HL720 3

WHEEL LOADER HYUNDAI HL720-3
HL720-3 Service Manual Open index screen
CONTENTS
Foreword
SECTION 1 GENERAL
Group 1 Safety Hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Group 2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Group 3 Operational checkout record sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
SECTION 2 ENGINE
Group 1 Structure and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
SECTION 3 POWER TRAIN SYSTEM

Group 1 Structure and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Group 2 Operational checks and troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Group 3 Tests and adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
Group 4 Disassembly and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44
SECTION 4 BRAKE SYSTEM

SECTION 5 STEERING SYSTEM

SECTION 6 WORK EQUIPMENT

SECTION 7 ELECTRICAL SYSTEM

Group 1 Component location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Group 2 Electrical circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Group 3 Monitoring system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
Group 4 Electrical component specification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32
Group 5 Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40
Group 6 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57
FOREWORD
1. STRUCTURE
This service manual has been prepared as an aid to improve the quality of repairs by giving the
serviceman an accurate understanding of the product and by showing him the correct way to perform
repairs and make judgements. Make sure you understand the contents of this manual and use it to
full effect at every opportunity.
This service manual mainly contains the necessary technical information for operations performed in
a service workshop.
For ease of understanding, the manual is divided into the following sections.
Structure and function

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Make certain all parts are reinstalled correctly if the
roll-over protective structure(ROPS) is loosened or
removed for any reason. Tighten mounting bolts
to proper torque.
The protection offered by ROPS will be impaired if
ROPS is subjected to structural damage, is
involved in an overturn incident, or is in any way
altered by welding, bending, drilling, or cutting. A
damaged ROPS should be replaced, not reused.
1-9
GROUP 2 SPECIFICATIONS
1. MAJOR COMPONENT
Tooth Bucket Tire Bucket cylinder Hydraulic tank Engine Radiator
Boom cylinder Main control valve Main pump Air cleaner Battery
Bucket link Bell crank Head light Cab Muffler Counterweight
Boom Front axle Steering cylinder Step Transmission Rear axle Fuel tank
1-10
2. SPECIFICATIONS
1) WITHOUT TOOTH AND CUTTING EDGE TYPE BUCKET
F
J
B
I
4506
H
3470
K
3033
40Ş
C
G
46
5200 54
D
E 1577
A
Description Unit Specification

Operating weight kg(lb) 7570(16690)
Struck 1.1(1.4)
Bucket capacity m3(yd3)
Heaped 1.3(1.7)
Overall length A 6295(20' 8")
Overall width B 2350( 7' 9")
Overall height C 3028( 9' 11")
Ground clearance D 333( 1' 1")
Wheelbase E mm(ft-in) 2600( 8' 6")
Tread F 1750( 5' 9")
Dump clearance at 50Ş G 2695( 8' 10")
Dump reach H 935( 3' 1")
Width over tires I 2138( 7' 0")
Dump angle J 45
Degree (Ş)
Roll back angle(Carry position) K 48
Lift(With load) 4.6
Cycle time Dump(With load) sec 1.0
Lower(Empty) 2.3
Maximum travel speed km/hr(mph) 40.1(25.0)
Braking distance 13(42' 8")
m(ft-in)
Minimum turning radius(Center of outside tire) 5.2(17' 1")
Gradability Degree (Ş) 30
First gear 7.2(4.5)
Second gear 13.6(8.5)
Forward
Third gear 28.6(17.8)
Travel speed Fourth gear km/hr(mph) 40.1(25.0)
First gear 7.2(4.5)
Reverse Second gear 13.6(8.5)
1-11
2) BOLT-ON CUTTING EDGE TYPE BUCKET
B
F
I
4506
H
3470
K
3033
4 0Ş
C
G
44
5
5230 0
D
E 1577
A

Struck 1.2(1.6)
Heaped 1.4(1.8)
Tread F 1750( 5' 9")
Dump angle J 45
Degree (Ş)
Lift(With load) 4.6
Lower(Empty) 2.3
m(ft-in)
First gear 7.2(4.5)
Forward
First gear 7.2(4.5)
1-12
3) WITH TOOTH TYPE BUCKET
B
F
I
4506
H
3470
K
3033
C
40Ş
G
44
5
5260 0
D
E 1577
A

Struck 1.1(1.4)
Heaped 1.3(1.7)
Tread F 1750( 5' 9")
Dump angle J 45
Degree (Ş)
Lift(With load) 4.6
Lower(Empty) 2.3
m(ft-in)
First gear 7.2(4.5)
Forward
First gear 7.2(4.5)
1-13
3. WEIGHT
Item kg lb
Front frame assembly 665 1466

Rear frame assembly 653 1440
Front fender(2EA) 22 49
Rear fender(2EA) 31 68
Counterweight 200 441
Cab assembly 640 1411
Engine assembly 380 838
Transmission 360 794
Drive shaft(Engine to transmission) 7 15
Drive shaft(Front) 16 35
Drive shaft(Center) 17 37
Drive shaft(Rear) 10 22
Front axle(Include differential) 475 1047
Rear axle(Include differential) 485 1069
Tire(4EA) 624 1376
Hydraulic tank 75 165
Fuel tank 130 287
Main pump assembly 24 53
Main control valve 23 51
Boom assy 460 1014
Bell crank assy 100 220
Bucket link 18 40
1.4m bucket, with bolt on cutting edge
3
628 1385
1.3m3 bucket, with tooth 569 1254
1.3m3 bucket, without tooth and cutting edge 500 1102
Boom cylinder assembly(2EA) 160 353
Bucket cylinder assembly 70 154
Steering cylinder assembly(2EA) 34 75
Seat 40 88
Battery 44 97
1-14
4. SPECIFICATION FOR MAJOR COMPONENTS
1) ENGINE
Item Specification
Model Deutz BF4M1012E

Type 4-cycle turbocharged diesel engine
Cooling method Water cooling
Number of cylinders and arrangement 4 cylinders, in-line
Firing order 1-3-4-2
Combustion chamber type Direct injection type
Cylinder bore ź stroke 94ź115mm(3.7"ź4.52")
Piston displacement 3190cc(195cu in)
Compression ratio 17.5 : 1
Rated gross horse power 84ps at 2300rpm
Maximum gross torque at 1500rpm 33kgfşm(239lbfşft)
Engine oil quantity 14ֻ (3.7 U.S. gal)
Dry weight 380kg(838lb)
High idling speed 2450 Ź 50rpm
Low idling speed 925 Ź 25rpm
Rated fuel consumption 171.4g/ps.h
Starting motor BOSCH(24V)
Alternator BOSCH(24V-55AMP)
Battery 2ź12Vź100Ah
2) MAIN PUMP
Item Specification
Type Fixed displacement tandem gear pump

Capacity 29*26cc/rev
Maximum operating pressure 210kgf/cm2(2987psi)
Rated oil quantity 125ֻ.min(33U.S.gpm)
Rated speed 2300rpm
1-15
3) BRAKE PUMP
Item Specification
Type Fixed displacement tandem gear pump

Capacity 5cc/rev
Maximum operating pressure 150kgf/cm2(2130psi)
Rated oil quantity 11ֻ/ min(2.9U.S.gpm)
4) MAIN CONTROL VALVE
Item Specification
Type 2 spool
Operating method Hydraulic pilot assist
Main relief valve pressure 210kgf/cm2(2987psi)
Overload relief valve pressure 240kgf/cm2(3414psi)
5) REMOTE CONTROL VALVE
Item Specification
Type Pressure reducing type

Minimum 5.8kgf/cm2(82.5psi)
Operating
Maximum 30kgf/cm2(427psi)
Single operation stroke Lever 77mm(3.0in)
6) CYLINDER
Item Specification
Boom cylinder Bore diaźRod diaźStroke ‫ ٻ‬95ź‫ٻ‬60ź675mm

Bucket cylinder Bore diaźRod diaźStroke ‫ٻ‬110ź‫ٻ‬65ź510mm
Steering cylinder Bore diaźRod diaźStroke ‫ ٻ‬60ź‫ٻ‬35ź370mm
1-16
7) DYNAMIC POWER TRANSMISSION DEVICES
Item Specification
Model ZF 4WG100
Torque converter
Type Single-stage, single-phase
Type Semi-automatic power shift
Transmission Gear shift Forward fourth gear, reverse third gear
Adjustment Electrical single lever type, kick-down system
Drive devices 4-wheel drive
Axle Front Front fixed location
Rear Oscillation 11Şof center pin-loaded
Wheels Tires 15.5-25, 12PR(L2)
Travel Four-wheel, wet-disc type, full hydraulic
Brakes Mechanical drum brake on transmission
Parking
output shaft
Type Full hydraulic, articulated
Steering
Steering angle 40Şto both right and left angle, respectively
1-17
5. TIGHTENING TORQUE OF MAJOR COMPONENT
No. Items Size kgfşm lbfşft
1 Engine mounting bolt, nut M12ź1.75 12.8 Ź 3.0 92.6Ź 22

2 Engine Radiator mounting bolt, nut M12ź1.75 12.8 Ź 3.0 92.6Ź 22
3 Fuel tank mounting bolt M16ź2.0 29.7 Ź 4.5 215Ź 33
4 Main pump housing mounting bolt M14ź2.0 19.6 Ź 2.9 142Ź 21
5 Main control valve mounting bolt M12ź1.75 12.8 Ź 3.0 92.6Ź 22
6 Hydraulic Steering unit mounting bolt M10ź1.5 6.9 Ź 1.4 49.9Ź
7 system Priority valve mounting bolt M 8ź1.25 2.5 Ź 0.5 10.1
8 Brake valve mounting bolt M 8ź1.25 2.5 Ź 0.5 18.1Ź 3.6
9 Hydraulic oil tank mounting bolt M12ź1.75 12.8 Ź 3.0 18.1Ź 3.6
10 Transmission mounting bolt M16ź1.75 29.7 Ź 4.5 92.6Ź 22
11 Front axle mounting bolt, nut M24ź2.0 107 Ź10.1 215Ź 33
Power train
12 Rear axle support mounting bolt, nut M24ź2.0 107 Ź10.1 774Ź 116
system
13 Tire mounting nut M22ź1.5 70 Ź 2.0 774Ź 116
14 Drive shaft joint mounting bolt, nut 3/8 UNC 6.9 Ź 1.4 506Ź 15
15 Counterweight mounting bolt M24ź2.0 107 Ź 16.1 50Ź 10
16 Others Operator's seat mounting bolt M 8ź1.25 2.5 Ź 0.5 774Ź 116
17 ROPS Cab mounting bolt(4EA) M24ź3.0 28 Ź 2.6 18.1Ź 3.6
1-18
6. TORQUE CHART
Use following table for unspecified torque.
1) BOLT AND NUT
(1) Coarse thread
8T 10T
Bolt size
kgfşm lbfşft kgfşm lbfşft
M 6 ź 1.0 0.85 ~ 1.25 6.15 ~ 9.04 1.14 ~ 1.74 8.2 ~ 12.6
M 8 ź 1.25 2.0 ~ 3.0 14.5 ~ 21.7 2.73 ~ 4.12 19.7 ~ 29.8
M10 ź 1.5 4.0 ~ 6.0 28.9 ~ 43.4 5.5 ~ 8.3 39.8 ~ 60
M12 ź 1.75 7.4 ~ 11.2 53.5 ~ 79.5 9.8 ~ 15.8 71 ~ 114
M14 ź 2.0 12.2 ~ 16.6 88.2 ~ 120 16.7 ~ 22.5 121 ~ 167
M16 ź 2.0 18.6 ~ 25.2 135 ~ 182 25.2 ~ 34.2 182 ~ 247
M18 ź 2.5 25.8 ~ 35.0 187 ~ 253 35.1 ~ 47.5 254 ~ 343
M20 ź 2.5 36.2 ~ 49.0 262 ~ 354 49.2 ~ 66.6 356 ~ 482
M22 ź 2.5 48.3 ~ 63.3 350 ~ 457 65.8 ~ 98.0 476 ~ 709
M24 ź 3.0 62.5 ~ 84.5 452 ~ 611 85.0 ~ 115 615 ~ 832
M30 ź 3.5 124 ~ 168 898 ~ 1214 169 ~ 229 1223 ~ 1655
M36 ź 4.0 174 ~ 236 1261 ~ 1703 250 ~ 310 1808 ~ 2242
(2) Fine thread

8T 10T
Bolt size
kgfşm lbfşft kgfşm lbfşft
M 8 ź 1.0 2.17 ~ 3.37 15.7 ~ 24.3 3.04 ~ 4.44 22.0 ~ 32.0
M10 ź 1.25 4.46 ~ 6.66 32.3 ~ 48.2 5.93 ~ 8.93 42.9 ~ 64.6
M12 ź 1.25 7.78 ~ 11.58 76.3 ~ 83.7 10.6 ~ 16.0 76.6 ~ 115
M14 ź 1.5 13.3 ~ 18.1 96.2 ~ 130 17.9 ~ 24.1 130 ~ 174
M16 ź 1.5 19.9 ~ 26.9 144 ~ 194 26.6 ~ 36.0 193 ~ 260
M18 ź 1.5 28.6 ~ 43.6 207 ~ 315 38.4 ~ 52.0 278 ~ 376
M20 ź 1.5 40.0 ~ 54.0 289 ~ 390 53.4 ~ 72.2 386 ~ 522
M22 ź 1.5 52.7 ~ 71.3 381 ~ 515 70.7 ~ 95.7 512 ~ 692
M24 ź 2.0 67.9 ~ 91.9 491 ~ 664 90.9 ~ 123 658 ~ 890
M30 ź 2.0 137 ~ 185 990 ~ 1338 182 ~ 248 1314 ~ 1795
M36 ź 3.0 192 ~ 260 1389 ~ 1879 262 ~ 354 1893 ~ 2561
1-19
2) PIPE AND HOSE
Thread size Width across flat'mm( kgfşm lbfşft

1/4" 19 3 21.7
3/8" 22 4 28.9
1/2" 27 5 36.2
3/4" 36 12 86.8
1" 41 14 101
3) FITTING
Thread size Width across flat'mm( kgfşm lbfşft

1/4" 19 4 28.9
3/8" 22 5 36.2
1/2" 27 6 43.4
3/4" 36 13 94.0
1" 41 15 109
1-20
7. RECOMMENDED LUBRICANTS
Use only oils listed below or equivalent.
Do not mix different brand oil.
Ambient temperature Ş
C( Ş
F)
Capacity
Service point Kind of fluid
ֻ(U.S. gal) -20 -10 0 10 20 30 40
(-4) (14) (32) (50) (68) (86) (104)
SAE 30
SAE 10W
Engine oil pan Engine oil 14(3.7)
SAE 10W-30
SAE 15W-40
Torque converter
Engine oil 17(4.5) SAE 15W-40
Transmission
Front : 12(3.2)
Axle Gear oil SAE 80W-90LSD/API GL-5
Rear : 12(3.2)
Tank: ISO VG 32
45(11.9)
Hydraulic tank Hydraulic oil ISO VG 46
System:
70(18.5) ISO VG 68
ASTM D975 NO.1

Fuel tank Diesel fuel 150(39.6)
ASTM D975 NO.2
NLGI NO.1
Fitting
Grease As required
(Grease nipple)
NLGI NO.2
Mixture of
antifreeze
Radiator 30(7.9) Ethylene glycol base permanent type
and water
50 : 50
1-21
GROUP 3 OPERATIONAL CHECKOUT RECORD SHEET
şOwner 9
şDate 9
şHours 9
şSerial No. 9
şTechnician 9
Ɠ Use this sheet to record operational

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

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

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

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

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

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

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

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

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

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

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

şTransmission
şFront, upper, center and rear drive shafts
şFront and rear axles
Engine power is transmitted to the transmission through the upper drive shaft and the torque converter.
The transmission is a hydraulically engaged four speed forward, three speed reverse countershaft type
power shift transmission. A drum type parking brake is located on the front of the transmission housing.
The transmission outputs through universal joints to three drive shaft assemblies. The front drive shaft
is a telescoping shaft which drives the front axle. The front axle is mounted directly to the loader front
frame. The front axle is equipped with limited slip differential.
The rear axle is mounted on an oscillating pivot. The rear axle is equipped with conventional
differential.
The power transmitted to front axle and rear axle is reduced by the pinion gear and ring gear of
differential. It then passes from the differential to the sun gear shaft(Axle shaft) of final drive.
The power of the sun gear is reduced by a planetary mechanism and is transmitted through the
planetary hub to the wheel.
3-1
HYDRAULIC CIRCUIT
K4
M5
KV
M3
On cluster:
Regulator main pressure
KR
M1
Pressure modulation
valve(with vent valve)
Pressure relief valve
(0.15bar)
Torque converter
Pressure for
converter
M4
M2
On cluster: Pressure
Converter outlet holding valve
temperature (2.0bar)
K3
K2
Pressure
reduction valve(10bar)
K1
Main pressure
valve(16+2bar) Main pump
Cooler bypass
(1.5bar) Heat exchanger
Safety valve Filter
(9+1bar)
Lubrication
Oil sump
Forward Reverse Neutral

Speed
1 2 3 4 1 2 3
M1 X X X
M2 X X
M3 X X X
M4 X X X X
M5 X
X : Solenoid engaged
3-2
2. TORQUE CONVERTER
5 1 2 3 4
1 Pump 3 Turbine 5 Input flange

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

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

about the same speed as
pump wheel.
3-4
3. TRANSMISSION
1) LAYOUT
14
13
12
11
10 7
8
9
1 1st clutch(K1) 8 Output shaft

2 Forward clutch(KV) 9 Converter side output flange
3 Engine-dependent power take-off 10 4th clutch(K4)
4 2nd clutch(K2) 11 Idler gear
5 Reverse clutch(KR) 12 Input shaft
6 3rd clutch(K3) 13 Converter
7 Parking brake 14 Transmission pump
3-5
2) INSTALLATION VIEW
14 1 9 8 10 3
4 4
4 4
5
6
12 4 4
7
4
13 15 2 11 16 13
1 Converter 9 Electro-hydraulic shift unit

2 Full flow filter 10 Power take-off;Coaxial;Engine-dependent
3 Fixing plate for assy 11 Parking brake
4 Gearbox mounting pads 12 Suction line
5 Inductive sensor-output speed 13 Oil drain plug
6 Type plate 14 Input flange
7 Oil filler tube with oil dipstick 15 Output flange-converter side
8 Breather 16 Output flange-rear side
3-6
3) OPERATION OF TRANSMISSION
(1) Forward
‫ ڸ‬Forward 1st
In 1st forward, FWD clutch and 1st clutch are engaged.
FWD clutch and 1st clutch are actuated by the hydraulic pressure applied to the clutch piston.
K1
KV
INPUT
K2
KR
K3
K4
OUTPUT OUTPUT
3-7
‫ ڹ‬Forward 2nd
In 2nd forward, FWD clutch and 2nd clutch are engaged.
FWD clutch and 2nd clutch are actuated by the hydraulic pressure applied to the clutch piston.
K1
KV
INPUT
K2
KR
K3
K4
OUTPUT OUTPUT
3-8
‫ ں‬Forward 3rd
In 3rd forward, FWD clutch and 3rd clutch are engaged.
FWD clutch and 3rd clutch are actuated by the hydraulic pressure applied to the clutch piston.
K1
KV
INPUT
K2
KR
K3
K4
OUTPUT OUTPUT
3-9
‫ ڻ‬Forward 4th
In 4th forward, 4th clutch and 3rd clutch are engaged.
4th clutch and 3rd clutch are actuated by the hydraulic pressure applied to the clutch piston.
K1
KV
INPUT
K2
KR
K3
K4
OUTPUT OUTPUT
3 - 10
(2) Reverse
‫ ڸ‬Reverse 1st
In 1st reverse, REV clutch and 1st clutch are engaged.
REV clutch and 1st clutch are actuated by the hydraulic pressure applied to the clutch piston.
K1
KV
INPUT
K2
KR
K3
K4
OUTPUT OUTPUT
3 - 11
‫ ڹ‬Reverse 2nd
In 2nd reverse, REV clutch and 2nd clutch are engaged.
REV clutch and 2nd clutch are actuated by the hydraulic pressure applied to the clutch piston.
K1
KV
INPUT
K2
KR
K3
K4
OUTPUT OUTPUT
3 - 12
‫ ں‬Reverse 3rd
In 3rd reverse, REV clutch and 3rd clutch are engaged.
REV clutch and 3rd clutch are actuated by the hydraulic pressure applied to the clutch piston.
K1
KV
INPUT
K2
KR
K3
K4
OUTPUT OUTPUT
3 - 13
4) ELECTRO-HYDRAULIC SHIFT UNIT
A B C D E
M4 F
M3
M5
G
M2
H
I
M1
N M L K J
A First and second shift valve F Pilot valve K Reset valve

B Solenoid pressure regulating valve G Two-stage piston L Fourth shift valve
C Check valve H Vent valve M First shift valve
D Pressure reducing valve I Check valve N Reverse shift valve
E Modulation valve J Forward shift valve O Solenoid valve
3 - 14
(1) The transmission control valve assembly regulates the hydraulic control circuit of the transmission.
The control valve receives electrical signals from the main controller to energize the solenoids
which direct oil to move the shift valves. When the shift valves move, oil pressure drops to start
modulation and fill the oncoming clutch pack.
(2) There are four gaskets and three plates between the transmission control valve and the housing.
Two plates are used to orifice oil to valves. The middle plate(Duct plate) is used to route oil from
the solenoids to the valves and then thru the hoses to transmission shafts. The main valve
contains pressure regulating valves, solenoid valves, shift valves, and valves for modulation.
(3) The pressure reducing valve(D) is a spring-loaded spool valve which regulates main pressure oil
by controlling flow into the control circuit. Excess oil from the control circuit flows to the torque
converter.
(4) Main pressure oil flows to the solenoid pressure regulating valve(B). The regulating valve
provides a constant oil pressure to the solenoids and is not affected by modulation. The five
solenoid valves(M) direct oil to the shift valves to provide machine direction and speed selection.
M1 Solenoid valve engages reverse shift valve(N).
M2 Solenoid valve engages first shift valve(M).
M3 Solenoid valve engages forward shift valve(J).
M4 Solenoid valve engages first, second shift valve(A).
M5 Solenoid valve engages fourth shift valve(L).
(5) The pressure regulating valve supplies a regulated pressure oil through a plate orifice to the
modulation valve(E). The modulation valve is a spring-loaded valve which controls the speed of
clutch engagement during a shift.
(6) When the first speed clutch is engaged, oil routed to the clutch pack also flows to the pilot valve
(F). The pilot valve, which is a spring-loaded shuttle valve, moves and blocks passage to the two-
stage piston(G). The two-stage piston is a stepping piston used to preload the modulation valve
springs to start clutch modulation at a higher pressure. In first speed, modulation starts at a lower
pressure to result in a less aggressive shift. In all other speeds, main pressure flows through the
pilot valve to the two-stage piston and preloads the modulation valve resulting in a higher starting
pressure.
(7) As modulation ends, the reset valve(K), which is a spring-loaded spool valve, moves and opens a
direct path through the modulation valve for fast clutch engagement.
(8) Two clutches have to be engaged for the machine to move. One from the directional clutch
packs either forward, reverse, or fourth. One from the speed clutch packs either first, second, or
third. Check valves(C and I) are used to prevent flow between a directional shift and a speed
shift. These check valves prevent a drop in clutch pack pressure in the engaged clutch.
3 - 15
5) SPEED CONTROL FUNCTIONAL DESCRIPTION
(1) Complete system
7 2
1 Transmission control unit 4 Battery 6 Inductive sensor output cable

2 Transmission 5 Control valves cable 7 Electro-hydraulic shift unit
3 Gear selector
3 - 16
(2) Description of basic functions
A specific speed range selector concept has been developed for use in wheel loaders equipped
with electro-hydraulically controlled power shift transmission, it incorporates the speed range
selector(DW-2) and micro-processor control unit(EST-17T).
This system processes all driver's instructions, such as direction of travel, selected gear as well as
the current machine speed and offers the following significant advantages:
‫ ڸ‬High adaptability to engine, machine and operation conditions through specific programming.
‫ ڹ‬Reversing possibility through all gears.
‫ ں‬Easy KD function(Semi-automatic).
‫ ڻ‬Waterproof, compact range selector with integrated KD button and neutral position interlock,
without any other active interlocks.
‫ ڼ‬Short circuit proof and overvoltage protected electrical system.
‫ ڽ‬Many safety features to protect against operating errors(Software).
(3) Block circuit diagram for micro-processor control unit(EST-17T)
Power supply
7 Digital inputs 8 Digital outputs
Micro -
2 Frequency inputs computer
Communication and
diagnostic interface EPROM
Safety
shifting
EST-17T
3 - 17
(4) Component description
‫ ڸ‬Gear(speed) selector
F
The gear selector has been designed for 1
2
3
N
4
attachment to left of steering column. R
Positions(Gears) 1-4 are selected by

turning, whereas the direction of travel is
selected by shifting the lever(Forward (V)
- Neutral (N) - Reverse (R)). On
transmission with 3 reverse speeds only
the gear 3R is selected on gear position N D
4R.
A neutral position interlock protects
against unintentional machine
movements during start-up. Lever
position D : Drive ; Position N : Shift lever
is locked in NEUTRAL position.
‫ ڹ‬Micro processor control unit
A. General
The short-circuit-poof and overvoltage-protected control unit must be installed in a protected
place in the driver's cab. via the by-packed buffers.
The control unit with inserted plug is splash-waterproof.
B. Direct control of solenoid valves
The solenoids of the electro-hydraulic control block at the transmission are directly controlled by
the electronics, i.e. without relays. Therefore, in normal practice just the outputs for the starter
interlock and reverse lights must be relay-controlled.
C. Gear selection
When ignition is turned on, the electronics remain in stand-by position and are ready for
operation when the lever is shifted into NEUTRAL position. Thereupon the gear can be
selected.
In general, the following applies for gear selection from NEUTRAL position : If road speed is too
high for the preselected gear(Risk of overreving), it is necessary to downshift to the lowest
permissible gear and then continue down-shifting in steps of 2.5 seconds until the preselected
gear is reached.
D. Kick down function
In gear positions 2V or 2R the 1st gear can be selected any time through slightly pushing the KD
button which is integrated in the shift lever. At proper road speed(Approx 95$ of max speed of
1st gear) up-shifting to the 2nd gear is performed automatically, however, not before 2.5
seconds.
This KD function remains in force also during reverse shifting, unless shift lever remains in
NEUTRAL position not longer than 1 second.
3 - 18
E. Passive reversing interlock
Since the gear selector DW-2 has no active reversing interlock, reversing is possible at any
time. Depending on current road speed resulting in :
ҶDirect reversing is possible at any time in gears 1 and 2(1V ‫ ؖ ؗ‬1R and 2V ‫ ؖ ؗ‬2R).
ҶThe sequence of road-speed-dependent reversing in gears 3 and 4 is as follows :
- Beyond a programmed speed limit(Normally the max speed of the 2nd gear) reversing is
performed via an immediate down-shift to the 2nd gear of the current direction of travel, a
shuttle-shift to the 2nd gear of the reverse direction of travel for 1.2 seconds, and finally up-
shifts to the preselected gear in steps of 2.5 seconds.
If speed drops below limit speed, reversing is performed immediately.
- Below this speed limit, reversing is performed directly, i.e. without prior down-shifts.
F. Up - shifts
If preselected gear is more than 2 gear steps beyond the currently selected gear, up-shifting is
performed in steps of 2.5 seconds.
G. Down - shifts
Down - shifts to the 2nd gear are performed immediately, even if gears are being skipped.
If 1st gear is to be selected from either the 3rd or 4th gear, it is necessary to first down - shift to
the 2nd gear for 1.2 seconds, and then continue to the 1st gear.
H. Pressure cut - off
The pressure cut - off device in the 1st and 2nd gear forward and reverse is activated by an
external positive signal(*). The transmission power-flow is interrupted as long as this positive
signal is being transmitted.
I. Cross shifts
If within the locking period of 1.2 seconds not only down but also reverse shifts are performed,
the transmission shifts to Neutral position till the end of this interval(Counted from the first
selected shifting point).
J. Direct solenoid control in NEUTRAL position
With the gear selector lever in NEUTRAL position certain transmission-specific solenoid
combinations are signalled for gear positions 1 and 2. These signals will be eliminated as soon
as max speed of 2nd gear is exceeded.
K. Detection of inductive sensor failure
The road speed is determined via the inductive sensor at the output side. Its failure will also be
assumed at a vehicle stand-still for longer than 10 seconds, although the 3rd or 4th gear is
engaged.
If the electronics have determined an inductive sensor failure, up-shifts beyond the 2nd gear are
not possible and from the 3rd and 4th gear, down-shifts can be performed only. Moreover,
reverse shifts from the 3rd or 4th gear are only possible to the 2nd gear in the reverse direction
of travel. The status inductive sensor failure will be eliminated as soon as the inductive sensor
signal can be sensed again. In this case, there is no automatic up-shifting to the preselected
higher gear(See L).
3 - 19
L. System performance in case of faults
The control unit constantly controls all inputs of the range selector as well as all outputs to the
solenoid valves. In case of inadmissible combinations(e.g. cable break, stray signals) the
electronics shift immediately to neutral condition and lock all outputs.
The same applies, if certain voltage limits are exceeded or in case of short-circuit.
This lock can be eliminated by shifting the range shift lever through the NEUTRAL position.
The same applies for the up-shift interlock after inductive sensor failure.
In case of repeated faults, it is imperative to check the machine's electrical circuit and to
exchange defective components immediately.
M. Wiring
All cable connections for solenoid valves, inductive sensor, speed range selector, electronics
and machine's electrical circuit are integrated in the compact wiring harness avoiding the
individual wiring.
This compact wiring harness is available from production in different lengths.
Ɠ A wiring system of single cables is available for prototype units in order to simplify
necessary modifications.
3 - 20
4. AXLE
1) OPERATION
ş The power from the engine passes through torque converter, transmission and drive shafts, and is
then sent to the front and rear axles.
ş Inside the axles, the power passes from the bevel pinion to the bevel gear and is sent at right
angles. At the same time, the speed is reduced and passes through the both differentials to the
axle shafts. The power of the axle shafts is further reduced by planetary-gear-type final drives and
is sent to the wheels.
(1) Front axle
1
1 Final drive 2 Differential 3 Axle
(2) Rear axle

1
1 Final drive 2 Differential 3 Axle
3 - 21
2) SECTION OF FRONT AXLE DIFFERENTIAL
A A
1
5
SECTION A-A
1 Bevel pinion 3 Sun gears 5 Side gear(Differential)

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

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

Pinion gear
When the machine is being driven straight
Side gear Side gear
forward and the right and left wheels are
rotating at the same speed, so the pinion Axle gear shaft
gear inside the differential assembly do not
rotate. The motive force of the carrier is
send through the pinion gear and the side
gear, therefore the power is equally Carrier
transmitted to the left and right axle gear Pinion gear
shaft.
(3) When turning Swing

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

2 Planetary gear
(1) To gain a large drive force, the final drive uses a planetary gear system to reduce the speed and
send drive force to the tires.
(2) The power transmitted from the differential through axle shaft(1) to sun gear(4) is transmitted to
planetary gear(2). The planetary gear rotates around the inside of a fixed ring gear(3) and in this
way transmits rotation at a reduced speed to the planetary carrier.
This power is then sent to the wheels which are installed to the planetary carriers.
3 - 27
5. TIRE AND WHEEL
4
6
1 Wheel rim 3 O-ring 5 Side ring

2 Tire 4 Lock ring 6 Valve assembly
1) The tire acts to absorb the shock from the ground surface to the machine, and at the same time
they must rotate in contact with the ground to gain the power which drives the machine.
2) Various types of tires are available to suit the purpose. Therefore it is very important to select the
correct tires for the type of work and bucket capacity.
3 - 28
GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING
1. POWER TRAIN OPERATIONAL CHECKS

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

up procedure brakes and release parking brake. Check completed.
TRANS Move gear selector lever to 3rd
speed.
Move gear selector lever to
forward "F" position.
Increase engine speed to high idle
for 30 seconds.
Move gear selector lever to
neutral "N" position and run for 15
seconds.
Repeat procedure until
transmission temperature gauge
arrow points to bar above dial.
Gear selector lever and Move gear selector lever to each OK

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

check 1700rpm. Check completed.
Engine running.
Drive unit with transmission in NOT OK
each forward and reverse speed. Go to transmission makes
excessive noise group 3.
LISTEN : Transmission must not
make excessive noise in any
range.
Engine rpm must not "lug down"
as unit is shifted between gears.
3-30
Transmission "quick Release parking brake and shift to OK

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

not shift down.
Forward, reverse and Park unit on level surface. OK

4th speed clutch pack Check completed.
Apply service brakes.
drag check
NOT OK
Ɠ Transmission must Move gear selector lever to
If unit moves, repair
be warmed up for neutral.
transmission.
this check.
Move gear selector lever to 1st.
Engine running.
Release parking brake and
service brakes.
Run engine at low idle.
LOOK : Unit must not move in
either direction.
NOTE : If unit moves forward,
either the forward pack or the 4th
speed pack is dragging.
3-31
Transmission pressure, Run engine at low idle. OK

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

modulation check 1700rpm. Check completed.
Engine running.
Put transmission in 1st forward, NOT OK
shift several times from forward to Go to unit shifts too fast,
reverse and reverse to forward. chapter 2 in this group.
Repeat check in 2nd gear.
LOOK : Unit must slow down and
change direction smoothly.
Torque converter check Start engine. Apply service OK

brakes and release parking brake. Check completed.
Move gear selector lever to 4th NOT OK
speed. If stall rpm are too low or
too high, problem may be
Move gear selector control lever
engine power or torque
to forward "F" position.
converter.
Increase engine speed to high
IF OK
idle.
Replace transmission
LOOK : Torque converter stall torque converter.
rpm must be within the following
range.
Stall rpm : 2250 ~ 2350rpm
Move gear selector control lever
to neutral "N" position and run for
15 seconds.
3-32
2. TROUBLESHOOTING
1) TRANSMISSION
Ɠ Diagnose malfunction charts are arranged from most probable and simplest to verify, to least
likely, more difficult to verify. Remember the following steps when troubleshooting a problem :
Step 1. Operational check out procedure(See group 3 in section 1.)
Step 2. Operational checks(In this group.)
Step 3. Troubleshooting
Step 4. Tests and/or adjustments(See group 3.)
Problem Cause Remedy
Transmission slippage Low oil level. Add oil.

Wrong oil grade. Change oil.
Restricted transmission pump Remove and clean screen.
suction screen.
Leak in transmission control Remove valve and inspect gaskets.
valve or gasket.
Low transmission pump flow Do transmission pump flow test.
due to worn pump.
Weak or broken pressure Do transmission system pressure test.
regulating valve spring.
3-33
Machine will not move Low oil level. Add oil.

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

engage in low gear control solenoid valve.
Stuck spool in transmission Remove and inspect transmission control valve
control valve. spools.
Stuck modulation valve. Remove end cover to inspect modulation valve.
Replace if necessary.
Malfunctioning transmission Check speed sensor.
speed sensor.
3-34
Transmission pressure Low oil level. Check transmission oil level and refill if
is low(All gears) necessary.
Failed transmission pressure Verify transmission system pressure. Do
switch. transmission system pressure test.
Plugged suction strainer. Transmission pump may be noisy if transmission
suction screen is clogged. Drain transmission.
Remove and clean suction screen.
Also, check condition of transmission filter.
Stuck transmission pressure Remove transmission pressure regulating valve.
regulating valve or broken Inspect for damage(See transmission control
spring. valve).
Failed control valve gasket. Inspect transmission control valve for external
leakage. Remove control valve.
Inspect or replace gasket.
Stuck modulation valve. Remove end cover to inspect modulation spool
and check torque on cap screws retaining control
valve to transmission.
Transmission system Failed transmission pump. Do pump flow test.

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

low
Low transmission pressure. Do transmission system pressure test.
Restricted transmission pump Remove and clean screen.
suction screen.
Low transmission pump flow. Do transmission pump flow test.
Excessive transmission Do transmission element leakage test using
element leakage. system pressure.
Stuck modulation valve. Remove end cover to inspect modulation spool.
Restricted modulation valve Remove orifice and inspect for contamination and
orifice. /or plugging.
Restricted oil passages Remove control valve and inspect oil passage.
between control valve and
transmission elements.
Incorrect transmission oil. Change oil.
3-35
Transmission shifts too Wrong transmission controller. Check if transmission controller has been
fast changed
System pressure too high. Do transmission system pressure test.
Stuck modulation valve. Remove and inspect modulation valve.
Replace if necessary. Also remove end cover to
inspect modulation valve and control valve
housing.
Stuck or missing check valves. Inspect transmission control valve.
Missing O-ring from end of Remove orifice and inspect port for O-ring.
modulation orifice.
Broken piston return spring. Disassemble and inspect clutch.
Machine "creeps" Warped disks and plates in Check transmission.

in neutral transmission.
Transmission hydraulic High oil level. Transmission overfilled or hydraulic pump seal
system overheats leaking.
Low oil level. Add oil.
Wrong oil grade. Change oil.
Park brake dragging. Check for heat in park brake area.
Pinched, restricted or leaking Check cooler lines.
lube lines.
Machine operated in too high Operate machine in correct gear range.
gear range.
Malfunction in temperature Install temperature sensor the verify temperature.
gauge or sensor. Do tachometer/temperature reader installation
procedure.
Restricted air flow through oil Do radiator air flow test.
cooler or radiator.
Failed oil cooler bypass Disassemble and inspect.
valve(In thermal bypass valve).
Failed thermal bypass valve. Remove thermal bypass valve and check to see if
machine still overheats. Do transmission oil
cooler thermal bypass valve test.
Internally restricted oil cooler. Do oil cooler restriction test.
Leakage in transmission Do transmission system pressure, element
hydraulic system. leakage test.
Malfunction in converter relief Do converter out pressure test.
valve.
Low transmission pump output. Do transmission pump flow test.
3-36
Excessive transmission Too low engine low idle. Check engine low idle speed.
noise(Under load or no
Worn parts or damaged in Remove transmission suction screen. Inspect
load)
transmission. for metal particles.
Repair as necessary.
Warped drive line between Inspect drive line.
engine and torque converter.
Low or no lube. Do converter-out and lube pressure test. Do
transmission pump flow test.
Foaming oil Incorrect type of oil. Change oil.

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

Low engine speed. Check engine speed.
Failed universal joints on Check universal joints.
transmission drive shaft or
differential drive shafts.
Machine lacks power Engine high idle speed set too Check high idle adjustment.
and acceleration low.
Aerated oil. Add oil.
Low transmission pressure. Do transmission system pressure test.
Warped transmission clutch. Do transmission clutch drag checks.
Torn transmission control valve Inspect gasket.
gasket.
Brake drag. Do brake drag check.
Failed torque converter. Do torque converter stall speed test.
Low engine power. Do engine power test.
Torque converter stall Aerated oil. Put clear hose on thermal bypass outlet port.
RPM too high Run machine to check for bubbles in oil.
Stuck open converter relief Do converter-out pressure test.
valve.
Leakage in torque converter Do converter-out pressure test.
seal.
Torque converter not Replace torque converter.
transferring power(Bent fins,
broken starter).
3-37
Torque converter stall Low engine power. Do engine power test.

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

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

light comes ON for each
No time delay in monitor. Do monitor check.
shift
Restriction in modulation orifice. Remove orifice and inspect for restriction and/or
plugging.
Stuck modulation valve. Remove and inspect.
Low transmission pressure Do transmission system pressure test.
circuit.
Leak in transmission pressure Do converter out pressure test.
circuit.
Failed transmission pump. Do transmission pump flow test.
Clogged filter. Inspect filter. Replace.
3-38
2) DIFFERENTIAL / AXLE
Insufficient braking 1. Incorrect adjustment. Inspect disc thickness and if discs are usable
readjust brakes to the specifications in page 3-
127.
2. Brake discs worn out. Inspect disc thickness and replace if necessary.
3. Incorrect brake fluid. Replace all seals in axle that have made contact
with the incorrect fluid and all brake hoses.
If incorrect fluid leaked into axle oil, seals and O-
rings in axle must be replaced.
4. Loss of brake fluid. Inspect for and repair any leaks in outside circuit.
If caused by incorrect brake fluid see correction
No.3. If leak is to the outside replace the O-rings
between the center and intermediate housings.
If leak is to the inside replace above O-rings and
brake piston O-rings.
5. Overheated axle causing See Overheating problem.
brake fluid to vaporize. (Brake
return when axle cools)
Soft brake pedal 6. Air in brake circuit. Bleed brakes as described in page 4-30.
Overheating 7. Oil level wrong. Drain, flush and refill oil to proper level.
8. Too small of a brake gap. Readjust brakes to the specifications in page 3-
127.
9. Incorrect brake fluid in See correction No.3.
system.
10. Restriction in brake lines. Inspect for and replace damage lines.
11. Restriction in return line of Inspect for and replace damaged return line.
brake Servo system. Inspect for and remove any filter, tee'd in line or
any other source of back pressure from the return
line.
12. Incorrect lubricant. Change the retaining rings of the brake circuit and
brake pump.
Diff-lock inoperative 13. Worn discs. Replace discs.
Oil coming out of 14. Leak in internal brake See correction No.2 and 3.
breather system.
NoSpin indexing noise 15. Unequal tire pressure left Inflate tires to the recommended pressure, or until
when driving straight and right. the rolling radius is equal.
ƓWith NoSpin, fatigue
16. Different style, size or brand Change tires to make the rolling radius equal.
damage can occure on
of tires between left and right Vary the tire pressure within the specifications
the side with the larger tire
hand side. until the rolling radius is equal.
Noise during coast and 17. Wheel bearings damaged. Replace and adjust.
under power the same
3-39
Noise under power 18. Low oil level. Refill oil to proper level.
greater than during
19. Incorrect lubricant. See correction No.12.
coast
20. Ring and pinion worn. Inspect through top cover. Replace and adjust.
21. Worn ring and pinion Replace and adjust.
bearings.
22. Worn planetary gears or Replace.
bearings.
Noise during coast 23. Loose pinion nut. Inspect ring, pinion and pinion bearings. If
greater than under undamaged, retighten nut.
power
24. Only pinion bearing See correction No.21.
damaged.
Noise during turn 25. Worn spider and/or side Replace.

(Without Nospin) gears.
26. Worn or damaged Inspect and replace.

cardanshaft.
27. Loose wheel. Inspect for wheel and wheel stud damage.
Replace if needed and retorque lugnuts.
3) DRIVE LINE
Excessive drive line Yokes not in line on drive Inspect. Align drive shaft yokes.
vibration or noise shafts.
Worn front drive line support Inspect, repair.
bearing.
Bent drive shaft. Inspect all drive shafts. Replace.
Loose yoke retaining nuts(Drive Inspect. Replace.
shafts wobble at high speed).
Rear axle oscillating support. Inspect, repair.
Lack of lubrication. Lubricate with proper grade of grease.
3-40
GROUP 3 TESTS AND ADJUSTMENTS
1. CLUTCH CUT-OFF PRESSURE SWITCH TEST

The setting pressure of the clutch cut-off
pressure switch should be suited with the Clutch cut off
specification. The rated pressure is 25 kgf/cm2. pressure switch
For the detailed method for pressure adjusting,
refer to page 4-22.
BR1
3-41
2. TRANSMISSION MEASURING POINTS AND CONNECTIONS
The measurements have to be carvied out at hot transmission(About 80~95Ɓ
C).
Y
57 66
55
63
56 X
R 2
PR
1
58 4 3
51
P
60 V
65
53
VIEW X
16
15
VIEW Y
1) OIL PRESSURE AND TEMPERATURE
Port Description Size
51 Converter inlet-opening pressure(9 bar) M10 ź 1

53 Forward clutch V M10 ź 1
55 Reverse clutch R M10 ź 1
56 1st slutch 1 M10 ź 1
57 2nd clutch 2 M10 ź 1
58 3rd clutch 3 M10 ź 1
60 4th clutch 4 M10 ź 1
63 Converter outlet temperature 100Ɓ
C, short-time 120Ɓ
C M14 ź 1.5
65 System pressure(16+2 bar) P M10 ź 1
66 Reducing valve(10 bar) PR M10 ź 1
3 - 42
2) DELEVERY RATES
Port Description Size
15 Connection to oil cooler M26 ź 1.5

16 Connection from oil cooler M26 ź 1.5
3) TESTING
Before testing is carried out, ensure that the oil is at the correct level and at normal operating
temperature.
4) TORQUE CONVERTER STALL TEST
Mark the engine crankshaft pulley with chalk or reflective tape and check the maximum no-load
speed of the engine using a stroboscopic tachometer.
Raise the loader arms and set the machine against fixed obstruction. Apply the parking brake
firmly and select forward highest. Apply the footbrake and, with the throttle fully open, check
engine speed which should be 2300Ź50rpm.
Ɠ Do not apply the clutch cut off switch during this test as the clutch disconnect will be activated and a
false reading will result.
Repeat the above test whilst simultaneously operating the loader arm raise service to blow off the
main relief valve.
Engine speed should be 2300Ź50rpm.
If engine speeds are appreciably below the stated figures, the engine is losing power and should be
serviced or overhauled. Where the engine speed does not change significantly from the governed
speed, check the transmission for clutch slippage or internal leakage.
5) PUMP FLOW TEST
(1) Make test connections as shown. Connect tachometer/temperature reader.
(2) Heat transmission oil up to test specifications.(See transmission oil warm-up procedure, this
group)
(3) Run engine at test specification(25lpm at 1000rpm). Measure flow. Flow meter loading valve must
be open.
Ɠ Before starting engine, check that flow meter loading valve is open.
Pump can be damaged if engine is started with loading valve closed.
FLOW
METER
3-43
SECTION 4 BRAKE SYSTEM
1. OUTLINE
Ɠ The brakes are operated by a pressure compensated, closed center hydraulic system.
Flow is supplied by a fixed displacement, gear type brake pump.
BRAKE SYSTEM
The fixed displacement brake pump supplies flow to service brake circuit. It flows to two
accumulator. The accumulator has a gas precharge and an inlet check valve to maintain a
pressurized volume of oil for reserve brake applications.
The front and rear brakes will operate simultaneously with only one brake pedal depressed.
The differential contains annular brake piston and double sided disk.
The brake system contains the following components:
şBrake pump
şBrake valve
şAccumulators
şPressure switches
4-1
FULL POWER HYDRAULIC BRAKE
SYSTEM
ADVANTAGES - The full power hydraulic Response time
brake system has several advantages over Full power brake actuation VS
Air/Hydraulic brake actuation
traditional brake actuation systems. These
systems are capable of supplying fluid to a 1000
range of very small and large volume
service brakes with actuation that is faster 900
than air brake systems. Figure represents 800
a time comparison between a typical Brake pressure
700 (Full power)
Brake torque(lbşin)
air/hydraulic and full power hydraulic brake
actuation system. 600
Brake pressure
Full power systems can supply significantly 500 (Air/hydraulic)
higher brake pressures with relatively low Brake torque
400
reactive pedal forces. The reactive pedal (Air/hydraulic)
force felt by the operator will be proportional 300
Brake torque
to the brake line pressure being generated. 200 (Full power)
This is referred to as brake pressure
modulation. 100
Another key design feature of full power
0 1 2 3 4
systems is the ability to control maximum
brake line pressure. In addition, because Time(Seconds)
these systems operate with hydraulic oil,
filtration can be utilized to provide long
component life and low maintenance
operation.
Because these systems are closed center,
by using a properly sized accumulator,
emergency power-off braking that is
identical to power-on braking can be
achieved. These systems can be either
dedicated, where the brake system pump
supplies only the demands of the brake
system or non-dedicated, where the pump
supplies the demands of the brake system
as well as some secondary down stream
hydraulic devise.
Another important note is that all seals
within these system must be compatible
with the fluid medium being used.
4-2
2. HYDRAULIC CIRCUIT
FRONT
24 REAR
13
13
16 14
6 BR1 BR2 M2
DS1
S1
S2
DS2 Return line
15 RCV lever
S3
T 10 P1
Steering system MCV
N 3MPa
U
P
P2 T
17
C B A 1
18
Return line
19
20 21 A 1st pump
B 2nd pump
C Brake pump
1 Main pump 15 Pressure switch 20 Return filter

6 Brake valve 16 Pressure switch 21 Bypass valve
10 Pilot supply unit 17 Line filter 24 Axle
13 Accumulator 18 Air breather
14 Pressure switch 19 Hydraulic tank
4-3
1) SERVICE BRAKE RELEASED
FRONT 24 REAR
13
13
16 14
6 BR1 BR2 M2
DS1
S1
S2
DS2 Return line
15 RCV lever
S3
T 10 P1
Steering system MCV
N 3MPa
U
P
P2 T
17
C B A 1
18
Return line
19
20 21 A 1st pump
B 2nd pump
C Brake pump
When the pedal of brake valve(6) is released, the operating force is eliminated by the force of the
spring, and the spool is returned.
When the spool removes up, the exhaust port is opened and the hydraulic oil in the piston of axles
(24) return to the tank(19).
Therefore, the service brake is kept released.
4-4
2) SERVICE BRAKE OPERATED
FRONT REAR
13
13
16 14
6 BR1 BR2 BR2 M2
DS1
S1
S2
DS2 Return line
15 RCV lever
S3
T 10 P1
Steering system MCV
N 3MPa
U
P
P2 T
17
C B A 1
18
Return line
19
21 A 1st pump
20
B 2nd pump
C Brake pump
When the pedal of brake valve(6) is depressed, the operating force overcomes the force of the
spring, and is transmitted to the spool. When the spool moves down, the inlet port is opened, and
at the same time the hydraulic oil controlled the pressure level by the other spool in the brake valve
enters the piston in the front and rear axles. Therefore, the service brake is applied.
4-5
3. BRAKE PUMP
1) STRUCTURE
22 23 26 28 27 31 32,33
24
21 27 29 30 26
25
21 Splined coupling 26 Bushing 31 Cover

22 Spacer plate 27 Bushing 32 Spring washer
23 O-ring 28 Driven gear 33 Bolt
24 Seal 29 Drive gear
25 Seal 30 Body
Hydraulic pumps used for the work equipment hydraulic units on construction machinery are pressure
loaded type gear pumps. This gear pump have a maximum delivery pressure of 150kgf/cm2(2130psi).
The pressure loaded type gear pump is designed so that the clearance between the gear and the side
plate can be automatically adjusted according to the delivery pressure. Therefore, the oil leakage from
the side plate is less than that in the case of the fixed side plate type under a high discharge pressure.
Consequently, no significant reduction of the pump delivery occurs, even when the pump is operated
under pressure.
4-6
2) PRINCIPLE OF OPERATION
(1) Mechanism for delivering oil

The drawing at right shows the
operational principle of an external gear
pump in which two gears are rotating in
mesh.
The oil entering through the suction port is
trapped in the space between two gear Suction Discharge
teeth, and is delivered to the discharge
port as the gear rotates.
Except for the oil at the bottom of the gear
teeth, the oil trapped between the gear
teeth, is prevented from returning to the
suction side with the gears in mesh.
Since the gears are constantly delivering
oil, the oil delivered to the discharge port
is forced out of the port.
The amount of discharge increases with
the speed of rotation of the gear.
If there is no resistance in the oil passage
into which the discharged oil flows, the oil
merely flows through the passage,
producing no increase in pressure.
If however, the oil passage is blocked with
something like a hydraulic cylinder, there
will be no other place for the oil to flow, so
the oil pressure will rise. But the pressure
which rises in this way will never go
higher, once the hydraulic cylinder piston
starts moving because of the oil pressure.
As described earlier, the pump produces
the oil flow, but not the oil pressure. We
can therefore conclude that pressure is a
consequence of load.
In other words, the pressure depends on
a counterpart.
4-9
(2) Internal oil leakage
Oil leaks from a place under higher
pressure to a place under lower pressure,
provided that a gap or a clearance exists
in between.
In the gear pump, small clearances are
provided between the gear and the case
and between the gear and the side plate
to allow the oil to leak out and to serve as
a lubricant so that the pump will be
e
protected from seizure and binding. charg
Dis
The drawing at right shows how the
leaked oil flows in the pump. As such,
there is always oil leakage in the pump
from the discharge side(Under higher
pressure) to the suction side. The
n
delivery of the pump is reduced by an ctio
Su
amount equal to the pump discharge.
In addition, the delivery of the pump will
also decrease as the amount of oil
leakage increases because of expanded
radial clearance resulting from the wear of
pump parts, the lower oil viscosity
resulting from increases in the oil
temperature, and the initial use of low
viscosity oil.
4-10
(3) Forces acting on the gear
The gear, whose outer surface is
subjected to oil pressure, receives forces
jointing towards its center.
Due to the action of the delivery pressure,
the oil pressure in higher on the delivery
side of the pump, and due to suction
pressure, is lower on the suction side. In
the intermediate section, the pressure will
gradually lower as the position moves
from the delivery side to the suction side. Drive gear
This phenomenon is shown in the
drawing at right.
In addition, the gears in mesh will receive
Suction Discharge
interacting forces. side side
These forces pushing the gears toward
the suction side are received by the
bearings. Since the gears are pressed
Driven gear
toward the suction side by these forces,
the radial clearance becomes smaller on
the suction side in the case. In some
pumps, the clearance may become zero,
thus allowing the gear teeth and the case Pressure distribution
to come into light contact.
For this reason, an excessive increase in
the delivery pressure must be avoided,
since it will produce a large force which
will act on the gears, placing an overload
on the bearings, and resulting in a
shortened service life of the bearing or
interference of the gear with the case.
4-9
(4) "Trapping" phenomenon of the oil
When a gear pump is rotating with the
gears in mesh as shown in the drawing at
right, in some instances two sets of gear
Delivery Suction side
teeth are in mesh while in other instances side
only one set of the gear teeth is in mesh.
When two sets of the teeth are in mesh
simultaneously, the oil in the space Trapping starts
between the meshed gear teeth will be
trapped inside-the front and rear exits will The space
reaches the
be completely shut. minimum
This is called the "trapping" phenomenon
of oil.
The space in which the oil is trapped Trapping ends
moves from the suction side to the
delivery side as the gears rotate. The
volume of the space gradually decreases
from the start of trapping until the space
reaches the center section, and then
gradually increases after leaving the
center section until the end of trapping. Fixed side plate type
Since the oil itself is non-shrinkable, a
reduction of the volume of space will
greatly increase the oil pressure, unless
Side plate
some plosion in made to relieve oil
pressure. The high pressure oil will
cause the pump to make noise and
vibrate.
To prevent this, relief notches are Relief notch
provided on the side plates to release the
oil to the delivery side.
As shown in the drawing at right, the relief
notches are provided in such a way that Pressure loaded type Bushing
the oil can be relieved from the tapping
space to the delivery side when the
volume of the space is reduced.
Relief notches are also provided on the
suction side to prevent the formation of a
vacuum in the space by allowing the oil to
enter the space from the suction side
when the space is reduced.
4-10
4. BRAKE VALVE
1) STRUCTURE
72
42 80
41
26
86
14
27 1.25
4
82
28
5 32
36
55 21
64 37
9 65 41
1
18
43
1.47
1.22
12
30
29
12 1.23
87 31
59
24
115
1 Housing 24 Reducer 43 Locking screw
1.22 Spool 26 Spring 55 O-ring
1.23 Spool 27 Spring 59 O-ring
1.25 Spool 28 Spring 64 Thrust ring
1.47 Spool 29 Spring 65 Shaft seal
4 Sleeve 30 Spring 72 Pedal unit
5 Sleeve 31 Spring 80 O-ring
9 Sleeve 32 Spring 82 Spring
12 Spring retainer 36 Circlip 86 Unit RV
14 Spring retainer 37 Circlip 87 Sleeve
18 Unit WVI 41 Locking screw 115 Locking screw
21 Spring retainer 42 Locking screw
4-11
2) OPERATION
A
M1
T S1
M2
BR1 BR2 M2
DS1
BR1
S1
DS2 S3
S2
DS2
S3
BR2 S2
T
N
VIEW A
Port Port name Size
P From main pump M18ź1.5

N To hydraulic tank M18ź1.5
BR1 To service brake in front axle M16ź1.5
BR2 To service brake in rear axle M16ź1.5
DS1 Pressure switch stop light M12ź1.5
DS2 Pressure switch accumulator pressure M12ź1.5
S1 Accumulator service brake M18ź1.5
S2 Accumulator service brake M18ź1.5
S3 Accumulator parking brake M16ź1.5
M2 Accumulator parking brake M12ź1.5
T To hydraulic tank M16ź1.5
4-12
(1) Accumulator charging valve
The accumulator loading valve or
pressure switch-off valve has the purpose
S2
to keep a pressure level within certain limit
values(Switch-off pressure, switch-on
pressure) in an accumulator circuit. The 1
switching pressure difference is approx S1
18% of the switch-off pressure. 3 T
Ɠ If actuators(N) downstream from the

N
pump produce a higher pressure than the
switch-off pressure of the accumulator
loading valve the accumulator circuit is
raised to this pressure level.
X P 2
The valve consists mainly of pilot control
with pressure setting element(1), pressure
compensator(2) and check valve(3).
Switching over of pump flow from accumulator load into neutral circulation
The pump delivers into the accumulator circuit via the check valve(3) during the loading
procedure. For this the pressure is passed to the load signal side of the pressure compensator(2)
via the control line and pilot control. This throttles the pump flow until the pressure, which builds
up in the accumulator circuit, overcomes the spring force of the pressure setting element(1).
The pilot control element switches the load signal line of the pressure compensator(2) from S1 to
T. The pressure compensator(2) then switches the pump flow from P to N and the check valve(3)
closes. The loading pressure is complete and the pump flow flows with low ՠp through the
loading valve.
Switching over of pump flow from neutral circulation into accumulator load
If the pressure in the accumulator circuit decreases to the lower switching point(Adding pressure)
P is connected to the load signal chamber of the pressure compensator(2) and the pump delivers
again into the accumulator circuit.
4-13
(2) 2 circuit brake valve
The 2-circuit remotely powered braking
valve is direct controlled pressure relief
valve in 3-way design with infinite
4 2 7 2 1
mechanical operation.
BR1 BR2 M2
It has a maximum pressure relief of
secondary circuits and infinite adjustability
DS1
of pressure in the secondary circuits
(Braking circuits) proportional to the
direction of the operating element(4).
With failure of one braking circuit the
SP1 T SP2
second braking circuit remains fully
functional because of the mechanical 3 5 2 1
contact of both spools(2).
The operating force at the pedal remains
unchanged.
The 2-circuit remotely powered brake valve consists mainly of housing(1) and control spool(2),
main compression spring(3), operating element(4) and the return springs(5) and (6).
The valve is operated via the operating element(4). It pushes the main control spring(3) against
both control spools(2). First the control edges close at channel T, afterwards the flow from SP and
BR is released in both braking circuits.
The pressure building up in the brake lines pushes simultaneously via the pilot oil drillings(7)
behind the control spool against the main compression spring(3) so that the braking
pressure(Secondary pressure) rises proportional to the operating element kept constant the
control spools(2) moves into control position and holds the controlled pressure in channels BR1
and BR2 constant. The operating force of the operating element is proportional to its deflection.
When the main compression spring(3) is unloaded the pressure springs and the control spools
move in such a way that they close SP towards BR and open BR towards T and thus close the
secondary circuits(Braking circuits).
4-14
5. BRAKE ACCUMULATOR
1) STRUCTURE
81L1-0004
Item
(Item13)
Diameter 121mm
Mounting height 151mm
Norminal volume 0.75m3
Priming pressure 50kgf/cm2
Operating medium Oil
B
Operating pressure Max 180kgf/cm2
Thread M18ź1.5
A
Operating
C -30 ~ 80Ş
C
temperature range
Priming gas Nitrogen
D
A Fluid portion C Diaphragm
B Gas portion D Valve disk
2) OPERATION
(1) Purpose
Fluids are practically incompressible and are thus incapable of accumulating pressure energy. In
hydropneumatic accumulators, the compressibility of a gas is utilized to accumulate fluid. The
compressible medium used in the accumulators is nitrogen.
In braking systems, the purpose of the accumulators is to store the energy supplied by the
hydraulic pump. They are also used as an energy reserve when the pump is not working, as a
compensator for any losses through leakage, and as oscillation dampers.
(2) Operation
The accumulator consists of a fluid portion(A) and a gas portion(B) with a diaphragm(C) as a gas-
tight dividing element. The fluid portion(A) is connected to the hydraulic circuit, causing the
diaphragm accumulator to be filled and the gas volume to be compressed as the pressure rises.
When the pressure falls, the compressed gas volume will expand, thus displacing the
accumulated pressure fluid into the circuit.
The diaphragm bottom contains a valve disk(D) which, if the diaphragm accumulator is
completely empty, closes the hydraulic outlet, thus preventing damage to the diaphragm.
(3) Installation requirements
The accumulators can be fitted in the hydraulic circuit, directly on a component or in blocks on
suitable consoles.
They should be fitted in as cool a location as possible.
Installation can be in any position.
4-15
(4) Maintenance of the accumulator
No special maintenance beyond the legal requirements is necessary.
The accumulator should be checked annually. It should be replaced if the initial gas
pressure has fallen by more than 30%(Please refer to Performance testing and
checking of the accumulator).
(5) Disposal of the accumulator
Before the accumulator is scrapped, its gas filling pressure must be reduced. For this
purpose, drill a hole through gas chamber(B) using a drill approx. 3mm in diameter. The
gas chamber is located on the side opposite the threaded port above the welding seam
around the center of the accumulator.
Ɠ Wear safety goggles when doing this job.
(6) Performance testing and checking of the accumulator
The accumulator is gradually pressurized via the test pump; until the initial gas pressure is
reached, the hydraulic pressure in the accumulator will rise abruptly. This is apparent
from gauge M. If the initial gas pressure is more than 30% below the prescribed value,
the accumulator needs to be replaced. If the measuring process needs to be repeated,
wait for intervals of 3 minutes between the individual tests. Any accumulator whose initial
gas pressure is insufficient must be scrapped following the instructions under Disposal of
the accumulator.
The amount of initial gas pressure can also be checked from the vehicle. Start the
vehicle's engine. The pump will now supply oil to the accumulators. Until the initial gas
pressure is reached, the hydraulic pressure in the accumulator will rise abruptly. This is
apparent from the gauge in the cab. If the initial gas pressure is more than 30% below the
prescribed value, that initial pressure lies outside the permissible range for at least one of
the accumulators fitted in the vehicle. This accumulator can be traced only by using the
method described above, i.e. all accumulators have to be individually tested. The
accumulator whose initial gas pressure is insufficient must be replaced and scrapped
following the instruction under Disposal of the accumulator.
Accumulator M
A Safety valve
4-16
(7) Repair work
When working on the braking system, always make sure that there is absolutely no
pressure in the system. Even when the engine in switched off there will be some residual
pressure in the system.
Ɠ When doing repair work, make sure your environment is very clean.
Immediately close all open ports on the components and on pipes using plugs.
For safety reasons the accumulators need to be replaced as a whole if damaged.
4-17
6. PRESSURE SWITCHES
1) STRUCTURE
şNormally closed
H1
şNormally open
H2
ş Technical data
H1 H2 Adjusting range Adjusting pressure Voltage
Item Type Medium G
mm mm kg/cm2 kg/cm2 V
Charging NC Oil M12ź1.5 55 9 50 ~ 150 100 Ź 10 Max 42

Brake stop NO Oil M12ź1.5 55 9 1 ~ 10 5Ź1 Max 42
Clutch cut off NO Oil M10ź1.0 55 9 20 ~ 50 25 Ź 1 Max 42
NC : Normally closed NO : Normally open
4-18
2) OPERATION
(1) Purpose
The pressure switches are used to visually or audibly warn the driver of the pressure within the
system.
(2) Make contact / circuit closer
The pressure switch can be fitted in the braking system or directly on one of its components.
The system pressure acts on an absorption area within the switch, making an electrical contact as
the pressure on that area is increased. The resulting current is used to activate a warning facility,
for instance.
(3) Break contact / circuit breaker
The pressure switch can be fitted in the braking system or directly on one of its components.
The system pressure acts on a absorption area within the switch, breaking an electrical contact
as the pressure on that area is increased. The current is now broken, e.g. to deactivate a
warning facility.
(4) Installation requirements
No special measures need to be taken.
(5) Maintenance of the pressure switch
No special maintenance beyond the legal requirements is necessary.
When using high-pressure cleaners on the vehicle, please make sure that the water jet is not
directed at the pressure switch(Corrosion of contacts).
(6) Repair work
When working on the braking system, always make sure that there is absolutely no
pressure in the system. Even when the engine is switched off there will be some residual
pressure in the system.
Ɠ When doing repair work, make sure your environment is very clean.
Immediately close all open ports on the components and on pipes using plugs.
Ɠ For safety reasons the pressure switch needs to be replaced as a whole if damaged.
4-19
(7) Adjusting and testing pressure switch
The adjusting screw located between the two contact plugs can be set to the desired value within
a certain range. For adjusting range, please refer to the table Technical data on the previous
page.
After making the adjustment, the adjusting screw should be secured using wax or a similar
material.
(,)
Screw
(+)
4-20
1. OPERATIONAL CHECKS
This procedure is designed so the mechanic can make a quick check of the system using a minimum
amount of diagnostic equipment. If you need additional information, read structure and function,
Group 1.
If verification is needed, you will be given next best source of information:
4-21
ƓHydraulic oil must be at operating temperature for these checks(Refer to page 6-56).
Parking brake capacity Start engine. OK

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

transmission lockout Check completed.
Place transmission in 2nd forward.
check
NOT OK
Engine running. Slowly increase engine speed to
Go to transmission control
high idle.
circuit in section 3.
LOOK : Machine must not move.
4-22
Service brake pump Stop engine. OK

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

check Check completed.
Apply service brakes, release park
Engine running.
brake and put transmission in 2nd NOT OK
forward. Check brake pressure in
group 3.
Increase engine speed to high
idle. IF OK
Inspect brake disk, see
LOOK : Machine may not move
group 3.
or move at a very slow speed.
Repeat check three times to
ensure accurate results.
4-23
Brake accumulator Start and run engine for 30 OK

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

ON STAR
T
Stop engine.
F
OF
NOT OK
Wait 2 minutes.
If brake leakage is
Turn key switch to ON and wait 5 indicated with brakes
seconds. released, check leakage
at accumulator inlet check
LOOK : Brake oil pressure
valve and brake valve. If
warning lamp must not come on
brake leakage is indicated
within 2 minutes after stopping
with brakes applied, check
engine.
for leakage at brake valve
and brake pistons.
Check individual
component leakage.
4-24
Service brake pedal Slowly depress brake pedal. OK

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

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

position. Check completed.
Release parking brake. NOT OK
Adjust clutch cut off
Run engine at half speed in 1st
switch.
forward.
Firmly depress brake pedal.
FEEL : Transmission must
disengage when brake pedal is
depressed at 30% of pedal stroke.
NOTE : Clutch cut off pressure
switch can be adjusted to operator
preference to match your loading
needs.
4-25
2. TROUBLESHOOTING
1) SERVICE BRAKE
Diagnose malfunction charts are arranged from most probable and simplest to verify, to least likely,
more difficult to verify. Remember the following steps when troubleshooting a problem :
Step 1. Operational check out procedure(See section 1)
Step 2. Operational checks(In this group)
Step 4. Tests and adjustments(See group 3)
Poor or no brakes Brake accumulator charge low. Do brake accumulator check.

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

Brake valve malfunction. Disassemble and inspect.
Low oil level. Check oil level.
Brakes drag Brake pedal not returning Inspect floor mat and pedal.
properly.
Debris holding valve partially Do brake valve pressure test.
open in brake valve.
Warped brake disk. Inspect brake disk.
Stuck brake piston. Repair.
Brakes lock up Brake valve malfunction. Clean or replace brake valve.
4-26
Brakes chatter Air in brake system. Do brake bleed procedure.

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

light will not go out or pressure warning switch.
stays on excessively
Brake accumulator pressure Recharge accumulator.
long after start-up
too low.
Low brake pump standby Do brake pump standby pressure test.
pressure setting.
Leakage in pressure reducing Do pressure reducing valve manifold leakage
manifold block. test.
Leakage in brake system. Do brake system components leakage tests.
Worn brake pump. Do brake pump flow test.
Leakage in parking brake Do parking brake pressure test.
solenoid.
4-27
2) PARKING BRAKE MALFUNCTIONS
Brake will not hold Worn brake drum and/or brake Disassemble, inspect, repair.
pads.
Brake drum overheats Pads out of adjustment. Adjust parking brake.

Brake not released. Release parking brake.
Disassemble, inspect brake.
Repair if necessary.
Parking brake indicator Faulty wiring or switch. Inspect for faulty wiring of brake indicator on the
in cluster does not cluster.
come on when brake Inspect for a faulty indicator on cluster. Replace
applied if necessary.
Brake will not apply Pads out of adjustment. Adjust parking brake.
Failure of parking brake lever. Check parking brake lever.
4-28
1. PARKING BRAKE PERFORMANCE

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

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

Remove axle housing and inspect for wear of
brake disks.
Replace brake disks if oil grooves of facing
material are no longer visible.
4-29
3. SERVICE BRAKE BLEEDING PROCEDURE
Escaping fluid under pressure can
penetrate the skin causing serious injury.
Avoid the hazard by relieving pressure
before disconnecting hydraulic or other
lines. Tighten all connections before
applying pressure.
B
Search for leaks with a piece of
cardboard. Protect hands and body from
high pressure fluids.
Ɠ If an accident occurs, see a doctor
immediately. Any fluid injected into the
skin must be surgically removed within a
few hours or gangrene may result.
Doctors unfamiliar with this type of injury
should reference a knowledgeable
medical source.
Two people are required to bleed brake
A
system oil, one to operate brake valve and
other to open and close bleed screws.
1) Install frame locking bar. Engage parking
brake.
2) Put a clear plastic tube on bleed screw(B)
to route low to hydraulic reservoir filler tube
or container(A).
3) Start engine and run at low idle.
4) Push and hold brake pedal down until
brake bleeding procedure is complete.
Ɠ If bubbles continue for more than 2
minutes, stop bleeding procedure.
Check for and correct problem, then
continue.
5) Open on bleed screw on differential and
axle assembly until hydraulic oil starts to Frame
flow. Close bleed screw when oil is free of locking bar
air. Release brake pedal.
6) Repeat steps 1) ~ 5) for each bleed screw.
7) Push either brake pedal and hold down.
8) Check hydraulic oil level.
4-30
GROUP 4 DISASSEMBLY AND ASSEMBLY
1. BRAKE PUMP
1) STRUCTURE
33
32
31
23
24
25
27
30
26 28
26
25
24
23 22
29
27
12
21
17
12 O-ring 24 Seal 29 Drive gear

17 O-ring 25 Seal 30 Body
21 Splined coupling 26 Bushing 31 Cover
22 Spacer plate 27 Bushing 32 Spring washer
23 O-ring 28 Driven gear 33 Bolt
4-31
2) GENERAL
(1) Introduction
Each unit comprises an end cover, body housing, the bush/gear assembly and a mounting flange
bolted together. The gear/bush assembly consists of a pair of meshing gears supported by plain
bearings in the bushes. The drive gear journal extends through the mounting flange to form the
drive shaft. A lip type shaft seal and O-rings provide external sealing whilst special lobe seals and
backing rings are used internally.
(2) Routine maintenance
No maintenance is necessary other than periodic checks for tightness of the mounting bolts and
visual examination for oil leakage. The unit should be kept externally clean, especially in the area
of the shaft seals as dirt can accelerate seal wear and cause leakage.
The unit must be operated only with clean oil and the system manufacturer's directions for
periodic renewal of system oil filter elements must be strictly observed.
(3) Field servicing
Seal kits and spare parts are available to enable units to be serviced.
4-32
3) DISASSEMBLY
33
32
31
23
24
25
27
30
26 28
26
25
24
23 22
29
27
12
21
17
Ɠ Before disassembling ensure that the unit itself, bench and tools are thoroughly clean.
(1) Lightly mark the end cover(31), body(30) and spacer plate(22) to ensure reassembly in the
correct position.
(2) Remove the bolts(33) and separate the brake pump unit from the main pump using a soft faced
hammer.
(3) Remove splined coupling(21) and O-rings(12, 17) sealing the internal passages between the
pump sections.
(4) Remove the spacer plate(22) from the body(30), free from spacer plate using a soft faced
hammer.
(5) Remove the backup seal(24), the seal element(25) and the body O-ring(23).
(6) Remove the end cover(31) from the body(30).
(7) Remove the backup seal(24), the seal element(25) and the body O-ring(23).
Ɠ Before removing the internal components each bushing(26, 27) must be marked to denote its
location within the body. On the plain area of the bush away from the seal location, lightly mark.
(8) With the unit laying on its side grasp hold of the drive shaft(29) and pull it squarely out of the body
(30) bringing the bushing(26, 27) with it.
(9) Remove the driven gear(28) and the two remaining bushing(26, 27).
4-33
4) INSPECTION AND REPAIR
(1) Assessment
Each components should be thoroughly cleaned, carefully examined and assessed for suitability
re-use. Below is a guide for inspecting the various components.
(2) Body
‫ ڸ‬Inspect the body bore cut-in where both gears wipe into the body.
‫ ڹ‬The body can only be re-used if the cut-in is bright and polished in appearance and the depth
does not exceed 0.15mm(0.006").
‫ ں‬The body should be replaced if the surface is scored, has a matt appearance or shows signs that
the tip of the gears have dug in and torn away the surface material.
‫ ڻ‬The body should be inspected to ensure that there is no superficial damage which may
adversely effect performance or sealing. Pay particular attention to the port threads and body O-
ring seal recesses.
(3) Spacer plate and end cover
‫ ڸ‬The inner surfaces should be inspected to ensure that there is no unusual wear or scoring in the
regions where the body O-rings and backing rings contact, which result in external leakage.
‫ ڹ‬Check the shaft seal recess for scoring or damage that could result in oil leakage around the
outer diameter of the shaft seal. Replacement shaft seals can be refitted with Loctite hydraulic
sealant to overcome slight damage in this area.
(4) Bushing
‫ ڸ‬The side faces which abut the gears should be perfectly flat showing no sign of scoring.
Characteristically there are bright polished areas on this surface caused by loading against the
gear side faces, which is often more pronounced on the low pressure side. The bush should be
replaced if there is any general scoring or fine scoring with a matt appearance or tearing of the
surface material. Often there is a witness where the tips of the opposing gears have wiped an
overlap reassembling a half moon shape. There must be no noticeable wear step as it is critical
that the bush side face is completely flat to the gear side face.
‫ ڹ‬The bearing liners are acceptable providing that they are not scored or show other damage.
The general outside area of the bush should not show any prominent signs of wear.
(5) Gears
‫ ڸ‬The gear side faces should be examined for bruising or scoring. Often operation on
contaminated fluid shows scoring between the root of the gear and the journal undercut, which
leaves a wear step. If a wear step can be felt, coincidental with the root diameter, by drawing a
sharp pointed tool across the surface from the undercut outwards towards the tip of the gear,
then the gear is unserviceable.
‫ ڹ‬The gear teeth should then be carefully examined to ensure that there are no signs of bruising or
pitting.
‫ ں‬The journal bearing surfaces should be completely free from scoring or bruising. The surface
should appear highly polished and smooth to touch.
‫ ڻ‬Examine the area where the shaft seal lips run on the drive shaft, this shows up as a polished
ring or rings. If a noticeable groove can be felt or there is scoring the shaft should be replaced.
‫ ڼ‬Provided the drive shaft is not damaged from the drive-coupling and the gears have not been
harmed as described above, then the gears can be re-used. If, however, the gears are
damaged they must be replaced as a matched pair.
‫ ڽ‬As a matter of good practice, when pumps have been disassembled, all the seals should be
replaced. It is most important that only the genuine seals are used.
4-34
5) ASSEMBLY
33
32
31
23
24
25
27
30
26 28
26
25
24
23 22
29
27
12
21
17
Ɠ Ensure that all parts are perfectly clean and lightly lubricate the bushes and gears with hydraulic
oil(Ensure body O-ring recess and end faces remain free from oil). This will assist with their
assembly when they are later fitted into the body.
(1) Refit the cover drive shaft bushing(26) and cover driven bushing(27) into the undowelled end of
the body(30) from where they were removed.
(2) Place the end cover(31) against the body(30) and then stand the assembly on the cover so that
the hollow dowels are uppermost, i.e. the bushing should be at the bottom with the bushings
against the cover.
(3) Fit the drive shaft(29) and driven gear(28) back into their original positions in the body(30).
(4) Refit the separate plate drive shaft bushing(27) and the separate plate driven bushing(26) into
their original bores.
(5) Fit the new body O-ring(23).
(6) Fit the new seal element(25) and backup seal(24) to the bushing.
(7) Carefully refit the spacer plate(22) to the body(30). If the spacer plate(22) is not fitted squarely
the backup seal(24) may become misplaced and trapped, resulting in internal damage if the unit
is run in this condition.
4-35
ASSEMBLY
33
32
31
23
24
25
27
30
26 28
26
25
24
23 22
29
27
12
21
17
(8) Fit O-rings(12, 17) and coupling(21) to the spacer plate(22).

(9) Holding the whole unit together carefully turn it over, making sure it is supported on the spacer
plate(22) not the shaft.
(10) Slide off the end over and fit seals as in (5) and (6) above.
(11) Fit the end cover(31), taking care not to dislodge the backup seal(24) and bolt(33) the unit
together. Tighten the bolts to the torque figures stated below.
şTightening torque : 4.8Ź0.4kgfşm(35Ź3lbfşft)
Ɠ Pour a small amount of oil into a port and check that the shaft can be rotated without undue force
using a smooth jawed hand wrench hooked around the shaft or a suitable half coupling locked
against the key.
4-36
6) RUNNING-IN
Pressure gauge
Test unit Variable

Microbic restrictor
filter
Flow
meter
Relief valve
Strainer
Tank
(1) A unit which has been re-assembled with either new gears, bushes or body, must be carefully
run-in before it is subjected to full working conditions.
(2) Ideally this should be done on a test rig(See figure) where pressure can be gradually applied and
any wipings from the body cut-in arrested by filters.
(3) It is recommended that the unit is run-in at 1500rpm, initially, at zero pressure for one minute then
in stages with the pressure increased by 500psi every minute, until maximum rated pressure has
been attained. Frequently check the system temperature, ensuring that it does not exceed the
maximum permissible figure of 80Ɓ C. If the temperature exceeds the system or unit specification
the test must be delayed and operated off-load until acceptable temperatures are obtained.
4-37
SECTION 5 STEERING SYSTEM
1. OUTLINE
The steering system of this machine consists of a fixed-displacement pump supplying a load sensing
steering system and an open center loader system.
The components of the steering system are :
şSteering pump(2nd pump)
şSteering unit
şPriority valve
şSteering cylinders
The steering pump, the second pump of main pump, draws hydraulic oil from the hydraulic tank.
Outlet flow from the pump flows to the priority valve. The priority valve preferentially supplies flow, on
demand, to the steering unit. When the machine is steered, the steering unit routes flow to the
steering cylinders to articulate the machine.
When the machine is not being steered, or if pump flow is greater than steering flow, the priority valve
supplies flow to the loader system.
That is, output flow from the steering pump enters into the first pump of main pump for the operation
of the attachment.
5-1
LH RH
L R
5
19.5MPa
MCV RCV lever

P T LS
23 25
4 CF EF
LS
P
Brake system
C B A 1
Return line
23 24
4 CF EF 18
Return line
LS
19
P A 1st pump
20 21
22 14 B 2nd pump
C Brake pump
1 Main pump 18 Air breather 23 Check valve(Option)

4 Priority valve 19 Hydraulic tank 24 Check valve(Option)
5 Steering unit 20 Return filter 25 Pressure switch(Option)
7 Steering cylinder 21 By pass valve
14 Pressure switch(Option) 22 Emergency pump(Option)
5-2
1) NEUTRAL
LH RH
L R
5
19.5MPa
MCV RCV lever
P T LS
4 CF EF
LS
P
Brake system
B A 1 A 1st pump
Return line B 2nd pump
18
Return line
19
20 21
ş The steering wheel is not being operated so control spool(G) does not move.
ş The oil from the steering pump(B) enters port P of the priority valve and the inlet pressure oil moves
the spool(D) to the right.
ş Oil flow into LS port to the hydraulic tank(19) through orifice and return filter.
ş So, the pump flow is routed to the loader system(Main control valve) through the EF port.
5-3
2) LEFT TURN
LH RH
L R
5
19.5MPa
MCV RCV lever
P T LS
4 CF EF
LS
P
Brake system
B A 1 A 1st pump
18
Return line
19
20 21
ş When the steering wheel(E) is turned to the left, the spool(G) within the steering unit(5) connected
with steering column turns in left hand direction.
ş At this time, the oil discharged from the steering pump flows into the spool(G) of the steering unit(5)
through the spool(D) of priority valve and flows into the gerotor(H).
ş Oil flow from the gerotor flows back into the spool(G) where it is directed out the left work port(L) to
the respective chamber of the steering cylinders(7).
ş Oil returned from left and right cylinder returns to hydraulic tank through the spool of the steering unit.
ş When the above operation is completed, the machine turns to the left.
5-4
3) RIGHT TURN
LH RH
L R
5
19.5MPa
MCV RCV lever
P T LS
4 CF EF
LS
P
Brake system
A 1st pump
B A 1
18
Return line
19
20 21
ş When the steering wheel(E) is turned to the right, the spool(G) within the steering unit(5) connected
with steering column turns in right hand direction.
ş At this time, the oil discharged from the steering pump flows into the spool(G) of the steering unit(5)
through the spool(D) of priority valve and flows into the gerotor(H).
ş Oil flow from the gerotor flows back into the spool(G) where it is directed out the right workport to the
respective chamber of the steering cylinders(7).
ş Oil returned from left and right cylinder returns to hydraulic tank through the spool of the steering unit.
ş When the above operation is completed, the machine turns to the right.
5-5
3. PRIORITY VALVE
1) STRUCTURE
1 2 3 4 9 6 5
LS
EF CF
1 Plug 4 Spool 9 Housing

2 Seal ring 5 Spring
3 Orifice 6 Plug
5-6
2) OPERATION
(1) Neutral
4 P A 5 A
CF EF
LS
LS
EF CF LOADER ACTUATED(D)
The priority valve is a pressure control valve that maintains priority pressure to the closed center
steering unit. With the steering unit in neutral, flow through is blocked and all flow through the priority
valve is directed out the EF port to the main control valve.
With the engine off, the spool(4) is pushed to the left(Viewed from sectional drawing at previous page)
by the spring(5). The passage to the EF port is blocked while the passage to the CF port is open.
When the machine is first started, all pump flow is routed to the steering unit which blocks the flow.
With the flow blocked, the pressure increases.
Steering inlet pressure is supplied through the pilot orifice to the left end of the spool. This causes the
priority valve spool(4) to shift to the right against the spring and open the EF port.
As long as the steering unit is in neutral, just enough pressure is maintained at the steering unit to keep
the priority valve spool shifted to the right.
The operating pressure in the loader system has no effect on the operation of the priority valve. With
the loader actuated in relief(D), the priority valve will not shift until the machine is steered.
Flow through the priority valve spool passes from the CF port through the orifice(A) and into the LS port.
It flows through the steering unit LS passage which is routed to return when the steering unit is in
neutral. This provides a warm-up circuit for the steering unit to prevent binding of the steering unit due
to oil temperature extremes.
5-7
(2) Midturn
4 P A 5 A
CF EF
LS
LS
FULL STEER RATE(D)

EF CF
When the machine is steered, load sensing pressure from the steering unit flows through the orifices LS
port in the priority valve. Load sensing pressure plus spring(5) force move the spool(4) to the against
the pilot pressure on the left end of the spool. This restricts flow to the loader through the EF port while
the CF port is opened to the steering unit.
The load sensing circuit is control circuit that routes steering workport pressure to the spring side of the
priority valve spool. It allows the priority valve spool to sense the pressure that is required to steer the
unit under varying conditions.
During normal steering conditions, oil is entered into the load sensing circuit through an orifice in the
steering unit. When steering at the full steer rate(D), the orifice opens to an unrestricted passage. At
low engine speed, the spool will shift to the full left position, directing all flow to the steering unit. At high
idle, the steering system can use about one-half of the pump flow. Therefore, the excess oil flows to
the main control valve.
The load-sensing circuit receives the majority of its flow from the load sensing orifice in the steering unit.
Some flow is also supplied from the CF port through orifice(A) in the priority valve spool.
5-8
(3) Full turn
4 P 5
CF EF
LS
LS
EF CF
When the machine is steered to a full turn, the frames bottom against the steering stops.
Pressure to the steering unit(Pilot pressure), which is sensed at the left end of the priority valve spool(4),
continues to increase until it can move the spool to the right against the load sensing pressure plus
spring force. At this time, all oil flows out of the EF port to the main control valve.
If the loader attachment is being operated while steering, the loader function will slow until the machine
reaches the steering stops. At that time, the loader cycle speed will increase until the machine is
steered again.
5-9
4. STEERING UNIT
1) STRUCTURE
26
2
26
1
2
24
27
2 29
7
32 3
4
33 8
9 2
11 13
12
14
16
16
17
18
21
15
22
18
20
1 Dust seal ring 12 Spring set 22 Name plate

2 Housing, spool, sleeve 13 O-ring 24 Pilot relief valve
3 Ball 14 Distributor plate 26 Shock valve
4 Bushing 15 Gearwheel set 27 Ball
5 Roto Glyd O-ring 16 O-ring 29 Pin bushing
7 Bearing assy 17 End cover 32 Check valve
8 Ring 18 Washer 33 LS check valve
9 Cross pin 20 Pin screw
11 Cardan shaft 21 Screw
5-10
2) OPERATION
A NEUTRAL
B
C Anti-cavitation valves
D Load sense port to priority valve
E Gerotor
System pressure oil

Spool I G Return
Work pressure oil
J H
G Trapped oil
Steering shaft Sleeve F
Return
From priority valve Return pressure oil
The steering unit consists of a spool(I) inside a sleeve(H) within a housing. When steering wheel is not
moving, the valve is in the neutral(A) position. In neutral, the spool and sleeve are aligned so that oil
flow through the valve is blocked. The steering cylinder(B) are held stationary by trapped oil in the left
and right workports.
When the steering unit is turned to the right, the spool rotates relative to the sleeve, and opens
passages which allow pump flow through the spool and sleeve assembly. Oil flows to the gerotor(E)
causing the gerotor gear to rotate. Oil flow from the gerotor flows back into the valve where it is
directed out the right workport to the respective ends of the steering cylinders.
A bypass orifice is machined into the spool and sleeve assembly. It is a variable orifice that introduces
a small leak into the pressure side of the steering unit. Its purpose is to dampen the initial pressure
surge when the steering wheel is partially turned. When the steering wheel is fully turned, the leak is
closed off.
Return oil flows back in through the left workport through the spool and sleeve assembly to return. The
load sensing orifice is located between the sleeve and the gerotor. This orifice feeds the load sensing
circuit between the steering unit and the priority valve through the LS port.
When the rotation of the steering wheel stops, the gerotor gear continues to move, turning the sleeve,
until the sleeve stops the flow to the gerotor. At this point, the valve is back in the neutral position and
will remain there until the steering wheel is moved again.
The valve has a variable steering which is proportional to the speed the steering wheel is rotated. A
variable orifice bypasses oil around the gerotor. Turning the steering wheel slowly takes approximately
seven turn(Variable orifice small) lock to lock versus four turns(Variable orifice large) when turning the
steering wheel quickly.
5-11
5. STEERING CYLINDER
1) STRUCTURE
22,23 8,9 10 5,6 7 11,12 4 3 2 1 13 14 15 16 17
18 19,20,21
1 Tube assy 9 Snap ring 17 Nylon nut

2 Rod assy 10 O-ring 18 Pipe assy
3 Gland 11 O-ring 19 U-bolt
4 Du bushing 12 Back up ring 20 Hexagon nut
5 Rod seal 13 Piston 21 Spring washer
6 Back up ring 14 O-ring 22 Bushing
7 Step seal 15 Piston seal 23 Dust seal
8 Dust wiper 16 Wear ring
2) OPERATION
This machine use to cross connected cylinder for steering operation.
The steering cylinder use a gland(3) to remove piston and sealed seals. Dust wiper(8) located on
the in side of the gland protects cylinder inner parts from dust. The piston(13) is fastened to the
rod(2) by a nut(17).
The piston uses a single wear ring(16) with a piston seal(15) to seal between the piston and tube.
The gland seals against the tube with two O-rings. The rod is sealed against the gland with a rod
seal(5).
5-12
This procedure is designed so the service man can make a quick check of the steering system using
a minimum amount of diagnostic equipment. If you need additional information, prefer to structure
and function in group 1.
Locate system check in the left column and read completely, following this sequence from left to right.
If verification is needed, you will be given next best source of information :
5-13
ƓHydraulic oil must be at operating temperature for these checks(Refer to page 6-54).
Steering unit check Run engine at low idle. OK

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

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

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

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

group 5. This oil flow provides a warm-
up flow to steering unit when not using
the steering.
Worn or damaged steering unit. Repair or replace steering unit.
Abrupt steering wheel Improperly timed gerotor gear in steering Time gerotor gear.
oscillation unit.
Steering wheel turns by Lines connected to wrong port. Reconnect lines.
itself
Worn or damaged steering unit. Repair or replace steering unit.
Vibration in steering High priority valve setting. Do priority valve pressure test in group 3.
system or hoses jump
Neutral position of Steering column and steering unit out of Align the steering column with steering
steering wheel cannot line. unit.
be obtained, i.e. there is
Too little or no play between steering Adjust the play and, if necessary, shorten
a tendency towards
column and steering unit input shaft. the splines journal.
"motoring"
Pinching between inner and outer Contact the nearest service shop.
spools.
"Motoring" effect. Leaf springs are stuck or broken and Replace leaf springs.
The steering wheel can have therefore reduced spring force.
turn on its own
Inner and outer spools pinch, possibly Clean steering unit or contact the
due to dirt. nearest service shop.
Return pressure in connection with the Reduce return pressure.
reaction between differential cylinder and
steering unit too high.
Backlash Cardan shaft fork worn or broken. Replace cardan shaft.
Leaf springs without spring force or Replace leaf springs.
broken.
Worn splines on the steering column. Replace steering column.
Jerky steering LS port orifice missing. Inspect orifice.
Orifice in top end of priority valve spool Disassemble and inspect.
missing.
ƕ Thermal shock is caused by a large temperature differential(Approx 30Ş C, 50ŞF) between the steering unit and
hydraulic oil. If the steering is not operated for a long period of time and the orifice in the bottom of the priority
valve spool is plugged, the steering unit may bind up when the steering is operated if the hydraulic oil is hot
enough.
5-18
"Shimmy" effect Air in the steering cylinder. Bleed cylinder.

The steered wheels Find and remove the reason for air
vibrate collection.
(Rough tread on tires
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 valves.
the steered wheels
One or both overload relief valves are Clean or replace.
turning
leaky.
Steering is too slow and Insufficient oil supply to steering unit, Replace pump or increase number of
heavy when trying to pump defective or number of revolutions revolutions.
turn quickly too low.
Relief valve setting too low. Adjust valve to correct setting.
Relief valve sticking owing to dirt. Clean the valve.
Spool in priority valve sticking owing to Clean the valve, check that spool moves
dirt. easily without spring.
Too weak spring in priority valve. Replace spring by a stronger.
"Kick back" in steering Fault in the system. Contact authorized man or shop.
wheel from system
Kicks from wheels
Heavy kick-back in Wrong setting of cardan shaft and Correct setting as shown in group 4.
steering wheel in both gear-wheel set.
directions
Turning the steering Hydraulic hoses for the steering Connect lines to correct ports.
wheel activates the cylinders have been switched around.
steered wheels opposite
Hard point when Spring force in priority valve too weak. Replace spring by a stronger.
starting to turn the
Air in LS and / or PP line. Bleed LS and PP line.
steering wheel
Clogged orifices in LS or PP side in Clean orifices in spool and in connecting
priority valve. plugs for LS and PP.
Oil is too thick(Cold). Let machine run until oil is warm.
Too little steering force Pump pressure too low. Correct pump pressure.
5-19
1. HYDRAULIC OIL CLEAN UP PROCEDURE USING PORTABLE FILTER CADDY

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

major component failure, remove and
disassemble steering cylinders to clean
debris from cylinders.
2) Install a new return filter element. Inspect
filter before installing new element.
Ɠ For a failure that creates a lot of debris,
remove access cover from hydraulic oil
tank. Drain and clean hydraulic oil tank
of fill the specified oil to hydraulic oil
tank through upper cover.
3) To minimize oil loss, pull a vacuum in
hydraulic oil tank using a vacuum pump.
Connect filter caddy suction line to drain
port at bottom of hydraulic oil tank using
connector. Check to be sure debris has not
closed drain port.
4) Put filter caddy discharge line into hydraulic
oil tank filler hole so end is as far away from
drain port as possible to obtain a thorough
cleaning of oil.
5-20
5) Start the filter caddy. Check to be sure oil
is flowing through the filters.
Operate filter caddy approximately 10
minutes so oil in hydraulic oil tank is
circulated through filter a minimum of four
times.
Ɠ Hydraulic tank capacity : 45ֻ(11.9U.S.
gal)
Leave filter caddy operating for the next
steps.
6) Start the engine and run it at high idle.
Ɠ For the most effective results, cleaning
procedure must start with the smallest
capacity circuit then proceed to the next
largest capacity circuit.
7) Operate all functions, one at a time, through
a complete cycle in the following order:
Clam, steering, bucket, and boom. Also
include all auxiliary hydraulic functions.
Repeat procedure until the total system
capacity has circulated through filter caddy
seven times, approximately 30 minutes.
Each function must go through a minimum
of three complete cycles for a through
cleaning for oil.
Ɠ Filtering time for machines with auxiliary
hydraulic functions must be increased
because system capacity is larger.
8) Stop the engine. Remove the filter caddy.
9) Install a new return filter element.

10) Check oil level in hydraulic oil tank ; Add oil
if necessary.
5-21
2. TEST TOOLS
1) CLAMP-ON ELECTRONIC TACHOMETER

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

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

The display monitor tachometer is accurate
enough for test work.
20 30
10 km/h 20
10 40
0 MPH 30
0 50
VDO
5-22
3. STEERING SYSTEM RESTRICTION TEST
ş SPECIFICATION
Oil temperature 65Ź6Ş C(150Ź10Ş F)
Engine speed High idle
Max return pressure 2.0Mpa(20bar, 285psi)
at steering unit
ş GAUGE AND TOOL
Gauge 0~7.0Mpa(0~70bar, 0~1000psi) 1EA
şThis test will check for restrictions in the

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

temperature reader installation procedure in
this group.)
2) Heat hydraulic oil to specifications.(See
hydraulic oil warm up procedure at page
6-56.)
3) Connect fitting(A) and gauge to steering
unit.
Do not operate steering or loader
functions or test gauge may be
damaged. T A
4) Run engine at specification and read

pressure gauges.
If pressure is more than specification at the
steering unit, inspect priority valve for a
stuck spool. Make sure orifice plugs are
installed in ends of priority valve spool.
Check for plugged orifice in priority valve LS
port.
5-23
4. STEERING UNIT LEAKAGE TEST
ş SPECIFICATION
Oil temperature 40Ź6Ş C(100Ź10Ş
F)
Maximum leakage 5.7cc/ 10min
T
ş GAUGE AND TOOL
Temperature reader
Measuring container(Approx 20ֻ)
Stop watch
1) Install frame locking bar to prevent machine

from turning.
this group.)
6-56.)
4) Disconnect return hose from fitting.
Install cap on fitting.
5) Run engine at specifications. Rotate
steering wheel against locking bar using
approximately 1.2kgşm of force.
Measure oil flow from return hose for 1
minute. Frame
locking bar
6) Leakage is greater than specifications,
repair or replace steering unit.
5-24
5. STEERING UNIT PRESSURE TEST
ş SPECIFICATION
Relief pressure 19~20Mpa
(190~200bar, 2760~2900psi)
ş GAUGE AND TOOL
Gauge 0~35.0Mpa(0~350bar, 0~5000psi)
Temperature reader CF
1) Connect test fitting and gauge to P port on P
steering unit.
2) Install temperature reader.(See temperature
installation procedure in this group.)
3) Install frame locking bar.
6-56.)
5) Run engine at specifications and turn
steering wheel rapidly hold approximately
22N(5lb force) pressure on wheel with
frames locked.
Frame locking bar
Ɠ If steering wheel is turned slowly, it will
continue to with the frames locked.
This will give an incorrect pressure
reading.
If steering wheel continues to turn
rapidly with the frames locked, steering Relief valve
system leakage is indicated.
6) Read pressure gauge. This is the steering
unit relief pressure.
A
7) If pressure in not to specification, remove
the plug(A) from steering unit. Turn
adjusting screw in relief cartridge using a
hex head wrench to adjust pressure.
If pressure cannot be adjusted to
specification, disassemble and inspect
steering unit.
5-25
6. PRIORITY VALVE "LS" PORT FLOW TEST
ş SPECIFICATION
Engine speed Low idle
LS port flow(Approx) 0.5ֻ/min(0.13gpm)
ş GAUGE AND TOOL
Temperature reader
Measuring container LS
Stop watch
Priority valve LS port flow test will check for a
plugged or missing orifice in the priority valve
spool. A plugged orifice will block warm up
flow to the steering unit which can cause
thermal shock.(See for an explanation of A
thermal shock, page 5-18). B
A missing orifice can cause the pump to be

loaded to high pressure at all times causing
overheating.

this group.)
6-56.)
3) Disconnect line from LS port and install
plug(A).
4) Connect line(B) to priority valve.
5) Start engine and run at specification.
6) Measure flow from LS port for 1 minute.
If flow is low, low steering system neutral
pressure or a plugged orifice in priority
valve spool is indicated.
If flow is high, remove priority valve spool
and inspect for a missing orifice.
Do hydraulic system restriction test in this
group.
5-26
1. PRIORITY VALVE
1) STRUCTURE
1
2
3
7 6
1 Plug 4 Spool 7 Name plate

2 Seal ring 5 Spring 8 Drive screw
3 Orifice 6 Plug 9 Housing
5-27
2) TOOLS
şOpen-end spanner 22mm.
şNylon pin.
şHexagon socket spanner 8mm.
şTorque wrench.
şSocket spanner 22mm.
şHexagon socket spanner insert 8mm.
3) DISASSEMBLY
Ɠ Cleanliness is the primary means of
assuring satisfactory the priority valve life.
Select clean place.
Before removing the piping, clean the
surrounding area of valve ports.
(1) Screw out the PP plug using the 8mm

hexagon socket spanner.
Remove the seal ring.
PP
(2) Loosen the LS plug using the 22mm open-

end spanner.
LS
5-28
(3) Pull out the plug with seal ring and spring.
LS
(4) Press out the spool using the nylon pin.
PP
LS
(5) Disassembled priority valve.
5-29
4) MODIFICATION
(1) The control spring pressure can be altered by replacing the spring(See table below). Replace
name plate so that code no. and control spring pressure match each other again.
Control spring
d(mm) Di(mm) L(mm)
pressure(bar)
4 1.8 6.9 54
7 Di
2.0 6.5 55
d
L
(2) Cleaning
Clean all parts carefully in low aromatic kerosene.
(3) Inspection and replacement
Check all parts carefully and make any replacements necessary. All seal rings must be replaced.
(4) Lubrication
Before assembly, lubricate all parts with hydraulic oil.
5) ASSEMBLY
(1) Guide the spool into the bore. Use the
nylon pin to center the spool in the bore.
PP
LS
(2) Put in the PP plug.

Remember seal ring.
PP
LS
5-30
(3) Guide the spring and LS plug into the
bore.
Remember seal ring.
LS
(4) Tighten the LS plug with torque wrench

using a 22 socket spanner insert.
şTighten torque : 5.1Ź1kgfşm
(36.9Ź7.2lbfşft)
LS
(5) Tighten the PP plug with a torque wrench

using a 8mm hexagon socket spanner
insert.
şTighten torque : 5.1Ź1kgfşm
(36.9Ź7.2lbfşft) PP
(6) The priority valve is now assembled.
PP
LS
5-31
6) TROUBLESHOOTING
Steering wheel 1. Relief valve of steering unit is clogged Disassembly, clean and reassembly.
is heavy with dirt.
2. Spool is stuck. Disassembly, clean and reassembly or
replace.
3. Orifice of plug and spool is clogged. Disassembly, clean and reassembly.
(Steering wheel a. Pump is faulty. Check pump.
is heavy at
engine low idle)
(Steering speed b. Control pressure is low. Reset control pressure.

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

2. O-ring is damaged. Replace.
5-32
2. STEERING UNIT
1) STRUCTURE
26
2
26
1
2
24
27
2 29
7
32 3
4
33 8
9 2
11 13
12
14
16
16
17
18
21
15
22
18
20
1 Dust seal ring 12 Spring set 22 Name plate

2 Housing, spool, sleeve 13 O-ring 24 Pilot relief valve
3 Ball 14 Distributor plate 26 Shock valve
4 Bushing 15 Gearwheel set 27 Ball
5 Roto Glyd O-ring 16 O-ring 29 Pin bushing
7 Bearing assy 17 End cover 32 Check valve
8 Ring 18 Washer 33 LS check valve
9 Cross pin 20 Pin screw
11 Cardan shaft 21 Screw
5-33
2) TOOLS
(1) Holding tool.
Part no. : SJ 150-9000-2
(2) Assembly tool for O-ring and kin-ring.

Part no. : SJ 150-9000-11
(3) Assembly tool for lip seal.

Part no. : SJ 150-9000-17
(4) Assembly tool for cardan shaft.

Part no. : SJ 150-9000-3
5-34
(5) Assembly tool for dust seal.
Part no. : SJ 150-9000-22
(6) Torque wrench 0~7.1kgfşm

(0~54.4lbfşft)
13mm socket spanner
6, 8mm and 12mm hexagon sockets
12mm screwdriver
2mm screwdriver
13mm ring spanner
6, 8 and 12mm hexagon socket spanners
Plastic hammer
Tweezers
5-35
3) TIGHTENING TORQUE AND HYDRAULIC CONNECTIONS
(1) Hydraulic connections
L: Left port
R: Right port
T: Tank
TLPR P: Pump
(2) Tightening torque

Max. tightening torque [ kgfşm(lbfşft) ]
Screwed
connection With cutting With copper With aluminum
edge washer washer With O - ring
1/4 BSP.F 4.1(29.7) 2.0(14.5) 3.1(22.4) -

3/8 BSP.F 6.1(44.1) 2.0(14.5) 5.1(36.9) -
1/2 BSP.F 10.2(73.8) 3.1(22.4) 8.2(59.3) -
7/16-20 UNF - - - 2.0(14.5)
3/4-16 UNF - - - 6.1(44.1)
M 12ź1.5 4.1(29.7) 2.0(14.5) 3.1(22.4) 2.0(14.5)
M 18ź1.5 7.1(51.4) 2.0(14.5) 5.1(36.9) 5.1(36.9)
M 22ź1.5 10.2(73.8) 3.1(22.4) 8.2(59.3) 7.1(51.4)
5-36
4) DISASSEMBLY
(1) Disassemble steering column from
steering unit and place the steering unit in
the holding tool.
Screw out the screws in the end cover(6-
off plus one special screw).
(2) Remove the end cover, sideways.
(3) Lift the gearwheel set (with spacer if fitted)

off the unit.
Take out the two O-rings.
(4) Remove cardan shaft.
5-37
(5) Remove distributor plate.
(6) Screw out the threaded bush over the

check valve.
(7) Remove O-ring.
(8) Shake out the check valve ball and

suction valve pins and balls.
5-38
(9) Take care to keep the cross pin in the
sleeve and spool horizontal. The pin can
be seen through the open end of the
spool. Press the spool inwards and the
sleeve, ring, bearing races and needle
bearing will be pushed out of the housing
together.
(10) Take ring, bearing races and needle

bearing from sleeve and spool. The outer
(thin) bearing race can sometimes "stick"
in the housing, therefore check that it has
come out.
(11) Press out the cross pin. Use the special

screw from the end cover.
Ɠ A small mark has been made with a

pumice stone on both spool and sleeve
close to one of the slots for the neutral
position springs (see drawing).
If the mark is not visible, remember to
leave a mark of your own on sleeve and
spool before the neutral position springs
are disassembled.
5-39
(12) Carefully press the spool out of the sleeve.
(13) Press the neutral position springs out of

their slots in the spool.
(14) Remove dust seal and O-ring.
Disassembling the dual shock valves

(15) Remove plugs from shock valves using a
6mm hexagon socket spanner.
5-40
(16) Remove seal washers(2-off).
(17) Unscrew the setting screws using a 6mm

(18) Shake out the two springs and two valve

balls into your hand. The valve seats are
bonded into the housing and cannot be
removed.
(19) The dual shock valves are now

disassembled.
5-41
Disassembling the pressure relief valve
(20) Screw out the plug using an 8mm hexagon
socket spanner. Remove seal washers.
(21) Unscrew the setting screws using an 8mm

(22) Shake out springs and piston. The valve

seat is bonded into the housing and
cannot be removed.
(23) The pressure relief valve is now

disassembled.
5-42
(24) The steering unit is now completely
disassembled.
Ɠ Cleaning
Clean all parts carefully in Shellsol K or
the like.
Ɠ Inspection and replacement
Replace all seals and washers. Check all
parts carefully and make any
replacements necessary.
Ɠ Lubrication
Before assembly, lubricate all parts with
hydraulic oil.
5-43
5) ASSEMBLY
(1) Assemble spool and sleeve.
Ɠ When assembling spool and sleeve only
one of two possible ways of positioning
the spring slots is correct. There are
three slots in the spool and three holes in
the sleeve in the end of the spool / sleeve
opposite to the end with spring slots.
Place the slots and holes opposite each
other so that parts of the holes in the
sleeve are visible through the slots in the
spool.
(2) Place the two flat neutral position springs

in the slot.
Place the curved springs between the flat
ones and press them into place (see
assembly pattern).
Ɠ Assembly pattern and color part no.

for neutral position springs
ş Weak springs (Blue)
2 - off flat, blue : Part no. 150-0748
2 - off curved, blue : Part no. 150-0749
ş Blue set
Spare set : Part no. 150-4265
(3) Line up the spring set.
5-44
(4) Guide the spool into the sleeve. Make
sure that spool and sleeve are placed
correctly in relation to each other(See
page 5-44).
(5) Press the springs together and push the

neutral position springs into place in the
sleeve.
(6) Line up the springs and center them.
(7) Guide the ring down over the sleeve.

Ɠ The ring should be able to rotate free of
the springs.
5-45
(8) Fit the cross pin into the spool / sleeve.
(9) Fit bearing races and needle bearing as

shown on below drawing.
Ɠ Assembly pattern for standard bearings

1
1 Outer bearing race 2
2 Needle bearing 3
3 Inner bearing race
ҵ
4 Spool
5 Sleeve 4
ҵ The inside chamber on the inner

5
bearing race must face the inner spool.
Installation instruction for O-ring

(10) Turn the steering unit until the bore is
horizontal. Guide the outer part of the
assembly tool into the bore for the spool /
sleeve.
5-46
(11) Grease O-ring with hydraulic oil and place
them on the tool.
(12) Hold the outer part of the assembly tool in

the bottom of the steering unit housing
and guide the inner part of the tool right to
the bottom.
(13) Press and turn the O-ring into position in

the housing.
5-47
(14) Draw the inner and outer parts of the
assembly tool out of the steering unit bore,
leaving the guide from the inner part in the
bore.
Installation instructions for lip seal

(15) Lubricate the lip seal with hydraulic oil and
place it on the assembly tool.
(16) Guide the assembly tool right to the

bottom.
5-48
(17) Press and turn the lip seal into place in the
housing.
(18) With a light turning movement, guide the

spool and sleeve into the bore.
Ɠ Fit the spool set holding the cross pin
horizontal.
(19) The spool set will push out the assembly

tool guide. The O-ring are now in
position.
(20) Turn the steering unit until the bore is

vertical again. Put the check valve ball
into the hole indicated by the arrow.
5-49
(21) Screw the threaded bush lightly into the
check valve bore. The top of the bush
must lie just below the surface of the
housing.
Assembly of the two suction valves

(22) Place a ball in the two holes indicated by
the arrows.
(23) Place a pin in the same two holes.
(24) Grease the O-ring with mineral oil approx.

viscosity 500 cSt at 20Ɓ
C.
5-50
(25) Place the distributor plate so that the
channel holes match the holes in the
housing.
(26) Guide the cardan shaft down into the bore

so that the slot is parallel with the
connection flange.
(27) Place the cardan shaft as shown - so that

it is held in position by the mounting fork.
(28) Grease the two O-rings with mineral oil

approx. viscosity 500 cSt at 20Ɓ C and
place them in the two grooves in the gear
rim. Fit the gearwheel and rim on the
cardan shaft.
5-51
(29) Important
Fit the gearwheel (rotor) and cardan shaft
so that a tooth base in the rotor is
positioned in relation to the shaft slot as
shown.
Turn the gear rim so that the seven
through holes match the holes in the
housing.
(30) Fit the spacer, if any.
(31) Place the end cover in position.
(32) Fit the special screw with washer and

place it in the hole shown.
5-52
(33) Fit the six screws with washers and insert
them. Cross-tighten all the screws and
the rolled pin.
şTightening torque : 3.1Ź0.6kgfşm
(22.4Ź4.3lbfşft)
(34) Place the dust seal ring in the housing.

Ɠ The dust seal ring must be placed only
after the pressure relief valve and shock
valves have been fitted.
(35) Fit the dust seal ring in the housing using

special tool SJ 150-9000-22 þSee page 5-
35(5)ÿand a plastic hammer.
Assembly of the pressure relief valve

(36) Fit the piston.
5-53
(37) Fit the spring.
(38) Screw in the setting screw with an 8mm

şSetting pressure : 195Ź5bar
(2830Ź73psi)
(39) Screw plug with dust seal into the housing

using an 8mm hexagon socket spanner.
şTightening torque : 5.1Ź1.0kgfşm
(36.9Ź7.2lbfşft)
Assembly of the dual shock valve

(40) Put a ball in the two holes indicated by the
arrows.
5-54
(41) Place springs and valve cones over the
two balls.
Ɠ The blue spring applies to setting range
90~180 bar. The untreated spring applies
to setting range 190~260 bar.
(42) Screw in the two setting screws using a

şSetting pressure : 250Ź10bar
(3630Ź145psi)
(43) Screw plug with seal ring into the two

shock valves and tighten them with a
torque of 3.05kgfşm(22.1lbfşft)using a
5-55
3. STEERING CYLINDER
1) STRUCTURE
22,23 8,9 10 5,6 7 11,12 4 3 2 1 13 14 15 16 17
18 19,20,21
1 Tube assy 9 Snap ring 17 Nylon nut

2 Rod assy 10 O-ring 18 Pipe assy
3 Gland 11 O-ring 19 U-bolt
4 Du bushing 12 Back up ring 20 Hexagon nut
5 Rod seal 13 Piston 21 Spring washer
6 Back up ring 14 O-ring 22 Bushing
7 Step seal 15 Piston seal 23 Dust seal
8 Dust wiper 16 Wear ring
5-56
2) TOOLS AND TIGHTENING TORQUE
(1) Tools
Tool name Remark
17 B
Spanner 32
36
Steel bar For gland
(-) Driver Small and large sizes
Torque wrench Capable of tightening with the specified torques

Torque
Part name Item Size
kgfşm lbfşft
Gland 3 M64 ź 1.5 65 Ź 7 470 Ź 51
Nylon nut 17 M24 ź 2 40 Ź 4 289 Ź 28.9
Nut(Pipe assy) 18 M22 ź 1.5 30 Ź 3 217 Ź 21.7
Nut 20 M10 ź 1.5 3.2 Ź 0.3 23.1Ź 2.2
5-57
3) DISASSEMBLY
(1) Remove cylinder head and piston rod
‫ ڸ‬Hold the clevis section of the tube in a
vise.
Ɠ Use mouth pieces so as not to damage
the machined surface of the cylinder
tube. Do not make use of the outside
piping as a locking means.
‫ ڹ‬Pull out piston rod(2) about 200mm

'7.1in(-Because the piston rod is rather
heavy, finish extending it with air pressure
m
0
m
after the oil draining operation. 20
‫ ں‬Loosen and remove the gland(3).

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

assembly together from cylinder tube(1).
Ɠ Since the piston rod assembly is heavy in Lift
this case, lift the tip of the piston rod(2)

with a crane or some means and draw it
out. However, when piston rod(2) has
been drawn out to approximately two
thirds of its length, lift it in its center to Full straight Oil pan
draw it completely. sideways
5-58
Ɠ Note that the plated surface of piston
rod(2) is to be lifted. For this reason, do
not use a wire sling and others that may
damage it, but use a strong cloth belt or
a rope.
‫ ڼ‬Place the removed piston rod assembly

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

‫ ڸ‬Remove the nylon nut(17). 14 15 16 13 17
‫ ڹ‬Remove piston assembly(13), and O-
ring(14).
‫ ڻ‬Remove the gland(3) assembly from

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

‫ ڸ‬Remove back up ring(11), and O-ring 8,9 12 5,6 7 10,11 4
(10).
‫ ڹ‬Remove O-ring(12).
‫ ں‬Remove snap ring(9) and dust wiper(8).
‫ ڻ‬Remove back up ring(6), rod seal(5).
‫ ڼ‬Remove buffer ring(7).
damage the grooves.
Ɠ Do not remove seal and ring, if does not
damaged.
5-60
4) ASSEMBLY
(1) Assemble gland assembly
Ɠ Check for scratches or rough surfaces if
found smooth with an oil stone.
‫ ڸ‬Coat the inner face of gland(3) with
hydraulic oil.
‫ ڹ‬Coat dust wiper(8) with grease and fit

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

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

Therefore, confirm it before fitting them. Push bar
Ɠ Fitting rod seal(5) and buffer ring(7) up
side down may damage its lip. Therefore
check the correct direction that is shown
in fig. 7
5,6
5-61
‫ ڽ‬Fit back up ring(11) to gland (3).
Ɠ Put the backup ring in the warm water of
30~50Ş C- 4
‫ ھ‬Fit O-ring(10) to gland(3). 10
‫ ڿ‬Fit O-ring(12) to gland(3). 11
3
12
(2) Assemble piston assembly

Ɠ Check for scratches or rough surfaces.
If found smooth with an oil stone.
‫ ڸ‬Coat the outer face of piston(13) with
hydraulic oil.
‫ ڹ‬Fit piston seal(15) to piston

Ɠ Put the piston seal in the warm water of
60~100Ş C for more than 5 minutes. 15
Ɠ After assembling the piston seal, press its
outer diameter to fit in.
‫ ں‬Fit wear ring(16) to piston(13).

‫ ڻ‬Fit O-ring(14) to piston(13). 14 15 16 13
5-62
(3) Install piston and gland
‫ ڸ‬Fix the piston rod assembly to the work
Gland assembly Piston rod
bench.
‫ ڹ‬Apply hydraulic oil to the outer surface of
piston rod(2), the inner surface of piston
and gland.
‫ ں‬Insert gland assembly to piston rod(2).
‫ ڻ‬Fit piston assembly to piston rod.

şTightening torque : 50Ź5kgfşm Piston assembly
(362Ź36lbfşft) Piston rod
‫ ڼ‬Tighten nylon nut(17) to piston rod(2).

şTightening torque : 75Ź8kgfşm 2 17
(542Ź58lbfşft)
5-63
(4) Overall assemble
Fix with a bar
‫ ڸ‬Place a V-block on a rigid work bench.
Mount the cylinder tube assembly(1) on it Lift
and fix the assembly by passing a bar
through the clevis pin hole to lock the
assembly.
Straight
‫ ڹ‬Insert the piston rod assembly in to the
cylinder tube assembly, while lifting and
moving the piston rod assembly with a
Apply liquid packing
crane.
Ɠ Be careful not to damage piston seal by
thread of cylinder tube.
‫ ں‬Match the bolts holes in the cylinder head
flange to the tapped holes in the cylinder Tube
tube assembly and tighten socket bolts to
a specified torque. Piston rod
Ɠ Refer to the table of tightening torque.
Wrench
Gland
5-64
SECTION 6 WORK EQUIPMENT
1. HYDRAULIC SYSTEM OUTLINE

The loader hydraulic system is a pilot operated, open center system which is supplied with flow from
the fixed displacement main hydraulic pump.
The pilot control system is a low pressure, closed center hydraulic system which is supplied with flow
from the first(Steering) pump.
The loader system components are :
Main pump
Main control valve
Bucket cylinder
Boom cylinders
Pilot supply unit
Remote control valve(Pilot control valve)
Safety valve
The pilot supply unit consists of the pressure reducing valve, relief valve and accumulator.
Flow from the main hydraulic pump not used by the steering system leaves the priority valve EF port.
It flows to the inlet port plate of four blocks type main control valve.
The main control valve is a tandem version spool type, open center valve which routes flow to the
boom, bucket or auxiliary cylinders(Not shown) when the respective spools are shifted.
Flow from the steering pump(The first pump) is routed to the pilot supply unit where the steering
pump outlet pressure is reduced to pilot circuit pressure. The pilot supply unit flow to the remote
control valve.
The remote control valve routed flow to either end of each spool valve section in the main control
valve to control spool stroke.
A accumulator mounted on pilot supply unit supplies a secondary pressure source to operated
remote control valve so the boom can be lowered if the engine is off.
The return circuit for the main hydraulic system have return filter inside the hydraulic tank. The return
filter uses a filter element and a bypass valve. The bypass valve is located in the upside of filter.
6-1
FRONT REAR
7 8 9
3
B.D/F B.U IN OUT
LH RH LH RH
P
L R 1 3 4 2
5
2
13
a2
2B
2A
14 24MPa Boom up Boom down
13 16 b2
12 T
Floating
6 BR1 BR2 M2 1B
P
1A
DS1 Dump Roll back
19.5Mpa b1 F2
24MPa
24MPa
S1
11
DS2 S2 a1
S3 P T LS F1
21MPa
15 10 P1
T P
3MPa
N 4 CF EF
U
P P2
LS T
17 P
C B A 1
23
18
22
A 1st pump
B 2nd pump 19
C Brake pump 20 21
1 Main pump 9 Boom cylinder 17 Line filter

2 Main control valve 10 Pilot supply unit 18 Air breather
3 Remote control valve 11 Line filter 19 Hydraulic tank
4 Priority valve 12 Safety valve 20 Return filter
5 Steering unit 13 Accumulator 21 By pass valve
6 Brake valve 14 Pressure switch 22 Oil cooler(Option)
7 Steering cylinder 15 Pressure switch 23 Check valve(Option)
8 Bucket cylinder 16 Pressure switch
6-2
3. WORK EQUIPMENT HYDRAULIC CIRCUIT
8 9
3
B.D/F B.U IN OUT
LH RH
P
1 3 4 2
2
a2
2B
2A
24MPa Boom up Boom down
b2
12 T
Floating
1B
P
1A
Dump Roll back
b1 F2
Steering system
24MPa
24MPa
11
a1
A 1st pump F1
B 2nd pump
21MPa
10 P1
P
C Brake pump
3MPa
4 CF EF
U
P2 T
Brake system
Return line
C B A 1
23
18
22
19
20 21
1 Main pump 9 Boom cylinder 19 Hydraulic tank

2 Main control valve 10 Pilot supply unit 20 Return filter
3 Remote control valve 11 Line filter 21 By pass valve
4 Priority valve 12 Safety valve 22 Oil cooler(Option)
8 Bucket cylinder 18 Air breather 23 Check valve(Option)
6-3
1) WHEN THE RCV LEVER IS IN THE RAISE POSITION
8 9
3
B.D/F B.U IN OUT
LH RH
P
1 3 4 2
2
a2
2B
2A
b2
12 T
Floating
1B
P
1A
Dump Roll back
b1 F2
Steering system
24MPa
24MPa
11
a1
A 1st pump F1
21MPa
10 P1
B 2nd pump P
3MPa
4 CF EF
U
P2 T
Brake system
Return line
B A 1
23
18
22
19
20 21
When the RCV lever(3) is pulled back, the boom spool on the second block is moved to raise
position by pilot oil pressure from port 3 of RCV.
The oil from main pump(1) flows into main control valve(2) and then goes to the large chamber of
boom cylinder(9) by pushing the load check valve of the boom spool through center bypass circuit
of the bucket spool.
The oil from the small chamber of boom cylinder(9) returns to hydraulic oil tank(19) through the
boom spool at the same time.
When this happens, the boom goes up.
6-4
2) WHEN THE RCV LEVER IS IN THE LOWER POSITION
8 9
3
B.D/F B.U IN OUT
LH RH
P
1 3 4 2
2
a2 Check valve
2B
2A
b2
12 T
Floating
1B
P
1A
Dump Roll back
b1 F2
Steering system
24MPa
24MPa
11
a1
A 1st pump F1
B 2nd pump
21MPa
10 P1
P
3MPa
4 CF EF
U
P2 T
Brake system
Return line
B A 1
23
18
22
19
20 21
When the RCV lever(3) is pushed forward, the boom spool on the second block is moved to lower
position by pilot pressure from port 1 of RCV.
The oil from main pump(1) flows into main control valve and then goes to small chamber of boom
cylinder(9) by pushing the load check valve of the boom spool through center bypass circuit of the
bucket spool.
The oil returned from large chamber of boom cylinder(9) returns to hydraulic tank(19) through the
boom spool at the same time.
When the lowering speed of boom is faster, the return oil from the large chamber of boom cylinder
combines with the oil from the pump through the check valve, and flows into the small chamber of
the cylinder.
This prevents cylinder cavitation by the negative pressure when the pump flow cannot match the
boom down speed.
6-5
3) WHEN THE RCV LEVER IS IN THE FLOAT POSITION
8 9
3
B.D/F B.U IN OUT
LH RH
P
1 3 4 2
2
a2
2B
2A
b2
12 T
Floating
1B
P
1A
Dump Roll back
b1 F2
Steering system
24MPa
24MPa
11
a1
A 1st pump
F1
B 2nd pump 21MPa
10 P1
P
3MPa
4 CF EF
U
P2 T
Brake system
Return line
B A 1
23
18
22
19
20 21
When the RCV lever(3) is pushed further forward from the lower position, the pilot pressure
reaches to 13-15 bar, then the boom spool on the second block is moved to floating position.
The work ports(2A), (2B) and the small chamber and the large chamber are connected to the
return passage, so the boom will be lowered due to it's own weight.
In this condition, when the bucket is in contact with the ground, it can be move up and down in
accordance with the shape of the ground.
6-6
4) WHEN THE RCV LEVER IS IN THE DUMP POSITION
8 9
3
B.D/F B.U IN OUT
LH RH
P
1 3 4 2
2
a2
2B
2A
b2
12 T
Floating
1B
P
1A
Dump Roll back
b1 F2
Steering system
24MPa
24MPa
11
a1
A 1st pump
B 2nd pump 21MPa
10 P1 F1
3MPa
4 CF EF
U
P2 T
Brake system
Return line
B A 1
23
18
22
19
20 21
If the RCV lever(3) is pushed right, the bucket spool on the first block is moved to dump position by
pilot oil pressure from port 2 of RCV.
The oil from main pump(1) flows into main control valve(2) and then goes to the small chamber of
bucket cylinder(8) by pushing the load check valve of the bucket spool.
The oil at the large chamber of bucket cylinder(8) returns to hydraulic tank(19) through the bucket
spool.
When this happens, the bucket is dumped.
When the dumping speed of bucket is faster, the oil returned from the large chamber of bucket
cylinder combines with the oil from the pump, and flows into the small chamber of the cylinder.
bucket dump speed.
6-7
5) WHEN THE RCV LEVER IS IN THE ROLL BACK(Retract) POSITION
8 9
3
B.D/F B.U IN OUT
LH RH
P
1 3 4 2
2
a2
2B
2A
b2
12 T
Floating
1B
P
1A
Dump Roll back
b1 F2
Steering system
24MPa
24MPa
11
a1
A 1st pump
F1
B 2nd pump 21MPa
10 P1
P
3MPa
4 CF EF
U
P2 T
Brake system
Return line
B A 1
23
18
22
19
20 21
If the RCV lever(3) is pulled left, the bucket spool on the first block is moved to roll back position by
pilot oil pressure from port 4 of RCV.
The oil from main pump(1) flows into main control valve(2) and then goes to the large chamber of
bucket cylinder by pushing the load check valve of the bucket spool.
The oil at the chamber of bucket cylinder(8) returns to hydraulic tank(19) through the bucket spool.
When this happens, the bucket roll back.
When the rolling speed of bucket is faster, the return oil from the small chamber of bucket cylinder
combines with the oil from the pump, and flows into the large chamber of the cylinder.
bucket rolling speed.
6-8
6) WHEN THE RCV LEVER IS IN THE HOLD POSITION
8 9
3
B.D/F B.U IN OUT
LH RH
P
1 3 4 2
2
a2
2B
2A
b2
12 T
Floating
1B
P
1A
Dump Roll back
b1 F2
Steering system
24MPa
24MPa
11
a1
A 1st pump F1
B 2nd pump
21MPa
10 P1
P
3MPa
4 CF EF
U
P2 T
Brake system
Return line
C B A 1
23
18
22
19
20 21
The oil from main pump(1) flows into main control valve(2).
In this time, the bucket spool and the boom spool are in neutral position, then the oil supplied to
main control valve(2) returns into hydraulic tank(19) through center bypass circuit of each spool.
In this condition, each cylinder keeps the neutral position, so the boom and the bucket is holded.
6-9
3. MAIN PUMP OPERATION
1) STRUCTURE
10
5
6
7
7
6
17 12 5
9
4
3 19
4 20
12 5
6
7
16 1
14
7 2
18 6
5
15
12
11
13
1 Shaft seal 8 Driven gear 15 Drive shaft

2 Circlip 9 Drive gear 16 Cover
3 Flange 10 Front body 17 O-ring
4 O-ring 11 Splined coupling 18 Stud assy
5 Seal 12 O-ring 19 Serrated washer
6 Seal 13 Center body 20 Nut
7 Balance plate 14 Driven gear
6-10
2) OPERATION
18 19,20 5,6,7 8 5,6,7 14
3 4 10 9 11 15 13 16
The main hydraulic pump is a fixed displacement gear type pump. The pump is drive at engine
speed by the transmission. The pump shafts are supported by balance plates(7), flange(3), front
body(10), center body(13) and cover(16).
As the drive gear(9) and (15) turns the driven gears(8, 14), the gear teeth come out of mesh. Oil
flows from the hydraulic tank through the inlet into the cavity between the gear teeth. As the gears
continue to rotate, the oil becomes trapped between the gear teeth and the balance plates(7).
The trapped oil is then carried to the pump outlet. Oil is forced out the outlet to supply the hydraulic
function. As the gears re-mesh, they form a seal to prevent oil from flowing between the gears and
back to the inlet.
The pump uses outlet pressure oil to load the balance plates(7) against the gear faces. This
controls internal leakage to maintain pump displacement.
Outlet pressure fills the area bounded by the seals(5, 6) to force the pressure plate against the high
pressure area or the gear faces. Pump shaft lubrication is achieved by routing outlet pressure oil
into the area between the gear shafts and the balance plates. The oil is collected at the end of the
shafts in the hollow areas in the port and flange plates and routed back to return.
6-11
4. REMOTE CONTROL VALVE
1) STRUCTURE
17
12
4 1
29 24 2 13
3
28 5 6
23
26
4 7
21 1 1
27
A
15
16 4 1
8
9 3 2
10
25
18 14
15 19 30
11
20
22
1 Spring pack 12 Prefeel cage assy 22 Hand coil

3 Spring 13 Spindle retainer 23 O-ring
4 Plunger assy 14 Spindle 24 Wiper seal
5 Plunger assy 15 Nut 25 Plug
6 Plunger assy 16 Lever assy 26 Boot retainer collar
7 Plunger assy 17 Handle assy 27 Handle adapter
8 Body kit 18 Lever assy 28 Nut
9 Prefeel kit 19 Socket screw 29 Nut
10 Prefeel kit 20 Connector assy 30 Insulation tube
11 Detent kit 21 Rubber boot
6-12
2) HYDRAULIC OPERATION
1 26
25
2 24
3
4 23
5 22
21
20
6
19
18
7 17
16
8 15
9 14
10
11
12 13
B.D/F B.U IN OUT Port Port name Port size

1 Boom down 1/4 BSPP
2 Bucket dump 1/4 BSPP
T
3 Boom raise 1/4 BSPP
P
1 3 4 2 4 Bucket crowd 1/4 BSPP
Hydraulic circuit P Supply pressure 1/4 BSPP
T Tank 1/4 BSPP
1 Piston attachment 10 Pressure reducing v/v housing 19 Spindle subassembly

2 Armature plate 11 Service port 20 Spindle guide retainer
3 Prefeel spindle 12 Inlet adapter 21 Mounting plate
4 Hold coil 13 Inlet port 22 Boot retaining plate
5 Retaining plate 14 Pressure reducing v/v piston 23 Guide
6 Prefeel cage assembly 15 Return spring 24 Spindle
7 Spring chamber 16 Spring pack subassembly 25 Universal joint
8 Body kit 17 Characteristic spring 26 Lever housing
9 Pressure chamber 18 Spindle guide subassembly
6-13
(1) Neutral position
2
1
The spring pack subassembly contains the pressure reducing piston(1) which has a center hole
machined from the service port end. This center hole links with a cross hole which in the normal
condition, that is with the lever not selected, connects the service port to the spring chamber(2). This
spring chamber(2) is in turn connected to tank and as such the pilot can on the MCV, to which this valve
is connected, would be connected to tank and the MCV spool would therefore be in the neutral position.
6-14
(2) Metering position
The lever housing is selected and this in turn operates the spindle(1) which in turn depresses the
operating spindle. This operating spindle now compresses the return spring(2) and starts to select the
characteristic spring. As there is currently no resistance, the pressure reducing valve piston(3) moves
further down in its bore. As this pressure reducing piston moves lower in its bore this service port
connection to tank, through the cross holes, is initially cut off as the cross hole pass under the land. As
the pressure reducing piston moves further then the cross holes open into the pressure chamber(4),
which is connected to the 30 bar supply, and so at that point the 30 bar supply is connected to the
service port. This also connects to the pilot end cap on the MCV and so spool movement in the MCV
occurs.
6-15
(3) End of metering
As the pressure builds up in the RCV service port and MCV pilot can, this same pressure acts on the
end of the pressure reducing valve piston(1), which was initially moved by a force applied to the top of
the characteristic spring. As this pressure increases it starts to react to the force in the characteristic
spring. The piston begins to move back in its bore, and at some point a force balance will occur. When
this happens, and the hydraulic force on the service port end of the piston just starts to exceed the
spring force on the opposite end then the pressure reducing piston moves back in its bore until the cross
hole moves back under the land and so the 30 bar supply to the port is cut off.
6-16
(4) Fully selected
If the operating lever is now selected further then the force balance on the pressure reducing valve
piston(1) is upset and supply pressure is once again connected to the service port, until a force balance
is restored.
Similarly, if the operating lever is moved back towards neutral then the force balance is once again
upset, this time in the opposite direction and the service port hydraulic force now being greater than the
characteristic spring force, the pressure reducing valve piston moves such that the cross holes open
into the spring chamber(2) and some pressure is lost until the balance is once again restored when the
cross hole moves back under the land.
In this way pressure supplied to the MCV pilot can, and so spool movement, is proportional to the lever
movement of the RCV.
There is a point in the stroke of some of the RCV assemblies where progressive movement of the MCV
spool is no longer necessary due to the spool position and flow/pressure characteristics and the
pressure reducing valve piston is mechanically forced into a position where the cross holes are
constantly held open to the pressure chamber. This happens when the pin fitted to the operating
spindle contacts the top of the pressure reducing valve piston and this mechanical force overrides any
hydraulic balancing forces.
The ports controlling boom up and down and bucket roll back are also fitted with a magnetic detents
and/or prefeel ramps.
The port controlling the power down function also controls the boom float function. A prefeel ramp is
fitted at the point on the pilot valve stroke which controls the spool on the MCV to its power lower
position. Moving the lever beyond this prefeel ramp position and to the end of its stroke gives an output
pressure from the RCV which drives the spool in the MCV into a float position. Details on prefeel ramps
can be seen in the next page.
6-17
3) MECHANICAL OPERATION
(1) The Bucket roll back and boom up and
down functions are fitted with a magnetic
detent. Armature plate
To prevent accidental engagement of this Hold coil(Magnet)
magnetic detent each of these detent has
Prefeel spindle
a prefeel position just before the armature
plate engages with the hold coil. The right Prefeel spring
figure shows the major components in this Prefeel ball
assembly.
Prefeel cage assy
(2) As the lever is operated the prefeel

spindle and armature plate are depressed
in the bore and towards the end of the
stroke, the prefeel ball, loaded by the
prefeel spring, contacts the ramp on the
prefeel spindle. This provides a physical
restriction to further lever movement as a
step increase in force is required to
overcome the preload of the prefeel
mechanism.
At this point there is still a gap between
the armature plate and the hold coil,
therefore the valve can be operated
without accidentally engaging magnetic
detent.
(3) If an extra amount of force is applied to

the operating lever the force of the prefeel
mechanism can be overcome and
magnetic detent engaged. This allows
the function to remain fully selected
without further operator demand. The
lever automatically returns to neutral
when the electric current is switched off
due to the position of the loader reaching
proximity sensors. Manual override from
magnetic detent is always possible.
6-18
5. MAIN CONTROL VALVE
1) STRUCTURE(1/2)
61
62
2, 3 63
4
5
59
60
58
39
22 T
2A
1 1A
2B
1B
P
38
24
40
73 41
42
7 72 24
6 71 43
62 69
61 70
25
5 21 68 65
4
73
72 24
71 23
74 25
75 26
76
77
70
68
1 Inlet housing 26 Bolt 63 Tie stud

2 O-ring 38 Spool 65 Stop
3 O-ring 39 Spool section 68 Housing
4 Plug 40 Seal extension 69 Check valve
5 O-ring 41 O-ring 70 O-ring
6 Plug 42 Sleeve 71 Back up ring
7 O-ring 43 Cover 72 O-ring
21 Spool 58 Outlet housing 73 Spring
22 Spool section 59 Plug 74 Check valve
23 Cover 60 O-ring 75 Poppet
24 O-ring 61 Hexagon nut 76 Spring
25 Lock washer 62 Washer 77 Adjusting screw
6-19
2) STRUCTURE(2/2)
64
25
54
66
52
48
50
44
55 45
56 57
47 28
36 49 44
25 35 51
32 46
31 53
20
33
19 34 37
27
16 30 24
15 29
14 28
17 37
10 27
18 24
68 13
70 11
77 2A T
76 12 1A
75 89 2B
74 P 1B
71
72
73
81
80
78
79
8 O-ring 25 Lock washer 46 Spring retainer 68 Housing

9 Back up ring 27 Seal retainer 47 Spring retainer 70 O-ring
10 Pin 28 O-ring 48 Shim 71 Back up ring
11 Plunger 29 Adapter 49 Shim 72 O-ring
12 Sleeve 30 Spring retainer 50 Spring retainer 73 Spring
13 Spring 31 Spring retainer 51 Spring 74 Check valve
14 O-ring 32 Screw 52 Spring 75 Poppet
15 Pilot housing 33 Spring 53 Spool cap 76 Spring
16 O-ring 34 Shim 54 Cover 77 Adjusting screw
17 Spring 35 Cover 55 Screw 78 O-ring
18 Poppet 36 Bolt 56 Washer 79 Cap
19 Adjusting screw 37 Shim 57 O-ring 80 Spring
20 Lock nut 44 Seal retainer 64 Screw 81 Check valve
24 O-ring 45 Circlip 66 Stop
6-20
STRUCTURE
b2
T
a2 2A 2B
a1 1A 1B b1
a2
2B
2A
24Mpa
Boom up Boom down

b2
Floating
1B
1A
Dump Roll back
b1
24Mpa
24Mpa
a1
21Mpa
Port Port name Port size

P From main pump 1 1/16UNF
T To hydraulic tank 1 5/16UNF
1A, 1B To bucket cylinder port 1 1/16UNF
2A, 2B To boom cylinder port 1 1/16UNF
a1, b1 Bucket pilot port 7/16UNF
a2, b2 Boom pilot port 7/16UNF
6-21
2) BOOM SECTION OPERATION
(1) Spool in neutral
NEUTRAL
a2
2B
2A
24Mpa
BOOM UP BOOM DOWN
b2
FLOATING
1B
1A
DUMP ROLL BACK
b1
24Mpa
24Mpa
a1
2A 2B
Low pressure passage
If the remote control valve is not operated, the oil supplied from the pump port passes through the
neutral passage to the low pressure passage at the outlet section, and then returns to the tank port.
6-22
(2) Boom raise position
a2
2B
2A
24Mpa
BOOM UP BOOM DOWN
b2
FLOATING
1B
1A
DUMP ROLL BACK
b1
24Mpa
a1 24Mpa
2A 2B
a2
Load check valve(1)
When the pilot pressure from remote control valve is supplied to the pilot port(a2), the spool moves to
the right and the neutral passage is closed.
The oil supplied from the pump pushes up the load check valve(1) and flow into boom cylinder port(2A).
The pump pressure reaches proportionally the load of cylinder and fine control finished by shut off of the
neutral passage.
The return oil from cylinder port(2B) flows into the tank via the low pressure passage.
6-23
(3) Boom lower position
a2 Check valve(2)
2B
2A
24Mpa
BOOM UP BOOM DOWN
b2
FLOATING
1B
1A
DUMP ROLL BACK
b1
24Mpa
24Mpa
a1
2A 2B
b2
Check valve(2)
Load check valve(1)
When the pilot pressure from remote control valve is supplied to the pilot port(b2), the spool moves to
the left and the neutral passage is closed.
The oil supplied from the pump pushes up the load check valve(1) and flow into boom cylinder port(2B).
neutral passage.
The return oil from cylinder port(2A) flows into the tank via the low pressure passage.
When the lowering speed of boom is faster, the return oil from the large chamber of boom cylinder
combines with the oil from the pump through the check valve(2), and flows into the small chamber of
cylinder. This prevents cylinder cavitation by the negative pressure when the pump flow cannot match
the boom lowering speed.
6-24
(4) Boom float position
a2
2B
2A BOOM BOOM
24Mpa
UP DOWN FLOATING
b2
1B
1A
DUMP ROLL BACK
b1
24Mpa
24Mpa
a1
2A 2B
b2
If the remote control lever pushes further more, the pilot pressure from remote control valve rises over
13-15bar and then the boom lowering spool is pushed to the boom floating position, opening up the
neutral passage to tank and simultaneously(2A), (2B) T.
In float position the boom drops quickly due to its own weight.
When the bucket touches the ground and the wheeled loader is moving, the bucket raised or lowered
following the unevenness of the ground due to the (2A), (2B) T connecting.
6-25
3) BUCKET SECTION OPERATION
(1) Spool in neutral
1B
1A
DUMP ROLL BACK
b1
24Mpa
24Mpa
a1
21Mpa
1A 1B
If the remote control valve is not operated, the oil supplied from the pump port passage through the
neutral passage to the low pressure passage at the outlet section, and then return to the tank port.
6-26
(2) Retract(Roll back) position
1B
1A
DUMP ROLL BACK
b1
24Mpa
24Mpa
a1
21Mpa
1A 1B
b1
Load check valve(1)
When the pilot pressure from remote control valve is supplied to the pilot port(b1), the spool moves to
the left and the neutral passage is closed.
The oil supplied from the pump pushes up the load check valve(1) and flow into bucket cylinder
port(1B).
neutral passage.
The return oil from cylinder port(1A) flows into the tank via the low pressure passage.
6-27
(3) Dump position
1B
1A
DUMP ROLL BACK
b1
24Mpa
24Mpa
a1
21Mpa
1A 1B
a1
Load check valve
When the pilot pressure from remote control valve is supplied to the pilot port(a1), the spool moves to
the right and the neutral passage is closed.
The oil supplied from the pump pushes up the load check valve(1) and flow into bucket cylinder
port(1A).
neutral passage.
The return oil from cylinder port(1B) flows into the tank via the low pressure passage.
6-28
4) MAIN RELIEF VALVE
The main relief valve is installed at the
inlet of the main control valve. When the
oil goes above the set pressure, the relief
valve drains the oil to the tank. Valve seat Valve poppet(C)
Main poppet(A) Lock nut
In this way, it sets the maximum pressure
in the hydraulic circuit and protects the Z
circuit.
The valve poppet(C) is connected via the
throttle drillings(D1) and (D2) with the P P
port.
If static pressure increases above the set T Y
pressure valve, the valve poppet(C) D1 D2 Pressure spring(F)
opens and allows oil to flow freely to Adjusting screw(E)
tank(Y). This oil generates a pressure
T
drop in the spring chamber of the main
poppet, the closing force of the spring(Z) 210bar
is cancelled, and the main poppet(A)

opens to allow the pump flow to flow to
tank(T). P
Damped opening and closing is obtained
by the throttled volumetric change.
P
T Y
P
T Y
T
210bar
6-29
5) PORT RELIEF VALVE
The overload relief valve(Combined
relief/anticavitation valve) is in the boom
cylinder and bucket cylinder circuit in the Inlet passage(1)
main control valve.
Spring(3) Valve(2) Spring(4)
If shock causes any abnormally high
pressure in the cylinder when the main
valves is at neutral, the overload relief
valve releases the abnormal pressure and AB
protects the cylinder from damage.
Pressure oil flows into passage(1). The
oil acts against the left side of valve(2), T
T
when is held closed by spring(4).
240bar
When a shock causes pressure in any of
the cylinders to rise, the increase in
pressure is also sensed in passage(1). P
As the pressure rises above the pressure
setting, the oil overcomes the force of
spring(4) and valve(2) will move to the
right. B
Oil in passage(1) then flows past the open
valve, through passage, and back to the T
hydraulic oil tank. T
240bar
When oil pressure returns to a level below
the pressure setting, spring(4) moves
valve(2) to the left and onto the seat.
P
If cavitation in the workport occurs, the oil
pressure in the workport drop below Spring(3) Poppet(5)
return pressure.
With the workport pressure below return
pressure, the return pressure works A
against the shoulder of the poppet(5),
causing it to open against the spring(3).
Return pressure oil flows into the workport T
to prevent cylinder cavitation. T
240bar
6-30
6) PRESSURE SETTING
A good pressure gage must be installed in
the line which is in communication with the
Lock nut
work port relief. A load must be applied in a
manner to reach the set pressure of the
relief unit.
(1) Main relief valve
Loosen lock nut. P
Set adjusting screw to desired pressure
setting. T Y
Tighten lock nut. Adjusting screw
Retest in similar manner as above.
T
210bar
(2) Port relief valve

Loosen valve housing.
Set adjusting screw to desired pressure
Valve housing
setting.
Tighten valve housing.
Retest in similar manner as above.
AB
T
Adjusting screw
240bar
6-31
6. PILOT OIL SUPPLY UNIT
1) STRUCTURE
19 20 21 34 17 15 14 13 9 8 12 10 11 2 3 4 16
P1
18 22 23 24 25 26 27 28 29 30 32 33 31
P2
Port Port name Port size
3Mpa
U P1 From main pump 3/4 UNF
P2 Pluging 3/4 UNF
4.5Mpa U Supply to RCV lever 9/16 UND
T To hydraulic tank 9/16 UND
P1 T
HYDRAULIC CIRCUIT
1 Plug 14 Plug 24 Valve seat

2 Plug 15 Copper washer 25 O-ring
3 Seat 16 Housing 26 Plug
4 Ball 17 Plug 27 Copper washer
8 Spring 18 O-ring 28 Valve poppet
9 Spring guide 19 Accumulator 29 Plug
10 Shim 20 Seal 30 Spring
11 Plug 21 Adapter 31 Adjusting screw
12 Seal 22 Spring 32 Washer
13 Spool 23 Check valve 33 Nut
6-32
2) OPERATION
19 20 21 34 17 15 14 13 9 8 12 10 11 2 3 4 16
P1
18 22 23 24 25 26 27 28 29 30 32 33 31
Pilot oil supply unit are a combination of valves which reduce the pressure of medium and high pressure
circuits in order to supply remote control valve with a low pressure supply of oil. They basically consist
of the accumulator(19), the housing(16), a seat(3), a direct operated pressure relief valve(28) and a
check valve(23).
Fluid flows from the high pressure via the shuttle valve(4) through port P1 into the unit and then to the
secondary circuit. The pressure is reduced to the required level by means of spool(13) and passes via
the check valve(23) into the accumulator(19) thus ensuring though port U greater control power and-
when necessary-emergency operation should the main circuit be switched off or become defective.
Pressure relief valve(28) protects the pilot circuit should the spool(13) fail to operate. Check valve(23)
prevents the accumulator emptying into the primary circuit.
Accumulator satisfies short term peak power demands and is a source of emergency power should the
main circuit pressure fail.
6-33
7. SAFETY VALVE UNIT
1) STRUCTURE
The safety valve locks or permits pilot oil flew to the main control valve operation.
P
12
T
13
6
2
9,10 5
7
11 4
P 14
1
T
1 Body 6 Handle 11 Spring plunger

2 Retainer 7 Spring pin 12 Knob
3 Adjust stem 8 O-ring 13 Socket set screw
4 Housing 9 O-ring 14 Spring pin
5 Clutch ring 10 Back up ring
6-34
8. BOOM AND BUCKET CYLINDER
The boom cylinders are two unit and the bucket cylinder is one unit. They use a bolt on rod guide.
The piston(12) threads on to the rod(2) and is retained by a nylon nut(18).
The piston seals(15) against the tube(1) with dust ring(17). Two wear rings(16) are located on each
side of the piston seal.
The gland(3, the rod guide) seals against the tube with an O-ring(10). The cylinder thread seals
against the rod with a lip type buffer ring(7) and a rod seal(5). A dust wiper(8) cleans the rod when it
is retracted.
1) BOOM CYLINDER
3 1 20 24 25,26 21 27,28
19 5,6 7 10,11 23 22 4 2 13,14 17 15 16 12 18
8,9
INTERNAL DETAIL
1 Tube assy 11 Back up ring 21 Pipe assy

2 Rod assy 12 Piston 22 O-ring
3 Gland 13 O-ring 23 Socket bolt
4 Bushing 14 Back up ring 24 Pipe clamp
5 Rod seal 15 Piston seal 25 Hexagon bolt
6 Back up ring 16 Wear ring 26 Spring washer
7 Buffer ring 17 Dust ring 27 Bushing
8 Dust wiper 18 Nylon nut 28 Dust seal
9 Snap ring 19 Socket bolt
10 O-ring 20 Pipe assy
6-35
2) BUCKET CYLINDER
1 25-1,25-2 25-3,25-4,25-6 21 24 26,27
25-4,25-5,25-6
19 5,6 3 7 10,11 4 2 13,14 17 15 16 12 18 22
8,9
INTERNAL DETAIL
1 Tube assy 12 Piston 25 Band assy

2 Rod assy 13 O-ring 25-1 Band sub assy
3 Gland 14 Back up ring 25-2 Band
4 Bushing 15 Piston seal 25-3 Hexagon bolt
5 Rod seal 16 Wear ring 25-4 Spring washer
6 Back up ring 17 Dust ring 25-5 U-bolt
7 Buffer ring 18 Set screw 25-6 Hexagon nut
8 Dust wiper 19 Socket bolt 26 Bushing
9 Snap ring 21 Pipe assy 27 Dust seal
10 O-ring 22 O-ring
11 Back up ring 24 Socket bolt
6-36
9. HYDRAULIC OIL TANK
1) STRUCTURE
The oil from the hydraulic tank is sent from the pump through control valve to the cylinders.
In the return circuit, the oil from various parts merges.
A part of oil is cooled in the oil cooler(If equipped), passes through the hydraulic filter and returns
to the hydraulic tank(1).
If the hydraulic return oil filter becomes clogged, return filter bypass valve(9) acts to allow the oil to
return directly to the hydraulic tank(1). This prevents damage to the hydraulic filter(8). The
bypass valve(9) is also actuated when negative pressure is generated in the circuit.
10
5,6 11
12
8
16,17
13
4
3 14,15
5,6 7
1 Hydraulic tank 7 Pipe 13 O-ring

2 Cover 8 Element 14 Bolt
3 Cover 9 Bypass valve 15 Hardened washer
4 O-ring 10 Spring 16 Overheat switch
5 Bolt 11 Air breather 17 O-ring
6 Hardened washer 12 Level gauge
6-37
2) RETURN OIL FILTER BYPASS VALVE
(1) When the filter is clogged
Bypass valve(1) is opened and the oil
returns directly to the tank without passing 1
through the filter.
Bypass valve set pressure : 1.36kgf/cm2
(19.3psi)
From MCV
6-38
3) AIR BREATHER
The air breather is equipped with the
capacity to perform three functions
simultaneously-as an air filter, breathing
valve, and as a lubrication opening.
(1) Preventing negative pressure inside
the tank
The tank is a pressurized sealed type, so
negative pressure is formed inside the
hydraulic tank when the oil level drops
during operations. When this happens, 4
the difference in pressure between the
tank and the outside atmospheric 1
pressure opens the poppet in the
breather, and air from the outside is let 2
into the tank or prevent negative pressure.
(2) Preventing excessive pressure inside 3
the tank
When the hydraulic cylinder is being used,
the oil level in the hydraulic system
increases and as temperature rises. If
the hydraulic pressure rises above the set
pressure, breather is actuated to release
the hydraulic pressure inside the tank. 1 Body 3 Strainer
2 Element 4 Cap
6-39
10. ACCUMULATOR
The accumulator is installed at the pilot oil 1
supply unit. When the boom is left the 2
raised position, and the control levers are
operated with the engine stopped the
pressure of the compressed nitrogen gas
inside the accumulator sends pilot pressure 3
to the control valve to actuate it and allow 4
the boom and bucket to come down under 5
their own weight.
Type of gas Nitrogen gas(N2)
Volume of gas 0.75 (0.2 U.S.gal)
Charging pressure of gas 16kgf/cm2(228psi)
1 Screw plug
Max actuating pressure 30kgf/cm2(427psi)
2 Sealing ring
3 Diaphragm
4 Closure button
5 Steel pressure vessel
6-40
This procedure is designed so the mechanic can make a quick check of the system using a minimum
amount of diagnostic equipment. If you need additional information, read Structure and function,
Group 1.
If verification is needed, you will be given next best source of information:
6-41
Ɠ Hydraulic oil must be at operating temperature for these checks(Refer to page 6-56).
Hydraulic system warm- Hold a hydraulic function over OK

up procedure relief to heat oil.(Don't keep relief Check completed.
Run engine at high idle. condition over 5 seconds at a
Refer to page 6-56. time)
Periodically cycle all hydraulic
functions to distribute warm oil.
Repeat procedure until oil is at
operating temperature.
FEEL : Hydraulic tank must be
uncomfortable to hold your hand
against.
(Approximately 45~55ŞC)
Hydraulic pump With bucket flat on ground, OK
performance check actuate boom raise. Time how Check completed.
Heat hydraulic oil to long it takes to raise boom to full
NOT OK
operating temperature. height.
Go to steering unit high
Run engine at high idle.
LOOK : Boom must raise to full pressure check at page
height in less than 4.6 seconds. 5-25.
IF OK
Do steering unit leakage
check at page 5-24.
IF OK
Do main hydraulic pump
flow test at page 6-57.
Control valve lift check With bucket partially dumped, OK

Run machine at low idle. lower boom to raise front of Check complete.
machine.
NOT OK
Slowly move boom control Repair lift checks in main
lever(RCV lever) to boom lower control valve.
position.
Slowly move bucket control lever
to bucket dump position.
LOOK : Boom must not raise
before moving down.
Bucket must not rollback before
dumping.
6-42
Bucket rollback circuit Position bucket at a 45Şangle OK

relief valve check against an immovable object. Check complete.
Engage transmission in 3rd speed NOT OK
forward. Replace boom lower
check valve.
LOOK : Bucket angle must not
change.
Bucket dump circuit Raise front of machine which OK
relief valve low pressure bucket at 45Şangle. Go to next check.
check
Backdrag with bucket while NOT OK
observing bucket angle. Do loader system and
circuit relief valve test at
LOOK : Bucket must not rollback
page 6-56.
Pilot control valve float With the bucket partially dumped, OK
check lower boom to raise front of Check complete.
Run engine at low idle. machine.
NOT OK
Push control lever to the float
Do pilot control valve
detent position and release lever.
pressure test in group 3.
LOOK : Front of machine lower to
the ground and valve must remain
in float position when lever is
released.
Boom cylinder and Set the boom and bucket OK
bucket cylinder drift horizontal, then stop the engine. Check complete.
check
Stop the engine, wait for 5 NOT OK
minutes, then start measuring. Go to next check.
Measure the amount the lift and
dump cylinder rods retract during
15 minutes.(Unloaded bucket)
B
A : Retraction of boom cylinder

rod
A
B : Retraction of bucket cylinder
rod
Boom cylinder must drift less than
30mm.
Bucket cylinder must drift less
than 30mm.
6-43
Boom cylinder leakage Dump bucket until teeth or cutting OK

check edge is perpendicular to the Drift is approximately the
Heat hydraulic oil to ground. same between first and
operating temperature. second measurement.
Raise boom until cutting edge is
about 1m(3ft) above ground. Repair main control valve
or circuit relief valve.
Stop engine. Measure drift from
tooth or cutting edge to ground for NOT OK
1 minute. If drift is considerably less
on second measurement,
Wait 10 minutes.
repair cylinder.
Measure drift from tooth or cutting
edge to ground for 1 minute.
LOOK : Compare the drift rate
between the first measurement
and the second measurement.
Bucket cylinder leakage Raise bucket about 1m(3ft) off OK
check ground with bucket level. Drift is approximately the
Heat hydraulic oil to same between first and
Stop engine. Place a support
operating temperature. second measurement.
under boom.
Repair main control valve
Measure drift from tooth or cutting
or circuit relief valve at
edge to ground for 1 minute.
page 6-58.
Wait 10 minutes.
NOT OK
Measure drift from tooth or cutting Drift is considerably less
edge to ground for 1 minute. on second measurement.
LOOK : Compare the drift rates Repair cylinder.
between the first measurement
and the second measurement.
Check valve of safety Put bucket level and position OK
valve leakage check about 1.2m(4ft) above ground. Check complete.
Place a piece of tape on cylinder NOT OK
rod at least 51mm(2in) from rod Check or replace safety
guide. valve.
Run engine at low idle in safety-
release position.
LOOK : Bucket must not drift up.
Pilot control valve Stop engine. Turn key switch to OK
(RCV lever) check OFF position. Check completed.
Move control lever to all positions
NOT OK
and then release.
Repair pilot control valve.
LOOK : Lever must return to
neutral when released from all
positions.
6-44
Bucket leveler Position bucket fully dumped just OK

(Positioner) check above ground level. Check complete.
Move control lever to bucket NOT OK
leveler detent position and Do bucket leveler checks
release. in group 3.
LOOK : Bucket must rollback to
the level position and control lever
must return to neutral.
If bucket is in a rolled back
position when key is turned ON,
control lever must be returned to
neutral manually if placed in the
bucket leveler detent position.
After bucket is dumped once,
bucket leveler will work normally.
Boom height kickout Position bucket flat on ground. OK
check Check complete.
Move control lever to boom raise
detent position and release. NOT OK
Do boom height kickout
LOOK : Boom must raise to the
check in group 3.
set height and stop.
Control lever must return to
neutral.
Cycle time check Function Operating condition. Cycle time
Boom raise Bucket flat on ground to full height. 4.6sec
Run engine at high idle. Boom lower Full height to level ground. 2.3sec
(Float)
Bucket dump Boom at full height. 1.0sec
Bucket rollback Boom at full height. 1.4sec
Steering(No. of Frame stop to frame stop. 1.6sec(4 turns)
turns)
OK
Check complete.
NOT OK
Go to slow hydraulic
functions in group 3.
6-45
Ɠ MEASURING BOOM AND BUCKET CYCLE TIME
1. MEASUREMENT CONDITION
şCoolant temperature : Inside operating range
şSteering position : Neutral
şHydraulic temperature : 45~55Ş C
şBucket : Unloaded
şEngine speed : High idling
2. MEASURING TOOL
şStop watch(1 EA)
3. MEASURING PROCEDURE
Lifting time of boom
1) LIFTING TIME OF BOOM
Set the bucket near the maximum tilt back
position and at the lowest position on the
ground. Raise the bucket and measure
the time taken for bucket to reach the
maximum height of the boom.
2) LOWERING TIME OF BOOM

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

Raise the boom to the maximum height and Dumping time of bucket
measure the time taken for the bucket to Rollback time of bucket
move from the maximum tilt back position
to the maximum dump position
4) ROLL BACK TIME OF BUCKET
Raise the boom to the maximum height and
measure the time taken for the bucket to
reach the maximum tilt back position.
6-46
2. TROUBLESHOOTING
Ɠ Diagnose malfunction charts are arranged from most probable and simplest to verify, to
least likely, more difficult to verify. Remember the following steps when troubleshooting a
problem :
Step 1. Operational check out procedure(See section 1)

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

functions
Cold oil. Warm oil up.
Slow engine speed. Adjust engine speed control linkage.
Check high idle speed.
Suction line air leak. Check for foamy oil.
Low oil supply. Add recommended oil.
Wrong oil viscosity. Use recommended oil.
Oil leaking past cylinders or control Check cylinder drift in group 2.
valve.
Blocked or damaged line. Inspect lines.
Faulty or misadjusted pilot oil supply Do pilot oil supply unit pressure test in
unit. group 3.
Faulty pilot control valve(RCV). Do pilot control valve(RCV) pressure
test in group 3.
Binding main control valve spool. Inspect valve.
Faulty priority valve. Check priority valve specification.
6-47
No steering or hydraulic Low oil level. Add recommended oil.
function
Failed hydraulic pump. Remove and inspect return filter for
metal pump particles.
Failed main hydraulic pump drive. Remove main hydraulic pump and
inspect drive gear.
No hydraulic functions Failed hydraulic pump. Remove and inspect return filter for
steering normal metal pump particles, or replace the
pump.
Failed pilot line filter. Remove and inspect line filter for RCV.
Faulty safety valve. Safety valve leakage test or ON, OFF
function test.
Stuck open system and port relief Replace relief valve.
valve.
Faulty or misadjusted pilot supply unit. Do pilot supply unit pressure test in
group 3.
Boom float function Low pilot control pressure. Do pilot supply unit pressure test in
does not work group 3.
Faulty pilot control valve(RCV). Do pilot control valve pressure test.
Main control valve spool binding in Do pressure reducing valve pressure
bore. test in group 3.
One hydraulic function Faulty pilot control valve(RCV). Do pilot control valve pressure test.
does not work
Stuck open port relief valve. Replace relief valve.
Oil leaking past cylinder packings. Do boom and bucket cylinder leakage
test in group 3.
Blockage in oil lines or valve. Inspect lines for damage.
Disconnect and inspect lines for internal
blockage.
Main control valve spool stuck in bore. Inspect and repair valve.
Low hydraulic power Leakage within work circuit. Do cylinder drift check in group 2.
Low system relief valve(Main relief Do loader system and port relief valve
valve) setting. pressure test in group 3.
Low port relief valve setting. Do loader system and port relief valve
pressure test in group 3.
Faulty or misadjusted pilot oil supply Do pilot oil supply unit pressure test in
unit . group 3.
Leaking system relief valve. Remove and inspect valve.
Worn hydraulic pump. Do hydraulic pump performance check
in group 2.
Faulty pilot control valve(RCV). Do pilot control valve(RCV) pressure
test in group 3.
6-48
Function drifts down Leaking cylinders. Do cylinder leakage checks in group 2.

Leaking seals in circuit relief valve(Port Inspect seals. Replace relief valve.
relief valve) or valve stuck open.
Leaking loader control valve. Repair or replace valve section.
Boom drifts up Leakage in boom down spool. Remove and inspect boom down spool.
Boom down does not Safety valve not operated. Operate valve.
work
Stuck pilot control valve. Inspect.
Engine off.
Faulty line filter. Remove and inspect filter.
Accumulation not operated. Inspect.
Main control valve spool stuck. Inspect and repair valve.
Oil overheats Low oil viscosity in hot weather. Use recommended oil.
Excessive load. Reduce load.
Holding hydraulic system over relief. Reduce load.
Leakage in work circuit. Do boom and bucket cylinder leakage
test in group 3.
Plugged fins in oil cooler. Inspect and clean oil cooler.
Internally plugged oil cooler. Do hydraulic oil cooler restriction test.
Incorrect system or circuit relief valve Do loader system and circuit relief valve
setting. pressure test in group 3.
Restriction in oil lines or main control Inspect for dented or kinked lines.
valve. Do hydraulic system restriction test in
group 3.
Pinched or restricted priority valve LS Run engine at low idle. Steer machine
line. back and forth. If engine load
decreases while steering, a restricted
LS line or priority valve malfunction is
indicated.
Do priority valve LS port flow test in
group 3.
Malfunctioning priority valve. Do hydraulic system restriction test in
group 3.
Leaking system main relief valve. Remove and inspect valve and seals.
Worn hydraulic pump(Internal leakage). Do hydraulic pump performance check
in group 2.
Function drops before Stuck open lift check valve. Do control valve lift check in group 2.
raising when valve is
activated
6-49
Hydraulic oil foams Low oil level. Add recommended oil.

Wrong oil. Change to recommended oil.
Water in oil. Change oil.
Loose or faulty suction lines(Air leak in Tighten or install new lines.
system).
Remote control valve Leaking plunger seals. Remove, inspect and replace plunger
(RCV) leaking seals.
RCV will not hold in No electrical supply. Check supply.

magnetic detent
Wires broken. Check supply.
Faulty connectors. Clean terminals or replace.
Contamination between armature and Examine and clean.
hold coil.
6-50
Ɠ 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 1-21, Recommended lubricants.) Never mix oil of
different makes of kinds.
7) To change the hydraulic oil, use a clean vessel and funnel for pouring it into the tank. Never use
cloth because it might cause the presence of lint in the circuit.
8) When removing the hydraulic equipment, be sure to put plugs or caps on hoses, tube lines and
ports. Also, enter mating marks for later identification.
9) Disassemble and/or assemble the hydraulic equipment only in a clean place free of dust. When
disassembling, be careful about the interchangeability of parts, and clean the disassembled parts
with pure and clean mineral cleansing oil. Clean the internal passages as well. After the parts
have dried, wipe them off with a clean lint-free cloth.
10) When overhauling the hydraulic equipment replace all O-rings, backup rings, etc. with new ones.
Assemble O-rings with grease or vaseline applied.
11) After installing the equipment, add more hydraulic oil to make up for that lost during disassembly.
12) Tighten joints correctly. Loose joints will cause the hydraulic oil to leak. If the oil leaks, the tank oil
level drops and air gets sucked in, so the pump will break down. Also loose joints in suction lines
will take air in and might cause abnormal noise, malfunction or damage to pumps.
6-51
1. HYDRAULIC OIL CLEAN UP PROCEDURE USING PORTABLE FILTER CADDY

Ɠ Service equipment and tool
şPortable filter caddy
şTwo 4000mm ź 1in 100R1 Hoses
şQuick disconnect fittings.
şDischarge wand
şVarious size fittings.
Ɠ Brake system uses oil from hydraulic oil
tank. Flush all lines in the brake, pilot.
Disassemble and clean major
components for hydraulic system.
Brake and steering components may fail
if brake and 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. Clean
filter housing before installing new element.
Ɠ For a failure that creates a lot of debris,
remove access cover from hydraulic oil
tank. Drain and clean hydraulic oil tank
of fill the specified oil to hydraulic oil
tank through upper cover.
3) To minimize oil loss, pull a vacuum in
hydraulic oil tank using a vacuum pump.
Connect filter caddy suction line to drain
port at bottom of hydraulic oil tank using
connector. Check to be sure debris has not
closed drain port.
4) Put filter caddy discharge line into hydraulic
oil tank filler hole so end is as far away from
drain port as possible to obtain a thorough
cleaning of oil.
6 -52
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.
Ɠ Hydraulic tank capacity : 45ֻ(11.9U.S.
gal)
Leave filter caddy operation for the next
steps.
6) Start the engine and run it at high idle.
Ɠ For the most effective results, cleaning
procedure must start with the smallest
capacity circuit then proceed to the next
largest capacity circuit.
7) Operate all functions, one at a time, through
a complete cycle in the following order:
Clam, steering, bucket, and boom. Also
include all auxiliary hydraulic functions.
Repeat procedure until the total system
capacity has circulated through filter caddy
seven times, approximately 30 minutes.
Each function must go through a minimum
of three complete cycles for a through
cleaning for oil.
Ɠ Filtering time for machines with auxiliary
hydraulic functions must be increased
because system capacity is larger.
8) Stop the engine. Remove the filter caddy.
9) Install a new return filter element.
10) Check oil level in hydraulic oil tank ; Add oil
if necessary.
6 -53
2. BOOM HEIGHT KICKOUT ADJUSTMENT
1) Lift the boom up to a desired height, set the
boom control lever at hold, then stop the Proximity switch
Front frame
engine.
Plate
Be careful lest work equipment fall
down.
Put the hydraulic safety lock lever in the
LOCK position.
Boom
2) Loosen bolts then tighten them after

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

between the plate(B) and the probe of the Proximity switch
Plate(B) Nut
proximate switch are 3Ź1mm.
3Ź1mm
4) Start the engine. Position the bucket on

the ground. Then lift the bucket to a Detent position
desired height by using the control lever
and release the hand.
Confirm the lever automatically returns to
the neutral position and the boom(The
bucket) stop at the adjusted position.
6 -54
3. TEST TOOLS
1) CLAMP-ON ELECTRONIC TACHOMETER
INSTALLATION
şService equipment and tools
Tachometer
A : Clamp on tachometer.
Remove paint using emery cloth and B
connect to a straight section of injection D
C
line within 100mm(4in) of pump. Finger
tighten only-do not over tighten.
B : Black clip(-). Connect to main frame.
C : Red clip(+). Connect to transducer. A
D : Tachometer readout. Install cable.
2) DIGITAL THERMOMETER INSTALLATION

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

The display monitor tachometer is accurate
enough for test work.
20 30
10 km/h 20
10 40
0 MPH 30
0 50
VDO
6 -55
4. HYDRAULIC OIL WARM UP PROCEDURE
1) Install temperature reader(See temperature
reader installation procedure in this group).
2) Run engine at high idle.
3) Hold a hydraulic function over relief to heat
the oil.
4) Periodically cycle all hydraulic functions to
distribute warm oil.
5) Heat oil to test specification(Approx 50Ɓ
C).
6 -56
5. MAIN HYDRAULIC PUMP FLOW TEST
ş SPECIFICATION
Oil temperature 65Ź6ƁC(150Ź10Ɓ F)
Engine speed 2300Ź25rpm
Test pressure 210Ź3bar(3046psi)
Maximum pump flow 66ֻ/min(17.4gpm)
ş FLOW METER GAUGE AND TOOL
Gauge 0~35MPa(0~350bar, 0~5000psi)
Temperature reader
1) Make test connections.
2) Install temperature reader.
(See temperature reader installation
procedure in this group.)
3) Heat hydraulic oil to specifications.
(See hydraulic oil warm up procedure in this
group.)
4) Run engine at test specifications.
5) Close flow meter loading valve to increase
pressure to test specifications.
6) Read flow meter.
TO MCV
7) If flow is below specifications, check suction
line and suction pressure for abnormality
before removing pump.
6 -57
6. LOADER SYSTEM AND PORT RELIEF
VALVE PRESSURE TEST
ş SPECIFICATION
Oil temperature(45~55Ɓ
C)
Relief valve Engine speed Relief pressure
210Ź3kgf/cm2
System(M) High
(3046Ź43psi)
Boom 240Ź5kgf/cm2
Low U
raise(U) (3410Ź70psi)
Bucket 240Ź5kgf/cm2 D T
Low
rollback(R) (3410Ź70psi)
M P
Bucket 240Ź5kgf/cm 2
Low
dump(D) (3410Ź70psi)
R
ş Gauge and tool

D : Bucket dump relief valve
M : System(Main) relief valve
R : Bucket rollback relief valve
U : Boom raise relief valve
1) Install pressure gauge to block(A) in pump
delivery line.
3) Heat hydraulic oil to specifications. Block
(Rear frame mounting)
(See hydraulic oil warm up procedure in this
group.)
4) To check the system relief valve(M), run
engine at high idle. Lower boom to
bottomed position.
Slowly activate boom down function while
watching pressure gauge. If pressure is not
to specification, loosen lock nut on system
relief valve(M) and adjust to specification.
6 -58
Ɠ Do not adjust the system relief valve
above 250kgf/cm2 (3560psi). Damage to
the pump will result from excessive
pressure settings.
5) To check the bucket dump, bucket rollback,
and boom raise, adjust the system relief
valve to 250kgf/cm2 (3560psi).
Run engine to maintain 800~850rpm when
hydraulic function is activated over relief.
Activate the function to be checked with the
cylinder bottomed. Read the pressure
gauge.
If pressure is not to specification cycle relief
valve over relief 10 times to flush.
Read pressure gauge again. Turn screw
to adjust valve to specification.
Ɠ Do not work machine with system relief
adjusted above specification or
structural damage may occur.
6) Adjust system relief valve to specification.
6 -59
7. HYDRAULIC SYSTEM RESTRICTION TEST
ş SPECIFICATION
Oil temperature 65Ź6Ɓ C(150Ź10Ɓ F)
Maximum pressure at steering(Orbitrol)
valve 2MPa(20bar, 285psi)
Maximum pressure at main control valve
1MPa(10bar, 145psi)
ş GAUGE AND TOOL
Gauge 0~7MPa(0~70bar, 0~1000psi) 2EA
This test will check for restrictions in the
hydraulic system which can cause
overheating of hydraulic oil.
1) Install temperature reader.(See temperature T
reader installation procedure in this group.)
hydraulic oil warm up procedure in this
group.)
3) Connect gauge to steering unit.
4) Connect fitting and gauge to main control
valve.
Do not operate steering or loader
functions or test gauge may be
damaged.
5) Run engine at specification and read
pressure gauges.
T
main control valve, check for a kinked,
dented or obstructed hydraulic line. Check
main control valve for a binding spool.
block, inspect neutral condition of the
steering valve and priority valve for a stuck
spool. Make sure orifice plugs are installed
in ends of priority valve spool.
Check for plugged orifice in priority valve LS
port and dynamic signal orifice on the spool
of priority valve.
6 -60
8. LOADER CYLINDER DRIFT TEST
A
ş SPECIFICATION
Oil temperature 40Ź6Ɓ
C(100Ź10Ɓ
F)
Boom horizontal
Bucket horizontal
Bucket unloaded
B
Item Standard value
Retraction of boom
30mm A : Retraction of bucket cylinder rod
cylinder rod
B : Retraction of boom cylinder rod
Retraction of bucket
30mm
cylinder rod
ş GAUGE AND TOOL

Stop watch
Temperature reader
Put the safety lock lever in the lock
position.
Do not go under the work equipment.
1) Set the boom and bucket horizontal, then
stop the engine.
2) Stop the engine, wait for 5 minutes, then
start measuring.
3) Measure the amount the boom and bucket
cylinder rods retract during 15 minutes.
6 -61
9. BOOM AND BUCKET CYLINDER LEAKAGE
TEST
ş SPECIFICATION
Oil temperature 40Ź6Ɓ C(100Ź10Ɓ
F)
Maximum leakage 12cc/10min
ş GAUGE AND TOOL
Temperature reader
Stop watch
Measuring container
1) Fasten temperature sensor to head end
port of cylinder to be tested. Cover sensor
with a shop towel.
group.)
Never work under raised equipment
unless it is supported with a hoist or
support stands.
3) Full extend the cylinder to be tested. If
testing the boom cylinders, restrain boom in
the fully raised position using a hoist or a
stand.
Ɠ Check cylinders for leakage in the fully
extended position only. In the retracted
position contacts the end of the cylinder
and seals off piston seal leakage.
4) Remove and plug cylinder rod end hose or
line.
5) Run engine at low idle. Activate control
lever to extend cylinder for 1 minute over
relief while measuring leakage for open
port.
If leakage is within specification, excessive
cylinder drift is caused by leakage in the
main control valve or circuit relief valve.
6 -62
10. PILOT CONTROL VALVE PRESSURE TEST
ş SPECIFICATION
Begin metering 1/4" of lever travel
Pressure at feel positionƕ:
Boom power down 18.1~19.0bar
Boom raise 19.0~30.0bar
Bucket rollback 19.0~30.0bar
Bucket dump 19.0~30.0bar
ş GAUGE AND TOOL
ƕ As the control lever is moved from neutral,
the pilot pressure will suddenly jump up to
approximately 5.8bar at 1/4in travel. The
pressure should then increase smoothly to
the specification at the FEEL position(Or
3/4 lever travel), and then jump up about
19.0bar as the lever is moved into detent.
This test will determine if adequate pilot
pressure is available to move the loader
control valve spools.
Ɠ The FEEL position is when lever is
moved to feel the ramp of the detent
before lever passes into detent position. Block
(Rear frame mounting)
1) Lower boom to ground.
2) Connect gauge to the pilot pressure port on
the bolck.
4) Heat hydraulic oil to specification.(See
group.)
6 -63
5) Run engine at specification. Activate
function to be checked and record pressure
reading.
Ɠ If boom raise or bucket rollback FEEL
positions are not operation due to boom
or bucket position, plug boom float
detent wires into bucket leveler solenoid
or boom height kickout solenoid. This
will provide a feel position on the
control lever.
6 -64
11. PILOT OIL SUPPLY UNIT PRESSURE TEST
ş SPECIFICATION
Engine speed Low idle and stop
Pilot pressure setting 30~35bar(430~500psi)
Relief valve setting pressure
45bar
Accumulator precharging pressure
16bar
ş GAUGE AND TOOL
The pilot supply unit consist of the pressure
reducing valve, the relief valve and an
accumulator. This regulates pressure to
Block
the pilot control circuit. (Rear frame mounting)
1) Connect gauge to test port on the block.
3) Heat hydraulic oil to specification.(See
group.)
4) Run engine at low idle for 1 minute and
stop engine, wait for 5 minutes. Then start
measuring.
5) If pressure in not within specifications,
replace valve. The valve is staked and
should not be adjusted.
6 -65
12. CYCLE TIME TEST
ş SPECIFICATION
Oil temperature 65Ź6Ɓ C(150Ź10Ɓ
F)
Function Operating conditions Maximum cycle time(Seconds)
Boom raise Bucket flat on ground to full height 4.6

Boom lower(Float) Full height to ground level 2.3
Bucket dump Boom at full height 1.0
Bucket rollback Boom at full height 1.4
Steering(Number of turns) Frame stop to stop 1.6(4 turns)
Hydraulic pump performance cycle time.
Function Operating conditions Maximum cycle time(Seconds)

Bucket flat on ground to full height
Boom raise 4.6
while holding steering over relief
6 -66
13. HYDRAULIC OIL FILTER INSPECTION
PROCEDURE
1) Lower the bucket to the ground, stop the
engine, move the control lever back and 1
forth several times, and clean all over the 2
upper surface of the hydraulic oil tank.
2) Remove the bolts(1) and take out the filter 3
case cover(3) and O-ring(4). 4
3) Remove the spring(5) and bypass valve(6).

5
4) Remove the filter element(7) from the tank.
6
5) Check the element and the filter case
bottom for debris. Excessive amounts of
brass and steel particles can indicate a 7
failed hydraulic pump or a pump failure in
process. A rubber type of material can
indicated cylinder packing or other packing
failure.
Ɠ The hydraulic oil filter in the filter case of
the hydraulic oil tank should be
replaced every 250 operating hours(For
the first replacement, at 50 hours) or
more often. When the filter element is
replaced, please keep as follows.
(1) Clean the inside of the filter case.
(2) Place new element in the proper positions
inside the filter case.
(3) Install the bypass valve and spring.
Make sure the element stand upright, and
check for complete contact of the element
bottom with the filter case bottom.
(4) Install the O-ring and filter case covers.
Tighten them with bolt. Replace the O-
ring with new one if damaged.
6 -67
1. MAIN PUMP
1) STRUCTURE
10
5
6
7
7
6
17 12 5
9
4
3 19
4 20
12 5
6
7
16 1
14
7 2
18 6
5
15
12
11
13
1 Shaft seal 8 Driven gear 15 Drive shaft

2 Circlip 9 Drive gear 16 Cover
3 Flange 10 Front body 17 O-ring
4 O-ring 11 Splined coupling 18 Stud assy
5 Seal 12 O-ring 19 Serrated washer
6 Seal 13 Center body 20 Nut
7 Balance plate 14 Driven gear
6 -68
2) GENERAL INSTRUCTION
(1) Cleanliness
‫ ڸ‬Cleanliness is the primary means of assuring satisfactory hydraulic pump life. Components
such as flanges and covers are best cleaned in soap and hot water, then air dried. Gears
should be washed in solvent, air dried, and oiled immediately.
Certain cleaning solvents are flammable. Do not allow sources of ignition in the area
when using cleaning solvents.
‫ ڹ‬Protect all exposed surfaces and open cavities from damage and foreign material.
Ɠ Gear journals and gear faces are super finished. Take care not to touch these surfaces
after oil and solvent have been removed.
(2) Lubrication of moving parts
During assembly, all running surfaces(Bushing and spacer plate) must be lightly lubricated with a
clean oil or aerosol lubricant.
(3) Tools required for assembly
‫ ڸ‬Torque wrench(0~20kgfşm, 0~150lbfşft)
‫ ڹ‬Open end wrenches
‫ ں‬Seal installation tools(Inner and outer)
‫ ڻ‬Shaft bullet(Seal protector)
‫ ڼ‬Installation plate
6 -69
3) DISASSEMBLY
10
5
6
7
7
6
17 12 5
9
4
3 19
4 20
12 5
6
7
16 1
14
7 2
18 6
5
15
12
11
13
Ɠ Prior to starting work ensure that the pump and the working area are thoroughly clean and free
from sources of contamination.
(1) Mark end cover(16), center body(13), front body(10) and mounting flange(3) to ensure correct
assembly.
(2) Remove the 4 bolts(18), serrated washers(19), nut(20) clamping the units together, separate the
pumps by removing the rear unit from the location dowels in the center body - use a soft faced
hammer.
(3) Remove splined coupling(11) and discard O-ring(12) sealing the internal passages between the
pump sections.
(4) Disassemble rear pump by removing the end cover(16) from the body(13), free cover front
location spigot using a soft faced hammer.
(5) Remove drive shaft(15) from its bore by pushing it out from the connection hole in the rear face,
this will also remove balance plate(7).
Ɠ Note position of gear and balance plate for correct reassembly.
6 -70
DISASSEMBLY
10
5
6
7
7
6
17 12 5
9
4
3 19
4 20
12 5
6
7
16 1
14
7 2
18 6
5
15
12
11
13
(6) Remove driven gear(14) and lower balance plate(7).

(7) Discard O-ring(4) from end cover, seal element(5) and seal energizer(6) from balance plates.
(8) Disassemble front pump by separating flange(3) from its location spigot in body(10) - use soft
faced hammer.
(9) Remove shaft seal(1) from flange(3). Flanges have two shaft seals fitted back to back and the
outer shaft seal must be removed first to gain access to retaining circlip(2).
(10) Remove circlip(2) and inner shaft seal(1) take care to ensure that the seal recess is not damaged
as this could result in leakage.
(11) Grasp drive shaft(9) and remove it with balance plate(7), finally remove driven gear(8) and lower
balance plate(7).
Ɠ Note their positions for correct assembly.
(12) Remove and discard O-ring(4) in flange recess and seal element(5) and seal energizer(6) from
balance plates.
(13) Clean off all loctite sealant from flange/ body and end cover/body interfaces.
6 -71
4) INSPECTION AND REPAIR
(1) Assessment
Each components should be thoroughly cleaned, carefully examined and assessed for suitability
re-use. Below is a guide for inspecting the various components.
(2) Body
‫ ڸ‬Inspect the body bore cut-in where both gears wipe into the body.
‫ ڹ‬The body can only be re-used if the cut-in is bright and polished in appearance and the depth
does not exceed 0.15mm(0.006").
‫ ں‬The body should be replaced if the surface is scored, has a matt appearance or shows signs that
the tip of the gears have dug in and torn away the surface material.
‫ ڻ‬The body should be inspected to ensure that there is no superficial damage which may adversely
effect performance or sealing. Pay particular attention to the port threads and body O-ring seal
recesses.
(3) Mounting flange and end cover
‫ ڸ‬The inner surfaces should be inspected to ensure that there is no unusual wear or scoring in the
regions where the body O-rings and backing rings contact, which result in external leakage.
‫ ڹ‬Check the shaft seal recess for scoring or damage that could result in oil leakage around the
outer diameter of the shaft seal. Replacement shaft seals can be refitted with Loctite hydraulic
sealant to overcome slight damage in this area.
(4) Balance plate
‫ ڸ‬The side faces which abut the gears should be perfectly flat showing no sign of scoring.
Characteristically there are bright polished areas on this surface caused by loading against the
gear side faces, which is often more pronounced on the low pressure side. The balance plate
should be replaced if there is any general scoring or fine scoring with a matt appearance or
tearing of the surface material. Often there is a witness where the tips of the opposing gears
have wiped an overlap reassembling a half moon shape. There must be no noticeable wear
step as it is critical that the balance plate side face is completely flat to the gear side face.
‫ ڹ‬The bearing liners are acceptable providing that they are not scored or show other damage. The
general outside area of the balance plate should not show any prominent signs of wear.
(5) Gears
‫ ڸ‬The gear side faces should be examined for bruising or scoring. Often operation on
contaminated fluid shows scoring between the root of the gear and the journal undercut, which
leaves a wear step. If a wear step can be felt, coincidental with the root diameter, by drawing a
sharp pointed tool across the surface from the undercut outwards towards the tip of the gear,
then the gear is unserviceable.
‫ ڹ‬The gear teeth should then be carefully examined to ensure that there are no signs of bruising or pitting.
‫ ں‬The journal bearing surfaces should be completely free from scoring or bruising. The surface
should appear highly polished and smooth to touch.
‫ ڻ‬Examine the area where the shaft seal lips run on the drive shaft, this shows up as a polished
ring or rings. If a noticeable groove can be felt or there is scoring the shaft should be replaced.
‫ ڼ‬Provided the drive shaft is not damaged from the drive-coupling and the gears have not been
harmed as described above, then the gears can be re-used. If, however, the gears are
damaged they must be replaced as a matched pair.
‫ ڽ‬As a matter of good practice, when pumps have been disassembled, all the seals should be
replaced. It is most important that only the genuine seals are used.
6 -72
5) ASSEMBLY
10
5
6
7
7
6
17 12 5
9
4
3 19
4 20
12 5
6
7
16 1
14
7 2
18 6
5
15
12
11
13
Ɠ Prior to assembly all parts must be perfectly clean and lubricated with clean hydraulic oil.
Ɠ Renew all seals using clean hydraulic oil as a lubricant.
(1) Front pump
‫ ڸ‬Fit inner shaft seal(1) into the recess in the mounting flange, with the garter spring facing into the
pump, refit circlip(2) into its groove.
Fit outer shaft seal with garter spring facing uppermost. Coat lips of seals with a high melting
point grease.
Ɠ If the seal recess has been scored, then seal outside diameter can be coated with loctite
hydraulic sealant to prevent leakage.
‫ ڹ‬Stand pump body on its rear face, fit seal element(5) and seal energizer(6) to the groove in the
balance plate. Carefully feed the balance plate into the body bores. Ensure that the seals
remain in position and that the two small holes through the balance plate are to the low pressure
side of the unit, i.e. side with large 4 bolt port pattern.
6 -73
ASSEMBLY
10
5
6
7
7
6
17 12 5
9
4
3 19
4 20
12 5
6
7
16 1
14
7 2
18 6
5
15
12
11
13
‫ ں‬Insert drive shaft(9) and driven gear(8) into their original bores.
‫ ڻ‬Replace top balance plate with small holes to low pressure side of the unit, fit seal element(5)
and seal energizer(6) to grooves in balance plate.
‫ ڼ‬Fit O-ring(4) to groove in mounting flange and apply a small amount of loctite sealant to the body
lower face, i.e. outboard of oval spigot. This sealant is to prevent moisture entering this area
preventing corrosion.
‫ ڽ‬Carefully feed mounting flange over the drive shaft, ensure flange is in its original position-4mm
hole in rear face of flange must be to the low pressure side of the unit. Tap flange on to its
location spigot with a soft faced hammer.
(2) Rear pump

‫ ڸ‬Support front pump on the mounting flange-not the drive shaft-fit O-rings(12) into the grooves
around connection passages in the rear face, replace splined coupling(11).
‫ ڹ‬Fit rear pump body to front pump ensuring that it locates on the dowels and the through holes
line up.
6 -74
10
5
6
7
7
6
17 12 5
9
4
3 19
4 20
12 5
6
7
16 1
14
7 2
18 6
5
15
12
11
13
‫ ں‬Fit seal element(5) and seal energizer(6) to grooves in balance plate(7) and carefully feed into
body bores. Ensure seals remain in position and that the two small holes through the balance
plate are to the low pressure side, i.e. the side without a port.
‫ ڻ‬Fit drive gear(15) ensuring that it locates in the splined coupling(11), fit driven gear(14).
‫ ڼ‬Replace upper balance plate in its original position, i.e. with 2 small holes to low pressure side, fit
seal element(5) and seal energizer(6) to groove in plate.
‫ ڽ‬Fit O-ring(4) to groove in end cover, apply a small amount of loctite sealant to lower face of body,
i.e. outboard of oval spigot.
‫ ھ‬Studs(18) to be screwed into cover(16). Prior to fitting flange(3) washers(19) and nuts(20).
şTightening torque : 9.5Ź0.7kgfşm(68.7Ź5.1lbfşft)
‫ ڿ‬Pour a small amount of clean hydraulic oil into ports and check that the unit rotates without undue
force. If excessive force it required then seals in balance plates are possibly trapped and the unit
should be disassembled and reassembled correctly.
6 -75
6) RUNNING-IN
Pressure gauge
Test unit Variable

Micronic restrictor
filter
Flow
meter
Relief valve
Strainer
Tank
(1) A unit which has been reassembled with either new gears, balance plate or body, must be
carefully run-in before it is subjected to full working conditions.
(2) Ideally this should be done on a test rig(See figure) where pressure can be gradually applied and
any wipings from the body cut-in arrested by filters.
(3) It is recommended that the unit is run-in at 1500rpm, initially, at zero pressure for one minute then
in stages with the pressure increased by 500psi every minute, until maximum rated pressure has
been attained. Frequently check the system temperature, ensuring that it does not exceed the
maximum permissible figure of 80Ɓ C. If the temperature exceeds the system or unit specification
the test must be delayed and operated off-load until acceptable temperatures are obtained.
6 -76
2. RCV LEVER
1) STRUCTURE
17
12
4 1
29 24 2 13
3
28 5 6
23
26
4 7
21 1 1
27
A
15
16 4 1
8
9 3 2
10
25
18 14
15 19 30
11
20
22
1 Spring pack 12 Prefeel cage assy 22 Hand coil

3 Spring 13 Spindle retainer 23 O-ring
4 Plunger assy 14 Spindle 24 Wiper seal
5 Plunger assy 15 Nut 25 Plug
6 Plunger assy 16 Lever assy 26 Boot retainer collar
7 Plunger assy 17 Handle assy 27 Handle adapter
8 Body kit 18 Lever assy 28 Nut
9 Prefeel kit 19 Socket screw 29 Nut
10 Prefeel kit 20 Connector assy 30 Insulation tube
11 Detent kit 21 Rubber boot
6 -77
2) DISASSEMBLY AND ASSEMBLY
(1) Remove the rubber boot(21), unscrew the
handle(17), remove the cables(30). 21
17
30
(2) Retain the lever pivot(16) and unscrew

the locknut(15). This will allow removal of
the lever pivot together with the prefeel
assemblies(10). Ensure that the prefeel
assemblies are identified, without
damage, and can be returned to the same 16
10
bores. Clean all parts, particularly the 15
armature and magnet faces and check for
any sign of damage. The universal joint,
which is held with a locknut, need not be
unscrewed if there was no free play in the
lever mechanism.
(3) The four capscrews(19) holding the

magnet retaining plate can now be
unscrewed.
şTorque limit : 1.02kgfşm(7.38lbfşft) 19
(4) This will release the hold coils(22), blanks,

prefeel cage assemblies(12), spindle
guides(13). These can all be removed 22 12
but ensure that they are identified so that
they can be repositioned in the same
bores.
13
6 -78
(5) The spindle guide/operating shaft
subassemblies are now exposed and can
be removed and disassembled.
These contain an O-ring seal on the insert
diameter and a rod seal/wiper inside the
bore. These O-rings and seals can be
removed and new components fitted.
Ensure that all parts are clean before
refitting.
(6) The piston assembly(1) can be removed

from its bore, together with the return
spring(3), again ensuring that each
1
assembly is identified so that it can be 3
correctly replaced. Take care to note the
positions of any shims if the sub assembly
is disassembled as these are critical to the
performance. The assembly is
disassembled by removing a C washer at
the top of the assembly. All other parts
can then be removed. Replace any parts
necessary and rebuild.
6 -79
3. MAIN CONTROL VALVE
1) STRUCTURE(1/2)
61
62
2, 3 63
4
5
59
60
58
39
22 T
2A
1 1A
2B
1B
P
38
24
40
73 41
42
7 72 24
6 71 43
62 69
61 70
25
5 21 68 65
4
73
72 24
71 23
74 25
75 26
76
77
70
68
1 Inlet housing 26 Bolt 63 Tie stud

2 O-ring 38 Spool 65 Stop
3 O-ring 39 Spool section 68 Housing
4 Plug 40 Seal extension 69 Check valve
5 O-ring 41 O-ring 70 O-ring
6 Plug 42 Sleeve 71 Back up ring
7 O-ring 43 Cover 72 O-ring
21 Spool 58 Outlet housing 73 Spring
22 Spool section 59 Plug 74 Check valve
23 Cover 60 O-ring 75 Poppet
24 O-ring 61 Hexagon nut 76 Spring
25 Lock washer 62 Washer 77 Adjusting screw
6 -80
2) STRUCTURE(2/2)
64
25
54
66
52
48
50
44
55 45
56 57
47 28
36 49 44
25 35 51
32 46
31 53
20
33
19 34 37
27
16 30 24
15 29
14 28
17 37
10 27
18 24
68 13
70 11
77 2A T
76 12 1A
75 89 2B
74 P 1B
71
72
73
81
80
78
79
8 O-ring 25 Lock washer 46 Spring retainer 68 Housing

9 Back up ring 27 Seal retainer 47 Spring retainer 70 O-ring
10 Pin 28 O-ring 48 Shim 71 Back up ring
11 Plunger 29 Adapter 49 Shim 72 O-ring
12 Sleeve 30 Spring retainer 50 Spring retainer 73 Spring
13 Spring 31 Spring retainer 51 Spring 74 Check valve
14 O-ring 32 Screw 52 Spring 75 Poppet
15 Pilot housing 33 Spring 53 Spool cap 76 Spring
16 O-ring 34 Shim 54 Cover 77 Adjusting screw
17 Spring 35 Cover 55 Screw 78 O-ring
18 Poppet 36 Bolt 56 Washer 79 Cap
19 Adjusting screw 37 Shim 57 O-ring 80 Spring
20 Lock nut 44 Seal retainer 64 Screw 81 Check valve
24 O-ring 45 Circlip 66 Stop
6 -81
2) DISASSEMBLY AND ASSEMBLY
Servicing intersection seals
(1) After ensuring that all external surfaces
are clean and with the valve stood on its
mounting feet loosen all 4 tie rod nuts.
(2) Stand the valve on its inlet cover end and

remove each of the 4 tie rod nuts from the
upper end of the tie rods. Lift of the cover,
check for damage, remove the existing O-
ring seals and discard.
(3) Remove the uppermost section, check for

damage, remove the existing O-rings and
discard. Repeat for the other sections.
Ensure that the sections are laid out in
order so that they can be rebuilt in the
same order. If the valve is disassembled
in this way always ensure that new seals
are used when rebuilding.
6 -82
(4) It is generally not a good policy to reuse
the original O-ring seals. Ensure that all
parts are clean, particularly the seal
grooves and the interface areas which Critical area
contact each other. Also check for any
signs of damage to these same areas.
Contamination under the seals may allow
the seals to leak, and contamination or
damage on the interface may cause either
leakage or spool stick. Pay particular
attention to the machined surfaces inside Intersection O-rings
the large O-ring seal area as these areas
rely on a metal to metal seal within this O-
ring.
(5) Starting with the inlet cover, fit new

intersection seals, and then refit the first
section, sliding over the tie rods and
ensuring that the section has located
correctly. Then fit new intersection seals
to that section and fit the next section.
After the sections have been fitted fit the
final set of interface O-ring seals and refit
the outlet cover.
Ɠ Take extra care during the assembly
process to ensure that all of the O-rings
are properly located and that none are
trapped.
Ensure that the valve is reassembled in
exactly the same order as failure to do so
may result in the valve not working to
specification.
(6) Once all the sections and outlet cover

have been refitted, the top 4 nuts can be
refitted. These should be initially finger
tightened, ensuring that there is an even
amount of thread at each end. Still with
the valve in this position evenly tighten
each nut in turn using spanners only
enough to ensure that the interfaces are
in proper contact with each other. This will
remove the danger of O-rings becoming
trapped when the valve is placed on its
mounting feet.
6 -83
(7) Stand the valve onto its mounting feet on
a level surface ensuring that all feet are in
contact with the surface. Progressively
tighten the tie rod nuts in turn and finally
torque load the nuts to 3.88/4.08kgfşm.
Do not overtighten as this may induce
spool stiction problems.
3) MAIN RELIEF VALVE SERVICING

Servicing of these units is normally limited
to replacing the O-ring seals. If a main relief
valve is stripped down then its actual setting Housing Adjuster
may be lost. If this occurs it must be reset
before it can be used on the machine.
Failure to do so may make the machine
unsafe.
There are 2 O-rings fitted onto this
assembly, one which seals between the
inlet gallery and the tank gallery and the Locknut
second which seals between the tank
gallery and atmosphere. Both of these
seals can be simply removed and replaced
with new ones. If this assembly has to be
removed for any reason then it is advised
that the seals are replaced.
şLocknut torque limit:
3.06~3.67kgfşm (22.1~26.5lbfşm)
şHousing torque limit:
4.18~4.89kgfşm (30.2~35.4lbfşm)
Ɠ Resetting procedure :
Ensure that an accurate pressure gauge is
used for this procedure.
Loosen the locknut and turn the adjuster to
change the setting. Tighten the locknut
apply the pressure a number of times and
then recheck the setting.
6 -84
4) PORT RELIEF VALVE SERVICING
to replacing the O-ring seals. If a service
port relief valve is stripped down then its
actual setting may be lost. If this occurs it
Cartridge
must be reset before it can be used on the
machine. Failure to do so may make the
machine unsafe.
service port and the tank gallery and the
gallery and atmosphere. Both of these Inner sleeve assembly Adjuster
seals can be simply removed and replaced
with new ones. If this assembly has to be
that the seals are replaced.
şCartridge torque limit:
4.18~4.89kgfşm (30.2~35.4lbfşm)
Ɠ Resetting procedure :
This valve is internally adjusted and as
such requires a special setting pot and as
such is normally factory set.
If setting is carried our ensure that an
accurate pressure gauge is used for this
procedure.
Remove the inner sleeve assembly from
the cartridge and turn the adjuster to
change the setting. Apply the pressure a
number of times and then recheck the
setting.
6 -85
5) ANTI CAVITATION VALVE SERVICING
to replacing the O-ring seals.
service port and the tank gallery and the
gallery and atmosphere. Both of these
seals can be simply removed and replace
with new ones. If this assembly has to be Cartridge
that the seals are replace.
şCartridge torque limit:
4.18~4.89kgfşm (30.2~35.4lbfşm)
6 -86
(2) Servicing spool assemblies
Ɠ It is recommended that spool assemblies
be removed from their respective
housings only when the valve sections
are bolted together. Removing spool
assemblies with the sections apart may
result in interface damage.
All O-ring seals can be replaced without
disassembling any of the spring
mechanisms so this should not normally
be necessary.
‫ ڸ‬Remove the bolts and pilot cans from

both ends of the valve.
‫ ڹ‬The spool and spring assembly can be

removed as an assembly from the spool
bore.
‫ ں‬Ensure that the spools are identified so

that they can be refitted into the same
bore.
6 -87
Ɠ The auxiliary and bucket sections have
Adapter
similar seal arrangements as shown in fig
A, while the boom section has a different
arrangement as shown if fig B.
Ɠ Adapter torque limit:
1.33kgfşm (9.62lbfşm)
Screw torque limit:
Pilot end cap bolts limit: Screw
Figure A
Ɠ Spool cap torque limit:

Spool cap
Screw torque limit:
Screw
Figure B
6 -88
4. BOOM AND BUCKET CYLINDER
1) BOOM CYLINDER
3 1 20 24 25,26 21 27,28
19 5,6 7 10,11 23 22 4 2 13,14 17 15 16 12 18
8,9
INTERNAL DETAIL
1 Tube assy 11 Back up ring 21 Pipe assy

2 Rod assy 12 Piston 22 O-ring
3 Gland 13 O-ring 23 Socket bolt
4 Bushing 14 Back up ring 24 Pipe clamp
5 Rod seal 15 Piston seal 25 Hexagon bolt
6 Back up ring 16 Wear ring 26 Spring washer
7 Buffer ring 17 Dust ring 27 Bushing
8 Dust wiper 18 Nylon nut 28 Dust seal
9 Snap ring 19 Socket bolt
10 O-ring 20 Pipe assy
6 -89
2) BUCKET CYLINDER
1 25-1,25-2 25-3,25-4,25-6 21 24 26,27
25-4,25-5,25-6
19 5,6 3 7 10,11 4 2 13,14 17 15 16 12 18 22
8,9
INTERNAL DETAIL
1 Tube assy 12 Piston 25 Band assy

2 Rod assy 13 O-ring 25-1 Band sub assy
3 Gland 14 Back up ring 25-2 Band
4 Bushing 15 Piston seal 25-3 Hexagon bolt
5 Rod seal 16 Wear ring 25-4 Spring washer
6 Back up ring 17 Dust ring 25-5 U-bolt
7 Buffer ring 18 Set screw 25-6 Hexagon nut
8 Dust wiper 19 Socket bolt 26 Bushing
9 Snap ring 21 Pipe assy 27 Dust seal
10 O-ring 22 O-ring
11 Back up ring 24 Socket bolt
6 -90
3) TOOLS AND TIGHTENING TORQUE
(1) Tools
Tool name Remark
8 B
Allen wrench
10
17
Spanner
19
(-) Driver Small and large sizes
Torque wrench Capable of tightening with the specified torques

Torque
Part name Item Size
kgfşm lbfşft
Bucket cylinder
19 M12ź1.75ź50 9.4Ź1 67.9Ź7.2
Boom cylinder
Socket head bolt
Bucket cylinder 24
M10ź1.5ź45 5.4Ź0.5 39.1Ź3.6
Boom cylinder 23
Nylon nut Boom cylinder 18 M45ź2.0ź45 250Ź20 1808Ź145
Boom cylinder 25 M12ź1.75ź40 5.5Ź0.6 39.8Ź4.3
Hex head bolt
Bucket cylinder 25-3 M10ź1.5ź30 3.2Ź0.3 23.1Ź2.2
U-bolt nut Bucket cylinder 25-5 M10ź1.5 3.2Ź0.3 23.1Ź2.2
Set screw Bucket cylinder 18 M10ź1.5ź12 5.4Ź0.5 39.1Ź3.6
Piston Bucket cylinder 12 - 200Ź20 1447Ź145
6 -91
4) DISASSEMBLY
(1) Remove gland and piston rod
‫ ڸ‬Hold the clevis section of the tube in a
vise. Use mouth pieces so as not to
damage the machined surface of the
cylinder tube. Do not make use of the
outside piping as a locking means.
‫ ڹ‬Pull out piston rod(2) about 200mm

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

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

assembly together from cylinder tube(1).
Lift 1
Ɠ Since the piston rod assembly is heavy
in this case, lift the tip of the piston rod(2)
with a crane or some means and draw it
out. However, when piston rod(2) has 3 2
been drawn out to approximately two
Oil pan
thirds of its length, lift it in its center to Pull straight
sideways
draw it completely.
6 -92
Ɠ Note that the plated surface of piston
rod(2) is to be lifted. For this reason, do
not use a wire sling and others that may
damage it, but use a strong cloth belt or a
rope.
‫ ڼ‬Place the removed piston rod assembly

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

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

Lift with a crane
rod(2).
Ɠ If is too heavy to move, move it by Plastic 3 4 2
Hammer
striking the flanged part of gland(3) with a
plastic hammer. Pull straight
Ɠ Pull it straight with gland assembly lifted
with a crane.
Exercise care so as not to damage the lip
of rod bushing(4) and packing(5, 6, 7, 8,
9) by the threads of piston rod(2).
6 -93
(3) Disassemble the piston assembly
‫ ڸ‬Remove wear ring(16), dusting(17), and 17 15 16
piston seal (15).
damage the grooves.
(4) Disassemble gland assembly

‫ ڸ‬Remove back up ring(11) and O-ring 8,9 5,6 7 11 10 4
(10).
‫ ڹ‬Remove snap ring(9) and dust wiper(8).
‫ ں‬Remove back up ring(6), rod seal(5) and
buffer ring(7).
damage the grooves.
Ɠ Do not remove seal and ring, if does not
damaged.
6 -94
5) ASSEMBLY
(1) Assemble gland assembly
‫ ڸ‬Coat the inner face of gland(3) with
hydraulic oil.
3
‫ ڹ‬Coat dust wiper(8) with grease and fit

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

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

Therefore, confirm it before fitting them.
Push bar
Ɠ Fitting rod seal(5) up side down may
damage its lip. Therefore check the
correct direction that is shown in fig.
5
6 -95
‫ ڼ‬Fit back up ring(11) to gland(3).
Ɠ Put the backup ring in the warm water of
30~50Ş C.
11
‫ ڽ‬Fit O-ring(9) to gland(3).
10
(2) Assemble piston assembly

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

Ɠ Put the piston seal in the warm water of
15
60~100Ş C for more than 5 minutes.
Ɠ After assembling the piston seal, press
its outer diameter to fit in.
‫ ں‬Fit wear ring(16), dust ring(17) to

piston(12). 17 15 16 12
‫ ڻ‬Fit O-ring(13) and backup ring(14) to
piston(12).
6 -96
(3) Install piston and gland assembly
‫ ڸ‬Fix the piston rod assembly to the work Gland assembly
bench.
Piston rod
‫ ڹ‬Apply hydraulic oil to the outer surface of
piston rod(2), the inner surface of piston
and gland.
‫ ں‬Insert gland assembly to piston rod(2).
‫ ڻ‬Fit piston assembly to piston rod.

şTightening torque : 200Ź20kgfşm Piston assembly
(Bucket cyl only) (1447Ź145lbfşft) Piston rod
‫ ڼ‬Tighten nylon nut(18) to piston rod(2)

şTightening torque : 250Ź20kgfşm 2 18
(1808Ź145lbfşft)
6 -97
(4) Overall assemble Fix with a bar
‫ ڸ‬Place a V-block on a rigid work bench.
Mount the cylinder tube assembly(1) on it
Lift
and fix the assembly by passing a bar
through the clevis hole to lock the
assembly.
‫ ڹ‬Insert the piston rod assembly in to the Straight
cylinder tube assembly, while lifting and

moving the piston rod assembly with a
Apply liquid packing
crane.
Ɠ Be careful not to damage piston seal by
thread of cylinder tube.
‫ ں‬Match the bolts holes in the cylinder Tube
head flange to the tapped holes in the
cylinder tube assembly and tighten
socket bolts to a specified torque. Piston rod
Ɠ Refer to the table of tightening torque. Hexagon
socket bolt
Gland
6 -98
SECTION 7 ELECTRICAL SYSTEM
GROUP 1 COMPONENT LOCATION
1. LOCATION 1
7 12
8 13
9 14
10
11
Switch panel
15
1 16
2 17
3
4
5
18
19
6
20
1 Horn button 8 Front work lamp switch 15 Aircon switch

2 Multi function switch 9 Main light switch 16 Hazard switch
3 Starting switch 10 Ride control switch(Option) 17 Kick down switch
4 Cluster 11 Clutch cut off switch 18 Check unit
5 Kick down switch 12 Beacon switch(Option) 19 Relay board
6 Service meter 13 Rear wiper/washer switch 20 Fuse box
7 Rear work lamp switch 14 Buzzer stop switch
7-1
2. LOCATION 2
5
2
6
7
1
8
10
11
15 12
14
13
1 Turn lamp 6 T/M oil pressure switch 11 Backup buzzer

2 Head lamp 7 E/G oil temperature sender 12 Rear combination lamp
3 Proximate switch 8 Water temperature switch 13 Fuel sender
4 Horn 9 Start relay 14 Glow timer
5 T/M temperature sender 10 Battery relay 15 Alternator
7-2
GROUP 2 ELECTRICAL CIRCUIT
7-2
CAB SIDE T/M HARNESS FRONT SIDE
GAUGE SIDE
7-4
1. ILLUMINATION CIRCUIT
1) OPERATING FLOW
Fuse box (No.2) Illumination switch [CS-39(1)] Switch ON, 1st step
[CS-39(7)] Hazard and illumination switch indicator lamp ON
[CS-39(5)] Fuse box(27) I/conn [CN-2(6)] RH Combi clearance lamp ON [CL-16(4)]
I/conn [CN-4(1)] LH Head lamp ON [CL-3(4)]
Fuse box(26) I/conn [CN-2(5)] No. plate lamp ON [CL-21(2)]
LH Combi clearance lamp ON [CL-15(4)]
I/conn [CN-4(2)] RH Head lamp ON [CL-4(4)]
I/conn [CN-7(14)] All cluster guage lamp ON
2) CHECK POINT
Engine Key switch Check point Voltage
‫ ڸ‬- GND (Switch input)

‫ ڹ‬- GND (Switch output)
OFF ON 20~25V
‫ ں‬- GND (To light)
‫ ڻ‬- GND (To gauge lamp)
Ɠ GND : Ground
7-5
ILLUMINATION CIRCUIT
FUSE BOX
106 GL
143 RG
046 RL
CN-36
LH HEAD LIGHT
2
CL-3
ILL & HEAD LAMP SW
RH HEAD LIGHT
3
CN-4
CL-4
3
NUMBERPLATE LAMP
CS-39
1
CL-21
RH COMBI
CN-8
3 CL-16
LH COMBI
CL-15
CN-2
0.5R SPEED METER
3 E
4 B km/h
0.5R 8 S
G3
CN-127
T/M TEMP
CS-41
CN-119
WATER TEMP
HAZARD SW
J2
CN-117
VOLT METER
CN-104
FUEL METER
CN-7
4
CN-107
7-6
2. HEAD LIGHT CIRCUIT
1) OPERATING FLOW
Fuse box(No.3) Head light switch [CS-39(4)] Light switch ON, 2nd step [CS-39(2)]
Multi function switch [CS-11(8)] Head light high beam power supply
Multi function switch MIDDLE [CS-11(7)] I/conn [CN-4(3)] LH Head light low beam
ON [CL-3(1)]
RH Head light low beam
ON [CL-4(1)]
Multi function switch DOWN [CS-11(6)] I/conn [CN-4(4)] LH Head light high beam
ON [CL-3(2)]
RH Head light high beam
ON [CL-4(2)]
I/conn [CN-7(3)] Cluster high beam pilot
lamp ON [CL-41(2)]
2) CHECK POINT

‫ ں‬- GND (Multi function input)
‫ ڻ‬- GND (Multi function output)
OFF ON 20~25V
‫ ڼ‬- GND (Multi function output)
‫ ڽ‬- GND (Low beam)
‫ ھ‬- GND (High beam)
‫ ڿ‬- GND (Passing B+)
Ɠ GND : Ground
7-7
HEAD LIGHT CIRCUIT
FUSE BOX
CN-36
LH HEAD LIGHT
ILL & HEAD LAMP SW
1
CL-3
RH HEAD LIGHT
CS-39
CL-4
2
CN-8
HI BEAM PILOT LAMP
7
CL-41
CN-4
4
3
5 8
CS-11
MULTI FUNCTION SW CN-7
7-8
3. WORK LIGHT SWITCH
1) OPERATING FLOW
Fuse box(No.12) Front work light switch [CS-21(6)] Work light switch ON [CS-21(2)]
I/conn [CN-5(4)] LH Front work lamp ON [CL-6(2)]
RH Front work lamp ON [CL-5(2)]
Front work lamp switch indicator lamp ON
Rear work light switch [CS-20(6)] Work light switch ON [CS-20(2)]
I/conn [CN-5(3)] LH Rear work lamp ON [CL-22(2)]
RH Rear work lamp ON [CL-23(2)]
Rear work lamp switch indicator lamp ON
2) CHECK POINT

OFF ON 20~25V
‫ ں‬- GND (Front work light)
‫ ڻ‬- GND (Rear work light)
Ɠ GND : Ground
7-9
WORK LIGHT SWITCH
FUSE BOX
CN-36
3
FRONT WORK
LIGHT,LH
FRONT WORK LAMP SW

CN-5 CL-6
FRONT WORK
LIGHT,RH
CL-5
1 3
CS-21
2 4
REAR WORK
LIGHT,LH
REAR WORK LAMP SW
CL-22
REAR WORK
LIGHT,RH
1 CL-23
CS-20 4
2
7-10
4. STARTING CIRCUIT
1) OPERATING FLOW
Battery(+) terminal Battery relay(M8, B+ terminal) Fusible link [CN-60(1)]
I/conn [CN-1(1)] Fuse box (No.15) Start switch [CS-2(1)]
Ɠ The gear selector lever is neutral position. It is necessary condition before the starting.
The gear selector lever has an output signal which is activated whenever the shift lever is in the
neutral position. This signal can be used to control a relay and prevent engine from starting
whenever the shift lever is not in the neutral position.
(1) When start key switch is in ON position
Start switch ON Start switch [CS-2(2)] I/conn [CN-2(2)] Battery relay [CR-1]
Battery relay operating(All power is supplied with the electric component)
Start switch [CS-2(3)] Fuse box [No.19] I/conn [CN-3(3)]
I/conn [CN-13(5)] Fuel shut off solenoid [CN-79]
(2) When start key switch is in START position
Start switch START [CS-2(5)] Start safety relay [CR-5(30)] Start safety relay [CR-5(87)]
I/conn [CN-3(2)] I/conn [CN-13(4)] Start relay [CR-23(1)]
Starter(Terminal B+ and M connector of start motor)
2) CHECK POINT
‫ ڸ‬- GND (Battery B+)

‫ ڹ‬- GND (Fusible link)
‫ ں‬- GND (Start key B+)
‫ ڻ‬- GND (Start key BR terminal)
‫ ڼ‬- GND (I/conn CN-2(2))
Running ON 20~28V
‫ ڽ‬- GND (Start key R2 terminal)
‫ ھ‬- GND (Start safety relay output)
‫ ڿ‬- GND (Check unit)
‫ ۀ‬- GND (Start key IG terminal)
‫ ہ‬- GND (Fuel shut off solenoid)
Ɠ GND : Ground
7-11
CN-111 CHECK UNIT
FUSE BOX
CN-58
8
SAFETY RY
7
CR-5
GEAR SELECTOR
CN-15
CN-36
1
MASTER SW
BATT RY
60R 60R 60B 60B
CS-61
CR-1
DO-3
STARTER
CN-1 CN-60
2
DO-2 CN-45
START RY
DO-1
GLOW PLUG CONTROLLER
5 3 4 8 GND 1 825 B
NC 2 CR-23
ACC 3 809 YL
START 4 810 BG EXCESS FUEL SOL
4 I> LAMP
5
9 5 U>
IN
9 OUT
IN
OUT
1
CN-62
6 3 CN-130
10
FUEL SHUT OFF SOL
CN-2
CS-2
CN-79
START SWITCH
CN-13
CN-3
7-12
5. FUEL SHUT OFF CIRCUIT
1) OPERATING FLOW
Start key OFF [CS-2(3)] Fuse box (No.19) I/conn [CN-3(3)] I/conn [CN-13(5)]
Fuel shut off solenoid [CN-79(1)]
2) CHECK POINT
‫ ۀ‬- GND (Start key IG terminal)

OFF OFF 0V
‫ ہ‬- GND (Fuel shut off solenoid)
Ɠ GND : Ground
3) WIRING DIAGRAM - See page 7-12.
7-13
6. CHARGING CIRCUIT
When the starter is activated and the engine is started, the operator releases the key switch to the
ON position.
Charging current generated by operating alternator flows into the battery through the battery
relay(CR-1).
The current also flows from alternator to each electrical component and controller through the fuse
box.
1) OPERATING FLOW
(1) Warning flow
Altermator [CN-74(D+)] I/conn [CN-13(3)] I/conn [CN-3(1)]
Check unit [CN-58(2)]
I/conn [CN-6(1)] Cluster charge warning lamp ON [CL-46(1), Below 24V]
J1(332)ơ(336) Volt meter [CN-104(B)]
(2) Charging flow
Alternator [CN-74(B+)] Battery relay [CR-1]
Battery(+) terminal Charging
I/conn [CN-60(1),(2)] I/conn [CN-1(1),(2)] Fuse box
2) CHECK POINT
‫ ڸ‬- GND (Battery)

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

Ɠ GND : Ground
7-14
CHARGING CIRCUIT
FUSE BOX
CHECK UNIT 6
CN-1 CN-60
CN-58
CN-36
CHARGE WARNING LAMP 2

1
MASTER SW
CL-46 BATT RY 60R

60R 60B 60B
7
TO STARTER
DO-5 CR-1
VOLT METER
CN-104
3
CN-6
ALTERNATOR
B+
W
D+
CN-74
CN-13
CN-3
7-15
7. ELECTRIC PARKING, DECLUTCH CIRCUIT
1) OPERATING FLOW
(1) Parking OFF
Fuse box (No.13) Parking switch [CS-4(1)‫(آ‬3)]
Parking relay [CR-28(30)‫(آ‬87)] Parking brake released
(2) Parking ON
Fuse box (No.13) Parking relay [CR-28(30)‫(آ‬87a)] I/conn [CN-15(6)]
Control unit [CN-111(22)] T/M declutch
Parking switch [CS-4(1)‫(آ‬2)] Check unit [CN-58(8)‫(آ‬4)] Parking switch indicator lamp ON
Parking brake applied
(3) Declutch ON
Fuse box (No.10) Clutch cut-off switch ON Clutch cut-off switch [CS-42(6)‫(آ‬2)]
Clutch cut-off switch indicator lamp ON
Clutch cut-off switch [CS-42(5)‫(آ‬1)]
Service brake applied
Service brake pressure switch ON [CD-5]
I/conn [CN-15(6)] Control
unit [CN-111(22)] Declutch
2) CHECK POINT
‫ ڸ‬- GND (Clutch cut-off press switch)

Running ON 20~28V
‫ ڹ‬- GND (Declutch input signal)
Ɠ GND : Ground
7-16
ELECTRIC PARKING, DECLUTCH CIRCUIT
CHECK UNIT CN-111 FUSE BOX
CN-58
2
CN-15
PARKING RY
CR-28
PARKING SW
CS-4
CN-36
CS-42
1
CLUTCH CUT-OFF SW
CD-5
CLUTCH CUT OFF
7-17
8. WIPER AND WASHER CIRCUIT
1) OPERATING FLOW
Fuse box (No.11) Wiper relay Hi [CR-4(30)‫(آ‬87a)] Front wiper motor [CN-21(1)]
Wiper relay Lo [CR-26(86), (87)]
Multi function switch [CS-12(6)]
Rear wiper & washer switch [CS-3(1)]
Rear wiper motor [CN-102(1)]
(1) Front washer switch ON
‫ ڸ‬Washer switch ON [CS-12(6)‫(آ‬2)] Washer tank [CN-22(2)] Washer operating
Check unit [CN-58(21)‫(آ‬15)] Wiper relay Lo
[CR-26(87)‫(آ‬30)] Wiper motor [CN-21(5)]
Wiper motor operating(Low)
(2) Front wiper switch ON
‫ ڸ‬INT position
Wiper switch ON [CS-12(6)‫(آ‬1)] Check unit [CN-58(10)‫(آ‬15)] intermittent signal Wiper
relay Lo [CR-26(87)‫(آ‬30)] Wiper motor [CN-21(5)] Wiper motor intermittently operating
‫ ڹ‬Lo position
Wiper switch ON [CS-12(6)‫(آ‬4)] Wiper relay Lo [CR-26(87a)‫(آ‬30)] Wiper motor
[CN-21(5)] Wiper motor operating (Low)
‫ ں‬Hi position
Wiper switch ON [CS-12(6)‫(آ‬3)] Wiper relay Hi [CR-4(30)‫(آ‬87)] Wiper motor [CN-
21(4)]
Wiper motor operating(High)
(3)
Auto-parking(When switch OFF)
Switch OFF Fuse box (No.11) Wiper relay Hi [CR-4(30)‫(آ‬87a)] Wiper motor
[CN-21(1)‫(آ‬2)] Multi function switch [CS-12(5)‫(آ‬4)] Wiper relay Lo [CR-26(87a)‫(آ‬30)]
Front wiper motor [CN-21(5)] Wiper motor stop
(4)
‫ ڸ‬Rear wiper and washer switch
Wiper switch ON(1st step)
Wiper switch ON [CS-3(1)‫(آ‬6)] Wiper motor [CN-102(5)] Wiper motor operating
‫ڹ‬ Rear wiper and washer switch indicator lamp ON
Washer switch ON(2nd step)
2) Washer switch ON [CS-3(1)‫(آ‬3)] Rear washer tank [CN-103(2)] Washer operating

‫ ڸ‬- GND (Front wiper switch power input)
‫ ڹ‬- GND (Rear wiper switch power input)
‫ ں‬- GND (Wiper relay power input)
‫ ڻ‬- GND (Front wiper motor Lo power input)
‫ ڼ‬- GND (Front wiper motor High power input)
Stop ON 20~25V
‫ ڽ‬- GND (Wiper relay power input)
‫ ھ‬- GND (Front washer power output)
‫ ڿ‬- GND (Rear washer power output)
‫ ۀ‬- GND (Front wiper motor power output)
‫ ہ‬- GND (Rear wiper motor power output)
Ɠ GND : Ground
7-18
WIPER AND WASHER CIRCUIT
REAR WIPER CHECK UNIT FUSE BOX
CN-102
CN-58
CN-36
6
WIPER RY Lo
CR-26
WIPER RY Hi
CR-4
3
9
1 7 5
4
CS-11
CS-12
CS-5
10
2
CN-21
CS-3
R/WASHER
F/WASHER
CN-103
CN-22
FRONT WIPER
REAR WIPER & WASHER SW
MULTIFUNCTION SWITCH
7-19
MONITORING CIRCUIT
CHECK UNIT T/M TEMP
BRAKE OIL
CN-119
CL-45
WATER TEMP
ENGINE OIL
CN-58
CL-49
OVER HEAT CN-117
HYD TEMP
FUEL METER
CL-48
PARKING CL-47
CL-44
CN-107
CN-6
T/M OIL TEMP
CD-29
CN-9
CN-7
FUEL SENDER
CD-2
CN-3
ENG OIL PRESS
CN-2
CD-18
CS-4
OVER HEAT SW
CD-3
CD-1
CD-9
WATER TEMP
PARKING SW BRAKE OIL PS
CN-13
HYD TEMP SW
CD-8
7-20
HAZARD, TURN AND ROTARY CIRCUIT
FUSE BOX
COMBI LAMP RH
CL-16
ROTARY LAMP
COMBI LAMP LH
CN-5 CL-7
CN-2
CL-15
FLASHER UNIT
CN-36
CR-11
RH TURN ,RR
CL-43
LH TURN ,RR
CL-42
CN-7
LH TURN,FR
CS-11
CS-12
CS-5
CL-24
RH TURN,FR
CN-8
CL-25
CS-41
CS-23
HAZARD SWITCH BEACON LAMP SWITCH MULTI FUNCTION SWITCH CN-4
7-21
3. MONITORING SYSTEM
1. CLUSTER
The gauges panel consists of gauges and monitors as shown below, to warn the operator in case of
abnormal machine operation or conditions for the appropriate operation and inspection.
ş Gauges : Indicate operating status of the machine.
ş Warning lamp : Indicate abnormality of the machine.
ş Pilot lamp : Indicate operating status of the machine.
Ɠ The monitor installed on this machine does not entirely guarantee the condition of the
machine.
Daily inspection should be performed according to chapter 6, MAINTENANCE.
Engine oil pressure warning lamp Glow pilot lamp

Steering warning lamp(Emergency) Ride control pilot lamp(ON)
Steering warning lamp(Primary) Ride control pilot lamp(AUTO)
Battery charging warning lamp Hyd oil temp warning lamp
Overheat warning lamp Brake fail warning lamp
Left turning pilot lamp Right turning pilot lamp
High beam pilot lamp Parking brake pilot lamp
AUT
P
ON
20 30
10 km/h 20
10 40
0 MPH 30
E F
0 50
VDO
WATER FUEL
TRANS BATT
T/M oil temperature gauge Battery volt meter

Speedometer Fuel gauge
Engine coolant temperature gauge T/M oil pressure warning lamp
1) SPEEDOMETER
(1) The speedometer displays the speed of machine in mph and
20 30
km/h.
10 km/h 20
10 40
0 MPH 30
0 50
VDO
7-22
2) FUEL GAUGE
(1) This gauge indicates the amount of fuel in the fuel tank.
Red
Red White
White
(2) Fill the fuel when the red range illuminates.
E F
(3) The gauge indicates continuously the current fuel amount
FUEL
even after turn OFF the starting switch. This does not mean
that the gauge is out of order.
Ɠ If the gauge illuminates the red range even though the
machine is on the normal condition, check the electric
device as that can be caused by the poor connection of
electricity or sensor.
3) ENGINE COOLANT TEMPERATURE GAUGE

(1) This indicates the temperature of coolant.
Green
Green Red
Red şGreen range : 37~105Ş C(99~221Ş F)
şRed range : 105Ş C(221ŞF) Above
(2) The green range illuminates when operating.
WATER
(3) Keep idling engine at low speed until the green range
illuminates, before operation of machine.
(4) When the red range illuminates, turn OFF the engine, check
the radiator and engine.
4) TRANSMISSION OIL TEMPERATURE GAUGE

(1) This range indicates the temperature of transmission oil.
Green
Green Red
Red şGreen range : 37~120Ş C(99~248ŞF)
şRed range : 120Ş C(248ŞF) Above
(2) The green range indicates when operating.
TRANS
(3) Keep idling engine at low speed until the green range
indicates, before operation of machine.
(4) If the indicator is in the red range, it means the transmission is
overheated. Be careful that the indicator does not move into
the red range.
7-23
5) BATTERY VOLT METER
(1) This gauge indicates the voltage in the charging system when
White
White Green
Green Red
Red the engine is running.
(2) If the indicator is below 24V(White range), it means that the
electricity is being discharged. If the indicator is above
BATT
30V(Red range), an unusually high voltage may damage the

alternator. Check the charging system in both cases.
6) DIRECTION PILOT LAMP

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

(1) This lamp works when the illuminating direction is upward.
(2) This lamp comes ON when the dimmer switch is operated,
e.g., when passing another vehicle.
8) PARKING BRAKE PILOT LAMP

(1) When the parking brake is actuated, the lamp lights ON.
Ɠ Check the lamp is OFF before driving.
P
9) BRAKE FAIL WARNING LAMP
(1) The lamp lights ON when the oil pressure of service brake
drops below the normal range.
(2) When the lamp is ON, stop the engine and check for its cause.
Ɠ Do not operate until any problems are corrected.
7-24
10) TRANSMISSION OIL PRESSURE WARNING LAMP
(1) The lamp lights ON when the oil pressure of the transmission
drops.
(2) When the lamp is ON, stop the engine and check the
transmission system.
11) GLOW PILOT LAMP

(1) This lamp lights ON when key ON, it will be ON to indicate the
glow plugs are being heated.
(2) When the lamp goes out the operator should start cranking the
engine.
12) BATTERY CHARGING WARNING LAMP

(1) This lamp is ON when key ON, it is turned OFF after starting
the engine.
(2) Check the battery charging circuit when this lamp comes ON,
during engine operation.
13) ENGINE OIL PRESSURE WARNING LAMP

(1) If lamp comes ON during engine operation, shut OFF engine
immediately. Check oil level.
14) OVERHEAT WARNING LAMP

(1) This lamp is turned ON when the temperature of cooling water
is over the normal temperature (110Ş
C, 230Ş
F).
(2) Check the cooling system when the lamp is ON.
7-25
15) HYDRAULIC OIL TEMP WARNING LAMP
(1) This warning lamp operates and the buzzer sounds when the
temperature of hydraulic oil is over 105Ş
C(221Ş
F).
(2) Check the hydraulic oil level when the lamp is turned ON.
(3) Check for debris between oil cooler and radiator.
16) STEERING WARNING LAMP(Option)

(1) Primary
If the oil pressure in the steering pump drops, the lamp will light
up. If this lamp flashes during operation, the action alarm
should sound.
Ɠ If the lamp lights up, immediately pull the machine to a
safe place and stop the machine.
(2) Emergency
This lamp will flash if the oil pressure in the emergency
steering pump drops. The lamp notifies the operator that if the
steering system also failed at this time, there is no emergency
steering system for backup.
Ɠ Immediately pull the machine to a convenient stop and
stop the engine.
Ɠ This machine is equipped with ground driven emergency
steering pump. It is normal for the lamp to flash after 5
seconds when the machine is stopped.
17) RIDE CONTROL PILOT LAMP(Option)

(1) Auto ride control
This lamp lights ON when push in the top of the ride control
switch in order to turn on the automatic ride control.
AUT
(2) Ride control

This lamp lights ON when push in the bottom of the ride control
switch in order to turn on the system for ride control.
ON
7-26
3. SWITCHES
Rear work lamp switch Beacon switch(Option)

Front work lamp switch Rear wiper/washer switch
Main light switch Buzzer stop switch
Ride control switch(Option)
Clutch cut off switch
Switch panel
Aircon switch
Horn button Hazard switch
Multi function switch Kick down switch
Starting switch
Kick down switch
1) STARTING SWITCH
(1) There are three positions, OFF, ON and START.
ON STAR
T
(2) OFF : None of electrical circuits activate.
F
OF
(3) ON : All the systems of machine operate.

(4) START : Use when operating the engine.
Release key immediately after starting.
7-27
2) HAZARD SWITCH
(1) Use for parking, or roading machine.
Ɠ If the switch is left ON for a long time, the battery may be
discharged.
(2) The below indicator lamp is turned ON when operating this switch.
3) CLUTCH CUT OFF SWITCH

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

(1) This switch use to operates the clearance lamp and head light by two
step.
ϦFirst step : Clearance lamp and cluster illumination lamp
comes ON. Also, the below indicator lamp comes
ON.
ϦSecond step : Head light comes ON.
5) FRONT WORK LAMP SWITCH

(1) This switch turns ON the working lamps located on the front of the
cab.
6) REAR WORK LAMP SWITCH

(1) This switch turns ON the working lamps located on the rear of the
cab.
7-28
7) AIR CONDITIONER SWITCH
(1) This switch use to operates the air conditioner.
(2) Refer to the air conditioner and heater for detail operation.
8) REAR WIPER AND WASHER SWITCH

(1) The switch use to operates the rear wiper and washer by two step.
şFirst step : The rear wiper operates.
şSecond step : The washer liquid is sprayed and the rear wiper is
operated only while pressing. If release the switch,
return to the first step position.
9) BUZZER STOP SWITCH

(1) The red lamp on the cluster lights ON and the buzzer sounds when
the machine has a problem.
In this case, if the switch is pressed, the buzzer will be stopped. Be
sure to check machine for problems.
(2) Wait until the lamp is turned OFF, if the red lamp lights ON after the
buzzer stopped.
If not, stop engine and check the system which the lamp is ON.
10) CAB LAMP SWITCH

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

Kick down switch (1) The kick-down switch into first gear is not allowed. Press the switch
and release the switch. The transmission downshifts one gear
speed, provided that an engine overspeed would not occur.
7-29
12) MULTI FUNCTION SWITCH
(1) Front wiper and washer switch
‫ ڸ‬When the switch is in J position, the wiper moves intermittently.
O J ѓє ‫ ڹ‬When placed in ѓ or є position, the wiper moves continuously.
‫ ں‬If you press a button at the end of the lever, washer liquid will be
sprayed and the wiper will be activated 2~3 times.
Ɠ Check the quantity of washer liquid in the tank. If the level of
the washer liquid is LOW, add the washer liquid (In cold, winter
days) or water. The capacity of the tank is 1 liter.
(2) Dimmer switch

‫ ڸ‬This switch is used to turn the head lights direction.
Up ‫ ڹ‬Switch positions
şUp : To flash for passing
M
şMiddle : Head lights low beam ON
Down şDown : Head lights high beam ON
‫ ں‬If you release the switch when it's in up position, the switch will return
to middle.
(3) Turning switch
Left turning ‫ ڸ‬This switch is used to warn or signal the turning direction of the
machine to other vehicles or equipment.
‫ ڹ‬Push the lever up for turning left, pull the lever down for turning right.
Right turning
13) HORN BUTTON

(1) If you press the button on the top of the multifunction switch, the horn
Horn button
will sound.
7-30
14) BEACON SWITCH(Option)
(1) This switch turns ON the rotary light on the cab.
15) RIDE CONTROL SWITCH(Option)

AUTO (1) AUTO position
Push in the top of the ride control switch in order to turn on the
automatic ride control. The automatic ride control automatically turns
on when the travel speed exceeds a preset speed of approximately
9.5km/h.
The automatic ride control automatically shuts off during low speed
travel mode.
ON (2) ON position
Push in the bottom of the ride control switch in order to turn on the
system for ride control. The ride control will smooth the ride of the
machine during travel.
(3) MIDDLE position

MIDDLE
Push the ride control switch to the middle position in order to turn off
the system for the ride control.
7-31
GROUP 4 ELECTRICAL COMPONENT SPECIFICATION
Part name Symbol Specifications Check
Ɠ Check specific gravity

12V ź 100Ah 1.280 Over : Over charged
Battery
(2EA) 1.280 ~ 1.250 : Normal
1.250 Below : Recharging
Ɠ Check coil resistance

Rated load : 24V Normal : About 50‫װ‬
Battery relay 100A(Continuity) Ɠ Check contact
1000A(30sec) Normal : ſ‫װ‬
CR-1
Ɠ Check disconnection
2 Normal : 0‫װ‬
Fusible link 24V 60A (Connect ring terminal and
1 check resistance between
CN-60 terminal 1 and 2)
105 BW
036 GY
001 LW
603 LR
Ɠ Check contact
OFF : ſ‫(װ‬For each terminal)
6 5 4 3 2 1
ON : 0‫(װ‬For terminal 1-3)
Start key -
ST
ſ‫(װ‬For terminal 1-5)
ACC START : 0‫(װ‬For terminal 1-3
OFF
HT and 1-5)
C R2 R1 IG BR B OFF CS-2
Pa Ɠ Check contact
Pressure switch N.C TYPE
Normal : 0‫(װ‬Close)
CD-3 CD-25
CD-39
Pa
Ɠ Check contact
Pressure switch N.O TYPE
Normal : ſ‫(װ‬Open)
CD-4 CD-5
CD-40
7-32
1 Pa
Pressure switch 0.5kg/cm2 Ɠ Check contact
(For engine oil) 2 (N.C TYPE) Normal : 0‫(װ‬Close)
CD-18
T Ɠ Check resistance
Coolant temp
- Normal : ſ‫װ‬
sensor
225Ş
F Over : 0‫װ‬
CD-9
Ş
Coolant - Ɠ Check resistance
temp sensor 192Ź13.5‫ װ‬at 73.9Ş
C
CD-8
1 Ɠ Check resistance
Fuel sender Reed switch :
Full : About 30‫װ‬
Magnetic type
2 Low level : About 300‫װ‬
CD-2
Transmission °C
Ɠ Check resistance
oil temperatur 1/2 P.T.F
137.2Ź14.5‫ װ‬at 87.8Ş
C
sender
CD-29
1 2 1
Ɠ Check resistance
2 Normal : About 200‫װ‬
Relay
3 24V 20A (For terminal 1-3)
(4pin)
4 4 3 : ſ‫װ‬
(For terminal 2-4)
AC RY1 AC RY2
7-33
86 30 87a Ɠ Check resistance

85 Normal : About 160‫װ‬
87 (For terminal 85-86)
Relay
24V 20A : 0‫װ‬
(5pin) 86
85 87 87a (For terminal 30-87a)
30
: ſ‫װ‬
CR-2 CR-4 CR-5 CR-7
(For terminal 30-87)
CR-26 CR-28 CR-30 CR-35
1 B
Proximate
2 S 24V 400mA -
switch
3 E
CN-100 CN-101
Ɠ Check resistance
Hydraulic - Normal : ſ‫װ‬
temperature
105Ş
C Over : 0‫װ‬
CD-1
Ɠ Check contact
2 Lo 1 Normal : 1.12‫װ‬
4 2
(For terminal 2-4)
Hi
Air conditioner - : 2.07‫װ‬
resistor 3 ML 3
(For terminal 3-4)
1 MH 4 : 3.17‫װ‬
(For terminal 4-1)
Speaker Ɠ Check resistance

4‫ װ‬20W
Normal : 50‫װ‬
CN-23(LH)
CN-24(RH)
10 9 8 7 6 5 4 3 2 1 Ɠ Check contact
10 6 5 OFF : ſ‫װ‬
Switch (For terminal 1-5, 2-6)
24V 8A
(Locing type) : 0‫װ‬
9 8 2 7 1
(For terminal 5-7, 6-8)
CS-21 CS-41 CS-50
CS-20 CS-23 CS-42 CS-54
7-34
10 9 8 7 6 5 4 3 2 1
Switch 10 4 1 Ɠ Check contact

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

(H1 TYPE) Normal : A few‫װ‬
CL-7
Ɠ Check operation
S Supply power(24V) to
Hour meter
G
h -
terminal No.2 and contact
terminal No.1 and ground
CN-48
Ɠ Check operation
Horn 22-28V 2A Supply power(24V) to each
110dB terminal and connect ground
CN-20 CN-25
PA 1 Ɠ Check contact
Receiver dryer 24V 2.5A
Normal : ſ‫װ‬
2
CN-29
7-35
1 SL+
2 ACC
3 NC
4 SR+ Ɠ Check resistance
Cassette radio 5 NC 24V 20W+20W Power ON : 4‫װ‬+4‫װ‬
6 SL-
7 B+
8 SR-
9 NC CN-27
Back up buzzer 24V 0.5A 110dB -
CN-65
1 Ɠ Check contact
Washer pump 24V 2.5A Normal : 26.4 ‫װ‬
2 (For terminal 1-2)
CN-103 CN-22
24V 1.5A
Hi
Wiper motor 2-speed -
E
Lo M
Auto parking
CN-102 CN-21
Cigar lighter 2 24V 5A -
CL-2
B+
G
W Ɠ Check voltage
3~
Alternator 24V 55A
D+ Normal : 24-28V
GND
CN-74
7-36
B+
M
Starter Bosch 24V Ɠ Operating or not
M
CN-45
1
Air conditioner Ɠ Check contact
24V 79W
compressor 2 Normal : 13.4‫װ‬
CN-28
1 Ɠ Check contact
Start relay 24V 200A
2 Normal : 11.3‫װ‬
CR-23
M 1 24V 9A
Blower -
2900Ź150rpm
2
1 GND
2 COM 2 4 5 3 6
Ɠ Check resistance
3 MH
Blower switch 4
- Normal : 0‫(װ‬For terminal 1-2,
LOW
5 ML 3, 4, 5, 6)
1
6 HI CS-58
M+ 1
Mode actuator M S+ 2
DC Servo motor
and M- 3
9-16V 300mA -
temperature FS 4
Max
actuator S- 5
NC 6
7-37
R 2 Ɠ Check resistance
Intake actuator 12V
M Normal : 2.0‫װ‬
F 1
Working
1 temperature of
Thermostat contact point -
2 A/C ON : 4.5Ş C
A/C OFF : 1.5ŞC
3 E
G 24V
Flasher unit 2 B 85 ~ 190 C/M -
1 L 50dB
CR-11
1 Lo
2 Hi 24V 75W/70W
Ɠ Check disconnection
Head lamp (H4 TYPE)
3 E Normal : A few‫װ‬
24V 4W(T4W)
4 C
CL-3 CL-4
4 C
3 T 24V 5W(R5W)
Combi lamp 2 E 2ź24V 21W -
1 S (P21W)
CL-15 CL-16
1
24V 21W -
Turn lamp
(P21W)
2
CL-24 CL-25
7-38
Continuous
Capacity :
Master switch 180Amp -
Push in capacity:
1000Amp
2
24V 200mA
Warning buzzer -
1 90Ź5dB(ֻm)
CN-26
M 1
Air conditioner
24V -
fan 2
CN-83
1
2
Buzzer stop 3
4 Ɠ Check contact
switch 5 5 1
6 24V 8A OFF : ſ‫װ‬
(Rocker switch 7 6 2
push button) 8
9
10 10 9 CS-34
1 Ɠ Check contact
5 BL- BL+ 1
2
6 BK- BK+ 2 Normal : 80~90‫װ‬
3
7 FL- FL+ 3
4 (For terminal 1-5, 2-6
Joy stick lever -
5
3-7, )
6
4 8
7 : ſ‫װ‬
8 CN-114 (For terminal 4-8)
7-39
GROUP 5 CONNECTORS
1. CONNECTOR DESTINATION
Connector No. of Connector part No.
Type Destination
number pin Female Male
CN-1 58 2 I/conn(Frame harness-Main harness) S813-030200 S813-130200
CN-2 SWP 12 I/conn(Frame harness-Main harness) S814-012000 S814-112000
CN-3 SWP 12 I/conn(Frame harness-Main harness) S814-012000 S814-112000
CN-4 SWP 8 I/conn(Front harness-Main harness) S814-008000 S814-108000
CN-5 SWP 8 I/conn(Cab harness-Main harness) S814-008000 S814-108000
CN-6 SWP 12 I/conn(Gauge harness-Main harness) S814-012000 S814-112000
CN-7 SWP 14 I/conn(Gauge harness-Main harness) S814-014000 S814-114000
CN-8 SWP 12 I/conn(Front harness-Main harness) S814-012000 S814-112000
CN-9 SWP 6 I/conn(T/M check harness-Main harness) S814-006000 S814-106000
CN-12 - 12 AC AVA assembly S814-012000
CN-13 Fasten 8 AC AVA assembly S814-012000
CN-14 SWP 12 I/conn(Frame-Engine harness) S814-012000 S814-112000
CN-15 - 15 I/conn(Main harness-T/M harness) AMP 1-480710 AMP 1-480710
CN-20 - 2 Horn 35215-0200
CN-21 - 6 Front wiper motor 6189-0133
CN-22 - 2 Front washer tank S814-002000
CN-23 Shur 1 Speaker(LH) S822-014000 S822-114004
CN-24 Shur 1 Speaker(RH) S822-014000 S822-114004
CN-25 - 2 Horn 35215-0200
CN-26 Fasten 2 Warning buzzer S810-002202
CN-27 PA 9 Cassette and radio S811-009003
CN-28 - 2 Compressor(Air conditioner) 0297-3407
CN-29 Grommet - Receiver drier 21L7-12000
CN-30 PA 13 Air conditioner controller S811-013002
CN-36 - - Fuse box 24L1-04100
CN-45 Ring term - Starter S820-410000 S820-310000
CN-48 - 12 Hour meter S814-112000
CN-58 - 36 Check unit 344111-1
CN-60 58 2 Fusible link S813-130200
CN-62 - 5 Glow controller 963013-1
CN-65 Shur 1 Back up buzzer S822-014000
CN-74 Ring term - Alternator S820-408000 S820-104000
CN-79 - 2 Fuel cut off solenoid 827551-2
CN-83 - 2 Air conditioner fan PH805-02028
CN-100 J 3 Boom kick out S816-003001
CN-101 J 3 Bucket leveler S816-003001
CN-102 - 6 Rear wiper motor 6189-0133
7-40
Type Destination
CN-103 - 2 Rear washer tank S814-002000
CN-104 Ring term - Volt meter S821-105000
CN-107 Ring term - Fuel gauge S821-105000
CN-110 - 12 I/conn(Main harness-T/M harness) AMP 350783-1
CN-114 - 8 Joy stick S816-008002
CN-117 Ring term - Water temp S821-105000
CN-119 Ring term - Transmission temp S821-105000
CN-125 Ring term - Glow terminal S820-308000
CN-127 - 8 Speed meter 1630070
CN-130 - 3 Excess fuel solenoid APV-P3AC
Relay
CR-1 Ring term - Battery relay S820-104000
CR-2 Fasten 4 Horn relay S810-004202
CR-4 Fasten 6 Wiper relay Hi S810-006202
CR-5 Fasten 4 Safety relay S810-004202
CR-7 Fasten 4 Air-con relay S810-004202
CR-11 Fasten 3 Flasher unit S810-003702
CR-23 J 2 Start relay S816-002003
CR-26 Fasten 4 Wiper relay Lo S810-004202
CR-30 Fasten 4 Back up relay S810-004202
CR-35 Fasten 6 Ride control relay S810-006202
Switch
CS-2 SWP 6 Start key switch S814-006000
CS-3 SWF 10 Rear wiper switch 593757
CS-4 Fasten 3 Parking switch S810-003202
CS-5 Shur 1 Horn switch S822-014000
CS-11 SWP 8 Multi function switch S814-008000
CS-12 SWP 6 Multi function switch S814-006000
CS-20 SWF 10 Rear work lamp switch 593757
CS-21 SWF 10 Front work lamp switch 593757
CS-23 SWF 10 Beacon switch 593757
CS-34 SWF 10 Buzzer stop switch 593757
CS-39 SWF 10 Illumination and head lamp switch 593757
CS-41 SWF 10 Hazard switch 593757
CS-42 SWF 10 Clutch cut off switch 593757
CS-50 SWF 10 Ride control 593757
CS-54 SWF 10 Air conditioner switch 593757
CS-58 Fasten 6 Blower switch S810-006202
7-41
Type Destination
Light
CL-1 - 2 Room lamp MG610392
CL-2 Fasten 3 Cigar lighter S810-003202
CL-3 SWP 4 Head light(LH) S814-004000
CL-4 SWP 4 Head light(RH) S814-004000
CL-5 SWP 2 Work light(LH) S814-002000
CL-6 SWP 2 Work light(RH) S814-002000
CL-7 Fasten 1 Beacon lamp S810-001202
CL-15 SWP 4 Combi lamp(RR, LH) S814-004000
CL-16 SWP 4 Combi lamp(RR, RH) S814-004000
CL-21 SWP 2 Numberplate lamp S814-002000
CL-22 SWP 2 Work light(LH) S814-002000
CL-23 SWP 2 Work light(RH) S814-002000
CL-24 SWP 2 Turn lamp(LH) S814-002000
CL-25 SWP 2 Turn lamp(RH) S814-002000
CL-41 SWF 2 Hi beam lamp(Dash board) 913328
CL-42 SWF 2 Turn lamp(LH, Dash board) 913328
CL-43 SWF 2 Turn lamp(RH, Dash board) 913328
CL-44 SWF 2 Parking lamp(Dash board) 913328
CL-45 SWF 2 Brake fail lamp(Dash board) 913328
CL-46 SWF 2 Charge lamp(Dash board) 913328
CL-47 SWF 2 Hydraulic oil lamp(Dash board) 913328
CL-48 SWF 2 Over heat lamp(Dash board) 913328
CL-49 SWF 2 Engine oil lamp(Dash board) 913328
CL-50 SWF 2 Transmission error 913328
CL-51 SWF 2 Transmission oil lamp(Dash board) 913328
CL-52 SWF 2 Glow lamp(Dash board) 913328
CL-53 SWF 2 Steering pressure lamp 913328
CL-54 SWF 2 Steering pump pressure lamp 913328
CL-55 SWF 2 Ride control ON lamp 913328
CL-56 SWF 2 Ride control AUTO lamp 913328
Sensor, sender
CD-1 - 1 Hyduaulic oil temp switch 1-150656
CD-2 SWP 2 Fuel sendor S814-002000
CD-3 Rubber cap 1 Brake fail pressure switch 21EA-00310
CD-4 Rubber cap 1 Stop lamp pressure switch 21EA-00300
CD-5 Rubber cap 1 Clutch cut off pressure switch 21EA-00310
CD-8 Ring term - Water temp sendor S820-105000
CD-9 - 1 Over heat switch 1-150656
CD-18 - 2 Engine oil pressure switch 827551-2
CD-25 Rubber cap - Transmission oil pressure switch 21EA-00310
7-42
Type Destination
CD-29 Ring term - Transmission temp sendor S821-105000
CD-39 Rubber cap - Steering pressure switch 21EA-00310
CD-40 Rubber cap - Emer steering pump pressure switch 21EA-00310
7-43
2. CONNECTION TABLE FOR CONNECTORS
1) 58-L TYPE CONNECTOR
No. of
Receptacle connector(Female) Plug connector(Male)
pin
1 1
S813-030100 S813-130100
1 2 1 2
S813-030200 S813-130200
7-44
2) PA TYPE CONNECTOR
No. of
pin
2 5 1 3
1 3 2 5
S811-005002 S811-105002
3 7 1 4
1 4 3 7
S811-007002 S811-107002
4 9 1 5
1 5 4 9
S811-009002 S811-109002
5 11 1 6
11
1 6 5 11
S811-011002 S811-111002
7-45
No. of
pin
6 13 1 7
13
1 7 6 13
S811-013002 S811-113002
8 17 1 9
17
1 9 8 17
S811-017002 S811-117002
10 21 1 11
21
1 11 10 21
S811-021002 S811-121002
7-46
3) 58-X TYPE CONNECTOR
No. of
pin
1 1
S813-060100 S813-160100
2 1
1 2
S813-060200 S813-160200
7-47
4) J TYPE CONNECTOR
No. of
pin
1 1
2 2
S816-002001 S816-102001
2 3 1
3 1 2
S816-003001 S816-103001
7-48
5) SWP TYPE CONNECTOR
No. of
pin
1 1
S814-001000 S814-101000
2 1
1 2
S814-002000 S814-102000
3 1
2 1 23
S814-003000 S814-103000
2 4 1 3
1 3 2 4
S814-004000 S814-104000
7-49
No. of
pin
3 6
1 4
1 4 3 6
S814-006000 S814-106000
4 8
1 5
1 5 4 8
S814-008000 S814-108000
4 12 1 9
12
4 12
1 9
S814-012000 S814-112000
3 14 1 11
14
1 11 3 14
S814-014000 S814-114000
7-50
6) CN TYPE CONNECTOR
No. of
pin
1 1
S810-001202 S810-101202
2 2
1 1
S810-002202 S810-102202
3 2
1 2 1 3
S810-003202 S810-103202
2 4 1 4
1 3 2 3
S810-004202 S810-104202
7-51
No. of
pin
3 6 1 4
1 4 3 6
S810-006202 S810-106202
4 8 1 5
1 5 4 8
S810-008202 S810-108202
7-52
7) BS TYPE CONNECTOR
No. of
pin
2 1
1 2
S812-002001 S812-102001
1 3 1 2
2 3
S812-003001 S812-103001
2 4 1 3
1 3 2 4
S812-004001 S812-104001
3 6 1 4
1 4 3 6
S812-006001 S812-106001
7-53
8) LC TYPE CONNECTOR
No. of
pin
5 10
10
1 6
S815-010000
6 12
12
1 7
S815-012000
8 16
16
1 9
S815-016000
9 18
18
1 10
S815-018000
7-54
No. of
pin
12 24
24
1 13
S815-024000
7-55
9) 375 FASTEN TYPE CONNECTOR
No. of
pin
1 2 1 2
S810-002402 S810-102402
7-56
GROUP 6 TROUBLESHOOTING
1. WHEN STARTING SWITCH IS TURNED ON, CLUSTER LAMP DOES NOT LIGHT UP
şBefore carrying out below procedure, check all the related connectors are properly inserted and the
fuse No.21 is not blown out and ON/OFF of bulb.
şAfter checking, connect the disconnected connectors again immediately unless otherwise specified.
Cause Remedy
YES
Defective cluster Replace
YES Check voltage
between CN-58
(1) and chassis
Disconnection in Repair or replace
NO
wiring harness or (After clean)
Check voltage poor contact
between CN-7(4) between
and chassis
CN-58(1) and
fuse No.20

NO
poor contact
between CN-7(4)
and fuse No.21
CLUSTER
FUSE
4
No.21
CN-7
CHECK UNIT
FUSE
1
No.20
CN-58
Check voltage
YES 20 ~ 28V
NO 0V
7-57
2. WHEN COOLANT OVERHEAT LAMP LIGHTS UP(Engine is started)
şBefore carrying out below procedure, check all the related connectors are properly inserted.
Cause Remedy
YES
Coolant overheat Check engine
(105Ş
CŹ2Ş C) system
YES
Defective Replace
Check resistance
YES overheat switch
between CN-13
Does display go (10) and chassis
off when Disconnection in Repair or replace
Starting switch : OFF NO
disconnect CD-9 wiring harness or (After clean)
Check resistance
and connector? YES poor contact
between CN-3(9)
Starting switch : ON between CD-9
Engine : start
and chassis
and CN-3(9)
Starting switch : OFF
Check resistance Disconnection in Repair or replace

NO
between CN-6(4) wiring harness or (After clean)
NO
and chassis poor contact
between CN-6(4)
Before checking, and CN-3(9)
disconnect CD-9

NO
CLUSTER OVERHEAT SWITCH

T
4 10 S
9
CN-6 CN-3 CN-13 CD-9
CHECK UNIT
24
CN-58
Check resistance
YES MAX 1‫װ‬
NO MIN 1M‫װ‬
7-58
3. WHEN ENGINE OIL PRESSURE LAMP LIGHTS UP(Engine is started)
Cause Remedy
YES
Engine oil leakage, Check engine oil
or defective switch level or replace
switch
YES
Does display go
off when wiring harness or (After clean)
disconnect CD-18 Check resistance poor contact
YES
and connector? between CN-13 between CN-13(7)
Starting switch : ON (7) and chassis -CD-18
Engine : start
Disconnection in Replace
Check resistance NO
wiring harness or
between CN-6(5)
NO
between CN-6(5) -
Starting switch : OFF CN-3(5)- CN-13(7)
Before checking,
disconnect CD-18
NO
CLUSTER ENGINE OIL PRESSURE SWITCH

5 5 7 1
Pa
CN-6 2
CN-3 CN-13
CD-18
CHECK UNIT
23
CN-58
Check resistance
YES MAX 1‫װ‬
NO MIN 1M‫װ‬
7-59
4. WHEN HYDRAULIC OIL TEMPERATURE LAMP LIGHTS UP(Engine is started)
Cause Remedy
YES
High temperature Check hydraulic
of hydraulic oil or oil temperature
defective switch (105Ş CŹ2Ş C),
hydraulic cooling
or replace switch
Does display go YES

off when Disconnection in
disconnect CD-1 wiring harness or
and connector? Check resistance poor contact
YES
Starting switch : ON between CN-2(10) between CN-6(8)
Engine : start and chassis and CN-2(10)
Before checking, Disconnection in Repair or replace
Check resistance disconnect CD-1 NO
between CN-6(8)
NO
between CN-
Before checking,
2(10) and CD-1
disconnect CD-1
NO
HYDRAULIC OIL
CLUSTER TEMPERATURE SWITCH
T
8 10
CN-6 CN-2 CD-1
CHECK UNIT
12
CN-58
Check resistance
YES MAX 1‫װ‬
NO MIN 1M‫װ‬
7-60
5. WHEN TORQUE CONVERTER OIL TEMPERATURE GAUGE DOES NOT OPERATE
(Check torque converter oil temperature lamp ON/OFF)
Cause Remedy
YES
YES
between CN-7 wiring harness or (After clean)
(10) and chassis poor contact
between CN-
Starting switch : ON Check resistance
7(10) and CN-9(4)
Engine : start between CN-9(4)
See : TABLE NO
and chassis YES
Starting switch : OFF wiring harness or (After clean)
See : TABLE
Check resistance poor contact
between CD-29 between CN-9(4)
NO
and chassis and CD-29
See : TABLE Defective sender Replace
NO
TRANS
TRANSMISSION OIL
CLUSTER TEMPERATURE SENDER
Ş
C
10 4
CN-7 CN-9 CD-29
Check resistance
YES MAX 1‫װ‬
NO MIN 1M‫װ‬
Check table
Temperature
50Ş
C 92Ş
C 120Ş
C 130Ş
C
Item
Unit resistance(‫)װ‬ 168.7 (34) 19.5 12.4
Tolerance 0Ş~ -10Ş (-) Ź3Ş +10Ş~ 0Ş
Angle -30Ş -8Ş +27Ş +30Ş
7-61
6. WHEN COOLANT TEMPERATURE GAUGE DOES NOT OPERATE
(Check coolant temperature lamp ON/OFF)
Cause Remedy
YES
YES
Check resistance wiring harness or (After clean)
between CN-7 poor contact
(11) and chassis
between CN-7
Starting switch : ON (11) and CN-3(7)
Engine : start Check resistance
See : TABLE between CN-3(7) YES
NO Disconnection in Repair or replace
and chassis
Before checking, poor contact
disconnect connector between CN-3(7)
See : TABLE
Check resistance and CN-13(8)
between CN-13
NO
(8) and chassis YES
Starting switch : OFF wiring harness or (After clean)
See : TABLE
Check resistance poor contact
between CD-8 between CN-13
NO
and chassis (8) and CD-8
See : TABLE Coolant overheat Check coolant
NO
TRANS
or defective temperature or
sender replace
CLUSTER WATER TEMPERATURE SENDER

Ş
C
11 7 8
CN-7 CN-3 CN-13 CD-8
Check resistance
YES MAX 1‫װ‬
NO MIN 1M‫װ‬
Check table
Temperature
(40Ş
C) 91Ş
C 105Ş
C 120Ş
C
Item
Unit resistance(‫)װ‬ 222 (41.3) 28 19.2
Tolerance Ź5Ş (-) Ź4.5 (-)
Angle -30Ş 0Ş +13Ş +30Ş
7-62
7. WHEN FUEL GAUGE DOES NOT OPERATE(Check warning lamp ON/OFF)
Cause Remedy
YES
YES
between CN-7 wiring harness or (After clean)
Starting switch : OFF between CN-7
See : TABLE (12) and CN-2(11)
Check resistance
between CN-2(11)
NO YES
and chassis Disconnection in Repair or replace
See : TABLE wiring harness or (After clean)
poor contact
Check resistance between CD-2(1)
between CD-2(2) and CN-2(11)
NO
and chassis
YES
See : TABLE Check circuit Repair or replace
Check resistance
between CD-2(2) (After clean)
between CD-2(2)
and chassis
NO and CD-2(1) with
chassis
See : TABLE Defective sensor Replace
NO
E F
FUEL
FUEL SENDER
CLUSTER
1
12 11 2
CD-2
CN-7 CN-2
Check resistance
YES MAX 1‫װ‬
NO MIN 1M‫װ‬
Check table
Temperature
Empty (1/2) Full
Item
Unit resistance(‫)װ‬ 95 (32.5) 7
Tolerance Ź2.5Ş Ź5Ş Ź2.5Ş
Angle -30Ş 0Ş +30Ş
7-63
8. WHEN GAUGES OF FUEL, HYDRAULIC OIL AND COOLANT INDICATE HIGH OR FULL
Cause Remedy
YES Defective cluster Replace
Check resistance
between CN-7
(13) and chassis
Starting switch : ON NO
Voltage : 20~28V
poor contact
between CN-7
(13) and chassis
CLUSTER
13
CN-7
Check resistance
YES MAX 1‫װ‬
NO MIN 1M‫װ‬
7-64
9. TRANSMISSION IS NOT RETURNED TO NEUTRAL WHEN PARKING BRAKE IS APPLIED
fuse No.13 is not blown out.
Cause Remedy
YES
Defective T/M Replace
YES Check voltage controller
between CN-111
(22) and chassis
Voltage : 20~28V NO
poor contact
between CN-
Check voltage
between CN-15 15(6) and CN-
(6) and chassis 111(22)
Starting switch : ON YES

Parking switch : ON Disconnection in Repair or replace
Prolix switch : OFF wiring harness or (After clean)
Voltage : 20~28V
poor contact
Check voltage
between CN-15
between CS-4
NO (6) and CS-4(87)
(87) and chassis
Voltage : 20~28V YES
Parking switch : ON Check voltage Defective relay Replace
between CS-4
NO
(30) and chassis Disconnection in Repair or replace
NO
Voltage : 20~28V wiring harness or (After clean)
poor contact
between CS-4(30)
and fuse No.13
CN-15
PARKING RELAY
87
FUSE
86
No.13
30
CS-4
7-65
10. MACHINE DOES NOT TRAVEL
fuse No.13 is not blown out. CHECK UNIT FUSE BOX
CN-58
CN-111
Cause Remedy
YES
Defective clutch Replace
cut-off pressure
switch
Check resistance
NO
between CD-5
and chassis
YES
Defective clutch Replace
Is voltage between
cut-off switch
NO CS-42(5) and
chassis 20-28V?
NO
poor contact
Is voltage between between CS-42(5)
CN-15(6) and and fuse No.10
chassis 20-28V?
YES
Starting switch : ON Defective parking Replace CN-15
Parking lever : released
YES
Is voltage between
Clutch cut-off relay
switch : ON
CR-28(86) and
chassis 20-28V?
NO
wiring harness or (After clean) PARKING RY
poor contact
Is voltage between between CR-
YES CS-4(3) and 28 (86) and fuse
chassis 20-28V? CR-28
No.13 PARKING SW
YES
Defecitve parking Replace CS-4
Is voltage between
switch CN-36
CS-4(2) and
NO CLUTCH CUT-OFF SW
chassis 20-28V?
NO
CD-5
poor contact
between CS-4(1)
and CS-4(3) CLUTCH CUT OFF
Check resistance CS-42
YES MAX 1‫װ‬

NO MIN 1M‫װ‬
7-66
11. WHEN STARTING SWITCH IS TURNED ON, HEAD LAMP DOES NOT LIGHTS UP
fuse No.3 is not blown out and ON/OFF of bulb.
FUSE BOX
Cause Remedy
YES
Defective bulb Replace
Check voltage
YES
between CL-3(1) -
(3) and CL-4(1) -(3)
Voltage : 20~28V Disconnection in Repair or replace
NO
Starting switch : ON wiring harness or (After clean)
Head lamp switch : ON CN-36
YES
between CN-4(3) between CN-4(3)-
LH HEAD LIGHT
and CN-8(1), (12) CL-3(1), 4(1) and ILL & HEAD LAMP SW
Voltage : 20~28V CL-3(3) - CN-8(1),

Starting switch : ON CL-4(3) - CN-8(12).
Head lamp switch : ON CL-3
Disconnection in Repair or replace RH HEAD LIGHT

NO
Check voltage
poor contact
between CS-11 CS-39
between CN-4(3) CL-4
(7) and chassis
and CS-11(7) CN-8
Starting switch : ON
Head lamp switch :
YES
ON-OFF Defective Replace
multifunction switch HI BEAM PILOT LAMP
Check voltage CL-41

YES
between CS-11 Disconnection in Repair or replace CN-4
NO
(8) and chassis wiring harness or (After clean)
Voltage : 20~28V poor contact
Starting switch : ON Check voltage between CS-11(8)
between CS-39 and CS-39(2)
NO
(2) and chassis
YES Defective head Replace switch
CS-11
Check voltage lamp switch
between CS-39
NO
(4) and chassis
NO
poor contact
between CS-39(4)
MULTI FUNCTION SW CN-7
and fuse No.3
7-67
12. WHEN STARTING SWITCH IS TURNED ON, WIPER MOTOR DOES NOT OPERATE
fuse No.11 is not blown out. CHECK UNIT FUSE BOX
Cause Remedy
CN-58
YES
Check voltage Defective front Replace
YES between front wiper motor
wiper motor and
chassis Poor connection of Replace
Check voltage Voltage : 20~28V
NO
YES chassis
between CN-21(5) Starting switch : ON
Wiper switch : 1st
and chassis
Voltage : 20~28V
Starting switch : ON Disconnection in Repair or replace
Check voltage Wiper switch : 1st NO
YES wiring harness or (After clean)
between CS-12
between CS-12(4) CN-36
Voltage : 20~28V
Check voltage Starting switch : ON
and CN-21(5)
WIPER RY Lo
between CS-12 Wiper switch : OFF
(6) and chassis Defective wiper Replace
NO
switch
Voltage : 20~28V
Wiper switch : 1st Disconnection in Repair or replace CR-26
NO
poor contact
between CS-12(6) WIPER RY Hi
and fuse No.11
CR-4
CS-11
CS-12
CS-5
CN-21
FRONT WIPER
MULTIFUNCTION SWITCH
7-68
13. WHEN STARTING SWITCH ON DOES NOT OPERATE
şBefore carrying out below procedure, check all the related connectors are properly inserted and and
the fuse No.15 is not blown out.
FUSE BOX
Cause Remedy
YES
Defective cable Repair or replace
Check voltage (After clean)
YES assembly
between CN-60(2)
and chassis
Short circuit or Replace
Voltage : 20~28V NO
Check voltage defect of fusible
YES
between CR-1 link or defective
(M4) and chassis
battery relay
Voltage : 20~28V
NO
Check voltage wiring harness or
YES between CS-2
(1)[and CS-2(2)] poor contact
and chassis between CS-2(2) -
Voltage : 20~28V
CN-2(2)-CR-1
CN-36
(M4)
MASTER SW
BATT RY
60R 60R 60B 60B
Check voltage NO
wiring harness or
and specific CR-1
gravity of battery poor contact

between fuse No. TO STARTER
Specific gravity : MIN 1.28
Voltage : MIN 24V 17 and CS-2(1) or
defect of start
CN-1 CN-60
switch
Battery capacity Repair or replace

NO
too low (After clean)
DO-1
CS-2
CN-2
START SWITCH
7-69
14. WHEN STARTING SWITCH IS TURNED ON, WORK LAMP DOES NOT LIGHTS UP
şBefore carrying out below procedure, check all the related connectors are properly inserted, and the
fuse No.12 is not blown out.
Cause Remedy
FUSE BOX
YES
Check voltage Defective lamp Replace
YES between each
lamp(2) and
chassis Disconnection in Repair or replace
NO
Voltage : 20~28V wiring harness or (After clean)
Starting switch : ON poor contact
Check voltage
YES between CN-5(3) -
between CN-5(4),
(3) and chassis CL-22(2), CL23(2)
and CN-5(4) - CL-
Voltage : 20~28V 5(2), CL-6(2)
Check voltage Disconnection in Repair or replace
YES between CS-21 NO
(2), CS-20(2) and poor contact
chassis between CN-5(3) -
Voltage : 20~28V
CS-20(2) and CN-
CN-36
5(4) - CS-21(2)
Check voltage
between CS-21 Defective work Replace switch
(6), CS-20(6) and NO
lamp switch
chassis FRONT WORK
LIGHT,LH
Voltage : 20~28V YES
Disconnection in Repair or replace FRONT WORK LAMP SW
wiring harness or (After clean) CN-5 CL-6
Check voltage poor contact FRONT WORK

between CS-21(6), LIGHT,RH
between fuse No.
NO CS-20(6) and fuse
12 and chassis CL-5
No.12
Voltage : 20~28V
Starting switch : ON Short circuit of fuse Replace CS-21
NO
REAR WORK
LIGHT,LH
REAR WORK LAMP SW
CL-22
REAR WORK
LIGHT,RH
CL-23
CS-20
7-70
15. WHEN ENGINE DOES NOT START
CN-111
şCheck supply of the power at engine stop solenoid while starting switch is ON.
şBefore carrying out below procedure, check all the related connectors are properly inserted. FUSE BOX
şAfter checking, connect the disconnected connectors again immediately unless other wise specified.
şCheck forward reverse switch at neutral position.
Cause Remedy
YES
Defective battery Check engine
SAFETY RY
system charge or
replace (After
checking specific
gravity of battery)
YES CR-5
Check voltage Defective magnet Replace
Check operation YES between starter of start motor GEAR SELECTOR(DW-2)
of start motor magnet coil and
chassis Defective start Replace
Starting switch : Start NO
Starting switch : Start relay
YES
‫ڞ‬
Check operation Check voltage CN-15
CN-36
NO of starter relay YES
between CR-5 CS-61
(87) and chassis

Starting switch : Start
wiring harness or
Check operation poor contact
of start safety between CN-3(2)
NO
relay and CR-5(87)
Check switch : Neutral YES
Defective relay Replace STARTER
TO BATT
Check voltage
between CR-5
NO
(86) and chassis
CN-45
‫ڟ‬
START RY
YES
Defective start Replace
Check voltage relay CR-23
‫ڞ‬ between CR-23
(1) and chassis
Voltage : 20~28V NO
Starting switch : ON wiring harness or
poor contact
FUEL SHUT OFF SOL
between CN-3(2)-
CR-23(1)
CS-2
CN-79
YES
wiring harness or
START SWITCH
‫ڟ‬ between CN-15 between CN-15(2)
CN-13
(2) and chassis and CR-5(86)
CN-3
Defective DW-2 Replace
NO
7-71

HL720 3

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WHEEL LOADER HYUNDAI HL720-3

HL720-3 Service Manual Open index screen

SECTION 3 POWER TRAIN SYSTEM

SECTION 4 BRAKE SYSTEM

SECTION 5 STEERING SYSTEM

SECTION 6 WORK EQUIPMENT

SECTION 7 ELECTRICAL SYSTEM

Structure and function

2. Convert 550mm into inches.

Millimeters to inches ‫ڟ‬

0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

Kilogram to Pound 1kg = 2.2046lb

0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84

0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378

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

0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980

7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1

14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0

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

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

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

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

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

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

FOLLOW SAFE PROCEDURE

WEAR PROTECTIVE CLOTHING

WARN OTHERS OF SERVICE WORK

USE HANDHOLDS AND STEPS

WORK IN CLEAN AREA

PROTECT AGAINST FLYING DEBRIS

PROTECT AGAINST NOISE

SUPPORT MACHINE PROPERLY

SERVICE COOLING SYSTEM SAFELY

HANDLE FLUIDS SAFELY-AVOID FIRES

BEWARE OF EXHAUST FUMES

REMOVE PAINT BEFORE WELDING OR

SERVICE MACHINE SAFELY

STAY CLEAR OF MOVING PARTS

AVOID HEATING NEAR PRESSURIZED FLUID

PREVENT BATTERY EXPLOSIONS

USE TOOLS PROPERLY

USE PROPER LIFTING EQUIPMENT

DISPOSE OF FLUIDS PROPERLY

LIVE WITH SAFETY

KEEP ROPS INSTALLED PROPERLY

Tooth Bucket Tire Bucket cylinder Hydraulic tank Engine Radiator

Bucket link Bell crank Head light Cab Muffler Counterweight

Description Unit Specification

Description Unit Specification

Description Unit Specification

Front frame assembly 665 1466

Model Deutz BF4M1012E

Type Fixed displacement tandem gear pump

Type Fixed displacement tandem gear pump

4) MAIN CONTROL VALVE

5) REMOTE CONTROL VALVE

Type Pressure reducing type

Boom cylinder Bore diaźRod diaźStroke ‫ ٻ‬95ź‫ٻ‬60ź675mm

1 Engine mounting bolt, nut M12ź1.75 12.8 Ź 3.0 92.6Ź 22

(2) Fine thread

Thread size Width across flat'mm( kgfşm lbfşft