTS AND ADJUSTMENTS
1. HYDRAULIC OIL CLEAN UP PROCEDURE USING PORTABLE FILTER CADDY

※ Service equipment and tool.
·Portable filter caddy
·Two 3658 mm (12 ft) × 1" I.D. 100R1
hoses with 3/4 M NPT ends
·Quick disconnect fittings
·Discharge wand
·Various size fittings and hoses
※ Steering system uses oil from hydraulic
oil tank. Flush all lines in the steering
system.
Disassemble and clean major compon-
ents for steering system.
Steering components may fail if steering
system is not cleaned after hydraulic oil
tank contamination.
1) If hydraulic system is contaminated due to a
major component failure, remove and dis-
assemble steering cylinders to clean debris
from cylinders.
2) Install a new return filter element. Clean fil-
ter housing before installing new element.
※ For a failure that creates a lot of debris,
remove access cover from hydraulic oil
tank. Drain and clean hydraulic oil tank of
fill the specified oil to hydraulic oil tank
through upper cover.
3) To minimize oil loss, pull a vacuum in
hydraulic oil tank using a vacuum pump.
Connect filter caddy suction line to drain
port at bottom of hydraulic oil tank using
connector. Check to be sure debris has not
closed drain port.
4) Put filter caddy discharge line into hydraulic
oil tank filter hole so end is as far away from
drain port as possible to obtain a through
cleaning of oil.
4-20
5) Start the filter caddy. Check to be sure oil
is flowing through the filters.
Operate filter caddy approximately 10 min-
utes so oil in hydraulic oil tank is circulated
through filter a minimum of four times.
※ Hydraulic oil tank capacity 150ℓ(39.6
U.S. gal).
Leave filter caddy operating for the next
steps.
6) Start the engine and run it at high idle.
※ For the most effective results, cleaning
procedure must start with the smallest
capacity circuit then proceed to the next
largest capacity circuit.
7) Operate all functions, one at a time, through
a complete cycle in the following order:
clam, steering, bucket, and boom. Also
include all auxiliary hydraulic functions.
Repeat procedure until the total system
capacity has circulated through filter caddy
seven times, approximately 30 minutes.
Each function must go through a minimum
of three complete cycles for a through
cleaning for oil.
※ Filtering time for machines with auxiliary
hydraulic functions must be increased
because system capacity is larger.
8) Stop the engine. Remove the filter caddy.
9) Install a new return filter element.
10) Check oil level in hydraulic oil tank ; Add oil
if necessary.
4-21
2. TEST TOOLS
1) CLAMP-ON ELECTRONIC TACHOMET-

ER INSTALLATION
· Service equipment and tools
Tachometer B
A : Clamp on tachometer.
Remove paint using emery cloth and
connect to a straight section of injec- C
tion line within 100 mm (4in) of pump.
Finger tighten only-do not over tighten.
D
B : Black clip (-). Connect to main
frame. A
C : Red clip (+). Connect to transducer.
D : Tachometer readout. Install cable.
75795SE32
2) DIGITAL THERMOMETER INSTALLATION

· Service equipment and tools
Digital thermometer
A : Temperature probe.
Fasten to a bare metal line using a A
C
tie band. Wrap with shop towel.
B
B : Cable.
C : Digital thermometer.
75795SE33
4-22
3. STEERING SYSTEM RESTRICTION TEST
· SPECIFICATION
Oil temperature 45±5˚C (113±9˚F)
Engine speed High idle
Maximum pressure 3.0MPa (30 bar, 430psi)
at steering unit
· GAUGE AND TOOL
Gauge 0~7 MPa (0~70 bar, 0~1000 psi) 2EA
· This test will check for restrictions in the
steering system which can cause overheat-
ing of hydraulic oil.
1) Install temperature reader.
(see temperature reader installation proce-
dure in this group).
P
2) Heat hydraulic oil to specifications.

(see hydraulic oil warm up procedure at
A
page 5-33).
3) Connect fitting (A) and install gauge.
Do not operate steering or loader funct-
ions or test gauge may be damaged.
4) Run engine at specification and read pres-
sure gauges.
If pressure is more than specification at the
steering unit, inspect steering unit for a pri-
ority valve spool. Make sure orifice plugs
installed in ends of priority valve spool. 850KSE37
4-23
4. STEERING UNIT LEAKAGE TEST
· SPECIFICATION
Maximum leakage 15ℓ/min (4 gpm)
· GAUGE AND TOOL Cap fitting
Temperature reader
Measuring container (approx. 20ℓ) T
L
Stop watch R
1) Install frame locking bar to prevent machine

from turning.
(see temperature reader installation proce-
dure in this group).
(see hydraulic oil warm up procedure at
page 5-33).
4) Disconnect return hose from fitting.
Install cap fitting.
5) Run engine at specifications. Rotate steer-
ing wheel against locking bar using approxi-
mately 1.2 kgf·m of force.
Measure oil flow from return hose for 1 min- Ssfety lock bar
ute.
6) Leakage is greater than specifications,
repair or replace steering unit.
850KSE38
4-24
5. STEERING UNIT PRESSURE TEST
· SPECIFICATION
Oil pressure 16 MPa
(160 bar, 1160 psi) EF CF
LS
· GAUGE AND TOOL Adjusting shim

P T
Gauge 0~35 MPa (0~350 bar, 0~5000 psi)
Priority valve
Temperature reader
1) Connect gauge to test port.
2) Install temperature reader (see installation
procedure in this group).
Test port
3) Install frame locking bar.
4) Heat hydraulic oil to specifications (see
hydraulic oil warm up procedure at page
5-33).
5) Run engine at specifications and turn steer-
ing wheel rapidly hold approximately 22N Steering cylinder
(5lb force) pressure on wheel with frames
locked.
※ If steering wheel is turned slowly, it will
continue to with the frames locked.
This will give an incorrect pressure read-
ing.
If steering wheel continues to turn rapidly
with the frames locked, steering system
leakage is indicated.
6) Read pressure gauge. This is the steering Safety lock bar
valve relief pressure.

7) If pressure in not to specification, turn
adjusting shim in relief cartridge using a
hex head wrench to adjust pressure.
If pressure cannot be adjusted to specifica-
tion, disassemble and inspect priority valve. 850KSE39
4-25
6. PRIORITY VALVE "LS" PORT FLOW TEST
· SPECIFICATION
Engine speed LowHigh idle
LS port flow (approx) 0.5ℓ/min (0.13 gpm)
· GAUGE AND TOOL
Temperature reader
Measuring container
Stop watch
Priority valve LS port flow test will check for
a plugged or missing orifice in the priority
valve spool. A plugged orifice will block
warm up flow to the steering unit which can
cause thermal shock (see for an explana- A
tion of thermal shock, page 4-18).
LS
A missing orifice can cause the pump to be
loaded to high pressure at all times causing
overheating.
1) Install temperature reader (see temperature Priority valve
reader installation procedure in this group.). B
hydraulic oil warm up procedure at page
5-33.)
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.
7) If flow is low, low steering system neutral
pressure or a plugged orifice in priority
valve spool is indicated.
If flow is high, remove priority valve spool
and inspect for a missing orifice.
Do hydraulic system restriction test in this
group. 850KSE40
4-26
Group 1 Hydraulic circuit --------------------------------------------------------------------------------------------------- 5-1

Group 2 Structure and function ---------------------------------------------------------------------------------------- 5-8
Group 3 Operational Checks and Troubleshooting -------------------------------------------------------- 5-21
Group 4 Test and Adjustments ----------------------------------------------------------------------------------------- 5-31
GROUP 1 HYDRAULIC CIRCUIT
1. HYDRAULIC CIRCUIT
4 5 6
3 LH RH
R L
8
P T LS
11
7
1
13
14 2
10
12
850K3HC01
1 Main pump 6 Steering cylinder 11 Orifice fitting

2 Steering pump 7 Priority valve 12 Bypass valve
3 Main control valve 8 Steering unit 13 Air breather
4 Boom cylinder 9 Oil cooler 14 Hydraulic tank
5 Bucket cylinder 10 Return filter
5-1
2. WORK EQUIPMENT HYDRAULIC CIRCUIT
4 5
B2
A2
B1
A1
P T
11
1
13
Steering system
14
10
12
850K3HC30
1 Main pump 10 Return filter

3 Main control valve 11 Orifice fitting
4 Boom cylinder 12 Bypass valve
5 Bucket cylinder 13 Air breather
9 Oil cooler 14 Hydraulic tank
5-2
1) WHEN THE BOOM CONTROL LEVER IS IN THE RAISE POSITION
4 5
B2
A2
B1
A1
P T
11
1
13
Steering system
14
10
12
850K3HC21
· When the boom control lever is pulled back, the boom spool is moved to raise position.
· The oil from main pump (1) flows into main control valve (3) and then goes to the large chamber of
boom cylinder (4).
· The oil from the small chamber of boom cylinder (4) returns to hydraulic oil tank (14) through the
boom spool at the same time.
· When this happens, the boom goes up.
5-3
2) WHEN THE BOOM CONTROL LEVER IS IN THE LOWER POSITION
4 5
B2
A2
B1
A1
P T
11
1
13
Steering system
14
10
12
850K3HC22
· When the boom control lever is pushed forward, the boom spool is moved to lower position.
The oil from main pump (1) flows into main control valve (3) and then goes to small chamber of
· boom cylinder (4).
The oil returned from large chamber of boom cylinder (4) returns to hydraulic tank (14) through the
· boom spool at the same time.
5-4
3) WHEN THE BOOM CONTROL LEVER IS IN THE FLOAT POSITION
4 5
B2
A2
B1
A1
P T
11
1
13
Steering system
14
10
12
850K3HC23
· When the boom control lever is pushed further forward from the lower position, then the boom
spool is moved to floating position.
· The work ports (A2), (B2) and the small chamber and the large chamber are connected to the
return passage, so the boom will be lowered due to it's own weight.
· In this condition, when the bucket is in contact with the ground, it can be move up and down in
accordance with the shape of the ground.
5-5
4) WHEN THE BUCKET CONTROL LEVER IS IN THE DUMP POSITION
4 5
B2
A2
B1
A1
P T
11
1
13
Steering system
14
10
12
850K3HC24
· If the bucket control lever (4) is pushed forward, the bucket spool is moved to dump position.
· The oil from main pump (1) flows into main control valve (3) and then goes to the small chamber of
bucket cylinder (5).
· The oil at the large chamber of bucket cylinder (5) returns to hydraulic tank (14).
· When this happens, the bucket is dumped.
5-6
5) WHEN THE BUCKET CONTROL LEVER IS IN THE ROLL BACK ((retract
retract)) POSITION
4 5
B2
A2
B1
A1
P T
11
1
13
Steering system
14
10
12
850K3HC25
· If the bucket control lever is pulled back, the bucket spool is moved to roll back position.
· The oil from main pump (1) flows into main control valve (3) and then goes to the large chamber of
bucket cylinder.
· The oil at the chamber of bucket cylinder (5) returns to hydraulic tank (14).
· When this happens, the bucket roll back.
5-7
1. MAIN PUMP
1) STRUCTURE
3
14
15 4
6
7
8
9
10
16 11
12
13
17
850KMP10
1 Snap ring 7 Seal 13 Driven gear

2 Dust seal 8 Seal 14 Rivet
3 Bearing 9 Seal 15 Name plate
4 Shaft seal 10 Seal 16 Housing
5 Front cover 11 Wear plate 17 Bolt
6 Bearing 12 Drive gear
5-8
2) MOUNTING REQUIREMENTS FOR GEAR PUMP
(1) Before mounting the gear pump, check its normal rotating direction and for being suitable to
whole system.
(2) Entry of gear pump should keep clean and no pollution. Interfacing surface of entry and discharge
should not be damaged and good sealing with O-ring seal should be guaranteed.
(3) Check if the depth of mounting hole for gear pump is longer than the length of the shaft of pump
so to prevent potential impact to the shaft and gear pump from burning out. Key shaft should be
assembled normally.
3) NOTES IN USING
(1) It’s strictly prohibited for user to disassemble the product, or the manufacturer will not guarantee
the performance of product.
(2) Viscosity of oil is dependant to temperature. When oil temperature increases, its viscosity
decreases. Therefore, oil temperature should be maintained under 80˚C. To secure the gear pump
working normally under different operating temperature, selected oil should feature little change
by variation of temperature, and have good chemical durability and foam resistance. Use of ISO
VG46 (ISO VG32, ISO VG68) anti-wear hydraulic oil is recommended.
(3) No impurities from machine and corrosive substance should be in oil. There should be filtering
devices with a precision of 25 µm in the system where the gear pump is working for.
(4) For transmission of gear pump, the manners that may produce radial force to pump (such as
direct geared and pulley transmission) are not permitted. Shaft bushing or elastic coupling can be
used. Requirements for concentricity: not more than 0.05 mm for shaft bushing type, no more than
0.1 mm for coupling type. Axial force is not permitted.
(5) The entry and discharge of gear pump should be assembled securely and sealing be reliable. Or
air may be included and oil leaks caused to lower the performance of gear pump.
(6) Max. pressure and max. rate of gear pump means momentary peak values permitted during
operation. Long time of continued use of gear pump may shorten its life span.
(7) Check if the depth of mounting hole for gear pump is longer than the length of the shaft of pump
so to prevent potential impact to the shaft and gear pump from burning out.
(8) Before mounting the gear pump, check the rotating direction of pump meets requirement.
5-9
4) TROUBLESHOOTING
Noise in pump Air in system. Fasten up all the connectors.
Insufficient oil supply. Refill oil to an adequate level.
Cold oil. Run slowly.
Contaminated suction filter. Clean or replace the filter.
Too thin suction pipe. Use a larger pipe.
Suction pipe is clogged. Remove the obstruction.
Clogged air filter in oil tank. Clean or replace the air filter.
Poor concentricity of pump and Inspect.
input shaft.
Severe resonance with tank, Check piping, elements and bolts for
peripheral parts of piping. being securely fastened.
Pump lags in response or no Insufficient oil supply. Refill oil to an adequate level.
response Improper pressure setting of Regulate the pressure of relief valve.
relief valve.
Worn or damaged pump. Repair or replace.
Worn, leaking or stuck valve. Repair or replace.
High oil temperature Too low pressure setting at Regulate pressure of overflow valve.
overflow valve.
Too low viscosity of hydraulic oil. Use recommended hydraulic oil.
Too low oil level. Refill oil to an adequate level.
Small tank. Add an oil cooler or replace with larger
tank.
Worn or damaged pump. Repair or replace.
Foam forms in oil Air has entered into oil tank Fasten up all the connectors.
through suction pipe.
Incorrect selection of oil. Use recommended oil.
Too low oil level. Refill oil to an adequate level.
Worn or damaged lip seal for Replace the lip seal for main shaft.
main shaft.
5-10
Insufficient
nsufficient flow of pump or Damaged side plate. Replace side plate.
pressure
Air has entered into the system. Fasten up all the connectors.
Too high viscosity of oil. Use recommended oil.
Leaks occur even after replacing Contaminated oil. Change all the oil.
lip seal for main shaft Damaged lip seal for main shaft Replace drive gear shaft.
has damaged the sealing area of
drive gear.
Worn or damaged seal ring. Replace seal ring.
5) NOTICE IN PLACING ORDER
TURN RIGHT TURN LEFT

(CLOCKWISE) (COUNTER CLOCKWISE)
850K3HC52
5-11
2. MAIN CONTROL VALVE
1) STRUCTURE
13 44 45 46 47 48 12 49
A
B
43
42
41 50
40 11
C C
39
10
38
37 9,17
36 16,17
35 8
7
B 5
6 51 A
4 5
SECTION A-A
34
52
33
32 3
31
14 15
SECTION C-C SECTION B-B

850KSE17
1 O-ring 15 Relief valve 41 Stopper

2 O-ring 16 Bolt 42 Spring
3 O-ring 17 Washer 43 Spring retainer
4 Ball 31 Plug 44 Spool
5 O-ring 32 Spring 45 Spool
6 O-ring 33 Poppet 46 Plug
7 O-ring 34 Body 47 Poppet
8 Dust seal 35 Spool 48 Spring
9 Bolt 36 End cover 49 Plate
10 Snap ring 37 Spring 50 Pin
11 Ring 38 Spacer 51 Plug
13 Relief valve 39 Spacer 52 Plug
14 Plug 40 Spring retainer
5-12
SAFETY RELIEF VALVE
20 2 21 22 3 23 4 24 5 6 25
19 18 17 16 15 14 13 12 1 11
850KSE18
1 Seal 12 Back up seal 19 Adjust screw

2 Lock nut 13 Spring seat 20 Cap
3 Seal 14 Spring seat 21 Body
4 O-ring 15 Poppet 22 Washer
5 Seal 16 Spring 23 Spring seat
6 Seal 17 Housing 24 Spring seat
11 Seat 18 Nut 25 Spring
5-13
2) OVERVIEW
Multi-way directional valve is of integrated slide valve structure which includes 2 spools valve
(bucket and boom spool) and triple multi-way valve (service spool, bucket spool, boom spool). Oil
ways include parallel and series connection. Multi-way valve has also various service valves
(overflow valve, overload valve, makeup valve) attached. As a hydraulic device for main equipment
of large and medium loader, the valve features compact structure, reliable functions, high
performance, good sealing, and convenient repair.
3) MODEL IDENTIFICATION
DFS - XX -XX
Product code
inner diameter
Series code
4) TECHNICAL DATA
Item Unit Specification

Nominated flow ℓ/min 250
Nominated pressure MPa 16
Pressure regulating range MPa 8 ~ 20
Center MPa <0.3
Pressure loss
Direction change MPa <0.6
Pressure regulating range of overload valve MPa 8 ~ 25
5-14
5) STRUCTURE AND WORKING PRINCIPLE
(1) Structure
A
Retract (roll back)

Neutral
Dump
Bucket
Boom
Float
Lower
Neutral
Lift
Section A - A
A
850K3HC51
(2) Working Principle
B2
BOOM A2
B1
BUCKET
A1
P T
Hydraulic circuit
850K3HC50
The Multi-way directional valve has boom control lever and bucket control lever. The bucket lever
has three positions, i.e. neutral, roll back and dump. Boom lever has four positions, i.e., hold,
raise, lower and float. Port P is flow inlet, T is flow return port and port A1 and B1 are connected
to large and small chamber bucket cylinder respectively, and port A2 and B2 are to large and
small chamber of boom cylinder.
5-15
① Neutral position
When bucket control lever and boom control lever are in neutral positions, the flow from pump
returns from inlet port P to tank through middle oil way.
② Bucket roll back and dump
When bucket control lever is shifted to back, the flow from pump opens one-way valve, and is
directed to A1 cavity, then to large chamber of bucket cylinder to make the bucket roll back, while
the flow in small cavity returns through cavity B1. Similarly, when bucket lever is shifted to
forward, the flow from pump opens one-way valve, and is directed to cavity B1, then to small
chamber of bucket cylinder to make the bucket dump, while flow in large chamber return through
cavity A1.
③ Float of Boom
When the boom control lever is shifted to back, the flow from pump opens one-way valve, and is
directed to cavity A2, then to large chamber of boom cylinder to make the boom to raise, while
the flow in small chamber returns through cavity B2. Likewise, when the boom control lever is
shifted to forward, the flow from pump opens one-way valve, and is directed to cavity B2, then to
small chamber of boom cylinder to make the boom to lower, while the flow in large chamber
returns through cavity A2. When the control lever of boom is in lower, move it further to forward
to get in float position. At the time, all of inlet port P and large and small chambers of cylinder are
connected to return way, and become under low pressure, and the cylinder is floating by the
weight of working equipment and bearing force of ground.
④ Function of main relief valve, overload valve and makeup valve
Main relief valve controls pressure in system. When pressure in system exceeds rated pressure,
the main relief valve opens and the flow returns to tank to protect the hydraulic system against
over pressure. When the bucket receives external impact or is interfered with by other
mechanism, overload valve opens for safety. Makeup valve functions to make up oil for cylinder
to prevent a chamber to be evacuated.
6) MOUNTING AND AND USING
(1) When transporting, mounting, and storing the product, be careful that the product does not
receive impacts that may damage the machined surface or flange face.
(2) Never disassemble the product in dust before assembling to machine to prevent dust from
entering.
(3) Check that rated pressure, sliding function, oil-way type and other features conform to system
requirements.
(4) Mounting plate should be level, mounting screws fastened in even torque, and the valves should
be in good alignment.
(5) Operating fluid should be clean, cleanliness meeting NAS 1638 10 grade and up.
(6) Allowable oil temperature range: -20 ~ 80˚C, normal oil temperature 50±5˚C.
(7) Connect each port correctly and piping shall not be too thin, too long.
(8) Our company offers three-guarantees to the product for one year from delivery for any
malfunctions resulted from problem in workmanship in case the user would have observed the
provisions given with regard to storage, use, installation and transportation.
5-16
7) TROUBLESHOOTING
No. Problem Cause Remedy
Insufficient operating 1. Pressure of main relief valve is on 1. Regulate pressure of main relief
pressure low side. valve.
2. Spool of main relief valve is stuck. 2. Remove and clean, or replace

valve spool.
1 3. Damaged pressure regulating 3. Replace with new product.

spring.
4. Too much pressure loss in system 4. Replace piping, or regulate

line. pressure of main relief valve within
the allowable range of pressure.
Insufficient operating 1. Oil supply to system is insufficient. Check oil source and repair oil pump.
flow 2. Too much leaks inside valve.
a. Too high oil temperature, low a. Take measures to reduce oil
viscosity temperature.
2 b. Improper hydraulic oil. b. Change hydraulic oil.

c. Too much clearance between c. Replace slide valve to keep a
slide valve and valve body. reasonable clearing.
3. Main relief valve failure. 3. Repair or replace the main relief

valve.
Malfunction in return. 1. Damaged or deformed return 1. Replace with new product.
spring.
3
2. Dirt between valve lever and valve 2. Clean part.
body.
External seeps and 1. Damaged seal ring. 1. Replace with new product.
leaks 2. Loose fastening pieces. 2. Fasten related fastening piece.
3. Too high oil temperature, low 3. Takes measures to reduce oil
4 viscosity temperature.
4. Poor sealing on flange surface. 4. Check fastening and sealing of

related parts.
5-17
8) NOTES IN DISASSEMBLY
(1) Keep clean field for assembly. Dust and dirt shall be strictly prevented.
(2) Never clean rubber sealing pieces with gasoline.
(3) To prevent from damage to part, never knock a part with an iron object when disassembling.
(4) Be sure to clean all the parts with kerosene or cleaner before assembling.
(5) After assembling, be sure to perform test and only passed product can be used.
5-18
3. BOOM CYLINDER
10
29
11
12
11
30
25
13
16
32
16
6
26 27
9
28
8 15
1
2
21
3
4
31
22
7
14 23
5
6
24
15
27
9
8
850KSE19E
1 Snap ring 11 Wear ring 25 Tube assembly

2 Dust wiper 12 Piston seal 26 Rod assembly
3 Rod seal 13 Set screw 27 Pipe clamp
4 Buffer ring 14 Socket bolt 28 Pipe assembly
5 Snap ring 15 Socket bolt 29 Piston
6 O-ring 16 Dust seal 30 Lock nut
7 Back up ring 21 Back up ring 31 Gland
8 Hexagon bolt 22 O-ring 32 Pin bushing
9 Spring washer 23 Du bushing
10 O-ring 24 Pipe assembly
5-19
4. BUCKET CYLINDER
21
30
21 22
1
2
23
3
4
19
20
24
25
11 5
7 31
27 18 26
17 6
9
8
9
28
14 34
33
15
10 16
34
15 21
16 30
13 21
12
29
11
32
18
17
850KSE20E
1 Snap ring 13 Spring washer 25 O-ring

2 Dust wiper 14 Hexagon bolt 26 Du bushing
3 Rod seal 15 Spring washer 27 Piston
4 Buffer ring 16 Hexagon nut 28 Lock nut
5 Back up ring 17 Socket bolt 29 Tube assembly
6 Snap ring 18 Spring washer 30 Pin bushing
7 O-ring 19 Socket bolt 31 Pipe assembly
8 Piston seal 20 Spring washer 32 Pipe assembly
9 Wear ring 21 Dust seal 33 Band assembly
10 Set screw 22 Rod assembly 34 U-bolt
11 O-ring 23 Back up ring
12 Hexagon bolt 24 Gland
5-20
GROUP 3 OPERATIONAL CHECKS AND TROUBLESHOOTING
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 2.
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 4 : Tests and adjustments
5-21
※ Hydraulic oil must be at operating temperature for these checks.

Hydraulic system warm-up Hold a hydraulic function over OK
procedure relief to heat oil (don't keep relief Check completed.
condition over 5 seconds at a
time).
Refer to page 5-33.
Periodically cycle all hydraulic
functions to distribute warm oil.
Repeat procedure until oil is at
operating temperature.
FEEL : Hydraulic reservoir must
be uncomfortable to hold your
hand against.
(approximately 40 ~50˚C)
Hydraulic pump With bucket flat on ground, OK
performance check actuate boom raise. Time how Check completed.
long it takes to raise boom to full
Heat hydraulic oil to NOT OK
height.
operating temperature. C h e ck t h e hy d r a u l i c
Run engine at high idle. LOOK : Boom must raise to full pump.
height in less than 7 seconds.
IF OK
Do steering system
leakage check at page
4-29.
IF OK
Do main hydraulic pump
flow test at page 5-34.
Control valve lift check With bucket partially dumped, OK
Run machine at low idle. lower boom to raise front of Check complete.
machine.
NOT OK
Slowly move boom control lever Repair lift checks in
to boom lower position. loader control valve.
Slowly move bucket control lever
to bucket dump position.
LOOK : Boom must not raise
before moving down.
Bucket must not rollback before
dumping.
5-22
Bucket rollback circuit relief Position bucket at a 45˚ angle OK
valve check against an immovable object. Check complete.
Engage transmission in 2nd NOT OK
speed forward. Replace boom lower
check valve.
LOOK : Bucket angle must not
change.
Bucket dump circuit relief Raise front of machine which OK
valve low pressure check bucket at 45˚ angle. Go to next check.
Backdrag with bucket while NOT OK
observing bucket angle. Do loader system and
circuit relief valve test at
LOOK : Bucket must not rollback
page 5-36.
Boom cylinder and bucket S e t t h e b o o m a n d bu cke t OK
cylinder drift check horizontal, then stop the engine. Check complete.
H e a t hy d r a u l i c o i l t o Stop the engine, wait for 5 NOT OK
operating temperature. minutes, then start measuring. Go to next check.
B
Measure the amount the lift and

A
dump cylinder rods retract during
15 minutes. (unloaded bucket)
A : Retraction of boom cylinder
rod
B : Retraction of bucket cylinder
rod
B Boom cylinder must drift less
than 25 mm
A
Bucket cylinder must drift less
than 40 mm
5-23
Boom cylinder leakage Dump bucket until teeth or cutting OK
check edge is perpendicular to the Drift is approximately the
ground. same between first and
H e a t hy d r a u l i c o i l t o
second measurement.
operating temperature. Raise boom until cutting edge is
about 1 m (3 ft) above ground.
Repair loader control
Stop engine. Measure drift from valve or circuit relief valve.
tooth or cutting edge to ground
for 1 minute. NOT OK
If drift is considerably less
Wait 10 minutes.
on second measurement,
Measure drift from tooth or repair cylinder.
cutting edge to ground for 1
minute.
LOOK : Compare the drift rate
between the first measurement
and the second measurement.
Bucket cylinder leakage Raise bucket about 1 m (3 ft) off OK
check ground with bucket level. Drift is approximately the
same between first and
H e a t hy d r a u l i c o i l t o Stop engine. Place a support
second measurement.
operating temperature. under boom.
Measure drift from tooth or Repair loader control
cutting edge to ground for 1 valve or circuit relief valve
minute. at page 5-36.
Wait 10 minutes.
NOT OK
Measure drift from tooth or Drift is considerably less
cutting edge to ground for 1 on second measurement.
minute.
Repair cylinder.
LOOK : Compare the drift rates
between the first measurement
and the second measurement.
Check valve of safety valve Put bucket level and position OK
leakage check about 1.2 m (4 ft) above ground. Check complete.
H e a t hy d r a u l i c o i l t o Place a piece of tape on cylinder
NOT OK
operating temperature. rod at least 51 mm (2 in) from rod
Check or replace safety
guide.
valve.
Run engine at low idle in safety-
release position.
LOOK : Bucket must not drift up.
Control lever check Stop engine. Turn key switch to OK
OFF position. Check completed.
Move bucket control lever to roll
NOT OK
back, dump positions and then
Repair bucket control
release.
lever.
LOOK : Lever must return to
neutral when released from roll
back, dump positions.
5-24
Cycle time check Function Operating condition. Maximum cycle time
H e a t hy d r a u l i c o i l t o Boom raise Bucket flat on ground to full 5.8 sec
operating temperature. height.
Boom lower Full height to level ground. 3.7 sec
Bucket dump Boom at full height. 1.1 sec
Bucket rollback Boom at full height. 1.7 sec
Steering [No. of Frame stop to frame stop. 4.5 turns
turns]
OK
Check complete.
NOT OK
Go to slow hydraulic
functions in group 3.
5-25
※ MEASURING BOOM AND BUCKET CYCLE TIME
1) MEASUREMENT CONDITION
·Coolant temperature : Inside operating range
·Steering position : Neutral
·Hydraulic temperature : 40~50˚C
·Bucket : Unloaded
·Engine speed : High idling
2) MEASU
MEASURING
RING TOOL
· Stop watch (1EA)
3) MEASURIN
MEASURING G PROCEDURE
(1) Lifting time of boom Lifting time of boom
Set the bucket near the maximum tilt back
position and at the lowest position on the
ground. Raise the bucket and measure
the time taken for bucket to reach the
maximum height of the boom.
850KWE35
(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.
850KWE36
(3) Dumping time of bucket

Raise the boom to the maximum height Dumping time of bucket
Rollback time of bucket
and measure the time taken for the bucket
to move from the maximum tilt back
position to the maximum dump position
(4) Roll back time of bucket
Raise the boom to the maximum height
and measure the time taken for the bucket
to reach the maximum tilt back position. 850KWE37
5-26
2. TROUBLESHOOTING
※ Diagnose malfunction charts are arranged from most probable and simplest to verify, to least likely,
more difficult to verify. Remember the following steps when troubleshooting a problem :
Step 1. Operational check out procedure (see section 1)

Step 2. Operational checks (see group 3)
Step 3. Troubleshooting
Step 4. Tests and adjustments (see group 4)

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 3. Do hydraulic pump flow test
in group 4.
No or Slow hydraulic Failed or worn hydrualic pump. Do performance check.
functions
Cold oil. Warm oil up.
Slow engine speed. Adjust engine speed.
Check high idle speed.
Suction line air leak. Check for foamy oil.
Low oil supply. Add recommended oil.
Wrong oil viscosity. Use recommended oil.
Oil leaking past cylinders or control Check cylinder drift in group 3.
valve.
Blocked or damaged line. Inspect lines.
Binding loader control valve (MCV) Inspect valve.

spool.
5-27
No steering or hydraulic Low oil level. Add recommended oil.
function
Failed hydraulic pump. Remove and inspect return filter for
metal pump particles.
No hydraulic functions Failed hydraulic pump. Remove and inspect return filter for
steering normal metal pump particles, or replace the
pump.
Stuck open port relief valve. Replace relief valve.
Boom float function Loader control valve (MCV) spool Do pressure reducing valve pressure
does not work binding in bore. test.
One hydraulic function Stuck open port relief valve. Replace relief valve.
does not work.
Oil leaking past cylinder packings. Do boom and bucket cylinder leakage
test in group 4.
Inspect lines for damage.
Blockage in oil lines or valve.
Disconnect and inspect lines for internal
blockage.
Loader control valve (MCV) spool stuck Inspect and repair valve.
in bore.
Low hydraulic power Leakage within work circuit. Do cylinder drift check in group 3.
Low system relief valve (main relief Do loader system and port relief valve
valve) setting. pressure test in group 4.
Low port relief valve setting. Do loader system and port relief valve
pressure test in group 4.
Leaking system relief valve. Remove and inspect valve.

Worn hydraulic pump. Do hydraulic pump performance check
in group 3.
5-28
Function drifts down Leaking cylinders. Do cylinder leakage checks in group 4.
Leaking seals in circuit relief valve (port Inspect seals. Replace relief valve.
relief valve) or valve stuck open.
Leaking loader control valve (MCV). Repair or replace valve section.
Boom drifts up Leakage in boom down spool. Remove and inspect boom down spool.
Boom down does not MCV spool stuck. Inspect and repair valve.
work (engine off)
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 4.
Plugged fins in oil cooler. Inspect and clean oil cooler.
Internally plugged oil cooler. Do hydraulic oil cooler restriction test.
Incorrect system or circuit relief valve Do loader system and circuit relief valve
setting. pressure test in group 4.
Restriction in oil lines or loader control Inspect for dented or kinked lines.
valve (MCV).
Malfunctioning steering unit. Do hydraulic system restriction test in
group 4.
Leaking system main relief valve. Do hydraulic system restriction test in
group 4.
Remove and inspect valve and seals.
Worn hydraulic pump (internal leakage). Do hydraulic pump performance check
in group 3.
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).
5-29
※ Followings are general precautions for the hydraulic system and equipment.
1) Every structure has its limit of strength and durability. The relief valve is installed to limit the
pressure on the hydraulic equipment and protect various parts of the wheel loader from possible
damage. Therefore, never change the preset pressure of the relief valve unless absolutely
necessary.
2) Since the hydraulic equipment is built with precision, the presence of only the slightest amount of
dust and / or other particles in the hydraulic circuit might cause wear and/or damage, resulting in
unstable functions and/or damage, resulting in unstable functions and/or unexpected accidents.
Therefore, always keep hydraulic oil clean. Periodically, check the filter in the return circuit and
replace the element as necessary.
3) Extract about 200cc of hydraulic oil from the tank as a sample every 6 months. If possible, have it
analyzed by a specialist to confirm that the oil can still be used. Never extract the oil for sampling
until the oil temperature has become the normal operating temperature. Since the replacement
period varies depending on operating conditions, refer to Operator's Manual and change oil.
4) Should the equipment get damaged due to the presence of metal particles and/or foreign matter in
the circuit drain out the hydraulic oil and carry out flushing. Also, replace the filter element and
clean the hydraulic tank. Change the hydraulic oil entirely.
5) When checking the filter, if found metal particles in the element, drain out the hydraulic oil entirely,
flush the whole circuit, and then fill with new oil. The presence of metal particles may indicate
internal damage to the equipment. In such a case, check carefully before flushing, and repair or
replace as required.
6) To add and/or change the hydraulic oil, always use recommended oil. (Refer to the list of
recommended oils and lubricants at page 1-19, Recommended lubricants.)
lubricants. Never mix oil of
different makes of kinds.
7) To change the hydraulic oil, use a clean vessel and funnel for pouring it into the tank. Never use
cloth because it might cause the presence of lint in the circuit.
8) When removing the hydraulic equipment, be sure to put plugs or caps on hoses, tube lines and
ports. Also, enter mating marks for later identification.
9) Disassemble and/or assemble the hydraulic equipment only in a clean place free of dust. When
disassembling, be careful about the interchangeability of parts, and clean the disassembled parts
with pure and clean mineral cleansing oil. Clean the internal passages as well. After the parts
have dried, wipe them off with a clean lint-free cloth.
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.
5-30
GROUP 4 TESTS AND ADJUSTMENTS
1. HYDRAULIC OIL CLEAN UP PROCEDURE USING PORTABLE FILTER CADDY

※ Service equipment and tool
·Portable filter caddy
·Two 4000 mm × 1in 100R1 Hoses
·Quick disconnect fittings.
·Discharge wand
·Various size fittings.
※ Flush all lines in the steering system and
cut off system. Disassemble and clean
major components for steering system.
Steering components may fail if steering
system is not cleaned after hydraulic oil
tank contamination.
1) If hydraulic system is contaminated due to a
major component failure, remove and
disassemble steering cylinders to clean
debris from cylinders.
2) Install a new return filter element. Inspect
filter housing before installing new element.
※ For a failure that creates a lot of debris,
remove access cover from hydraulic oil
tank. Drain and clean hydraulic oil tank of fill
the specified oil to hydraulic oil tank through
upper cover.
3) To minimize oil loss, pull a vacuum in
hydraulic oil tank using a vacuum pump.
Connect filter caddy suction line to drain
port at bottom of hydraulic oil tank using
connector. Check to be sure debris has not
closed drain port.
4) Put filter caddy discharge line into hydraulic
oil tank filler hole so end is as far away from
drain port as possible to obtain a thorough
cleaning of oil.
5-31
5) Start the filter caddy. Check to be sure oil is
flowing through the filters.
Operate filter caddy approximately 10
minutes so oil in hydraulic oil tank is
circulated through filter a minimum of four
times.
※ Hydraulic oil tank capacity : 150ℓ(39.6 U.S.
gal)
Leave filter caddy operation for the next
steps.
6) Start the engine and run it at high idle.
※ For the most effective results, cleaning
procedure must start with the smallest
capacity circuit then proceed to the next
largest capacity circuit.
7) Operate all functions, one at a time, through
a complete cycle in the following order :
Steering, bucket, and boom. Also include all
auxiliary hydraulic functions.
Repeat procedure until the total system
capacity has circulated through filter caddy
seven times, approximately 30 minutes.
Each function must go through a minimum
of three complete cycles for a through
cleaning for oil.
※ Filtering time for machines with auxiliary
hydraulic functions must be increased
because system capacity is larger.
8) Stop the engine. Remove the filter caddy.
9) Install a new return filter element.
10) Check oil level in reservoir; Add oil if

necessary.
5-32
2. TEST TOOLS
1) CLAMP-ON ELECTRONIC TACHOMETER

INSTALLATION
·Service equipment and tools
Tachometer B
A : Clamp on tachometer.
Remove paint using emery cloth and
connect to a straight section of injection C
line within 100 mm (4 in) of pump. Finger
Tighten only-do not over tighten.
D
B : Black clip ( - ). Connect to main frame.
C : Red clip (+). Connect to transducer. A
D : Tachometer readout. Install cable.
75795SE32
2) DIGITAL THERMOMETER INSTALLATION

·Service equipment and tools
Digital thermometer
A : Temperature probe.
Fasten to a bare metal line using a tie A
band. Wrap with shop towel. C
B : Cable. B
C : Digital thermometer.
75795SE33
3. HYDRAULIC OIL WARM UP PROCEDURE

1) Install temperature reader (see temperature
reader installation procedure in this group).
2) Run engine at high idle.
3) Hold a hydraulic function over relief to heat
the oil.
4) Periodically cycle all hydraulic functions to
distribute warm oil.
5) Heat oil to test specification (approx. 45˚C).
5-33
4. MAIN HYDRAULIC PUMP FLOW TEST
· SPECIFICATION
Engine speed 2200±25 rpm
Test pressure 190±5 bar (2760 psi)
Maximum pump flow 332ℓ/min (87.7 gpm)
· FLOW METER GAUGE AND TOOL
Gauge 0~35 MPa (0~350 bar, 0~5000 psi)
Temperature reader To MCV
1) Make test connections. Flow meter

(see temperature reader installation
procedure in this group)
(see hydraulic oil warm up procedure in this
group)
4) Run engine at test specifications. Main pump
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. 850KWE33
5-34
5. L
LOADER
ADER SYSTEM AND PORT RELIEF
VALVE PRESSURE TEST
· SPECIFICATION
Oil temperature (40~50˚C)
Relief valve Engine speed Relief pressure
190±5 kg/cm2
System (M) Low
(2700±70 psi)
M
Bucket 200±5 kg/cm2
Low
rollback (R) (2840±70 psi)
Bucket 130±5 kg/cm2
Low
dump (D) (1850±70 psi)
· Gauge and tool

Bucket
Gauge 0~35 MPa (0~350 bar, 0~5000 psi) Boom
M : System (main) relief valve R
D
R : Bucket rollback relief
D : Bucket dump relief
1) Install fitting and pressure gauge to test port
in pump delivery line.
MCV
group)
4) To check the system relief (M), run engine
at low idle. Lower boom to bottomed
position. Hyd tank
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.
※ Do not adjust the system relief valve above
190 kg/cm2 (2760 psi). Damage to the pump
will result from excessive pressure settings. 850KWE34
5-35
6. HYDRAULIC SYSTEM RESTRICTION TEST
· SPECIFICATION
Maximum pressure at steering unit
3 MPa (30 bar, 43 psi)
Maximum pressure at main control valve
1 MPa (10 bar, 145 psi)
· GAUGE AND TOOL
Gauge 0~7 MPa (0~70 bar, 0~1000 psi) 2EA
This test will check for restrictions in the
hydraulic system which can cause
overheating of hydraulic oil.
T
2) Heat hydraulic oil to specifications. Steering unit
group)
3) Connect fitting and gauge to steering valve.
4) Connect fitting and gauge to main control
valve.
Do not operate steering or loader funct-
ions or test gauge may be damaged.
T
5) Run engine at specification and read MCV
pressure gauges.
loader control valve, check for a kinked,
dented or obstructed hydraulic line. Check
loader control valve for a binding spool.
steering unit, inspect neutral condition of
the steering unit and priority valve for a
stuck spool. Make sure orifice plugs are
installed in ends of priority valve spool.
Check for plugged orifice in priority valve LS
port and dynamic signal orifice on the spool
of priority valve. 850KWE42
5-36
7. LOADER CYLINDER DRIFT TEST
· SPECIFICATION
Boom horizontal
Bucket horizontal
Bucket unloaded
Item Standard value
Retraction of boom
25 mm
cylinder rod
B
Retraction of bucket
40 mm
cylinder rod
· GAUG
GAUGE E AND TOOL
Stop watch A
Temperature reader
A : Retraction of boom cylinder rod
Put the safety lock lever in the lock
B : Retraction of bucket cylinder rod
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
7577AWE31
cylinder rods retract during 15 minutes.
5-37
8. BOOM AND BUCKET CYLINDER LEAKAGE TEST
· SPECIFICATION
Engine speed Low idle
Maximum leakage 15 mℓ/min (1/2 oz/min)
· GAUGE AND TOOL
Temperature reader
Stop watch
Measuring container
1) Fasten temperature sensor to head end
port of cylinder to be tested. Cover sensor
with a shop towel.
hydraulic oil warm up procedure in this
group).
Never work under raised equipment
unless it is supported with a hoist or
support stands.
3) Full extend the cylinder to be tested. If
testing the boom cylinders, restrain boom in
the fully raised position using a hoist or a
stand.
※ Check cylinders for leakage in the fully
extended position only. In the retracted
position contacts the end of the cylinder
and seals off piston seal leakage.
4) Remove and plug cylinder rod end hose or
line.
5) Run engine at slow idle. Activate control
lever to extend cylinder for 1 minute over
relief while measuring leakage for open
port.
If leakage is within specification, excessive
cylinder drift is caused by leakage in the
loader control valve or circuit relief valve. (770-3ATM) 6-56
5-38
9. CYCLE TIME TEST
· SPECIFICATION
Function Operating conditions Maximum cycle time (seconds)

Boom raise Bucket flat on ground to full height 5.8
Boom lower (float) Full height to ground level 3.7
Bucket dump Boom at full height 1.1
Bucket rollback Boom at full height 1.7
Steering (number of turns) Frame stop to stop 4.5 turns
Hydraulic pump performance cycle time.

Function Operating conditions Maximum cycle time (seconds)
Bucket flat on ground to full height
Boom raise 8.0
while holding steering over relief
5-39
10. HYDRAULIC OIL FILTER INSPECTION
PROCEDURE
1) Lower the bucket to the ground, stop the
engine, move the control lever back and
forth several times, and clean all over the
upper surface of the hydraulic oil tank.
2) Remove the bolts and take out the filter
case cover and O-ring.
3) Remove the spring and bypass valve.
4) Remove the filter element from the tank.
5) Check the element and the filter case
Cover
bottom for debris. Excessive amounts of O-ring
brass and steel particles can indicate a Spring
failed hydraulic pump or a pump failure in By-pass valve
process. A rubber type of material can
Return filter
indicated cylinder packing or other packing
failure.
※ The hydraulic oil filter in the filter case of
the hydraulic oil tank should be replaced
every 1000 operating hours or more
often. When the filter element is replaced,
please keep as follows.
(1) Clean the inside of the filter case.
(2) Place new element in the proper positions
inside the filter case.
(3) Install the bypass valve and spring. Make
sure the element stand upright, and check
for complete contact of the element
bottom with the filter case bottom.
(4) Install the O-ring and filter case covers.
Tighten them with bolt. Replace the O-ring
with new one if damaged. 850KWE40
5-40
Group 1 Component location -------------------------------------------------------------------------------------------- 6-1

Group 2 Electrical circuit ---------------------------------------------------------------------------------------------------- 6-3
Group 3 Monitoring system ----------------------------------------------------------------------------------------------- 6-4
Group 4 Connector ------------------------------------------------------------------------------------------------------------ 6-13
GROUP 1 COMPONENT LOCATION
1. LOCATION 1
10
Cab ceiling(LH)
1
11
Front
12
C
A
B
R
O
O
F
9
8
7
6
5
4 16
3
17 13 14 15
850K7EL02E
1 Beacon switch 8 Multi function switch 14 Battery volt meter and

3 Work lamp switch 9 Horn button hour meter
4 Front wiper/washer switch 10 Electric fan 15 Cigar lighter
5 Gear selector lever 11 Radio and MP3 player 16 Clutch cut off lever
6 Hazard switch 12 Aircon and heater switch 17 Parking brake lever
7 Cluster 13 Starting Switch
6-1
2. LOCATION 2
5 4 6
1 2 3
7
8
9
10
15 11
12
13
14 10 11
850K7EL02-1
1 Head lamp 6 Electric fan 11 Rear combi lamp

2 Horn 7 Coolant temperator sensor 12 Fuel sender
3 Multi function switch 8 Engine oil pressure sensor 13 Back buzzer
4 Work lamp 9 Work lamp 14 Battery relay
5 Beacon lamp 10 Battery 15 Air tank pressure switch
6-2
CN-55
WORK LAMP SW WIPER SW HAZARD SW
1
2
8
7
7
8
1
5
9
9
9
CN-56
2
(6) (1) (11) (7) (5) 751H
I
0 I
M
I 0 30 L R 57/58 H 862 862 ROr
BARO
6
METER
B
284D
E
Pf
Hi
Lo
0,
I G15J
1 2
1
4
5
6
4
10
2
3
10
CN-53
10 10
1
6
4
2
1
2
3
7
9
3
7
9
3
7
9
5
3
2
6
2
6
2
6
1
4
5
8
1
4
5
8
1
4
5
8
10
10
FRONT WIPER SW
CS-35
CS-36
E
CN-21
CS-41
BACKING
751G
CN-171
B
SOCKET
2
L
892 892 W
B
Y
B
B
SERVICE
Gr
R
R
R
G
W
7
Or
B
VOr
ROr
ROr
ROr
S
VOr
Or
GAUGE
BrW
BrW
284C
TC TEMP
L H G15I
LP
1 2
56b
261
311
261
301
293
352
363
360
362
226
234
211
211
360
362
352
56a
G26
G26
G26
G25
GEAR SELECTOR LEVER
290F
290C
(10)
500
(8) (9)
G06
CN-54
EARTH4
1
E
G01 751H
9
8
5
1
6
3
2
11
10
7
I
CS-45
878 878 Or
15
CS-11
S
GAUGE
Y
Y
B
R
284B
Or
GY
VW
WB
ROr
BrW
G15G
1 2
CN-22
FUEL LEVEL
B G02 CN-4
1
234
211
325
333
261
251
343
226
351
G26
Gr 361 361 Gr 363
M 2 1
FRONT
WASHER
CL-51A
223 223 Y
1
CR-30
87a
G15F B TURN LH
86 30
B G01 913 913A RW
11
85
V 321 751E CHARGE
1 2 1 2
87
Y 320 320 Y 325
86 2 CL-51B
85 87 87a
GROUP 2 ELECTRICAL CIRCUIT
ROr 250A
30 CL-52A
323 323 V
3
G15D B HIGH BEAM
CR-40
751E R
86 30 87a
B G01A 250 ROr 251 CN-56 872 Y 872 Y BRAKE LOW
1 2 1 2
10
85 3
GW 331 PRESSURE
87 CL-52B
VW 330 330 VW 333 226 Y
86 4 CL-26A
85 87 87a ROr 250 234 Or 472 472 VW
16
30
290 ROr 293 934 G 751D PARKING
5
HIGH BEAM RY LOW BEAM RY

863 ROr
CR-2
893 W
1 2 1 2
86 30 87a
13
B G01B 883 LW
85 CL-26B
VW 341 873 Y
87 CL-53A
GY 340 340 GY 343 914 RW 233 233 Or
4
86 6
85 87 87a
HORN RY
W 350A 350 W 352 904 Gr G15C TURN RH
30 7
751D
879 Or 933 933 G ENGINE OIL
5
1 2 1 2
CR-11 211
BrW 210 210 BrW 473 VW
1 4 5 6 7 9 10 11 12 13 15 16
L 87 8 CL-53B
G R 225
UNIT
B 85
B G01C 324 V
E 86
FLASHER
285 LW
8R 600 752 R
3 14 2
CN-52
E
FUSE BOX CN-37 751A

I
TEMP
20A WORK LMAP_FRONT GW 100 G26 B 903 903 Gr

8
1 12
ENGINE
20A WORK LMAP_REAR Gr 150 284 284A LW

COOLENT
2 14
20A STOP LAMP R 200 G15 G15A
3
1 2
20A HEAD LAMP ROr 250

8R 4 CN-51
20A WIPER & BACK BUZZER W 350 751
2
5
E
30A AIR-CON/HEATER 2R 400 751 R

6
I
20A CIGAR Or 450 923 923 Br

GAUGE BOARD SIDE
TM OIL
7
9
261
234
324
285
752
934
904
914
893
883
863
873
879
473
311
301
351
226
S
G25
30A
G26
SERVICE POWER1 R 500 284 LW
8
PRESSURE
20A COWL OPEN RL 530 G15

9
1 2
SIDE
B
B
Y
Y
20A ILL LAMP
G
G
256
W
ROr
DASH
Gr
Or
10
LW
WB
VW
RW
ROr
20A BEACON LAMP W 266
FRONT
8R 11
10A FAN CLUTCH Y 683
9
16
15
9
8
7
6
5
4
3
2
1
14
13
12
12
10
11
12
11
15
14
13
16
10
20A FUEL WARMER, PUMP 2 YB 693A
CN-4
CN-5
13
20A FUEL WARMER, PUMP 1 YB 693 2.0
Y
V
14
R
G
Or
Or
WB
Gr
LW
LW
30A
VW
IGNITION SWITCH
ROr
2Or 650
ROr
RW
15
RH
30A POWER RELAY
LH
2Gr 680
RH
16
FUSE BOX
10A
1
2
ROOM LAMP, RADIO(+)

8
7
9
SIDE
17
Y 700
230
876
471
280
750
932
902
912
891
881
861
871
321
260
354
220
310
300
10A TURN LAMP
G04
G01
18
R 225
SPEAKER
SPEAKER
20A AIRCON(+) L 425

19
30A SPARE
BEACON SW
20
5
6
30A SPARE
CONSOLE
21
10A GAUGE 24V R 750
10 10
3
7
9
2
6
22
1
4
5
8
1
2
2
1
10A
CN-24
RADIO(IG)
CN-23
G 800
CS-23
23
20A SPARE
L
W
24
LW
W
GY
RW
OR
20A SPARE CN-7

25
20A SPARE 400 R CN-7
1
26
704
703
283
G14
702
705
267
111
5A ILLUMINATION 1 LW 280 267

8
27
5A ILLUMINATION 2 ROr 290
28
800 G
280C LW
Br 270
CL-7
111 RW
2 3 4 5
2
2Br 670 G13A B
1
700 Y
BEACON
3R 550 266 W
110 RW
6 8 7
CN-27
801 801 G
CR-35 1 ACC
G14 B
2 5
86 30 87a 2 ILL-
B G01H
85 3 NC
RELAY
2Br 670 703 GY
POWER
87 4 SPK FRT RH-
R 667 702 L
86 5 SPK FRT LH-
85 87 87a 2Gr 680
30 6 TEL MUTE
7 ANT 12V
701 701 Y
CR-21 8 BACK UP+
283 283 LW
6 3
86 30 87a 9 ILL+
G01I
RADIE & MP3 PLAYER
85 10 NC
Br 270 704 OR
87 11 SPK FRT RH+
LAMP RY
R 260
86 12 REMOCON+
85 87 87a ROr 256 CN-9
CLEARLENCE
30 13 REMOCON GND
290A ROr 705 W
7
14 SPK FRT LH+

CR-3 15 NC
341 VW G14A B
3
86 30 87a 16 GND
B G01J
85
FRONT
RW 110
8
87
G 300
86 CL-1
85 87 87a GW 100 321 V 701A Y
5
30 2
WORK LAMP RY
G14
1
LAMP
280C LW
ROOM
CR-55 230 Or
2 6
86 30 87a AC-3
B G01K 411 411 R
1
85 2
REAR
R 160 331 GW G14 B
FAN
87 1
L 310 220 Y
4 1
86
85 87 87a Gr 150
30 CL-5
111 111 RW
WORK LAMP RY
2
CAB CHASSIS SIDE
G13A B
7 4
CR-63 1
86 30 87a
G01L
FRONT
85 CL-6
Br 203 G14 111A RW
87 2
G 205 G13B B
86 1
WORK LAMP
85 87 87a R 200B G13

EARTH7
30
STOP LAMP RY
CR-58
6-3
86 30 87a
WB 354
85
L 380 G02C B
87
BACK-UP
290E ROr
86
BUZZER RY
85 87 87a W 350 450 Or
CIGAR
30
CL-2
CN-26
Y 871
1
R 200A 650 2Or 1
2
H0 I
BUZZER
660A R
WARNING
2
0, I
660 R 4
H
3
4 1
B
START SWITCH
2
5 3
BR ACC
CN-11 663 2W 6
AC CONTROLLER GND
B G30
1 1 CS-2 5
B G30 6
ST C
2 BLOWER MOTOR GND 2

2R 400
3 AC 24V 3
4 NC 4 CN-48
A
L 425
5 AC CONTROLLER B+ 5
Y 448 HRM(-)
6 AC COMP 6 750 CL-3
BW 445 KEYSWITCH 332A GW G
7 AC CONDENSOR FAN 7 2 Lo
ROr 290 NC 322 V R
8 ILLUMINATION 8 2.0 1 Hi
NC G12B B B
G15B 3
CR-7 GND CN-9
448 912 RW
86 30 87a HRM(+) LW 282 282 LW Br
CHINA
ROr 447 447 750 2 1 C

85 24V B E
LW 446 446
650
693
657
692
657
660
1 2 3 4 5 6 7 8
G15
G15
87
COMP
NC Y 222 222 Y
RELAY
R 2
Y T
400 1
86
AIR-CON
85 87 87a R 400 444
HOURMETER & VOLTMETER
30 CL-24
CN-20
1.2B
1.2B
2.0Y
1.2R
1.2R
1.2R
1.2Or
G12A B
2.0YB
CR-33 1
342A VW
8 2
LOW
86 30 87a
HORN
BW 445
FAN
85
87
30
85
86
3
4
1
2
87a
BrW 444
FUEL
CR-96
87 CN-25
RELAY
G11B B
CN-125
R 400
AIRCON
86 1
85 87 87a R VW 342 342 VW
87a 87
30
400 3 2
GPS CONN.
30
HIGH
876
600
550
205
200
290
692
160
530
692
380
280
663
667
932
902
912
891
881
871
861
471
444
446
447
448
683
203
2
4
1
85
86
HORN
220A
230A
CONDENSOR
CL-4
WARMER & PUMP
GW 332 332 GW G
L
Y
CN-125A
Y
Y
Y
Y
Y
R
R
R
G
G
2 Lo
R
4
Br
Or
Or
Gr
8R
3R
RL
LW
2W
LW
LW
322
VW
RW
V 322 V R
ROr
ROr
ROr
BrW
5 1 Hi
G11 B B
R 668
668
3
4
7
2
8
5
9
7
3
1
8
6
9
5
6
2
1
4
3
1
12
2
10
15
13
14
15
13
14
12
11
10
11
CN-2
CN-3
CN-1
G12
G11
ROr 292 292 ROr Br

CHINA
Y
Y
Y
Y
Y
R
R
R
G
G
7 1 C
W
Y
Br
Or
Or
Gr
8R
3R
RL
FRONT FRAME SIDE
LW
2W
G11A B
VW
ROr
LW
ROr
B E
BrW
CN-83 Or 232 232 Or Y T

G08 6 2
877
470
601
551
684
204
202
201
221
291
691
161
691
352
231
281
664
661
931
901
RW 911
890
LW 880
870
ROr 860
531
441
440
449
443
G10 449 BrW

EARTH5
CL-25
FAN
G29 G25 B
1 2
EARTH3
AC COND
CN-12 CN-29
CN-79
G G10 2B 685 440 Y
G
9
665 2W 2W 664A 441
Pa
W
PRESS
P
1 2
ENGINE SIDE
8
SOL
SWITCH
AIR-CON
662 R R 661
FUEL
R
H
CB A
2
CUT OFF
CD-48
CD-18
OIL
880 LW
G 1
E
Pa
Pa
930 G G 931 1
PRESS
WK 3
TM OIL
AC-1 AC-11
PRESS
ENGINE
3
WOr 39 2
SENSOR
WB 15
CN-74
16 BW
1
INLET MOTOR(REC) 1 1
U
BW 38 3
G
BW 16
CN-45
2
CD-8 INLET MOTOR(FRE) 2 2
4
M
M
L 37 LR 17
~3
3
CD-26
INLET M/ACT
TEMP MOTOR ACT(+) 3 3

STARTER
900 Gr Gr 901 BOr 36 BG 5

TEMP
4 4 18
TEMP MOTOR ACT(-) 4 4
7
470 VW 6
˚C
G
D+
35 GL
B+
ALTERNATOR
5 19 15 WB
TEMP M/ACT(PBR) 5 5
M
COOLENT
B+
7
Pa
Y 34 Y 20
PRESS
6
MOTOR ACT(REF) 6 6
SWITCH
GY 33 GW 21
PARKING
7 17 LR
BW
MODE M/ACT(DEF) 7 7
1
15 R 1
BW 32 8 BG 22 20 Y
940
MODE M/ACT(FOOT) 8 8
RELAY
START
2
CR-23 WOr 31 WR 23
M
5W 9
910
MODE M/ACT(M+) 9 9 3
G29 B
4
LW 30 10 LB 24 18 BG
941
5 MODE M/ACT(M-) 10 10 4
666 W W 664 Y 29 YB
2
5R 6
11 25 19 GL
MODE M/ACT(PBR) 11 11 5
5
TEMP M/ACT
LW 28 12 LG 26
BLOWER RELAY(LO) 12 12 6
910 BW BW 911 YW 27 YBr 27 9A GB
7
13
7 BLOWER RELAY(M1) 13 13 7
BOr 26 14 BG 28
BLOWER RELAY(M2) 14 14
YW 25 15 YB 29 1
BLOWER RELAY(HI) 15 15
3
LW 24 16 LW 30 2
CD-4 COMPRESSOR(DPS) 16 16 21 GW
442 LW 443
COMP
1 VW Y 23 17 LY 31 3
10 CONDENSER FAN 17 17
AIR-CON
201 R 4
M
18
CN-28 18 18
LAMP
STOP
202 G
Pa
5
MODE(D/FOOT)
SWITCH
7
BrW 47 1 BR 1 6
GND 1 1 22 BG
BrW 46 2 BR 2 7
CD-3 GND 2 2
˚C RW 45 RW 3 23 WR
1
3
BATTERY(+) 3 3 1
G08 B 860 ROr
AIR
RW 44 RW 4 20A Y
CN-97
1
4
G BATTERY(+) 4 4 2
Pa
870 Y G 43 G
M
WK 5 5
ILLUMINATION 5 5 3
REAR FRAME SIDE
4
685 Y 42
FAN CLUTCH
R RY 6 24 LB
2
AC & HEATER CONTROLLER
6
POWER IG 6 6 4
PRESSURE
2
10A 7 25 YB
NC 7 7 5
5
CD-49
MODE(VENT)
BW 41 8 BrR 8
DUCT SENSOR(+) 8 8 6
G08 2B GW 40 GB 9 9B GB
7
890 W 9
DUCT SENSOR(GND) 9 9 7
TM
-
GND
Y 691 OrW 52
CONT.
FUEL
GB 10
˚C
CN-96
10
TEMP
+ 11 REVERSE FAN SIG 10 10

690 2Y 690 Y Y 691 26 LG
1
M
12 NC 11
11
11 Lo 1
IG
35 YW
NC 12
12
12 2 MH 3
PRE-FILTER
27 YBr
NC 13
13
13 3 ML 2
RESISTOR
36A L
1
14
NC 14 14 4 Hi 4
AC-2 AC-22 29 YB
2
1 2 1
1.25LgB 9
1 33 R
CN-71 1.25G 8 2
G09 B 2 6B RY
3
3
RELAY(HI)
531 RL 36 L
6
7A 4 4 3
DUCT SENSOR
552 3R 28 BG
1 2 1
5
6
COWL OPEN SWITCH

31
30
33
10
33A R
32
1,2
2
EARTH6
6A RY
669 R 3
601
552
RELAY(M2)
35 YW
G
352
LY
2B
231
2R
RY
BR
4 4 3
LW
204
221
291
281
161
RW
877
G28
G28
G28
G07
204A
G27
G07A
8R
3R
2
32 2B
L
CS-74
B
B
161A R
R
M
B
B
1
Y
B
B
Br
Or
Or
LW
Br
36 L
ROr
8
7
6
2
5
4
3
1
G25 2
1
2
CN-11
BLOWER
G27
2
1
2
2
1
1
CN-95
1
2
3
3
2
2
1
4
1
4
4
1
3
2
CD-2
CL-22
AIRCON
G09
CL-16
CL-23
CL-15
CN-65
2.0
CR-1
0.85
E
E
T
T
S
S
C
C
669 G07
G06B
6p : 1,6
G28
6p : 4,6
FUSIBLE LINK
M
BACK WORK WORK FUEL

669A
G06C
BUZZER LAMP LH LAMP LEVEL

B
REAR COMBI LH REAR COMBI RH RH

ENSOR
R
EARTH2
1
2
BATTERY RY
MSTER SWITCH(IF EQUIPPED)
DO-2
DIODE
BATTERY
EARTH1
850K7EL10
GROUP 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.
· Gauges : Indicate operating status of the machine.
· Warning lamp : Indicate abnormality of the machine.
· Pilot lamp : Indicate operating status of the machine.
※ The monitor installed on this machine does not entirely guarantee the condition of the machine.
Daily inspection should be performed according to chapter 6, Maintenance in operator's manual.
※ When the monitor provides a warning immediately check the problem, and perform the required
action.
Fuel gauge Parking brake warning lamp
High beam pilot lamp Right turning pilot lamp
Left turning pilot lamp
Battery charging warning lamp Engine oil pressure

Brake air pressure warning lamp warning lamp
Engine coolant temperature gauge

T/M oil pressure gauge
Brake air pressure gauge T/M oil temperature gauge
830K3CD02K
6-4
1) FUEL GAUGE
(1) This gauge indicates the amount of fuel in the fuel tank.
(2) Fill the fuel when the indicator moves 0 point, refuel as soon as
possible to avoid running out of fuel.
※ If the gauge indicates below 0 point even though the
machine is on the normal condition, check the electric
850K3CD04
device as that can be caused by the poor connection of
electricity or sensor.
2) ENGINE COOLANT TEMPERATURE GAUGE

Operating range (1) This gauge indicates the temperature of coolant.
·Red range : Above 100˚C (219˚F)
Red (2) If the indicator is in operating range, it is normal.
(3) Keep idling engine at low speed until the indicator is in the
operating range.
850K3CD05
(4) If the indicator is in the red range, turn OFF the engine, check
the radiator and engine.
3) TRANSMISSION OIL TEMPERATURE GAUGE

(1) This gauge indicates the temperature of transmission oil.
Operating range
·Red range : Above 120˚C (225˚F)
Red (2) If the indicator is in operating range, it is normal.
(3) Keep idling engine at low speed until the indicator is in the
operating range.
850K3CD07 (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.
4) TRANSMISSION OIL PRESSURE GAUGE

g (1) This gauge indicates the pressure of transmission oil.
tin Red
era ge
Op ran (2) If the indicator is in operating range, it is normal.
(3) If the indicator is in the red range, stop the engine and check
the transmission system.
850K3CD08
6-5
5) BRAKE AIR PRESSURE GAUGE
Oper (1) This gauge indicates the air pressure of service brake.
ating
range ·Red range : Below 0.4 MPa
Red
(2) If the indicator is in operating range, it is normal.
(3) If the indicator is in the red range, keep idling engine at low
speed until the operating range indicates.
850K3CD06
6) DIRECTION PILOT LAMP

(1) This lamp flashes when the signal indicator lever is moved.
(2) When the lamp lights up, the alarm (50 dB) sounds.
77073CD10
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.
77073CD12
8) PARKING BRAKE WARNING LAMP

(1) When the parking brake is actuated, the lamp lights ON.
※ Check the lamp is OFF before driving.
77073CD13
9) BRAKE AIR PRESSURE WARNING LAMP

(1) The lamp lights ON when the air pressure of service brake
drops below the normal range.
(2) When the lamp is ON, stop the engine and check for its cause.
※ Do not operate until any problems are corrected.
850K3CD16
6-6
10) ENGINE OIL PRESSURE WARNING LAMP
(1) This lamp is comes ON after starting the engine because of
the low oil pressure.
(2) If the lamp comes ON during engine operation, shut OFF
engine immediately. Check oil level.
77073CD18
11) BATTERY CHARGING WARNING LAMP

(1) This lamp is ON when key ON, it is turned OFF after starting
the engine.
(2) Check the battery charging circuit when this lamp comes ON
during engine operation.
77073CD22
6-7
2. SWITCH
Front
Cab ceiling (LH) Beacon switch
Starting switch
Horn button
Multi function switch
Hazard switch
Front wiper/washer switch
Work lamp switch
Engine cover switch

850K3CD29
1) STARTING SWITCH
(1) There are three positions, OFF, ON and START.
· (OFF) : None of electrical circuits activate.
· (ON) : All the systems of machine operate.
· (START) : Use when star ting the engine. Release key
immediately after starting.
77073CD41
6-8
2) HAZARD SWITCH
(1) Use for parking, or roading machine.
OFF
(2) Both turn signal lights will flash simultaneously.
ON
※ If the switch is left ON for a long time, the battery may be
discharged.
77073CD42
3) WORK LAMP SWITCH

(1) This switch use to operate the front and rear work lamps by two step.
·First step : Front work lamp located on the cab comes ON.
·Second step : Rear work lamp located on the cowl comes ON.
77073CD46
4) FRONT WIPER AND WASHER SWITCH

(1) The switch use to operate the front wiper and washer by two step.
·First step : The front wiper operates.
·Second step : The washer liquid is sprayed and the front wiper is
operated only while pressing. If release the switch,
return to the first step position.
77073CD47
5) BEACON SWITCH (option)

(1) This switch turns ON the rotary light on the cab.
77073CD50
6) HORN BUTTON
(1) If you press the button on the top of the multifunction switch, the horn
Horn button will sound.
850K3CD28A
6-9
7) CAB LAMP SWITCH
(1) This switch turns ON the cab room lamp.
73033CD24
8) MULTI FUNCTION SWITCH

(1) Dimmer switch
① This switch is used to turn the head lights direction.
② Switch positions
Up
·Up : To flash for passing
M ·Middle : Head lights low beam ON
Down ·Down : Head lights high beam ON
③ If you release the switch when it's in up position, the switch will return
850K3CD30
to middle
(2) Turning switch

① This switch is used to warn or signal the turning direction of the
Left turning
machine to other vehicles or equipment.
② Push the lever up for turning left, pull the lever down for turning right.
Right turning
850K3CD31
9) ENGINE COVER SWITCH

(1) This switch is used to open or close the engine cover.
(2) Turn the staring switch to the ON position, press the button.
·Green button : Open the engine cover
Green
Red ·Red button : Close the engine cover
830K3CD46
6-10
3. CONTROL DEVICE
Control lever Parking brake lever

Steering wheel Clutch cut off lever
Gear selector lever
Brake pedal
Accelerator pedal
850K3CD30-2E
1) CONTROL LEVER
(1) These levers are used to control the boom and the bucket.
Bucket
Boom
850K3CD36
2) GEAR SELECTOR LEVER

(1) This lever is used for gear selection, forward 2 stages and reverse 1
Forward 2nd stages.
Forward
1 1st (2) If you push the gear selector lever, the machine moves forward, but if
pull the gear selector lever, the machine moves backward.
Reverse 1st
1
850K3CD39
6-11
3) STEERING WHEEL
(1) Two multi-motion cylinders in the center of the machine will operate
Right
the steering function.
Left
(2) If the steering wheel is turned to left, the machine will move to the left
and turn it to the right, the machine will move to the right.
850K3CD33
4) BRAKE PEDAL
(1) If the pedal is pushed, this will generate braking force and bring the
machine to a stop.
(2) If the power train operation is to be cut off, set the clutch cut off lever
to ON position and press the pedal.
Even if the brake is applied while clutch cut off lever is OFF
850K3CD31-1
position,, power train will not cut off.
5) ACCELERATOR PEDAL
(1) This pedal controls the engine speed. The engine speed will
increase in proportion to the degree of force applied to this pedal.
(2) Unless this pedal is pressed, the machine will run at low idling.
850K3CD32
6) PARKING BRAKE LEVER

Parking brake lever (1) If this lever is pulled up, the parking brake will engage and the gauge
panel warning lamp will come ON.
※ When operating the gear selector lever, be sure to release the
PULL
parking brake. If the machine is operated with the parking brake
engaged, the brake will overheat and may cause the brake
PRESS system to go out of order.
850K3CD35
7) CLUTCH CUT OFF LEVER

(1) Push the lever to the ON position, it will cut off the clutch when brake
Clutch cut off lever
Å¬·¯Ä¡ Â÷´Ü ½ºÀ§Ä¡ operates.
OFF ※ Be careful not to use this lever when driving on a slope.
ON
850K3CD37
6-12
GROUP 4 CONNECTOR
1. MAIN HARNESS
Connector No. of
Type Destination Connector part no.
number pin
CL-2 HES 1 CIGAR S810-001202
S822-014000
S822-114000
CS-2 HES 6 START SWITCH S814-006000
CN-125 CHINA 4 GPS DJ7041-6.3-21
CN-125A CHINA 4 GPS DJ7041-6.3-11
CN-171 TYCO 2 SERVICE SOCKET 174198-1
CS-58 SWF 10 FAN 593757
CN-22 - 2 FRONT WASHER MG640605
CR-55 HELLA 5 WORK LAMP (FR) RELAY 8JA003526-001
CR-3 WORK LAMP (RR) RELAY
CR-40 LOW BEAM RELAY
CR-2 HORN RELAY
CR-63 STOP LAMP RELAY
CR-35 POWER RELAY
CR-21 CLEARANCE LAMP RELAY
CR-30 HIGH BEAM RELAY
CR-33 AIRCON CONDENSOR FAN RELAY
CR-7 AIRCON COMPRESSOR RELAY
CR-58 BACK UP BUZZER RELAY
CR-11 FLASHER UNIT RELAY
CN-37 - 20 FUSE BOX 21N8-20041
CN-26 TYCO 2 WARNING BUZZER 174198-1
CN-1 HES 2 REAR FRAME SIDE 1 S813-130200
CN-2 TYCO 15 REAR FRAME SIDE 2 368301-1
CN-3 TYCO 15 REAR FRAME SIDE 3 2-85262-1
CN-11 DEUTSCH 8 HEATER SIDE DT06-8S
EARTH4 KSC 2620 1 - R8-10
CN-9 CHINA 8 - DJ7081-6.3-21
CN-7 CHINA 8 - DJ7081-6.3-21
CN-4 TYCO 16 TO DASH 368047-1
CN-5 TYCO 15 TO DASH 85223-1
CN-48 MOLEX 8 HOURMETER & VOLTMETER 39-01-2085
6-13
2. CAB HARNESS
Connector No. of
number pin
CN-7 CHINA 8 CAB CHASSIS SIDE DJ7081-6.3-11
CL-7 TYCO 2 BEACON 174198-1
CN-23
KET 2 SPEAKER 7123-1520
CN-24
CL-1 - 3 ROOM LAMP MG651032
CN-27 - 16 RADIO & MP3 player PK145-16017
CL-5 DEUTSCH 2 WORK LAMP FRONT DT06-2S
CL-6 DEUTSCH 2 WORK LAMP FRONT DT06-2S
CS-23 SWF 10 BEACON SWITCH 593757
EARTH7 KSC 2620 1 RING TERMINAL R3-10
AC-3 - 2 FAN DJ7021-6-3-10
3. DASHBOARD HARNESS
Connector No. of
number pin
CS-11 TYCO 11 TURN LEVER 172497-1
CN-21 TYCO 6 FRONT WIPER 936257-1
CS-41 SWF 10 HAZARD SWITCH 593757
CN-56 TYCO 16 GAUGE BOARD SIDE 368047-1
CN-4 TYCO 16 TO MAIN 368050-1
CN-5 TYCO 15 TO MAIN 2-85262-1
CS-35 SWF 10 WIPER SWITCH 593757
CS-36 SWF 10 WORK LAMP SWITCH 593757
CS-45 SWF 2 BACK-UP SWITCH MATING WITH DJ7021-6.3-10
6-14
4. REAR FRAME HARNESS
Connector No. of
number pin
CD-49 KET 1 TM TEMP 710197
CD-48 KET 1 TM OIL PRESSURE 710197
CD-3 KET 1×2 AIR PRESSURE 710197
CD-4 KET 1×2 STOP LAMP SWITCH 710197
CL-23 DEUTSCH 2 WORK LAMP-RH DT06-2S
CL-22 DEUTSCH 2 WORK LAMP-LH DT06-2S
CN-65 DEUTSCH 2 BACK BUZZER DT06-2S
CL-16 HES 4 REAR COMBI-RH S814-004000
CL-15 HES 4 REAR COMBI-LH S814-004000
CD-26 KET 1 PARKING PRESSURE SWITCH 710197
CN-29 - 2 AIRCON PRESSURE SWITCH MG 640795
CN-83 KUM 2 FAN PB625-02027
CN-95 HES 2 FUSIBLE LINK S813-130200
- 2 FUSIBLE LINK 21EA-40171
DO-2 - 2 DIODE S816-002002
- 2 DIODE 21EA-50550
CR-1 HES 1×2 BATTERY RELAY S820-104002
CN-1 HES 2 - S813-030200
CN-2 TYCO 15 - 2-85262-1
CN-3 TYCO 15 - 368301-1
CN-12 CHINA 12 - DJ7041-6.3-21
CN-71 CHINA 2 - DJ7041-6.3-21
CD-2 - 2 - S814-002000
CS-74 - 1 MASTER SWITCH (IF EQUIPPED) S820-205000
- 1 MASTER SWITCH (IF EQUIPPED) ST710287-2
5. FRONT HARNESS
Connector No. of
number pin
CN-9 CHINA 8 FRONT FRAME, SIDE DJ7081-6.3-11
CL-3 TYCO 3 COMBI-FRONT, LH 174200-1
CL-24 TYCO 2 HEAD LIGHT, LH 174198-1
CN-20 MOLEX 2 HORN-LOW 36825-0211
CN-25 MOLEX 2 HORN-HIGH 26825-0211
CL-4 TYCO 3 COMBI-FRONT, RH 174200-1
CL-25 TYCO 2 HEAD UGHT, RH 174198-1
6-15
6. GAUGE HARNESS
Connector
Type No. of pin Destination Connector part no.
number
CN-55 BARO METER

CN-53 TC TEMP GAUGE
SWF 2 913328
CN-54 FUEL LEVEL GAUGE
KSC2620 1×3 R 1.25-4
CN-52 ENGINE COOLANT TEMP
CN-51 TM OIL PRESSURE
CL-51 A,B TURN-LH, CHARGE

CL-52 A,B HIGH BEAM, BRAKE LOW PRESSURE
CHINA 2×2 DJ702256-6.3-21
CL-26 A,B PARKING
CL-53 A,B TURN-RH, ENGINE OIL PRESSURE
CN-56 TYCO 16 GAUGE BOARD 368050-1
7. ENGINE HARNESS
Connector
Type No. of pin Destination Connector part no.
number
CN-79 HES 3 FUEL CUT OFF SOL S818-020311
CD-18 KSC 2620 1 ENGINE OIL PRESSURE Rl.25-4
CD-8 TYCO 1 COOLANT TEMP Rl.25-4
ST710384-2
CR-23 KET 2×2 START RELAY
ST710589-2
KSC 2620 1 R14-12

CN-45 STARTER
KET 1 ST710246-2
KSC 2620 1 R14-8

CN-74 ALTERNATOR
KSC 2620 1 Rl.25-4
CN-12 TYCO 12 ENGINE SIDE DJ7121-6.3-11
KSC 2620 1 NMWP01F-B

CN-28 COMPRESSOR
KSC 2620 1 Rl.25-10
KSC 2620 1 EARTH R2.0-12

CN-96
KSC 2620 1 POWER R2.0-4
CN-97 TYCO 2 FAN CLUTCH 282080-1
EARTH 6 KSC 2620 1 EARTH R3.0-12
6-16
8. CONNECTION TABLE FOR CONNECTORS
1) 58-L TYPE CONNECTOR
No. of
Receptacle connector (female) Plug connector (male)
pin
1 1
S813-030100 S813-130100
1 2 1 2
S813-030200 S813-130200
6-17
2) PA TYPE CONNECTOR
No. of
pin
2 5 1 3
1 3 2 5
S811-005002 S811-105002
3 7 1 4
1 4 3 7
S811-007002 S811-107002
4 9
1 5
1 5
4 9
S811-009002 S811-109002
5 11 1 6
11
1 6 5 11
S811-011002 S811-111002
6-18
No. of
pin
6 13 1 7
13
1 7 6 13
S811-013002 S811-113002
1 9
8 17
17
1 9 8 17
S811-017002 S811-117002
10
1 21 1 11
21
1 11 1
10 21
S811-021002 S811-121002
6-19
3) J TYPE CONNECTOR
No. of
pin Receptacle connector (female) Plug connector (male)
1 2
1
2 12
S816-002001 S816-102001
2 3 1
3 1 2
S816-003001 S816-103001
3 1 4 2
4 2 3 1
S816-004001 S816-104001
8 5 2
6 3 1
8 5 2 6 3 1
S816-008001 S816-108001
6-20
4) SWP TYPE CONNECTOR
No. of
Receptacle connector (Female) Plug connector (male)
pin
1 1
S814-001000 S814-101000
2 1
1 2
S814-002000 S814-102000
3 1
2 1 23
S814-003000 S814-103000
2 4 1 3
1 3 2 4
S814-004000 S814-104000
6-21
No. of
3 6 1 4
3 6
1 4
S814-006000 S814-106000
4 8 1 5
4 8
1 5
S814-008000 S814-108000
4 12 1 9
12
4 12
1 9
S814-012000 S814-112000
3 14 11
1
14
1 11 3 14
S814-014000 S814-114000
6-22
5) CN TYPE CONNECTOR
No. of
1 1
S810-001202 S810-101202
2 2
1 1
S810-002202 S810-102202
3 2
1 2 1 3
S810-003202 S810-103202
2 4 1 3
1 3 2 44
S810-004202 S810-104202
6-23
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
6-24
6) ITT SWF CONNECTOR
No. of
2
10
1 10
9
SWF593757
7) MWP NMWP CONNECTOR

No. of
1
1
NMWP01F-B
6-25
8) DEUTSCH DT CONNECTORS
DT 06 - 3S - ★★★★
Modifications (see below)

Number of contacts (P : Pin, S : Socket)
04 : Receptacle, 06 : Plug
Deutsch connetors
※ Modification
E003 : Standard end cap - gray
E004 : Color of connector to be black
E005 : Combination - E004 & E003
EP04 : End cap
EP06 : Combination P012 & EP04
P012 : Front seal enhancement - connectors color to black for 2, 3, 4 & 6pin
No. of
1 2 2 1
2
DT06-2S DT04-2P
2 1 1 2
3 3
DT06-3S DT04-3P
4 1 1 4
3 2 2 3
DT06-4S DT04-4P
6-26
No. of
6 1 1 6
4 3 3 4
DT06-6S DT04-6P
4 5 5 4
1 8
8 1
DT06-8S DT04-8P
7 6
6 7
12
1 12 12 1
DT06-12S DT04-12P
6-27
9) ECONOSEAL J TYPE CONNECTORS
No. of
S816-001002 S816-101002
1 2 1
2
S816-002002 S816-102002
S816-003002 S816-103002
S816-004002 S816-104002
6-28
No. of
S816-006002 S816-106002
S816-008002 S816-108002
10
S816-010002 S816-110002
12
S816-012002 S816-112002
6-29
No. of
15
368301-1 2-85262-1
10) KET 090 CONNECTOR

No. of
1
2
MG610070
6-30
11) KET 090 WP CONNECTORS
No. of
1
2
MG640605
2 1
MG640795
12) CHINA CONNECTORS

No. of
2 1 1 2
4 3 3 4
DJ7041-6.3-11 DJ7041-6.3-21
8 4
5
8
DJ7081-6.3-21
6-31
13) TYCO CONNECTOR
No. of
2 1
282080-1
2
174198-1
5 11
11
1 6
172497-1
6-32

Hyundai SL760

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Hyundai SL760

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CONTENTS

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

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

SECTION 3 BRAKE SYSTEM

Group 1 Structure ------------------------------------------------------------------------------------------------------------- 3-1

SECTION 4 STEERING SYSTEM

Group 1 Hydraulic Circuit ------------------------------------------------------------------------------------------------- 4-1

SECTION 5 WORK EQUIPMENT

Group 1 Hydraulic Circuit ------------------------------------------------------------------------------------------------- 5-1

SECTION 6 ELECTRICAL SYSTEM

Group 1 Component Location ----------------------------------------------------------------------------------------- 6-1

Structure and function

2. Convert 550 mm into inches.

0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

Kilogram to Pound 1kg = 2.2046lb

0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84

0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378

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

0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980

7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1

14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0

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

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

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

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

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

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

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

FOLLOW SAFE PROCEDURE

WEAR PROTECTIVE CLOTHING

WARN OTHERS OF SERVICE WORK

USE HANDHOLDS AND STEPS

Be careful of slippery conditions on platforms,

WORK IN CLEAN AREA

PROTECT AGAINST FLYING DEBRIS

PROTECT AGAINST NOISE

SUPPORT MACHINE PROPERLY

SERVICE COOLING SYSTEM SAFELY

HANDLE FLUIDS SAFELY-AVOID FIRES

BEWARE OF EXHAUST FUMES

REMOVE PAINT BEFORE WELDING OR

SERVICE MACHINE SAFELY

STAY CLEAR OF MOVING PARTS

AVOID HEATING NEAR PRESSURIZED

PREVENT BATTERY EXPLOSIONS

USE TOOLS PROPERLY

damaged rims or missing lug bolts and nuts.

USE PROPER LIFTING EQUIPMENT

DISPOSE OF FLUIDS PROPERLY

LIVE WITH SAFETY

KEEP ROPS INSTALLED PROPERLY (option)

Bucket Tire Head light Hydraulic tank Air cleaner Raidator

Boom Boom cylinder Main control valve Battery Counterweight

Description Unit Specification

Description Unit Specification

4) MAIN CONTROL VALVE

(1) Coarse thread

(2) Fine thread

3) PIPE AND HOSE (ORFS type)

Thread size Width across flat (mm) kgf·m lbf·ft

Transmission Gear oil 50 (13.2) ATF DEXRON Ⅲ

ASTM D975 NO.1