Foreword: 1. Structure

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(ΗΘΙÄ)
Any additions, amendments or other changes will When a manual is revised, an edition mark is
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 ö 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 ͽ, then draw a horizontal
line from ͽ.
(2) Locate the number 5 in the row across the top, take this as ;, then draw a perpendicular line
down from ;.
(3) Take the point where the two lines cross as Ϳ. This point Ϳ gives 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 ;
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
Ϳ
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
ͽ
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 1˶ = 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 1˶ = 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
kgÂm to lbÂft 1kgÂm = 7.233lbÂft
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.
ä
C ä
F ä
C ä
F ä
C ä
F ä
C ä
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
CONTENTS
SECTION 1 GENERAL
Group 1 Safety Hints - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1
Group 2 Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-10
Group 3 Operational Checkout Record Sheet - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-25
SECTION 2 ENGINE
Group 1 Structure and Function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1
Group 2 Fuel warmer system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-7
Group 3 Engine speed and Stall rpm - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-8
SECTION 3 POWER TRAIN SYSTEM

Group 2 Operational Checks and Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-64
Group 3 Test and Adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-75
Group 4 Disassembly and Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-78
SECTION 4 BRAKE SYSTEM

Group 3 Tests and Adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-31
SECTION 5 STEERING SYSTEM

SECTION 6 WORK EQUIPMENT

SECTION 7 ELECTRICAL SYSTEM
Group 1 Component Location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-1
Group 2 Electrical Circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
Group 3 Monitoring System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-21
Group 4 Electrical Component Specification - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-40
Group 5 Connectors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-47
Group 6 Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-67
SECTION 1 GENERAL
Group 1 Safety Hints - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1

Group 2 Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-10
Group 3 Operational Checkout Record Sheet - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-25
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.
73031GE01
WARN OTHERS OF SERVICE WORK

Unexpected machine movement can cause
serious injury.
Before performing any work on the wheel
loader, attach aÖDo Not Operate×tag on the
right side controller lever. WARN
DO
NOT
OPERATE
7407AGE02
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, 73031E01
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.
73031GE03
WORK IN CLEAN AREA

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

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

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

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

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

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

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

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

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

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

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

Keep sparks, lighted matches, and flame away
from the top of battery. Battery gas can
explode.
Never check battery charge by placing a metal
object across the posts. Use a volt-meter or
hydrometer.
Do not charge a frozen battery; It may explode.
73031GE17
Warm battery to 16ÁC (60Á
F).
1-6
PREVENT ACID BURNS
Sulfuric acid in battery electrolyte is poisonous. It
is strong enough to burn skin, eat holes in clothing,
and cause blindness if splashed into eyes.
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. 73031GE18
USE TOOLS PROPERLY

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

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

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

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

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. 73031GE22
1-9
GROUP 2 SPECIFICATION
1. MAJOR COMPONENT(HL730-7A, HL730XTD-7A)
Bucket Tire Hydraulic tank Radiator
Boom Main control valve Cab Air cleaner Counterweight
Bucket link Bell crank Bucket cylinder Main pump Engine Muffler
Boom cylinder Front axle Steering cylinder Transmission Rear axle Fuel tank
7307A2SP01
1-10
MAJOR COMPONENT(HL730TM-7A)
Bucket Tire Hydraulic tank Radiator
Boom Main control valve Cab Air cleaner Counterweight
Quick coupler Link Bucket cylinder Main pump Engine Muffler
Boom Front axle Steering cylinder Transmission Rear axle Fuel tank
730TM7A2SP01
1-11
2. SPECIFICATIONS
1) WITH BOLT-ON CUTTING EDGE TYPE BUCKET(HL730-7A)
F
B
I
J
4790
H
3640
K
C
G
40
47
0
5595 0
D
E 1830
A
7307A2SP02
Description Unit Specification

Operating weight kg(lb) 9700(21400)
Struck 1.5(2.0)
Bucket capacity m3(yd3)
Heaped 1.8(2.4)
Overall length A 6850(22' 6")
Overall width B 2450(8' 0")
Overall height C 3170(10' 5")
Ground clearance D 370(1' 3")
Wheelbase E mm(ft-in) 2750(9' 0")
Tread F 1850(6' 0")
Dump clearance at 45Á G 2730(8' 11")
Dump reach(Full lift) H 1005(3' 4")
Width over tires I 2295(7' 6")
Dump angle J 48
Degree (Á)
Roll back angle(Carry position) K 48
Lift(With load) 5.6
Cycle time Dump(With load) sec 1.0
Lower(Empty) 2.8
Maximum travel speed km/hr(mph) 36.0(22.4)
Braking distance 12(39' 4")
m(ft-in)
Minimum turning radius(Center of outside tire) 4.7(15' 5")
Gradability Degree (Á) 30
First gear 6.2(3.9)
Second gear 11.4(7.1)
Forward
Third gear 22.1(13.7)
Travel speed Fourth gear km/hr(mph) 36.0(22.4)
First gear 6.5(4.0)
Reverse Second gear 12.0(7.5)
1-12
WITH BOLT-ON CUTTING EDGE TYPE BUCKET(HL730XTD-7A)
F
B
I
J
5120
H
3970
K
C
G
40
47
0
5755 0
D
E 1855
A
7307A2SP02-1

Struck 1.5(2.0)
Heaped 1.8(2.4)
Tread F 1850(6' 0")
Dump angle J 48
Degree (Á)
Lift(With load) 5.6
Lower(Empty) 2.8
m(ft-in)
First gear 6.2(3.9)
Forward
First gear 6.5(4.0)
1-13
WITH BOLT-ON CUTTING EDGE TYPE BUCKET(HL730TM-7A)
B
F
I
4870
H
3780
K
C
G
40
47
0
D
5444 0
E 1830
A
730TM7A2SP03

Struck 1.4(1.8)
Heaped 1.6(2.1)
Overall width B 2400( 7'10")
Ground clearance D 370( 1' 3")
Wheelbase E mm(ft-in) 2750( 9' 0")
Tread F 1850( 6' 0")
Dump clearance at 45Á G 2785( 9' 2")
Dump reach(Full lift) H 1140( 3' 9")
Width over tires I 2295( 7' 6")
Dump angle J 50
Degree (Á)
Lift(With load) 5.4
Lower(Empty) 2.4
m(ft-in)
First gear 6.2(3.9)
Forward
First gear 6.5(4.0)
1-14
2) WITH TOOTH TYPE BUCKET(HL730-7A)
F
B
I
J
4790
H
3640
C
40
G
K
47
5640 00
D
E 1830
A
7307A2SP04

Struck 1.4(1.9)
Heaped 1.7(2.2)
Overall width B 2480( 8' 2")
Ground clearance D 370( 1' 3")
Wheelbase E mm(ft-in) 2750( 9' 0")
Tread F 1850( 6' 0")
Dump clearance at 45Á G 2640( 8' 8")
Dump reach(Full lift) H 1075( 3' 6")
Width over tires I 2295( 7' 6")
Dump angle J 48
Degree (Á)
Lift(With load) 5.6
Lower(Empty) 2.8
m(ft-in)
First gear 6.2(3.9)
Forward
Fourth gear km/hr(mph) 36.0(22.4)
Travel speed
First gear 6.5(4.0)
1-15
WITH TOOTH TYPE BUCKET(HL730XTD-7A)
F
B
I
J
5120
H
3970
C
40
G
K
47
5800 00
D
E 1855
A
7307A2SP04-1

Struck 1.4(1.9)
Heaped 1.7(2.2)
Tread F 1850(6' 0")
Dump angle J 48
Degree (Á)
Lift(With load) 5.6
Lower(Empty) 2.8
m(ft-in)
First gear 6.2(3.9)
Forward
Fourth gear km/hr(mph) 36.0(22.4)
Travel speed
First gear 6.5(4.0)
1-16
3. WEIGHT
Item kg lb
HL730-7A, HL730XTD-7A 750 1650
Front frame assembly
HL730TM-7A 775 1710
Rear frame assembly 1000 2200
Front fender(LH & RH) 20 44
Rear fender(LH & RH) 33 73
HL730-7A 300 660
Counterweight
HL730XTD-7A, HL730TM-7A 410 900
Cab assembly 820 1810
Engine assembly 370 820
Transmission assembly 380 840
Drive shaft(Upper, engine to transmission) 7 15
Drive shaft(Front) 17 37
Drive shaft(Center) 17 37
Drive shaft(Rear) 9 20
Front axle(Include differential) 480 1060
Rear axle(Include differential) 490 1080
Tire(17.5-25, 12PR L3) 130 290
Hydraulic tank assembly 165 360
Fuel tank assembly 240 530
Main pump assembly 26 57
Main control valve 22 49
Boom assembly HL730-7A / HL730XTD-7A 540 / 620 1190 / 1370
HL730TM-7A 510 1120
Bell crank assembly 140 310
Bucket link 27 60
1.8m3 bucket, with bolt on cutting edge 710 1570
1.7m bucket, with tooth
3
780 1720
Boom cylinder assembly 70 150
HL730-7A, HL730XTD-7A 78 170
Bucket cylinder assembly
HL730TM-7A 62 140
Steering cylinder assembly 15 30
Seat 40 88
Battery 28 62
Quick coupler assembly 210 460
1-17
4. SPECIFICATION FOR MAJOR COMPONENTS
1) ENGINE
Item Specification
Model Cummins QSB4.5

Type 4-cycle turbocharged and after cooled diesel engine
Cooling method Water cooling
Number of cylinders and arrangement 4 cylinders, in-line
Firing order 1-3-2-4
Combustion chamber type Direct injection type
Cylinder bore Ý stroke 107Ý124mm(4.21"Ý4.88")
Piston displacement 4500cc(275cu in)
Compression ratio 17.2 : 1
Rated gross horse power 125hp at 2100rpm
Maximum gross torque at 1400rpm 56kgfÂm(408lbfÂft)
Engine oil quantity 11˶ (2.9 U.S. gal)
Dry weight 371kg(818lb)
High idling speed 2230 Ü 50rpm
Low idling speed 950 Ü 25rpm
Rated fuel consumption 237g/kwÂhr
Starting motor Nippondenso 228000-7902 (24V-3.7kw)
Alternator Delco Remy 24SI(24V-70Amp)
Battery 2Ý12VÝ100Ah
1-18
2) MAIN PUMP
Item Specification
Type Fixed displacement helical gear pump
Capacity 36+32.3cc/rev
Maximum operating pressure 210kgf/cm2(2990psi)
Rated operating speed 2100rpm
Rated output flow 140˶min(40U.S.gpm)
3) FAN AND BRAKE PUMP

Specification
Item
Fan Brake
Type Fixed displacement tandem helical gear pump
Capacity 14cc/rev 8.7cc/rev
Maximum operating pressure 100kgf/cm2(1422psi) 150kgf/cm2(2130psi)
Rated operating speed 2100rpm
Rated output flow 29˶min(7.7U.S.gpm) 18˶min(4.8U.S.gpm)
4) MAIN CONTROL VALVE

Item Specification
Type 2 spool(sectional block)

Operating method Hydraulic pilot assist
Main relief valve set pressure 210kgf/cm2(2990psi)
Overload relief valve set pressure 240kgf/cm2(3414psi)
5) REMOTE CONTROL VALVE
Item Specification
Type Joystick(or with aux lever)

Minimum 3.7kgf/cm2(52.6psi)
Control pressure
Maximum 30kgf/cm2(427psi)
6) CYLINDER
Item Specification
Boom cylinder Bore diaÝRod diaÝStroke ͚105Ý͚65Ý772mm

Bucket cylinder Bore diaÝRod diaÝStroke ͚120Ý͚70Ý510mm
Steering cylinder Bore diaÝRod diaÝStroke ͚ 60Ý͚35Ý412mm
1-19
7) DYNAMIC POWER TRANSMISSION DEVICES
Item Specification
Model ZF 4WG130
Torque converter
Type Single-stage, single-phase
Type Full-automatic power shift
Transmission Gear shift Forward fourth gear, reverse third gear
Control Electrical single lever type, kick-down system
Drive devices 4-wheel drive
Axle Front Front fixed location
Rear Oscillation Ü13Áof center pin-loaded
Wheels Tires 17.5-25, 12PR(L3)
Travel Four-wheel, wet-disc type, full hydraulic
Brakes Spring applied, hydraulic released brake in front
Parking axle
Type Full hydraulic, articulated
Steering
Steering angle 40Áto both right and left angle, respectively
1-20
5. TIGHTENING TORQUE OF MAJOR COMPONENT
No Items Size kgfÂm lbfÂft
1 Engine mounting bolt, nut(4EA) M16Ý2.0 29.7Ü4.5 215Ü32.5

2 Engine mounting bolt(Bracket) M12Ý1.75 10.7Ü1.6 77.4Ü11.6
3 Engine Radiator mounting bolt M16Ý2.0 29.7Ü4.5 215Ü32.5
4 Fuel tank mounting bolt M16Ý2.0 29.7Ü4.5 215Ü32.5
5 Air cleaner mounting bolt(4EA) M 8Ý1.25 2.5Ü0.5 18.1Ü3.6
6 Main pump housing mounting bolt M14Ý2.0 19.6Ü2.9 142Ü20.9
7 Main control valve mounting bolt M12Ý1.75 12.8Ü3.0 92.6Ü21.7
8 Steering unit mounting bolt M10Ý1.5 6.9Ü1.4 49.9Ü10.1
9 Priority valve M 8Ý1.25 2.5Ü0.5 18.1Ü3.6
10 Brake valve mounting bolt M 8Ý1.25 2.5Ü0.5 18.1Ü3.6
Hydraulic
11 Fan and brake pump mounting bolt M10Ý1.5 6.9Ü1.4 49.9Ü10.1
system
12 Cut-off valve mounting bolt M12Ý1.75 12.8Ü3.0 92.6Ü21.7
13 Remote control lever mounting bolt M 6Ý1.0 1.1Ü0.2 8.0Ü1.4
14 Pilot supply unit mounting bolt M 8Ý1.25 2.5Ü0.5 18.1Ü3.6
15 Safety valve M 8Ý1.25 2.5Ü0.5 18.1Ü3.6
16 Hydraulic oil tank mounting bolt M16Ý2.0 29.7Ü4.5 215Ü32.5
17 Transmission mounting bolt(Bracket, front) M20Ý2.5 57.9Ü8.7 419Ü62.9
18 Transmission mounting bolt(Bracket, rear) M16Ý2.0 18.4Ü2.0 133Ü14.5
19 Power train Front axle mounting bolt, nut M24Ý2.5 100Ü15 723Ü109
20 system Rear axle support mounting bolt, nut M24Ý2.0 100Ü15 723Ü109
21 Tire mounting nut(17.5-25, 12PR, L3) M22Ý1.5 79Ü2.5 570Ü18.1
22 Drive shaft joint mounting bolt 3/8-24UNF 6.0Ü0.8 43.4Ü5.8
23 Counterweight mounting bolt, nut M24Ý3.0 100Ü15 723Ü108
24 Others Operator’s seat mounting bolt M 8Ý1.25 3.4Ü0.8 24.6Ü5
25 ROPS Cab mounting bolt(4EA) M24Ý3.0 27.5Ü2.5 199Ü18.1
1-21
6. TORQUE CHART
Use following table for unspecified torque.
1) BOLT AND NUT
(1) Coarse thread
8T 10T
Bolt size
kgfÂm lbfÂft kgfÂm lbfÂft
M 6 Ý 1.0 0.85 ~ 1.25 6.15 ~ 9.04 1.14 ~ 1.74 8.2 ~ 12.6
M 8 Ý 1.25 2.0 ~ 3.0 14.5 ~ 21.7 2.73 ~ 4.12 19.7 ~ 29.8
M10 Ý 1.5 4.0 ~ 6.0 28.9 ~ 43.4 5.5 ~ 8.3 39.8 ~ 60
M12 Ý 1.75 7.4 ~ 11.2 53.5 ~ 79.5 9.8 ~ 15.8 71 ~ 114
M14 Ý 2.0 12.2 ~ 16.6 88.2 ~ 120 16.7 ~ 22.5 121 ~ 167
M16 Ý 2.0 18.6 ~ 25.2 135 ~ 182 25.2 ~ 34.2 182 ~ 247
M18 Ý 2.5 25.8 ~ 35.0 187 ~ 253 35.1 ~ 47.5 254 ~ 343
M20 Ý 2.5 36.2 ~ 49.0 262 ~ 354 49.2 ~ 66.6 356 ~ 482
M22 Ý 2.5 48.3 ~ 63.3 350 ~ 457 65.8 ~ 98.0 476 ~ 709
M24 Ý 3.0 62.5 ~ 84.5 452 ~ 611 85.0 ~ 115 615 ~ 832
M30 Ý 3.5 124 ~ 168 898 ~ 1214 169 ~ 229 1223 ~ 1655
M36 Ý 4.0 174 ~ 236 1261 ~ 1703 250 ~ 310 1808 ~ 2242
(2) Fine thread

8T 10T
Bolt size
kgfÂm lbfÂft kgfÂm lbfÂft
M 8 Ý 1.0 2.17 ~ 3.37 15.7 ~ 24.3 3.04 ~ 4.44 22.0 ~ 32.0
M10 Ý 1.25 4.46 ~ 6.66 32.3 ~ 48.2 5.93 ~ 8.93 42.9 ~ 64.6
M12 Ý 1.25 7.78 ~ 11.58 76.3 ~ 83.7 10.6 ~ 16.0 76.6 ~ 115
M14 Ý 1.5 13.3 ~ 18.1 96.2 ~ 130 17.9 ~ 24.1 130 ~ 174
M16 Ý 1.5 19.9 ~ 26.9 144 ~ 194 26.6 ~ 36.0 193 ~ 260
M18 Ý 1.5 28.6 ~ 43.6 207 ~ 315 38.4 ~ 52.0 278 ~ 376
M20 Ý 1.5 40.0 ~ 54.0 289 ~ 390 53.4 ~ 72.2 386 ~ 522
M22 Ý 1.5 52.7 ~ 71.3 381 ~ 515 70.7 ~ 95.7 512 ~ 692
M24 Ý 2.0 67.9 ~ 91.9 491 ~ 664 90.9 ~ 123 658 ~ 890
M30 Ý 2.0 137 ~ 185 990 ~ 1338 182 ~ 248 1314 ~ 1795
M36 Ý 3.0 192 ~ 260 1389 ~ 1879 262 ~ 354 1893 ~ 2561
1-22
2) PIPE AND HOSE(FLARE TYPE)
Thread size Width across flat mm

kgfÂm lbfÂft
1/4" 19 4 28.9
3/8" 22 5 36.2
1/2" 27 9.5 68.7
3/4" 36 18 130
1" 41 21 152
1-1/4" 50 35 253
3) PIPE AND HOSE(ORFS TYPE)

kgfÂm lbfÂft
9/16-18 19 4 28.9
11/16-16 22 5 36.2
13/16-16 27 9.5 68.7
1-3/16-12 36 18 130
1-7/16-12 41 21 152
1-11/16-12 50 35 253
4) FITTING

kgfÂm lbfÂft
1/4" 19 4 28.9
3/8" 22 5 36.2
1/2" 27 9.5 68.7
3/4" 36 18 130
1" 41 21 152
1-1/4" 50 35 253
1-23
7. RECOMMENDED LUBRICANTS
Use only oils listed below or equivalent.
Do not mix different brand oil.
Ambient temperature Á
C( Á
F)
Capacity
Service point Kind of fluid -20 -10 0 10 20 30 40
˶(U.S. gal)
(-4) (14) (32) (50) (68) (86) (104)
SAE 30
SAE 10W
Engine oil pan Engine oil 11(2.9)
SAE 10W-30
SAE 15W-40
Torque converter SAE 10W-30

Transmission Oil 20(5.3)
SAE 15W-40
Front : 18.4(4.9)
Axle Gear oil SAE 80W-90LSD/API GL-5
Rear : 18.4(4.9)
Tank: ISO VG 32
90(24)
Hydraulic tank Hydraulic oil ISO VG 46
System:
125(33) ISO VG 68
ASTM D975 NO. 1

Fuel tank Diesel fuel 202(53)
ASTM D975 NO. 2
NLGI NO. 1
Fitting
Grease As required
(Grease nipple)
NLGI NO. 2
Mixture of
antifreeze Ethylene glycol base permanent type
Radiator and water 30(7.9)
50 : 50
SAE : Society of Automotive Engineers
API : American Petroleum Institute
ISO : International Organization for Standardization
NLGI : National Lubricating Grease Institute
ASTM : American Society of Testing and Material
1-24
GROUP 3 OPERATIONAL CHECKOUT RECORD SHEET
ÂOwner
ÂDate
ÂHours
ÂSerial No.
ÂTechnician
ö U se this sheet to record operational
checkout results.
Perform the operational check before
installing any test equipment. 7307AGE02
NOT
Item OK OK Comments
1. Monitor indicator and gauge checks(Engine OFF)
Â Hourmeter and gauge check

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

switch and reverse warning alarm switch checks
Â Transmission control lever and neutral

Â Neutral start and reverse warning
Â Alarm circuit checks
3. Monitor indicator and gauge checks(Engine running)
Â Monitor display and alternator output checks

Â Monitor bypass circuit and seat belt indicator check
Â Monitor primary and secondary level check
Â Transmission oil warm up procedure
Â Transmission temperature gauge check
1-25
4. Brake system and clutch cut off checks
Â Park brake capacity check

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

Â Transmission noise check
Â Speedometer check
Â Transmission kick down system check
Â 1st, 2nd, 3rd and 4th speed clutch pack drag check
Â Transmission pressure, pump flow and leakage check
Â Transmission shift modulation check
Â Torque converter check
Â Engine power check
6. Hydraulic system checks
Â Hydraulic system warm up procedure

Â Hydraulic pump performance check
Â Pilot control valve boom float check
Â Boom down solenoid valve check
Â Control valve lift check
Â Bucket rollback circuit relief valve check
Â Bucket dump circuit relief
Low pressure check
High pressure check
Â Boom and bucket cylinder drift check
Â Boom down solenoid valve leakage check
Â Pilot controller check
Â Return to dig check
Â Boom height kickout check-if equipped
1-26
7. Steering system checks
Â Steering valve check

Â Steering system leakage check
Â Priority valve
Low check pressure
High check pressure
8. Accessory checks
Â Operating lights check

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

Â Cab door hold open latch check
Â Cab door release button check
Â Cab door lock check
Â Cab door window check
Â Cab window latch check
Â Steering column adjustment check
Â Seat and seat belt check
Â Air intake filter door check
Â Engine side panels check
Â Radiator cap access door check
Â Frame locking bar check
Â Boom lock check
Â Service decal check
1-27
SECTION 2 ENGINE

Group 2 Fuel warmer system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-7
Group 3 Engine speed and Stall rpm - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-8
SECTION 2 ENGINE
GROUP 1 STRUCTURE AND FUNCTION
1. STRUCTURE
Turbocharger Exhaust outlet connection
Coolant heater starting aid
Alternator
Starting motor Lubricating oil filter

Water inlet
connection
Flywheel housing
Engine oil cooler
Air intake connection Lifting bracket
Fuel filter
Fan pilot spacer
Engine control
module(ECM)
Fuel pump
Front engine support
Oil pan
7307AEG01
Â Direct 4-stroke, 4-cylinders, water-cooling and charge air cooled diesel engine in installed, cylinder
block and cylinder head are made of case iron and turbocharger is attached.
2-1
2. SYSTEM DIAGRAMS
The following drawings show the flow through the engine systems.
1) FUEL SYSTEM
7607AEG02
1 From fuel tank 11 Fuel rail

2 Water/fuel separator(not mounted on engine) 12 To injectors
3 ECM cooling plate 13 High-pressure connector
4 To fuel gear pump 14 Injector
5 To fuel filter 15 Fuel return from injectors and fuel rail to fuel
6 Fuel filter head filter head
7 Fuel filter 16 Fuel return from high-pressure pump to fuel
8 To high-pressure pump filter head
9 High-pressure pump 17 To fuel tank
10 To fuel rail
2-2
2) LUBRICATING OIL SYSTEM
7607AEG03
1 Gerotor lubricating oil pump 8 Filter bypass valve

2 From lubricating oil pump 9 Filter bypass valve closed
3 Pressure regulating valve closed 10 Filter bypass valve open
4 Pressure regulating valve open 11 To lubricating oil filter
5 To lubricating oil cooler 12 Full-flow lubricating oil filter
6 To lubricating oil pump supply 13 From lubricating oil filter
7 Lubricating oil cooler 14 Main lubricating oil rifle
(1) Lubrication for the turbocharger
7607AEG04
1 Turbocharger lubricating oil supply 2 Turbocharger lubricating oil drain
2-3
(2) Lubrication for the power components
7607AEG05
1 From lubricating oil cooler 6 To camshaft

2 Main lubricating oil rifle 7 Crankshaft main journal
3 To valve train 8 Oil supply to rod bearings
4 From main lubricating oil rifle 9 Directed piston-cooling nozzle
5 To piston-cooling nozzle 10 To internal lubrication of air compressor
(3) Lubrication for the overhead
7607AEG06
1 Main lubricating oil rifle 4 Rocker lever shaft

2 Rocker lever support 5 Rocker lever bore
3 Transfer slot 6 Rocker lever
2-4
3) COOLING SYSTEM
7607AEG07
1 Coolant inlet 7 Coolant flow to thermostat housing

2 Pump lmpeller 8 Coolant bypass passage
3 Coolant flow past lubricating oil cooler 9 Coolant flow back to radiator
4 Coolant flow past cylinders 10 Bypass closed
5 Coolant flow from cylinder block to cylinder head 11 Coolant bypass in cylinder head
6 Coolant flow between cylinders 12 Coolant flow to water pump inlet
4) AIR INTAKE SYSTEM
7607AEG08
1 Intake air inlet to turbocharger 4 Intake manifold

2 Turbocharger air to charge air cooler (Integral part of cylinder head)
3 Charge air cooler 5 Intake valve
2-5
5) EXHAUST SYSTEM
7607AEG09
1 Exhaust valve 3 Turbocharger

2 Exhaust manifold 4 Turbocharger exhaust outlet
2-6
GROUP 2 FUEL WARMER SYSTEM
1. SPECIFICATION
1) Operating voltage : 24Ü4V
2) Power : 350Ü50W
3) Current : 15A
2. OPERATION
1) The current of fuel warmer system is automatically Fuel warmer
controlled without thermostat according to fuel
temperature.
2) At the first state, the 15A current flows to the fuel
warmer and engine may be started in 1~2
Prefilter
minutes.
3) If the fuel starts to flow, ceramic-disk in the fuel
warmer heater senses the fuel temperature to
reduce the current as low as 1.5A.
So, fuel is protected from overheating by this
2507A5MS12
mechanism.
3. ELECTRIC CIRCUIT
CS-74
CN-1 CN-60
34 3R 1 5R
1 2
33 5W
2 1
MASTER SW
CN-95
2 5W
2
69 5W
1
FUSIBLE LINK
CR-1
BATTERY
BATTERY RY
TO STARTER
MCU
15 MECHANICAL ENG(GND)
11
20
21
22
23
24
25
26
27
28
10
12
13
14
15
16
17
18
19
1
3 REVERSE FAN SOL

REVERSE FAN SIG
8 PROGRAM DUMP
NEUTRAL RY/J/STICK F/R 10A
30A
EM'CY STEER/RIDE CON. 20A
30A
20A
BEACON/RR WORK LAMP 20A
20A
20A
10A
CIGARLIGHTER/MIRROR 20A
30A
20A
20A
30A
30A
10A
10A
10A
10A
10A
30A
10A
10A
10A
10A
5A
5A
5A
23 STOP LAMP PS
17 POWER IG(NC)
16 POWER IG(NC)
2 FUEL HEATER
19 HOUR METER
18 BATTERY 24V
10 OPTION PS 2
9 OPTION PS 1
CASSETTE/RM LAMP
ILLUMINATION LAMP
ILLUMINATION LAMP
FRONT WORK LAMP
HORN/CONVERTER
7 RS232 RX
6 RS232 TX
BACK.STOP LAMP
AIR-CON/HEATER
AIR-CON/HEATER
14 OPTION
13 OPTION
12 OPTION
11 OPTION
22 OTMP1
21 ODP2
20 ODP1
CLUSTER/MCU
5 GND
4 Gr PRE-HEATER
1 NC
TURN LAMP
HEAD LAMP
21 3Or START KEY
CASSETTE
CN-59
CLUSTER
ILL.LAMP
SWITCH
CN-36
WIPER
4
ECM
MCU
23 3W ECM
RCV
TCU
TCU
143 BOr
27 RW
MCU IG 24V
CN-13
1
CN-3 2
CR-35
1 3
86 30 87a 149 LW 16 LW LW 23
B G14 2 4 CN-96
85 16A LW LW 23A 23 LW
3Br 31 3 5 1
87 G2 B
G 65A 4 6 2
86
85 87 87a 3Or 21 5 7 3
30
6 8 4
POWER RY
7 9
CR-25 FUEL WARMER
8 10
86 3087a
B G15 9 11
85
3Y 32 10 12
87
G 65 11 CN-12
85 87 87a 86 Or 21A 12 12 CN-94
30 13A W
13 13 4 BATT (+)
ECM POWER RY W 15 13 13E W
14 14 3 BATT (+)
15 15 B
15 2 BATT (-)
LW 149
BOr 143
16 B
Gr 4A
Gr 4E
H BR ACC ST C
6
CS-2 1 BATT (-)
Gr 4
5
6 ECM EARTH
3 5 (BATTERY(-) TERMINAL)
CR-46
CR-36
87
2
30
87a
85
86
87
30
87a
85
85 8787a 86
4
B
1
G 65
4 3
85 8787a
0, I
2
H 0 I II
86 30
86 30
Or 21E
1
START SWITCH FUEL WARMER RY PREHEAT RY
7407AEL08
2-7
GROUP 3 ENGINE SPEED & STALL RPM
1. TEST CONDITION
1) Normal temperature of the whole system
- Coolant : Approx 80 äC (176 ä
F)
- Hydraulic oil : 45 Ü 5 ä
C (113 Ü 10 ä F)
- Transmission oil : 75 Ü 5 ä
C (167 Ü 10 ä F)
2) Normal operating pressure : See page 6-54.
2. SPECIFICATION
Engine speed, rpm
Remark
Low idle High idle Pump stall Converter stall Full stall
950Ü25 Ü50
2230Ü 2130Ü70 Ü70
2150Ü 1750Ü100
3. ENGINE RPM CHECK

Remark : If the checked data is not normal, it indicates that the related system is not working properly.
Therefore, it is required to check the related system pressure : See page 6-54.
1) Pump stall rpm
- Start the engine and raise the bucket approx
45 cm (1.5 ft) as the figure.
- Press the accelerator pedal fully and operate
the bucket control lever to the retract position
45cm
fully.
- Check the engine rpm at the above condition.
7307Awe66
2) Convertor stall rpm
- Start the engine and lower the bucket on the
ground as the figure. Released position
- Set the clutch cut off switch at the released

position.
Clutch cut off sw
- Press the brake pedal and accelerator pedal
fully.
- Shift the transmission lever to the 3rd forward
position.
7307Awe67
3) Full stall rpm

- Start the engine and raise the bucket approx Released position
45 cm (1.5 ft) as the figure.

- Set the clutch cut off switch at the released
Clutch cut off sw
position.
- Press the brake pedal and accelerator pedal
45cm
fully .
- Shift the transmission lever to the 2nd forward
position and operate the bucket lever to the
retract position fully. 7307Awe68
2-8
Group 1 Structure and Function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1

Group 2 Operational Checks and Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-64
Group 3 Tests and Adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-75
Group 4 Disassembly and Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-78
1. POWER TRAIN COMPONENT OVERVIEW
Front drive shaft Upper drive shaft Engine
Front axle Transmission Rear axle

Center drive shaft Rear drive shaft
7307APT01
The power train consists of the following components :

ÂTransmission
ÂFront, upper, center and rear drive shafts
ÂFront and rear axles
Engine power is transmitted to the transmission through the torque converter.
The transmission is a hydraulically engaged four speed forward, three speed reverse counter shaft type
power shift transmission. A disk type parking brake is located in the front axle.
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 KR K1 K3 KV K2
P1 F 60 P2 E 55 P3 D 56 P4 C 58 P5 B 53 P6 A 57
B D B D B D B D B D B D
Y1 NFS Y2 NFS Y3 NFS Y4 NFS Y5 NFS Y6 NFS
Pressure
Temp reducing
sensor valve
9+0.5 bar
System
pressure
Valve block control circuit valve
16+2 bar
Filter pressure
differential valve
Converter
Relief Filter
valve
11+2 bar
Oil cooler Bcak

pressure
valve Pump
Bypass 4.3+3 bar
valve 16+2 bar
3 bar
Oil sump
Lubrication Main oil circuit
7607APT18
NFS Follow-on slide P3 Proportional valve K1

D Vibration damper P4 Proportional valve K3
B Orifice P5 Proportional valve KV
P1 Proportional valve K4 P6 Proportional valve K2
P2 Proportional valve KR Y1~Y6 Pressure regulator
Current
Forward Reverse Engaged Positions No. of the
Speed Neutral clutch on the measuring
valve block points
1 2 3 4 1 2 3
Y1 X K4 F 60
Y2 X X X KR E 55
Y3 X X K1 D 56
Y4 X X X K3 C 58
Y5 X X X KV B 53
Y6 X X K2 A 57
Engaged
K1,KV KV,K2 K3,KV K4,K3 KR,K1 KR,K2 KR, K3 - - -
clutch
X : Pressure regulator under voltage
3-2
2. TORQUE CONVERTER
5 1 2 3 4
73033TM00
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 is designed according to the engine power so that the most favorable operating conditions
are obtained for each installation case.
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 from the transmission pump is constantly streaming 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 via the escaping oil.
The oil which is streaming out of the pump wheel, enters the turbine wheel and is there inversed in the
direction of flow.
According to the rate of reversion, the turbine wheel and with it also the output shaft is receiving a more
or less high reaction torque. The stator(Reaction member), following the turbine, has the task to reverse
the oil streaming out of the turbine once more and to deliver it under the suitable discharge direction to
the pump wheel.
Due to the reversion, the stator receiving a reaction torque.
The relation turbine torque/pump torque is called torque multiplication. This is the higher, the greater the
speed difference of pump wheel and turbine wheel will be.
Therefore, the maximum torque multiplication is created at stationary turbine wheel.
With increasing output speed, the torque multiplication is decreasing. The adaption of the output speed
to a certain required output torque will be infinitely variable and automatically achieved by the torque
converter.
3-3
when the turbine speed is reaching about 80% of the pump speed, the torque multiplication becomes
1.0 i.e. the turbine torque becomes equal to that of the pump torque.
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, in the torque multiplication
range it is backing-up the torque upon the housing, and is released in the clutch 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 nT = 0
condition 1 Reaction member
1.5
(Stator) 2.5 Machine standing
still
Intermediate
condition 1 <1.5 <2.5
nT < n engine
Condition in the
coupling point 1 1 nT = 0.8n engine
0
7577APT100
3-4
3. TRANSMISSION
1) LAYOUT
12
11
2
10
3
15
4
14
6
13 7
7407APT03
1 Reverse clutch(KR) 6 Rear output flange 11 Converter

2 Engine-dependent 7 Converter side output 12 Inductive transmitter
power take-off flange for engine speed
3 Forward clutch(KV) 8 Output shaft 13 4th clutch(K4)
4 2nd clutch(K2) 9 Transmission pump 14 Converter relief valve
5 3rd clutch(K3) 10 Input flange 15 1st clutch(K1)
3-5
2) INSTALLATION VIEW
1 2 9 10 11 12 14
15
20
3 16
19
8
3 13 18
4 17
7 6 5
7407PT02
1 Lifting lugs 11 Breather

2 Input flange-input through universal shaft 12 Transmission-case cover
3 Transmission suspension threads M20 13 Transmission case
4 Output flange-converter side 14 Power take-off; Coaxial;
5 Oil drain plug with magnetic insert M38Ý1.5 Engine-dependent
6 Model identification plate 15 Electro-hydraulic control
7 Attachment possibility for oil level tube 16 Oil level tube with oil dipstick
with oil dipstick(Converter side) 17 Transmission suspension threads M20
8 Attachment possibility for emergency 18 Output flange-rear
steering pump 19 Exchange filter(Fine filter)
9 Cover 20 Filter head with connection for filter
10 Converter bell housing restriction switch
3-6
3) OPERATION OF TRANSMISSION
(1) Forward
Η Forward 1st
In 1st forward, forward clutch and 1st clutch are engaged.
Forward clutch and 1st clutch are actuated by the hydraulic pressure applied to the clutch piston.
KR KR
KV IN
K4
K2
INPUT
K3 K1
KV
OUT
GEAR PATTERN
K2
K1 K3
K4
OUTPUT OUTPUT
7607PT04
3-7
Θ Forward 2nd
In 2nd forward, forward clutch and 2nd clutch are engaged.
Forward clutch and 2nd clutch are actuated by the hydraulic pressure applied to the clutch
piston.
KR KR
KV IN
K4
K2
INPUT
K3 K1
KV
OUT
GEAR PATTERN
K2
K1 K3
K4
OUTPUT OUTPUT
7607PT05
3-8
Ι Forward 3rd
In 3rd forward, forward clutch and 3rd clutch are engaged.
Forward clutch and 3rd clutch are actuated by the hydraulic pressure applied to the clutch piston.
KR KR
KV IN
K4
K2
INPUT
K3 K1
KV
OUT
GEAR PATTERN
K2
K1 K3
K4
OUTPUT OUTPUT
7607PT06
3-9
Κ Forward 4th
In 4th forward, 4th clutch and 3rd clutch are engaged.
4th clutch and 3rd clutch are actuated by the hydraulic pressure applied to the clutch piston.
KR KR
KV IN
K4
K2
INPUT
K3 K1
KV
OUT
GEAR PATTERN
K2
K1 K3
K4
OUTPUT OUTPUT
7607PT07
3-10
(2) Reverse
Η Reverse 1st
In 1st reverse, reverse clutch and 1st clutch are engaged.
Reverse clutch and 1st clutch are actuated by the hydraulic pressure applied to the clutch piston.
KR KR
KV IN
K4
K2
INPUT
K3 K1
KV
OUT
GEAR PATTERN
K2
K1 K3
K4
OUTPUT OUTPUT
7607PT08
3-11
Θ Reverse 2nd
In 2nd reverse, reverse clutch and 2nd clutch are engaged.
Reverse clutch and 2nd clutch are actuated by the hydraulic pressure applied to the clutch
piston.
KR KR
KV IN
K4
K2
INPUT
K3 K1
KV
OUT
GEAR PATTERN
K2
K1 K3
K4
OUTPUT OUTPUT
7607PT09
3-12
Ι Reverse 3rd
In 3rd reverse, reverse clutch and 3rd clutch are engaged.
Reverse clutch and 3rd clutch are actuated by the hydraulic pressure applied to the clutch piston.
KR KR
KV IN
K4
K2
INPUT
K3 K1
KV
OUT
GEAR PATTERN
K2
K1 K3
K4
OUTPUT OUTPUT
7607PT10
3-13
4) ELECTRO-HYDRAULIC SHIFT CONTROL WITH PROPORTIONAL VALVE
2 1 3
A A
Y6 Y1
Y5 Y2
B
Y4 Y3
3 6
2 6 1 4 11 9 10
Y5
SECTION A-A SECTION B-B

8 7
73033CV01
1 Pressure reducing valve(9bar) 7 Intermediate sheet

2 System pressure valve(16+2bar) 8 Duct plate
3 Housing 9 Oscillation damper
4 Cable harness 10 Follow-on slide
5 Cover 11 Pressure regulator
6 Valve block
Transmission control, see schedule of hydraulic circuit, electro-hydraulic control unit and measuring
points at page 3-2, 3-14 and 3-76.
The six clutches of the transmission are selected via the 6 proportional valves P1 to P6. The
proportional valve(Pressure regulator unit) is composed of pressure regulator(e.g. Y1), follow-on
slide and vibration damper.
The control pressure of 9 bar for the actuation of the follow-on slides is created by the pressure
reducing valve. The pressure oil (16+2bar) is directed via the follow-on slide to the respective clutch.
3-14
Due to the direct proportional selection with separated pressure modulation for each clutch, the
pressures to the clutches, which are engaged in the gear change, will be controlled. In this way, a
hydraulic intersection of the clutches to be engaged and disengaged becomes possible.
This is creating spontaneous shiftings without traction force interruption.
At the shifting, the following criteria are considered:
- Speed of engine, turbine, central gear train and output.
- Transmission temperature.
- Shifting mode(Up-, down-, reverse shifting and speed engagement out of neutral).
- Load condition(Full and part load, traction, overrun inclusive consideration of load cycles during
the shifting).
The main pressure valve is limiting the maximum control pressure to 16+2 bar and releases the
main stream to the converter and lubricating circuit.
In the inlet to the converter, a converter safety valve is installed which protects the converter from
high internal pressures(Opening pressure 11bar).
Within the converter, the oil serves to transmit the power according to the well-known hydrodynamic
principle(See torque converter, page 3-3).
To avoid cavitation, the converter must be always completely filled with oil.
This is achieved by a converter back pressure back-up valve, rear-mounted to the converter, with an
opening pressure of at least 4.3bar.
The oil, escaping out of the converter, is directed to a oil cooler.
The oil is directed from the oil cooler to the transmission and from there to the lubricating oil circuit,
so that all lubricating points are supplied with cooled oil.
In the electro-hydraulic control unit are 6 pressure regulators installed.
5) GEAR SELECTOR(DW-3)
The gear selector is designed for the
mounting on the left side of the steering
column. The positions(Speeds) 1 to 4 are F
selected by a rotary motion, the driving 1

2
3
N
4
R
direction Forward(F)-Neutral(N)-Reverse(R)
by tilting the gear selector lever.
The gear selector is also available with
integrated kickdown push button.
For the protection from unintended start off,
a neutral interlock is installed.
N D
Position N - Gear selector lever blocked in
this position.
Position D - Driving. 73033TM17
3-15
6) LCD
1 LCD
2( ) Right, Buzzer stop
Move to the next selection
1
3( ) Select(Enter)
Activate the currently chosen item
2 4( ) Escape
3 Return to the previous menu
4 5( ) Main, Menu
5 - Display menu
7707A3CD04
- Return to the main display
(1) Main display
2
TYPE 1 TYPE 2
1
4
c
a
3 e 5
b
d
7
6
8 9
7707A3CD10
No Symbol Meaning Remark

Job timer, Odometer, Hydraulic temperature, Battery
1 Job Time 1.26h Monitoring information
voltage, Coolant temperature, T/M oil temperature.
Buzzer, Fan state, Ride state(option), Steering
2 AUTO State information
joystick(option), Warming up
a When operating intermittently, it shows an operating time interval
3 Wiper display
b Wiper motor intermittently operating
Forward, reverse, neutral LCD type 1
F, R, N Forward, reverse, neutral LCD type 2
4 Actual gear display
1, 2, 3, 4 Actual gear
P Parking brake mode active
c, d Up and down shifting c: Forward, d: Reverse
5 Select gear display Automatic mode
e Pre-selected gear
Fault
6 71 Fault code display Fault code state display
7 0 RPM Engine rpm display Now engine rpm state display
8 11.0Hr Hour meter display Hour meter state display
9 PM 12:05 Timer & alarm display Now time & alarm state display
ö Both type1 and type2 are LCD modes and they can be changed each other by operator’s selection.
(Adjustment/Display, see page 3-18)
3-16
(2) Display map
Main Menu Sub menu Activate item
7707A3CD11
Main group Sub group Meaning Display on LCD

Accessory ÂMeasure the various job time.
Job timer Job Time 1.26h
ÂPress : Display ON, OFF or RESET
ÂMeasures time in seconds.
Stop watch -
ÂPress : Start. Press again : Stop.
Latest ÂDistance until recent times. Latest 20.5 Km

Odometer
Total ÂTotal distance. Total 30.5 Km
ÂControl of LCD display luminosity.

Light control -
ÂBrightness control : .
Clock ÂWhen 12H or 24H is selected, the current
Time set hour appears.
Â : input, : setting. PM 22:05
Clock ON/OFF Â : Clock display ON or OFF.
1
ÂAlarm setting. It is possible to set 3 alarms.
Alarm 2
ÂStop alarming :
3
User Alternate ON ÂRaise the idle rpm to 1200rpm automatically
-
idle OFF to warm up the engine.
Mode 1 ÂAutomatic travelling speed is applied from 1st -

Auto (1st-4th) to 4th gear.
select Mode 2 ÂAutomatic travelling speed is applied from -
(2nd-4th) 2nd to 4th gear.
Mode 1 ÂPress button once : Shift down, press button -
Quick (Down/Up) again ; shift up.
shift Mode 2 ÂPress button every time : Shift to lower gear -
(Down only) respectively.
Auto ÂON : Transmission auto condition.
select ÂOFF : Transmission semi-auto condition.
Aux-sw
Clutch ÂON : Clutch cut-off is activated.
cut-off ÂOFF : Clutch cut-off is cancelled. -
Forward ÂForward active

Fan
control Reverse ÂReverse activeø
øReverse mode cleans out quickly dirt and dust on radiator and cooler by reverse rotation of cooling fan.
3-17
Adjustment MKS Total 50.7 Km
Unit ÂChoose between metric and inch unit display.
ENG Total 31.5 Mile
Wiper ÂWhen using the intermittent function of wiper
motor, it regulates operation time.
Intermittence ÂRegulate idle rpm.

ÂPress : Adjust idle rpm increments -
(or decrement) by 25rpm.
ÂPress : Modification. -
ÂIt controls the disk interval of the transmission,
automatically.
Alternate RPM ÂIt is set at the factory, so there's no need to
-
change.
Pulse ÂEnglish : Display in English.
-
ÂKorean : Display in Korean.
ÂType 1 : Indicate with the symbol.
AEB
ÂType 2 : Indicate with a letter. ,
Diagnostics Fault ÂError code display.

-
code ÂRefer to page 3-19.
Machine ÂHydraulic temperature and battery voltage HYD temp 100.6 C
Monitor display. Bat Volt 27.5 V
ÂPress : Display ON or OFF.
Fault ÂError code display. -
code ÂConsult a Hyundai dealer to error code.
Engine
ÂEngine coolant temperature display.
Monitor Coolant Temp 57.6 C
Fault ÂError code display.

-
Transmis- code ÂConsult a Hyundai dealer to error code.
sion Transmission oil temperature display.
Monitor ÂPress : Display ON or OFF.
Oil Temp 37.6 C
Version ÂDisplay the controller(MCU) and cluster version. -
3-18
(3) Machine fault code
When selecting the fault code menu, it shows all of the fault codes which mean abnormal
conditions of present time.
3 's FAULT 71
34 71 72 TCU Communication Error
7707A3CD36
ö To go out from fault explanation window, press button.

(Press , to go out to main.)
ö No error will be indicated in case that there’s no fault.
Description Code Meaning Remark
010 Power input voltage low Below 18V

011 Power input voltage high Above 38V
Electrical 012 Alternator voltage low Below 5V
system 013 Alternator voltage high Above 36V
014 Buzzer circuit open or short to ground
015 Buzzer circuit short to power
Hydraulic 020 Hydraulic oil temperature sensor open or short to power
system 021 Hydraulic oil temperature sensor short to ground
030 Fuel level sensor open or short to power
Engine 031 Fuel level sensor short to ground
system 034 Cooling fan driving valve open or short to ground
035 Cooling fan driving valve short to power
050 Auto select switch supply power open or short to power
051 Auto select switch supply power short to ground
T/M system
052 Clutch cutoff supply power open or short to power
053 Clutch cutoff supply power short to ground
Steering 060 Emergency steering relay open or short to ground Option
system 061 Emergency steering relay short to power Option
070 MCU communication error
Communication 071 TCU communication error
072 ECM communication error
MCU : Machine control unit TCU : Transmission control unit ECM : Engine control module
3-19
(4) Transmission warning
Symbol Meaning Remarks
LF, LR Limp home gear -

F/R/Ā/Ă flashing Direction F or R selected while turbine
speed is too high, CAUTION gear will -
engage if turbine speed drops
Oil temperature too low, no gear available Warm up engine / transmission
WS Warning sump temperature Changes between actual gear/direction
while driving, in neutral only displayed if no
fault is detected
WT Warning torque converter temperature Changes between actual gear/direction
fault is detected
WE Warning high engine speed Changes between actual gear/direction
fault is detected
3-20
(5) Display during AEB mode
K1~K4, KV, KR Calibrating clutch K1~K4, KV

or KR respectively
- And Kx Wait for start, initialization of
clutch Kx, x : 1, 2, 3, 4, V, R
And Kx Fast fill time determination of
clutch Kx
= And Kx Compensating pressure
determination of clutch Kx
OK Calibration for all clutches Transmission stays in neutral, you have to restart the
finished TCU(Ignition off/on)
STOP AEB canceled(Activation Transmission stays in neutral, you have to restart the
stopped) TCU(Ignition off/on)
STOP and Kx AEB stopped, clutch Kx can't Transmission stays in neutral, you have to restart the
be calibrated TCU(Ignition off/on)
Spanner and Kx Kx couldn't be calibrated, AEB Transmission stays in neutral, you have to restart the
ĀE Engine speed too low,
- Raise engine speed
ĂE Engine speed too high,
- Lower engine speed
ĀT Transmission oil temperature
too low,
- Heat up transmission
ĂT Transmission oil temperature
too high,
- Cool down transmission
FT Transmission temperature not Transmission stays in neutral, you have to restart the
in defined range during TCU(Ignition off/on)
calibration
FB Operating mode not NORMAL Transmission stays in neutral, you have to restart the
or transmission temperature TCU(Ignition off/on)
sensor defective or storing of
calibrated values to EEPROM
has failed
FO Output speed not zero Transmission stays in neutral, you have to restart the
TCU(Ignition off/on)
FN Shift lever not in neutral Transmission stays in neutral, you have to restart the
position TCU(Ignition off/on)
FP Park brake not applied Transmission stays in neutral, you have to restart the
ö AEB mode : It controls the disk internal of the transmission, automatically.
3-21
(6) Engine fault codes
Fault code No. Reason Effect (only when fault code is active)
Engine control module critical internal failure - Possible no noticeable performance effects,
Bad intelligent device or component. Error engine dying, or hard starting.
111
internal to the ECM related to memory hardware
failures or internal ECM voltage supply circuits.
Engine magnetic crankshaft speed/position lost Fueling to injectors is disabled and the engine
both of two signals - Data erratic, intermittent, or can not be started.
115 incorrect. The ECM has detected that the
primary engine speed sensor and the backup
engine speed sensor signals are reversed.
Intake manifold 1 pressure sensor circuit - Engine power derate.
Voltage above normal, or shorted to high
122
source. High signal voltage detected at the
intake manifold pressure circuit.
Intake manifold 1 pressure sensor circuit - Engine power derate.
Voltage below normal, or shorted to low Source.
123
Low signal voltage or open circuit detected at the
intake manifold pressure circuit.
Intake manifold 1 pressure - Data valid but Engine power derate.
above normal operational range - Moderately
124 severe level. Intake manifold pressure has
exceeded the maximum limit for the given
engine rating.
Accelerator pedal or lever position sensor 1 Severe derate in power output of the engine.
circuit - Voltage above normal, or shorted to high Limp home power only.
131
source. High voltage detected at accelerator
pedal position circuit.
Accelerator pedal or lever position sensor 1 Severe derate in power output of the engine.
circuit - Voltage below normal, or shorted to low Limp home power only.
132
source. Low voltage detected at accelerator
pedal position signal circuit.
Remote accelerator pedal or lever position Remote accelerator will not operate. Remote
sensor 1 circuit - Voltage above normal, or accelerator position will be set to zero percent.
133
shorted to high source. High voltage detected at
remote accelerator pedal position circuit.
Remote accelerator pedal or lever position Remote accelerator will not operate. Remote
sensor 1 circuit - Voltage below normal, or accelerator position will be set to zero percent.
134
shorted to low source. Low voltage detected at
remote accelerator pedal position signal circuit.
Engine oil rifle pressure 1 sensor circuit - Voltage None on performance. No engine protection
above normal, or shorted to high source. High for oil pressure.
135
signal voltage detected at the engine oil
pressure circuit.
Engine oil rifle pressure 1 sensor circuit - Voltage None on performance. No engine protection
below normal, or shorted to low source. Low for oil pressure.
141
signal voltage detected at engine oil pressure
circuit.
Engine oil rifle pressure - Data valid but below None on performance.
143 normal operational range - Moderately severe
level.
Engine coolant temperature 1 sensor circuit - Possible white smoke. Fan will stay ON if
Voltage above normal, or shorted to high controlled by ECM. No engine protection for
144
source. High signal voltage or open circuit engine coolant temperature.
detected at engine coolant temperature circuit.
3-22
Engine Coolant Temperature 1 Sensor Circuit - Possible white smoke. Fan will stay ON if
145 Voltage Below Normal, or Shorted to Low controlled by ECM. No engine protection for
Source. Low signal voltage detected at engine engine coolant temperature.
coolant temperature circuit.
Engine Coolant Temperature - Data Valid but Progressive power derate increasing in
Above Normal Operational Range - Moderately severity from time of alert.
146 Severe Level. Engine coolant temperature signal
indicates engine coolant temperature is above
engine protection warning limit.
Accelerator Pedal or Lever Position 1 Sensor Severe derate in power output of the engine.
Circuit Frequency - Data Valid but Below Normal Limp home power only.
147 Operational Range - Most Severe Level. A
frequency of less than 100 Hz has been
detected at the frequency throttle input to the
ECM.
Accelerator Pedal or Lever Position Sensor 1 - Severe derate in power output of the engine.
Data Valid but Above Normal Operational Limp home power only.
148 Range - Most Severe Level. A frequency of
more than 1500 Hz has been detected at the
frequency throttle input to the ECM.
Engine Coolant Temperature - Data Valid but Progressive power derate increasing in
Above Normal Operational Range - Most severity from time of alert. If Engine Protection
151 Severe Level. Engine coolant temperature signal Shutdown feature is enabled, engine will shut
indicates engine coolant temperature above down 30 seconds after Red Stop Lamp starts
engine protection critical limit. flashing.
Intake Manifold 1 Temperature Sensor Circuit - Possible white smoke. Fan will stay ON if
153 Voltage Above Normal, or Shorted to High controlled by ECM. No engine protection for
Source. High signal voltage detected at intake intake manifold air temperature.
manifold air temperature circuit.
Intake Manifold 1 Temperature Sensor Circuit - Possible white smoke. Fan will stay ON if
154 Voltage Below Normal, or Shorted to Low controlled by ECM. No engine protection for
Source. Low signal voltage detected at intake intake manifold air temperature.
manifold air temperature circuit.
Intake Manifold 1 Temperature - Data Valid but Progressive power derate increasing in
Above Normal Operational Range - Most severity from time of alert. If Engine Protection
155 Severe Level. Intake manifold air temperature Shutdown feature is enabled, engine will shut
signal indicates intake manifold air temperature down 30 seconds after Red Stop Lamp starts
above engine protection critical limit. flashing.
Sensor Supply 2 Circuit - Voltage Below Normal, Engine power derate.
187 or Shorted to Low Source. Low voltage detected
at the sensor supply number 2 circuit.
Coolant Level Sensor 1 Circuit - Voltage Above None on performance.
195 Normal, or Shorted to High Source. High signal
voltage detected at engine coolant level circuit.
Coolant Level Sensor 1 Circuit - Voltage Below None on performance.
196 Normal, or Shorted to Low Source. Low signal
voltage detected at engine coolant level circuit.
Coolant Level - Data Valid but Below Normal None on performance.
197 Operational Range - Moderately Severe Level.
Low coolant level has been detected.
Barometric Pressure Sensor Circuit - Voltage Engine power derate.
221 Above Normal, or Shorted to High Source. High
signal voltage detected at barometric pressure
circuit.
3-23
Barometric Pressure Sensor Circuit - Voltage Engine power derate.
222 Below Normal, or Shorted to Low Source. Low
signal voltage detected at barometric pressure
circuit.
Engine Crankshaft Speed/Position - Data Valid Fuel injection disabled until engine speed falls
234 but Above Normal Operational Range - Most below the overspeed limit.
Severe Level. Engine speed signal indicates
engine speed above engine protection limit.
Coolant Level - Data Valid but Below Normal Progressive power derate increasing in
Operational Range - Most Severe Level. Low severity from time of alert. If Engine Protection
235 engine coolant level detected. Shutdown feature is enabled, engine will shut
down 30 seconds after Red Stop Lamp starts
flashing.
External Speed Command Input (Multiple Unit
Synchronization) - Data Erratic, Intermittent, or
237 Incorrect. Communication between multiple
engines may be intermittent.
Sensor Supply 3 Circuit - Voltage Below Normal, Possible hard starting and rough running.
or Shorted to Low Source. Low voltage detected
238 on the +5 volt sensor supply circuit to the engine
speed sensor.
Wheel-based vehicle speed - Data erratic, Engine speed limited to ,maximum engine
intermittent, or incorrect. The ECM lost the speed without VSS parameter value. Cruise
241 vehicle speed signal. control, gear-down protection, and road speed
governor will not work.
Wheel-based vehicle speed sensor circuit Engine speed limited to maximum engine
tampering has been detected - Abnormal rate of speed without VSS parameter value. Cruise
242 change. Signal indicates an intermittent control, gear-down protection, and road speed
connection or VSS tampering. g+H53overnor will not work.
Fan control circuit - Voltage below normal, or The fan may stay on continuously or not run at
shorted to low source. Low signal voltage all.
245 detected at the fan control circuit when
commanded on.
Fuel pump pressurizing assembly 1 circuit - Engine will run poorly at idle. Engine will have
Voltage below normal, or shorted to low source. low power. Fuel pressure will be higher than
271 Low signal voltage detected at the fuel pump commanded.
actuator circuit.
Fuel pump pressurizing assembly 1 circuit - Engine will not run or engine will run poorly.
272 source. High signal voltage or open circuit
detected at the fuel pump actuator circuit.
Fuel pump pressurizing assembly 1 - Engine will not run or possible low power.
281 Mechanical system not responding properly or
out of adjustment.
SAE J1939 multiplexing PGN timeout error - At least one multiplexed device will not operate
Abnormal update rate. The ECM expected properly.
285 information from a multiplexed device but did not
receive it soon enough or did not receive it at all.
SAE J1939 multiplexing configuration error - Out At least one multiplexed device will not operate
of calibration. The ECM expected information properly.
286 from a multiplexed device but only received a
portion of the necessary information.
SAE J1939 multiplexed accelerator pedal or Engine may only idle or engine will not
lever sensor system - received network data In accelerate to full speed.
287 error. The OEM vehicle electronic control unit
(VECU) detected a fault with its accelerator
pedal.
3-24
SAE J1939 Multiplexing Remote Accelerator The engine will not respond to the remote
Pedal or Lever Position Sensor Circuit - throttle. Engine may only idle. The primary or
288 Received Network Data In Error. The OEM cab accelerator may be able to be used.
vehicle electronic control unit (VECU) detected a
fault with the remote accelerator.
292 Auxiliary temperature Sensor Input 1 - Special Possible engine power derate.
instructions.
Auxiliary temperature sensor input 1 circuit - None on performance.
293 source. High signal voltage or open circuit
detected at the OEM auxiliary temperature
circuit.
Auxiliary temperature sensor input 1 circuit - None on performance.
294 Voltage below normal, or shorted to low source.
Low signal voltage detected at the OEM
auxiliary temperature circuit.
296 Auxiliary pressure sensor input 1 - Special Possible engine power derate.
instructions.
Auxiliary pressure sensor input 1 circuit - Voltage None on performance.
297 above normal, or shorted to high source. High
signal voltage detected at the OEM pressure
circuit.
Auxiliary pressure sensor input 1 circuit - Voltage None on performance.
298 below normal, or shorted to low source. Low
signal voltage or open circuit detected at the
OEM pressure circuit.
Real time clock power interrupt - Data erratic, None on performance. Data in the ECM will
319 intermittent, or incorrect. Real time clock lost not have accurate time and date information.
power.
Injector solenoid driver cylinder 1 circuit - Engine can possibly misfire or run rough.
Current below normal, or open circuit. High
322 resistance detected on injector number 1 circuit
or no current detected at number 1 injector driver
or return pin when the voltage supply at the
harness is on.
harness is on.
harness is on.
harness is on.
3-25
harness is on.
harness is on.
Engine coolant temperature - Data erratic, The ECM will estimate engine coolant
334 intermittent, or incorrect. The engine coolant temperature.
temperature reading is not changing with engine
operating conditions.
Electronic calibration code incompatibility - Out Possible no noticeable performance effects,
342 of calibration. An incompatible calibration has engine dying, or hard starting.
been detected in the ECM.
Engine control module warning internal No performance effects or possible severe
343 hardware failure - Bad intelligent device or power derate.
component. Internal ECM failure.
Injector power supply - Bad intelligent device or Possible smoke, low power, engine misfire,
351 component. The ECM measured injector boost and/or engine will not start.
voltage is low.
Sensor supply 1 circuit - Voltage below normal, Engine power derate.
352 or shorted to low source. Low voltage detected
at sensor supply number 1 circuit.
Sensor supply 1 circuit - Voltage above normal, Engine power derate.
386 or shorted to high source. High voltage detected
at sensor supply number 1 circuit.
Engine oil rifle pressure - Data valid but below Progressive power derate increasing in
normal operational range - Most severe level. Oil severity from time of alert. If engine protection
415 pressure signal indicates oil pressure below the shutdown feature is enabled, engine will shut
engine protection critical limit. down 30 seconds after red stop lamp starts
flashing.
Water in fuel indicator - Data valid but above Possible white smoke, loss of power, or hard
418 normal operational range - Least severe level. starting.
water has been detected in the fuel filter.
Water in fuel indicator sensor circuit - Voltage None on performance. No water in fuel
428 above normal, or shorted to high source. High warning available.
voltage detected at the water in fuel circuit.
Water in fuel indicator sensor circuit - Voltage None on performance. No water in fuel
429 below normal, or shorted to low source. Low warning available.
voltage detected at the water in fuel circuit.
Accelerator pedal or lever idle validation switch - Engine will only idle.
431 Data erratic, intermittent, or incorrect. Voltage
detected simultaneously on both idle validation
and off-idle validation switches.
Accelerator pedal or lever idle validation circuit - Engine will only idle.
432 Out of calibration. Voltage at idle validation on-
idle and off-idle circuit does not match
accelerator pedal position.
Engine oil rifle pressure - Data erratic, None on performance. No engine protection
435 intermittent, or incorrect. An error in the engine for oil pressure.
oil pressure switch signal was detected by the
ECM.
3-26
Battery 1 voltage - Data valid but below normal Engine may stop running or be difficult to start.
operational range - Moderately severe level.
441
ECM supply voltage is below the minimum
system voltage level.
Battery 1 Voltage - Data valid but above normal Possible electrical damage to all electrical
operational range - Moderately severe level. components.
442
ECM supply voltage is above the maximum
system voltage level.
Injector metering rail 1 pressure - Data valid but None or possible engine noise associated with
449 above normal operational range - Most severe higher injection pressures (especially at idle or
level. light load). Engine power is reduced.
Injector metering rail 1 pressure sensor circuit - Power and or speed derate.
451
source. High signal voltage detected at the rail
fuel pressure sensor circuit.
Injector metering rail 1 pressure sensor circuit - Power and or speed derate.
Voltage below normal, or shorted to low
452
source. Low signal voltage detected at the rail
fuel pressure sensor circuit.
Intake manifold 1 temperature - Data valid but Progressive power derate increasing in
above normal operational range - Moderately severity from time of alert.
488 severe level. Intake manifold air temperature
signal indicates intake manifold air temperature
is above the engine protection warning limit.
Multiple unit synchronization switch - Data
497
erratic, intermittent, or incorrect.
Auxiliary intermediate (PTO) speed switch None on performance.
523 validation - Data erratic, intermittent, or
incorrect.
Auxiliary input/output 2 circuit - Voltage above None on performance.
normal, or shorted to high source. High signal
527
voltage or open circuit has been detected at the
auxiliary input/output 2 circuit.
Auxiliary alternate torque validation switch - None on performance.
528
Data erratic, intermittent, or incorrect.
Auxiliary input/output 3 circuit - Voltage above
normal, or shorted to high source. Low signal
529
voltage has been detected at the auxiliary
input/output 2 circuit.
Injector metering rail 1 pressure - Data valid but The ECM will estimate fuel pressure and
above normal operational range - Moderately power is reduced.
553
severe level. The ECM has detected that fuel
pressure is higher than commanded pressure.
Injector metering rail 1 pressure - Data erratic, Possibly hard to start, low power, or engine
Intermittent, or incorrect. The ECM has smoke.
554
detected that the fuel pressure signal is not
changing.
Injector metering rail 1 pressure - Data Valid Either the engine will not start or the engine
but Below Normal Operational Range - will not have starter lockout protection.
559 Moderately Severe Level. The ECM has
detected that fuel pressure is lower than
commanded pressure.
Starter relay driver circuit - Voltage above The engine will not have starter lockout
normal, or shorted to high source. Open circuit protection.
584
or high voltage detected at starter lockout
circuit.
3-27
Starter relay driver circuit - Voltage below Engine power derate. The ECM uses an
585 normal, or shorted to low source. Low voltage estimated turbocharger speed.
detected at starter lockout circuit.
Turbocharger 1 speed - Data valid but above Amber lamp will light until high battery voltage
normal operational range - Moderately severe condition is corrected.
595
level. High turbocharger speed has been
detected.
Auxiliary commanded dual output shutdown - None or possible engine noise associated with
599 Special instructions. higher injection pressures (especially at idle or
light load). Engine power is reduced.
Turbocharger 1 speed - Data valid but below Engine can run rough. Possibly poor starting
normal operational range - Moderately severe capability. Engine runs using backup speed
687
level. Low turbocharger speed detected by the sensor. Engine power is reduced.
ECM.
Engine crankshaft speed/position - Data erratic, Engine power derate.
689 intermittent, or incorrect. Loss of signal from
crankshaft sensor.
Turbocharger 1 compressor inlet temperature Engine power derate.
circuit - Voltage above normal, or shorted to
691 high source. High signal voltage detected at
turbocharger compressor inlet air temperature
circuit.
Turbocharger 1 compressor inlet temperature Engine will run derated. Excessive black
circuit - Voltage below normal, or shorted to low smoke, hard start, and rough idle possible.
692
source. Low signal voltage detected at
turbocharger compressor inlet air tempera
Engine speed / position camshaft and Possible no noticeable performance effects,
crankshaft misalignment - Mechanical system engine dying, or hard starting.
not responding properly or out of adjustment.
731
mechanical misalignment between the
crankshaft and camshaft engine speed
sensors.
Electronic control module data lost - Condition Possible poor starting. Engine power derate.
757
exists. Severe loss of data from the ECM.
Engine camshaft speed / position sensor - Data Possible engine power derate.
erratic, intermittent, or incorrect. The ECM has
778
detected an error in the camshaft position
sensor signal.
Auxiliary equipment sensor input 3 - Root Possible no noticeable performance effects or
cause not known. engine dying or hard starting. Fault
779
information, trip information, and maintenance
monitor data may be inaccurate.
Power supply lost with ignition on - Data erratic, Engine will shut down.
intermittent, or incorrect. Supply voltage to the
ECM fell below 6.2 volts momentarily, or the
1117
ECM was not allowed to power down correctly
(retain battery voltage for 30 seconds after key
OFF).
OEM datalink cannot transmit - Data erratic, Engine will only idle.
1633 intermittent, or incorrect. Communications
within the OEM datalink network is intermittent.
Sensor supply 4 circuit - Voltage above normal, Engine will only idle.
or shorted to high source. High voltage
2185
detected at +5 volt sensor supply circuit to the
accelerator pedal position sensor.
3-28
Sensor supply 4 circuit - Voltage below normal, Possibly hard to start, low power, or engine
or shorted to low source. Low voltage detected smoke.
2186
at +5 volt sensor supply circuit to the
accelerator pedal position sensor.
Injector metering rail 1 pressure - Data valid but Engine may be difficult to start.
below normal operational range - Most severe
2249
level. The ECM has detected that fuel pressure
is lower than commanded pressure.
Electric lift pump for engine fuel supply circuit - Engine may be difficult to start.
2265
source. High voltage or open detected at the
fuel lift pump signal circuit.
Electric lift pump for engine fuel supply circuit - Possible low power.
Voltage below normal, or shorted to low
2266
source. Low signal voltage detected at the fuel
lift pump circuit.
Electronic fuel injection control valve circuit - Engine may exhibit misfire as control switches
Condition exists. Fuel pump actuator circuit from the primary to the backup speed sensor.
2311
resistance too high or too low. Engine power is reduced while the engine
operates on the backup speed sensor.
Engine crankshaft speed/position - Data erratic, Possible low power.
2321 intermittent, or incorrect. crankshaft engine
speed sensor intermittent synchronization.
Engine camshaft speed / position sensor - Data Engine power derate.
erratic, intermittent, or incorrect. Camshaft
2322 engine speed sensor intermittent
synchronization.
Turbocharger 1 Speed - Abnormal rate of Engine power derate.
2345 change. The turbocharger speed sensor has
detected an erroneous speed value.
Turbocharger turbine inlet temperature Engine power derate.
(Calculated) - Data valid but above normal
2346 operational range - Least severe level.
Turbocharger turbine inlet temperature has
exceeded the engine protection limit.
Turbocharger compressor outlet temperature Engine brake on cylinders 1, 2, and 3 can not
2347 (Calculated) - Data valid but above normal be activated or exhaust brake will not operate.
operational range - Least severe level.
Fan control circuit - Voltage above normal, or Variable geometry turbocharger will go to the
2377 shorted to high source. Open circuit or high open position.
voltage detected at the fan control circuit.
VGT actuator driver circuit - Voltage below Variable geometry turbocharger may be in
2384 normal, or shorted to low source. Low voltage either the open or closed position.
detected at turbocharger control valve circuit.
VGT actuator driver circuit - Voltage above The intake air heaters may be ON or OFF all
normal, or shorted to high source. Open circuit the time.
2385 or high voltage detected at turbocharger control
valve circuit.
Intake air heater 1 circuit - Voltage above The intake air heaters may be ON or OFF all
2555 normal, or shorted to high source. High voltage the time.
detected at the intake air heater signal circuit.
Intake air heater 1 circuit - Voltage below Can not control transmission.
2556 normal, or shorted to low source. Low voltage
detected at the intake air heater signal circuit.
Auxiliary PWM driver 1 circuit - Voltage above Can not control transmission.
2557 normal, or shorted to high source. High signal
voltage detected at the analog torque circuit.
3-29
Auxiliary PWM driver 1 circuit - Voltage below Power derate and possible engine shutdown if
2558 normal, or shorted to low source. Low signal engine protection shutdown feature is enabled.
voltage detected at the analog torque circuit.
Intake manifold 1 pressure - Data erratic,
intermittent, or incorrect. The ECM has
2973 detected an intake manifold pressure signal
that is too high or low for current engine
operating conditions.
3-30
(7) DEFINITION OF OPERATING MODES
Η Normal
There's no failure detected in the transmission system or the failure has no or slight effects on
transmission control. TCU will work without or in special cases with little limitations.(See
following table)
Θ Substitute clutch control
TCU can't change the gears or the direction under the control of the normal clutch modulation.
TCU uses the substitute strategy for clutch control. All modulations are only time controlled.
(Comparable with EST 25)
Ι Limp-home
The detected failure in the system has strong limitations to transmission control. TCU can
engage only one gear in each direction. In some cases only one direction will be possible.
TCU will shift the transmission into neutral at the first occurrence of the failure. First, the operator
must shift the gear selector into neutral position.
If output speed is less than a threshold for neutral to gear and the operator shifts the gear
selector into forward or reverse, the TCU will select the limp-home gear.
If output speed is less than a threshold for reversal speed and TCU has changed into the limp-
home gear and the operator selects a shuttle shift, TCU will shift immediately into the limp-home
gear of the selected direction.
If output speed is greater than the threshold, TCU will shift the transmission into neutral. The
operator has to slow down the vehicle and must shift the gear selector into neutral position.
Κ Transmission-shutdown
TCU has detected a severe failure that disables control of the transmission.
TCU will shut off the solenoid valves for the clutches and also the common power supply(VPS1).
Transmission shifts to neutral. The park brake will operate normally, also the other functions
which use ADM1 to ADM8.
The operator has to slow down the vehicle. The transmission will stay in neutral.
Λ TCU-shutdown
TCU has detected a severe failure that disables control of system.
TCU will shut off all solenoid valves and also both common power supplies(VPS1, VPS2). The
park brake will engage, also functions are disabled which use ADM 1 to ADM 8.
The transmission will stay in neutral.
ö Abbreviations
OC : Open circuit
SC : Short circuit
OP mode : Operating mode
TCU : Transmission control unit
EEC : Electronic engine controller
PTO : Power take off
3-31
(8) Transmission fault codes
Fault code Meaning of the fault code

(Hex) possible reason for fault detection Reaction of the TCU Possible steps to repair
11 Logical error at gear range signal TCU shifts transmission to Â Check the cables from TCU to
TCU detected a wrong signal combination neutral shift lever
for the gear range OP-mode : Transmission Â Check signal combinations of shift
ÂCable from shift lever to TCU is broken shutdown lever positions for gear range
ÂCable is defective and is contacted to ö Failure cannot be detected in
battery voltage or vehicle ground systems with DW2/DW3 shift lever.
ÂShift lever is defective Fault is taken back if TCU detects
a valid signal for the position
12 Logical error at direction select signal TCU shifts transmission to Â Check the cables from TCU to
TCU detected a wrong signal combination neutral shift lever
for the direction OP-Mode : Transmission Â Check signal combinations of shift
ÂCable from shift lever to TCU is broken shutdown lever positions F-N-R
ÂCable is defective and is contacted to ö Fault is taken back if TCU detects
battery voltage or vehicle ground a valid signal for the direction at
ÂShift lever is defective the shift lever
13 Logical error at engine derating device After selecting neutral, TCU Â Check engine derating device
TCU detected no reaction of engine while change to OP mode limp ö This fault is reset after power up of
derating device active home TCU
15 Logical error at direction select signal 2 TCU shifts transmission to Â Check the cables from TCU to
shift lever neutral if selector active shift lever 2
TCU detected a wrong signal combination OP mode : Transmission Â Check signal combinations of shift
for the direction shutdown if elector lever positions F-N-R
ÂCable from shift lever 2 to TCU is broken active ö Fault is taken back if TCU detects
ÂCable is defective and is contacted to a valid neutral signal for the
battery voltage or vehicle ground direction at the shift lever
ÂShift lever is defective
16 Logical error at axle connection OP mode : Normal Â Check the cables from TCU to
Feedback axle connection measured by TCU feedback axle connection switch
and output signal axle connection don't fit Â Check signals of the feedback
ÂAxle can't be connected or disconnected axle connection switch
due to mechanical problem
ÂOne of the cables from feedback axle
connection switch to TCU is broken
21 S.C. to battery voltage at clutch cut off Clutch cut off function is Â Check the cable from TCU to the
input disabled sensor
The measured voltage is too high: OP mode : Normal Â Check the connectors
ÂCable is defective and is contacted to Â Check the clutch cut off sensor
battery voltage
ÂClutch cut off sensor has an internal
defect
ÂConnector pin is contacted to battery
voltage
22 S.C. to ground or O.C. at clutch cut off Clutch cut off function is Â Check the cable from TCU to the
input disabled sensor
The measured voltage is too low: OP mode : Normal Â Check the connectors
ÂCable is defective and is contacted to Â Check the clutch cut off sensor
vehicle ground
ÂCable has no connection to TCU
ÂClutch cut off sensor has an internal
defect
ÂConnector pin is contacted to vehicle
ground or is broken
3-32
23 S.C. to battery voltage at load sensor Retarder function is affected Â Check the cable from TCU to the
input TCU uses default load sensor
ÂCable is defective and is contacted to Â Check the load sensor
battery voltage Â Check the assembly tolerances of
ÂLoad sensor has an internal defect load sensor
ÂConnector pin is contacted to battery ö Availability of retarder depends on
voltage default load
24 S.C. to ground or O.C. at load sensor Retarder function is affected Â Check the cable from TCU to the
input TCU use default load sensor
ÂCable is defective and is contacted to Â Check the load sensor
vehicle ground Â Check the assembly tolerances of
ÂCable has no connection to TCU load sensor
ÂLoad sensor has as internal defect ö Availability of retarder depends on
ÂConnector pin is contacted to vehicle default load
ground or is broken
25 S .C. to battery voltage or O.C. at No reaction, TCU use default Â Check the cable from TCU to the
transmi-ssion sump temperature sensor temperature sensor
input OP mode : Normal Â Check the connectors
The measured voltage is too high: Â Check the temperature sensor
ÂCable is defective and is contacted to
battery voltage
ÂTemperature sensor has an internal
defect
voltage or is broken
26 S .C. to battery voltage or O.C. at No reaction, TCU uses default Â Check the cable from TCU to the
transmi-ssion sump temperature sensor temperature sensor
The measured voltage is too low: Â Check the temperature sensor
vehicle ground
defect
ground
retarder temperature sensor input temperature sensor
ÂCable is defective and is contacted to Â Check the temperature sensor
battery voltage
defect
3-33
28 S.C. to ground at retarder temperature No reaction, TCU uses default Â Check the cable from TCU to the
sensor input temperature sensor
vehicle ground
defect
ground
converter output temperature sensor temperature sensor
The measured voltage is too high: Â Check the temperature sensor
battery voltage
defect
30 S .C. to ground at converter output No reaction, TCU uses default Â Check the cable from TCU to the
temperature sensor input temperature sensor
vehicle ground
defect
ground
31 S.C. to battery voltage or O.C. at engine OP mode : Substitute clutch Â Check the cable from TCU to the
speed input control sensor
TCU measures a voltage higher than Â Check the connectors
7.00V at speed input pin Â Check the speed sensor
battery voltage
ÂSpeed sensor has an internal defect
voltage or has no contact
32 S.C. to ground at engine speed input OP mode : Substitute clutch Â Check the cable from TCU to the
TCU measures a voltage less than 0.45V at control sensor
speed input pin Â Check the connectors
ÂCable/connector is defective and is Â Check the speed sensor
contacted to vehicle ground
3-34
33 Logical error at engine speed input OP mode : Substitute clutch Â Check the cable from TCU to the
TCU measures a engine speed over a control sensor
threshold and the next moment the Â Check the connectors
measured speed is zero Â Check the speed sensor
ÂCable/connector is defective and has Â Check the sensor gap
bad contact ö This fault is reset after power up of
ÂSpeed sensor has an internal defect TCU
ÂSensor gap has the wrong size
34 S.C. to battery voltage or O.C. at turbine OP mode : Substitute clutch Â Check the cable from TCU to the
speed input control sensor
TCU measures a voltage higher than If a failure is existing at output Â Check the connectors
7.00V at speed input pin speed, Â Check the speed sensor
ÂCable is defective and is contacted to TCU shifts to neutral
vehicle battery voltage OP mode : Limp home
35 S.C. to ground at turbine speed input OP mode : Substitute clutch Â Check the cable from TCU to the
TCU measures a voltage less than 0.45V control sensor
at speed input pin If a failure is existing at output Â Check the connectors
ÂCable/connector is defective and is speed, Â Check the speed sensor
contacted to vehicle ground TCU shifts to neutral ö This fault is reset after power up of
ÂSpeed sensor has an internal defect OP mode : Limp home TCU
36 Logical error at turbine speed input OP mode : Substitute clutch Â Check the cable from TCU to the
TCU measures a turbine speed over a control sensor
threshold and at the next moment the If a failure is existing at output Â Check the connectors
measured speed is zero speed, Â Check the speed sensor
ÂCable/connector is defective and has TCU shifts to neutral Â Check the sensor gap
bad contact OP mode : Limp home
37 S .C. to battery voltage or O.C. at OP mode : Substitute clutch Â Check the cable from TCU to the
internal speed input control sensor
TCU measures a voltage higher than Â Check the connectors
7.00V at speed input pin Â Check the speed sensor
vehicle battery voltage
38 S.C. to ground at turbine speed input OP mode : Substitute clutch Â Check the cable from TCU to the
TCU measures a voltage less than 0.45V control sensor
at speed input pin Â Check the connectors
ÂCable/connector is defective and is Â Check the speed sensor
3-35
39 Logical error at internal speed input OP mode : Substitute clutch Â Check the cable from TCU to the
TCU measures a internal speed over a control sensor
threshold and at the next moment the Â Check the connectors
measured speed is zero Â Check the speed sensor
ÂCable/connector is defective and has Â Check the sensor gap
bad contact ö This fault is reset after power up of
3A S.C. to battery voltage or O.C. at output Special mode for gear selection Â Check the cable from TCU to the
speed input OP mode : Substitute clutch sensor
TCU measures a voltage higher than control Â Check the connectors
12.5V at speed input pin If a failure is existing at turbine Â Check the speed sensor
ÂCable is defective and is contacted to speed,
battery voltage TCU shifts to neutral
ÂCable has no connection to TCU OP mode : lamp home
3B S.C. to ground at output speed input Special mode for gear selection Â Check the cable from TCU to the
TCU measures a voltage less than 1.00V OP mode : Substitute clutch sensor
at speed input pin control Â Check the connectors
ÂCable/connector is defective and is If a failure is existing at turbine Â Check the speed sensor
contacted to vehicle ground speed,
ÂSpeed sensor has an internal defect TCU shifts to neutral
OP mode : lamp home
3C Logical error at output speed input Special mode for gear selection Â Check the cable from TCU to the
TCU measures a turbine speed over a OP mode : Substitute clutch sensor
threshold and at the next moment the control Â Check the connectors
measured speed is zero If a failure is existing at turbine Â Check the speed sensor
ÂCable/connector is defective and has speed, Â Check the sensor gap
bad contact TCU shifts to neutral ö This fault is reset after power up of
ÂSpeed sensor has an internal defect OP mode : lamp home TCU
3D Turbine speed zero doesn't fit to other - ö Not used
speed signals
3E Output speed zero doesn't fit to other Special mode for gear selection Â Check the sensor signal of output
speed signals OP mode : Substitute clutch speed sensor
If transmission is not neutral and the control Â Check the sensor gap of output
shifting has finished, If a failure is existing at turbine speed sensor
TCU measures output speed zero and speed, Â Check the cable from TCU to the
turbine speed or internal speed not equal TCU shifts to neutral sensor
to zero. OP mode : lamp home ö This fault is reset after power up of
3-36
71 S.C. to battery voltage at clutch K1 TCU shifts to neutral Â Check the cable from TCU to the
The measured resistance value of the valve OP mode : Limp home gearbox
is out of limit, the voltage at K1 valve is too If failure at another clutch is Â Check the connectors from TCU
high pending to the gearbox
ÂCable/connector is defective and has TCU shifts to neutral Â Check the regulator resistance*
contact to battery voltage OP mode : TCU shutdown Â Check internal wire harness of the
ÂCable/connector is defective and has gearbox
contact to another regulator output of the * See page 3-52
TCU
ÂRegulator has an internal defect
72 S.C. to ground at clutch K1 TCU shifts to neutral Â Check the cable from TCU to the
is out of limit, the voltage at K1 valve is too If failure at another clutch is Â Check the connectors from
low pending gearbox to TCU
contact to vehicle ground OP mode : TCU shutdown Â Check internal wire harness of the
ÂRegulator has an internal defect gearbox
* See page 3-52
73 O.C. at clutch K1 TCU shifts to neutral Â Check the cable from TCU to the
The measured resistance value of the OP mode : Limp home gearbox
valve is out of limit If failure at another clutch is Â Check the connectors from
ÂCable/connector is defective and has no pending gearbox to TCU
contact to TCU TCU shifts to neutral Â Check the regulator resistance*
ÂRegulator has an internal defect OP mode : TCU shutdown Â Check internal wire harness of the
gearbox
* See page 3-52
valve is out of limit, the voltage at K2 valve If failure at another clutch is Â Check the connectors from
is too high pending gearbox to TCU
TCU
* See page 3-52
gearbox
* See page 3-52
3-37
TCU
* See page 3-52
Cable/connector is defective and has no pending gearbox to TCU
Regulator has an internal defect OP mode : TCU shutdown Â Check internal wire harness of the
gearbox
* See page 3-52
7A S .C. to battery voltage at converter - -
clutch
7B S.C. to ground at converter clutch - -
7C O.C. at converter clutch - ö Not used
7D S.C. ground at engine derating device Engine derating will be on until Â Check the cable from TCU to the
ÂCable is defective and is contacted to TCU power down even if fault engine derating device
vehicle ground vanishes(Loose connection) Â Check the connectors from engine
ÂEngine derating device has an internal OP mode : Normal derating device to TCU
defect Â Check the resistance* of engine
ÂConnector pin is contacted to vehicle derating device
ground ö Not used
* See page 3-52
7E S.C. battery voltage at engine derating No reaction Â Check the cable from TCU to the
device OP mode : Normal engine derating device
ÂCable/connector is defective and is Â Check the connectors from
contacted to battery voltage backup alarm device to TCU
ÂEngine derating device has an internal Â Check the resistance* of backup
defect alarm device
* See page 3-52
3-38
7F O.C. at engine derating device No reaction Â Check the cable from TCU to the
TCU detected a wrong voltage at the OP mode : Normal engine derating device
output pin, that looks like a O.C. for this Â Check the connectors from engine
output pin derating device to TCU
ÂCable is defective and has no Â Check the resistance* of engine
connection to TCU derating device
ÂEngine derating device has an internal * See page 3-52
defect
ÂConnector has no connection to TCU
TCU
The measured resistance value of the valve OP mode : Limp home engine derating device
* See page 3-52
ÂCable/connector is defective and has pending gearbox to TCU
gearbox
* See page 3-52
TCU
85 S.C. to ground at clutch KV TCU shifts to neutral Â Check the cable from TCU to the
* See page 3-52
3-39
86 O.C. at clutch KV TCU shifts to neutral Â Check the cable from TCU to the
ÂCable/connector is defective and has pending gearbox to TCU
gearbox
* See page 3-52
87 S.C. to battery voltage at clutch KR TCU shifts to neutral Â Check the cable from TCU to the
valve is out of limit, the voltage at KR valve is If failure at another clutch is Â Check the connectors from
too high pending gearbox to TCU
TCU
88 S.C. to ground at clutch KR TCU shifts to neutral Â Check the cable from TCU to the
is out of limit, the voltage at KR valve is too If failure at another clutch is Â Check the connectors from
* See page 3-52
89 O.C. at clutch KR TCU shifts to neutral Â Check the cable from TCU to the
gearbox
* See page 3-52
91 S.C. to ground at relay reverse warning Backup alarm will be on until Â Check the cable from TCU to the
alarm TCU power down even if fault backup alarm device
TCU detected a wrong voltage at the vanishes(Loose connection) Â Check the connectors from
output pin, that looks like a S.C. to vehicle OP mode : Normal backup alarm device to TCU
ground Â Check the resistance* of backup
ÂCable is defective and is contact to alarm device
vehicle ground * See page 3-52
ÂBackup alarm device has an internal
defect
ground
3-40
92 S.C. to battery voltage at relay reverse No reaction Â Check the cable from TCU to the
warning alarm OP mode : Normal backup alarm device
TCU detected a wrong voltage at the Â Check the connectors from
output pin, that looks like a S.C. to battery backup alarm device to TCU
voltage Â Check the resistance* of backup
ÂCable is defective and is contacted to alarm device
battery voltage * See page 3-52
ÂBackup alarm device has an internal
defect
voltage
93 O.C. at relay reverse warning alarm No reaction Â Check the cable from TCU to the
TCU detected a wrong voltage at the OP mode : Normal backup alarm device
output pin, that looks like a O.C. for this Â Check the connectors from
output pin backup alarm device to TCU
ÂCable is defective and has no Â Check the resistance* of backup
connection to TCU alarm device
ÂBackup alarm device has an internal * See page 3-52
defect
94 S.C. to ground at relay starter interlock No reaction Â Check the cable from TCU to the
TCU detected a wrong voltage at the OP mode : Normal starter interlock relay
output pin, that looks like a S.C. to vehicle Â Check the connectors from starter
ground interlock relay to TCU
ÂCable is defective and is connection to Â Check the resistance* of starter
vehicle ground interlock relay
ÂStarter interlock relay has an internal * See page 3-52
defect
ground
95 S.C. to battery voltage at relay starter No reaction Â Check the cable from TCU to the
interlock OP mode : Normal starter interlock relay
TCU detected a wrong voltage at the Â Check the connectors from starter
output pin, that looks like a S.C. to battery interlock relay to TCU
voltage Â Check the resistance* of starter
ÂCable is defective and has no interlock relay
connection to battery voltage * See page 3-52
ÂStarter interlock relay has an internal defect
voltage
96 O.C. at relay starter interlock No reaction Â Check the cable from TCU to the
TCU detected a wrong voltage at the OP mode : Normal starter interlock relay
output pin, that looks like a O.C. for this Â Check the connectors from starter
output pin interlock relay to TCU
ÂCable is defective and has no Â Check the resistance* of starter
connection to TCU interlock relay
ÂStarter interlock relay has an internal defect * See page 3-52
3-41
97 S.C. to ground at park brake solenoid No reaction Â Check the cable from TCU to the
TCU detected a wrong voltage at the OP mode : Normal park brake solenoid
output pin, that looks like a S.C. to vehicle Â Check the connectors from park
ground brake solenoid to TCU
ÂCable is defective and is connection to Â Check the resistance* of park
vehicle ground brake solenoid
ÂPark brake solenoid has an internal * See page 3-52
defect
ground
98 S .C. to battery voltage at park brake No reaction Â Check the cable from TCU to the
solenoid Optional : (Some customers) park brake solenoid
TCU detected a wrong voltage at the TCU shifts to neutral caused Â Check the connectors from park
output pin, that looks like a S.C. to battery by park brake feed back brake solenoid to TCU
voltage OP mode : Normal Â Check the resistance* of park
ÂCable is defective and is connection to brake solenoid
ÂPark brake solenoid has an internal
defect
voltage
99 O.C. at park brake solenoid No reaction Â Check the cable from TCU to the
TCU detected a wrong voltage at the Optional : Some customers park brake solenoid
output pin, that looks like a O.C. for this TCU shifts to neutral caused Â Check the connectors from park
output pin by park brake feed back brake solenoid to TCU
ÂCable is defective and has no OP mode : Normal Â Check the resistance* of park
connection to TCU brake solenoid
ÂPark brake solenoid has an internal * See page 3-52
defect
9A S .C. to ground at converter lock up No reaction Â Check the cable from TCU to the
clutch solenoid OP mode : Normal converter clutch solenoid
output pin, that looks like a S.C. to vehicle converter clutch solenoid to TCU
ground Â Check the resistance* of park
ÂCable is defective and is contacted to brake solenoid
ÂConverter clutch solenoid has an
internal defect
ground
9B O .C. at converter lock up clutch Converter clutch always open, Â Check the cable from TCU to the
solenoid retarder not available converter clutch solenoid
TCU detected a wrong voltage at the OP mode : Normal Â Check the connectors from
output pin, that looks like a O.C. for this converter clutch solenoid to TCU
output pin Â Check the resistance* of park
ÂCable is defective and has no brake solenoid
connection to TCU * See page 3-52
internal defect
3-42
9C S.C. to battery voltage at converter lock No reaction Â Check the cable from TCU to the
up clutch solenoid OP mode : Normal converter clutch solenoid
output pin, that looks like a S.C. to battery converter clutch solenoid to TCU
voltage Â Check the resistance* of converter
ÂCable is defective and has no contacted clutch solenoid
to battery voltage * See page 3-52
internal defect
voltage
9D S.C. to ground at retarder solenoid No reaction Â Check the cable from TCU to the
TCU detected a wrong voltage at the OP mode : Normal retarder solenoid
output pin, that looks like a S.C. to vehicle Â Check the connectors from
ground retarder solenoid to TCU
ÂCable is defective and is contacted to Â Check the resistance* of retarder
vehicle ground solenoid
ÂRetarder solenoid has an internal defect * See page 3-52
ground
9E O.C. at retarder solenoid No reaction Â Check the cable from TCU to the
TCU detected a wrong voltage at the OP mode : Normal retarder solenoid
output pin retarder solenoid to TCU
ÂCable is defective and has no Â Check the resistance* of retarder
connection to TCU solenoid
ÂRetarder solenoid has an internal defect * See page 3-52
9F S .C. to battery voltage at retarder No reaction Â Check the cable from TCU to the
solenoid OP mode : Normal retarder solenoid
output pin, that looks like a S.C. to battery retarder solenoid to TCU
voltage Â Check the resistance* of retarder
ÂCable is defective and has no solenoid
ÂRetarder solenoid has an internal defect
voltage
3-43
A1 S.C. to ground at difflock or axle No reaction Â Check the cable from TCU to the
connection solenoid OP mode : Normal difflock solenoid
TCU detected a wrong voltage at the Â Check the connectors from difflock
output pin, that looks like a S.C. to vehicle solenoid to TCU
ground Â Check the resistance* of difflock
ÂCable is defective and is contacted to solenoid
ÂDifflock solenoid has an internal defect
ground
A2 S.C. to battery voltage at difflock or axle No reaction Â Check the cable from TCU to the
connection solenoid OP mode : Normal difflock solenoid
output pin, that looks like a S.C. to battery solenoid to TCU
voltage Â Check the resistance* of difflock
voltage
A3 O .C. at difflock or axle connection No reaction Â Check the cable from TCU to the
solenoid OP mode : Normal difflock solenoid
output pin, that looks like a O.C. for this solenoid to TCU
output pin Â Check the resistance* of difflock
connection to TCU * See page 3-52
A4 S.C. to ground at warning signal output No reaction Â Check the cable from TCU to the
TCU detected a wrong voltage at the OP mode : Normal warning device
output pin, that looks like a S.C. to vehicle Â Check the connectors from
ground warning device to TCU
ÂCable is defective and is contacted to Â Check the resistance* of warning
vehicle ground device
ÂWarning device has an internal defect * See page 3-52
ground
A5 O.C. voltage at warning signal output No reaction Â Check the cable from TCU to the
TCU detected a wrong voltage at the OP mode : Normal warning device
output pin warning device to TCU
ÂCable is defective and has no Â Check the resistance* of warning
connection to TCU device
ÂWarning device has an internal defect * See page 3-52
A6 S.C. to battery voltage at warning signal No reaction Â Check the cable from TCU to the
output OP mode : Normal warning device
output pin, that looks like a S.C. to battery warning device to TCU
voltage Â Check the resistance* of warning
ÂCable is defective and has is contacted device
to battery voltage * See page 3-52
ÂWarning device has an internal defect
voltage
3-44
B1 Slippage at clutch K1 TCU shifts to neutral Â Check pressure at clutch K1

TCU calculates a differential speed at OP mode : Limp home Â Check main pressure in the
closed clutch K1. If this calculated value If failure at another clutch is system
is out of range, TCU interprets this as pending Â Check sensor gap at internal
slipping clutch TCU shifts to neutral speed sensor
ÂLow pressure at clutch K1 OP mode : TCU shutdown Â Check sensor gap at output speed
ÂLow main pressure sensor
ÂWrong signal at internal speed sensor Â Check signal at internal speed
ÂWrong signal at output speed sensor sensor
ÂWrong size of the sensor gap Â Check signal at output speed
ÂClutch is defective sensor
Â Replace clutch
Â Replace clutch
Â Replace clutch
ÂLow pressure at clutch K4 OP mode : TCU shutdown Â Check sensor gap at turbine
ÂLow main pressure speed sensor
ÂWrong signal at turbine speed sensor sensor
ÂWrong size of the sensor gap Â Check signal at turbine speed
Â Replace clutch
3-45
B5 Slippage at clutch KV TCU shifts to neutral Â Check pressure at clutch KV

closed clutch KV. If this calculated value If failure at another clutch is system
ÂLow pressure at clutch KV OP mode : TCU shutdown Â Check sensor gap at turbine
Â Replace clutch
B6 Slippage at clutch KR TCU shifts to neutral Â Check pressure at clutch KR
closed clutch KR. If this calculated value If failure at another clutch is system
ÂLow pressure at clutch KR OP mode : TCU shutdown Â Check sensor gap at turbine
Â Replace clutch
B7 Overtemp sump No reaction Â Cool down machine
TCU measured a temperature in the oil OP mode : Normal Â Check oil level
sump that is over the allowed threshold. Â Check temperature sensor
B8 Overtemp retarder TCU disables retarder Â Cool down machine
TCU measured a temperature in the OP mode : Normal Â Check oil level
retarder oil that is over the allowed Â Check temperature sensor
threshold
B9 Overspend engine Retarder applies
-
OP mode : Normal
BA Differential pressure oil filter No reaction Â Check oil filter
TCU measured a voltage at differential OP mode : Normal Â Check wiring from TCU to
pressure switch out of the allowed range differential pressure switch
ÂOil filter is polluted Â Check differential pressure
ÂCable/connector is broken or cable/ switch(Measure resistance)
connector is contacted to battery voltage
or vehicle ground
ÂDifferential pressure switch is defective
3-46
BB Slippage at converter lockup clutch Â Check pressure at converter

TCU calculates a differential speed at lockup clutch
closed converter lockup clutch. If this Â Check main pressure in the
calculated value is out of range, TCU system
interprets this as slipping clutch Â Check sensor gap at engine
ÂLow pressure at converter lockup clutch speed sensor
ÂLow main pressure Â Check sensor gap at turbine
ÂWrong signal at engine speed sensor speed sensor
ÂWrong signal at turbine speed sensor Â Check signal at engine speed
ÂWrong size of the sensor gap sensor
ÂClutch is defective Â Check signal at turbine speed
sensor
Â Replace clutch
BD S.C. to ground at engine brake solenoid No reaction Â Check the cable from TCU to
TCU detected a wrong voltage at the OP mode : Normal engine brake solenoid
output pin, that looks like a S.C. to vehicle Â Check the connectors from engine
ground brake solenoid to TCU
ÂCable is defective and is contacted to Â Check the resistance* of engine
vehicle ground brake solenoid
ÂEngine brake solenoid has an internal * See page 3-52
defect
ground
BE S.C. to battery voltage at engine brake No reaction Â Check the cable from TCU to the
output pin, that looks like a S.C. to battery Â Check the connectors from engine
voltage brake solenoid to TCU
ÂCable is defective and is contacted to Â Check the resistance* of engine
battery voltage brake solenoid
defect
voltage
BF O.C. at engine brake No reaction Â Check the cable from TCU to the
output pin, that looks like a O.C. for this Â Check the connectors from engine
output pin brake solenoid to TCU
ÂCable is defective and has no Â Check the resistance* of engine
connection to TCU brake solenoid
defect
3-47
C3 Overtemp converter output No reaction Â Cool down machine

TCU measured a oil temperature at the OP mode : Normal Â Check oil level
converter output that is the allowed Â Check temperature sensor
threshold
C4 S.C. to ground at joystick status No reaction Â Check the cable from TCU to
indicator OP mode : Normal joystick status indicator
output pin, that looks like a S.C. to vehicle joystick status indicator to TCU
ground Â Check the resistance* of joystick
ÂCable is defective and is contacted to status indicator
ÂJoystick status indicator has an internal
defect
ground
C5 S.C. to battery voltage at joystick status No reaction Â Check the cable from TCU to
indicator OP mode : Normal joystick status indicator
output pin, that looks like a S.C. to battery joystick status indicator to TCU
voltage Â Check the resistance* of joystick
ÂCable is defective and is contacted to status indicator
ÂJoystick status indicator has an internal
defect
voltage
C6 O.C. at joystick status indicator No reaction Â Check the cable from TCU to
TCU detected a wrong voltage at the OP mode : Normal joystick status indicator
output pin joystick status indicator to TCU
ÂCable is defective and has no Â Check the resistance* of joystick
connection to TCU status indicator
ÂJoystick status indicator has an internal * See page 3-52
defect
ÂConnector pin has no connection to
TCU
3-48
D1 S.C. to battery voltage at power supply See fault codes No.21 to 2C Â Check cables and connectors to
for sensors sensors, which are supplied from
TCU measures more than 6V at the pin AU1
AU1 (5V sensor supply) Â Check the power supply at the pin
AU1(Should be appx. 5V)
ö Fault codes No.21 to No.2C may
be reaction of this fault
D2 S.C. to ground at power supply for See fault codes No.21 to 2C Â Check cables and connectors to
sensors sensors, which are supplied from
TCU measures less than 4V at the pin AU1
AU1 (5V sensor supply) Â Check the power supply at the pin
AU1(Should be appx. 5V)
ö Fault codes No.21 to No.2C may
be reaction of this fault
D3 Low voltage at battery Shift to neutral Â Check power supply battery
Measured voltage at power supply is lower OP mode : TCU shutdown Â Check cables from batteries to
than 18V(24V device) TCU
Â Check connectors from batteries
to TCU
D4 High voltage at battery Shift to neutral Â Check power supply battery
Measured voltage at power supply is OP mode : TCU shutdown Â Check cables from batteries to
higher than 32.5V(24V device) TCU
Â Check connectors from batteries
to TCU
D5 Error at valve power supply VPS1 Shift to neutral Â Check fuse
TCU switched on VPS1 and measured OP mode : TCU shutdown Â Check cables from gearbox to
VPS1 is off or TCU switched off VPS1 and TCU
measured VPS1 is still on Â Check connectors from gearbox to
ÂCable or connectors are defect and are TCU
contacted to battery voltage Â Replace TCU
ÂCable or connectors are defect and are
ÂPermanent power supply KL30 missing
ÂTCU has an internal defect
D6 Error at valve power supply VPS2 Shift to neutral Â Check fuse
TCU switched on VPS2 and measured OP mode : TCU shutdown Â Check cables from gearbox to
VPS2 is off or TCU switched off VPS2 and TCU
measured VPS2 is still on Â Check connectors from gearbox to
ÂCable or connectors are defect and are TCU
contacted to battery voltage Â Replace TCU
ÂCable or connectors are defect and are
ÂPermanent power supply KL30 missing
ÂTCU has an internal defect
3-49
E1 S.C. battery voltage at speedometer - ö Not used

output
E2 S.C. to ground or O.C at speedometer ö Not used
output -
E3 S.C. to battery voltage at display output No reaction Â Check the cable from TCU to the
TCU sends data to the display and OP mode : Normal display
measures always a high voltage level on Â Check the connectors at the
the connector display
ÂCable or connectors are defective and Â Change display
are contacted to battery voltage
ÂDisplay has an internal defect
E4 S.C. to ground at display output No reaction Â Check the cable from TCU to the
TCU sends data to the display and OP mode : Normal display
measures always a high voltage level on Â Check the connectors at the
the connector display
ÂCable or connectors are defective and Â Change display
are contacted to battery voltage
ÂDisplay has an internal defect
E5 Communication failure on DeviceNet Shift to neutral Â Check Omron master
OP mode : TCU shutdown Â Check wire of DeviceNet-Bus
Â Check cable to Omron master
E5 DISPID1 timeout TCU select parameter set with Â Check display controller
Timeout of CAN-massage DISPID1 from ID0 Â Check wire of CAN-Bus
display controller OP mode : Limp home Â Check cable display controller
ÂInterference on CAN-Bus
ÂCAN wire/connector is defective
ÂCan wire/connector is defective and has
contact to vehicle ground or battery
voltage
3-50
F1 General EEPROM fault No reaction Â Replace TCU

TCU can't read non volatile memory OP mode : Normal ö Often shown together with fault
ÂTCU is defective code F2
F2 Configuration lost Transmission stay neutral Â Reprogram the correct configurat-
TCU has lost the correct configuration and OP mode : TCU shutdown ion for the vehicle (e.g. with cluster
can't control the transmission controller,...)
ÂInterference during saving data on non
volatile memory
ÂTCU is brand new or from another
vehicle
F3 Application error Transmission stay neutral Â Replace TCU
Something of this application is wrong OP mode : TCU shutdown ö This fault occurs only if an test
engineer did something wrong in
the application of the vehicle
F5 Clutch failure Transmission stay neutral Â Check clutch
AEB was not able to adjust clutch filling OP mode : TCU shutdown ö TCU shows also the affected
parameters clutch on the display
ÂOne of the AEB-Values is out of limit
F6 Clutch adjustment data lost No reaction, Â Execute AEB
TCU was not able to read correct clutch Default values : 0 for AEB
adjustment parameters Offsets used
ÂInterference during saving data on non OP mode : Normal
volatile memory
ÂTCU is brand new
3-51
(9) Measuring of resistance at actuator/sensor and cable
Η Actuator
2 G
76043PT19
Open circuit R12 = R1G = R2G = â

Short cut to ground R12 = R; R1G = 0, R2G = R or R1G = R, R2G = 0
(For S.C. to ground, G is connected to vehicle ground)
Short cut to battery R12 = R; R1G = 0, R2G = R or R1G = R, R2G = 0
(For S.C. to battery, G is connected to battery voltage)
Θ Cable
UBat
P(Power supply)
TCU
1 2 Actuator/
Sensor
C(Chassis)
Ground
76043PT20
Open circuit R12 = R1P = R1C = R2P = R2C= â

Short cut to ground R12 = 0; R1C = R2C = 0, R1P = R2P = â
Short cut to battery R12 = 0; R1C = R2C = 0, R1P = R2P = 0
3-52
7) ELECTRIC CONTROL UNIT
(1) Complete system
1
2
14 12
10
5 4 15 9
3
7
A
13
2
6
11
8
7407APT11
1 Transmission control unit(EST-37A)

2 Kickdown switch
3 Clutch cut off switch
4 Full automatic switch
5 LCD
6 Gear selector(DW-3) with integrated kickdown switch
7 Power supply connection
8 Transmission
9 Cable to inductive transmitter - speed central gear train
10 Cable to inductive transmitter - speed turbine
11 Cable to inductive transmitter - speed engine
12 Cable to speed sensor output and speedometer
13 Cable to plug connection on the electro - hydraulic control unit
14 CAN-Connection
15 Wiring
(2) Description of the basic functions
The powershift transmissions is equipped is electronic transmission control unit(EST-37A),
developed for it.
The system is processing the desire of the driver according to the following criteria.
ÂGear determination depending on controller position, driving speed and load condition.
3-53
ÂProtection from operating errors as far as necessary, is possible via electronic protection
(programming).
ÂProtection from over-speeds(On the basis of engine and turbine speed).
ÂAutomatic reversing(Driving speed-dependent).
ÂPressure cut-off possible(Disconnecting of the drive train for maximum power on the power
take-off).
ÂChange-over possibility for Auto-/Manual mode.
ÂKick down functions possible.
(3) Driving and shifting
- Neutral position :
Neutral position will be selected via the controller.
After the ignition is switched on, the electronics remains in the waiting state. By the position
NEUTRAL of the controller, resp. by pressing the pushbutton NEUTRAL, the EST-37A becomes
ready for operation.
Now, a gear can be engaged.
- Starting :
The starting of the engine has always to be carried out in the NEUTRAL POSITION of the
controller.
For safety reasons it is to recommend to brake the machine securely in position with the parking
brake prior to start the engine.
After the starting of the engine and the preselection of the driving direction and the gear, the
machine can be set in motion by acceleration.
At the start off, the converter takes over the function of a master clutch.
On a level road it is possible to start off also in higher gears.
- Upshifting under load
Upshifting under load will be then realized if the machine can still accelerate by it.
- Downshifting under load
Downshifting under load will be realized if more traction force is needed.
- Upshifting in overrunning condition
In the overrunning mode, the upshifting will be suppressed by accelerator pedal idling position, if
the speed of the machine on a downgrade should not be further increased.
- Downshifting in overrunning condition
Downshiftings in overrunning mode will be then carried out if the machine should be retarded.
If the machine will be stopped and is standing with running engine and engaged transmission,
the engine cannot be stalled. On a level and horizontal roadway it is possible that the machine
begins to crawl, because the engine is creating at idling speed a slight drag torque via the
converter.
It is convenient to brake the machine at every stop securely in position with the parking brake.
At longer stops, the controller has to be shifted to the NEUTRAL POSITION.
At the start off, the parking brake has to be released. We know from experience that at a
converter transmission it might not immediately be noted to have forgotten this quite normal
operating step because a converter, due to its high ratio, can easily overcome the braking torque
of the parking brake.
3-54
Temperature increases in the converter oil as well as overheated brakes will be the
consequences to be find out later.
Neutral position of the selector switch at higher machine speeds(above stepping speed) is not
admissible.
Either a suitable gear is to be shifted immediately, or the machine must be stopped at once.
(4) Independent calibration of the shifting elements(AEB)
The AEB has the task to compensate tolerances(plate clearance and pressure level) which are
influencing the filling procedure of the clutches. For each clutch, the correct filling parameters are
determined in one test cycle for :
ÂPeriod of the quick-filling time
ÂLevel of the filling compensating pressure
The filling parameters are stored, together with the AEB-program and the driving program in the
transmission electronics. Because the electronics will be separately supplied, the AEB-cycle must
be started only after the installation of both components in the machine, thus ensuring the correct
mating(Transmission and electronics).
ö It is imperative, to respect the following test conditions :
- Shifting position neutral
- Engine in idling speed
- Parking brake actuated
- Transmission in operating temperature
ö After a replacement of the transmission, the electrohydraulic control or the TCU in the machine,
the AEB-cycle must be as well carried out again.
The AEB-cycle continues for about 3 to 4 minutes. The determined filling parameters are stored
in the EEProm of the electronics. In this way, the error message F6 shown on the display will be
cancelled also at non-performed AEB.
(5) Pressure cut-off
In order to provide the full engine power for the hydraulic system, the control can be enlarged for
the function of a pressure cut-off in the 1st and 2nd speed. In this way, the pressure in the
powershift clutches will be cut-off, and the torque transmission in the drive train will be eliminated
by it. This function will be released at the actuation of a switch, arranged on the brake pedal.
For a soft restart, the pressure will be build-up via a freely programmable characteristic line.
3-55
5. AXLE
1) OPERATION
Â The power from the engine passes through torque converter, transmission and drive shafts, and is
then sent to the front and rear axles.
Â 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
73033AX01A
1 Final drive 2 Differential 3 Axle
(2) Rear axle

3
73033AX01B
1 Final drive 2 Differential 3 Axle
3-56
2) SECTION OF FRONT AXLE DIFFERENTIAL(LIMITED SLIP)
(1) Structure
1 2 3
6 5
7803ASPT15
1 Axle shaft 4 Clutch

2 Case 5 Side gear
3 Pinion gear 6 Pinion shaft
2) Operation
No driving When driving
N F
Ramp
Pinion shaft F
7803ASPT16
When the differential case is rotated, pinion shaft is moved up on the ramp by the resistance force of
tires as the figure, and then force P is generated. This force P becomes the engaging force of clutch.
Η When travelling straight(equal resistance from road surface to left and right tires). Under this
condition, both clutch are engaged and the left and right side gears are driven with the same
force.
Θ When travelling on soft ground(Resistance from road surface to right tire is smaller). At rotating
speed of right tire becomes faster than left due to the smaller resistance of right tive, right clutch is
engaged and torque of faster rotating right axle shaft is added to left axle shaft through
differenting gear case.
3-57
3) SECTION OF REAR AXLE DIFFERENTIAL(CONVENTIONAL)
2 1
76043PT19
1 Bevel pinion 3 Side gear(Differential) 5 Bevel gear

2 Shaft 4 Sun gear
3-58
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). 770-3 [3-26(1)]
(2) When driving straight forward

Pinion gear
When the machine is being driven straight
forward and the right and left wheels are Side gear Side gear
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.
770-3 [3-26(2)]
(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
770-3 [3-26(3)]
3-59
5) TORQUE PROPORTIONING DIFFERENTIAL
(1) Function
Η Because of the nature of their work, 4-
wheel-drive loaders have to work in
places where the road surface is bad.
In such places, if the tires slip, the ability
to work as a loader is reduced, and also
the life of the tire is reduced.
The torque proportioning differential is
installed to overcome this problem.
In structure it resembles the differential of
an automobile, but the differential pinion
gear has an odd number of teeth.
Because of the difference in the
resistance from the road surface, the
position of meshing of the pinion gear
and side gear changes, and this changes
the traction of the left and right tires.
(2) Operation
Spider rotating
Η When traveling straight(Equal resista- direction
nce from road surface to left and right
tires)
Under this condition, the distances
involving the engaging points between
FL FR
right and left side gears and pinion-a and Engaging a b
Engaging
point point
b-are equal and the pinion is balanced as
FLÝa=FRÝb. Thus, FL=FR, and the
right and left side gears are driven with
Left side gear Pinion Right side gear
the same force.
(740-3A) 3-27
3-60
Θ When 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
Ýa=FRÝb, 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
(740-3A) 3-27
wheels reaches about 30%.
3-61
6) FINAL DRIVE(Front & rear)
7403APT03
1 Axle shaft 2 Ring gear

3 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) 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.
3-62
6. TIRE AND WHEEL
7407APT10
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.
3-63
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
3-64
ö 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.
Select full automatic switch to
manual modeΗ.
Move gear selector lever to 3rd
speed.
Move gear selector lever to
forward "F" position.
1
2 Increase engine speed to high idle
for 30 seconds.
A
Move gear selector lever to

neutral "N" position and run for 15
seconds.
1
4
2
3
F
N
R
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 1
4
2
3
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.
Engage neutral lock.
Apply slight effort to move lever
into forward(F) and reverse(R).
LOOK : Neutral lock must stay
engaged.
Automatic shifting Start engine. OK

check Check completed.
Move gear selector lever to 4th
F
speed.
1
2
4
3 N
R
NOT OK
Turn full automatic switch ON.
Go to transmission error
code group at page 3-32~
LOOK : Automatic sign on
3-51.
display.
Repair or replace the
Automatic sign Move gear selector lever to display or harness.
forward or reverse position.
Increase engine rpm.
LOOK : Speed on display must
vary with machine speed.
ÂMode 1 : 1st Ĉ 4th
ÂMode 2 : 2nd Ĉ 4th
3-65
Transmission noise Run engine at approximately OK

check 1
4
2
3
1600rpm. Check completed.
Engine running.
Drive unit with transmission in NOT OK
each forward and reverse speed. Go to transmission makes
excessive noise, chapter
LISTEN : Transmission must not
2 in this group.
make excessive noise in any
range.
Engine rpm must not "lug down"
as unit is shifted between gears.
Transmission "quick Release parking brake and select

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

shift back to 2nd gear.
Shift to (3rd or 4th) gear and press
gear selector lever kick down
switch once.
not shift down.
Select full automatic switch to
automatic modeΘ.
Drive machine at approximately
90 speed of max speed in each
gear(2nd or 3rd or 4th).
Shift to(2nd or 3rd or 4th) gear in
each forward and reverse speed
and press gear selector kick down
lever switch or RCV lever switch
once.
LOOK/FEEL : It shift down quickly
from current gear to one step lower
speed and recover to original
speed quickly when push the
switch one more time.(Mode 1)
3-66
LOOK/FEEL : If shifts down from

current gear to one step lower
speed when push the switch
everytime and recover when push
the switch in 1st gear.(Mode 2)
Forward, reverse and Park unit on level surface. OK

4th speed clutch pack 1
2
3
Check completed.
Apply service brakes.
4
drag check
NOT OK
ö 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.
Transmission shift Run engine at approximately OK

modulation check 1
4
2
3
1300rpm. 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

1
4
2
3
brakes and release parking brake. Check completed.
Move gear selector lever to 3rd 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 : 2150Ü70rpm
Move gear selector control lever
to neutral "N" position and run for
15 seconds.
3-67
2. TROUBLESHOOTING
1) TRANSMISSION
ö 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 valve Remove valve and inspect gaskets.
or gasket.
Low transmission pump flow due Do transmission pump flow test.
to worn pump.
Weak or broken pressure regulat- Do transmission system pressure test.
ing valve spring.
Error code on display Something wrong in transmission. Go to transmission error code group at page
3-32~3-51.
3-68
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 contro- Check transmission controller fuse.
ller.
Malfunctioning parking brake Remove and inspect parking brake solenoid
solenoid valve. valve.
Check for power to solenoid valve.
Restricted orifice of PPC valve. Remove orifice and check for contamination
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 PPC valve. Remove end cover to inspect PPC valve.
Replace if necessary.
Malfunctioning transmission Check speed sensor.
speed sensor.
3-69
Transmission pressure is Low oil level. Check transmission oil level and refill if
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 spring. Inspect for damage(See transmission control
valve).
Failed control valve gasket. Inspect transmission control valve for external
leakage. Remove control valve.
Inspect or replace gasket.
Stuck PPC 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 valve Inspect transmission control valve for external
two gears)
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 PPC valve. Remove end cover to inspect modulation spool.
Restricted PPC valve orifice. Remove orifice and inspect for contamination
and /or plugging.
Restricted oil passages between Remove control valve and inspect oil passage.
control valve and transmission
elements.
Incorrect transmission oil. Change oil(SAE 10W-30/15W-40)
3-70
Transmission shifts too Wrong transmission controller. Check if transmission controller has been
fast changed
System pressure too high. Do transmission system pressure test.
Stuck PPC valve. Remove and inspect PPC valve.
Replace if necessary. Also remove end cover to
inspect PPC 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.
Incorrect transmission oil. Change oil(SAE 10W-30/15W-40)
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 lube Check cooler lines.
lines.
Machine operated in too high gear Operate machine in correct gear range.
range.
Malfunction in temperature gauge Install temperature sensor the verify temperature.
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 valve(In Disassemble and inspect.
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 hydraulic Do transmission system pressure, element
system. leakage test.
Malfunction in converter relief Do converter out pressure test.
valve.
Low transmission pump output. Do transmission pump flow test.
3-71
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 engine Inspect drive line.
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 pump. Check oil pickup tube on side of transmission.
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.
Incorrect transmission oil. Change oil.
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 valve. Do converter-out pressure test.
Leakage in torque converter seal. Do converter-out pressure test.
Torque converter not
transferring power(Bent fins, Replace torque converter.
broken starter).
3-72
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 PPC valve. Remove and inspect.
Low transmission pressure circuit. Do transmission system pressure test.
Leak in transmission pressure Do converter out pressure test.

circuit.
Failed transmission pump. Do transmission pump flow test.
Clogged filter. Inspect filter. Replace.
3-73
2) DIFFERENTIAL / AXLE
Differential low on oil External leakage. Inspect axle and differential for leaks.
Excessive differential Low oil level in differential. Check oil. Remove drain plug and inspect for
and/or axle noise metal particles in differential case.
Disassemble and determine cause.
Incorrect type of oil. Change oil
Dragging brakes. Do brake check.
Failed pinion bearing. Remove and inspect pinion.
Check to ensure pinion housing was indexed.
Incorrect gear mesh pattern Remove pinion gear housing and inspect ring
between ring and pinion gear. and pinion gear.
Failed differential pinion gears Remove differential housing drain plug and
and/or cross shafts. inspect for metal particles. Disassemble and
inspect.
Failed axle bearing. Do axle bearing adjustment check.
Mechanical failure in axle Remove differential. Inspect, repair.
planetary.
Oil seeping from outer Excessive end play in axle. Do axle bearing adjustment check.
axle seal
Worn outer bearing and/or cup. Disassemble and inspect outer axle bearing,
cup, spacer, and seal. Replace, if necessary.
Overfilled differential. Check differential oil return system for excessive
internal restriction.
Axle overheats Low differential oil. Add oil.

Overfilled differential. See differential overfills with oil in this group.
Brake drag. See brakes drag in this group.
3) DRIVE LINE
Excessive drive line Yokes not in line on drive shafts. Inspect. Align drive shaft yokes.
vibration or noise
Worn front drive line support Inspect, repair.
bearing.
Bent drive shaft. Inspect all drive shafts. Replace.
Loose yoke retaining nuts(Drive Inspect. Replace.
shafts wobble at high speed).
Rear axle oscillating support. Inspect, repair.
Lack of lubrication. Lubricate with proper grade of grease.
3-74
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
specification. The rated pressure is 25kgf/cm2.
For the detailed method for pressure
adjusting, refer to page 4-22.
BL1
Clutch cut off

pressure switch
Brake valve
7707PT12
3-75
2. TRANSMISSION MEASURING POINTS AND CONNECTIONS
The measurements have to be carried out at hot transmission(About 80~95Á
C ).
48 47 21
54
34
65 51 68
69 49
H J
K
G
57 60
A F
B E 16
53 55 15
C D
58 56 52,63
VIEW X VIEW Y
7407APT15
1) OIL PRESSURE AND TEMPERATURE
Port Description Size
51 Converter inlet-opening pressure(11bar) H M10Ý1

52 Converter outlet-opening pressure(4.3bar) M14Ý1.5
53 Forward clutch(16+2bar) B M10Ý1
55 Reverse clutch(16+2bar) E M10Ý1
56 1st clutch(16+2bar) D M10Ý1
57 2nd clutch(16+2bar) A M10Ý1
58 3rd clutch(16+2bar) C M10Ý1
60 4th clutch(16+2bar) F M10Ý1
63 Converter outlet temperature 100ÁC , short-time 120ÁC M14Ý1.5
65 System pressure(16+2bar) K M10Ý1
3-76
2) DELIVERY RATES
15 Connection to oil cooler 1 5/16"-12UN-2B

16 Connection from the oil cooler 1 5/16"-12UN-2B
3) INDUCTIVE TRANSMITTER AND SPEED SENSOR
21 Inductive transmitter n turbine M18Ý1.5

34 Speed sensor n output and speedometer -
47 Inductive transmitter n central gear train M18Ý1.5
48 Inductive transmitter n engine M18Ý1.5
54 Filter contamination switch M14Ý1.5
4) CONNECTIONS
49 Plug connection on the hydraulic control unit -

68 Pilot pressure(Option) J M16Ý1.5
69 System pressure(Option) G M16Ý1.5
3-77
GROUP 4 DISASSEMBLY AND ASSEMBLY
1. CONTROL VALVE
1) DISASSEMBLY
(1) Illustration on the right shows the
complete control unit.
73073CV001
(2) Mark the installation position of the

different covers, the housing and cable
harness with the valve housing.
73073CV002
(3) Loosen socket head screws.

Separate duct plate, 1st gasket,
intermediate plate and 2nd gasket from
the valve housing.
ö Special tool
Box spanner 5873 042 002
73073CV003
(4) Remove retaining clip.
73073CV004
3-78
(5) Loosen socket head screws.
Separate cover from housing and cable
harness.
ö Special tool
73073CV005
(6) Disassemble opposite cover.

Disconnect pressure regulator and
remove cable harness.
73073CV006
(7) Loosen socket head screws, remove fixing

plate and pressure regulators(3EA).
ö Special tool
73073CV007
(8) Loosen two socket head screws and

locate housing provisionally, using
adjusting screws(Housing is under spring
preload).
Now, loosen remaining socket head
screws.
ö Special tool
Adjusting screws 5870 204 036
73073CV008
3-79
(9) Separate housing from valve housing by
loosening the adjusting screws uniformly.
ö Special tool
73073CV009
(10) Remove components.
73073CV010
(11) Remove opposite pressure regulators,

housing as well as components
accordingly.
73073CV011
3-80
2) ASSEMBLY
ö Check all components for damage and
renew if necessary.
Prior to the installation, check free travel of
all moving parts in the housing.
Spools can be exchanged individually.
Oil the components prior to the assembly.
Insert diaphragms with the concave side
showing upward until contact is obtained.
ö Installation position, see arrows.
73073CV015
(1) Illustration on the right shows the following

components.
1 Vibration damper
2 Follow-on slide
3 Pressure reducing valve
73073CV016
(2) Install components according to figure (1).

ö Preload compression spring of the follow-
on slides and locate spool provisionally by
means of cylindrical pins ͚ 5.0mm
(Assembly aid), see arrows.
73073CV017
(3) Install two adjusting screws.

Assemble gasket(Arrow 1) and housing
cover. Now, position the housing cover
uniformly, using adjusting screws, until
contact is obtained and remove cylindrical
pins(Assembly aid) again(See the next
figure).
ö Pay attention to the different housing covers.
Install recess ͚15mm (Arrow 2), facing the
spring of the pressure reducing valve.
Adjusting screws 5870 204 036 73073CV018
3-81
73073CV019
(4) Fasten housing cover by means of socket

head screws.
ÂTorque limit : 0.56kgfÂm(4.06lbfÂft)
ö Special tool
73073CV020
(5) Introduce pressure regulators and fix by

means of fixing plates and socket head
screws.
ö Install fixing plate, with the claw showing
downward.
Pay attention to the radial installation
position of the pressure regulators, see
figure.
ö Special tool 73073CV021
Pre assemble opposite side

(6) Illustration on the right shows the following
components.
1 Main pressure valve
2 Follow on slide
3 Vibration damper
73073CV022
3-82
(7) Install components according to figure (6).
Preload compression springs of the follow-
on slides and locate spool provisionally by
means of cylindrical pins ͚ 5.0mm
(Assembly aid), see arrows.
Install two adjusting screws.
Assemble gasket(Arrow 1) and housing
cover, and position them uniformly against
shoulder, using adjusting screws.
ö Pay attention to the different housing
covers-install the recess ͚19mm(Arrow 2), 73073CV023
facing the main pressure valve.
Now, fasten housing cover by means of
socket head screws.
Remove cylindrical pins(Assembly aid)
again.
ö Special tool
(8) Introduce pressure regulators and fix by

means of fixing plates and socket head
screws.
ö Install fixing plates, with the claw showing
downward.
Pay attention to the radial installation
position of the pressure regulators, see
figure.
ö Special tool
Box spanner 5873 042 002 73073CV024
(9) Introduce cable harness and connect

pressure regulators(6EA).
ö Pay attention to the installation position of
the cable harness, see also markings
(See figure(2), page 3-78).
73073CV025
3-83
(10) Introduce female connector against
shoulder, with the groove facing the guide
nose of the cover.
Install gasket(Arrow) and fasten cover by
means of socket head screws.
ö Special tool
73073CV026
(11) Fix female connector by means of

retaining clamp, see figure.
Install opposite cover.
73073CV027
(12) Install two adjusting screws and mount

gasket Ɇ.
ö Pay attention to the different gaskets, see
on the right figure and (15).
ö Special tool
73073CV028
Intermediate plate-Version with screens

(13) Insert screws(6EA) flush mounted into the
bore of the intermediate plate, see arrow.
ö Pay attention to the installation position-
screws are showing upward(Facing the
duct plate).
73073CV029
3-84
(14) Mount intermediate plate, with the screens
showing upward.
73073CV030
(15) Mount gasket ɇ.
73073CV031
(16) Mount duct plate and fasten it uniformly by

means of socket head screws.
ö Special tool
73073CV032
(17) Equip screw plug(8EA) with new O-rings

and install them.
ö The installation of the hydraulic control unit
is described, starting from page 3-139.
73073CV033
3-85
2. TRANSMISSION
1) DISASSEMBLY
(1) Remove filter unit
Η Demount warning switch(Arrow) from
filter head.
73073TM002
Θ Separate oil filter from filter head.

ö Special tool
Belt spanner 5870 105 005
73073TM003
Ι Loosen hexagon head screws and

separate filter head from duct plate.
73073TM004
(2) Separate hydraulic control unit and duct

plate from gearbox housing
Η Loosen socket head screws, install two
adjusting screws and separate control
unit from duct plate.
ö Special tool
Adjusting screw 5870 204 031
73073TM004
3-86
Θ Remove both gaskets as well as
intermediate plate.
ö Special tool
75773TM051
Ι Loosen socket head screws and hexagon

nuts and separate duct plate from
gearbox housing.
Now, remove flat gasket.
ö Special tool
75773TM052
(3) R emove and disassemble converter

safety valve
Η Pull converter safety valve out of the
housing bore.
75773TM053
Θ Illustration on the right shows the

required special tool for the
disassembling of the converter safety
valve.
1 Converter safety valve
ö Special tool
Assembly aid 5870 345 084
73073TM009
3-87
Ι Preload compression spring carefully,
remove cylindrical pin(See on the right
figure) and demount components(See on
the below figure).
73073TM010
73073TM011
(4) Engine connection-Converter

Η Remove lock plate and loosen hexagon
head screws.
Remove disk and pry input flange from
the shaft.
73073TM015
Θ Loosen screw connection.

ö Mark radial installation position of the
housing cover.
73073TM016
3-88
Ι Separate cover along with converter from
the transmission, using lifting device.
ö Special tool
Set of eye bolts 5870 204 002
75773TM057
Κ Press input shaft, respectively converter

out of the cover(Ball bearing).
75773TM058
Λ Squeeze circlip out and remove ball

bearing.
ö Special tool
Set of internal pliers 5870 900 013
75773TM059
Μ Loosen hexagon head screws and

separate membrane from converter.
75773TM060
3-89
Ν Loosen hexagon head screws and
separate input shaft from the membrane.
75773TM061
Ξ Remove inductive transmitter(n Enging).
75773TM062
Ο Loosen hexagon head screws and

remove converter housing.
75773TM063
(5) Remove transmission pump

Η Loosen socket head screws.
75773TM064
3-90
Θ Apply separating device on the splines
runout of the stator shaft and pull pump
out of the housing bores, using two-leg
puller.
ö Special tool
Separating device 5870 300 024
Two-leg puller 5870 970 004
75773TM065
Ι Separate transmission pump from stator.

Separate cam plate from pump.
ö If traces of wear should be encountered
in the pump housing or the cam disk, the
complete pump has to be renewed.
Now, fit cam disk again and fix it by
means of grooved pins(2EA).
75773TM066
Κ Loosen hexagon head screws and

remove oil feed housing.
Now, remove flat gasket.
75773TM067
(6) Converter pressure valve

Η Pull converter pressure valve out of the
housing bore.
73073TM028
3-91
Θ Illustration on the right shows the special
tool required for the disassembling of the
converter pressure valve.
1 Converter pressure valve
ö Special tool
73073TM029
Ι Preload compression spring carefully,

drive roll pin out and remove
components.
ö Special tool
73073TM030
Κ Loosen hexagon head screws, demount

cover and remove flat gasket.
73073TM031
(7) Demount output, input and clutches

Η Remove lock plate, loosen hexagon head
screws, and pry the converter-side output
flange from the shaft.
Now, pry shaft seal out of the housing
bore.
Tilt gearbox 180Áand remove rear output
flange accordingly.
ö Special tool
Pry bar 5870 345 065 73073TM035
3-92
Θ Demount speed sensor as well as both
inductive transmitters(Arrows).
73073TM036
Ι Loosen hexagon nuts and remove the

two covers(Arrows).
Loosen screw connection.
73073TM037
Κ Drive both cylindrical pins(Arrows) out.
73073TM038
Λ Separate housing cover carefully from

gearbox housing, using lifting device.
ö Special tool
Lifting chain 5870 281 047
73073TM039
3-93
Μ On the right figure shows the installation
position of the single clutches as well as
of the input and output.
KV Forward clutch
KR Reverse clutch
K1 1st speed clutch
K2 2nd speed clutch
K3 3rd speed clutch
K4 4th speed clutch
AN Input
AB Output 73073TM040
ö The following figures describe the

common removal of all clutches.
For this purpose, the housing cover,
combined with special tool is necessary.
The removal of single clutches without
help of the housing cover and the
handles is extremely difficult because of
the installation condition.
Besides, there is the danger of injuries.
ö Prior to the common removal of the
clutches, the output shaft must be
removed, see the below figure.
Ν Loosen socket head screws and remove

output shaft as well as both oil baffle
plates.
73073TM042
3-94
Ξ Assemble housing cover carefully until
contact is obtained.
Fix all clutches in the housing cover,
using handles.
ö Special tool
Handle(6EA needed) 5870 260 010
73073TM201
Ο Separate housing cover along with

clutches from gearbox housing, using
lifting device.
ö Special tool
73073TM200
Π Fasten housing cover on assembly car.
73073TM045
Ρ Tilt housing cover 180Á.

Remove handles.
ö Special tool
73073TM046
3-95
΢ Remove K2 clutch.
73073TM047
Σ Remove K1 clutch, at the same time, lift

K4 clutch.
73073TM048
Τ Lift K3 clutch out of the housing cover.
73073TM049
Υ Remove K4 clutch, at the same time lift

input slightly.
73073TM050
3-96
§ Separate KV and KR clutches together
with input from the housing cover.
73073TM051
§æ Remove bearing outer race and pull

output shaft(Power take-off) out of the
housing bore.
73073TM180
§ Squeeze rectangular ring(Arrow) out and

separate ball bearing from shaft.
73073TM179
ö If contrary to the recommendation, the

tapered roller bearings of the clutches as
well as of the input and output would not
be renewed, the allocation of the inner
and outer races to the single assemblies
must at least be maintained.
ö Mark bearing inner and outer races
accordingly.
3-97
(8) Disassemble KV and KR clutch
ö The following figures show the
disassembly of the KV clutch.
The disassembly of the KR clutch is
analogous.
Η Squeeze rectangular ring(Arrow) out.
73073TM54
Θ Pull tapered roller bearing from the shaft.

Demount opposite tapered roller bearing
accordingly.
ö Special tool
Grab sleeve 5873 001 057
Basic set 5873 001 000
73073TM55
Ι Separate plate carrier from shaft.

ö Special tool
Hammer 5870 280 004
73073TM56
Κ Squeeze snap ring out and remove plate

pack.
73073TM57
3-98
Λ Preload compression spring, squeeze
circlip out and remove components.
ö Special tool
Set of external pliers 5870 900 015
73073TM58
Μ Lift piston by means of compressed air

out of the cylinder bore and remove it.
73073TM59
Ν Remove both O-rings.
73073TM60
Ξ Squeeze inner circlip(Shaft) out.

ö Special tool
73073TM61
3-99
Ο Locate idler gear by means of separating
device(See on the right figure) and press
it from the shaft(See on the below figure).
Remove released needle bearing.
ö Special tool
Separating device 5870 300 028
73073TM62
73073TM63
Π Squeeze circlip out and remove ball

bearing.
ö The disassembly of the KR clutch has to
be carried out accordingly.
ö Special tool
73073TM64
(9) Disassemble K1, K2 and K3 clutch

ö The following Figures show the
disassembly of the K3 clutch.
The disassembly of the K1 and K2
clutches is analogous.
Η Squeeze rectangular ring(Arrow) out.
73073TM65
3-100
Θ Pull tapered roller bearing from the shaft.
Remove opposite tapered roller bearing
accordingly, see Figure Η , Θ.
ö Special tool
(K3 on output side)
Basic set 5873 001 000
73073TM66
Ι Remove running disk, axial needle cage

and axial washer.
73073TM67
Κ Remove idler gear.
73073TM68
Λ Remove both needle bearings as well as

axial bearing.
73073TM69
3-101
Μ Squeeze snap ring out and remove plate
pack.
73073TM70
Ν Preload compression spring, squeeze

ö Special tool
Assembly aid(K2 and K3) 5870 345 085
Assembly aid(K1) 5870 345 086
73073TM71
Ξ Press piston out of the plate carrier, using

compressed air.
73073TM72
Ο Pry plate carrier from the shaft.

ö Special tool
Pry bar 5870 345 065
73073TM73
3-102
(10) Disassemble K4 clutch
Η Squeeze rectangular ring out and pull
tapered roller bearing from the shaft.
Remove opposite tapered roller bearing
accordingly.
ö Special tool
Basic set 5873 001 000
73073TM74
Θ Squeeze circlip out and separate plate

carrier from the shaft.
ö Special tool
73073TM75
Ι Squeeze snap ring out and demount

plate pack.
73073TM76
Κ Preload compression spring, squeeze

Demount piston.
ö The separation of shaft and gear is not
possible(Shrink fit).
ö Special tool
73073TM77
3-103
(11) Disassemble input shaft
Η If necessary, press turbine shaft out of
the input shaft.
ö The turbine shaft is axially fixed by
means of a snap ring which will be
destroyed at the pressing out.
73073TM78
Θ Squeeze rectangular ring out and pull off

the tapered roller bearing.
Pull off the opposite tapered roller
bearing.
ö The separation of input shaft 1 and gear
2 is not possible(Shrink fit).
ö Special tool
Basic set 5873 001 000
73073TM79
3-104
2) ASSEMBLY
ö If contrary to the recommendation, the
tapered roller bearings of the clutches as
well as of the input and output would not
be renewed, the allocation of the inner and
outer races to the single assemblies must
at least be maintained.
(1) Mount oil pipes
ö To ensure the correct assembly of the oil
pipes, the use of the specified special tool
is imperative. 73073TM090
Η Install studs(Arrows).
ö Insert studs with Loctite.
Θ Place distance tubes over the studs.
73073TM091
Ι Insert suction tube 1, pressure pipe 2 and

pressure pipe lubrication 3 into the
housing bores.
Fasten suction tube 1 and pressure pipes
2 provisionally by means of socket head
screw and hexagon nuts.
73073TM092
3-105
Κ Locate both pressure pipes by means of
special device.
ö Special tool
Tension bar 5870 654 030
73073TM093
Λ Tilt housing 180Á.

Roll in suction tubes as well as pressure
pipes(Arrows) into the housing bores,
using special tool.
ö Pipe end of pressure pipes(Arrows) must
be slightly below the housing plane face,
if necessary equalize.
ö Special tool
Rolling tool 5870 600 003
Rolling tool 5870 600 004 73073TM094
Λ Tilt housing 180Á.

Check installation position of the two
pressure pipes and correct if necessary.
ö Pipes must be located in the special
device without play and pressure.
Now, remove special device.
ö Special tool
Tension bar 5870 654 030
73073TM095
Μ Equip screw plug with new O-ring and

install it.
73073TM096
3-106
Ν Insert all bearing outer races into the
housing bore.
ö In the case that already run bearings are
reused, pay attention to the allocation of
the bearing outer races, see also Note,
page 3-101.
ö Pay attention to the corresponding
markings.
73073TM097
Ξ Insert both oil pipes(Arrows) into the

housing cover, tilt housing cover 180Á
and roll in oil pipes into the housing
bores.
ö The pipe end must be situated slightly
below the housing plane face.
ö Special tool
73073TM098
Ο Install studs (M8Ý25, 27EA) according

to the figure on the right.
73073TM099
Π Insert set screws(2EA) into the housing

bores(Arrows).
73073TM099A
3-107
Assemble KV and KR clutch
The following figures describe the
assembly of the KV clutch.
Pre-assemble plate carrier(Figure Ρ~Τ)
Ρ Check function of the drain valve.
ö Ball may not seize, if necessary clean by
means if compressed air.
Insert both O-rings(Arrows) scroll free
into the recesses of the piston and oil
73073TM100
΢ Assemble piston until contact is obtained.

ö Pay attention to the installation position,
see on the right figure.
73073TM101
Σ Introduce compression spring along with

spring cup(2EA).
73073TM102
Τ Preload compression spring and fix it by

means of circlip.
ö Special tool
73073TM103
3-108
KV, KR plate pack
ö The plate equipment, respectively
stacking of KV and KR clutch is identical.
The following draft shows the installation +0.2
2.5 mm
position of the components.
1 Plate carrier 1 3 5 3 6
2 Piston
3 Outer plate-one-sided coated
4 Inner plates
5 Outer plates-coated on both sides
6 Snap ring(Optional s = 2.1~4.2mm)
7 End shim
ö Install outer plate 3 with the uncoated
side facing the piston, respectively the 4
end shim. 2 7
Install on the end shim side two outer and
inner plates each.
ÂEffective number of friction surfaces =18.
73033TM13
Κ Adjust plate clearance = 2.5+0.2mm.

ö For the adjustment of the plate clearance
there are snap rings of different thickness
available.
To ensure a faultless measuring result,
install plates for the moment without oil.
ö Introduce plate pack according to the
upper draft.
73073TM105
3-109
§ Mount end shim and squeeze snap
ring(e.g. s = 3.0mm) in.
73073TM106
§æ Press end shim on with about 10kg and

measure DimensionɆfrom the end
face/plate carrier to the end shim.
Dimension Ɇ e.g. 7.25mm
ö Special tool
Digital-Depth gauge 5870 200 072
73073TM107
§ Press end shim against snap ring

(Upward) until contact is obtained and
determine Dimension ɇ
Dimension ɇ e.g. 4.75mm
ö Special tool
73073TM108
EXAMPLE
Dimension Ɇ 7.25mm
Dimension ɇ - 4.75mm
Difference = Plate clearance = 2.50mm
ö In case of deviations from the required
plate clearance, correct by means of
corresponding snap ring(s = 2.1~4.2mm).
Now, remove plate pack, oil and install it
again.
3-110
§ Introduce idler gear until all inner plates
are accommodated.
ö This step makes the later assembling of
the idler gear easier.
Now, remove idler gear again.
73073TM109
§ Install stud(Arrow).
ö Use Loctite.
73073TM110
͇ Insert ball bearing until contact is

obtained and fix it by means of circlip.
73073TM111
͈ Assemble needle bearing.
73073TM112
3-111
͉ Press idler gear against shoulder.
ö Support it on the bearing inner race.
73073TM113
͊ Fix idler gear axially by means of circlip.

ö At KR clutch there is no recess in the
shaft-assemble circlip until contact on the
bearing inner race is obtained.
ö Special tool
73073TM114
͋ Assemble pre-assembled plate carrier

until contact is obtained.
ö Only if the plate carrier plane face is
overlapping with the shaft collar, the
accommodation of all inner plates is
ensured, see on the below figure.
73073TM115
73073TM116
3-112
͌ Press tapered roller bearing against
shoulder.
Install opposite tapered roller bearing.
73073TM117
͍ Check function of clutch by means of

compressed air.
ö At correctly installed components, the
closing, respectively opening of the clutch
is clearly audible.
73073TM118
(2) Assemble K1, K2 and K3 clutch

assemble of the K3 clutch.
The assembly of the K1 and K2 clutches
has to be carried out accordingly.
Η Install stud(Arrow).
ö Use Loctite.
73073TM125
Θ Assemble plate carrier until contact is

obtained.
73073TM126
3-113
Ι Check function of the drain valve.
means of compressed air.
into the piston recesses and oil them.
73073TM127
Κ Introduce piston until contact is obtained.

73073TM128
Λ Introduce compression spring along with

spring cup(2EA).
73073TM129
Μ Preload compression spring and fix it by

means of circlip.
ö Special tool
Assembly aid(K2 and K3) 5870 345 085
Assembly aid(K1) 5870 345 086
73073TM130
3-114
K1, K2 and K3 plate pack
ö The K1, K2 and K3 plate stacking of
clutches are identical.
The following draft shows the installation +0.2
2.1 mm
position of the components.
1 Plate carrier 1 3 5 6
2 Piston
4 Inner plates
6 Snap ring(Optional s = 2.1~4.2mm)
7 End shim
ö Install outer plate 3 with the uncoated
side facing the piston. 4
ÂEffective number of the friction surfaces 2 7
= 14.
73033TM15
Ν Adjust plate clearance = 2.1+0.2mm :

ö For the plate clearance adjustment there
are snap rings of different thickness
available.
install the plates for the moment without
oil.
ö Introduce plate pack according to the
upper draft.
73073TM135
Ξ Fit end shim and squeeze snap ring(e.g.

3.0mm) in.
73073TM136
3-115
Ο Press end shim on with about 10kg, and
DimensionɆ e.g. 8.20mm
ö Special tool
73073TM137
Π Press end shim against snap

ring(Upward) until contact is obtained,
and determine Dimensionɇ.
Dimensionɇ e.g. 6.00mm
ö Special tool
73073TM138
EXAMPLE :
Dimensionɇ e.g. - 6.00mm
Difference = Plate clearance = 2.20mm
corresponding snap ring(S =2.1~4.2mm).
ö Now, demount plate pack, oil and install it
again.
Ρ Assemble running disk 1(50Ý70Ý4),

axial needle cage 2 and axial washer 3
(50Ý70Ý1).
ö Install running disk 1 with the chamfer
facing the axial needle cage.
73073TM139
3-116
΢ Assemble both needle bearings.
73073TM140
Σ Introduce idler gear until all inner plates

are accommodated.
73073TM141
Τ Assemble axial washer 3(50Ý70Ý1),

axial needle cage 2 and running disk 1
(50Ý70Ý4).
facing the axial needle cage.
ö Only if the running disk is overlapping
with the shaft collar, the accommodation
of all inner plates is ensured.
73073TM142
Υ Press tapered roller bearing against

shoulder.
73073TM143
3-117
§ Press tapered roller bearing against
shoulder.
73073TM144
§æ Check function of the clutch by means of

compressed air.
is clearly audible.
73073TM145
(3) Assemble K4 clutch

Η Undercool shaft(About -80ÁC), heat
gear(About +120ÁC) and assemble it until
73073TM150
Θ Locate gear axially by means of circlip.

ö Special tool
73073TM151
3-118
Ι Install stud(Arrow).
ö Use Loctite.
73073TM152
Κ Check function of the drain valve.

means of compressed air.
into the piston recesses and oil them.
73073TM153
Λ Introduce piston until contact is obtained.

73073TM154
Μ Install compression spring and spring

cup(2EA), preload and fix by means of
circlip.
ö Special tool
73073TM155
3-119
K4 plate pack
The following draft shows the installation
+0.2
position of the components. 1.2 mm
1 Plate carrier
1 3 5 6
2 Piston
4 Inner plates
6 Snap ring(Optional s = 2.1~4.2mm) 7
7 End shim
ö Install outer plate 3 with the uncoated side
facing the piston.
4
ÂEffective number of friction surfaces = 2
10.
73033TM16
Ν Adjust plate clearance = 1.2+0.2mm :

ö For the plate clearance adjustment there
are snap rings of different thickness
available.
install the plates for the moment without
oil.
Introduce plate pack according to the
draft(See the preceding page).
73073TM160
Ξ Fit end shim and squeeze circlip(e.g. s =

3.0mm) in.
73073TM161
3-120
Ο Press end shim on with about 10kg and
ö Special tool
73073TM162
Π Press end shim against snap ring

(Upward) until contact is obtained and
determine Dimension ɇ.
Dimension ɇ e.g. 6.00mm
ö Special tool
73073TM163
EXAMPLE
Dimensionɇ e.g. - 6.00mm
Difference = Plate clearance =1.20mm
corresponding snap ring(S = 2.1~4.2mm).
Ρ Introduce idler gear until all inner plates
are accommodated.
ö This step makes the later assembling of
the idler gear easier.
Now, remove idler gear again.
73073TM164
3-121
΢ Assemble both axial washers as well as
needle cage.
ö Upper and lower axial washer have the
same thickness(50Ý70Ý1).
73073TM165
Σ Assemble both needle bearings.
73073TM166
Τ Assemble idler gear.
73073TM167
Υ Assemble axial washer 3(50Ý70Ý1)

needle cage 2 and running disk 1(50Ý70
Ý4).
facing the needle cage.
73073TM168
3-122
§ Assemble pre-assembled plate carrier
until all inner plates are accommodated.
73073TM169
§æ Fix plate carrier axially by means of

circlip.
ö Special tool
Handle 5870 260 010
73073TM170
§ Press tapered roller bearing against

shoulder.
Install opposite tapered roller bearing.
73073TM171
§ Check function of the clutch by means of

compressed air.
is clearly audible.
73073TM173
3-123
(4) Pre-assemble input shaft
Η Undercool the input shaft(About -80ÁC),
heat gear(About +120ÁC) and assemble it
73073TM174
Θ Fix gear axially by means of circlip.
73073TM175
Ι Squeeze snap ring into the recess of the

turbine shaft.
73073TM176
Κ Introduce turbine shaft until the snap ring

snaps into the recess of the input shaft-
turbine shaft is axially fixed.
73073TM177
3-124
Λ Press both bearing inner races against
shoulder.
73073TM178
Μ Install ball bearing.

Squeeze rectangular ring(Arrow) in and
hook it in.
73073TM179
Ν Insert output shaft into the housing bore

73073TM180
3-125
(5) Install pre-assembled output shaft and
clutches
common installation of all clutches.
For it, the housing cover, combined with
special tool is needed.
The assembly of single clutches without
housing cover and handles is extremely
difficult because of the installation
conditions.
Besides, there is the danger of injury.
Η Insert all bearing outer races into the

housing cover until contact is obtained.
ö In the case that already run bearings are
reused, pay attention to the allocation of
the bearing outer races, see also Note,
page 3-105.
73073TM190
Θ Insert KR clutch, input shaft and KV

clutch together into the housing cover.
73073TM191
Ι Install K4 clutch.
73073TM192
3-126
Κ Install K3 clutch.
73073TM193
Λ Position K1 clutch.
73073TM194
Μ Insert K2 clutch.
73073TM195
Ν Figure on the right shows the installation

position of the single clutches in the
housing cover.
73073TM196
3-127
Ξ Locate all clutches by means of handles.
ö Special tool
73073TM197
Ο Squeeze rectangular rings(7 pieces, see

Arrows) in and hook them in.
Now, grease rectangular rings and align
them centrically.
73073TM198
Π Tilt housing cover 180Á.

Mount eye bolts, see Arrows.
ö Special tool
Eye bolt M20(2EA) 0636 804 003
Eye bolt M16(1EA) 0636 804 001
Puller device 5870 000 017
73073TM199
Ρ Install adjusting screws.

Position housing cover by means of lifting
device carefully on the gearbox housing
until contact is obtained, respectively
position the clutches in the gearbox
housing.
ö Pay attention to the overlapping of the oil
pipes with the bores in the housing cover.
ö Special tool
Lifting chain 5870 281 047 73073TM200
Adjusting screws 5870
3-128
΢ Remove handles again.
ö Special tool
73073TM201
Σ Separate housing cover from gearbox

housing, using lifting device.
ö Special tool
73073TM202
(6) Output
Η Assemble sheet and press both bearing
inner races against shoulder until contact
is obtained.
73073TM203
Θ Insert bearing outer race(Arrow) into the

housing bore until contact is obtained.
73073TM204
3-129
Ι Position screening plate.
73073TM205
Κ Insert output shaft.
73073TM206
Λ Fasten both sheets by means of socket

head screws(4EA).
ö Insert socket head screws with Loctite.
73073TM207
Μ Squeeze rectangular rings(6EA) into the

recesses of the clutch shafts and hook
them in.
Now, grease rectangular rings and align
them centrically.
73073TM208
3-130
Ν Insert both O-rings(Arrows) into the
annular groove of the oil pipes and
grease them.
73073TM209
Ξ Cover mounting face with sealing

compound Loctite.
Install adjusting screws(S) and position
housing cover carefully against gearbox
housing until contact is obtained, using
lifting device.
ö Pay attention to the overlapping of the oil
pipe with the bores in the housing cover.
ö Special tool
Adjusting screws 5870 204 007 73073TM210
Ο Install both cylindrical pins.
73073TM211
Π Fasten housing cover by means of

hexagon head screws.
ö Pay attention to the position of the fixing
plate, see Arrow.
73073TM212
3-131
Ρ Install shaft seal, with the sealing lip
facing the oil chamber.
ö By application of the prescribed driver,
the exact installation position is obtained.
Wet rubber-coated outer diameter with
spirit.
Grease sealing lip.
ö Special tool
Driver 5870 048 057
73073TM213
΢ Heat the output flange(Maximum 90ÁC),

assemble it and fix it by means of washer
and hexagon head screws.
ö Wet contact area of washer with sealing
compound Loctite.
73073TM214
Σ Fix hexagon head screws by means of

lock plate.
Install output flange on the converter side
accordingly(Figure Ρ~Σ).
ö Special tool
Driver 5870 057 011
Handle 5870 260 002
73073TM215
(7) Converter pressure valve

Η The illustration on the right shows the
components of the converter pressure
valve.
1 Piston
2 Compression spring
3 Valve insert
4 Roll pin
73073TM220
3-132
Θ Introduce compression spring and piston,
preload and fix them by means of roll pin.
ö Special tool
73073TM221
Ι Insert pre-assembled converter pressure

valve into the housing bore.
73073TM222
(8) Oil feed housing-Transmission pump

Η Install two adjusting screws(Arrows) and
mount flat gasket.
ö Special tool
73073TM223
Θ Mount oil feed housing and fix it

provisionally by means of washers and
ö Screw the hexagon head screws in only
do not tighten.
until contact is obtained-d
73073TM224
3-133
Ι Install two adjusting screws and introduce
stator shaft until contact is obtained.
ö Pay attention to the overlapping of the
bores.
ö Special tool
73073TM225
Κ Install O-ring(Arrow) and oil it.
73073TM226
Λ Introduce transmission pump until

ö Pay attention to the overlapping of the
bores.
73073TM227
Μ Equip socket head screws with new O-

rings(Arrow).
ö Grease O-rings.
73073TM228
3-134
Ν Fasten transmission pump by means of
socket head screws.
73073TM229
Ξ Fix oil feed housing finally by means of

hexagon head screws(Mount flat
washers).
the fixing plate(Arrow), see the next
figure.
73073TM230
73073TM231
Ο Fit flat gasket and fasten cover by means

of hexagon head screws.
73073TM232
3-135
(9) Engine connection-Converter
Η Fasten converter housing by means of
73073TM233
Θ Fasten input shaft, membrane and disk

by means of hexagon head screws.
73073TM234
Ι Fasten membrane on the converter,

using hexagon head screws(Mount flat
washers).
ö Insert hexagon head screws with Loctite.
73073TM235
Κ Introduce converter until contact is

obtained.
ö Impulse disk of the converter must be
centrally to the bore of the inductive
transmitter, see on the below figure.
Only in this way it is ensured that the
converter has been completely
introduced.
73073TM236
3-136
73073TM237
Λ Insert ball bearing until contact is

obtained and fix it by means of circlip.
ö Special tool
73073TM238
Μ Assemble housing cover.

Install input flange, fit disk and pull cover
by means of hexagon head screws
evenly against shoulder.
ö Pay attention to the radial installation
position of the cover.
73073TM239
Ν Fasten cover by means of hexagon head

screws and nuts on the converter
housing.
73073TM240
3-137
Ξ Fasten input flange finally and fix
hexagon head screws by means of lock
plate.
ö Special tool
Driver 5870 057 010
Handle 5870 260 002
73073TM241
(10) Converter safety valve

components of the converter safety valve.
1 Plate
2 Ball
3 Compression spring
4 Valve insert
5 Valve sleeve
6 Cylindrical pin
73073TM245
Θ Assemble components according to

figure Η, preload and fix by means of
cylindrical pin.
ö Special tool
73073TM246
Ι Insert converter safety valve into the

housing bore until contact is obtained.
73073TM247
3-138
(11) Fit duct plate
Η Install both screw plugs(Arrows),
ö Install new sealing rings.
73073TM248
Θ Install gasket, place duct plate against

shoulder and fasten it by means of socket
head screws and hexagon nuts(Mount
flat washers).
73073TM249
(12) Fit hydraulic control unit

Η Install two adjusting screws.
Mount gasket 1, intermediate plate 2 and
gasket 3.
the different gaskets, see also the
following draft.
ö Special tool
73073TM250
3
2
1
3-135(4) (740-7)
3-139
Θ Fasten complete control unit on the duct
plate, using socket head screws.
73073TM251
(13) Filter
components of the filter unit.
ö Install new O-rings(Arrows)
73073TM252
Θ Fasten intermediate plate and filter head

by means of hexagon head screws
(Mount flat washers).
73073TM253
Ι Oil gasket and tighten exchange filter

hand-tight.
73073TM254
3-140
Κ If necessary, install warning switch
(According to the version).
73073TM255
Λ Insert O-ring(Arrow) into the annular

groove of the oil feed covers.
73073TM256
Μ Fasten the two covers(Arrows) by means

of hexagon nuts(Mount flat washers) on
the housing.
73073TM257
Ν Mount oil level tube.

Install screw plug(Arrow).
ö Install new gaskets.
ÂTorque limit(Screw plug M26Ý1.5) :
8.16kgfÂm(59.0lbfÂft)
73073TM258
3-141
(14) Speed sensor and inductive transmitter
Η Grease O-ring, introduce speed
sensor(Arrow) and fasten it by means of
socket head screw.
34 Speed-output and -speedometer
73073TM259
Θ Equip the inductive transmitters with new

O-rings and install them.
48 Speed-engine
47 Speed-central gear train
21 Speed-turbine
Install breather(Arrow).
73073TM260
Ι Install gasket and cover plate, arrow 1.

Equip screw plug(Arrow 2) with new O-
ring and install it.
73073TM261
3-142
3. AXLE
1) BRAKES
WEAR CHECK AND REPLACEMENT OF
BRAKE DISCS
(1) Use till minimum thickness of s = 4.5mm.
(2) Loose fixing nuts and remove horizontally

the axle housing.
(3) Remove brake discs.

ö If the brake discs must not been replaced,
remove the complete pack without
changing the position of the discs.
(4) For assembling proceed in opposite

sense, align lubrification holes.
3-143
(5) Adjustment of brake disc gap. Adjusting
bolts counterclockwise and turn them a
3/4 revolution clockwise ; This
corresponds to a gap of 0.75mm between
the brake discs.
(6) Remove brake pistons.
(7) Install O-rings and brake pistons.

ö Observe that neither the pistons nor the
cylinders have gratches or incrostations.
(8) Tight checking with compressed air at

0.5~1bar for 10 minutes each side.
3-144
Loctite
Lo
te
it2
2 c 222
Loctite
Lo
te
it7
2 c 270
3.1~3.6kgfÂm
(22~26lbfÂft)
iLoctite
Lo
te
2t7
c 270
3-145
2) SAFETY BRAKE
(1) Introduce in the hydraulic circuit 25~35 bar
pressure, then remove the axle housing.
(2) Loose the 4 assembling stud bolts and

disassemble the intermediate covers.
(3) Disassembling of spring applied safety

brake pistons. Reassemble the
components in opposite sense.
(4) Check quote of cover.
3-146
2-͚45.5
22.5
22
.
45
2-.
60
6
4
(5) Remove brake discs.
(6) For assembling align lubrification holes of

brake discs.
(7) Remove pinion and ring gear.
3-147
(8) Assemble of internal leverism.
(9) Introduce in the hydraulic circuit 25~35

bar pressure and assemble the axen.
Lo
te
it2
2 c
Loctite 222
2.5~2.9kgfÂm(18~21lbfÂft)
2.0kgfÂm(14.7lbfÂft)
Lo
te
iLoctite
2t7
c 270
3.1~3.6kgfÂm(22~26lbfÂft)
Loctite
Lo
te
it7
2 c 270
Loctite
Lo
te
it2
2 c 222
3-148
ADJUSTMENT
(1) Introduce pressure in the hydraulic circuit
with 25~35 bar.
Remove bolt and locking plate.
(2) Turn the pinion with 0.82kgfÂm(5.9lbfÂft)

torque counterclockwise till it stops. Adjust
the gap between the brake discs by
turning 3 complete revolutions clockwise.
(3) Adjust the bolts to unlock the safety brake

at 47mm and lock the counter nut.
+
-
47m
47m
3-149
DISASSEMBLY
(1) Actuate the hydraulic circuit with bar.
See following page.
ADJUSTMENT
(1) See brake disk play adjustment on page
3-146. Near the adjuster screw to the
level until the idle stroke has been
eliminated (Internal spring action).
(2) Mount the brake cylinder after pressuriz-

ing and adjust the screw so that the two
levers rest on the end of travel screws.
Now tighten the lock nut using loctite 242.
(3) Pressure according to the type of cylinder

and spring load curve. Cu
ve
m(rm
Curve(mm)
14bar
14
a
b 30bar
30
a
b 52bar
52
a
b
100
90
80
70
60
50
40
30
20
10
N 0 500 1000 1500 2000 2500 3000 3500 4000
3-150
PARKING BRAKE ADJUSTMENT OF
CAT 3 AXLES WITH ADJUSTABLE
MECHANICAL STOPS.
1. Free both transmission levers from the
control wire and from further connections.
2. Apply an 0.8~1.0kgf load to the levers so
that the lever rests on the thruster disk
without deforming the lever mechanisms.
3. Once in this position, set the adjuster 0.
k8g
0 1 0.8~1.0kgf
.~
screws of the stops in contact with the
levers without deforming the lever
mechanisms.
4. Reconnect the control wires to the levers
once this position has been obtained.
5. Check that both transmission levers rest
against the stop screws during the brake
disengagement phase.
3-151
3) WHEEL HUB
DISASSEMBLING AND ASSEMBLING
(1) Disassembling of wheel hub.
(2) Disassembling the crown wheel

Η Use partially threaded M18Ý1.5 screws
to support the puller.
3-152
Θ Assembling of wheel hub
a. Installation of outer races of taper roller
bearings.
b. Assembling of bearing.
c. Fitting of seal.
d. Fitting of wheel studs.
3-153
Ι Assembling of wheel hub, seal and
center rings.
3-154
4) WHEEL HUB ONTO AXLE HOUSING
(1) Fitting the gear rim on the wheel center.
(2) M18Ý1.5, 10K screws. Mount with loctite

270.
Clamping torque 46.9~47.4kgfÂ m
(339~343lbfÂft).
3-155
(3) Torque of new bearings with seal : From
3.1~4.1kgfÂm(22~30lbfÂft).
3-156
5) WHEEL CENTER VERSION WITH 10
PILOT BOLTS
(1) Demounting the wheel center version with
10 pilot bolts.
(2) Clamping torque for bolts M18Ý1.5, 10K

46.9~47.4kgfÂm(339~343lbfÂft).
Torque of new bearings with seal : From
3.1~4.1kgfÂm(22~30lbfÂft).
3-157
6) PLANETARY REDUCTION 6.23
(1) Disassembly
3-158
(2) Reassembly
(3) Check the reference numbers.

Torque the screws at 32.1~32.6kgfÂm
(232~236lbfÂft).
3-159
3-160
7) FINAL DRIVE 244-143
DEMOUNTING
(1) Use partially tightened screws as pullers.
(2) Lock the ring nut then remove the hub

gear.
(3) Disassembly the hub cover.

Replace the retaining ring.
ASSEMBLY
(1) Assembling the stud bolts.
3-161
(2) Dust excluder and oil ring.
(3) Mounting the bearings.
(4) Heat the gear to 140ÁC for assembly.
3-162
(5) Tighten the ring nut at 81.6~91.8kgfÂm
(590~664lbfÂft) using loctite 270.
(6) Chamfer the ring nut.
(7) Pinion assembly.
(8) Assembly with loctite 275 on the surfaces.

Take great care to clean the surfaces.
3-163
ASSEMBLY AND ADJUSTMENT
(1) Preassembly with the same shims as
those removed during disassembly, or
with 1.00mm shims.
(2) Axle shaft oil seal assembly.

Η Check the rotation torque applied
tangentially to the wheel studs, which
must be max 14.3~20.4kgf(With ring).
To correct, add or remove shims
considering that a 0.05mm variation
cause a variation of ~2.0kgf.
Θ Assembly using loctite 275.

Tighten the screws with a torque wrench
23.4~23.8kgfÂm(170~172lbfÂft).
AX114
3-164
Loctite
Lo
te
it4
2 c 242
Lo
te
it4
2 c
Loctite 242
Lo
te
iLoctite
2t7
c 270
A
Lo
te
iLoctite
2t4
c 242
A
Lo
te
it7
2 c
Loctite 270
Lo
te
iLoctite
2t7
c 270
3-165
8) REAR AXLE BEVEL PINION SUPPORT
(1) Removal of bevel pinion support.
(2) Flange input.
(3) Flanged to the reduction gear.
(4) Demounting the bearing plus thrust

plates.
3-166
(5) Assemble the external races.
Taper roller bearings.
Check cover measurement A.
(6) Determination of shim pack S1 for the

preload of the taper roller bearings S1 = B
- C + X.
X = Value to add in order to obtain the
correct preload of the taper roller bearings.
T26/P65 Flange input.

C
B
Value X = See figure. I = 13.5mm

X = 0.09~0.11mm
270
ctite
Lo
60~80kgfÂm
3-167
(7) Assembly of bevel pinion support and
seal.
(8) Fitting the dust guard on the flange.
(9) Assembly with loctite 242.
3-168
FLANGE INPUT VERSION
(1) Tighten the nut with a torque wrench.
(2) Check rotation torque : See figure

S
S1
I=m
5
3
1
I=135mm 12
1-
12-13NÂcm
3-169
9) FRONT AXLE PINION SUPPORT
(1) Demounting the pinions and bearing
plates.
(2) How to establish shims S2 to position the

bevel pinion. Insert the dummy bearing
and check the difference(Photo Κ) after
having zeroed the instrument on a surface
plate with a 20mm shim(Photo Ι

Measured difference corresponds to S2.
Add or remove the differential shims when
the center distances differ from
150mm(Dimension stamped on the
pinion).
Example
Center distance : 149.8
Shims = (150 -149.8) + S2
I=150
I=5
1 S2
S
Loctite
Lo
te
it1
5 c 510
Lo
te
it4
2 c
Loctite 242
51~71kgfÂm(369~516lbfÂft)
"I"
"Io
m
s"D
atie Dimension stamped at
sip
n
m
d e
re
n
o
rearpifa
r of pinion
Lo
te
it1
5 c
Loctite 510
3-170
(3) Establishing the pinion bearing preload
shims. See page 3-167 and figure.
C
B
Loctite
Lo
te
it4
2 c 242
51~71kgfÂm(369~516lbfÂft)
(4) Check the measurement(Photo Η) after

having mounted the shims and thrust
plate. It must be 0.10mm~0.15mm less
than zero. This difference is annulled by
the effect of bearing interference in the
definitive assembly.
(5) Chamfer.
3-171
(6) Check the final center distance and stamp
it on the cover.
3-172
10) 276 -176 -143 AXLE ADJUSTMENT OF
BEVEL GEAR SET
(1) Determination of shim pack S2 for
adjustment of bevel pinion position : S2 =
(I + A) - (D + r).
Photo Θ = D, Photo Η = ͚/2 = r

Photo Ι = I (Dimension stamped on the
pinion).
Photo Κ = A (Dimension stamped on the

cover pinion).
A
A=28.60
A=
68
.2
(2) Assembly of bevel pinion support with A

shim pack S2. S2
S
Loctite
Lo
te
it7
2 c 270
I=3
1
64
S1
S
=2
͚26
r= /2 D
3-173
(3) Assembling central axle housing.
ö Be careful not to damage the tight
surfaces of the O-rings while inserting the
differential case into the central axle
housing.
Play : 0.18~0.25
(4) Screw in the adjusting nuts to obtain

approximate 0.20~0.27mm backlash
between the teeth of the bevel gear set,
without preloading the taper roller
bearings. Check the rotating torque of
pinion and differential. Tighten nut on
opposite site to the crown wheel to obtain
a 0.05~0.07kgfÂm(0.37~0.52lbfÂft) higher
rotating torque on the pinion.
(5) Mark both ring nuts. To adjust the

backlash move ring nuts only. Loosen the
one on bevel crown wheel side and
tighten the opposite one for the equal
measure if the backlash is too low ;
Viceversa if the backlash is too high.
3-174
(6) Mount locking tabs in the best position
and punch in place.
3-175
11) DIFFERENTIAL HOUSING
(1) Removal of the differential from the axle.
ö Replace the fitting bolts of the crown wheel

every time that they have to be removed.
36.5mm
36
5m
. 25.5mm
25
5m
.
3-176
(2) Mounting sun wheels and planet gears.
(3) Insert the spring pins half way up the pin.
(4) Torque all bolts M12Ý35Ý1.25-10K and

M12Ý 30Ý 1.25-10K with a torque
wrench bolts clamping torque
13.8~14.1kgfÂm(100~102lbfÂft).
Use loctite 270.
3-177
REAR Lo
tLoctite
it7
2
e c 270
Lo
te
it2
2 c
Loctite 222
Lo
te
it7
2 c
Loctite 270
Lo
te
itc2
2
Loctite 222
FRONT
Loctite
Lo
t2
iet2
c 222
Loctite
Lo
te
it4
2 c 242
Loctite
Lo
t2
iet7
c 270
Lo
te
it2
2 c
Loctite 222
Lo
te
iLoctite
2t4
c 242
3-178
12) CENTRAL PART OF FRONT AXLE
DISASSEMBLY
(1) Demount the intermediate cover on the
opposite side to the gear rim and insert
tool.
(2) Slacken the screws. Insert tool and pull

out the differential housing. Remove the
gear rim from the pinion bearing side.
T24
P64
ASSEMBLY
(1) Center the gear rim on tool.
3-179
(2) Insert the differential housing with tool and
torque the screws.
(3) Take care to prevent damage to the brake

retention zones when assembling the
parts.
(4) Mount the intermediate cover on the gear

rim side using tools. Fit on the other
intermediate cover.
3-180
Lo
te
it2
2 c
Loctite 222
Lo
te
it7
2 c
Loctite 270
Lo
tLoctite
it1
5
e c 510 Lo
te
it7
2 c
Loctite 270
iLoctite
Lo
te
2t2
c 222
3-181
Group 1 Structure and Function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1

Group 2 Operational Checks and Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-23
1. OUTLINE
ö The brakes are operated by a pressure compensated, closed center hydraulic system.
Flow is supplied by a fixed displacement, gear type brake pump.
BRAKE SYSTEM
The fixed displacement brake pump supplies flow to the cut-off valve for service brake circuit and
park brake circuits. It flows to three accumulator. The accumulator has a gas precharge and an
inlet check valve to maintain a pressurized volume of oil for reserve brake applications.
Oil through the accumulator flows to the brake valves. The brake valve is a closed center design,
dual circuit operated by a pedal.
The front and rear brakes will operate simultaneously with only one brake pedal depressed.
The differential contains annular brake piston and double sided disk.
Brake pump flow also goes to the parking brake solenoid valve in cut off valve.
The brake system contains the following components:
ÂBrake pump
ÂParking brake solenoid valve in cut off valve.
ÂCut-off valve
ÂBrake valve
ÂAccumulators
ÂPressure switches
4-1
FULL POWER HYDRAULIC BRAKE
SYSTEM
ADVANTAGES - The full power hydraulic Response time
brake system has several advantages over Full power brake actuation VS
Air/Hydraulic brake actuation
traditional brake actuation systems. These
systems are capable of supplying fluid to a 1000
range of very small and large volume
service brakes with actuation that is faster 900
than air brake systems. Figure represents 800
a time comparison between a typical Brake pressure
700 (Full power)
air/hydraulic and full power hydraulic brake
Brake torque(lbÂin)
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
39 REAR
17
20
BL1 BR1 BL2 BR2
8
T1 P1 T2 P2
15 15
7 A1 A2
18
PS
P1
T1
A3
16
B
PS1
19 MCV
P T
Parking Return line
brake solenoid 21
Steering system RCV lever
Fan drive motor
2 1
24
Return
line
25
26 27
7407ABS01
1 Main pump 17 Pressure switch 24 Air breather

2 Brake & fan pump 18 Pressure switch 25 Hydraulic tank
7 Cut off valve 19 Pressure switch 26 Return filter
8 Brake valve 20 Pressure switch 27 Bypass valve
15 Accumulator 21 Line filter 39 Axle
16 Accumulator
4-3
1) SERVICE BRAKE RELEASED
FRONT
39 REAR
17
20
BL1 BR1 BL2 BR2
8
T1 P1 T2 P2
15 15
7 A1 A2
18
PS
P1
T1
A3
16
B
PS1
19 MCV
P T
Return line
21
Fan drive motor
2 1
24 Return
line
25
26 27
7407ABS02
When the pedal of brake valve(8) is released, the operating force is eliminated by the force of the
spring, and the spool is returned.
When the spool removes up, the drain port is opened and the hydraulic oil in the piston of axles
return to the tank(25).
Therefore, the service brake is kept released.
4-4
2) SERVICE BRAKE OPERATED
FRONT
39 REAR
17
20
BL1 BR1 BL2 BR2
8
T1 P1 T2 P2
15 15
7 A1 A2
18
PS
P1
T1
A3
16
B
PS1
19 MCV
P T
Return line
21
Fan drive motor
2 1
24 Return
line
25
26 27
7407ABS03
When the pedal of brake valve(8) is depressed, the operating force overcomes the force of the
spring, and is transmitted to the spool. When the spool moves down, the inlet port is opened, and
at the same time the hydraulic oil controlled the pressure level by the cut-off valve(7) enters the
piston in the front and rear axles. Therefore, the service brake is applied.
4-5
3) PARKING BRAKE RELEASED
FRONT
39 REAR
17
20
BL1 BR1 BL2 BR2
8
T1 P1 T2 P2
15 15
B
A
7 A1 A2
18
PS
P1
T1 Parking brake switch

A3
16
B
PS1
19
MCV
P T
Parking Return line
brake solenoid 21
Fan drive motor
2 1
24 Return
line
25
26 27
7407ABS04
When the parking brake switch is pressed B position, the solenoid valve is energized and the
hydraulic oil enters the front axle. It overcomes the force of the spring and pushes the piston rod.
This releases the brake.
Therefore, the hydraulic oil pressure is applied to the parking brake piston in front axle through the
solenoid valve and the parking brake is kept released.
4-6
4) PARKING BRAKE OPERATED
FRONT
39 REAR
17
20
BL1 BR1 BL2 BR2
8
T1 P1 T2 P2
15 15
B
A
7 A1 A2
18
PS
P1
T1 Parking brake switch

A3
16
B
PS1
19 MCV
P T
Parking Return line
brake solenoid 21
Fan drive motor
2 1
24 Return
line
25
26 27
7407ABS05
When the parking brake switch is pressed A position, the solenoid valve is deenergized and the
valve open the drain port.
At the same time, the hydraulic oil return to the tank through the solenoid valve. When the piston
rod is returned by the force of the spring, the parking brake is applied.
4-7
3. BRAKE PUMP(+FAN PUMP)
1) STRUCTURE
19
Fan pump
12
20
5 0
17
11 12 16
1 8
11 15
6 10
12
4 5
18 15
13 15
21
14 5
2
23
15
12
3
11 19
4
22
11 4
Brake pump
7407ABS19-1
1 Body 10 Washer 17 Shaft

2 Front cover 11 Seal 18 Spring
3 Rear cover 12 Seal 19 Dowel pin
4 Plate 13 Shaft seal 20 Drive shaft
5 Plate 14 Ring 21 Drive gear
6 Driven gear 15 Back up ring 22 Driven gear
8 Screw bolt 16 Flange 23 Body
This gear pump have a maximum delivery pressure of 150kgf/cm2.

The pressure loaded type gear pump is designed so that the clearance between the gear and the
bushing can be automatically adjusted according to the delivery pressure. Therefore, the oil leakage
from the bushing is less than that in the case of the fixed bushing type under a high discharge pressure.
Consequently, no significant reduction of the pump delivery occurs, even when the pump is operated
under pressure.
4-8
2) PRINCIPLE OF OPERATION
(1) Mechanism for delivering oil
The drawing at right shows the
operational principle of an external gear
pump in which two gears are rotating in
mesh.
The oil entering through the suction port is Suction Discharge
trapped in the space between two gear
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.
(770-3ATM) 4-9
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
rge
protected from seizure and binding.
scha
Di
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
(770-3ATM) 4-10
viscosity oil.
4-10
(3) Forces acting on the gear
The gear, whose outer surface is
subjected to oil pressure, receives forces
jointing towards its center.
Due to the action of the delivery pressure,
the oil pressure in higher on the delivery
side of the pump, and due to suction
pressure, is lower on the suction side. In
the intermediate section, the pressure will
gradually lower as the position moves
from the delivery side to the suction side.
Drive gear
This phenomenon is shown in the drawing
at right.
In addition, the gears in mesh will receive
Suction Discharge
interacting forces. side side
These forces pushing the gears toward
the suction side are received by the
bearings. Since the gears are pressed
Driven gear
toward the suction side by these forces,
the radial clearance becomes smaller on
the suction side in the case. In some
pumps, the clearance may become zero,
Pressure distribution
thus allowing the gear teeth and the case
to come into light contact.
For this reason, an excessive increase in
the delivery pressure must be avoided,
since it will produce a large force which
will act on the gears, placing an overload
on the bearings, and resulting in a
shortened service life of the bearing or
(770-3ATM) 4-11
interference of the gear with the case.
4-11
4. BRAKE VALVE
1) STRUCTURE
18
17 19
23 22
24
21
2
33
20 8,31,32
9
25 29
25
16 14
T
BL
15 7
5 BR
P 13
30
12 T 6
BL
10
26 P
4
BR
11
3
7307ABS21
1 Lower body 11 O-ring 21 Torsion spring

2 Upper body 12 Oil seal 22 Stop ring
3 Spool 13 Spring guide 23 Hexagon bolt
4 Plug 14 Stop ring 24 Hexagon nut
5 Holder 15 Bushing 25 Bolt
6 Lower spring 16 Pedal plate 26 Spring washer
7 Upper spring 17 Pedal assy 29 Plate washer
8 Main spring 1 18 Rubber(Pedal) 30 Stop ring
9 Spring retainer 1 19 Cover 31 Spring retainer 2
10 O-ring 20 Lock pin 1 32 Main spring 2
33 Taper plug
4-12
2) OPERATION
BL1 BR1 BL2 BR2
T1 P1 T2 P2
Hydraulic circuit
Port Port name Port size
T1 P1, P2 Port PF3/8

BL1
T1, T2 Drain port PF3/8
P1
BR1, BR2 Brake cylinder port PF3/8
BR1
BL1 Pressure switch port PF1/4
T2 BL2 Pressure switch port M12Ý1.5
BL2
P2
BR2
7307ABS22
4-13
(1) Purpose
The purpose of the brake valve is to sensitively increase and decrease the braking pressure when
the brake pedal is actuated.
(2) Ready position
When the braking system is ready for operation, its accumulator pressure acts directly on ports
(P1, P2) of the brake valve. A connection is established between ports(BR1, BR2) and ports(T1,
T2) so that the wheel brakes ports(BR1, BR2) are pressureless via the returns ports(T1, T2).
(3) Partial braking
When the brake valve is actuated, an amount of hydraulic pressure is output as a ratio of the foot
force applied.
The spring assembly(8) beneath pedal plate(16) is designed in such a way that the braking
pressure changes depending on the angle. In the lower braking pressure range, the machine
can be slowed sensitively.
When the braking process is commenced, the upper spool is mechanically actuated via spring
assembly(8), and the lower spool is actuated hydraulically by spool. As spools(3) move
downward, they will first close returns(T1, T2) via the control edges, thus establishing a
connection between accumulator ports(P1, P2) and ports(BR1, BR2) for the wheel brake
cylinders. The foot force applied now determines the output braking pressure. The control
spools(3) are held in the control position by the force applied(Spring assembly above the spools
and the hydraulic pressure below the spool(Balance of forces).
After output of the braking pressure, spools(3) are in a partial braking position, causing ports(P1,
P2) and ports(T1, T2) to close and holding the pressure in ports(BR1, BR2).
(4) Full braking position
When pedal is fully actuated, end position of the brakes is reached and a connection established
between accumulator ports(P1, P2) and brake cylinder ports(BR1, BR2). Returns(T1, T2) are
closed at this point.
When the braking process is ended, a connection is once again established between brake
cylinder ports(BR1, BR2) and return ports(T1, T2), closing accumulator ports(P1, P2).
The arrangement of spools in the valve ensures that even if one braking circuit fails the other
remains fully operational. This is achieved by means of the mechanical actuation of both spools
and requires slightly more pedal travel.
(5) Limiting the braking pressure
Pedal restriction hexagon bolt(23) on base plate below pedal is used to limit the braking pressure.
(6) Failure of a circuit
In the event of the lower circuit failing, the upper circuit will remain operational. Spring assembly
(8) will mechanically actuate spool. In the event of the upper circuit failing, the lower circuit will
remain operational since the lower spool is mechanically actuated by spring assembly(21) and
spool.
(7) Installation requirements
Return lines(T1, T2) must be connected directly to the tank.
The connecting lines must be installed is such a way as to permit proper bleeding.
4-14
(8) Maintenance of the brake valve
No special maintenance beyond the legal requirements is necessary.
When using high-pressure cleaners on the machine, please make sure that the water jet is not
aimed directly at the brake valve(To prevent damaging the bellows).
For safety reasons the whole of the brake valve must be replaced if parts other than those
listed above are damaged.
(9) Repair work
When working on the braking system, always make sure that there is absolutely no
pressure in the system. Even when the engine is switched off there will be some residual
pressure in the system.
ö When doing repair work, make sure your environment is very clean.
Immediately close all open ports on the components and on pipes using plugs.
(10) Replacing the pedal cover
Pedal rubber(18) is simply pulled of by hand. The new pedal cover is pushed over pedal assy(17)
and tightened manually. Fasten the bellows with the strap retainers.
(11) Replacing the complete actuating mechanism
Carefully clamp the unit vertically in a fixture. The actuating mechanism can be removed by
taking out the four bolts. Make sure that spring assembly(8) does not fall out. When installing the
new actuating mechanism, make sure that spring assembly(8) is fitted in the right order. Tighten
the four bolts(25).
(12) Replacing the bellows
To change bellows(19) it is advisable to remove pedal(17). For this purpose, loosen stop ring (22)
and knock out pin(20) using a mandrill. When knocking out the bolt, make sure that the mandrill
is applied to the side of the bolt without a knurl. Remove pedal(17) and bellows(19).
Now fit the new bellows and proceed in reverse order as described above. The upper portion of
bellows is fastened to piston, its lower portion to pedal plate(16) secure the bellows using clamps.
4-15
5. CUT-OFF VALVE
1) STRUCTURE
3
4 C B
2
D D
5
P1
T
T1
PS
P PS1 A A
C B
SECTION A - A SECTION B - B
1 2
A1 A2
1 PS
P1
A3
A3 T1
A1
PS1
A2
B
P T
SECTION C - C SECTION D - D HYDRAULIC CIRCUIT
7407ABS11
1 Cut-off valve 4 Coil

2 Relief valve 5 Solenoid valve
3 Check valve
2) OPERATION
When the pump works, the oil under the pressure flows into P port.
The oil in P port is stored in the accumulator on A1 or A2 port.
As the pressure on P line rises to 150bar, the cut off valve(1) starts cut-offing and the oil in the P
port is unloaded. The pressure on P line goes down 120bar by the minute leakage from valve and
other factors.
At this pressure, the cut-off valve starts cut-ining.
This process is repeated in the regular period of 30~40 seconds.
4-16
6. BRAKE ACCUMULATOR
1) STRUCTURE
81L1-0004 31EC-02190
Item
(Item15) (Item16)
Diameter 121mm 136mm
Mounting height 146mm 160mm
Nominal volume 0.75˶ 1.0˶
Priming pressure 50kgf/cm2 50kgf/cm2
Operating medium Oil Oil
B
Operating pressure Max 210kgf/cm 2
Max 200kgf/cm2
Thread M18Ý1.5 M18Ý1.5
A
C Priming gas Nitrogen Nitrogen
A Fluid portion C Diaphragm

D B Gas portion D Valve disk
(770-3ATM) 4-22
2) OPERATION
(1) Purpose
Fluids are practically incompressible and are thus incapable of accumulating pressure energy. In
hydropneumatic accumulators, the compressibility of a gas is utilized to accumulate fluid. The
compressible medium used in the accumulators is nitrogen.
In braking systems, the purpose of the accumulators is to store the energy supplied by the
hydraulic pump. They are also used as an energy reserve when the pump is not working, as a
compensator for any losses through leakage, and as oscillation dampers.
(2) Operation
The accumulator consists of a fluid portion (A) and a gas portion (B) with a diaphragm (C) as a
gas-tight dividing element. The fluid portion (A) is connected to the hydraulic circuit, causing the
diaphragm accumulator to be filled and the gas volume to be compressed as the pressure rises.
When the pressure falls, the compressed gas volume will expand, thus displacing the
accumulated pressure fluid into the circuit.
The diaphragm bottom contains a valve disk (D) which, if the diaphragm accumulator is
completely empty, closes the hydraulic outlet, thus preventing damage to the diaphragm.
The accumulators can be fitted in the hydraulic circuit, directly on a component or in blocks on
suitable consoles.
They should be fitted in as cool a location as possible.
Installation can be in any position.
4-17
(4) Maintenance of the accumulator
The accumulator should be checked annually. It should be replaced if the initial gas pressure has
fallen by more than 30%(Please refer to Performance testing and checking of the accumulator).
(5) Disposal of the accumulator
Before the accumulator is scrapped, its gas filling pressure must be reduced. For this purpose,
drill a hole through gas chamber(B) using a drill approx. 3mm in diameter. The gas chamber is
located on the side opposite the threaded port above the welding seam around the center of the
accumulator.
ö 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
Safety valve
A
(770-3ATM) 4-23
4-18
(7) Repair work
pressure in the system. Even when the engine in switched off there will be some residual
For safety reasons the accumulators need to be replaced as a whole if damaged.
4-19
7. PRESSURE SWITCHES
1) STRUCTURE
- Normally closed
300mm
H1
- Normally open
H2
H1 G
H2
G
BRAKE STOP(HL730-7A / TM-7A)

CHARGING(HL730-7A)
7307ABS19
ÂTechnical data
H1 H2 Adjusting range Adjusting pressure Voltage
Item Type Medium G
mm mm kgf/cm2 kgf/cm2 V
Parking NC Oil M12Ý1.5 55 9 10 ~ 20 13 Ü 1 Max 42

PF 1/4" 49 11 50 ~ 150 95 Ü 5 Max 48
Charging NC Oil ø ø ø ø ø ø
M12Ý1.5 51 9 20 ~ 50 45 Ü 5 Max 42
Brake stop NO Oil PF 1/4" 77 11 1 ~ 10 5Ü1 Max 42
Clutch cut-off NO Oil PF 1/4" 55 9 20 ~ 50 24 Ü 2 Max 42
NC : Normally closed NO : Normally open ø HL730TM-7A
4-20
2) OPERATION
(1) Purpose
The pressure switches are used to visually or audibly warn the driver of the pressure within the
system.
(2) Make contact / circuit closer
The pressure switch can be fitted in the braking system or directly on one of its components.
The system pressure acts on an absorption area within the switch, making an electrical contact as
the pressure on that area is increased. The resulting current is used to activate a warning facility,
for instance.
(3) Break contact / circuit breaker
The pressure switch can be fitted in the braking system or directly on one of its components.
The system pressure acts on a absorption area within the switch, breaking an electrical contact
as the pressure on that area is increased. The current is now broken, e.g. to deactivate a
warning facility.
No special measures need to be taken.
(5) Maintenance of the pressure switch
When using high-pressure cleaners on the vehicle, please make sure that the water jet is not
directed at the pressure switch(Corrosion of contacts).
(6) Repair work
pressure in the system. Even when the engine is switched off there will be some residual
ö For safety reasons the pressure switch needs to be replaced as a whole if damaged.
4-21
(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
(770-3ATM) 4-25
4-22
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:
4-23
öHydraulic oil must be at operating temperature for these checks(Refer to page 6-52).
Parking brake capacity Start engine. OK

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

transmission lockout Check completed.
Place transmission in 1st forward.
check
NOT OK
Engine running. Slowly increase engine speed to
Go to transmission control
high idle.
circuit in section 3.
LOOK : Machine must not move.
4-24
Service brake pump flow Stop engine. OK

Operate brake pedal approximately 20
ö Hydraulic oil must be at NOT OK
times.
operating temperature Check for brake circuit
Start engine and run at low idle.
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 brake
time engine starts. valve and repeat pump
flow check.
NOTE : Indicator will not come on
approximately 1 second after If time does not decrease,
starting engine. check for worn brake
pump. Go to brake pump
flow test.
Turn clutch cut-off switch OFF. OK

Service brake capacity Check completed.
Apply service brakes, release
check
park brake and put transmission NOT OK
Engine running. Check brake pressure.
in 2nd forward.
Increase engine speed to high IF OK
idle. Inspect brake disk, see
group 3.
LOOK : Machine may not move or
move at a very slow speed.
Repeat check three times to
ensure accurate results.
4-25
Brake accumulator Start and run engine for 30 OK
precharge check seconds. Check completed.
ö The axles and
Stop engine and turn start switch NOT OK
hydraulic oil must be at
to ON and wait 5 seconds. Make sure brake pedal is
operating temperature
not binding and keeping
for this check. NOTE : Engine oil pressure lamp
brakes partially engaged.
will be on due to no engine oil
pressure. Bleed brakes in group 3.
Count the number of times the Check brake system
brake pedal can be fully depressed pressure.
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 cluster while applying
brake pedal with maximum force.
LOOK/LISTEN : Brake pressure
indicator must not come ON.
Brake system leakage ON Start engine and wait 30 seconds. OK

Stop engine.
NOT OK
Wait 2 minutes.
If brake leakage is
Turn start switch to ON and wait 5 indicated with brakes
seconds. released, check leakage at
accumulator inlet check
LOOK : Brake oil pressure warning
valve and brake valve. If
lamp must not come on within 2
brake leakage is indicated
minutes after stopping engine.
with brakes applied, check
for leakage at brake valve
and brake pistons.
Check individual
component leakage.
4-26
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(2 in) from ground.
Adjust park brake, go to
Release parking and service group 3.
brakes.
NOT OK
LOOK : Machine must move or
Check floor mat
coast.
interference to pedal or
NOTE : If machine does not debris build-up.
move, check brake pedals to be
sure they fully release when feet IF OK
are removed from pedals. Check for brake pressure
when brake is released.
Drive machine at high speed for
about 5 minutes.
Go to brake pressure test.
Brake drag is indicated if brake
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 switch.
Run engine at half speed in 1st
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.
4-27
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.
öIIt is normal for the oil level to be slightly
above the check plug.
Aggressive brakes Internal restriction in circuit Remove lines and components.

Clutch cut-off switch out of Adjust switch.
adjustment
Brake valve malfunction Disassemble and inspect.
Low oil level Check oil level.
Brakes drag Brake pedal not returning Inspect floor mat and pedal.
properly
Debris holding valve partially Do brake valve pressure test.
open in brake valve
Warped brake disk Inspect brake disk.
Stuck brake piston Repair.
Brakes lock up Brake valve malfunction Clean or replace brake valve.
4-28
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 brake Do brake system leakage test.
brake pedal is held with piston
engine stopped
Brake pressure warning Malfunction in brake low Replace switch.

light will not go out or pressure warning switch
stays on excessively long
Brake accumulator pressure too Recharge accumulator.
after start-up
low
Low brake pump standby Do brake pump standby pressure test.
pressure setting.
Leakage in pressure reducing Do pressure reducing valve manifold leakage test.
manifold block
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
4-29
2) PARKING BRAKE MALFUNCTIONS
Brake will not hold Pads not adjusted correctly Adjust parking brake.
Malfunctioning parking brake Inspect and replace.
solenoid
Worn brake disk and / or brake Disassemble, inspect, repair.
pads
Brake piston hangs up in bore Remove and inspect. Repair.
Brake disk overheats Pads out of adjustment Adjust parking brake.

Brake not released Release parking brake.
Disassemble, inspect brake.
Repair if necessary.
Inspect for loosen or broken lines between brake
pressure switch and indicator on dash.
Parking brake indicator Faulty wiring or switch Inspect for loose or broken lines between brake
in monitor does not pressure switch and indicator on dash.
come on when brake Inspect for a faulty indicator on dash. Replace if
applied necessary.
Brake will not apply Pads out of adjustment Adjust parking brake.
Malfunctioning wiring, switch, or Check electric circuit.
solenoid
Restriction between brake valve Remove hose and inspect. Replace.
and brake
4-30
1. PARKING BRAKE PERFORMANCE

1) MEASUREMENT CONDITION
(1) Tire inflation pressure:Specified pressure
(2) Road surface : Flat, dry, paved surface
with 1/5(11ä
20') gradient.
(3) Machine : In operating condition 20%

gradient
11 20'
Item Standard valve
Parking brake Keep machine on 20%
performance (11ä
20') gradient 7307ABS31
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 11 20' gradient
and the machine must be kept stopped.
ö The measurement must be made with the
machine facing either up or down the
slope. 7307ABS32
2. EXTERNAL BRAKE INSPECTION

Remove axle housing and inspect for wear of
brake disks.
Replace brake disks if oil grooves of facing
material are no longer visible.
7407BS08
4-31
3. HYDRAULIC 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 B
applying pressure.
Search for leaks with a piece of cardboard.
Protect hands and body from high
pressure fluids.
ö 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
system oil, one to operate brake valve and
other to open and close bleed screws. A
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.
ö 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 Safety lock bar
axle assembly until hydraulic oil starts to
flow. Close bleed screw when oil is free of
air. Release brake pedal.
6) Repeat steps 1-5 for each bleed screw.
7) Push either brake pedal and hold down.
8) Check hydraulic oil level. 7307ABS09
4-32
1. BRAKE PUMP
1) STRUCTURE
Fan pump
0
17
16
10
12
5
15
21
5
23
15
12
3
11 19
18 4
22
11 4
Brake pump
7407ABS19
3 Rear cover 11 Seal 18 Spring

4 Plate 12 Seal 19 Dowel pin
5 Plate 15 Back up ring 21 Drive gear
8 Screw bolt 16 Flange 22 Driven gear
10 Washer 17 Shaft 23 Body
4-33
2) DISASSEMBLY
Fan pump
0
17
16
10
12
5
15
21
5
23
15
12
3
11 19
18 4
22
11 4
Brake pump
7407ABS19
ö Before disassembling ensure that the unit itself, bench and tools are thoroughly clean.
(1) Lightly mark the rear cover(3), body(23) and flange(16) to ensure reassembly in the correct
position.
(2) Remove the bolts(8) and separate the brake pump unit from the fan pump using a soft faced
hammer.
(3) Remove splined shaft(17).
(4) Remove the flange(16) from the body(23), free from flange using a soft faced hammer.
(5) Remove the back up ring(15), the seal element(11) and the body seal(12).
(6) Remove the rear cover(3) from the body(23).
(7) Remove the back up ring(15), the seal element(11) and the body seal(12).
ö Before removing the internal components each plate(4,5) 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 gear(21) and pull it squarely out of the
body(23) bringing the plate(4,5) with it.
(9) Remove the driven gear(22) and the remaining plate(4,5).
4-34
3) 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
Η Inspect the body bore cut-in where both gears wipe into the body.
Θ The 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").
Ι The 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.
Κ The 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 seal
recesses.
(3) Plate and cover
Η The inner surfaces should be inspected to ensure that there is no unusual wear or scoring in the
regions where the body seals and back up rings contact, which result in external leakage.
Θ Check 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) Bushes
Η The 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.
Θ The 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
Η The 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.
Θ The gear teeth should then be carefully examined to ensure that there are no signs of bruising or
pitting.
Ι The journal bearing surfaces should be completely free from scoring or bruising. The surface
should appear highly polished and smooth to touch.
Κ Examine 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.
Λ Provided the drive shaft is not damaged from the drive-coupling and the gears have not been
harmed as described above, then the gears can be re-used. If, however, the gears are
damaged they must be replaced as a matched pair.
Μ As a matter of good practice, when pumps have been disassembled, all the seals should be
replaced. It is most important that only the genuine seals are used.
4-35
4) ASSEMBLY
Fan pump
0
17
16
10
12
5
15
21
5
23
15
12
3
11 19
18 4
22
11 4
Brake pump
7407ABS19
ö Ensure that all parts are perfectly clean and lightly lubricate the bushes and gears with hydraulic
oil(Ensure body seal 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 plate(4,5) into the undowelled end of the body(23) from where they were removed.
(2) Place the rear cover(3) against the body(23) and then stand the assembly on the cover so that the
hollow dowels are uppermost, i.e. the plate should be at the bottom with the plates against the
cover.
(3) Fit the drive shaft(21) and driven gear(22) back into their original positions in the body(23).
(4) Refit the plate bushing(4,5) into their original bores.
(5) Fit the new body seal(12).
(6) Fit the new seal element(11) and back up ring(15) to the plate.
(7) Carefully refit the flange(16) to the body(23). If the flange(16) is not fitted squarely the seal(11)
may become misplaced and trapped, resulting in internal damage if the unit is run in this
condition.
4-36
ASSEMBLY
Fan pump
0
17
16
10
12
5
15
21
5
23
15
12
3
11 19
18 4
22
11 4
Brake pump
7407ABS19
(8) Fit shaft(17) to the flange(16).

(9) Holding the whole unit together carefully turn it over, making sure it is supported on the spacer
flange(16) not the shaft.
(10) Slide off the rear over and fit seals as in(5) and (6) above.
(11) Fit the rear cover(3), taking care not to dislodge the seal(11) and bolt(8) the unit together.
ÂTightening torque : 7.1kgfÂm(51lbfÂft)
ö 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.
4-37
5) RUNNING-IN
Pressure gauge
Test unit Variable

Microbic restrictor
filter
Flow
meter
Relief valve
Strainer
Tank
(730TM-3C) 4-48
(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 80ä C. If the temperature exceeds the system or unit specification
the test must be delayed and operated off-load until acceptable temperatures are obtained.
4-38

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 :
ÂSteering pump(1st pump)
ÂSteering unit
ÂOverload valve block
ÂPriority valve
ÂSteering cylinders
The steering pump, the first pump of main pump, draws hydraulic oil from the hydraulic tank.
Outlet flow from the pump flows to the priority valve. The priority valve preferentially supplies flow, on
demand, to the steering 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
2. HYDRAULIC CIRCUIT
LH RH
5
L
P 21MPa
LS
Brake system
CF EF MCV
6 A 1st pump
Return line B 2nd pump
LS
P
RCV lever
Fan drive motor
2 B A 1
32
M1
24 Return
A
P1 line
31 M2
30 25
P2
M 29 26 27
Parking brake solenoid
7307ASE01
1 Main pump 24 Air breather 30 Check valve(option)

2 Fan & brake pump 25 Hydraulic tank 31 Pressure switch(option)
5 Steering unit 26 Return filter 32 Pressure switch(option)
6 Priority valve 27 By pass valve
9 Steering cylinder 29 Motor pump(option)
5-2
1) NEUTRAL
LH RH
5
L
P 21MPa
LS
MCV
CF EF
6
D LS
P
RCV lever
Brake system Fan drive motor
2 1
Return line
24 Return
line
25
26 27
7307ASE02
The steering wheel is not being operated so control spool(G) does not move.
The oil from the steering pump enters port P of the priority valve and the inlet pressure oil moves the
spool(D) to the right.
Oil flow into LS port to the hydraulic tank(25) through orifice and return filter.
So, the pump flow is routed to the loader system(Main control valve) through the EF port.
5-3
2) LEFT TURN
LH RH
5
L
P 21MPa
LS
MCV
CF EF
6
D LS
P
RCV lever
2 1
Return line
24 Return
line
25
26 27
7307ASE03
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.
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(6) and flows into the gerotor(H).
Oil flow from the gerotor flows back into the spool(G) where it is directed out the left work port(L) to
the respective chamber of the steering cylinders(9).
Oil returned from left and right cylinder returns to hydraulic tank through the spool of the steering unit.
When the above operation is completed, the machine turns to the left.
5-4
3) RIGHT TURN
LH RH
5
L
E
R
P 21MPa
LS
MCV
CF EF
6
D LS
P
RCV lever
2 1
Return line
24 Return
line
25
26 27
7307ASE04
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.
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(6) and flows into the gerotor(H).
Oil flow from the gerotor flows back into the spool(G) where it is directed out the right workport to the
respective chamber of the steering cylinders(9).
Oil returned from left and right cylinder returns to hydraulic tank through the spool of the steering unit.
When the above operation is completed, the machine turns to the right.
5-5
3. STEERING UNIT
1) STRUCTURE
21
1
VALVE BLOCK
2 5
38 31
37 6
36
35 33
34 7
8
39 2
34
35 10
39 36
38 9
37 11
12
13
14
13
15
19
13
16
17
18
7307ASE05
1 Dust seal ring 11 O-ring 21 Complete relief valve without seat

2 Housing, spool, sleeve 12 Intermediate plate 31 Set of o-rings
3 Ball 13 O-ring 33 Rolled pin
4 Thread bushing 14 Distributor plate 34 Screw
5 Roto glyd ring 15 Gearwheel set 35 Shock valve
6 Bearing assembly 16 End cover 36 Spring
7 Ring 17 Washer 37 O-ring
8 Cross pin 18 Screw with pin 38 Plug
9 Set of spring 19 Screw 39 Housing, check valve
10 Cardan shaft
5-6
2) OPERATION
9 10
2 39
A A
14
15
16
SECTION A - A
7407SE06
The steering unit consists of a rotary valve and a rotary meter.

Via a steering column the steering unit is connected to the steering wheel of the machine.
When the steering wheel is turned, oil is directed from the steering system pump via the rotary valve
(spool and sleeve) and rotary meter(gear wheel set) to the cylinder ports L or R, depending on the
direction of turn. The rotary meter meters the oil flow to the steering cylinder in proportion to the angular
rotation of the steering wheel.
Spool is connected directly to the drive shaft(10) of steering wheel. It is connected to sleeve by cross
pin(8) (not in contact with the spool when the steering wheel is at neutral) and neutral position spring(9).
Cardan shaft(10) is meshed at the top with cross pin(8) and forms one unit with sleeve.
At the same time, it is meshed with gear rim of the gerotor set by spline.
There are four ports in valve body. They are connected to the pump circuit, tank circuit, and the head,
and left and right steering cylinder. In addition, the pump port and tank port are connected inside the
body by the check valve. Therefore, if there is any failure in the pump of engine, oil can be sucked in
directly from the tank through the check valve.
5-7
4. PRIORITY VALVE
1) STRUCTURE
1 2 3 4 9 6 5
LS
EF CF
73035PR06
1 Plug 4 Spool 6 Plug

2 Seal ring 5 Spring 9 Housing
3 Orifice
5-8
2) OPERATION
(1) Neutral
4 P A 5 A
CF EF
LS
LS
EF CF LOADER ACTUATED(D)
73035PR07
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.
5-9
(2) Midturn
4 P A 5 A
CF EF
LS
LS
FULL STEER RATE(D)

EF CF
73035PR09
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.
5-10
(3) Full turn
4 P 5
CF EF
LS
LS
EF CF
73035PR08
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.
5-11
5. STEERING CYLINDER
1) STRUCTURE
22,23 8,9 10 5,6 7 11,12 4 3 1 2 13 14 15 16 17 24 25
18 19,20,21
7307SE07
1 Tube assy 10 O-ring 18 Pipe assy

2 Rod assy 11 O-ring 19 U-bolt
3 Gland 12 Back up ring 20 Hexagon nut
4 Du bushing 13 Piston 21 Spring washer
5 Rod seal 14 O-ring 22 Bushing
6 Back up ring 15 Piston seal 23 Dust seal
7 Step seal 16 Wear ring 24 Spherical bearing
8 Dust wiper 17 Nylon nut 25 Retaining ring
9 Snap 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
öHydraulic oil must be at operating temperature for these checks(Refer to page 6-52).
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 Left Right Turn steering wheel rapidly until OK
check frames are against stops. Check completed.
Heat hydraulic oil to
operating temperature. Hold approximately 2kgf on NOT OK
Run engine at high idle. steering wheel. Do steering system
leakage test in group 3
Count steering wheel revolutions to isolate the leakage.
for 1 minute.
Repeat test in opposite direction.
LOOK : Steering wheel should
rotate less than 5rpm.
NOTE : Use good judgment;
Excessive steering wheel rpm
does not mean steering will be
affected.
Priority valve low press- Park machine on a hard surface. OK
ure check Check completed.
Hold brake pedal down.
NOT OK
Run engine at high idle. Do priority valve pressure
Steer machine to the right and left test.
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.
hold, observe engine rpm.
LOOK : Steering stall engine rpm
must be higher than hydraulic stall
rpm.
5-15
2. TROUBLESHOOTING
öDiagnose malfunction charts are arranged from most probable and simplest to verify, to least
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 steering unit stuck open. Do 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.
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 with Broken steering column or splined of Remove and inspect.
no resistance and causes steering unit.
no frame movement
Lack of oil in steering unit. Start engine and check steering
operation.
Leakage in steering system. Do steering system leakage test in group
3.
Erratic steering Air in oil. Check for foamy oil.
Low oil level. Add recommended oil.
Sticking priority valve spool. Remove and inspect spool.
Loose cylinder piston. Remove rod to inspect piston.
Damaged steering 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.
ø 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.
system or hoses jump
Neutral position of Steering column and steering unit out of Align the steering column with steering
steering wheel cannot be line. unit.
obtained, i.e. there is a
Too little or no play between steering Adjust the play and, if necessary, shorten
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.
ø Thermal shock is caused by a large temperature differential(Approx 30Á C, 50Á
F) between the steering unit
and hydraulic oil. If the steering is not operated for a long period of time and the orifice in the bottom of
the priority valve spool is plugged, the steering unit may bind up when the steering is operated if the
hydraulic oil is hot enough.
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 gives
Mechanical connections or wheel Replace worn parts.
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 turn pump defective or number of revolutions revolutions.
quickly too low.
Relief valve setting too low. Adjust valve to correct setting.
Relief valve sticking owing to dirt. Clean the valve.
Spool in priority valve sticking owing to Clean the valve, check that spool moves
dirt. easily without spring.
Too weak spring in priority valve. Replace spring by a stronger.
"Kick back" in steering Fault in the system. Contact authorized man or shop.
wheel from system
Kicks from wheels
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 cylinders Connect lines to correct ports.
wheel activates the have been switched around.
steered wheels opposite
Hard point when starting Spring force in priority valve too weak. Replace spring by a stronger.
to turn the steering wheel
Air in LS and / or PP line. Bleed LS and PP line.
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
ö Service equipment and tool

ÂPortable filter caddy
ÂTwo 4000mm Ý 1" 100R1 Hoses
ÂQuick disconnect fittings
ÂDischarge wand
ÂConnectors
ö Steering system use oil from hydraulic oil
tank. Flush all lines in the steering
system.
ö Disassemble and clean major compon-
ents for steering system.
Steering components may fail if steering
system is not cleaned after hydraulic oil
tank contamination.
1) If hydraulic system is contaminated due to a

major component failure, remove and
disassemble steering cylinders to clean
debris from cylinders.
2) Install a new return filter element. Inspect
filter before installing new element.
ö 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.
ö Hydraulic tank capacity : 90˶ ˶(24U.S. gal)
Leave filter caddy operating for the next
steps.
6) Start the engine and run it at high idle.
ö 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.
ö 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 TACHOMET-

ER INSTALLATION
Â 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. A
C : Red clip(+). Connect to transducer.
D : Tachometer readout. Install cable. 73035SV01
2) DIGITAL THERMOMETER INSTALLATION

Â 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
73035SV02
3) DISPLAY MONITOR TACHOMETER

The display monitor tachometer is accurate
enough for test work.
mph
7807A3CD03
5-22
3. STEERING SYSTEM RESTRICTION TEST
Â SPECIFICATION
Oil temperature 45Ü5Á C(113Ü9Á F)
Engine speed High idle
Maximum pressure 20Mpa(20bar, 285psi)
at steering unit
Â GAUGE AND TOOL
Gauge 0~7.0Mpa(0~70bar, 0~1000psi) 1EA
ÂThis test will check for restrictions in the

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

ure reader installation procedure in this P
group.)
2) Heat hydraulic oil to specifications.(See A
hydraulic oil warm up procedure at page
6-52.)
3) Connect fitting(A) and gauge to steering
unit.
Do not operate steering or loader
functions or test gauge may be
damaged.
4) Run engine at specification and read
pressure gauges.
If pressure is more than specification at the
steering 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 7303ASE16
port.
5-23
4. STEERING UNIT LEAKAGE TEST
Â SPECIFICATION
Oil temperature 45Ü5ÁC (113Ü9ÁF )
Maximum leakage 10˶/min Cap fitting
Â GAUGE AND TOOL

Temperature reader
Measuring container(Approx 20˶) Steering unit
Stop watch
1) Install frame locking bar to prevent machine

from turning.
2) Install temperature reader.
(See temperature reader installation
procedure in this group.)
3) Heat hydraulic oil to specifications.(See
6-52.)
4) Disconnect return hose from fitting.
Install cap fitting.
5) Run engine at specifications. Rotate
steering wheel against locking bar using
approximately 1.2kgÂm of force.
Measure oil flow from return hose for 1 Safety lock bar
minute.
6) Leakage is greater than specifications,
repair or replace steering unit. 7307ASE09
5-24
5. STEERING UNIT PRESSURE TEST
Â SPECIFICATION
Relief pressure 20.5~21.5Mpa
(205~215bar, 3200~3300psi) LS
Â GAUGE AND TOOL CF
Gauge 0~35.0Mpa(0~350bar, 0~5000psi)

Temperature reader
P
1) Connect test fitting and gauge to P port on
steering unit.
(See temperature installation procedure in
this group.)
3) Install frame locking bar.
6-52.)
5) Run engine at specifications and turn
steering wheel rapidly hold approximately
22N(5lb force) pressure on wheel with
frames locked.
ö If steering wheel is turned slowly, it will
Safety lock bar
continue to with the frames locked.
This will give an incorrect pressure
reading.
Relief valve
If steering wheel continues to turn rapidly
with the frames locked, steering system
leakage is indicated.
A
6) Read pressure gauge. This is the steering B
unit relief pressure.
7) If pressure in not to specification, remove

the plug(A) from steering unit. Turn
adjusting screw(B) in relief cartridge using a
hex head wrench(8mm) to adjust pressure.
If pressure cannot be adjusted to
specification, disassemble and inspect 7307ASE10
steering unit.
5-25
6. PRIORITY VALVE "LS" PORT FLOW TEST
Â SPECIFICATION
A
Engine speed Low idle LS
LS port flow(Approx) 0.5˶/min(0.13gpm)

Â GAUGE AND TOOL
B
Temperature reader
Measuring container
Stop watch
Priority valve LS port flow test will check for a
plugged or missing orifice in the priority valve
spool. A plugged orifice will block warm up
flow to the steering unit which can cause
thermal shock.(See for an explanation of
thermal shock, page 5-18).
A missing orifice can cause the pump to be

loaded to high pressure at all times causing
overheating.
1) Install temperature reader.(See

temperature reader installation procedure in
this group.)
6-52.)
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. 7303ASE09
5-26
1. PRIORITY VALVE
1) STRUCTURE
1
2
3
7 6
73035PR01
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
ÂOpen-end spanner 22mm.
ÂNylon pin.
ÂHexagon socket spanner 8mm.
ÂTorque wrench.
ÂSocket spanner 22mm.
ÂHexagon socket spanner insert 8mm.
73035PR02A
3) DISASSEMBLY
ö 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
73035PR02B
(2) Loosen the LS plug using the 22mm open-

end spanner.
LS
73035PR02C
5-28
(3) Pull out the plug with seal ring and spring.
LS
73035PR02D
(4) Press out the spool using the nylon pin.
PP
LS
73035PR03A
(5) Disassembled priority valve.
73035PR03B
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
Di
7 2.0 6.5 55
d
L
73035PR03C
(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
73035PR04A
(2) Put in the PP plug.

Remember seal ring.
PP
LS
73035PR04B
5-30
(3) Guide the spring and LS plug into the
bore.
Remember seal ring.
LS
73035PR02D
(4) Tighten the LS plug with torque wrench

using a 22 socket spanner insert.
ÂTighten torque : 5.1Ü1kgfÂm
(36.9Ü7.2lbfÂft)
LS
73035PR04C
(5) Tighten the PP plug with a torque wrench

using a 8mm hexagon socket spanner
insert.
ÂTighten torque : 5.1Ü1kgfÂm
(36.9Ü7.2lbfÂft) PP
73035PR05A
(6) The priority valve is now assembled.
PP
LS
73035PR05B
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
21
VALVE BLOCK
2 5
38 31
37 6
36
35 33
34 7
8
39 2
34
35 10
39 36
38 9
37 11
12
13
14
13
15
19
13
16
17
18
7407SE11
1 Dust seal ring 11 O-ring 21 Complete relief valve without seat

2 Housing, spool, sleeve 12 Intermediate plate 31 Set of o-rings
3 Ball 13 O-ring 33 Rolled pin
4 Thread bushing 14 Distributor plate 34 Screw
5 Roto glyd ring 15 Gearwheel set 35 Shock valve
6 Bearing assembly 16 End cover 36 Spring
7 Ring 17 Washer 37 O-ring
8 Cross pin 18 Screw with pin 38 Plug
9 Set of spring 19 Screw 39 Housing, check valve
10 Cardan shaft
5-33
2) TOOLS
(1) Holding tool.
7405S STVLV38(1)
(2) Assembly tool for O-ring and kin-ring.
7405S STVLV38(2)
(3) Assembly tool for dust seal.
7405S STVLV38(3)
(4) Torque wrench 0-7.1kgfÂm(0-51.6lbÂft).

13mm socket spanner
12mm screwdriver
6mm screwdriver
2mm screwdriver
Plastic hammer
Ratchet spanner
7405S STVLV38(4)
5-34
3) 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(7-off-one rolled pin).
7405S STVLV39(1)
(2) Remove the end cover, sideways.
7405S STVLV39(2)
(3) Lift the gearwheel set with spacer

bushing(and spacer if fitted) off the unit.
Take out the two O-rings.
7405S STVLV39(3)
(4) Remove spacer bushing and spacer(if

fitted) from the gearwheel.
7405S STVLV39(4)
5-35
(5) Remove cardan shaft.
7405S STVLV40(1)
(6) Remove distributor plate.
7405S STVLV40(2)
(7) Remove O-ring.
7405S STVLV40(3)
(8) Lift off intermediate plate.
7405S STVLV40(4)
5-36
(9) Remove O-ring.
7405S STVLV41(1)
(10) Screw out the threaded bushing.
7405S STVLV41(2)
(11) Remove cross pin.
7405S STVLV41(3)
(12) Shake out the ball(͚8.5mm).
7405S STVLV41(4)
5-37
(13) Pull sleeve and spool out of the housing.
7405S STVLV42(1)
(14) 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.
7405S STVLV42(2)
(15) Carefully pull the spool out of the sleeve.
7405S STVLV42(3)
(16) Press the neutral position springs out of

their slots in the spool.
7405S STVLV42(4)
5-38
(17) Remove dust seal and O-ring.
7405S STVLV43(1)
(18) The steering unit is now completely

disassembled.
7405S STVLV43(2)
Cleaning
Clamp all parts carefully in Shellsol K or the
like.
Inspection an replacement
Replace all seals and washer. Check all
parts carefully and make any replacements
necessary.
Lubrication
Before assembly, lubricate all parts with
hydraulic oil.
5-39
4) ASSEMBLY
(1) Assemble spool and sleeve.
ö The sleeve and spool are correctly B A
assembled when
Η The slots-in sleeve and spool-for the
neutral position springs are opposite
each other and
Θ One of the 3 T-shaped grooves(A) in the
spool is opposite one of the sets(B) of
7405S STVLV44(1)
small holes in the sleeve.
(2) Place the two flat neutral position springs

in the slot.
7405S STVLV44(2)
(3) Place the curved springs between the flat

ones and press them into place.
7405S STVLV44(3)
(4) Line up the spring set.
7405S STVLV44(4)
5-40
(5) Guide the spool into the sleeve.
7405S STVLV45(1)
(6) Press the springs together and push the

neutral position springs into place in the
sleeve.
7405S STVLV45(2)
(7) Line up the springs and center them.
7405S STVLV45(3)
(8) Guide the ring down over the sleeve.

ö The ring should be able to rotate-free of
the springs.
7405S STVLV45(4)
5-41
(9) Fit the cross pin into the spool/sleeve.
7405S STVLV46(1)
(10) Fit bearing races and needle bearing as

shown on below drawing.
7405S STVLV46(2)
1 Outer bearing race

1
2 Needle bearing
2
3 Inner bearing race
3
4 Spool
5 Sleeve *
Inside chamfer on inner bearing race 4
must face inner spool.
5
7405S STVLV46(3)
(11) Grease O-ring and kin-ring with hydraulic

oil and place them on the tool. See next
page.
7405S STVLV46(4)
5-42
7405S STVLV47(1)
(12) Put the steering unit in the holding tool

keeping the bore vertical. Guide the outer
part of the assembly tool into the bore.
Guide the inner part of the tool right to the
bottom.
7405S STVLV47(2)
(13) Press and turn the O-ring into position in

the housing. Draw the inner and outer
parts of the assembly tool out of the
steering unit bore, leaving the guide in the
bore.
7405S STVLV47(3)
(14) Take the steering unit out of the holding

tool and place it horizontally. With a light
turning movement, guide the spool and
sleeve into the bore.
7405S STVLV47(4)
5-43
(15) The spool set will push out the assembly
tool guide. The O-ring is now in position.
7405S STVLV48(1)
(16) Put the steering unit back into the holding

tool keeping the bore vertical. Place the
cross pin in the spool/sleeve so that it is
parallel to the port flange.
7405S STVLV48(2)
(17) Put the ball into the hole indicated by the

arrow.
7405S STVLV48(3)
(18) Screw the threaded bushing lightly into the

bore. The top of the bushing must lie just
below the surface of the housing.
7405S STVLV48(4)
5-44
(19) Grease the O-ring with mineral oil
approximate viscosity 500 cSt at 20 ÁC
and place it in the groove.
7405S STVLV49(1)
(20) Place the intermediate plate so that the

channel holes match the holes in the
housing.
7405S STVLV49(2)
(21) Grease the O-ring with mineral oil

and place it in the groove.
7405S STVLV49(3)
(22) Place the distributor plate so that the

channel holes match the holes in the
intermediate plate and the housing.
7405S STVLV49(4)
5-45
(23) Guide the cardan shaft down into the bore
so that the slot is parallel with the
connection flange.
7405S STVLV50(1)
(24) Place the gear wheel(Rotor) so that the

cross pin from item 33 is positioned in
relation to two tooth bases - as the screw
driver indicates.
7405S STVLV50(2)
(25) Grease the two O-rings with mineral oil

and place them in the two grooves in the
gear rim. Fit the gear rim so that the seven
through holes match the holes in the
distributor plate.
ö Turn the gear rim so that the smaller
diameter of the holes face the distributor
plate.
7405S STVLV50(3)
(26) Orientate the holes with a single screw.
7405S STVLV50(4)
5-46
(27) Place the end cover in position.
7405S STVLV51(3)
(28) Place the washers over the holes and the

rolled pin in the hole shown.
7405S STVLV51(4)
(29) Fit the other six screws. Cross - tighten all

the screws and the rolled pin with a torque
of 3Ü0.6kgfÂm(22Ü4.4lbÂft). Steering unit
can now be function tested.
7405S STVLV52(1)
(30) Turn the steering unit 180Áand place the

dust seal ring in the housing.
7405S STVLV52(2)
5-47
(31) Fit the dust seal ring in the housing using
special tool and a plastic hammer.
7405S STVLV52(3)
(32) Press the plastic plugs into the connection

ports. Do not use a hammer.
7405S STVLV52(4)
5-48
3. VALVE BLOCK
1) STRUCTURE
31
33
38
37
36
35
39
34
35
39 36
37
38
P,T,L,R port PF 1/2

Shock valves 270-290 bar
7407SE12
31 Set of springs 36 Spring

33 Rolled pin 37 O-ring
34 Screw 38 Plug
35 Shock valve 39 Housing and check valve
5-49
2) TOOLS
(1) Hexagon socket spanner, 8mm.
7405S OVLOAD63(1)
(2) Torque wrench, 0~7.1kgfÂm(0~51lbÂft)

with 8mm hexagon socket spanner.
7405S OVLOAD63(2)
(3) Adjustable wrench.
7405S OVLOAD63(3)
5-50
3) DISASSEMBLY
(1) Remove the rolled pin.
7405S OVLOAD64(1)
(2) Remove the plug(38) and O-ring(37).

8
38
7
37
7405S OVLOAD64(2)
(3) Remove the spring(36) and shock

valve(35). 6
36
5
35
7405S OVLOAD64(3)
(4) Remove the O-ring set(31).

1,2
31
7405S OVLOAD64(4)
5-51
(5) Remove the check valve(39).
9
39
7405S OVLOAD65(1)
(6) The overload valve is now disassembled.
7405S OVLOAD65(2)
5-52
4) ASSEMBLY
Cleaning
Clean all parts carefully in Shellsol K or the
like.
Inspection an replacement
Replace all seals and washers. Check all
parts carefully and make any replacements
necessary.
Lubrication
Before assembly, lubricate all parts with
hydraulic oil.
(1) Fit check valve(39).

9
39
7405S OVLOAD66(1)
(2) Fit the shock valve(35) and spring(36).

6
36
5
35
7405S OVLOAD66(2)
(3) Fit the O-ring(37) and screw the plug(38).

8
38
7
37
7405S OVLOAD66(3)
5-53
(4) Fit the rolled pin.
7405S OVLOAD66(4)
(5) The overload valve is now assembled. It

can be checked for leakage separately or
when mounted on a steering unit.
7405S OVLOAD67(1)
(6) Locate the four O-rings between overload

valve and steering unit and fit these
components together.
7405S OVLOAD67(2)
(7) Tighten the hexagon socket screws with a

torque of 6.6+0.5
0 kgfÂm(47.7+3.6
0 lbÂft).
7405S OVLOAD67(3)
5-54
(8) Press the plastic plugs into the connection
ports. The overload valve is now
assembled.
7405S OVLOAD67(4)
5) TROUBLESHOOTING
Steering wheel 1. Over tighten mounting torque. Retighten as specified torque.

is heavy
2. Over load valve seat side is clogged Disassembly, clean, reassembly.
with dirt.
Steering cylinder 1. Overload valve seat side is clogged Disassembly, clean, reassembly.
reaction is bad with dirt.
2. Anti cavitation check valve seat is Disassembly, clean, reassembly.
clogged with dirt.
3. Damage of O-ring for adjusting. Replace.
Abnormal noise 1. Overload valve seat side clogged Disassembly, clean, reassembly.
with dirt.
Leakage 1. Loosen 2 mounting bolt. Retighten as specified torque.

2. Damage of O-ring. Replace.
3. Leakage through plug. Apply seal tape to thread and retighten
as specified torque.
5-55
4. STEERING CYLINDER
1) STRUCTURE
22,23 8,9 10 5,6 7 11,12 4 3 1 2 13 14 15 16 17 24 25
18 19,20,21
7307SE07
1 Tube assy 10 O-ring 18 Pipe assy

2 Rod assy 11 O-ring 19 U-bolt
3 Gland 12 Back up ring 20 Hexagon nut
4 Du bushing 13 Piston 21 Washer spring
5 Rod seal 14 O-ring 22 Bushing
6 Back up ring 15 Piston seal 23 Dust seal
7 Step seal 16 Wear ring 24 Spherical bearing
8 Dust wiper 17 Nylon nut 25 Retaining ring
9 Snap 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
(2) Tightening torque

Torque
Part name Item Size
kgfÂm lbfÂft
Gland 3 M64 Ý 1.5 65 Ü 7 470 Ü 51
Nylon nut 17 M24 Ý 2.0 40 Ü 4 289 Ü 29
Nut(Pipe assy) 18 M22 Ý 1.5 30 Ü 3 217 Ü21.7
Nut 20 M10 Ý 1.5 3.2 Ü 0.3 23.1Ü 2.2
5-57
3) DISASSEMBLY
(1) Remove cylinder head and piston rod
Η Hold the clevis section of the tube in a
vise.
ö 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.
Θ Pull out piston rod(2) about 200mm

7.1in
Because the piston rod is
rather heavy, finish extending it with air m
0m
20
pressure after the oil draining operation.
7405S 5-65(1)
Ι Loosen and remove the gland(3).

ö Cover the extracted piston rod(2) with rag Wrench
to prevent it from being accidentally
damaged during operation.
3
2
7405S 5-65(2)
Κ Draw out gland(3) and piston rod (2)

assembly together from cylinder tube(1).
Lift
ö Since the piston rod assembly is heavy in
this case, lift the tip of the piston rod(2)
with a crane or some means and draw it
out. However, when piston rod(2) has
been drawn out to approximately two
thirds of its length, lift it in its center to Full straight Oil pan
draw it completely. sideways
7405S 5-65(3)
5-58
ö 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.
Λ Place the removed piston rod assembly

on a wooden V-block that is set level.
ö Cover a V-block with soft rag. Piston
Pistonrod assy
assy
Wooden block
7405S 5-66(1)
(2) Remove piston and gland assembly

Η Remove the nylon nut(17). 14 15 16 13 17
Θ Remove piston assembly(13), and O-
ring(14).
7307SE11
Κ Remove the gland(3) assembly from

piston rod(2). Lift with a crane
ö 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
ö Pull it straight with cylinder head
assembly lifted with a crane.
Exercise care so as not to damage the lip
of rod bushing(4) and packing (5,6,7,8,9)
by the threads of piston rod(2). 3 2
7405S 5-66(3)
5-59
(3) Disassemble the piston assembly
Η Remove wear ring(16) and piston seal 15 16
(15).
ö Exercise care in this operation not to
damage the grooves.
7307SE12
(4) Disassemble gland assembly

Η Remove back up ring(12), and O-ring 8,9 10 5,6 7 11,12 4
(11).
Θ Remove O-ring(10).
Ι Remove snap ring(9) and dust wiper(8).
Κ Remove back up ring(6), rod seal(5).
Λ Remove step seal(7).
damage the grooves.
7307SE13
ö Do not remove seal and ring, if does not
damaged.
5-60
4) ASSEMBLY
(1) Assemble gland assembly
ö Check for scratches or rough surfaces if
found smooth with an oil stone.
Η Coat the inner face of gland(3) with
hydraulic oil.
3
7405S 5-68(1)
Θ Coat 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.
Ι Fit snap ring(9) to the stop face.
7405S 5-68(2)
Κ Fit back up ring(6) and rod seal(5) to

corresponding grooves, in that order.
Λ Fit step seal(7).
ö Coat each packing with hydraulic oil Wrong Right
before fitting it.
ö Insert the back up ring until onside of it is
inserted into groove.
7405S 5-68(3)
ö Rod seal(5) has its own fitting direction.

Therefore, confirm it before fitting them. Push bar
ö Fitting rod seal(5) and step seal(7) up
side down may damage its lip. Therefore
check the correct direction that is shown
in fig. 7
5,6
7405S 5-68(4)
5-61
Μ Fit back up ring(12) to gland (3).
ö Put the back up ring in the warm water of 8,9 10 5,6 7 11,12 4
30~50ÁC
Ν Fit O-ring(11) to gland(3).
Ξ Fit O-ring(10) to gland(3).
7307SE13
(2) Assemble piston assembly

ö Check for scratches or rough surfaces.
If found smooth with an oil stone.
Η Coat the outer face of piston(13) with
hydraulic oil.
7405S 5-69(2)
Θ Fit piston seal(15) to piston

ö Put the piston seal in the warm water of
60~100ÁC for more than 5 minutes. 15
ö After assembling the piston seal, press
its outer diameter to fit in.
7405S 5-69(3)
Ι Fit wear ring(16) to piston(13).

Κ Fit O-ring(14) to piston(13). 14 15 16 13
7307SE14
5-62
(3) Install piston and gland assembly
Η Fix the piston rod assembly to the work Gland assembly Piston rod
bench.
Θ Apply hydraulic oil to the outer surface of
piston rod(2), the inner surface of piston
and gland.
Ι Insert gland assembly to piston rod(2).
7405S 5-70(1)
Κ Fit piston assembly to piston rod.

ÂTightening torque : 65Ü7kgfÂm Piston assembly
(470Ü51lbfÂft) Piston rod
7307SE16
Λ Tighten nylon nut(17) to piston rod(2).

ÂTightening torque : 40Ü4kgfÂm 2 17
(289Ü29lbfÂft)
7307SE15
5-63
(4) Overall assemble Fix with a bar
Η Place 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
Θ Insert the piston rod assembly in to the
cylinder tube assembly, while lifting and
moving the piston rod assembly with a Apply liquid packing
7405S 5-71(1)
crane.
ö Be careful not to damage piston seal by
thread of cylinder tube.
Ι Match the bolts holes in the cylinder
head flange to the tapped holes in the Tube
cylinder tube assembly and tighten
socket bolts to a specified torque. Piston rod
ö Refer to the table of tightening torque.
Wrench
Gland
7405S 5-71(2)
5-64
5. CENTER PIVOT PIN
1) CONSTRUCTION
Figure shows the construction of the center pivot pin assembly. This assembly serves to connect
the front frame with the rear frame; two sets of assemblies are provided, one each for the upper and
lower parts.
17,19 2 15 18,22 17,19 6 3 16
REAR FRAME REAR FRAME

5
4
9,10 9,10
FRONT FRAME FRONT FRAME
14
13
REAR FRAME 1 REAR FRAME
7 11,12
8
1 15 20 16
UPPER LOWER
7307SE17
1 Bearing 8 Plate 15 Dust seal

2 Pin 9 Shim(0.1T) 16 Dust seal
3 Pin 10 Shim(0.5T) 17 Hexagon bolt
4 Cover 11 Shim(0.1T) 18 Hardened washer
5 Cover 12 Shim(0.5T) 19 Hardened washer
6 Collar 13 Cover 20 Hexagon bolt
7 Collar 14 Cover 22 Hexagon bolt
5-65
2) DISASSEMBLY
After supporting the front frame and the
rear frame as horizontally as possible using
wood blocks and jacks, disassemble as
follows: In order to facilitate the
disassembly/assembly of the center pivot
pins, remove the drive shaft, hydraulic line
and steering cylinder first.
(1) Maintain the horizontal level of front frame
2 18,22
and rear frame, and then remove hexagon
bolt(22).
(2) Take out upper pin(2) to the upside using
a metal punch. REAR FRAME
FRONT FRAME
REAR FRAME
7307SE18
(3) Maintain the front frame horizontal level, 3

remove hexagon bolts(20) and then
remove the plate(8) and shims(11,12).
(4) Take out lower pin(3) to the upside using a REAR FRAME
metal punch carefully.

(5) Jack up or lifting the front frame slightly, FRONT FRAME
the collar(7) protrudes over the rear frame.

Remove the collar(7). 7
REAR FRAME
(6) Lift the frame by passing the slinging wire
rope at four positions of front frame, in 11,12
8
order to separate it from the rear frame.
(7) Support the front frame safely. 20 7307SE19
5-66
(8) Remove bolt(17) and then take out
17,19
17, 19 4 15 9,10
cover(4,13) and shims(9,10).
(9) Take out dust seal(15) from the cover(4).
(10) Remove the bearing(1), and dust
FRONT FRAME
seal(15).
13 15 1
7307SE20
(11) Remove bolt(17) and then take out

cover(5,14) and shims(9,10). 17, 19 5
17,19 6 16 9,10
(12) Take out the dust seal(16) from the

cover(5).
FRONT FRAME
(13) Remove the bearing(1), collar(6) and dust
seal(16).
14 16 1
7307SE21
3) INSPECTION
(1) Check the bearing sliding surface for excessive wear, scorching or scratches; replace if necessary.
(2) Replace all dust seals(15, 16) with new ones.
(3) Grind any pins(2, 3) dented with an oilstone or replace any pins abrasive excessively.
(4) Check inside cover(4, 5, 13, 14) and collar(6, 7) for dents or scratches; if any damage is found,
correct with a grinder or replace.
(5) The serviceable limit of pins and bushings is shown in the table below. Unit : mm
Std Serviceable limit

Item No. Name dimension Remedy
Outer dia Inner dia Clearance
2, 3 Pin 59 -
1 Spherical bearing 60 - 60.5 1 Replace
6, 7 Collar - 60.5
15, 16 Dust seal When removed Replace
5-67
4) ASSEMBLY
17,19 2 15 18,22 17,19 6 3 16
REAR FRAME REAR FRAME

5
4
9,10 9,10
FRONT FRAME FRONT FRAME
14
13
REAR FRAME 1 REAR FRAME
7 11,12
8
1 15 20 16
UPPER LOWER 7307SE17
Assemble the center pivot group by reversing the order of disassembly while paying close attention
to the following.
(1) Put the dust seal(15, 16) into cover(4, 5, 13, 14).
ö Apply grease to the lip of the dust seal. Insert the dust seal so that the dust seal lip faces out and
punch four places on the outer circumference of the seal to lock it.
(2) Apply grease to the inside of spherical bearing(1) and install it to front frame.
(3) Assemble cover(4, 5, 13, 14). At this time, adjust shims(9, 10) to press shoulder of the bearing(1)
against cover(4, 5, 13, 14).(Shim thickness 0.1mm, 0.5mm)
(4) After setting the bearing so that its upper surface is horizontal, tighten the bolt(17).
After tightening, confirm that spherical bearing(1) moves lightly; if does not move smoothly, add
shims(9, 10).
ÂTightening torque : 29.7Ü4.5kgfÂm(215Ü32.5lbfÂft)
ö Apply locktite #242.
(5) Apply grease to upper collar(6) and insert it to the upper of spherical bearing(1).
(6) Insert collar (7) to the upper of the lower side rear frame.
(7) Move the front frame and join it to the rear frame so that match the pin hole at the center.
(8) Apply grease to pin(2, 3) and insert it into spherical bearing(1).
(9) Set plate(8); tighten hexagon bolt.
ö Tightening torque
ÂItem 18 : 29.7Ü4.5kgfÂm(215Ü32.5lbfÂft)
ÂItem 20 : 12.8Ü3kgfÂm(92.6Ü21.7lbfÂft)
ö Apply locktite #242.
(10) Connect the piping, pins, electrical wiring, links, etc. and remove the wooden block supporting the
frame.
(11) Check the pin function at low revolution; and apply grease if no irregularity is found.
5-68
5) TROUBLESHOOTING
Trouble Probable cause Remedy
Shock is felt when steering Capscrew for fixing steering valve is loose Retighten
Faulty center pivot pin mounting bolts Retighten
Center pivot pins have worn out Readjust or replace
Faulty hydraulic system See hydraulic system
Shock is felt when moving Fault fixing of connecting capscrews Retighten
backward or forward
Center pins have worn out Readjust or replace
Bearings of support unit have worn out Retighten
Drive shaft damaged See drive system
Faulty transmission See transmission system
5-69

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 :
ÂMain pump
ÂMain control valve
ÂBucket cylinder
ÂBoom cylinders
ÂPilot supply unit
ÂRemote control valve(Pilot control valve)
ÂSafety 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
2. HYDRAULIC CIRCUIT(HL730-7A, HL730XTD-7A)
34
T X2
9 10 11 MX
FRONT REAR
33 4 B.D/F B.U IN OUT
LH RH LH RH
T
B A
17 P
1 3 4 2 5 6
20
8 BL1 BR1 BL2 BR2 3 T
T1 P1 T2 P2 3B
3A 24MPa
BOOM
5 a3 BOOM UP DOWN b3
35
15 15 L FLOATING
24MPa
28
2B
14 T
7 A1 A2
2A
18 R
a2 24MPa
DUMP ROLL BACK
b2
P
PS
24MPa
P1 T F2
T1
1B 13
A3 P 21MPa 1A
16 a1
AUX
b1
24MPa
B LS F1
P2 12
PS1 CF EF
6 3MPa
19 21MPa U
P T P
LS
21 P
P1 T
1 A : 1st(Steering) pump
2 B A
B : 2nd(Loader) pump
32
M1
24
A
P1
31 M2 25
30 T P
P2
26 27 22
23
M 29
C
7307AWE01
1 Main pump 14 Safety valve 27 Bypass valve

2 Fan+Brake pump 15 Accumulator 28 Shockless valve
3 Main control valve 16 Accumulator 29 Pump motor(Option)
4 Remote control valve 17 Pressure switch 30 Check valve(Option)
5 Steering unit 18 Pressure switch 31 Pressure switch(Option)
6 Priority valve 19 Pressure switch 32 Pressure switch(Option)
7 Cut off valve 20 Pressure switch 33 Ride control valve(Option)
8 Brake valve 21 Line filter 34 Accumulator(Option)
9 Steering cylinder 22 Fan drive motor 35 Pressure switch(Option)
10 Bucket cylinder 23 Oil cooler
11 Boom cylinder 24 Air breather
12 Pilot supply unit 25 Hydraulic tank
13 Line filter 26 Return filter
6-2
HYDRAULIC CIRCUIT(HL730TM-7A)
36
T X2
MX
30 9 10 11
FRONT REAR
35
LH RH LH RH LH RH
B A
17
4 B.D/F B.U IN OUT
20 29 A B
BL1 BR1 BL2 BR2 3 T

T
8 P T
P
T1 P1 T2 P2 3B 1 3 4 2 5 6
3A 24MPa
BOOM
5 a3 BOOM UP DOWN
b3
L
FLOATING
12MPa
15 15 28
2B
37 14 T
7 A1 A2
2A
ROLL
18 R
a2 24MPa
BACK DUMP
b2
P
PS
24MPa
P1
T F2
1B
T1 13
A3 P 21MPa 1A
16 AUX
a1 24MPa b1
B LS F1
P2 12
CF EF
PS1
6 3MPa
19 21MPa U
P T P
LS
P
21 P1 T
2 1 B A A : 1st(Steering) pump
B : 2nd(Loader) pump
34
M1 24
A
P1
33 M2 25
32 T P
P2 26 27
23 22
M 31
C
7307AWE02
1 Main pump 15 Accumulator 28 Shockless valve

2 Fan+Brake pump 16 Accumulator 29 Solenoid valve
3 Main control valve 17 Pressure switch 30 Quick coupler cylinder
4 Remote control valve 18 Pressure switch 31 Pump motor(Option)
5 Steering unit 19 Pressure switch 32 Check valve(Option)
6 Priority valve 20 Pressure switch 33 Pressure switch(Option)
7 Cut off valve 21 Line filter 34 Pressure switch(Option)
8 Brake valve 22 Fan motor 35 Ride control valve(Option)
9 Steering cylinder 23 Oil cooler 36 Accumulator(Option)
10 Bucket cylinder 24 Air breather 37 Pressure switch(Option)
11 Boom cylinder 25 Hydraulic tank
12 Pilot supply unit 26 Return filter
13 Line filter 27 Bypass valve
14 Safety valve
6-3
3. WORK EQUIPMENT HYDRAULIC CIRCUIT
10 11
4 B.D/F B.U IN OUT
LH RH
3 T T
P
1 3 4 2 5 6
3B
3A 24MPa
BOOM
a3 BOOM UP DOWN b3
28
FLOATING
24MPa
14 T
2B
2A P
DUMP ROLL BACK
a2 24MPa b2
F2
24MPa 13
1B
1A
F1
a1 24MPa
AUX
b1
P2 12
3MPa
U
21MPa
P
P1 T
Priority valve EF port
Steering system
Brake system
1
Return line
24
25
T P
26 27 23 22
7307AWE03
1 Main pump 12 Pilot supply unit 24 Air breather

3 Main control valve 13 Line filter 25 Hydraulic tank
4 Remote control valve 14 Safety valve 26 Return filter
10 Bucket cylinder 22 Fan motor 27 Bypass valve
11 Boom cylinder 23 Oil cooler 28 Shockless valve
6-4
1) WHEN THE RCV LEVER IS IN THE RAISE POSITION
10 11
4 B.D/F B.U IN OUT
LH RH
3 T T
P
1 3 4 2 5 6
3B
3A
BOOM
a3 BOOM UP DOWN b3
FLOATING
28 14 T
2B
Load check valve
2A P
DUMP ROLL BACK
a2 b2
F2
13
1B
1A
F1
a1
AUX
b1
P2 12
3MPa
U
P
P1 T
Steering system
Brake system
2 1
Return line
24
25
T P
26 27 22
23
7307WE04
When the RCV lever(4) is pulled back, the boom spool is moved to raise position by pilot oil
pressure from port 3 of RCV through shockless valve(28).
The oil from main pump(1) flows into main control valve(3) and then goes to the large chamber of
boom cylinder (11) by pushing the load check valve of the boom spool through center bypass circuit
of the bucket spool.
The oil from the small chamber of boom cylinder(11) returns to hydraulic oil tank(25) through the
boom spool at the same time.
When this happens, the boom goes up.
6-5
2) WHEN THE RCV LEVER IS IN THE LOWER POSITION
10 11
4 B.D/F B.U IN OUT
Check valve
LH RH
3 T T
P
1 3 4 2 5 6
3B
3A
BOOM
a3 BOOM UP DOWN b3
FLOATING 39 14 T
28
2B Load
check
2A valve
P
DUMP ROLL BACK
a2 b2
F2
13
1B
1A
F1
a1
AUX
b1
P2 12
3MPa
U
P
P1 T
Steering system
Brake system
2 1
Return line
24
25
T P
26 27 22
23

7307WE05
When the RCV lever(3) is pushed forward, the boom spool is moved to lower position by pilot
pressure from port 1 of RCV through orifice connector(39).
The oil from main pump(1) flows into main control valve and then goes to small chamber of boom
cylinder(11) by pushing the load check valve of the boom spool through center bypass circuit of the
bucket spool.
The oil returned from large chamber of boom cylinder(11) returns to hydraulic tank(25) 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.
6-6
3) WHEN THE RCV LEVER IS IN THE FLOAT POSITION
10 11
4 B.D/F B.U IN OUT
LH RH
3 T T
P
1 3 4 2 5 6
3B
3A
BOOM
a3 BOOM UP DOWN b3
FLOATING
28 14 T
2B
2A P
DUMP ROLL BACK
a2 b2
F2
13
1B
1A
F1
a1
AUX
b1
P2 12
3MPa
U
P
P1 T
Steering system
Brake system
2 1
Return line
24
25
T P
26 27 22
23
7307WE06
When the RCV lever(4) is pushed further forward from the lower position, the pilot pressure reaches
to 13-15 bar, then the boom spool is moved to floating position.
The work ports(3A), (3B) 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.
6-7
4) WHEN THE RCV LEVER IS IN THE DUMP POSITION
10 11
4 B.D/F B.U IN OUT
LH RH
3 T T
P
1 3 4 2 5 6
3B
3A
BOOM
a3 BOOM UP DOWN b3
FLOATING
28 14 T
2B
2A P
DUMP ROLL BACK
a2 b2
F2
Load
13
check
1B valve
1A
F1
a1
AUX
b1
P2 12
3MPa
U
P
P1 T
Steering system
Brake system
2 1
Return line
24
25
T P
26 27 22
23
7307AWE07
If the RCV lever(4) is pushed right, the bucket spool 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(3) and then goes to the small chamber of
bucket cylinder(10) by pushing the load check valve of the bucket spool.
The oil at the large chamber of bucket cylinder(10) returns to hydraulic tank(25) 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.
6-8
5) WHEN THE RCV LEVER IS IN THE ROLL BACK(retract) POSITION
10 11
4 B.D/F B.U IN OUT
LH RH
3 T T
P
1 3 4 2 5 6
3B
3A
BOOM
a3 BOOM UP DOWN b3
FLOATING
28 14 T
2B
2A P
DUMP ROLL BACK
a2 b2
F2
Load 13
check
1B valve
1A
F1
a1
AUX
b1
P2 12
3MPa
U
P
P1 T
Steering system
Brake system
2 1
Return line
24
25
T P
26 27 22
23

7307WE08
If the RCV lever(4) is pulled left, the bucket spool 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(3) 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(10) returns to hydraulic tank(25) 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.
6-9
6) WHEN THE RCV LEVER IS IN THE HOLD POSITION
10 11
4 B.D/F B.U IN OUT
LH RH
3 T T
P
1 3 4 2 5 6
3B
3A
BOOM
a3 BOOM UP DOWN b3
FLOATING
28 14 T
2B
2A P
DUMP ROLL BACK
a2 b2
F2
13
1B
1A
F1
a1
AUX
b1
P2 12
3MPa
U
P
P1 T
Steering system
Brake system
2 1
Return line
24
25
T P
26 27 22
23
7307AWE09
The oil from main pump(1) flows into main control valve(3).
In this time, the bucket spool and the boom spool are in neutral position, then the oil supplied to
main control valve(3) returns into hydraulic tank(25) through center bypass circuit of each spool.
In this condition, each cylinder keeps the neutral position, so the boom and the bucket is holded.
6-10
4. MAIN PUMP
1) STRUCTURE
21
20
22
14
13
11 12
19
8 15
7 16
6
18 14
13 17
12
11
9
15
8
2 7
6
10
7307AWE12
1 Shaft seal 11 Wearplate 17 Spline coupling

2 Adapter 12 O-ring seal 18 Rear driven gear
6 Back up seal 13 Back up seal 19 Rear drive gear
7 O-ring seal 14 Interface seal 20 Stud
8 Wearplate 15 Dowel 21 Flanged nut
9 Front drive gear 16 Front body 22 Rear body
10 Front driven gear
6-11
2) OPERATION
The main hydraulic pump is a fixed displacement helical gear type pump. The pump is drive at
engine speed by the transmission. The pump shafts are supported by shaft seal(1) adapter(2),
front body(16) and rear body(22). The wearplate(8, 11) are located between the gear surface and
adapter(1), rear body(22) and front body(16).
As the drive gear(9) and (19) turns the idler gears(10, 18), 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 front body(16).
The trapped oil is the 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 wearplate(8, 11) against the gear faces. This
controls intenal leakage to maintain pump displacement.
Outlet pressure fills the area bounded by the pressure balance moduled seals(6, 7) to force the
wearplate against the high pressure area or the gear faces.
6-12
5. REMOTE CONTROL VALVE
1) STRUCTURE
4,3,1
4 1
10 3 2 12
30
11
2
33 30
4,3,1 14 32
40
15
40
4 1 42
20 3 2
22
21
23 4 1
3 2
25
26
45
7707WE11
1 Handle 14 Shim set 26 Bushing kit

3 Lever kit 15 Joint 30 Plunger kit
4 Bellows 20 Flange 32 Regulating unit
5 Nut 21 Solenoid complete 33 Regulating unit
10 Bracket 22 Plunger kit 40 Spring set
11 Detent kit 23 Plunger guide 42 Prefeel point kit
12 Plunger kit 25 Electric bracket 45 Plug set
6-13
2) OPERATION
T P
B.D/F B.U IN OUT
1 34 2
HYDRAULIC CIRCUIT
(3 Electromagnetic locks)
Electromagnetic lock 9
10
11 5
4
12
(1) Hydraulic functional principle 3
Pilot devices with end position locks operate as 2
7
direct operated pressure reducing valves.
They basically comprise of control lever(1), four T 8
x
pressure reducing valves, housing(6) and locks. P
Each pressure reducing valve comprises of a

control spool(2), a control spring(3), a return 6
spring(4) a plunger(5).
At rest, control lever(1) is held in its neutral position Port 4 Port 2
by return springs(4). Ports(1, 2, 3, 4) are connected 7707WE12
to tank port T via drilling(8).

When control lever(1) is deflected, plunger(5) is pressed against return spring(4) and control
spring(3).
Control spring(3) initially moves control spool(2) downwards and closes the connection between
the relevant port and tank port T. At the same time the relevant port is connected to port P via
drilling(8). The control phase starts as soon as control spool(2) finds its balance between the
force from control spring(3) and the force, which results from the hydraulic pressure in the relevant
port(ports 1, 2, 3 or 4).
Due to the interaction between control spool(2) and control spring(3) the pressure in the relevant
port is proportional to the stroke of plunger(5) and hence to the position of control lever(1).
This pressure control which is dependent on the position of the control lever and the
characteristics of the control spring permits the proportional hydraulic control of the main
directional valves and high response valves for hydraulic pumps.
A rubber bellows(9) protects the mechanical components in the housing from contamination.
6-14
(2) End position lock
Only those control ports, for which it is necessary to hold the control lever in a deflected position
are equipped with end position locks.
Electromagnetic lock
An additional spring(7), which is fitted below an additional plate(12) warns, by means of an
increased force, which is required for compressing this spring, that the plunger(5) and the control
lever(1) have almost reached their end position.
When this threshold is overcome, a ring(10) contacts the solenoid armature(11); if the solenoid is
energized, then control lever(1) is held in its end position by magnetic force.
This lock is released automatically when the solenoid is deenergized.
6-15
6. MAIN CONTROL VALVE
1) STRUCTURE
20
17 1
6 39
19
11 7
4 40
3 38
23 21 34
13 8 36
30 35
25
24
5 8
16
17 33 11
18 8
1 37 9
29
32
22
8 13
31
28 26
2 13
40 21 14
13 4
12 19
27
13
14
4
19
17
17 15
20
10
7403AWE12
1 Special nut 15 Cap screw 29 Spool

2 Plug 16 Anti void assy 30 Spring
3 O-ring 17 Retainer 31 Spring
4 O-ring 18 Spool cap 32 Back up ring
5 Cap screw 19 Spool cap 33 Inlet housing
6 Plug 20 Cap screw 34 Housing
7 O-ring 21 Retainer 35 Housing
8 O-ring 22 Retainer 36 Outlet housing
9 Spring 23 Shoulder screw 37 Poppet
10 Main relief valve 24 Flat washer 38 Tie rod
11 Port relief valve 25 Spacer 39 Tie rod
12 Spacer 26 Spring 40 Special nut
13 Flat washer 27 Spring
14 Shoulder screw 28 Spool
6-16
STRUCTURE
P T
A1 A2
B1 B2
b1(a1) b2(a2)
a1 A1 B1 a2 A2 B2
240bar 240bar 240bar Port Port name Port size

P From main pump 1 3/16-12UN
210bar T To hydraulic tank 1 5/16-12UN
A1, B1 To bucket cylinder port 1 3/16-12UN
P T
A2, B2 To boom cylinder port 1 3/16-12UN
a1, b1 Bucket pilot port 9/16-18UNF
a2, b2 Boom pilot port 9/16-18UNF
b1 b2
HYDRAULIC CIRCUIT
7307AWE10
6-17
2) BOOM SECTION OPERATION
(1) Spool in neutral
2B
2A
24Mpa BOOM UP BOOM DOWN

a2 b2
FLOATING
24Mpa
1B
1A
24Mpa DUMP ROLL BACK

a1 b1
2A 2B
a2 b2
Low pressure passage
7407AWE11
If the remote control valve is not operated, the oil supplied from the pump port passes through the
neutral passage to the low pressure passage at the outlet section, and then returns to the tank port.
6-18
(2) Boom raise position
2B
2A
24Mpa BOOM UP
a2 b2
24Mpa
1B
1A

a1 b1
Load check valve(1)
SECTION A-A
2A 2B
A A
a2
b2
7407AWE12
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.
6-19
(3) Boom lower position
Check valve(2)
T
2B
2A
24Mpa BOOM DOWN

a2 b2
24Mpa
1B
1A

a1 b1
Load check valve(1)
SECTION A-A
2A 2B
A A
b2
a2

7407AWE13
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.
6-20
(4) Boom float position
2B
2A
24Mpa FLOATING
a2 b2
24Mpa
1B
1A

b1
a1
2A 2B
b2
a2
7407AWE14
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) Ą 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) Ą T connecting.
6-21
3) BUCKET SECTION OPERATION
(1) Spool in neutral
24Mpa
1B
1A

a1 b1
21Mpa
1A 1B
a1 b1
7307AWE15
If the remote control valve is not operated, the oil supplied from the pump port passage through the
neutral passage to the low pressure passage at the outlet section, and then return to the tank port.
6-22
(2) Retract(Roll back) position
24Mpa
1B
1A
24Mpa ROLL BACK

a1 b1
Load check valve(1)

21Mpa
SECTION A-A
1A 1B
A A
b1
a1
7307AWE16
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.
6-23
(3) Dump position
24Mpa
1B
1A
24Mpa DUMP
a1 b1
Load check valve(1)

21Mpa
SECTION A-A
1A 1B
A A
a1
b1
7307AWE17
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.
6-24
4) PRESSURE SETTING
A good pressure gage must be installed in
Relief valve Check valve Pilot section
the line which is in communication with the poppet(D) poppet(K)
work port relief. A load must be applied in a Pilot poppet(E) Lock nut
manner to reach the set pressure of the
relief unit.
(1) Main relief valve
Η Loosen lock nut.
Θ Set adjusting nut to desired pressure
setting. Piston poppet(C) Housing O-ring
Ι If desired pressure setting cannot be Piston spring Pilot spring Adjust nut
achieved, add or remove shims as
required.
Κ Tighten lock nut. T
Λ Retest in similar manner as above. 210bar
P
7307AWE49
(2) Port relief valve

Η Loosen lock nut.
Relief valve Check valve Pilot section
Θ Set adjusting screw to desired pressure poppet(D) poppet(K)
setting. Pilot poppet(E) Lock nut
Ι Tighten lock nut.
Κ Retest in similar manner as above.
Piston poppet(C) Pilot spring O-ring

Piston spring Housing Adjust screw
T
240bar
7407AWE51
6-25
5) MAIN RELIEF VALVE
(1) As relief
The relief valve is in communication A D B K
between the high pressure port HP and
low pressure LP. Oil is admitted through
the hole in poppet C and because of the
HP
differential area between diameters A and
B relief valve poppet D and check valve
LP
poppet K are tightly seated as shown in
C
the first step.
The oil pressure in the high pressure port

E
HP has reached the setting of the pilot
poppet spring force and unseats the pilot
poppet E and oil flows around the poppet
HP
through the cross drilled holes and to the
low pressure area LP.
LP
The loss of oil behind poppet C, effected D E

by the opening of pilot poppet E, causes
poppet C to move back and seat against
pilot poppet E. This shuts off the oil flow HP
to the area behind relief valve poppet D,
and causes a low pressure area internally.
LP
The imbalance of pressure on the inside

as compared to that of the high pressure HP
port HP, forces the relief valve poppet D to
open and relieve the oil directly to the low
LP
pressure chamber LP in the valve.
7407AWE52
6-26
(2) As anti void
The anti-void unit supplies oil to the high
pressure port HP when cavitation has K G
occurred. A lower pressure exists in the A
port HP compared to the low pressure
chamber LP. The difference between the HP
effective area of diameter A and G causes
imbalance of the check valve poppet K
LP
which unseats, thus allowing oil from the
low pressure chamber LP to enter the port
HP and fill the void. 7407AWE53
(3) As separate anti void

The anti-void check valve opens when M O-ring
cavitation occurs in the high pressure port
HP and supplies oil from the reservoir LP
to help fill this void. The poppet M is held
A1
A2
on its seat by the port pressure HP, acting HP
on the larger area behind the O-ring.
When pressure HP drops below
LP
atmosphere, the tank pressure LP
Spring
operating on the annular area A1-A2 will
overcome the port pressure HP and the 7407AWE54
spring force to open the poppet. When the

void is eliminated the spring will return the
poppet which will then be tightly seated by
the port pressure HP.
6-27
6) PORT RELIEF VALVE
(1) As relief
The relief valve is in communication
A D LP B K
between the high pressure port HP and
low pressure LP. Oil is admitted through
the hole in poppet C and because of the
differential area between diameters A and HP
B relief valve poppet D and check valve
poppet K are tightly seated as shown in
the first step. LP C
The oil pressure in the high pressure port

LP E
HP has reached the setting of the pilot
poppet spring force and unseats the pilot
poppet E and oil flows around the poppet
through the cross drilled holes and to the HP
low pressure area LP.
LP
The loss of oil behind poppet C, effected D LP E

by the opening of pilot poppet E, causes
poppet C to move back and seat against
pilot poppet E. This shuts off the oil flow to HP
the area behind relief valve poppet D, and
causes a low pressure area internally.
LP C
LP D
The imbalance of pressure on the inside
as compared to that of the high pressure
port HP, forces the relief valve poppet D to
HP
open and relieve the oil directly to the low
pressure chamber LP in the valve.
LP
7407AWE55
6-28
(2) As anti void
The anti-void unit supplies oil to the high
A LP K G
pressure port HP when cavitation has
occurred. A lower pressure exists in the
port HP compared to the low pressure
chamber LP. The difference between the HP
effective area of diameter A and G causes
imbalance of the check valve poppet K
which unseats, thus allowing oil from the LP
low pressure chamber LP to enter the port
HP and fill the void. 7407AWE56
(3) As separate anti void

The anti-void check valve opens when M O-ring
cavitation occurs in the high pressure port LP
HP and supplies oil from the reservoir LP
to help fill this void. The poppet M is held
A1
A2
on its seat by the port pressure HP, acting HP
on the larger area behind the O-ring.
When pressure HP drops below
LP
atmosphere, the tank pressure LP
Spring
operating on the annular area A1-A2 will
overcome the port pressure HP and the 7407AWE57
spring force to open the poppet. When the

void is eliminated the spring will return the
poppet which will then be tightly seated by
the port pressure HP.
6-29
7. PILOT OIL SUPPLY UNIT
1) STRUCTURE
5
1
P
2
U
T
6
P2 2
PILOT SUPPLY UNIT
3MPa Port Port name Port size

U
P1 From steering pump 3/4-16UNF
P2 Pluging 3/4-16UNF
4.5MPa
U Supply to RCV lever 9/16-18UNF
T T To hydraulic tank 9/16-18UNF
P1
HYDRAULIC CIRCUIT 7807AWE49
1 Manifold complete 4 Accumulator

2 Reducing valve 5 Gasket
3 Seal kit 6 Relife valve
(2) OPERATION
The pilot supply manifold reduces the pressure from the high pressure circuit to a low pressure
circuit in order to supply the remote control valve.
The accumulator satisfies short term peak power demands and is a source of emergency power
in case of main circuit pressure failures.
The unit consists of the housing, the accumulator(4), the relief valve(6), the check valve and the
reducing valve(2).
The flow path is from the high pressure circuit through port P2 to the pressure reducing valve(2).
The pressure is reduced in the reducing valve(2) and oil passes the check valve into the
accumulator(4) and to the port U, which is connected with the remote control valve.
The pressure relief valve(6) protects the pilot circuit in case of the reducing valve(2) failures or
external increase of pressure.
6-30
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 against the tube(1) with glyd ring(15). 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
19 7 3 10,11 23 22 4 1 2 13,14 17 15 16 12 18
5,6
8,9
20 24 25,26 21 27,28
7307WE10
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 Glyd ring 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
6-31
2) BUCKET CYLINDER
19 7 3 10,11 4 1 2 13,14 17 15 16 12 18 23 22
5,6
8,9
20 24
25,26
21
7307WE11
1 Tube assy 10 O-ring 19 Socket bolt

2 Rod assy 11 Back up ring 20 Pipe assy
3 Gland 12 Piston 21 Pipe assy
4 Bushing 13 O-ring 22 O-ring
5 Rod seal 14 Back up ring 23 Socket bolt
6 Back up ring 15 Piston seal 24 Band assy
7 Buffer ring 16 Wear ring 25 Bushing
8 Dust wiper 17 Dust ring 26 Dust seal
9 Snap ring 18 Nylon nut
6-32
9. HYDRAULIC OIL TANK
1) STRUCTURE
Â The oil from the hydraulic tank is sent from the pump through main control valve to the cylinders.
In the return circuit, the oil from various parts merges.
Â A part of oil is cooled in the oil cooler(If equipped), passes through the hydraulic filter and returns
to the hydraulic tank(1).
Â If the hydraulic return oil filter becomes clogged, return filter bypass valve(6) acts to allow the oil to
return directly to the hydraulic tank(1). This prevents damage to the hydraulic filter(5). The
bypass valve(6) is also actuated when negative pressure is generated in the circuit.
15 11,13 4 9
7
3
A 6
5
SECTION A - A
2,8
15 12,14 10
7307AWE58
1 Hydraulic tank 6 By pass valve 11 Cover

2 Pipe assy 7 Spring 12 Cover
3 Sight gauge 8 O-ring 13 O-ring
4 Air breather 9 Socket bolt 14 O-ring
5 Element assy 10 Bolt 15 Bolt
6-33
2) RETURN OIL FILTER BYPASS VALVE
(1) When the filter is clogged
Bypass valve(1) is opened and the oil
returns directly to the tank without passing 1
through the filter.
Bypass valve set pressure : 1.36kg/cm2
(19.3psi)
From MCV
(740-3A) 6-33
6-34
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 Air breather
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,
the difference in pressure between the
tank and the outside atmospheric
pressure opens the poppet in the
breather, and air from the outside is let
into the tank or prevent negative pressure.
(2) Preventing excessive pressure inside
the tank
When the hydraulic cylinder is being used,
the oil level in the hydraulic system
increases and as temperature rises. If the
hydraulic pressure rises above the set
pressure, breather is actuated to release
the hydraulic pressure inside the tank. 7307AWE59
6-35
10. ACCUMULATOR
The accumulator is installed at the pilot oil
supply unit. When the boom is left the
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
to the control valve to actuate it and allow the 1
boom and bucket to come down under their 2
own weight. 3
Type of gas Nitrogen gas(N2)

Volume of gas 0.75˶(0.2 U.S.gal)
Charging pressure of gas 16kg/cm2(228psi)
Max actuating pressure 30kg/cm2(427psi)
1 Diaphragm
2 Steel pressure vessel
3 Closure button
7803AWE56
6-36
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:
6-37
ö Hydraulic oil must be at operating temperature for these checks(Refer to page 6-52).

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 6-52. 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 40~50ÁC)
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 6.5 seconds. 5-25.
IF OK
Do steering unit leakage
check at page 5-24.
IF OK
Do main hydraulic pump
flow test in group 3.
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.
6-38
Bucket rollback circuit Position bucket at a 45Áangle OK

relief valve check against an immovable object. Check complete.
Engage transmission in 3rd speed NOT OK
forward. Replace boom lower
check valve.
L OOK : Bucket angle must not
change.
Bucket dump circuit Raise front of machine which OK
relief valve low pressure bucket at 45Áangle. Go to next check.
check
Backdrag with bucket while NOT OK
observing bucket angle. Do loader system and
circuit relief valve test in
LOOK : Bucket must not rollback
group 3.
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 detent
Do pilot control valve
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 horizontal, OK
bucket cylinder drift then stop the engine. Check complete.
check
Stop the engine, wait for 5 minutes, NOT OK
then start measuring. Go to next check.
Measure the amount the lift and
B
dump cylinder rods retract during 15

A minutes.(Unloaded bucket)
A : Retraction of boom cylinder
rod
B : Retraction of bucket cylinder
rod
B Boom cylinder must drift less than
30mm(HL730-7A); 40mm(HL730TM-7A)
A
Bucket cylinder must drift less than
30mm.
6-39
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 in
edge to ground for 1 minute.
group 3.
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.
6-40
Bucket leveler Position bucket fully dumped just OK

(Positioner) check above ground level. Check complete.
Move control lever to bucket NOT OK
leveler detent position and Do bucket leveler checks
release. in group 3.
LOOK : Bucket must rollback to
the level position and control lever
must return to neutral.
If bucket is in a rolled back
position when key is turned ON,
control lever must be returned to
neutral manually if placed in the
bucket leveler detent position.
After bucket is dumped once,
bucket leveler will work normally.
Boom height kickout Position bucket flat on ground. OK
check Check complete.
Move control lever to boom raise
detent position and release. NOT OK
Do boom height kickout
LOOK : Boom must raise to the
check in group 3.
set height and stop.
Control lever must return to
neutral.
Cycle time check Function Operating condition. Maximum cycle time
Heat hydraulic oil to HL730-7A HL730TM-7A
Run engine at high idle. Boom raise Bucket flat on ground to full height. 5.6sec 5.4sec
Boom lower Full height to level ground. 2.8sec 2.4sec
Bucket dump Boom at full height. 1.0sec 1.4sec
Bucket rollback Boom at full height. 1.9sec 1.2sec
Steering(No. of Frame stop to frame stop. 2.5sec(4.0 turns)

turns)
OK
Check complete.
NOT OK
Go to slow hydraulic
functions.
6-41
ö MEASURING BOOM AND BUCKET CYCLE TIME
1. MEASUREMENT CONDITION
ÂCoolant temperature : Inside operating range
ÂSteering position : Neutral
ÂHydraulic temperature : 40~50Á$
ÂBucket : Unloaded
ÂEngine speed : High idling
2. MEASURING TOOL
ÂStop 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.
7307AWE18
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.
7307AWE19
3) DUMPING TIME OF BUCKET

Raise the boom to the maximum height and Dumping time of bucket
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
reach the maximum tilt back position. 7307AWE20
6-42
2. TROUBLESHOOTING
ö Diagnose malfunction charts are arranged from most probable and simplest to verify, to least
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 3.
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.
6-43
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.
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 3.
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.
Do pilot control valve(RCV) pressure
Faulty pilot control valve(RCV). test in group 3.
6-44
Function drifts down Leaking cylinders. Do cylinder leakage checks in group 3.

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.
Function drops before Stuck open lift check valve. Do control valve lift check in group 2.
raising when valve is
activated
6-45
Hydraulic oil foams Low oil level. Add recommended oil.

Wrong oil. Change to recommended oil.
Water in oil. Change oil.
Loose or faulty suction lines(Air leak in Tighten or install new lines.
system).
Remote control valve Leaking plunger seals. Remove, inspect and replace plunger
(RCV) leaking seals.
6-46
ö 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 1-24, 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.
6-47
1. HYDRAULIC OIL CLEAN UP PROCEDURE USING PORTABLE FILTER CADDY
ö Service equipment and tool

ÂPortable filter caddy
ÂTwo 4000mm Ý 1in 100R1 Hoses
ÂQuick disconnect fittings.
ÂDischarge wand
ÂVarious size fittings.
ö Loader system uses oil from hydraulic oil
tank. Flush all lines in the loader, pilot
system. Disassemble and clean major
components for hydraulic system.
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.
ö 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 -48
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.
ö Hydraulic tank capacity : 90˶ ˶(24U.S. gal)
Leave filter caddy operation for the next
steps.
6) Start the engine and run it at high idle.
ö 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.
ö 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 -49
2. BOOM HEIGHT KICKOUT ADJUSTMENT
1) Start the engine. Lift the boom up to a
desired height, set the boom control lever at
hold, then stop the engine.
Be careful lest work equipment fall down.
With the attachment raised, proper Boom
support must be provided for the
attachment and/or linkage.
Put the hydraulic safety lock lever in the
LOCK position. Proximate switch
7707WE20
2) Loosen the bolts(or nuts). Move the plate

(or proximity switch) so that the boom is in Bolt
line with the center of the sensing surface of Nut
proximity switch.
Then tighten the bolts(or nuts). Boom
Plate
7707WE21
3) Loosen the nuts so that a clearance

between the plate and the probe of the
proximity switch are maximum 6mm. Max 6mm
Boom
7707WE22
4) To check the adjustment, start the engine.

Position the bucket on the ground. Then lift Neutral
the bucket to a desired height by using the
control lever and release the hand. Confirm Detent position
the lever automatically returns to the neutral
position and the boom(the bucket) stop at
the adjusted position.
7407A4OP27
6 -50
3. TEST TOOLS
1) CLAMP-ON ELECTRONIC TACHOMET-
ER INSTALLATION
ÂService 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.
A
C : Red clip(+). Connect to transducer.
D : Tachometer readout. Install cable.
73035SV01
2) DIGITAL THERMOMETER INSTALLATION

ÂService equipment and tools
Digital thermometer
A : Temperature probe. A
Fasten to a bare metal line using a tie
band. Wrap with shop towel.
B C
B : Cable.
C : Digital thermometer.
73035SV02
3) DISPLAY MONITOR TACHOMETER

The display monitor tachometer is accurate
enough for test work.
mph
7807A3CD03
6 -51
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. 45ä
C).
ö Ride control system(Option)

Attention Ride control valve
1) Before carrying out any maintenance work
the accumulators must be unloaded(Zero
pressure). AB
2) For this, unscrew the plug(A) then rotate the
drain screw(B), located under the plug(A), 2
turns anti-clockwise with 3mm L-wrench.
3) The lifting system must firstly be secured
against lowering. 7707AWE21
4) After carrying out maintenance work, screw

the plug(A) and drain screw(B).
ÂTightening torque
A : 0.71kgfÂm(5.16lbfÂft)
B : 0.36kgfÂm(2.58lbfÂft)
6 -52
5. MAIN HYDRAULIC PUMP FLOW TEST
Â SPECIFICATION
Oil temperature 45Ü5äC (113Ü41äF )
Flow meter
Engine speed 2100Ü50rpm
Test pressure 210Ü10bar(3190psi)
Maximum pump flow 140˶/min(40U.S.gpm) To MCV
Â FLOW METER GAUGE AND TOOL
Gauge 0~35MPa(0~350bar, 0~5000psi)
EF
Temperature reader P
1) Make test connections.

Priority
2) Install temperature reader. valve
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 Main pump Hyd tank
pressure to test specifications.
6) Read flow meter.
7) If flow is below specifications, check suction
line and suction pressure for abnormality
7307WE22
before removing pump.
6 -53
6. LOADER SYSTEM AND PORT RELIEF VALVE PRESSURE TEST
Â SPECIFICATION
Oil temperature(40~50äC )
Relief valve Engine speed Relief pressure
210Ü5kgf/cm2
System(M) High
(2990Ü70psi)
Boom 240Ü5kgf/cm2 U R
Low D
raise(U) (3410Ü70psi)
Bucket 240Ü5kgf/cm2
Low
rollback(R) (3410Ü70psi)
HL730-7A :
240Ü5kgf/cm2 M
Bucket (3410Ü70psi)
dump(D) Low
HL730TM-7A :
Main control valve
120Ü5kgf/cm2
(1710Ü70psi)
Â Gauge and tool

D : Bucket dump relief valve
M : System(Main) relief valve
R : Bucket rollback relief valve
U : Boom raise relief valve To MCV
1) Install pressure gauge to plate in pump

delivery line.
3) Heat hydraulic oil to specifications.
Main pump Hyd tank
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
7307WE23
relief valve(M) and adjust to specification.
6 -54
ö 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.
ö Do not work machine with system relief
adjusted above specification or
structural damage may occur.
6) Adjust system relief valve to specification.
6 -55
7. HYDRAULIC SYSTEM RESTRICTION TEST
Â SPECIFICATION
Maximum pressure at steering unit
2MPa(20bar, 285psi)
Maximum pressure at main control valve
1MPa(10bar, 145psi)
Â 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. T
1) Install temperature reader.(See temperature

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 T
damaged.
5) Run engine at specification and read
pressure gauges.
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. 7403AWE18
6 -56
8. LOADER CYLINDER DRIFT TEST HL730-7A
Â SPECIFICATION
A
Boom horizontal
Bucket horizontal
Bucket unloaded
Item Standard value
B
Retraction of boom HL730-7A : 30mm
cylinder rod HL730TM-7A : 40mm
Retraction of bucket
cylinder rod 30mm HL730TM-7A
Â 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.
2) Stop the engine, then start measuring. A : Retraction of bucket cylinder rod
3) Measure the amount the boom and bucket B : Retraction of boom cylinder rod
cylinder rods retract during 5 minutes.
(740-3A) 6-56, 7430AWE21
6 -57
9. BOOM AND BUCKET CYLINDER LEAKAGE TEST
Â SPECIFICATION
Oil temperature 45Ü5ä C(113Ü9ä
F)
Engine speed Low idle
Maximum leakage 12cc/10min
Â GAUGE AND TOOL
Temperature reader
Stop watch
Measuring container
1) Fasten temperature sensor to head end
port of cylinder to be tested. Cover sensor
with a shop towel.
hydraulic oil warm up procedure in this
group.)
Never work under raised equipment
unless it is supported with a hoist or
support stands.
3) Full extend the cylinder to be tested. If
testing the boom cylinders, restrain boom in
the fully raised position using a hoist or a
stand.
ö 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.
(740-3A) 6-57
6 -58
10. PILOT CONTROL VALVE PRESSURE TEST
Â SPECIFICATION
Engine speed Low idle
Begin metering 1/5 of lever travel
Boom float detent pressure 17~30bar
RCV
Pressure at feel positionø:
Boom power down 13~17bar
Boom raise 13~18bar
Bucket rollback 13~18bar
Boom power down pressure ~17bar
Boom raise pressure ~18bar
Bucket roll back pressure ~18bar
Bucket dump pressure ~18bar
Â GAUGE AND TOOL
ø As the control lever is moved from neutral,
the pilot pressure will suddenly jump up to
approximately 3.7bar at 1/5 travel. The
pressure should then increase smoothly to
the specification at the FEEL position(Or
4/5 lever travel).
This test will determine if adequate pilot
pressure is available to move the loader
Hyd tank
control valve spools.
ö The FEEL position is when lever is
moved to feel the ramp of the detent
before lever passes into detent position.
1) Lower boom to ground.
2) Connect gauge to the pilot pressure port of
Pilot line filter
function to be checked.
4) Heat hydraulic oil to specification. 7407AWE24

group.)
6 -59
5) Run engine at specification. Activate
function to be checked and record pressure
reading.
ö 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 -60
11. PILOT OIL SUPPLY UNIT PRESSURE TEST
Â SPECIFICATION
Engine speed Low idle and stop
Pilot pressure setting 30~35bar(430~500psi)
Relief valve setting pressure
45bar
Accumulator precharging pressure
16bar
Â GAUGE AND TOOL
P2
Gauge 0~7MPa(0~70bar, 0~1000psi) U
T
The pilot supply unit consist of the pressure

reducing valve, the relief valve and an
accumulator. This regulates pressure to the
pilot control circuit.
1) Connect gauge to test port on the block.
3) Heat hydraulic oil to specification.(See
hydraulic oil warm up procedure in this Pilot line filter
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. 7407WE25
6 -61
12. CYCLE TIME TEST
Â SPECIFICATION
Maximum cycle time(Seconds)

Function Operating conditions
HL730-7A HL730TM-7A
Boom raise Bucket flat on ground to full height 5.6 5.4
Boom lower(Float) Full height to ground level 2.8 2.4
Bucket dump Boom at full height 1.0 1.4
Bucket rollback Boom at full height 1.9 1.2
Steering(Number of turns) Frame stop to stop 2.5(4.0 turns)
Hydraulic pump performance cycle time.
Function Operating conditions Maximum cycle time(Seconds)
Bucket flat on ground to full height

Boom raise 6.5
while holding steering over relief
6 -62
13. HYDRAULIC OIL FILTER INSPECTION PROCEDURE
1) Lower the bucket to the ground, stop the
engine, move the control lever back and
forth several times, and clean all over the
upper surface of the hydraulic oil tank.
2) Remove the bolts(1) and take out the filter
case cover(2) and O-ring(3).
3) Remove the spring(4) and bypass valve(5).
4) Remove the filter element(6) from the tank.
1
5) Check the element and the filter case
bottom for debris. Excessive amounts of 2
brass and steel particles can indicate a 3
failed hydraulic pump or a pump failure in 4
process. A rubber type of material can 5
indicated cylinder packing or other packing 6
failure.
ö 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.
7307AWE26
6 -63
1. MAIN PUMP
1) STRUCTURE
21
20
22
14
13
11 12
19
8 15
7 16
6
18 14
13 17
12
11
9
15
8
2 7
6
10
7307WE12
1 Shaft seal 11 Wearplate 17 Spline coupling

2 Adapter 12 O-ring seal 18 Rear driven gear
6 Back up seal 13 Back up seal 19 Rear drive gear
7 O-ring seal 14 Interface seal 20 Stud
8 Wearplate 15 Dowel 21 Flanged nut
9 Front drive gear 16 Front body 22 Rear body
10 Front driven gear
6-64
2) DISASSEMBLY
21
20
22
14
13
11 12
19
8 15
7 16
6
18 14
13 17
12
11
9
15
8
2 7
6
10
1
7307WE26
ö Plug all ports prior to cleaning and disassembling pump to prevent ingress of debris or
contamination.
ö Clean the pump thoroughly with a solvent, ensuring no loose debris or contamination remains on
the unit.
ö Mark each interface and then separate into individual pump sections.
(1) Securely clamp pump horizontally on one port face, ensuring that no damage is sustained to the
port face and remove the stud(20) and nut(21).
(2) Remove the front adaptor(2) from the body(16) using a pulling tool centered on the drive shaft(9).
ö Under NO circumstances attempt to prise or chisel cover from body as such action could damage
the machined sealing faces.
(3) Remove and discard the shaft seal(1) from adaptor making sure that no damage is sustained to
the surface of the seal bore.
(4) Unclamp pump and place it vertically with drive shaft up.
(5) Before removing wearplate from the body mark it using a soft pencil or a felt-tip pen to ensure
correct reassembly. Remove wearplate(8) complete with O-ring seal(7) and back up seal(6).
6-65
DISASSEMBLY
21
20
22
14
13
11 12
19
8 15
7 16
6
18 14
13 17
12
11
9
15
8
2 7
6
10
1
7307WE26
(6) Mark the gears using a soft pencil or felt-

tip pen to ensure assembly in the same
relative position, see figure on the right,
then withdraw the drive shaft/gear(9) and
driven gear(10) separately to prevent
jamming.
(7) Again, to ensure correct assembly, mark
remaining wearplate(11) using a soft
pencil or a felt-tip pen. Remove wearplate
from body complete with O-ring seal(12) 7607WE34
and back up seal(13).

(8) Discard interface seal(14).
(9) Having separated into individual pumps,
proceed as per paragraph (1)~(7).
6-66
3) MANDATORY REPLACEMENT PARTS
Discard all seals including interface seals, shaft seals, wear plate seals and back up seals. Fit new
seals on reassembly. Wearplates should also be replaced with new items from seal kit.
4) HANDLING/STORAGE
While disassembling pump, ensure no surfaces are scored or marked in any way. A rubber
surfaced table will be beneficial. All components must be placed in a clean, dry and safe area.
Leakage will be created by scratches on components. If parts are to be left for any period ensure
they are not exposed to dirt, dust and corrosion. Keep gears separate from each other in
protective boxes.
5) INSPECTION OF PARTS
Wash all parts in a solvent and dry.
(1) Adaptor housing and cover
The pump must be replaced if the damage listed is present.
Feature Damage
Corrosion, nicks or burrs(slight burrs can be removed
Surfaces
using and india stone)
Machined sealing lnterfaces Scores, cracks or corrosion
Bearing Loose
(2) Gears
Feature Damage
Surfaces using an lndia stone).
Wear due to seal(s)
Journals Pitting, wear, sufficient wear to change outside diameter
Tooth Cracks or heavy scoring or chipped
Splines/keyways Distortion of wear
End faces Wear, cracks
6-67
(3) Floating wear plates
Feature Damage
Corrosion, nicks or burrs, amounts of scoring,erosion

Surfaces or any cracks, discoloration caused by overheating
Removing burrs or minor scoring from Scoring of wear plate.

end faces and teeth of the gears.
(4) Bolts/Studs
The pump should be replaced if the damage listed is present.
Feature Damage

Surfaces using an lndia stone), cracks or scoring,
distortion or damage to thread form
(5) Plain bearings

Feature Damage
Surfaces Cracks or scoring

PTEF Coating Worn-bronze, sub-layer showing
Bearing Loose in housing/cover
(6) Coupling
This must be replaced if damage listed is present.
Feature Damage
Surfaces Corrosion, nicks or burrs, erosion, cracks or pitting

Splines Distorted or badly worn
6-68
6) ASSEMBLY
21
20
22
14
13
11 12
19
8 15
7 16
6
18 14
13 17
12
11
9
15
8
2 7
6
10
1
7307WE12
ö It is critical that the wearplates are assembled into the pump with regard to the following:
-The seal side of the wearplate must be adjacent to the adaptor or body.
-The high pressure side of the wearplate must be adjacent to the outlet port.
ö This must take place in a clean dry area, ensuring that all parts are clean and free from
contamination or loose particles. Lightly oil all surfaces.
(1) Place body vertically with gear pockets upper most.
(2) Slide wearplate(11) complete with O-ring seal(12) and back up seal(13) down through the
housing to the bottom of the gear pockets.
ö Be sure to refit the wearplate the same as that marked from this position during disassembly.
(3) Fit the gears(18,19) within the housing taking care to replace as marked, with the teeth
reassembled to their original related position.
(4) Fit the wearplate(8) complete with O-ring seal(7) and back up seal(6).
ö Be sure to refit the wearplate the same as that marked from this position during disassembly.
6-69
ASSEMBLY
21
20
22
14
13
11 12
19
8 15
7 16
6
18 14
13 17
12
11
9
15
8
2 7
6
10
7307WE12
(5) Fit new interface seal(14) into groove in body.

(6) Proceed as per paragraph(1)~(5).
(7) Fit adaptor(2) over the drive gear(9) and fit stud(22).
(8) Securely clamp unit and tighten nut(21) to half torque and then full torque.
ÂTightening torque : 23.2kgfÂm(168lbfÂft)
(9) Fit shaft seal(1) using appropriate tooling, in correct position and orientation.
(10) Pour a little clean hydraulic oil into the ports.
6-70
2. REMOTE CONTROL VALVE
1) STRUCTURE
2
1
3-1
3-2
Locite 262
3-3
5
11-1
11-2 12-1
4,3,1 12-2
4 1
10 3 2
30
11-3 12-3
11-4 12-4
2
33 30
11-5
11-6
4,3,1 14 32
40
15
40
4 1
20-1 42
20 3 2
22
21
23 4 1
3 2
25
26
7707WE64
1 Handle 11-4 Cardan 21 Solenoid

2 Push button 11-5 Armature 22 Intermediary plunger kit
3-1 Locking pin 11-6 Spring ring 23 Intermediary plunger guide
3-2 Bent lever 12-1 Counter nut 25 Electric bracket
3-3 Nut 12-2 Spring ring 26 Bushing
4 Rubber boot 12-3 Switch plate screw 30 Plunger kit
5 Locking nut 12-4 Press screw 32 Regulation unit
10 Cardan bracket 14 Shims(0.1, 0.2, 0.5mm) 33 Regulation unit
11-1 Self-locking nut 15 Cardan 40 Return spring
11-2 Washer 20 Flange 42 Prefeeling point kit
11-3 Washer
6-71
2) DISASSEMBLY AND ASSEMBLY
(1) Push button
ö The remote control valve does not need to be removed from the machine to perform this
operation.
Remove worn pushbutton using a small screwdriver.
The installation of new elements is performed without any special tools; the parts are simply
pressed into place.
(2) Rubber boot
Η Remove the remote control valve from the machine or free the valve by unscrewing the 4 screws
fixing the plate in order to release the electrical cable.
ÂAssembly
Torque : 1.02kgfÂm(7.4lbfÂft)
Hold the remote control valve using a vice or a vice-grip wrench(clamp onto the body).
ö The pilot unit does not need to be removed from the machine to release the cable. However, it is
recommended to lift the control unit by undoing the 4 fixing screws on the arm rest.
ö It is unnecessary to remove the units with no electrical functions.
Θ Lift and turn the boot inside out.
Ι Remove the grommet(7) from its emplacement to free the cable.
Κ Loosen the handle mounting nut(3-3) using a 19mm open-end wrench.
ÂAssembly : torque 4.08kgfÂm(29.5lbfÂft)
Λ Unscrew and remove the handle(1).
ÂAssembly
- Add loctite 262 onto the lever thread
- Torque : 4.08kgfÂm(29.5lbfÂft)
Μ Replace the faulty rubber boot(4) with a new one.
Ν Replace the handle(1) following the disassembly instructions in reverse order.
(3) Handle
Η Clamp the threaded section of the lever(3-2) in a vice fitted with V-shaped vice clamp.
Θ Remove the pin(3-1) using a 5mm pin driver.
Ι Replace the lever(3-2) onto the new handle(1) and secure it with the pin(3-1) using a 5mm pin
driver.
ö Respect the position of the curved lever to ensure that the handle is correctly oriented as
indicated by the machine’s technical specifications.
Κ Replace the nut(3-3) on the threaded section and replace the boot(4).
6-72
(4) Detent cardan bracket kit
ö Remove the 2 grommets(20-1) from the W
flange (20).
V
ö Place centering sleeves V & W to avoid
damaging the cardan knuckles while
loosening the nuts.
ö Unscrew the locking nut(5) using a
23mm open-end wrench.
ÂAssembly : Torque 4.08Ü0.4kgfÂm
(29.5Ü2.9lbfÂft)
Η Unscrew the self-locking nut(11-1) using Before loosening the nuts
a 13mm open-end wrench.

ÂAssembly W
- Torque 1.02kgfÂm(7.4lbfÂft)
- Place centering sleeves(V-W) to avoid
damaging the cardan knuckles while
screwing the nuts.
Θ Remove : - Friction washer(11-2) V
- Friction washer(11-3)
- Cardan/armature assembly
7707WE65
(11-4 ~ 11-6)
(5) Non-detent plunger kit

Η Unscrew the self-locking nut(12-1) using a 13mm open-end wrench.
ÂReassembly : - Torque 1.02kgfÂm(7.4lbfÂft)
- Place centering sleeves(V-W) to avoid damaging the cardan knuckles while
screwing the nuts.
Θ Undo the snap ring(12-2) using a flat-end screwdriver.
Ι Remove the screw assembly(12-3, 12-4)
(6) Cardan
Η Remove the centering sleeves V & W.
Θ Remove the cardan bracket(10) and the shims(14).
Ι Unscrew the cardan(15) using a 17mm open-end wrench.
ÂReassembly : - Ungrease the cardan threads
- Add loctite 262 onto the cardan threads(both end)
- Torque 4.08kgfÂm(29.5lbfÂft)
(7) Solenoid and connector
ö It is advised to mount the connector onto the solenoid cable once the remote control valve is
assembled.
Η Remove the flange(20) and the electrical bracket(25),
Θ Remove the protecting bushes(26) from the electrical bracket(25).
Ι Undo the solenoid(21) from the electric bracket(25).
Κ Replace the solenoid.
ö Clean the polar face using a piece of cloth and pay attention not to hit them.
Λ Assembly : Place the solenoid cable in its emplacement on the electric bracket before fitting the
protection bushes.
6-73
(8) Intermediary plunger kit
Η Undo the intermediary plunger guide(23).
Θ Remove and replace the intermediary plunger kit assembly(22).
(9) Guide / plunger and regulation unit
ö Beware of the plungers that might jump out due to the spring return.
Η Remove : - Guide/plunger assembly(30).
- Regulation unit(32/33).
- Return spring(40).
- Pre-feeling point kit(42).
Θ The remote control valve is now totally disassembled.
Assemble in reverse order following the torque specification.
6-74
3. MAIN CONTROL VALVE
1) Lay out valve components on a clean, flat
working surface. The inlet assembly will
include an O-ring, and the spool section(s)
include an O-ring, a load check poppet and
a load check spring. Tools required for
basic valve assembly include 3/4 and 11/16
open or box end wrenches and a torque
wrench with thin wall sockets.
7406S MCV05(1)
2) Assemble tie rod nuts to one end of each

tie rod with one or two threads showing.
Insert tie rods through tie rod holes of
inlet(Large tie rod at top). Lay inlet on end
with tie rods up, place O-ring into position.
7406S MCV05(2)
3) Place first spool section(O-ring side up) on

inlet section, position O-ring and insert load
check poppet(Nose down) and
spring(Behind poppet) into load check
cavity as shown. Repeat this procedure for
each spool section ; The load check springs
are compressed by the following sections
during assembly.
7406S MCV05(3)
4) Position end section on last spool section

as shown and hand tighten tie rod nuts. The
end section on picture is a "turn around"
section without ports. Universal
outlet/power beyond section and power
beyond and closed center sections are also
used as end sections. These end sections
do not have O-ring grooves.
7406S MCV05(4)
6-75
5) Position valve assembly with the mounting
pads of the end sections on a flat surface.
To obtain proper alignment of end sections
relative to the spool sections apply
downward pressure to the end sections ;
Snug tie rod nuts to about 10lbfÂft.
Final torque the two 11/16 nuts to 48Ü
5lbfÂft ; Final torque the 3/4 nut to 74Ü
8lbfÂft. Check for proper spool movement.
7406S MCV06(1)
6) Install auxiliary valves and plugs and torque

to proper specifications.
ö General assembly notes :
A. Lever assemblies can be installed on
section before or after complete valve
assembly.
B. The load check and spring may be
omitter from assembly in certain circuit
conditions(i.e., motor spools).
7406S MCV06(2)
6-76
4. BOOM AND BUCKET CYLINDER
1) BOOM CYLINDER
19 7 3 10,11 23 22 4 1 2 13,14 17 15 16 12 18
5,6
8,9
20 24 25,26 21 27,28
7307WE10
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 Glyd ring 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
6-77
2) BUCKET CYLINDER
19 7 3 10,11 4 1 2 13,14 17 15 16 12 18 23 22
5,6
8,9
20 24 24-1
25,26
21
7307WE24
1 Tube assy 10 O-ring 19 Socket bolt

2 Rod assy 11 Back up ring 20 Pipe assy
3 Gland 12 Piston 21 Pipe assy
4 Bushing 13 O-ring 22 O-ring
5 Rod seal 14 Back up ring 23 Socket bolt
6 Back up ring 15 Piston seal 24 Band assy
7 Buffer ring 16 Wear ring 24-1 Hexagon bolt
8 Dust wiper 17 Dust ring 25 Bushing
9 Snap ring 18 Nylon nut 26 Dust seal
6-78
3) TOOLS AND TIGHTENING TORQUE
(1) Tools
Tool name Remark
8
Allen wrench B
12
17
Spanner
19
(-) Driver Small and large sizes
Torque wrench Capable of tightening with the specified torques
(2) Tightening torque

Torque
Part name Item Size
kgfÂm lbfÂft
Bucket cylinder
19 M14Ý2.0Ý55 15Ü2 110Ü14.5
Boom cylinder
Socket head bolt
Bucket cylinder
23 M10Ý1.5Ý45 5.4Ü0.5 39Ü3.6
Boom cylinder
Bucket cylinder M48Ý2.0 250Ü25 1810Ü180
Nylon nut 18
Boom cylinder M27Ý3.0 200Ü20 1450Ü140
Bucket cylinder 24-1 M10Ý1.5Ý35 3.2Ü0.3 23Ü2.2
Hex head bolt
Boom cylinder 25 M12Ý1.75Ý40 5.5Ü0.6 40Ü4.3
6-79
4) DISASSEMBLY
(1) Remove gland and piston rod
ö Procedures are base on the boom
cylinder.
Η Hold 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.
Θ Pull out piston rod(2) about 200mm

(7.8 in). Because the piston rod is rather
heavy, finish extending it with air pressure
after the oil draining operation. m
0m
20
7407AWE30
Ι Loosen and remove socket bolts(19) of

Hex socket wrench
the gland(3) in sequence.
ö Cover the extracted piston rod(2) with rag
to prevent it from being accidentally
damaged during operation.
3
2 19
Cover here
with rag
7407AWE31
Κ Draw out gland(3) and piston rod (2)

assembly together from cylinder tube(1).
ö Since the piston rod assembly is heavy in Lift 1
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
been drawn out to approximately two 2
thirds of its length, lift it in its center to Full straight Oil pan
draw it completely. sideways
7407AWE32
6-80
ö 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.
Λ Place the removed piston rod assembly

on a wooden V-block that is set level.
ö Cover a V-block with soft rag.
Piston rod assy
Wooden block
7407AWE33
(2) Remove piston and gland assembly

Η Remove the nylon nut(18). 13,14 12 18
Θ Remove piston assembly(12) and O-ring
(13), back up ring(14).
7307WE27
Ι Remove the gland assembly from piston

rod(2). Lift with a crane
Plastic
ö If is too heavy to move, move it by hammer 3 4
striking the flanged part of gland(3) with a
plastic hammer. Pull straight
ö Pull it straight with gland assembly lifted
with a crane.
Exercise care so as not to damage the lip
2
of rod bushing(4) and packing(5, 6, 7, 8,
7407AWE35
9) by the threads of piston rod(2).
6-81
(3) Disassemble the piston assembly
17 15 16
Η Remove wear ring(16), dusting(17), and
piston seal (15).
damage the grooves.
7307WE28
(4) Disassemble gland assembly

Η Remove back up ring(11) and O-ring 8,9 5,6 7 11,10 4
(10).
Θ Remove snap ring(9) and dust wiper(8).
Ι Remove back up ring(6), rod seal(5) and
buffer ring(7).
damage the grooves.
ö Do not remove seal and ring, if does not
7307WE29
damaged.
6-82
5) ASSEMBLY
(1) Assemble gland assembly
Η Coat the inner face of gland(3) with
hydraulic oil.
7407AWE38
Θ Coat dust wiper(8) with grease and fit

dust wiper(8) to the bottom of the hole of Press here(Straight down)
dust wiper.
Ι At this time, press a pad metal to the
Metal
metal ring of dust seal. 8
Fit snap ring(9) to the stop face.
7407AWE39
Κ Fit back up ring(6), rod seal(5) and buffer

ring(7) to corresponding grooves, in that
order.
ö Coat each packing with hydraulic oil
Wrong Right
before fitting it.
ö Insert the backup ring until onside of it is
inserted into groove.
7577ASE42
ö Rod seal(5) has its own fitting direction.

Therefore, confirm it before fitting them. Push bar
ö Fitting rod seal(5) up side down may
damage its lip. Therefore check the
correct direction that is shown in fig.
5
7407AWE40
6-83
Λ Fit back up ring(11) to gland(3).
ö Put the backup ring in the warm water of 3 11 10
30~50ÁC.
Μ Fit O-ring(10) to gland(3).
7307WE30
(2) Assemble piston assembly

Η Coat the outer face of piston(12) with
hydraulic oil. 12
7407AWE42
Θ Fit piston seal(15) to piston

ö Put the piston seal in the warm water of
60~100ÁC for more than 5 minutes. 15
ö After assembling the piston seal, press
its outer diameter to fit in.
7407AWE43
Ι Fit wear ring(16), dust ring(17) to

piston(12). 12 17 15 16
Κ Fit O-ring(13) and backup ring(14) to
piston(12).
7307WE31
6-84
(3) Install piston and gland assembly
Η Fix the piston rod assembly to the work Grand assembly
bench. Piston rod
Θ Apply hydraulic oil to the outer surface of
piston rod(2), the inner surface of piston
and gland.
Ι Insert gland assembly to piston rod(2).
7407AWE45
Κ Fit piston assembly to piston rod.

Piston assembly
Piston rod
7307WE32
Λ Tighten nylon nut(18) to piston rod(2).

ö Tightening torque 2 18
ÂBucket cylinder : 250Ü25kgfÂm
(1810Ü180lbfÂft)
ÂBoom cylinder : 200Ü20kgfÂm
(1450Ü140lbfÂft)
7307WE33
6-85
(4) Overall assemble
Fix with a bar
Η Place 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.
Θ Insert the piston rod assembly in to the
cylinder tube assembly, while lifting and
Apply liquid packing
moving the piston rod assembly with a
7407AWE48
crane.
ö Be careful not to damage piston seal by
thread of cylinder tube.
Ι Match the bolts holes in the cylinder
head flange to the tapped holes in the
cylinder tube assembly and tighten Piston rod
socket bolts to a specified torque.
ö Refer to the table of tightening torque. Tube
Gland
Hex socket
wrench
7407AWE49
6-86
Group 1 Component Location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-1

Group 2 Electrical Circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
Group 3 Monitoring System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-21
Group 4 Electrical Component Specification - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-40
Group 5 Connectors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-47
Group 6 Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-67
GROUP 1 COMPONENT LOCATION
1. LOCATION 1
1
2
3 12
4 13 Cab roof
ECO
NO
Front 14 17
15 18
LH SIDE 16 19
22 20
5 23 21
6
7
8
A
9
A
10
11
24 7307AEL02
1 Rear wiper/washer switch 10 Attachment unlock switch 18 Clutch cut off switch
2 Mirror defrost switch(Option) 11 Attachment lock switch 19 Ride control switch(Option)
3 Beacon switch(Option) 12 Radio & cassette(STD) 20 Heated seat switch(Option)
4 ECONO switch Radio & CD player(OPT) 21 Pump motor switch(Option)
5 Horn button 13 Aircon & heater switch 22 12V socket(Option)
6 Multi function switch 14 Work lamp switch 23 Starting switch
7 Hazard switch 15 Main light switch 24 Engine control module(ECM)
8 Cluster 16 Parking brake switch
9 Kick down switch 17 Auto select switch
7-1
2. LOCATION 2
1 2 3 4 5
6
7
18
10
8 9
17
16
15
11 12 13 14
7307AEL02-1
1 Proximity switch 7 Front turn lamp 13 Rear combi lamp

2 Proximity switch 8 Fuse box 14 Back up buzzer
3 Horn 9 Machine control unit(MCU) 15 Number plate lamp
4 Work lamp 10 Transmission control unit(TCU) 16 Master switch
5 Switch 11 Start relay 17 Rear combi lamp
6 Head lamp 12 Battery 18 Fuel sender
7-2
GROUP 2 ELECTRICAL CIRCUIT
5W 33 MCU
MECHANICAL ENG(GND)
EM'CY PARKING
3R 34 PUMP MOTOR SW BRAKE PS PS WARNING
CLUTCH CUT-OFF PS
10 CLUTCH CUT-OFF SW
STEERING RY RESISTER
4 AGRICULTUAL CONDENSOR
HYD TEMP SENDER
SPEEDMETER SIG.
3Br 31 BUZZER
2
R 35
REVERSE FAN SOL
RIDE CONT. AUTO
STEERING P/P PS
REVERSE FAN SIG
TACHO SENSOR+
TACHO SENSOR-
B
14 ELEC.STEERING
PROGRAM DUMP
A
COOLANT TEMP
Pa
Pa
3Y 32
RIDE CONT. ON
AUTO SEL.TCU
MAIN PUMP PS
WIPER INT SIG

FUEL SENDOR
FAN CLUTCH+
CLUSTER SERIAL GND
87a87 85
STOP LAMP PS
11 AUTO SEL.SW
30 86
POWER IG(NC)
POWER IG(NC)
STEERING RY
MULTI SW- LIGHT COM
NEUTRAL SIG
FAN CLUTCH-
CLUSTER HIGH BEAM
PARKING SIG
FUEL HEATER
MULTI SW- WIPER Lo
HOUR METER
MULTI SW- WIPER Hi
PREHEATER
MULTI SW- WASHER
CLUSTER SERIAL-Lo
OPTION PS 2
OPTION PS 1
CLUSTER SERIAL Hi
SAFETY RY
AIR FILTER
CD-26
ALT LEVEL
CD-3
BRAKE PS
WIPER RY
WASH SIG
MULTI SW- HORN
SERIAL-H
TURN LAMP COM
WIPER MOTOR Lo
CN-26
SERIAL-L
ATT. UNLOCK SW
WIPER MOTOR Hi
MIRROR HEATED
CN-98
RS232 RX
2
1
RS232 TX
1
WIPER MOTOR B
MULTI SW- COM
MULTI SW- Hi IG
BUZZER
6
TURN LAMP RH
ACCEL RETURN
LIGHT Lo BEAM
10
10
18
19
20
21
22
23
24
25
26
27
28
11
12
13
14
15
16
17
TURN LAMP LH
LIGHT Hi BEAM
ACCEL SUPPLY
OPTION
OPTION
OPTION
OPTION
MULTI SW- INT
1
2
3
4
5
6
7
8
9
ACCEL SIGNAL
CR-37
CLUSTER GND
CAN-H
IG 24V
2
1
OTMP1
ATT. LOCK SW
ILLUMINATION
CAN-L
C
CS-75
B
Bat24V
A
SPARE
JOYSTICK F/R
X2B-FWD-ED4
ATT. SW COM
X2D-NEU-ED6
X2C-REV-ED5
87a
X1C-AD1-ED1
X1B-AD2-ED2
X1A-AD3-ED3
ODP2
ODP1
GND
10A
BEACON/REAR WORK LAMP 20A
20A
20A
10A
30A
30A
CIGARLIGHTER/MIRROR 30A
30A
20A
30A
EM'CY STEER/RIDE CON. 20A
30A
20A
30A
10A
10A
10A
10A
10A
10A
10A
30
10A
X1D-KD-ED7
86
85
GND
20A
87
10A
CN-170
CASSETTE/ROOM LAMP 5A
5A
5A
10
1
2
70A B
3
8
9
7
6
4
70E B
125 V
126 L
NC
BATT. 24V
27A RW
2
1
OFF IDLE
CR-35
RETURN
115 W
CN-58
ON IDLE
CN-59
53G G
52F V
X2A-VP
IG 24V
NEUTRAL RY/JOYSTICK F/R
ILLUMINATION LAMP
ILLUMINATION LAMP
86 3087a
FRONT WORK LAMP
27
26
24
23
21
28
25
20
GrW
36
35
34
33
32
31
30
29
22
19
OrW
17
18
16
15
13
12
HORN/CONVERTER
23
22
21
20
6
7
3
2
1
OrW
8
9
19
18
17
16
15
14
13
12
11
10
G41 B
GND
9
8
7
1
5
2
G14
3
B
4
G
NC
NC
BACK.STOP LAMP
AIR-CON/HEATER
AIR-CON/HEATER
NC
NC
NC
NC
NC
NC
NC
NC
85
G
B
64E Or
3Br 31 G23
G11 B
CLUSTER/MCU
G43
87
G19
OrW
GrW
WOr
GOr
GOr
GOr
16A
73 BOr
BOr
106
174
24A ROr
143 BOr
174
RW
PRE-HEATER
123 GW
YW
BW
128
LW
15
14
13
12
11
10
G SEAT 177
11
65A
12
12
11
10
10
15
14
13
12
11
10
100 W
1V
104 Or
Or
Or
102 G
160 Or
7
Br
TURN LAMP
9
8
HEAD LAMP
103 B
9
8
7
6
5
4
W
72A Br
4
3
2
1
3
2
1
101 L
CN-156
G
9
8
5
START KEY
4
3
2
1
5
9
8
7
6
4
3
2
1
86
Y
B
V
L
L
CASSETTE
85 87 87a 3Or 21 G21
CLUSTER
ILL.LAMP
B
A
30
CN-36
69A
SWITCH
105
106
107
108
109
110
111
112
113
114
175
115
116
183
117
118
188
120
121
122
192
124
125
126
CN-15
CN-17
CN-16
57
53
52
55
70
27
WIPER
CN-163
ECM
POWER RY
15
14
13
12
11
10
MCU
ECM
7
11
9
8
RCV
12
5
4
3
2
1
12
11
10
6
TCU
TCU
10
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
7
9
8
5
4
3
2
1
5
9
8
7
6
4
3
2
1
6
CR-25
12F LW
G5 B
86 30 87a
BrW
ROr
ROr
OrW
OrW
WOr
GrW
WOr
GW
GrW
16K GrW
YW
GOr
VW
ROr
ROr
LW
BOr
LW
GY
154 GW
G15
VOr
3Or
B
RW
RW
SH
YW
VW
RW
LW
3W
LW
Gr
Or
Br
W
W
TO: FRONT HARNESS
Gr
2L
Or
Gr
Gr
85 CN-9
W
W
V
B
Y
155 W
Br
CS-59
W
L
G
172 G
R
173 R
B
Y
G61 B
L
L
L
3Y 32 GOr
CN-126
B G37 116
87 1
11E
1 MAIN PUMP PS
14F
10 10
159
120
163
162
161
134
158
68A
92A
181
28A
108
182
107
142
141
140
139
138
137
65 9
12
G
10
13
14
15
19
21
23
11
16
22
24
25
26
69
68
66
67
G
64
17
20
27
28
29
30
4
3
1
2
R 124
7E
1K
90
24
29
51
81
83
49
85
82
74
2
5
7
6
86 9 2 2 STEERING PUMP PS
8
85 87 87a Or 21A 16B GrW
30 8 TO:PC 3 3 NC
8 128 OrW
ECM POWER RY 6 7 4 4 NC
2 129 V
6 5 5 HORN
7 WOr 3 130 LW
5 5 6 6 BOOM DOWN PS
H BR ACC ST C
6 1 131 G
5 CS-2 4 SH 182 7 7 BUCKET LEVELER
132 Br
6 3 8 8 BOOM KICK OUT
GrW 157 SH 187 133 Or
3 5 2 9 9 BOOM DOWN PS
2 GrW 118 155 W
B
1 4 1 10 10 ATT. UNLOCK SOL

G 65 70 B
4 3 AUTO/MANUAL SW 11 11 STEERING PS(GND)
L 153
0, I
154 GW
2 12 12 ATT. LOCK SOL
Or 21E
H0 I
1
CN-10
2H R
1 1 PROXIMITY SW 24V
68 V
START SWITCH 2 2 HEAD LIGHT Hi
G23 B
3 3 GND
G24 B
4 4 GND
177 B
5 5 PROXIMITY SW(GND)
7A ROr
6 6 ILLUMINATION RH
6A RW
CR-33 7 7 ILLUMINATION LH
134 GW
86 30 87a 8 8 HEAD LIGHT Lo
BW 191 67 Y
85 9 9 TURN LAMP LH
BrW 176 66 Or
87 10 10 TURN LAMP RH
L 9G 152 BW
86 11 11 GND TM
85 87 87a L 9F 144 BOr
30 12 12 GND STD
13 13
CN-92A
AC CONDENSOR FAN RY G21 2B

14 14 HEAD LIGHT GND
15 15
CN-11 36 CN-134
CN-92
AC CONTROLLER GND B 96A 6

1
DIAGNOSTIC
1
B 96 5
2 BLOWER MOTOR GND 2
2L 9 47 BW
3 AC 24V 3 4
Or 160 36E B
4 REVERSE FAN SIGNAL 4 3
R 25 44 Gr
5 AC CONTROLLER B+ 5 2
Y 145 28E L
6 AC COMP 6 1
AC CONDENSOR FAN BW 186
7 7
R 1A CN-157
8 ILLUMINATION 8
BW 192 36 B
1 VM1-GND
CR-7 36A B
87a 2 VM2-GND
86 30
V
CN-92B 37 B
146 3 VMG1-SPEED PICK-UP COM
85 38 BOr
VW 147 4 VMG2-SPEED SENSOR OUTPUT
87 39 ROr
L 9E 8 VPS2-RIDE CONT. RY(+)
86 40 LW
85 8787a L 9A 9 AIP5-GEAR BOX Y5
30 41 YW
10 AIP2-GEAR BOX Y2
AIR-CON RY
6 ADM3-TM ERROR
CR-26 43 W
12 VPS1-GEAR BOX VPS1(+)
G 162
86 30 87a 43A W
GOr 105 CN-148 13 VPS1-GEAR BOX VPS1(+)
85 54E B 44 Gr
W 8 C 15 SDDK-DIAGNOSTIC
87 53F G 45 WOr
W 8A B 17 ER3-SW FILTER RESTRICTION
86 52E V 46 BOr
85 87 87a R 173 A 49 ER2-SENSOR TEMP CONVERTER
30 47 BW
DATA LINK 18 EUPR-DIAGNOSTIC
WIPER RY LO 48 W
19 EF1-SPEED PICK-UP ENG
49 RW
CR-4 20 ED3-SHIFT LEVER-X1A-B3
W 8E 50 YW
86 30 87a 21 ED10-PARKING BRAKE SW(+)
B G13 51 VOr
85 22 ED7-SHIFT LEVER-X1D-KD
G 172 22A R
87 23 VPE1-CONTINUANCE 24V
Br 163 52A V
86 25 CANF_H
85 8787a L 14A 53A G
30 26 CANF_L
WIPER RY HI 27 CANF_T
54A SH
28 VGS-CAN SHIELD
55 Or
TO: CABIN HARNESS CN-7 29 ED11-SW AUTO/MANU SIG(+)
G 30 56 OrW
CASSETTE IG24V 1 1 32 AIP3-GEAR BOX Y3
RW 57 Y
WORK LAMP FRONT 2 2 171 36 SD4-SPEED METER CLUSTER
Y 20 58 BW
CASSETT B+/ROOM LAMP 3 3 39 ER1-GEAR BOX TEMP
LW 169 59 W
MIRROR HEATER SW 4 4 41 EF2-SPEED PICK-UP TURBIN
Or 183 60 W
MCU 5 5 42 EF3-SPEED PICK-UP GEAR
B 178 74 Br
GND (CASSETTE) 6 6 43 ED4-SHIFT LEVER X2B-FWD
R 28 L
ILLUMINATION 7 7 1 45 VPI-POWER IG
3B 179 75 BOr
GND 8 8 46 VMGA2-GEAR BOX TEMP(COM)
B 178A 76 G
ELEC.STEERING 9 9 51 AIP6-GEAR BOX Y6
B G1 77 V
GND 10 10 55 AIP4-GEAR BOX Y4
G 5A 78 Gr
BEACON SW 11 11 56 AIP1-GEAR BOX Y1
B 179A 79 GOr
NC 12 12 57 ADM5-RY RIDE CONT.(-)
80 Br
NC 13 13 62 EF4-SPEED SENSOR(SIG)
R 63 81 LW
WORK LAMP REAR 14 14 63 ED1-SHIFT LEVER X1C-B1
82 GrW
15 15 64 ED5-SHIFT LEVER X2C-REV
83 L
65 ED2-SHIFT LEVER X1B-B2
CN-8 84 Gr
L 14 66 ED9-CLUTCH CUT-OFF SW(+)
REAR WIPER 24V 1 1 85 W
V 67 ED6-SHIFT LEVER X2D-NEU
WIPER SW-WASHER 2 2 166 22 R
W 68 VPE2-CONTINUANCE 24V
WIPER SW-PF 3 165 86 BOr
3 44 ED8-FWD-JOYSTICK
Or 164 87 Or
WIPER SW-ON 4 4 31 ED13-REV-JOYSTICK
5 5 168 BW
VW 92 30 ED12-NEU-JOYSTICK
MIRROR HEATER 6 6 88 BOr
52 ADM1-START INTERLOCK RY(-)
STEERING SW 7 7 89 WOr
5 ADM4-REVERSE DRIVE RY(-)
STEERING SW 8 8 90 LW
7 ADM2-JOYSTICK SELECT LAMP(-)
91 OrW
CR-3 59 ADM5-JOYSTICK SELLECTER(+)
86 30 87a G16
B TM CONTROLER
85
RW 171 CN-6
87 1
G 170 1 NC
86 75 BOr
85 87 87a Gr 15 2 2 GEAR BOX -TEMP(COM)
30 48 W
3 3 ENG.PICK-UP SENSOR
WORK LAMP FRONT 37 B 4 4 ENG.PICK-UP SENSOR
CR-55 45 WOr 5 5 FILTER RESTRICTION
86 30 87a 46 BOr
B G17 6 6 TEMP CONVERTER
85
R 63 7 7 NC
87 58 BW
L 180 8 8 GEAR BOX -TEMP
86 76 G
85 87 87a Gr 5 9 9 GEAR BOX -Y6
30 40 LW
10 10 GEAR BOX -Y5
WORK LAMP REAR 77 V
11 11 GEAR BOX -Y4
56 OrW
CS-36 G36 12 12 GEAR BOX -Y3
B 78 Gr
9 10 10 13 13 GEAR BOX -Y2
R 1G 43 W
9 14 14 GEAR BOX -VPS1+
4 8 41 YW
15 15 GEAR BOX -Y1
2 G 170
7
CN-5
7 1 6
5 1 1 NC
5 70F B
R 1F 2 2 GND-MCU
4 111 Br
3 3 HYD TEMP SENSOR
3 117 BOr
180 4 4 AIR CLEANER SW
I 0
L
2 110 V
R 1E 5 5 FUEL SENDOR
1 59 W
6 6 TURBIN PICK-UP SENSOR
WORK LAMP SW 37A B
7 7 TURBIN PICK-UP SENSOR
CS-21 G35 8 8 NC
B 38 BOr
9 10 10 9 9 SPEED SENSOR-VMG2
R 1H 80 Br
9 10 10 SPEED SENSOR-EF4(2)
4 28F L
8 11 11 SPEED SENSOR-24V
2 R 1 37E B
7 12 12 INTER GEAR PICK-UP SENSOR
60 W
7 1 6 13 13 INTER GEAR PICK-UP SENSOR
5 R 35
5 14 14 NC
YW 11
4 15 15 NC
3
161 CN-4
I 0
W
2
OrW 10 1 1
1 176 BrW
2 2 AC CONDENSOR FAN
ILL.HEAD LAMP SW
3 3
16G GrW
SW 2 CR-56 4 4 FAN REVERSE SOL
3 B G52 123 GW
IG 1 5 5 FAN REVERSE SOL
LW 169 145 Y
2 6 6 AC R/DRYER
Or 64 146 V
3 7 7 AC R/DRYER
VW 92 147 VW
4 4 8 8 AC COMP
GND 1 148 L
OUT 9 9 BACK BUZZER
6 RW
MIRROR HEAT 10 10 ILLUMINATION
66A Or
11 11 RH TURN LAMP
7 ROr
CN-138 12 12 ILLUMINATION
VW 13A 67A Y
24V 24V A 13 13 LH TURN LAMP
B G53
GND B 14 14 WORK LAMP
Or 167 72 Br
12V 12V C 15 15 STOP LAMP
DC/DC CONVERTER CN-3
184 Or
CN-139 1 1 ECU
Or 167 149 LW
2 2 FUEL HEATER
2 185 BOr
B G32 3 3 ECU
1 151 BW
4 4 START RY
112 YW
12V SOCKET 5 5 ALT I
187 SH
6 6 SHIELD
150 G
CL-2 7 7 PRE-HEAT RY
Or 64A
8 8 NC
R 1T 153 L
9 9 BATT.RY (DO-1)
B G31 114 Y
10 10 FAN PROPORTIONAL V/V
113 L
CIGAR B 11 11 FAN PROPORTIONAL V/V
12 12 NC
13 13 NC
23 3.0W
14 14 ECM Bat 24V
15 15 NC
CN-1
34 3R
1 1 MASTER SW
33 5W
2 2 FUSIBLE LINK
CN-2
52 V 1 1 ECM-J1939+
53 G 2 2 ECM-J1939-
54 SH
3 3 SHIELD
135 LW
G38
B G39
B G34
L 14E
Or 164
4
G18
W 165
G51
GrW 16E
BOr 73A
B G4
Or 104
GrW 157
Br 156
WOr 122
LW 130
Y 127
OrW119
BW 151
GOr 121
4 ECM-AIR HEATER OUT

17A
G40
LW 12A
1N
R 1R
GY 159
BrW 158
R 1S
V 129
WOr 3A
WOr 3E
WOr 3F
L 148
YW 50
G3
GrW 16
G2
166
17
BOr 185
136
Or 184
BW
88
73
69
19
VW 13
WOr89
LW 12
1L
5 ECM-AIR HEATER RETURN
189
190
G12
BW 168
144
OrW 119
26
BOr
BOr
WOr
152
131
132
189A
G42
LW 12H
LW 12E
2A
6
BOr 86
87
Br 72B
R
B
B G62
62
61
64F
Or 133
Br 156
WOr 3H
6
LW 149
POWER IG
189
BOr 143
G25
G 17E
VOr 51A
G
G
R 190
2
L 189
B
Y 127
B
V
Gr 4A
Gr 4E
Br 72
Gr
G 109
W 188
R
B
GOr 79
ROr 39
OrW 91
Gr 84
1V
137 BOr
2E
W 61
R
L 62
B
BW136
LW135
G 150
7
62A
R
61A
7 ECM-SW RETURN
Br 189
L
B G7
2G
BOr
2F
138 GOr
BW
Gr 4
CS-55
8
Or
Or
Br
B
CS-17
CN-102
8
CR-5
ECM-OFF IDLE
Br
W
CR-38
CS-42
B
CR-58
Br
R
R
B
L
CR-11
4
3
R
6
5
2
CD-5
CR-2
10 10
CS-80
7
CN-103
139 OrW
8
CN-22
9
87
30
85
86
87a
CD-4A
87
87
30
5
10 10
85
6
86
30
4
87a
85
10 10
86
2
87a
3
1
7
8
6
5
7
4
6
5
9
2
3
9
1
9
1
87
30
85
86
87a
W
9 ECM-ON IDLE
CN-246
3
1
1
1
2
R
CN-71
R
2
10 10
CD-4
L
8
6
5
4
2
9
1
2
1
140 Gr
CN-170
CR-46
CR-59
1
10
2
85 8787a
10 ECM-ACCEL POS SUPPLY

85 8787a
CS-82
1
2
1
2
85 8787a
85 8787a
B
E
8 7 6 5 4 3 2 1
6
5
L
87
CN-114
30
CR-40
85
86
87a
CR-36
87
141
30
85
86
87a
CR-41
M
Lo 5
1
M
3
2
5
Hi 4
10 10
7
8
6
5
4
2
9
11
86 30
JOYSTICK SELECT 10
12
11
87
87
30
85
87
30
86
85
11
86
87a
ECM-ACCEL POS SIG
30
86 30
87a
85
86
86 30
87a
6
5
4
3
2
1
8
9
7
2
1
86 30
Pa
DO-4
142
DO-5
B
85 8787a
E
B
Pf
1
1
2
2
85 8787a
12 12 ECM-ACCEL POS RETURN
85 8787a
R/WASHER
6
Pa
FRONT
Pa
85 8787a
85 8787a
ILLUMINATION
86 30
86 30
24V(DETEND)
24V(HANDLE)
SEAT HEATER PARKING WASHER CLUTCH FLASHER
86 30
86 30
86 30
M
KICK DOWN
9
7
8
2
BUCKET(-)
UNIT
9
9
7
8
STOP CUT-OFFF
7
2
STOP
2
NEUTRAL
SAFETY RY NEUTRAL BACK-UP RY
9
HORN RY
7
8
2
BOOM(-)
LAMP LAMP CLUTCH CUT-OFF SW PARKING SW RIDE CONTROL SW
ECONO SW
FWD
GND
REV
RIDE CONTROL FUEL WARMER
9
7
8
2
NC
REAR WIPER BOOM UP BUCKET PREHEAT RY
SEAT HEAT SW 7307AEL00
7-3
CN-99
7A V INLET M/ACT TEMP M/ACT MODE(D/FOOT) MODE(VENT) RESISTOR RELAY(HI) RELAY(M2)
A A
8A G CN-23
B ELEC. STEERING SW 17 2 7 2 7
MIRROR HEATER SW BEACON LAMP SW W 1 M 4 1 M 4
BLOWER
3
1 3 M
1
C B 3 M 7 7
Lo 1
8
18
Hi 4
9
ML 2
MH 3
1 2 L
2
8
7
9
CN-12 2 5 5
M
CN-93
4
2
2
10 GOr GOr 1 1 GOr BEACON
5
6
7
1
2
3
4
5
6
7
1
2
3
4
5
6
7
1
2
3
4
5
6
7
1
2
3
4
1 1 OFF IDLE SW 1 SPEAKER LH
11 OrW OrW 2 2 OrW LAMP
1
2
3
4
2
1
2
11 ON IDLE SW
1
4
4
2
3
2
3
DO-7
GW
14 3 3
23 WR
B B B
BW
WB
BG
BG
GB
GB
M
GL
YB
LR
LB
10 10
3 23 ACCEL POSITION RETURN
10 10
5 5
7 6
20A Y
5 6
CS-76
CS-80
5 5
7 6
27 YBr
13 4 4
CS-23
35 YW
W W W CN-24
26 LG
YW
BG
4
RY
RY
YB
2B
9 ACCEL POSITION SIGNAL
CL-7
19
36A L
OR
L
1
12 5 5
9
10
9A
9B
Gr Gr Gr
L
6
21
22
17
20
18
19
24
25
16
15
1
1
3
3
9
9
2
4
5
6
8
7
5 22
GrW
ACCEL POSITION SUPPLY
ROr
9 BOr BOr 6 6 BOr 20 GY
33A
Gr
2
6B
6A
32
36
29
33
36
28
35
6 34 SWITCH RETURN
L
L
3 V V 7 7 V
7
22 GY
46 J1939(+)
LW
22 GY
SPEAKER RH
G1 B
W
0.85
0.85
3A 0.85
G
4 8 8
0.85
0.85
0.85
G G G
7H R
6E B
11 B
7E R
7F R
G4 B
G5 B
G7 B
8 47 J1939(-)
5 SH SH 9 9 SH
9 37 J1939 SHIELD
9
6 LW LW 10 10 LW CN-27
2
3
3
10 40 AIR-HEATER OUTPUT 17 W
7 BW BW 11 11 BW 1 S.L+
11 42 AIR-HEATER RETURN 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 G
8 WOr WOr 12 12 WOr 2 ACC
12 39 POWER IG 7 R
67 Or Or 26 26 Or 3 ILL+
13 31 ALT TORQUE CN-246A CN-246B 19 OR
15 W W 13 21 BOr 4 S.R+
14 28 COOLANT LEVEL 6A B
68 BOr BOr 21A 21 BOr 5 ILL-
15 32 COOLANT LEVEL RETURN
ONE PEDAL DUAL PEDAL 18 L
6 S.L- CN-11 NO.
3 Y DESTINATION
7 B+ 1,2 BR
CN-94 20 GY 1 1 GND(CONTROLLER)
13A W 8 S.R- 32 2B
13E W
15 B
4
3
BATT (+)
BATT (+) BRAKE PEDAL TYPE 6 B
9 GND 6
10
RY
RW
2
3
2
3
GND(BLOWER)
FUSE(IG)
2 BATT (-) CASSETTE RADIO 4 4 MCU
16 B 33 2R
1 BATT (-) 5 5 FUSE(Battery)
30 LW
6 6 DPS(COMPRESSOR)
CN-7 31 LY
CD-45 G 1 7 7 CONDENSOR FAN
24 Br 1 FUSE-CASSETTE 1 5 G
2 RW 2 8 8 ILLUMINATION
CN-13 25 V 2 WORK LAMP RY FRONT 2 CL-1
1 Y 3 3A Y AIR CON
1 3 FUSE-CASSETTE/ROOM LAMP 3 2
WIF SENSOR LW 4 21 Or
2 4 MIRROR HEATER CONT. 4 1
WB 15
BW 16
LR 17
BG 18
GL 19
Y 20
GW 21
BG 22
WR 23
LB 24
YB 25
LG 26
YBr 27
BG 28
YB 29
LW 30
LY 31
GB 10
5 G2 B
1
2
3
4
5
6
BrR 8
GB 9
3 WIF 5 NC B 6
16 LW LW 23
RW
RW
25 V 6
BR
BR
RY
1.25LgB 9
6
8
4 1 14 WIF SIGNAL GND
ROOM LAMP
G
16A LW LW 23A R 7
24 Br 7 ILLUMINATION 7
5 2 47 WIF RETURN B G21 CL-30
1.25G
6 8 GND 8 3E Y
CUMMINS CONNECTER 2
10
11
12
13
14
15
16
17
18
10
11
12
13
14
18 BW BW 17
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
7 9 NC 9 21A Or
19 YW YW 18 B G1 1
TEMP MOTOR ACT(+)
DUCT SENSOR(GND)
10
TEMP MOTOR ACT(-)

CN-28
BLOWER RELAY(M1)
BLOWER RELAY(M2)
COMPRESSOR(DPS)
BLOWER RELAY(LO)
10 GND
MODE M/ACT(FOOT)
8
INLET MOTOR(REC)
BLOWER RELAY(HI)
INLET MOTOR(FRE)
G 9 G3 B
MODE M/ACT(PBR)
VW VW
MODE M/ACT(DEF)
REVERSE FAN SIG

34 19 19 VW
TEMP M/ACT(PBR)
11
MOTOR ACT(REF)
CONDENSER FAN
DUCT SENSOR(+)
MODE M/ACT(M+)
11 FUSE BOX
1
2
9 1
MODE M/ACT(M-)
G21 B B G3 B G27
12 GND 12
ILLUMINATION
10
G22 B B G1 CS-1
BATTERY(+)
BATTERY(+)
11 13 MCU 13
R 10 21 Or
POWER IG
20 G G 20 AIR COMP. 14
12 CN-96 14 WORK LAMP REAR
15 15
23 LW DUCT
GND
GND
1
NC
NC
NC
NC
NC
G2 B CN-8 DOOR SW SENSOR
2
L 13
3 1 FUSE BOX 1
V 14
4 2 REAR WASHER 2 AIR CONDITIONER & HEATER CONTROLLER
W 15
3 WIPER PF 3
FUEL HEATER 4
Or 16
4 WIPER ON SIG
CR-24 CN-80 5 NC 5
15R VW 12
20 G 6 MIRROR HEAT TIMER 6
W 8
7 STEERING SW 7
CN-45 CR-23 PREHEATER GrW11
8 FUSE 8
M B G1
1
M BW 17 PREHEATER RY.
2
B+
START RY.
STARTER
G8
7A
15
14
13
16
G25
G30
B G21
B G22
B G24
B G23
G26
G29
10A
10E
10F
Or
FROM BATT.RY
RW 2F
W
RW 2A
RW 2E
10
R
V
B
RW 2
G10
VW 12A
G9
VW 12
CN-74 15 R
CS-35
R
R
R
B
B
B
B
R 22 22 R
10 10
5
4
1
6
2
9
3
B+ 2
B
18A YW 3W/300
CL-22
CL-6
CL-5
CL-23
G 1
6
3
CL-35
CL-36
CL-32
CL-33
P 1
1
2
2
0,
I
CN-149
~ 3 YW 18 RS-1
CN-150
L 2
1
2
1
2
U FI 3
NC 4
ENGINE HARNESS 0 I
1
8
ALT WORK LAMP FR WORK LAMP FRONT WORK LAMP REAR WORK LAMP REAR
REAR WIPER SW
MIRROR HEATER
CS-74
OPTION
CN-60 AC-11 AC-1
1 5R
2 18 18
1 Y 23 23 Y
17 17 CONDENSER FAN
LW 24 24 LW
16 16 COMPRESSOR(DPS)
MASTER SW YW 25 25 YW
15 15 BLOWER RELAY(HI)
BOr 26 26 BOr
14 14 BLOWER RELAY(M2)
YW 27 27 YW
13 13 BLOWER RELAY(M1)
LW 28 28 LW
CN-95 12 12 BLOWER RELAY(LO)
2 5W Y 29 29 Y
2 11 11 MODE M/ACT(PBR)
69 5W LW 30 30 LW
1 10 10 MODE M/ACT(M-)
WOr 31 31 WOr
FUSIBLE LINK 9 9 MODE M/ACT(M+)
CR-1 BW 32 32 BW
8 8 MODE M/ACT(FOOT)
66 GY 33 33 GY
G 7 7 MODE M/ACT(DEF)
Y 34 34 Y
G12 B 6 6 MOTOR ACT(REF)
G 35 35 G
5 5 TEMP M/ACT(PBR)
BATTERY BOr 36 36 BOr
BATT. RY 4 4 TEMP MOTOR ACT(-)
L 37 37 L
3 3 TEMP MOTOR ACT(+)
BW 38 38 BW
TO STARTER 2 2 INLET MOTOR(FRE)
WOr 39 39 WOr
1 1 INLET MOTOR(REC)
66A G
2
G13 B AC-22
1 AC-2
DO-2 14 14 NC
66 G 13 13 NC
CN-1 2
5R 1 22 L 12 12 NC
1 FUSE BOX 1 1
5W 2 11
2 FUSE BOX 2 11 NC
DO-1 GW 40 40 GW
10 10 NC
GW 40 40 GW
9 9 DUCT SENSOR(GND)
CN-2 BW 41 41 BW
V 3 8 8 DUCT SENSOR(+)
1 J1939+ 1
G 4 7 7 NC
2 J1939- 2 R 42 42 R
SH 5 6 6 POWER IG
3 SHIELD 3 G 43 43 G
LW 6 5 5 ILLUMINATION
4 AIR-HEATER RY+ 4 RW 44 44 RW
BW 7 4 4 BATTERY(+)
5 AIR-HEATER RY RETURN 5 RW 45 45 RW
WOr 8 3 3 BATTERY(+)
6 FUSE-IG 6 BrW 46 46 BrW
BOr 9 2 2 GND
7 THROTTLE RETURN 7 BrW 47 47 BrW
GOr 10 1 1 GND
8 THROTTLE OFF-IDLE 8
OrW 11
9 THROTTLE ON-IDLE 9
Gr 12
10 ACCEL-SUPPLY 10
W 13
11 ACCEL SIG 11
B 14
12 ACCEL RETURN 12
CABIN HARNESS
CN-3
Or 67
1 ECONO SW 1
2
3
FUEL HEATER RY OUT
ECONO SW
2
3
LW 16
BOr 68 FRONT HARNESS(HL730TM-7A)
BW 18
4 ANTI-RESTART RY 4
YW 19
5 MCU-ALT 5
SH 24
6 SHIELD 6
G 20
7 PRE-HEAT RY OUT 7 6
BrW 21 FROM BATT. RY
8 NC 8 ON IDLE
L 22
9 START KEY SW-br 9 4
Y 25
10 MCU-FAN CLUTCH+ 10
L 26
M
1
11 MCU-FAN CLUTCH- 11 BOr 46 MOTOR RY
ROr 23 6
12 NC 12 GOr 47
2 5
13 NC 13 CN-154(GRAY) OrW 48
W 15 25 Y 4
14 FUSE-Bat24V 14 2 3 Gr 49 CD-40
26 L 3
15 NC 15 1 W 50 CN-19 5A B
2 2 Pa
5 B 51 3 OrW OrW 1 3 G
FAN PROPORTIONAL V/V OFF IDLE 1 1 1
CN-4 4 GrW GrW 2
L 27 CN-155(BLACK) SOL 2
1 NC 1 30 G THROTTLE ASSEMBLY CN-162 CONT.VALVE BOOM DOWN 2 G
3
G 3 STR PUMP PS
2 BrW 28 2
2 AC CON FAN RY 31 GW 1 GOr GOr 4 CD-39
Y 29 1 4
CN-136
3 NC 3 10 B B 5 5 B
Pa
G 30 FAN REVERSE SOL 5 2 Pa
SHIFT LEVER
CD-41
4 FUSE-beacon/steering 4 MULTI FUNCTION SWITCH 4 GOr
GW 31 CS-79 6 1
2
1
5 5
AD7
AS AD6
R AD5
V AD4
B3 AD3
B2 AD2
B1 AD1
MCU-revese sol CLUSTER
1
2
Lo Y 7
Y 32
B 5
WB 8
BG 3
BW2
1 MAIN PUMP PS
VM
6 AC CONTROLLER 6
VP
ED
Or
V 33 42 W
B
7 AC COMP RY 7 CN-83 2
MIRROR HEATED
LW
PROGRAM DUMP
Or
VW 34 28 BrW
8 AC COMP RY OUT 8 1 M 3 EMERGENCY STEERING
ILLUMINATION
4 3 2 1 4 3 2 1 4 3 2 1
R
O
35 G11 B
L
L
2
3
4
F
9 BACK-UP RY OUT 9 2
HIGH BEAM
Lo Hi F
CN-18
F/R SIGNAL
2
1
B+
RW 36
C
BATT. 24V
1
5
SERIAL_H
RS232 RX
SERIAL_L
RS232 TX
FRONT WIPER
RH TURN
10 FUSE-ILLUMINATION 10 AC COND FAN

LH TURN
Or 37 45 Or 1 LW LW 6
OUTPUT SIGNAL
11 6 1 CL-3
IG 24V
IG 24V
11 MULTI-FUNCTION SW -RH
O
1A LW Or 9 15A GW
II
I
ROr 38 CN-29
GND
OJ
GND
GND
2
12 FUSE-ILLUMINATION 12 2 1 Lo
6 RW W
32 Y
4 BWG C
NC
NC
NC
1 BY C
B G1
Hi
3 B 12A
HO
39 V
J
Y 2 Pa
I
R
Hi
CN-56
13 MULTI-FUNCTION SW -LH 13 3 2
X1
33 V
X2
R 40 7E ROr 14 G
M
1
AD5(R) C
AD6(N) D
A
D
C
AD4(F) B
A
9 4 3
2 Gr
C
6 W
14 NC 14
5 G
4 L
G5 B G32
16
14
19
18
17
13
12
10
20
15
11
B
Br 41
RIDE CONTROL
9
7
8
1
5
4
3
2
15 STOP LAMP SW 15 R/DRY 10 4 E

Y
AD1
AD2
AD3
3
3 E
2 Pf
5 Lo
ED1(VP)
4 Hi
SPARE
AD7(KD)
HEAD LIGHT LH
N
CD-1
BrW
ROr
ROr
1
CS-11
CS-12
43 Br
Or
Or
CS-5
W
W
CS-77
G
CL-24
R
B
V
37A B
Y
V
L
4
5
HAZARD SW
2
2 C
6
1
3
4
1
3
2
7
CN-5 42 B G2 B
CN-21
1 1
2
1
5
3
1
1
2
8
7
9
12A
1 NC 1 44 L 16 Y
7A
2E
1E
D
15
37
14
13
40
10
11
12
K
CN-178 2
BrW
VOr
2
6
9
4
5
B
GW
42 HYD. TEMP
CN-158
LW
YW
GY
2 GND-MCU
Gr
Br
Or
W
2 GW 1
CN-159
G
CN-140 COMBI LH
X1
3
X2
Br 2
VOr
43
C
D
D
B
A
B
A
3 MCU-HYD TEMP 3 CD-10 B 3 GW 18
W
1 GW
G
R
B
BOr 44 44 BOr 4 1 1
4 MCU-AIR CLEANER CN-20
16
22
23
24
25
17
18
19
20
38
21
4 Pa 2 W W 19 G11 B
10 10
3
2
1
42A B 5
5 5
7 6
CS-41
V 45 2
G1
ATT. LOCK
GrW
5 MCU-FUEL SENDOR 1
26
27
38
28
5 41A GrW
RW
VOr
3 B B G14
LW
W 6 5 V
Br
46
W
6 3
3
TCU-EF2
L
2
2
6
1
8
9
6
B
AIR-CLEANER 7 6 2 CN-177
7 TCU-VMG1 47 W 2
7 2 HORN
8
36
29
30
31
32
33
34
35
ROr
B
BrW
BrW
8 NC 8 CD-46 7F ROr 3A CN-25

1
Or
BOr 48 BOr 9 G12 B

Y
9 TCU-VMG2 48 1
9 1 G4 B
10 10 9
10 Br 49 49 Br ATT. UNLOCK QUICK COUPLER 5A V
G2
TCU-EF4 2
1A
2A
3A
3E
10 2
7
11 FUSE-TCU L 50 50 L ATT.LOCK
11 3
12 TCU-VMG1 B 51 CN-9 CL-4
12 SPEED SENSOR OUTPUT CS-78 GW
W 52 GOr 1 15
13 TCU-EF3 13 1 MCU 1 1 Lo
CD-47(BLACK) 1 G 2 12 V
14 NC 14 51 B 43 GW 2 MCU 2 2 Hi
2 2 OrW 3 13 ROr
15 NC 15 52 W 3 NC 3 3 C
1 3 GrW 4 G31 B
4 NC 4 4 E
INTER GEAR PICK-UP CL-21 4 V 5
CN-6 36A RW 5 HORN RY 5 HEAD LIGHT RH
2 5 LW 6
1 NC 1
CD-27(GRAY) G1 B 41 GrW RIDE CONTROL SW 6
46 W 1 6 G 7
BOr 58 6
2 TCU-VMGA2 2 1 7 BUCKET RY 7 CL-25
W 54 47 B NUMBER PLATE LAMP 7 6 2 Br 8 G3 B
3 TCU-EF1 3 2 8 BOOM UP RY 8 1
B 55 CD-2 8 Or 9 17 Or
4 TCU-VMG1 4 TURBIN PICK-UP 42E 7H ROr 9 RIDE CONT. RY 9 2
13
BrW 14
15
B 9 W 19
6
G1
WOr 56 1
B 6A
16
17
18
19
20
21
22
23
24
25
10
37
V 40
ROr 11
W 12
26
27
28
29
30
31
32
33
34
35
36
5 TCU-ER3
B 51
W 50
Gr 49
OrW48
GOr 47
BOr 46
Or 45
44
GW 43
GrW41
W 42
10
3
2
1
5 V G3 B COMBI RH
4
ROr 7
45 10 ATT. UNLOCK SW
BOr 57 CD-17 2 10 10 9 B 10
GrW
BrW
6 TCU-ER2 11
GW
W
VOr
54
YW
6
RW
LW
11 GND(MCU)
G
GY
R
LW
Or
Gr
Or
GW 18
Br
1
V
B
Y
Br
FUEL SENDER
W
W
L
G
V
ATT.UNLOCK
B
L
L
L
L
7 NC 7 55 B 12 ATT. LOCK SW 12
CN-169
CN-16
CN-163
BW 53 2 CN-17
CN-15
8 TCU-ER1 8 CN-65
4
3
1
2
59
10
10
G ENG. PICK-UP
12
15
14
13
12
15
14
13
12
11
10
11
11
G5 CN-10 CN-100
7
6
5
4
3
2
1
7
6
5
4
3
2
1
9
9
8
12
11
10
9 TCU-AIP6 B
9
8
7
6
5
4
3
2
1
9
8
7
6
5
4
3
2
1
9 1 11 11
LW 60 35 1 FUSE R R
10 TCU-AIP5 10 CD-48 L 2 1 1 B
61 56 WOr V 12 G21 B
MULTI-FUNCTION SW(Hi-BEAM)
11 TCU-AIP4 V 2 MULTIFUNCTION SW 2 3 E
11 1
OrW 62 58E BOr BACK BUZZER 3 GND B G1 8 Br
12 TCU-AIP3 12 Pa 3 4 S
TM CONTROLER(ED4-FWD)
2
TM CONTROLER(ED6-NEU)
TM CONTROLER(ED5-REV)
Gr 63 4 GND B G11
13 TCU-AIP1 4
RW CL-16 BOOM KICK OUT
13 G21
W 64 FILTER RESTRICTION 36 B
MCU&FRONT WASHER
14 TCU-VPS1 5 GND 5
TM CONTROLER(ED1)
TM CONTROLER(ED2)
TM CONTROLER(ED3)
MIROR HEATED CON.
14 4 C
FUSE BOX(BATT 24V)
TM CONTROLER(KD)
YW 65 CD-49 37 Or 6 ILLUMINATION(FUSE) ROr 13

15 TCU-AIP2 6
TM CONT.(ERROR)
15 58A BOr 3 T
FLASHER UNIT(L)
RW 14
ATT.UNLOCK SOL
G4 B 7
DESTINATION
ELEC.STEERING
DESTINATION
WIPER RY-Hi&Lo
C ILLUMINATION(FUSE) 7 CN-101
2 E
ACCEL RETURN
TURN LAMP (R)
57 BOr
MCU(SERAL-H)
TURN LAMP (L)
ACCEL SUPPLY
HEAD LAMP-Lo
11A R
MCU(SERAL-L)
HEAD LAMP-Hi
15
ILLUMINATION
GW
ATT.LOCK SOL
41
MCU (INT SIG)
Br
FUSE BOX(IG)
1 8 MULTIFUNCTION SW
SHIELD(GND)
1
WIPER RY-Lo
WIPER RY-Lo
8 B
WIPER RY-Hi
WIPER RY-Hi
1 S Y 16 G22 B
9 MULTIFUNCTION SW
FUSE BOX
FUSE BOX
FUSE BOX
ACCEL SIG
TEMP CONVERTER 9 3 E
LIGHT SW
FUSE BOX
F/R LAMP
HORN RY
17 7 G
IDLE OFF
REAR COMBI RH Or
RETURN
10 MULTIFUNCTION SW
IDLE ON
CN-112 10 4 S
11 GND TM 11
GND
GND
16 CL-15 BUCKET LEVELER

17
NC
NC
NC
NC
NC
58 BOr 38 ROr Or
NC
NC
NC
9 TEMP 4 C 12 GND STD 12
53 BW 39 Y 13 NC 13
8 TEMP 3 T
64 W G6 B B G31
NO.
NO.
GND
12
11
10
15
14
13
12
11
10
15
14
13
12
11
10
FWD REV 14 14
12
11
10
7 VPS1(+) 2 E
9
8
7
6
5
4
3
2
1
9
8
7
6
5
4
3
2
1
9
8
7
6
5
4
3
2
1
9
8
7
6
5
4
3
2
1
59 G 1 2 3 4 1 2 3 41A Br 15 NC 15
6 Y6 1 S
60 LW Y5
G21
5 Y5
G11
G1
61 V Y2
73
4 Y4 REAR COMBI LH
62 OrW Y3
3 Y3 Y6
65
63
YW
Gr
2
1
Y2
Y1
Y4
Y1
FRAME HARNESS FRONT HARNESS(HL730-7A)
GEARBOX EARTH1
TRANSMISSION
7307AEL01
7-4
MEMORANDUM
7-5
1. ILLUMINATION CIRCUIT
1) OPERATING FLOW
Fuse box (No.2) Illumination switch [CS-21(1)] Switch ON, 1st step
[CS-21(7)] All switch indicator lamp ON
[CS-21(5)] Fuse box(27) I/conn [CN-4(12)] LH Combi clearance lamp ON [CL-15(4)]
I/conn [CN-10(6)] RH Head lamp ON [CL-4(3)]
I/conn [CN-15(10)] Cluster [CN-56(17)] All cluster gauge and
LCD lamp ON
Hazard switch indicator lamp ON
Attachment lock / unlock switch ON
Fuse box(28) I/conn [CN-4(10) Number plate lamp ON [CL-21(2)]
RH Combi clearance lamp ON [CL-16(4)]
I/conn [CN-10(7)] LH Head lamp ON [CL-3(3)]
2) CHECK POINT
Engine Key switch Check point Voltage
Η - GND (Switch input)

Θ - GND (Switch output)
OFF ON 20~25V
Ι - GND (To light)
Κ - GND (To cluster)
ö GND : Ground
7-6
ILLUMINATION CIRCUIT
FUSE BOX
BEACON/RR WORKLAMP 20A
1
10 OrW ILL.LAMP 20A
2
HEAD LAMP 20A
3
BACK/STOP LAMP 10A
4
24
CLUSTER 10A
25
CASSETTE 10A
26
7 ROr ILLUMINATION LAMP 5A
27
6 RW ILLUMINATION LAMP 5A
28
CN-36
R 35
LH HEAD LIGHT
3 1 Lo
1 2 Hi
14 G
2 3 C
G32 B
3 4 E
2 4 CL-3
5
ILL & HEAD LAMP SW 7A ROr ROr 13
6
B G35 6A RW RW 14
9 10 10 R 1H
7 RH HEAD LIGHT
9 8 3 1 Lo
4 8 9 2 Hi
2 R 1 13 ROr
7 10 3 C
7 G31 B
1 6 11 4 E
5 R 35
5 12 CL-4
4 13
3
B G31 NUMBERPLATE LAMP
3 14 36A RW
II I 0
2 2
15 G1 B
OrW 10 1
1 CN-10
CS-21 CL-21
3
1
1 2 RH COMBI REAR
3 36 RW
4 C
4
3 T
5 G4 B
2 E
6
ALL SWITCH INDICATOR LAMP ON 1 S
7
CL-16
8
6 RW
9
RW 36 3 LH COMBI REAR
10
38 ROr
11 4 C
7 ROr ROr 38
12 3 T
G6 B
13 2 E
14 1 S
CN-4 CL-15
CLUSTER
12 20 RS232 RX
19 GND
11 18 NC
7E ROr 7A ROr
10 17 ILLUMINATION
9 16 F/R SIGNAL
15 SERIAL-L
4 8 14 SERIAL-H
7 13 NC
B 37 37A B
6 12 GND
5 11 GND
37 B 10 RS232 TX
CN-15 9 PROGRAM DUMP
8 NC
7 MIRROR HEATED
6 HIGH BEAM
5 RH TURN
4 LH.TURN
10 10 7H ROr
10 10 7F ROr
10 10 7 ROr
3 BATT 24V
2 IG 24V
1 IG 24V
CS-78
CS-77
CS-41
CN-56
9
8
6 7
6
5 5
4
3
2
1
9
8
6 7
6
5
4
3
2
1
9
8
6 7
6
5
4
3
2
1
8
2
7
1
9
9
9
2
ATTACH UNLOCK SW ATTACH LOCK SW HAZARD SW
7307AEL03
7-7
2. HEAD LIGHT CIRCUIT
1) OPERATING FLOW
Fuse box(No.3) Head light switch [CS-21(4)] Light switch ON, 2nd step [CS-21(2)]
I/conn [CN-16(7)] Multi function switch [CS-11(8)]
Multi function switch MIDDLE [CS-11(7)] I/conn [CN-16(6)] I/conn [CN-10(8)]
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-16(5)]
I/conn [CN-10(2)]
LH Head light high beam ON [CL-3(2)]
RH Head light high beam ON [CL-4(2)]
I/conn [CN-15(7)]
Cluster high beam pilot lamp ON [CN-56(6)]
2) CHECK POINT
Η - GND (Switch input)

Θ - GND (Switch output)
Ι - GND (Multi function input)
Κ - GND (Multi function output)
OFF ON 20~25V
Λ - GND (Multi function output)
Μ - GND (Low beam)
Ν - GND (High beam)
Ξ - GND (Passing B+)
ö GND : Ground
7-8
HEAD LIGHT CIRCUIT
FUSE BOX
1
ILL.LAMP 20A
2
11 YW HEAD LAMP 20A
3
BACK/STOP LAMP 10A
4
24
CLUSTER 10A
25
CASSETTE 10A
26
ILLUMINATION LAMP 5A
27
28
CN-36
LH HEAD LIGHT
15A GW
1 Lo
7 12A V
2 Hi
3 C
ILL & HEAD LAMP SW 1 G32 B
68 V V 12 4 E
2
9 10 10 1
9 3 CL-3
4 8 4
2 RH HEAD LIGHT
7 5 6 15 GW
1 Lo
7 1 6 6 12 V
5 2 Hi
5 7
11 YW GW 15 3 C
4 8 G31 B
134 GW 4 E
11E YW
3 9
161 W
II I 0
2 13 CL-4
1 B G31
14
CS-21 15
CN-10
2
CLUSTER
20 RS232 RX
19 GND
CN-16
18 NC
1
2
3
4
5
6
7
8
9
17 ILLUMINATION
16 F/R SIGNAL
15 SERIAL-L
14 SERIAL-H
13 NC
12 12 GND
11 11 GND
10 10 RS232 TX
9 PROGRAM DUMP
9 8 NC
68A V 8 7 MIRROR HEATED
10 V
7 6 HIGH BEAM
6 5 RH TURN
5 4 LH.TURN
3 BATT 24V
4 2 IG 24V
3 1 IG 24V
4 2
GW
YW
CN-56
W
3 1
5
25
22
23
24
CN-15
8
CS-11
5
8
4
7
3
2
1
BWG 4
W6
Hi
C
Lo
Hi
B+
C
F
R
L
O
R
L
7 Y Lo
2 BW
8 WB
3 BG
5B
MULTI FUNCTION SW
7707AEL04
7-9
3. WORK LIGHT SWITCH
1) OPERATING FLOW
ö Illumination switch : ON position(1st step)
(1) Work lamp switch ON (1st step)
ILL & head lamp switch [CS-21(7)] Work lamp switch indicate lamp ON
Work lamp switch [CS-36(1)Ą(7)]
Front work lamp relay[CR-3(30)Ą(87)] I/conn [CN-7(2)]
RH Front work lamp ON [CL-5(2)]
LH Front work lamp ON [CL-6(2)]
(2) Work lamp switch (2nd step)
Work lamp switch [CS-36(4)Ą(2)] Rear work lamp relay [CR-55(30)Ą(87)]
I/conn [CN-7(14)] LH Rear work lamp ON [CL-22(2)]
RH Rear work lamp ON [CL-23(2)]
2) CHECK POINT
Η - GND (Work lamp power input)

Θ - GND (Work lamp power output)
OFF ON 20~25V
Ι - GND (Front work lamp)
Κ - GND (Rear work lamp)
ö GND : Ground
7-10
WORK LIGHT SWITCH
FUSE BOX
5 G BEACON/RR WORK LAMP 20A
1
10 OrW ILL.LAMP 20A
2
HEAD LAMP 20A
3
BACK/STOP LAMP 10A
4
HORN/CONVERTER 30A
5
AIR-CON/HEATER 30A
6
CIGAR LIGHTER/MIRROR 30A
7
SWITCH 30A
8
WIPER 20A
9
15 Gr FR WORK LAMP 30A
10
EMER STEER/RIDE CON 20A
11
CN-36
OPT
FRONT WORK LAMP
RW 2F
2
B G24
1
CL-36
FRONT WORK LAMP
2 RW 2E
2
B G23
FR WORK LAMP RY 1
86 30 87a CL-35
B G16
85 1
RW 171 RW 2 FRONT WORK
87 2 LAMP,LH
G 170 RW 2A
86 3 2
85 87 87a Gr 15 B G22
30 4 1
CR-3 5 CL-6
6 3
1 7 B G21 FRONT WORK
8 LAMP,RH
RW 2
9 2
B G1 B G21
10 1
11 CL-5
12 OPT
13 REAR WORK LAMP
R 10 R 10
14 2
B G25
15 1
2 CN-7 CL-32
RR WORK LAMP RY REAR WORK LAMP
86 30 87a R 10A 2
B G17 B G26
85 1
R 63
87 CL-33
L 180
86
85 87 87a Gr 5 REAR WORK
30
LAMP,LH
CR-55 10E R
2
G29 B
1 1
WORK LAMP SW CL-22
B G36
9 10 10
9 R 1G 4
4 8 REAR WORK
2 G 170 LAMP,RH
7 10F R
2
7 1 6 G30 B
5 1
5
R 1F CL-23
4
3
L 180
II I 0
2
1 R 1E
CS-36
CS-21
9 10 10
9
4 8
2 R 1
7
7 1 6
5 5
4
3
II I 0
2
OrW 10
1
ILL & HEAD LAMP SW : ON(1st step)
7407AEL05
7-11
4. STARTING CIRCUIT
1) OPERATING FLOW
Battery(+) terminal Fusible link [CN-60(1)Ą(2)] Master switch [CS-74]
I/conn [CN-1(1)] Fuse box (No.15) Start switch [CS-2(1)]
ECM power relay [CR-25(30)]
Power relay [CR-35(30)]
ö The gear selector lever is neutral position. It is necessary condition before the starting.
The gear selector 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-3(9)] Battery relay [CR-1]
Battery relay operating(All power is supplied with the electric component)
Start switch [CS-2(3)] ECM power relay [CR-25(30)Ą(87)] Fuse box[No.21]
I/conn [CN-2(6)] I/conn [CN-12(12)]
ECM[CN-93(39)]
Power relay[CR-35(30)Ą(87)] Fuse box[No.23]
MCU[CN-58(12)]
(2) When start key switch is in START position
Start switch START [CS-2(5)] Start safety relay [CR-5(30)Ą(87)] I/conn [CN-3(4)]
I/conn[CN-13(7)] Start relay [CR-23(2)] Starter(Terminal B and M connector of start motor)
+
2) CHECK POINT
Η - GND (Battery B+)

Θ - GND (Fusible link)
Ι - GND (Start key B terminal)
Κ - GND (Start key BR terminal)
Running ON Λ - GND (I/conn CN-3(9)) 20~25V
Μ - GND (Start key ST terminal)

Ν - GND (Start safety relay output)
Ξ - GND (Start key ACC terminal)
ö GND : Ground
ö ECM : Electronic control module
ö MCU : Machine control unit
7-12
STARTING CIRCUIT
T/M CONTROL UNIT MCU

WARNING
HYD TEMP SENDER
FAN CLUTCH +
CLUTCH CUT-OFF PS
SAFETY RY
BUZZER
COOLANT TEMP
WIPER RY
STEERING RY
ALT LEVEL
FUEL SENSOR
PREHEATER
SERIAL-H
NEUTRAL SIG
FAN CLUTCH -
ADM2-JOYSTICK SELECT LAMP(-)
ELEC STEERING
ADM5-JOYSTICK SELLECTER(+)
CLUTCH CUT-OFF SW
SERIAL-L
GND
AUTO SEL.SW
ADM1-START INTERLOCK RY(-)
AIR FILTER
IG 24V
BUZZER
ED9-CLUTCH CUT-OFF SW(+)
ADM4-REVERSE DRIVE RY(-)

ED6-SHIFT LEVER X2D-NEU
CN-26
ED2-SHIFT LEVER X1B-B2
VPE2-CONTINUANCE 24V
FUSE BOX
ED14-NEU-JOYSTICK
ED13-REV-JOYSTICK
ED8-FWD-JOYSTICK
2
1
10
27A RW
115 W
11
17 G NEUTRAL RY/JOYSTICK F/R 10A
12
PREHEATER 30A
22
21
23
35
34
24
36
31
26
25
32
33
27
30
29
28
11
12
10
13
14
NEUTRAL RY 13
GEAR SELECTOR LEVER X-1 G 17 TURN LAMP
30 14
65
85 W 66
67
68
44
31
30
52
59
115 W
VM OUTPUT SIGNAL A
5
7
27 RW
K CN-58
73 BOr
G 17A 85 3R 34
86 87a 87
VP F B N D B CN-157 15
C BOr 73 21 3Or START KEY 30A
ED 1 2 3 4 1 2 3 4 1 2 3 4 87 16
AD1 B1 D BOr 88 TCU 10A
AD2 B2
85 17
CN-158 ECM 10A
AD3 B3 87a 30 86 18
AD4 V X-2 CR-38 CLUSTER/MCU 10A
19
AD5 R A 1 AC & HEATER 20A
SAFETY RY 20
AD6 AS B 2 GrW 157
30 26 WOr ECM 10A
AD7 C 3 21
85
86 87a 87
W 33 BOr 73A RCV
A AD3 D 4 10A
BW 151 22
B AD2 CN-159 5 87 27 RW MCU 10A
Or 104 23
C AD1 6 85 10A
TCU
D AD7(KD) 7 24
X1 87a 30 86 CLUSTER 10A
8 25
A ED1(VP) 9 7 CR-5 CASSETTE 10A
26
D AD6 10 ILLUMINATION LAMP 5A
B AD4 27
11 5A
ILLUMINATION LAMP
C AD5 12 28
X2
13
14 CN-36
15 MASTER SW
CN-17
34 3R 1 5R
1 2
2 1
CS-74 FUSIBLE LINK
CN-1 2 5W CN-60
2
69 5W
1
2
BATTERY
BATT RY CN-95
66 G
G12 B
CR-1
1 1
2 STARTER
3 B+
BW 18
4 G 66A
5 2
B G13
6 1 M
7 DO-2 CN-45
G 66
8 2
L 22 L 22 START RY
9 1
21E Or
153 L
157 GrW
65 G
DO-1 G1 B
8 4 10
17 BW
1
11 2
5
12 5
6 3 13
6 CR-23
7
21 3Or
14
G14 B
31 3Br
65A G
G15 B
32 3Y
65 G
21A Or
CS-2
15 8
5
4
1
6
2
3
9 ECM
CN-3
46 J1939 (+)
CR-35
CR-25
87a 85 87 86 30 87a 85 87 86 30 B 10
0, I 47 J1939 (-)
1
11
87a 87a 9 37 J1939 SHIELD
12
30 87 30 87 4 10 40 AIR-HEATER OUTPUT
86 86 CN-13
85 85
H 0 I II
5 11 42 AIR-HEATER RETURN
4
6
5
3
2
8 WOr 12 WOr
C ST ACC BR
H
6 12 39 POWER IG
POWER RY ECM POWER RY START SWITCH 7 13 31 ALT TORQUE
8 14 CN-93
9 15
10 CN-12
11
12
CN-2
7407AEL06
7-13
5. 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
Alternator [CN-74(2)] I/conn [CN-13(8)] I/conn [CN-3(5)] MCU[CN-58(25)]
Cluster charge warning lamp ON
(2) Charging flow
Alternator Starter [CN-45(B+)] Battery relay [CR-1]
Battery(+) terminal Charging
Fusible link [CN-95(1)Ą(2)] I/conn [CN-1(2)] Fuse box
2) CHECK POINT
Η - GND (Battery)
Θ - GND (Battery relay)
Ι - GND (Alternator B+)
Running ON 20~28V
Κ - GND (Alternator 2)
Λ - GND (MCU)
Μ - GND (Fuse box)
ö GND : Ground
ö MCU : Machine control unit
7-14
CHARGING CIRCUIT
FUSE BOX
1
ILL.LAMP 20A
2
HEAD LAMP 20A
3
BACK/STOP LAMP 10A
4
HORN/CONVERTER 30A
5
AIR-CON/HEATER 30A
6
CIGAR/MIRROR 30A
7 MASTER SW
SWITCH 30A
8 1 5R
WIPER 20A 34 3R 2
9
1
33 5W
FR WORK LAMP 30A 2 1
10 FUSIBLE LINK
EMER STEER/RIDE CON 20A CN-1 CS-74 2 5W CN-60
11 2
NEUTRAL RY/JOYSTICK F/R 10A 69 5W
12 1
PREHEATER 30A
13
6 CN-95
BATTERY
TURN LAMP 20A
BATT RY
14
15
START KEY 30A
16
TCU 10A
17 CR-1 1
CN-36 2
STARTER
M
MCU
B+
HYD TEMP SENDER
CLUTCH CUT-OFF PS
SPEEDMETER SIG.
RIDE CONT. AUTO

SAFETY RY
COOLANT TEMP
BUZZER STOP
ELEC STEERING
WIPER RY
STEERING RY
ALT LEVEL
FUEL SENSOR
TACHO SENSOR+
PREHEATER
SERIAL-H
MAIN PUMP PS
WASH SIG
NEUTRAL SIG
CAN-H
AUTO SEL.TCU
CAN-L
CLUTCH CUT-OFF SW
STEERING P/P PS
RIDE CONT. ON
WIPER INT SIG
PARKING SIG
SERIAL-L
GND
BUZZER
AUTO SEL.SW
FAN CLUTCH +
BRAKE PS
TAHCO SENSOR -
AIR FILTER
CN-45
IG 24V
FAN CLUTCH -
23
35
34
24
36
31
26
32
25
33
27
21
20
30
29
28
22
17
19
11
18
16
12
10
13
15
14
1
2
3
6
8
4
5
7
9
CN-58
112 YW
1
2
3
1 4
2 5
3 6
22 R
4 7 2
112 YW 19 YW YW 18 18A YW 3W/300
5 8 1
6 9 RS-1
7 10 15 R CN-74
8 11 22 R
B+
9 12 G
18 YW
3 1 P
3~
10 CN-13 2 L
11 3 FI U
12 4 NC
4
13 ALTERNATOR
14
15
CN-3
7407AEL07
7-15
6. ELECTRIC PARKING, DECLUTCH CIRCUIT
1) OPERATING FLOW
(1) Parking OFF
Fuse box (No.8) Parking switch OFF [CS-17(6)Ą(8)] Parking solenoid ON (Activated)
Parking brake released (By hydraulic pressure)
[CS-17(5)Ą(7)] T/M control unit[CN-157(21)]
(2) Parking ON
Fuse box (No.8) Parking switch ON Parking solenoid [CN-71] OFF
Parking brake applied [By spring force]
(3) Declutch ON
Fuse box (No.8) Clutch cut-off switch ON Clutch cut-off switch [CS-42(5)Ą(1)]
I/conn[CN-246(2)Ą(3)] MCU [CN-58(10)Ą(29)] I/conn[CN-246(4)Ą(7)]
Service brake applied Service brake pressure switch ON [CD-5] I/conn[CN-246(6)Ą(5)]
T/M control unit [CN-157(66)] Declutch
2) CHECK POINT
Η - GND (Parking switch input)

Θ - GND (Parking switch output)
Ι - GND (Parking switch input)
Running ON 20~25V
Κ - GND (Parking switch output)
Λ - GND (Parking solenoid)
Μ - GND (Pressure switch clutch cut-off)
ö GND : Ground
7-16
ELECTRIC PARKING, DECLUTCH CIRCUIT
CLUTCH CUT-OFF PS
SERIAL-L
RIDE CONT. AUTO

SAFETY RY
BUZZER STOP
WIPER RY
STEERING RY
FUEL SENSOR
PREHEATER
WASH SIG
NEUTRAL SIG
CLUTCH CUT-OFF SW
STEERING P/P PS
TACHO +
RIDE CONT. ON
WIPER INT SIG
PARKING SIG
SERIAL-H
AUTO SEL.SW
BRAKE PS
ED10-PARKING BRAKE SW(+)

ED5-SHIFT LEVER X2C-REV
ED7-SHIFT LEVER-X1D-KD
ED3-SHIFT LEVER-X1A-B3
ED1-SHIFT LEVER X1C-B1

EF1-SPEED PICK-UP ENG
VGS-CAN SHIELD
CANF_H
36 35 34 33 32 31 30 29 28 11 10 9 8 7 6 5 4 3 2 1
CANF_T
CANF_L
109 G
188 W
125 V
CN-58
19
20
21
22
23
25
26
27
28
63
64
65
66
67
68
50 YW
CN-157
84 Gr
8
190 R
7
189 L
6
84 Gr 3 0.85L
5
109 G 2 0.85 ROr
4
188 W
3
FUSE BOX[CN-36(2)] 119 OrW 1 0.85 GrW
2
1
CN-246
9 10 10
9
4 8
2 R 1
7
7 1 6
5 5
4
3
II I 0
2
OrW 10
1
ILL & HEAD LAMP SW : ON(1st step) FUSE BOX
1
ILL.LAMP 10A
4 2 1 2
HEAD LAMP 20A
3
PARKING SW BACK/STOP LAMP 10A
B G34 4
HORN/CONVERTER 30A
9 10 10 R 1R 5
9 AIR-CON/HEATER 20A
Y 127 6
8 CIGAR/MIRROR 20A
8 YW 50 7
6 7
2 WOr 3E 3 WOr SWITCH 10A
6 8
7 WOr 3F WIPER 20A
5 5 9
1
4 CN-36
3
2
1
CS-17
3
CLUTCH CUT-OFF SW
B G38
9 10 10 R 1N
9
8
8
6 7
2
B G25
Y 127
6
6
L 189
R 190
125 V
7 WOr 3A
70E B
5 5 5
1
4
CD-26
3
CD-5
2
1
1
2
2
OrW 119 1 2
1
CN-71
CS-42
Pa
Pa
PARK PARK PS CLUTCH

SOLENOID CUT-OFF
7307AEL08
7-17
7. WIPER AND WASHER CIRCUIT
1) OPERATING FLOW
Fuse box (No.9) Wiper relay [CR-4(30)Ą(87a)] I/conn [CN-17(9)]
Front wiper motor [CN-21(1)]
Wiper relay Lo [CR-26(86), (87)]
I/conn [CN-16(8)] Multi function switch [CS-12(6)]
I/conn [CN-8(1)] Rear wiper & washer switch [CS-35(1)]
Rear wiper motor [CN-102(1)]
(1) Front washer switch ON
Η Washer switch ON [CS-12(6)Ą(2)] Washer tank [CN-16(12)] Washer operating
MCU [CN-58(5)Ą(33)] Front wiper relay Lo
[CR-26(87)Ą(30)] I/conn [CN-17(13)]
Front wiper motor [CN-21(5)] Wiper motor operating(Low)
(2) Front wiper switch ON
Η INT position
Wiper switch ON [CS-12(6)Ą(1)] I/conn [CN-16(13)] MCU [CN-58(8)Ą(33)]
Wiper relay Lo [CR-26(87)Ą(30)] I/conn [CN-17(13)] Front wiper motor [CN-21(5)]
Front wiper motor intermittently operating
Θ Lo position
Wiper switch ON [CS-12(6)Ą(4)] I/conn [CN-16(10)] Wiper relay Lo [CR-26(87a)Ą(30)]
I/conn [CN-17(13)] Front wiper motor [CN-21(5)] Front wiper motor operating (Low)
Ι Hi position
Wiper switch ON [CS-12(6)Ą(3)] I/conn [CN-16(11)] Wiper relay Hi [CR-4(30)Ą(87)]
I/conn [CN-17(12)] Front wiper motor [CN-21(4)] Front wiper motor operating(High)
(3) Auto-parking(When switch OFF)
Switch OFF Fuse box (No.9) Wiper relay Hi [CR-4(30)Ą(87a)] I/conn [CN-17(9)]
Front wiper motor [CN-21(1)Ą(2)] Multi function switch [CS-12(5)Ą(4)] I/conn [CN-16(10)]
Wiper relay Lo [CR-26(87a)Ą(30)] I/conn [CN-17(13)] Front wiper motor [CN-21(5)]
Wiper motor stop
(4) Rear wiper and washer switch
Η Wiper switch ON(1st step)
Wiper switch ON [CS-35(1)Ą(6)] I/conn [CN-8(4)] Rear wiper motor [CN-102(5)]
Rear wiper motor operating
Θ Washer switch ON(2nd step)
Washer switch ON [CS-35(1)Ą(3)] I/conn [CN-8(2)] Rear washer tank [CN-103(2)]
Washer operating
2) CHECK POINT
Condition Check point
Η - GND (Front wiper switch power input) Μ - GND (Wiper relay power input)
Engine : Stop Θ - GND (Rear wiper switch power input) Ν - GND (Front washer power output)
Key switch : ON Ι - GND (Wiper relay power input) Ξ - GND (Rear washer power output)
Voltage : 20~25V Κ - GND (Front wiper motor Lo power input) Ο - GND (Front wiper motor power output)
Λ - GND (Front wiper motor High power input) Π - GND (Rear wiper motor power output)
ö GND : Ground
7-18
CS-35
B G8
9 10 10 1
9 2
W 15
3 8 3
7 4 6 5 Lo M
8 Or 16 5 Or 164
6 6 5 4 Hi
1 6 4
5 7 B G4
3 1B
10
4 8 W 165
0,I
V 14 2 2Pf
3 L 14E
REAR WIPER
CN-8 1 3E
2 CN-102
WIPER AND WASHER CIRCUIT
L 13
II I 0
REAR WIPER & WASHER SW

1
8
2
36 NEUTRAL SIG
MCU
35 SAFETY RY
34 PREHEATER
105 GOr
33 WIPER RY
32 STEERING RY
CN-22 31 SERIAL-H
B G2
M 1 30 SERIAL-L
Gr 69
2 29 CLUTCH CUT-OFF PS
28 FUEL SENSOR
FRONT WASHER
27 HYD TEMP SENDER
CN-103 26 COOLANT TEMP
B G3
M 1 25 ALT LEVEL
V 166
2 24 FAN CLUTCH -
23 FAN CLUTCH +
22 GND
21
REAR WASHER
BUZZER
20 SPEEDMETER SIG.
19 CAN-L
18 CAN-H
17 AUTO SEL.TCU
16 TAHCO SENSOR -
15 MAIN PUMP PS
14 ELEC STEERING
13 AIR FILTER
12 IG 24V
11 AUTO SEL.SW
10 CLUTCH CUT-OFF SW
8 9 TACHO SENSOR+
120 LW
Hi 7 8 WIPER INT SIG
F Lo
6 7 RIDE CONT. ON
L 6 RIDE CONT. AUTO
O 5 69A G
R 5 WASH SIG
4
5B 4 BUZZER STOP
B+ 3
3 STEERING P/P PS
2 2 PARKING SIG
7-19
1 1 BRAKE PS
CN-58
MULTI FUNCTION SWITCH

CS-11
8 WB
7 Y Lo W6
Hi
2 BW L
BWG 4
3 BG C
R
II
1
9
I
0
6
J 0 G 5
CS-12 7
II BVi 3 L 21 14F L
6 8
I L 4 VOr 38
5 9
G 20 162 G
4 10
J BY 1 Br 19 163 Br
3 11
C RW 6 Gr 18 69 Gr
2 12
W Gr 2 LW 17 120 LW
1 13
14
HO Y 15
CN-16
CS-5
7
14 L
1
2
3
4
WIPER
SWITCH
ILL.LAMP
5
FUSE BOX
6
HEAD LAMP
7
CIGAR/MIRROR
CN-21
FR WORK LAMP
28 W 8 8 W
AIR-CON/HEATER
BACK/STOP LAMP
3E 1 9
HORN/CONVERTER
38 VOr
2Pf 2 10 G61 B
G1 B
1B 3 11
30A
10A
20A
30A
20A
30A
30A
20A
27 G
30A
172 G
4 26 R 12
173 R
2
1
7
3
9
8
4
6
5
10
4 Hi 5 13
CN-36
FRONT WIPER
M
5 Lo 6 14
15
5
CN-17
8 W
8A W
173 R
162 G
6
105 GOr
14A L
BE W
172 G
G13 B
163 Br
4
3
85
87
86
30
85
87
86
30
87a
CR-4
87a
CR-26
30 86
30 86
87a 87 85
87a 87 85
WIPER RY LO
WIPER RY HI
7707AEL09
HAZARD, TURN AND ROTARY CIRCUIT
1
2
3 1
4 REAR COMBI RH 2
5 3
4 C
6 37 Or 4 BEACON LAMP
3 T 22 GY
7 G4 B 5
2 E G1 B FUSE BOX
8 1 S 6 5 G BEACON/RR WORK LAMP 20A
ILL & HEAD LAMP 1
9 CL-16
SW : ON(1st step)
7 CL-7 ILL. LAMP 20A
10 8 2
66A Or HEAD LAMP 20A
11 REAR COMBI LH 9 3
BACK/STOP LAMP 10A
12 4 C 10 4
67A Y 39 Y HORN/CONVERTER 30A
13 3 T 11 5
G6 B
14 2 E 12 AIR-CON/HEATER 30A
6
CN-4 1 S
13 CIGAR/MIRROR 30A
CL-15 7
14 SWITCH 30A
8
15 WIPER 20A
CN-7 9
FR WORK LAMP 30A
10
11
NEUTRAL RY/JOYSTICK F/R 5A
12
PREHEATER 30A
13
TURN LAMP 20A
14
1 RADIO/ROOM LAMP 5A
15
2 START KEY 30A
3 FLASHER UNIT 16
BrW 158 TCU 10A
4 1 L 17
R 19
5 2 B G CN-36
6 B G51
3 E
CN-16
CLUSTER
7
6
5
4
3
2
1
7 CR-11
8 20 RS232 RX
19 GND
9 18 NC
ILL & HEAD LAMP 7A ROr
10 17 ILLUMINATION
SW : ON(1st step) 16
11 F/R SIGNAL
15 SERIAL-L
12 14 SERIAL-H
CN-15 13 NC
12 GND
11 GND
10 RS232 TX
9 PROGRAM DUMP
8 NC
7 MIRROR HEATED
2E Or 6 HIGH BEAM
5 RH TURN
4 LH.TURN
1E Y 3 BATT 24V
2 IG 24V
1 IG 24V
CN-56
1
2 COMBI LH
G2 B
3 1
3 BrW
16 Y
2 Or
4 2
1 Y
5 CL-24
CS-12
CS-11
CS-5
6
6
5
4
3
2
1
8
7
6
5
4
3
2
1
7
8 COMBI RH
67 Y G3 B
BWG 4
1
RW 6
W6
9
BVi 3
L 4
G 5
BY 1
Gr 2
66 Or 17 Or
3E BrW
3A BrW
10 2
Y
22 GY
7 ROr
2A Or
G2 B
G7 B
7H R
1A Y
11 CL-25
9 G
HO
12
W
II
I
Hi
C
J 0
J
C CN-10
0
II
CS-41
I
CS-23
Lo
10 10
10
9
8
7
6
5
4
3
2
1
9
8
7
6
5
4
3
2
1
Hi
B+
F
10
5
6
R
L
O
R
L
7 Y Lo
8 WB
2 BW
3 BG
5B
9
8
2
7
1
8
2
7
1
HAZARD SWITCH BEACON LAMP SWITCH MULTI FUNCTION SWITCH
7607AEL10
7-20
GROUP 3 MONITORING SYSTEM
1. CLUSTER
The gauges panel consists of gauges and monitors as shown below, to warn the operator in case of
abnormal machine operation or conditions for the appropriate operation and inspection.
Â Gauges : Indicate operating status of the machine.
Â Warning lamp : Indicate abnormality of the machine.
Â Pilot lamp : Indicate operating status of the machine.
ö The monitor installed on this machine does not entirely guarantee the condition of the
machine. Daily inspection should be performed according to chapter 6, MAINTENANCE
in operator's manual.
ö When the monitor provides a warning immediately check the problem, and perform the
required action.
Warning lamp High beam pilot lamp

Mirror defrost pilot lamp Right turning pilot lamp
Left turning pilot lamp Parking brake warning lamp
Preheater pilot lamp Hyd oil temp warning lamp
Brake fail warning lamp Clutch cut off pilot lamp
Steering joystic pilot lamp Battery charging warning lamp
Steering warning lamp Fan control pilot lamp
(Emergency) Fuel low level warning lamp
Steering warning lamp FNR select pilot lamp
(Primary)
Engine overheat Air cleaner warning lamp
warning lamp T/M error warning lamp
Engine oil pressure
warning lamp
LCD
mph
Km/h
Select(Enter) key
Right/Buzzer stop key

Hyd oil temp gauge Escape key
T/M oil temperature gauge Main/Menu key
Battery volt meter Speedometer
Engine coolant temperature gauge Fuel gauge 7707A3CD02
1) SPEEDOMETER
(1) The speedometer displays the speed of machine in mph and
km/h.
mph
7807A3CD03
7-21
2) FUEL GAUGE
(1) This gauge indicates the amount of fuel in the fuel tank.
(2) Fill the fuel when the indicator moves E point, refuel as soon as
possible to avoid running out of fuel.
ö If the gauge indicates below E point even though the
machine is on the normal condition, check the electric device
7807A3CD04 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.
Red
ÂRed range : Above 104ÁC (219ÁF)
(2) Keep idling engine at low speed until the indicator is in the
operating range.
Operating
(3) If the indicator is in the red range, turn OFF the engine, check the
range 7807A3CD05 radiator and engine.
4) TRANSMISSION OIL TEMPERATURE GAUGE

(1) This range indicates the temperature of transmission oil.
Red
operating range.
Operating (3) If the indicator is in the red range, it means the transmission is
range 7807A3CD06 overheated. Be careful that the indicator does not move into the
red range.
5) BATTERY VOLT METER

(1) This gauge indicates the voltage in the charging system when
the engine is running.
(2) If the indicator is below 24V(Yellow range), it means that the
electricity is being discharged. If the indicator is above 30V(Red
range), an unusually high voltage may damage the alternator.
Check the charging system in both cases.
7807A3CD08
6) HYD OIL TEMPERATURE GAUGE

(1) This range indicates the temperature of hydraulic oil.
Red
operating range.
Operating (3) If the indicator is in the red range, reduce the load on the system.
range 7807A3CD08 If the gauge stays in the red range, stop the machine and check
the cause of the problem.
7-22
7) WARNING LAMP
(1) When all warning lamp or fault codes are being displayed, this
warning lamp will flash.
(2) When this warning lamp flashes, machine must be checked or
serviced as soon as possible.
77073CD09
8) DIRECTION PILOT LAMP

(1) This lamp flashes when the signal indicator lever is moved.
77073CD10
9) MIRROR DEFROST PILOT LAMP(Option)

(1) This lamp comes ON when mirror defrost switch is pressed.
7807A3CD11
10) HIGH BEAM PILOT LAMP

(1) This lamp works when the illuminating direction is upward.
(2) This lamp comes ON when the dimmer switch is operated, e.g.,
when passing another vehicle.
77073CD12
11) PARKING BRAKE WARNING LAMP

(1) When the parking brake is actuated, the lamp lights ON.
ö Check the lamp is OFF before driving.
77073CD13
7-23
12) PREHEATER PILOT LAMP
(1) This lamp lights ON when start switch is turned clockwise to the
ON position. Light will turn off after approximately 5~45 seconds,
depending on engine temperature, indicating that preheating is
completed.
(2) When the lamp goes out the operator should start cranking the
77073CD14 engine.
13) CLUTCH CUT OFF PILOT LAMP

(1) When the clutch cut off switch is pressed, the lamp lights ON.
77073CD65
14) 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.
ö Do not operate until any problems are corrected.
77073CD16
15) ENGINE OVERHEAT WARNING LAMP

(1) This lamp is turned ON when the temperature of cooling water is
over the normal temperature(104ÁC, 219ÁF).
(2) Check the cooling system when the lamp is ON.
77073CD17
16) ENGINE OIL PRESSURE WARNING LAMP

(1) This lamp is comes ON after starting the engine because of the
low engine oil pressure.
(2) If the lamp comes ON during engine operation, shut OFF engine
immediately. Check engine oil level.
77073CD18
7-24
17) TRANSMISSION ERROR WARNING LAMP
(1) This lamp lights ON and the LCD display show the error codes when
an error occurs in the transmission.
(2) Immediately pull the machine to a convenient stop. Stop the
engine. Investigate the cause.
ö Consult a HYUNDAI dealer to investigate the cause.
77073CD19
ö Do not operate until the cause has been corrected.
18) AIR CLEANER WARNING LAMP

(1) This lamp operates by the vacuum caused inside when the filter
of air cleaner is clogged.
(2) Check the filter and clean or replace it when the lamp is ON.
77073CD20
19) HYD OIL TEMPERATURE WARNING LAMP

(1) This warning lamp operates and the buzzer sounds when the
temperature of hydraulic oil is over 105ÁC (221ÁF).
(2) Check the hydraulic oil level when the lamp is turned ON.
(3) Check for debris between oil cooler and radiator.
77073CD21
20) BATTERY CHARGING WARNING LAMP

(1) This lamp is ON when key ON, it is turned OFF after starting the
engine.
(2) Check the battery charging circuit when this lamp comes ON,
during engine operation.
77073CD22
21) FUEL LOW LEVEL WARNING LAMP

(1) Fill the fuel immediately when the lamp is turned ON.
77073CD23
7-25
22) FNR SELECT PILOT LAMP(Option)
(1) The lamp comes ON when FNR select button on the optional
FNR remote control lever is pressed.
7807A3CD24
23) STEERING WARNING LAMP(Option)

(1) Primary
This lamp indicates that the primary steering has failed. When
the indicators come on and the action alarm sounds, steer the
machine immediately to a convenient location and stop the
machine. Stop the engine and investigate the cause.
ö Do not operate the machine until the cause has been
77073CD66
corrected.
(2) Emergency
This lamp indicates the emergency steering system is active.
ö Immediately pull the machine to a convenient stop and
stop the engine.
ö The emergency steering system can be manually tested.
Refer to page 7-39.
77073CD15
24) FAN CONTROL PILOT LAMP(Option)

(1) This lamp lights ON when cooling fan is selected to reverse
mode.
ö Refer to page 7-28.
77073CD40
25) STEERING JOYSTICK PILOT LAMP(Option)

(1) This lamp lights ON when steering joystick is operated.
77073CD41
7-26
26) LCD
1 LCD
2( ) Right, Buzzer stop
Move to the next selection
1
3( ) Select(Enter)
Activate the currently chosen item
2 4( ) Escape
3 Return to the previous menu
4 5( ) Main, Menu
5 - Display menu
7707A3CD04
- Return to the main display
(1) Main display
2
TYPE 1 TYPE 2
1
4
c
a
3 e 5
b
d
7
6
8 9
7707A3CD10
No Symbol Meaning Remark

Job timer, Odometer, Hydraulic temperature, Battery
1 Job Time 1.26h Monitoring information
voltage, Coolant temperature, T/M oil temperature.
Buzzer, Fan state, Ride state(option), Steering
2 AUTO State information
joystick(option), Warming up
a When operating intermittently, it shows an operating time interval
3 Wiper display
b Wiper motor intermittently operating
Forward, reverse, neutral LCD type 1
F, R, N Forward, reverse, neutral LCD type 2
4 Actual gear display
1, 2, 3, 4 Actual gear
P Parking brake mode active
c, d Up and down shifting c: Forward, d: Reverse
5 Select gear display Automatic mode
e Pre-selected gear
Fault
6 71 Fault code display Fault code state display
7 0 RPM Engine rpm display Now engine rpm state display
8 11.0Hr Hour meter display Hour meter state display
9 PM 12:05 Timer & alarm display Now time & alarm state display
ö Both type1 and type2 are LCD modes and they can be changed each other by operator’s selection.
(Adjustment/Display, see page 7-29)
7-27
(2) Display map
Main Menu Sub menu Activate item
7707A3CD11

Accessory ÂMeasure the various job time.
Job timer Job Time 1.26h
ÂPress : Display ON, OFF or RESET
ÂMeasures time in seconds.
Stop watch -
ÂPress : Start. Press again : Stop.
Latest ÂDistance until recent times. Latest 20.5 Km

Odometer
Total ÂTotal distance. Total 30.5 Km
ÂControl of LCD display luminosity.

Light control -
ÂBrightness control : .
Clock ÂWhen 12H or 24H is selected, the current
Time set hour appears.
Â : input, : setting. PM 22:05
Clock ON/OFF Â : Clock display ON or OFF.
1
ÂAlarm setting. It is possible to set 3 alarms.
Alarm 2
ÂStop alarming :
3
User Alternate ON ÂRaise the idle rpm to 1200rpm automatically
-
idle OFF to warm up the engine.
Mode 1 ÂAutomatic travelling speed is applied from 1st -

Auto (1st-4th) to 4th gear.
select Mode 2 ÂAutomatic travelling speed is applied from -
(2nd-4th) 2nd to 4th gear.
Mode 1 ÂPress button once : Shift down, press button -
Quick (Down/Up) again ; shift up.
shift Mode 2 ÂPress button every time : Shift to lower gear -
(Down only) respectively.
Auto ÂON : Transmission auto condition.
select ÂOFF : Transmission semi-auto condition.
Aux-sw
Clutch ÂON : Clutch cut-off is activated. -
cut-off ÂOFF : Clutch cut-off is cancelled.
Fan Forward ÂForward active
control Reverse ÂReverse activeø
øReverse mode cleans out quickly dirt and dust on radiator and cooler by reverse rotation of cooling fan.
7-28
Adjustment MKS Total 50.7 Km
Unit ÂChoose between metric and inch unit display.
ENG Total 31.5 Mile
Wiper ÂWhen using the intermittent function of wiper
Intermittence motor, it regulates operation time.
ÂRegulate idle rpm.
Alternate RPM ÂPress : Adjust idle rpm increments -
(or decrement) by 25rpm.
Pulse ÂPress : Modification. -

ÂIt controls the disk interval of the transmission,
AEB automatically.
ÂIt is set at the factory, so there's no need to
Model -
change.
ÂEnglish : Display in English.
ENG/KOR -
ÂKorean : Display in Korean.
ÂType 1 : Indicate with the symbol.
Display 1/2 ÂType 2 : Indicate with a letter. ,
Diagnostics Fault ÂError code display.

-
code ÂRefer to page 7-30.
Machine ÂHydraulic temperature and battery voltage HYD temp 100.6 C
Monitor display. Bat Volt 27.5 V
Fault ÂError code display. -
code ÂConsult a Hyundai dealer to error code.
Engine
ÂEngine coolant temperature display.
Monitor Coolant Temp 57.6 C
Fault ÂError code display.

-
Transmis- code ÂConsult a Hyundai dealer to error code.
sion Transmission oil temperature display.
Monitor ÂPress : Display ON or OFF.
Oil Temp 37.6 C
Version ÂDisplay the controller(MCU) and cluster version. -
7-29
(3) Machine fault code
When selecting the fault code menu, it shows all of the fault codes which mean abnormal
conditions of present time.
3 's FAULT 71
34 71 72 TCU Communication Error
7707A3CD36
ö To go out from fault explanation window, press button.

(Press , to go out to main.)
ö No error will be indicated in case that there’s no fault.
Description Code Meaning Remark
010 Power input voltage low Below 18V

011 Power input voltage high Above 38V
Electrical 012 Alternator voltage low Below 5V
system 013 Alternator voltage high Above 36V
014 Buzzer circuit open or short to ground
015 Buzzer circuit short to power
Hydraulic 020 Hydraulic oil temperature sensor open or short to power
system 021 Hydraulic oil temperature sensor short to ground
030 Fuel level sensor open or short to power
Engine 031 Fuel level sensor short to ground
system 034 Cooling fan driving valve open or short to ground
035 Cooling fan driving valve short to power
050 Auto select switch supply power open or short to power
051 Auto select switch supply power short to ground
T/M system
052 Clutch cutoff supply power open or short to power
053 Clutch cutoff supply power short to ground
Steering 060 Emergency steering relay open or short to ground Option
system 061 Emergency steering relay short to power Option
070 MCU communication error
Communication 071 TCU communication error
072 ECM communication error
MCU : Machine control unit TCU : Transmission control unit ECM : Engine control module
7-30
(4) Transmission warning
LF, LR Limp home gear -

F/R/Ā/Ă flashing Direction F or R selected while turbine
speed is too high, CAUTION gear will -
engage if turbine speed drops
Oil temperature too low, no gear available Warm up engine / transmission
WS Warning sump temperature Changes between actual gear/direction
fault is detected
WT Warning torque converter temperature Changes between actual gear/direction
fault is detected
WE Warning high engine speed Changes between actual gear/direction
fault is detected
7-31
(5) Display during AEB mode
K1~K4, KV, KR Calibrating clutch K1~K4, KV

or KR respectively
- And Kx Wait for start, initialization of
clutch Kx, x : 1, 2, 3, 4, V, R
óAnd Kx Fast fill time determination of
clutch Kx
= And Kx Compensating pressure
determination of clutch Kx
OK Calibration for all clutches Transmission stays in neutral, you have to restart the
STOP AEB canceled(Activation Transmission stays in neutral, you have to restart the
stopped) TCU(Ignition off/on)
STOP and Kx AEB stopped, clutch Kx can't Transmission stays in neutral, you have to restart the
be calibrated TCU(Ignition off/on)
Spanner and Kx Kx couldn't be calibrated, AEB Transmission stays in neutral, you have to restart the
ĀE Engine speed too low,
- Raise engine speed
ĂE Engine speed too high,
- Lower engine speed
ĀT Transmission oil temperature
too low,
- Heat up transmission
ĂT Transmission oil temperature
too high,
- Cool down transmission
FT Transmission temperature not Transmission stays in neutral, you have to restart the
in defined range during TCU(Ignition off/on)
calibration
FB Operating mode not NORMAL Transmission stays in neutral, you have to restart the
or transmission temperature TCU(Ignition off/on)
sensor defective or storing of
calibrated values to EEPROM
has failed
FO Output speed not zero Transmission stays in neutral, you have to restart the
FN Shift lever not in neutral Transmission stays in neutral, you have to restart the
position TCU(Ignition off/on)
FP Park brake not applied Transmission stays in neutral, you have to restart the
ö AEB mode : It controls the disk internal of the transmission, automatically.
7-32
2. SWITCHES
ECONO switch
Beacon switch(option)
Mirror defrost switch(option)
Rear wiper/washer switch
Work lamp switch Auto select switch

Main light switch Clutch cut off switch
Parking brake switch Ride control switch(option)
EC
ON
O
Front Heated seat switch(option)

Pump motor switch(option)
LH SIDE
A
Kick down switch
Horn button
Multi function switch
Hazard switch
Kick down switch
A
Attachment
unlock switch
Attachment
lock switch
7307A3CD03
1) STARTING SWITCH
(1) There are three positions, OFF, ON and START.
Â (OFF) : None of electrical circuits activate.
Â (ON) : All the systems of machine operate.
Â (START) : Use when starting the engine.
Release key immediately after starting.
ö Key must be in the ON position with engine running maintain
77073CD41
electrical and hydraulic function and prevent serious machine
damage.
7-33
2) HAZARD SWITCH
(1) Use for parking, or roading machine.
OFF
ö If the switch is left ON for a long time, the battery may be
ON
discharged.
77073CD42
3) CLUTCH CUT OFF SWITCH

(1) This switch is pressed, it will cut off the clutch when brake operates.
ö Be careful not to use this switch when driving on a slope.
(2) When the switch failure occurs, it will be able to operate a clutch off
function from LCD.
77073CD43
4) PARKING BRAKE SWITCH

(1) This switch is pressed, the parking brake will start to operate and the
gauge panel warning lamp will comes ON.
ö When operating the gear selector lever, be sure to release the
parking brake. If the machine is operated with the parking
brake engaged, the brake will overheat and may cause the
brake system to go out of order.
77073CD44
5) MAIN LIGHT SWITCH

(1) This switch use to operates the clearance lamp and head light by
two step.
ÂFirst step : Clearance lamp and cluster illumination lamp comes
ON. Also, all indicator lamp of switches come ON.
ÂSecond step : Head light comes ON.
77073CD45
6) WORK LAMP SWITCH

(1) This switch use to operates the front and rear work lamps by two
step.
ÂFirst step : Front work lamp located on the cab comes ON.
ÂSecond step : Rear work lamp located on the cab comes ON.
77073CD46
7-34
7) REAR WIPER AND WASHER SWITCH
(1) The switch use to operates the rear wiper and washer by two step.
ÂFirst step : The rear wiper operates.
ÂSecond 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.
77073CD47
8) 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
77073CD48 buzzer stopped.
If not, stop engine and check the system which the lamp is ON.
9) AUTO SELECT SWITCH

(1) Manual mode(Η Η)
Press the top of the switch for the manual mode of the autoshift
function. The operator selects the desired speed and the desired
direction in the manual mode with the gear selector lever.
(2) Automatic mode(Θ)
77073CD49 Press the bottom of the switch for the autoshift function in the
automatic mode. Press the bottom of the switch prior to shifting the
transmission into forward or reverse in order to activate the autoshift
function.
ö Highest gear is controlled by the position of the gear selector lever.
ö The operator can select two kinds of automatic modes.
(1st Ĉ 4th, 2nd Ĉ 4th)
ö When the switch failure occurs, it will be able to operate a auto
select function from LCD.
10) BEACON SWITCH (Option)

(1) This switch turns ON the rotary light on the cab.
77073CD50
7-35
11) RIDE CONTROL SWITCH (Option)
(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 8km/h travel mode.
77073CD51
(2) ON position
Push in the bottom of the ride control switch in order to turn on the
system for ride control regardless speed. The ride control will
smooth the ride of the machine during travel.
77073CD51-1
(3) MIDDLE position

Push the ride control switch to the middle position in order to turn off
the system for the ride control.
77073CD51-2
12) HORN BUTTON

(1) If you press the button on the top of the multifunction switch, the
Horn button
horn will sound.
73033CD28A
13) CAB LAMP SWITCH

(1) This switch turns ON the cab room lamp.
73033CD24
7-36
14) KICK DOWN SWITCH
(1) Manual mode
Kick down switch
It is effective 2nd speed to 1st speed only and recover to 2nd speed
quickly when push the switch one more time.
(2) Automatic mode
Η Mode 1(Down/Up)
It shifts down quickly from current gear to one step lower speed by
pushing the switch and recover to current speed quickly when push
the switch one more time.
Θ Mode 2(Down)
It shifts down from current gear to one step lower speed when push
7807ACD34 the switch every time.
The kick down function is released in only 1st speed.
ö The normal autoshift function continues after the kick down
switch is released.
15) MULTI FUNCTION SWITCH

O J Ɇ ɇ (1) Front wiper and washer switch
Η When the switch is in J position, the wiper moves intermittently.
Θ When placed in Ɇ or ɇ position, the wiper moves continuously.
Ι If you push the grip of the lever, washer liquid will be sprayed and
the wiper will be activated 2-3 times.
73033CD29
ö 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.
Up (2) Dimmer switch

Η This switch is used to turn the head lights direction.
M
Θ Switch positions
Down ÂUp : To flash for passing
ÂMiddle : Head lights low beam ON
73033CD30 ÂDown : Head lights high beam ON
Ι If you release the switch when it's in up position, the switch will
return to middle.
Left turning (3) Turning switch

Η This switch is used to warn or signal the turning direction of the
machine to other vehicles or equipment.
Θ Push the lever up for turning left, pull the lever down for turning
Right turning right.
73033CD31
7-37
16) MIRROR DEFROST SWITCH(Option)
(1) If the mirror defrost switch is pressed in condition of key ON, it
operates for 15 minutes. After 15 minutes, the defrost function stops
automatically.
(2) One more pressing the switch in operation also stops defrost
function.
7807A3CD48
17) HEATED SEAT SWITCH(Option)

(1) This switch is used to heat the seat.
7707A3CD47
18) ECONO SWITCH

(1) This switch offers two selectable operating mode.
The operator can adjust the machine's performance with this
selection switch.
E
C
O
N
O
(2) Push in the bottom of the switch in order to turn on the ECO-mode.
Â ECO-mode : This mode provides maximum fuel efficiency for
7577A3CD51 general loading.
(3) Push in the top of the switch in order to turn on the power mode.
Â Power mode : This mode provides maximum power output for hard
digging operation or hill climb.
19) ATTACHMENT LOCK SWITCH(Option)

(1) This switch is use to engage the quick coupler pins.
(2) If this switch is pressed for 5 seconds, the quick coupler pins move
in the engaged position.
If the switch is released, the quick coupler pins will remain in the
engaged position.
7577A3CD52
ö Check for engagement as followings.
Η Put down pressure on the attachment.
Θ Back up the machine and make sure that there is no movement
between the quick coupler and attachment.
7-38
20) ATTACHMENT UNLOCK SWITCH(Option)
(1) This switch is use to disengage the quick coupler pins.
(2) If this switch is pressed for 5 seconds, the quick coupler pins move
in the disengaged position.
If the switch is released, the quick coupler pins will remain in the
disengaged position.
7577A3CD53
21) PUMP MOTOR SWITCH (Option)

(1) The emergency steering system can be manually tested. Push the
pump motor switch in order to determine if the emergency steering
and the emergency steering lamp are functional.
(2) When the switch is pushed, the emergency steering pump motor will
run. The emergency steering lamp will light. If the emergency
77073CD52 steering lamp does not light, do not operate the machine.
7-39
GROUP 4 ELECTRICAL COMPONENT SPECIFICATION
Part name Symbol Specifications Check item
Gravity
12V Ý 100Ah 1.280 over : over charged
Battery
(2EA) 1.280 ~ 1.250 : normal
1.250 below : discharged
Rated load : 24V Coil resistance

100A(Continuity) braked : approx 50̫
Battery relay 1000A(30seconds) connected :â̫
CR-1
Resistance between ring

2 terminal and each connector pin
Fusible link 1 24V 60A 0̫: normal
CN-60 CN-95
H BR ACC ST C
23 56
H 0 I II 4
Resistance between each pin
B-BR : 24V 1A
0, I 1
Key off : â̫(for each pin)
Start key B B-ACC : 24V 10A
Key on : 0̫(for pin 1-2 & 1-3)
1 2 3 4 5 6 B-ST : 20V 40A
Start : 0̫(for pin 1-5)
CS-2
1
Pa
Resistance
Pressure switch 2
N.C TYPE 0̫: normal (close)
CD-3 CD-26
CD-39 CD-41
1
Resistance
Pressure switch 2 Pa N.O TYPE â̫ normal (open)
CD-4 CD-4A CD-5
CD-40 CD-48
7-40
Parking brake/
1
Resistance
Attach lock, 2 24V 1A normal : 15~25̫
unlock solenoid
CN-71 CN-177 CN-178
Pa 635mmH2O
Air cleaner Resistance
(N.O type)
pressure switch â̫ normal (open)
CD-10
Ride control
2 ö Check LED lamp
valve / Fan 1 24V 1.2A ö Check resistance
solenoid about 24̫
CN-136 CN-154 CN-155
CN-71
Resistance at fuel levels

1 full level : 50̫
2 - 9/12 level : 200̫
Fuel sender
6/12 level : 350̫
CD-2 3/12 level : 500̫
empty : 700̫
1 2 1
2
Resistance at normal position
Relay 3
about 200̫between pin 1-3
24V 20A
(4pin) 4 4 3
â̫ between pin 2-4
AC RY(H1)
CR-2 ACAC
CR-26 RY(M2)
RY1
CR-5 CR-30 AC RY2
30
87a 87 85
86
87 Resistance
Relay
85 normal : about 160̫
87a 30 86 24V 20A
(5pin) (for pin 85~86)
CR-2 CR-3 CR-4 CR-5 CR-7 0̫(for pin 30~87)
CR-25 CR-26 CR-33 CR-35 CR-36
CR-37 CR-38 CR-40 CR-41 CR-46 â̫(for pin 30~87)
CR-55 CR-58 CR-59
7-41
1 B
3 E
Proximate
24V 400mA
switch 4 S
CN-100 CN-101
Resistance
Hydraulic 2 C
normal : â̫
temperature 1
105Á C over : 0̫
CD-1
1 Lo 1 Resistance
2 MH 3 1.12̫(for pin 4-2)
Aircon resistor 24V
3 ML 2 2.07̫(for pin 2-3)
4 Hi 4 3.17̫(for pin 3-1)
1
Resistance
Speaker 2 4̫ 20W normal : 4̫
CN-23(LH)
CN-24(RH)
10 9 8 7 6 5 4 3 2 1
10 6 5
Resistance at switch off position
Switch
24V 8A â̫between pin 1-5 and 2-6
(Locking type) 9 8 2 7 1
0̫between pin 5-7 and 6-8
CS-17 CS-23
CS-17 CS-23 CS-41
CS-42
CS-42 CS-59
CS-21 CS-41 CS-80
CS-54
CS-82
10 9 8 7 6 5 4 3 2 1
Switch 10 4 1 Resistance at switch off position

(Non-locking 24V 8A â̫between pin 1-5 and 2-6
type) 9 2 75 0̫between pin 5-7 and 6-8
CS-21
CS-3 CS-35
CS-34 CS-36
CS-39
7-42
1 Work lamp
Work lamp, 24V 65W
2 Resistance
Room lamp, Number plate lamp
Number plate CL-1
CL-1 CL-5
CL-6 CL-6
CL-22 normal : 1.2̫
CL-21
CL-5 CL-22
CL-21CL-23
CL-23 Room lamp
lamp
CL-30 24V 10W
M 24V 70W Resistance

Beacon lamp
(H1 TYPE) normal : 1.1̫
CL-7
24V A Resistance
24V
DC/DC GND B 8.8̫(for pin A-B)
12V 3A
Converter 12V 7.7̫(for pin B-C)
12V C
Operation by external power

source
Horn 24V 2A - connect 24V power to (+)
CN-20 CN-25 terminal
- ground the (-) terminal
2 PA Resistance
Receiver dryer 1 24V 2.5A 0̫: 2.1Ü0.3~27Ü2kgf/cmЅ
CN-29 â̫: ~2.1Ü0.3, 27Ü2~kgf/cmЅ
1 S.L+
2 ACC
3 ILL+
4 S.R+ Resistance
5 ILL-
Cassette radio 6 S.L- 24V 20W+20W Power ON : 4̫+4̫
7 B+
8 S.R-
9 GND
(for pin 1-6, 4-8)
CN-27
7-43
24V 0.5A Resistance

Back up buzzer normal : 5.2̫
110dB
CN-65
M 1 Resistance
Washer pump 2 24V 2.5A normal : 26.4 ̫
(for pin1-2)
CN-103 CN-22
CN-22(FR) CN-103(RR)
1 2 3 4 5 6
24V 1.5A
Hi
Wiper motor E M Lo
2-speed -
Auto parking
CN-21(FR) CN-102(RR)
B
A
Cigar lighter 24V 5A 1.4W Coil resistance
1
normal : about 1M̫
CL-2
B+
G
1 P ~
3
2 L
U
Voltage
Alternator 3 FI 24V 70A
4 NC normal : 24~28V
CN-74
Nippondenso
Starter Operating or not
B+ M 24V-3.7kW
CN-45
7-44
1
Aircon Resistance
24V 79W
compressor normal : 13.4̫
CN-28
Coil resistance
normal : 1-2̫
Start relay 24V 300A Switch connection
â̫at normal open position
CR-23 0̫when engaged
Resistance at each switch

M 1 24V 9.5A position
Blower
2 normal : 0.5-2̫
Resistance
1 0 ̫(for pin 1-2),
1ÁC OFF
Duct sensor (the atmosphere temp
2 4ÁC ON
over 4ÁC)
Resistance
Door switch 24V 2W normal : about 5M̫
CS-1 CS-55
3 E
G 24V
2 B
Flasher unit 85 ~ 190 C/M -
1 L
50dB
CR-11
7-45
1 Lo
Hi 24V 75W/70W
2
(H4 TYPE) Resistance
Head lamp 3 E
24V 4W normal : a few̫
4 C (T4W)
CL-3 CL-4
4 C
24V 5W
3 T
Combi lamp (R5W)
2 E -
(Rear) 2Ý24V 21W
1 S
(P21W)
CL-15 CL-16
1
24V 21W
Turn lamp 2 -
(P21W)
CL-24 CL-25
Continuous
capacity :
Master switch 180Amp -
Push in capacity :
1000Amp
CS-74
2
24V 200mA
Warning buzzer 1 -
90Ü5dB(˶m)
CN-26
7-46
GROUP 5 CONNECTORS
1. CONNECTOR DESTINATION
Connector No. of Connector part No.
number Type pin Destination
Female Male
CN-1 58 2 I/conn(Main harness-Frame harness) S813-030200 S813-130200
CN-2 Econoseal J 12 I/conn(Main harness-Frame harness) S816-012002 S816-112002
CN-3 AMP 15 I/conn(Frame harness-Main harness) 2-85262-1 368301-1
CN-4 AMP 15 I/conn(Main harness-Frame harness) 2-85262-1 368301-1
CN-5 AMP 15 I/conn(Frame harness-Main harness) 2-85262-1 368301-1
CN-6 AMP 15 I/conn(Main harness-Frame harness) 2-85262-1 368301-1
CN-7 AMP 15 I/conn(Main harness-Cab harness) 2-85262-1 368301-1
CN-8 Econoseal J 8 I/conn(Main harness-Cab harness) S816-008002 S816-108002
CN-9 Econoseal J 12 I/conn(Main harness-Front harness) S816-012002 S816-112002
CN-10 AMP 15 I/conn(Main harness-Front harness) 2-85262-1 368301-1
CN-11 DEUTSCH 8 I/conn(Main harness-Aircon harness) DT06-8S -
CN-12 AMP 15 I/conn(Frame harness-Engine harness) 2-85262-1 368301-1
CN-13 Econoseal J 12 I/conn(Frame harness-Engine harness) S816-012002 S816-112002
CN-18 Econoseal J 4 I/conn(Ride control harness-Front harness) S816-004002 S816-104002
CN-20 Molex 2 Horn 36825-0211 -
CN-21 HW090 6 Front wiper motor 6189-0133 -
sealed
CN-22 SWP 2 Front washer tank S814-002000 -
CN-23 KET 2 Speaker(LH) 7123-1520 -
CN-24 KET 2 Speaker(RH) 7123-1520 -
CN-25 Molex 2 Horn 36825-0211 -
CN-26 250 2 Warning buzzer S810-002202 -
CN-27 PA 9 Cassette and radio S811-009003 -
CN-28 MWP 1 Comp(Air-con) NMWP01F-B -
CN-29 KET 2 Receiver drier MG640795 -
CN-45 Ring term - Starter S820-414000 -
CN-56 AMP 20 Cluster 174047-2 -
CN-58 Econoseal III 36 Machine control unit (MCU) 344111-1 -
CN-59 AMP 23 Machine control unit (MCU) 770680-1 -
CN-65 DEUTSCH 2 Back up buzzer DT06-2S-EP06 -
CN-71 DEUTSCH 2 Parking solenoid DT06-2S-EP06 -
CN-74 PACKARD 4 Alternator 1218-6568 -
CN-83 NMWP 2 Aircon fan PB625-02027 -
CN-93 DEUTSCH 50 Engine control module (ECM) DRC26-50S-04 -
CN-94 DEUTSCH 4 ECM power DTP06-4S-EP06 -
7-47
Type Destination
number pin Female Male
CN-96 PACKARD 4 Fuel heater 2-967325-3 -
CN-99 DEUTSCH 2 Resister DT04-3P-EP10 -
CN-100 Autonics Cable Boom kick out 21L6-20020 -
CN-101 Autonics Cable Bucket leveler 21L6-20020 -
CN-102 HW090 6 Rear wiper motor 6189-01330 -
sealed
CN-103 SWP 2 Rear washer tank S814-002000 -
CN-112 - 16 Gear box 21L7-60290 -
CN-114 Econoseal J 12 Joy stick - S816-112002
CN-136 AMP 2 Ride control valve solenoid 85202-1 -
CN-138 DEUTSCH 3 DC/DC Converter DT06-3S-EP06 -
CN-139 DEUTSCH 2 12V socket - DT04-2P-E005
CN-140 Econoseal J 3 Quick coupler S816-003002 -
CN-154 AMP 2 Fan clutch 85202-5 -
CN-155 AMP 2 Reverse solenoid 85202-1 -
CN-157 AMP 68 T/M control unit (TCU) 962175 -
CN-158 PACKARD 4 Gear shift lever - 1201-0974
CN-159 PACKARD 4 Gear shift lever 1201-5797 -
CN-162 Econoseal J 6 Pedal S816-006002 -
Relay
CR-1 Ring term - Battery relay S820-104000 -
CR-2 250 4 Horn relay S810-004202 -
CR-3 250 4 Front work lamp relay S810-004202 -
CR-4 250 6 Wiper relay(Hi) S810-006202 -
CR-5 250 2 Safety relay S810-006202 -
CR-7 250 4 Aircon relay S810-004202 -
CR-11 250 3 Flasher unit S810-003702 -
CR-23 SWP 2 Start relay - S814-102001
CR-24 Shur 1 Preheater relay S822-014000 -
CR-36 250 4 Preheater relay S810-004202 -
CR-46 250 4 Fuel warmer relay S810-004202 -
CR-55 250 4 Rear work lamp relay S810-004202 -
CR-58 250 1 Back up relay S810-004202 -
Switch
CS-1 Shur 1 Door switch S822-014004 -
CS-2 SWP 6 Start key switch S814-006000 -
CS-5 Shur 1 Horn switch S822-014000 -
CS-11 SWP 8 Multi function switch S814-008000 -
7-48
Type Destination
CS-12 SWP 6 Multi function switch S814-006000 -
CS-17 SWF 10 Parking switch 593757 -
CS-21 SWF 10 Main light switch 593757 -
CS-23 SWF 10 Beacon switch 593757 -
CS-35 SWF 10 Rear wiper 593757 -
CS-36 SWF 10 Work lamp switch 593757 -
CS-41 SWF 10 Hazard switch 593757 -
CS-42 SWF 10 Clutch cut off switch 593757 -
CS-55 SWF 10 Ride control switch 593757 -
CS-59 SWF 10 Auto/manual switch 593757 -
CS-74 Ring term - Master switch ST710287-2 -
CS-75 SWF 10 Steering pump switch 593757 -
CS-76 SWF 10 Mirror heater 593757 -
CS-80 SWF 10 Electric steering 593757 -
CS-82 SWF 10 Seat heater 593757 -
Light
CL-2 250 3 Cigar lighter S810-003202 -
CL-3 DEUTSCH 4 Head light - DT04-4P-E005
CL-4 DEUTSCH 4 Head light - DT04-4P-E005
CL-5 DEUTSCH 2 Work light(LH) - DT04-2P-E005
CL-6 DEUTSCH 2 Work light(RH) - DT04-2P-E005
CL-7 AMP 2 Beacon lamp S822-014004 S822-114004
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 DEUTSCH 2 Work light(LH) - DT04-2P-E005
CL-23 DEUTSCH 2 Work light(RH) - DT04-2P-E005
CL-24 SWP 2 Turn lamp(LH) S814-002000 -
CL-25 SWP 2 Turn lamp(RH) S814-002000 -
CL-30 KET 2 Room lamp MG610392 -
CL-32 DEUTSCH 2 Rear work light(RH) - DT04-2P-E005
CL-33 DEUTSCH 2 Rear work light(LH) - DT04-2P-E005
Sensor, sender
CD-1 AMP 2 Hydraulic oil temp sendor 85202-1 -
CD-2 SWP 2 Fuel sendor S814-002000 -
CD-3 Rubber cap - Brake fail pressure switch 21EA-003100 -
CD-4 Rubber cap - Stop lamp pressure switch 21EA-003100 -
7-49
Type Destination
CD-5 Rubber cap - Clutch cut off pressure switch 21EA-003100 -
CD-10 Ring term - Air cleaner switch S820-105002 -
CD-17 AMP 2 Engine pick-up sensor 85202-1 -
CD-26 Rubber cap - Parking pressure switch 21EA-003100 -
CD-27 AMP 2 Turbin pick up sensor 85202-5 -
CD-35 PACKARD 2 Fuel filter 1204-0753 -
CD-39 Rubber cap 2 Main pump pressure switch 21EA-00310 -
CD-40 DEUTSCH 2 Emergency steering pump pressure switch - DT04-2P-E005
CD-41 Rubber cap 2 Boom down pressure switch 21EA-00310 -
CD-45 DEUTSCH 2 WIF sensor DT06-2S-EP06 -
CD-46 AMP 3 Output speed sensor 282087 -
CD-47 AMP 2 Gear chain sensor 85202-1 -
CD-48 AMP 2 Oil filter 282080 -
CD-49 AMP 2 Converter sensor 85202-1 -
7-50
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
7-51
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
7-52
No. of
pin
6 13 1 7
13
1 7 6 13
S811-013002 S811-113002
1 9
8 17
17
1 9 8 17
S811-017002 S811-117002
110 21 1 11
21
1 11 10
1 21
S811-021002 S811-121002
7-53
3) J TYPE CONNECTOR
No. of
pin
1 2
1
2 12
S816-002001 S816-102001
2 3 1
3 1 2
S816-003001 S816-103001
3 1 4 2
4 2 3 1
S816-004001 S816-104001
8 5 2
6 3 1
8 5 2 6 3 1
S816-008001 S816-108001
7-54
4) 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
7-55
No. of
pin
3 6 1 4
3 6
1 4
S814-006000 S814-106000
4 8 1 5
4 8
1 5
S814-008000 S814-108000
4 12 1 9
12
4 12
1 9
S814-012000 S814-112000
3 14 11
1
14
1 11 3 14
S814-014000 S814-114000
7-56
5) 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 3
1 3 2 44
S810-004202 S810-104202
7-57
No. of
pin
3 6 1 4
1 4 3 6
S810-006202 S810-106202
4 8 1 5
1 5 8
4
S810-008202 S810-108202
7-58
6) ITT SWF CONNECTOR
No. of
pin Receptacle connector(Female) Plug connector(Male)
2
10
1 10
9
SWF593757
7) HW090 SEALED CONNECTOR

No. of
6 3
4
6
6189-0133
8) MWP02F-B CONNECTOR
No. of
2 1
2
PH805-02028
7-59
9) AMP ECONOSEAL CONNECTOR
No. of
12
1
12
13 24
36
25
24 36 1
13
36
25
344111-1
344111-1 344108-1
344108-1
10) AMP TIMER CONNECTOR

No. of
pin
85202-1
11) AMP 040 MULTILOCK CONNECTOR

No. of
pin
12 1 6
7 12
174045-2
7-60
12) KET 090 WP CONNECTORS
No. of
pin
2 1
MG640795
13) ITT SWF CONNECTOR

No. of
pin
2
10
1 10
9
SWF593757
14) MWP NMWP CONNECTOR

No. of
pin
1
1
NMWP01F-B
7-61
15) DEUTSCH DT CONNECTORS
DT 06 - 3S - øøøø
Modifications(See below)
Number of contacts(P : Pin, S : Socket)
04 : Receptacle, 06 : Plug
Deutsch connectors
ö Modification
E003 : Standard end cap - gray
E004 : Color of connector to be black
E005 : Combination - E004 & E003
EP04 : End cap
EP06 : Combination P012 & EP04
P012 : Front seal enhancement - connectors color to black for 2, 3, 4 & 6pin
No. of
pin
1 2 2 1
2
DT06-2S DT04-2P
2 1 1 2
3 3
DT06-3S DT04-3P
4 1 1 4
3 2 2 3
DT06-4S DT04-4P
7-62
No. of
pin
6 1 1 6
4 3 3 4
DT06-6S DT04-6P
4 5 5 4
1 8 1
8
DT06-8S DT04-8P
6 7 7 6
12
1 12 12 1
DT06-12S DT04-12P
7-63
16) ECONOSEAL J TYPE CONNECTORS
No. of
pin
S816-001002 S816-101002
S816-002002 S816-102002
S816-003002 S816-103002
S816-004002 S816-104002
7-64
No. of
pin
S816-006002 S816-106002
S816-008002 S816-108002
10
S816-010002 S816-110002
12
S816-012002 S816-112002
7-65
No. of
pin
15
368301-1 2-85262-1
17) METRI-PACK TYPE CONNECTOR

No. of
pin
12040753
7-66
GROUP 6 TROUBLESHOOTING
1. WHEN STARTING SWITCH IS TURNED ON, CLUSTER LAMP DOES NOT LIGHT UP
ÂBefore carrying out below procedure, check all the related connectors are properly inserted and the
fuse No.25 is not blown out and ON/OFF of bulb.
ÂAfter checking, connect the disconnected connectors again immediately unless otherwise specified.
Cause Remedy
YES
Defective cluster Replace
Check voltage
YES
between CN-56
(1, 2) and chassis
NO Disconnection in Repair or replace

wiring harness or (After clean)
Check voltage
poor contact
between CN-15
(1) and chassis between
CN-56(1, 2) and
CN-15(1)
NO
Disconnection in Repair or replace
poor contact
between CN-15(1)
and fuse No.25
CLUSTER
1
FUSE
2 1
No.25
CN-56
CN-15
Check voltage
YES 20 ~ 30V
NO 0V
7807AEL15
7-67
2. WHEN BATTERY LAMP LIGHTS UP(Engine is started)
ÂBefore carrying out below procedure, check all the related connectors are properly inserted.
Cause Remedy
YES
Defective controller Replace
Check voltage
YES
between CN-58
(25) and chassis
NO Disconnection in Repair or replace
Voltage : 27.5~30V wiring harness or (After clean)
poor contact
Check voltage between CN-58
YES between CN-3(5)
(25) and CN-3(5)
and chassis
YES
Voltage : 26~30V Disconnection in Repair or replace
Check voltage poor contact
between CN- between CN-13(8)
NO
Check voltage 13(8) and chassis and CN-3(5)
between
alternator terminal Disconnection in Repair or replace
"2" and chassis NO
Voltage : 26~30V poor contact
Starting switch : ON
between CN-13(8)
and alternator
terminal " 2 "
Defective alternator Replace

NO
CONTROLLER(MCU)
ALTERNATOR
25 5 8 " 2 " TERMINAL
CN-3 CN-13
CN-58
Check voltage
YES 20 ~ 30V
NO 0V 7707AEL16
7-68
3. WHEN PARKING SOLENOID DOES NOT WORK
fuse No.8 is not blown out.
Cause Remedy
YES
Defective parking Replace
Check voltage brake solenoid
between CN-71
(2) and chassis YES
Defective parking Replace
Check voltage
Starting switch : ON switch
Parking switch : ON-OFF NO
between CS-17
Voltage : 20~30V (6) and chassis
NO
Voltage : 20~30V
poor contact
between CS-17
(6) and Fuse
No.8
PARKING SWITCH
8 2
1
5
CN-71
6
CS-17 FUSE
No.8
7707EL24
7-69
4. TRANSMISSION IS NOT RETURNED TO NEUTRAL WHEN PARKING BRAKE IS APPLIED
fuse No.17(T/M control unit) and No.8 are not blown out.
Cause Remedy
YES
Defective T/M Replace
control unit
Check voltage YES

between CN-157
(21) and chassis
poor contact
Starting switch : ON Check voltage between CN-157
Parking switch : ON between CS-17
Voltage : 20~30V NO (21) and CS-17(7)
(7) and chassis
YES
Voltage : 20~30V Defective switch Replace
Parking switch : ON Check voltage
between CS-17
NO
(5) and chassis
NO
Voltage : 20~30V wiring harness or (After clean)
poor contact
between CS-17(5)
and fuse No.8
PARKING SWITCH
FUSE
6
5 No.8
7 T/M CONTROL UNIT
CS-17 21
CN-157
Check resistance
YES MAX 1̫
7807AEL17
NO MIN 1M̫
7-70
5. MACHINE DOES NOT TRAVEL
fuse No.17(Transmission controller) is not blown out.
ÂWiring diagram : See page 7-17.
Cause Remedy
YES
Defective clutch Replace
cut-off switch
Check resistance
YES
between CD-5
and chassis
NO Is there continuity Defective T/M Replace

between CN-157 NO
(66) and chassis? control unit
NO
Defective T/M Replace
Is voltage between
control unit
CN-157(21) and
chassis 20-28V? YES
Defective Replace
Parking switch : OFF
parking switch
Clutch cut-off
Is there continuity
switch : ON between CS-17(7)
YES
and chassis?
Disconnection Repair or replace

NO
poor contact
between CN-157
(21) and CS-17(7)
Check resistance
YES MAX 1̫
NO MIN 1M̫
7-71
6. WHEN STARTING SWITCH IS TURNED ON, WIPER MOTOR DOES NOT OPERATE
fuse No.9 is not blown out.
ÂAfter checking, connect the disconnected connectors again immediately unless otherwise specified. MCU
HYD TEMP SENDER
FAN CLUTCH +
CLUTCH CUT-OFF PS
SPEEDMETER SIG.
RIDE CONT. AUTO

SAFETY RY
COOLANT TEMP
BUZZER STOP
WIPER RY
STEERING RY
ALT LEVEL
FUEL SENSOR
TACHO SENSOR+
PREHEATER
SERIAL-H
WASH SIG
NEUTRAL SIG
FAN CLUTCH -
CAN-H
AUTO SEL.TCU
ELEC STEERING
CAN-L
MAIN PUMP PS
CLUTCH CUT-OFF SW
STEERING P/P PS
RIDE CONT. ON
WIPER INT SIG
PARKING SIG
SERIAL-L
GND
BUZZER
AUTO SEL.SW
BRAKE PS
TAHCO SENSOR -
AIR FILTER
IG 24V
FUSE BOX
1
ILL.LAMP 20A
2
Cause Remedy HEAD LAMP 20A
3
YES BACK/STOP LAMP 10A
23
35
34
24
36
31
26
32
25
33
27
21
20
30
29
28
22
17
19
11
18
16
12
10
13
15
14
1
4
2
3
Defective front Replace
6
8
4
5
7
9
Check voltage HORN/CONVERTER 30A
5
105 GOr
120 LW
CN-58
69A G
YES between front wiper motor AIR-CON/HEATER 30A
6
CIGAR/MIRROR
wiper motor and 30A
7
SWITCH 30A
chassis Poor connection of Replace 8
NO 14 L WIPER 20A
Check voltage Voltage : 20~30V chassis FR WORK LAMP
9
YES Starting switch : ON
30A
10
between CN-21(5)
Wiper switch : 1st CN-36
and chassis
WIPER RY LO
Voltage : 20~30V 173 R
30
8A W 87a 87 85
Starting switch : ON Disconnection in Repair or replace 86
Check voltage Wiper switch : 1st NO 8 W
87
105 GOr
YES between CS-12 wiring harness or (After clean) 85
162 G
87a 30 86
(4), CN-16(10) poor contact CR-26
and chassis between CN-16(10)
Voltage : 20~30V and CN-21(5),
Wiper switch : OFF CN-17(13) WIPER RY HI
14A L
30
163 Br 87a 87 85
86
172 G
NO Defective wiper Repair or replace G13 B
87
85
switch or (After clean) BE W
87a 30 86
Check voltage disconnection in CR-4
CS-12(6) wiring harness or

poor contact
Voltage : 20~30V between CS-12(4)
120 LW
163 Br
162 G
and CN-16(10).
14F L
69 Gr
Wiper switch : 1st
YES
CN-16
10
11
12
13
14
15
Disconnection in
6
7
9
Repair or replace
8
between CN-16(8) between CN-16(8)
G61 B
172 G
173 R
NO
8 W
VOr 38
and chassis. and fuse No.9
LW 17
Gr 18
Br 19
G 20
L 21
CN-17
10
11
12
13
14
15
1
2
3
4
5
6
7
8
9
CS-11
CS-12
CS-5
6
5
4
3
2
1
8
7
6
5
4
3
2
1
NO
38 VOr
BWG 4
RW 6
W6
BVi 3
L 4
G 5
BY 1
poor contact
Gr 2
VOr
W
Y
B
G
R
between CS-12(6)
G1
28
38
27
26
HO
W
II
I
Hi
C
J 0
J
C
CN-21
and CN-16(8).
1
2
3
5
4
6
0
II
I
Lo
Hi
5 Lo
4 Hi
3E
B+
2Pf
1B
F
R
L
O
R
L
M
7 Y Lo
8 WB
2 BW
3 BG
5B
FRONT WIPER
MULTI FUNCTION SWITCH
7577AEL12
7-72
7. WHEN STARTING SWITCH "ON" DOES NOT OPERATE
ÂBefore carrying out below procedure, check all the related connectors are properly inserted and and
the fuse No.16 is not blown out.
FUSE BOX
Cause Remedy EMER STEER/RIDE CON 20A
10
11
YES NEUTRAL RY/JOYSTICK F/R 10A
Defective cable Repair or replace 12
PREHEATER 30A
Check voltage 13
YES assembly (After clean) TURN LAMP
14
between CN-60(2) CASSETTE/ROOM LAMP 5A 3R 34
15
and chassis 21 3Or START KEY 30A
16
TCU
Short circuit or Replace 10A
17
Voltage : 20~30V NO ECM 10A
18
Check voltage defect of fusible CLUSTER/MCU 10A
YES 19
between CR-1 link or defective AC & HEATER 20A
20
ECM 10A
and chassis 21
battery relay RCV 10A
22
Voltage : 20~30V MCU 10A
23
TCU 10A
24
Disconnection in Repair or replace CLUSTER 10A
25
NO CASSETTE 10A
Check voltage wiring harness or (After clean) 26
YES between CS-2 ILLUMINATION LAMP 5A
27
(1)[and CS-2(2)] poor contact 28
and chassis between CS-2(2) CN-36

Voltage : 20~30V MASTER SW
- CN-3(9)-CR-1.
34 3R 1 3R
1 2
2 1
CS-74 FUSIBLE LINK
CN-1 2 5W CN-60
2
69 5W
Disconnection in Repair or replace 1
Check voltage NO CN-95
BATTERY
BATT RY
and specific 66 G
gravity of battery poor contact G12 B
between fuse CR-1

Specific gravity : MIN 1.28
Voltage : MIN 24V No. 16 and CS- 1
2
2(1) or defect of 3
4
start switch 5
6
7
G 66
Battery capacity Repair or replace 8 2
NO 9
L 22
1
too low (After clean)
21E Or
153 L
10 DO-1
11
12
CN-3
CS-2
5
4
1
6
2
3
B
0, I
1
H 0 I II
4
6
5
3
2
H
C ST ACC BR
START SWITCH
7607AEL19
7-73
8. WHEN STARTING SWITCH IS TURNED ON, WORK LAMP DOES NOT LIGHTS UP
ÂBefore carrying out below procedure, check all the related connectors are properly inserted, and the
fuse No.1, 10 is not blown out.
ÂAfter checking, connect the disconnected connectors again immediately unless otherwise specified. FUSE BOX
5 G BEACON/RR WORK LAMP 20A
1
10 OrW ILL.LAMP 20A
2
HEAD LAMP 20A
3
BACK/STOP LAMP 10A
4
HORN/CONVERTER 30A
Cause Remedy AIR-CON/HEATER 30A
5
6
YES CIGAR LIGHTER/MIRROR 30A
Check voltage Defective lamp Replace SWITCH 30A

7
8
YES
between each WIPER 20A
9
15 Gr FR WORK LAMP 30A
lamp and chassis 10
Disconnection in Repair or replace EMER STEER/RIDE CON 20A
11
NO
Voltage : 20~30V wiring harness or (After clean) CN-36
Check voltage Starting switch : ON poor contact OPT
YES between CN-7(2), between CL-6(2), RW 2F
FRONT WORK LAMP
2
CN-4(14) and CL-5(2), CL-22(2),
B G24
1
chassis CL-23(2) and CN-
CL-36
FRONT WORK LAMP
Voltage : 20~30V RW 2E
7(2), CN-4(14). B G23
2
Starting switch : ON FR WORK LAMP RY 1
87a CL-35
Check voltage 86 30
B G16
Disconnection in Repair or replace 85 1 FRONT WORK
YES between CR- NO 87
RW 171
2
RW 2
LAMP,LH
wiring harness or (After clean) G 170 RW 2A
3(87), CR-55(87) 85 87 87a
86 3 2
poor contact 30
Gr 15 4 B G22
1
and chassis CR-3 5
between CN-7(2) - 6
CL-6
Voltage : 20~30V 7 FRONT WORK
CR-3(87) and CN- 8
B G21
LAMP,RH
RW 2
4(14) - CR-55(87) 9 B G1 B G21
2
Check voltage 10
11
1
CL-5
between CR- Defective work Replace relay 12 OPT
REAR WORK LAMP
3(30), CR-55(30) NO 13 R 10 R 10
lamp relay 14
B G25
2
and chassis 15 1
CN-7 CL-32
Voltage : 20~30V YES RR WORK LAMP RY
Disconnection in Repair or replace R 10A
REAR WORK LAMP
Starting switch : ON 86 30 87a
B G17
2
wiring harness or (After clean) 85 B G26
1
R 63
Check voltage poor contact 87
L 180
CL-33
86
between fuse No. between CR- 85 87 87a
30
Gr 5 REAR WORK
LAMP,LH
NO 3(30), CR-55(30) CR-55 10E R
2
1, 10 and chassis G29 B
and fuse No.1, 10 1
WORK LAMP SW CL-22
Voltage : 20~30V B G36
9 10 10
Starting switch : ON Short circuit of fuse Replace 9 R 1G
NO 4 8 REAR WORK
LAMP,RH
2 G 170 10F R
7
2
7 1 6 G30 B
5 1
5
R 1F CL-23
4
3
L 180
II I 0
2
1 R 1E
CS-36
CS-21
9 10 10
9
4 8
2
7 R 1
7 1 6
5 5
4
3
II I 0
2
OrW 10
1
ILL & HEAD LAMP SW : ON(1st step)
7307AEL09
7-74
9. WHEN ENGINE DOES NOT START
ÂCheck supply of the power at engine stop solenoid while starting switch is ON.
ÂBefore carrying out below procedure, check all the related connectors are properly inserted.
ÂAfter checking, connect the disconnected connectors again immediately unless other wise specified.
ÂCheck forward reverse switch at neutral position.
ADM2-JOYSTICK SELECT LAMP(-)
SAFETY RY
ADM5-JOYSTICK SELLECTER(+)
WIPER RY
STEERING RY
PREHEATER
NEUTRAL SIG
ADM1-START INTERLOCK RY(-)
ADM4-REVERSE DRIVE RY(-)

ED14-NEU-JOYSTICK
ED13-REV-JOYSTICK
FUSE BOX
ED8-FWD-JOYSTICK
10
Cause Remedy EMER STEER/RIDE CON 20A
11
17 G NEUTRAL RY/JOYSTICK F/R 10A
YES 12
Defective batteryCheck engine PREHEATER 30A
35
34
36
32
33
SAFETY RY 13
TURN LAMP
system charge or G 17
30
65
66
67
68
44
31
30
52
59
CN-58 14
5
7
73 BOr
85
86 87a 87
G 17A CASSETTE/ROOM LAMP 5A
replace (after CN-157
85 W
15
BOr 73 21 3Or START KEY 30A
87 16
checking specific BOr 88
85 TCU 10A
17
gravity of battery) 87a 30 86 ECM 10A
18
YES CLUSTER/MCU 10A
Check voltage Defective magnet Replace CR-5 19
Check operation SAFETY RY AC & HEATER 20A
YES between starter of start motor GrW 157 ECM
20
30 10A
of start motor magnet coil and 85 21
BOr 73A
86 87a 87 RCV 10A
22
BW 151
chassis Defective start Replace GEAR SELECTOR LEVER X-1 87 MCU 10A
23
Starting switch : start NO VM OUTPUT SIGNAL K A 85 TCU 10A
Starting switch : start relay 24
VP F B N D B 87a 30 86 CLUSTER 10A
ED 1 2 3 4 1 2 3 4 1 2 3 4 C 25
CR-5 CASSETTE 10A
YES AD1 B1 D 26
ͽ AD2 B2 CN-158 ILLUMINATION LAMP 5A
27
Check operation Check voltage
AD3
AD4
B3
V X-2
28
NO of starter relay YES AD5 R A 1
between CR-5 AD6 AS B 2 CN-36
AD7 C 3
(87) and chassis A AD3 D
W 33
4
Starting switch : start
NO
Disconnection in Replace B AD2 CN-159 5
Starting switch : OFF 6
wiring harness or C AD1
D AD7(KD) 7
X1
Check operation poor contact 8
A ED1(VP) 9
of start safety between CN-3(4) D AD6 10
NO B AD4 11
relay and CR-5(87) C AD5 12 STARTER
X2 TO BATT
13 B+
Check switch : neutral YES 14
Defective relay Replace CN-17
Check voltage M
between CR-5 CN-45
NO 1
(86) and chassis 2 5
START RY
G1 B
Starting switch : OFF NO
; 3
BW 18
6 1
4 7 2
17 BW
YES 5 8
CR-23
Defective start Replace 6 9
Check voltage relay 7 10
8 11
ͽ between CR-23
21E Or
157 GrW
65 G
9 12
(2) and chassis 10 CN-13
Disconnection in Repair or replace 11
Voltage : 20~30V NO 12
Starting switch : ON wiring harness or
21 3Or
G14 B
31 3Br
65A G
G15 B
32 3Y
65 G
21A Or
CN-3
CS-2
poor contact
5
4
1
6
2
3
between CN-3(4) -
CR-35
CR-25
87a 85 87 86 30 87a 85 87 86 30 B
0, I
1
CN-13(7)-CR-23(2) 87a 87a
30 87 30 87
YES 86 85 86 85
H 0 I II
4
6
5
3
2
H
C ST ACC BR
wiring harness or POWER RY ECM POWER RY START SWITCH
; between CN-17 between CN-17(4)
(4) and chassis and CN-157
Starting switch : OFF
NO
Defective DW-3 Replace 7707AEL21
7-75

Foreword: 1. Structure

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Foreword: 1. Structure

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FOREWORD

Structure and function

2. Convert 550mm into inches.

0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

Kilogram to Pound 1kg = 2.2046lb

0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84

0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378

Liter to U.K. Gallon 1˶ = 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

-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 117.8

-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

SECTION 3 POWER TRAIN SYSTEM

SECTION 4 BRAKE SYSTEM

SECTION 5 STEERING SYSTEM

SECTION 6 WORK EQUIPMENT

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

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

PREVENT BATTERY EXPLOSIONS

USE TOOLS PROPERLY

USE PROPER LIFTING EQUIPMENT

DISPOSE OF FLUIDS PROPERLY

LIVE WITH SAFETY

KEEP ROPS INSTALLED PROPERLY

1. MAJOR COMPONENT(HL730-7A, HL730XTD-7A)

Bucket Tire Hydraulic tank Radiator

Boom Main control valve Cab Air cleaner Counterweight

Bucket Tire Hydraulic tank Radiator

Boom Main control valve Cab Air cleaner Counterweight

Quick coupler Link Bucket cylinder Main pump Engine Muffler

Description Unit Specification

Description Unit Specification

Description Unit Specification

Description Unit Specification

Description Unit Specification

Model Cummins QSB4.5

3) FAN AND BRAKE PUMP

4) MAIN CONTROL VALVE

Type 2 spool(sectional block)

5) REMOTE CONTROL VALVE

Type Joystick(or with aux lever)