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Manual D Serviço DL250 PDF
Manual D Serviço DL250 PDF
DL250TC
Shop Manual
K1023773BE
Serial Number 5001 and Up
DOOSAN reserves the right to improve our products in a continuing process to provide the best possible
product to the market place. These improvements can be implemented at any time with no obligation to
change materials on previously sold products. It is recommended that consumers periodically contact their
distributors for recent documentation on purchased equipment.
This documentation may include attachments and optional equipment that is not available in your
machine's package. Please call your distributor for additional items that you may require.
Illustrations used throughout this manual are used only as a representation of the actual piece of
equipment, and may vary from the actual item.
Instructions
Specifications
Specification for DL250/DL250TC....................................................... SP001562
General Maintenance
General Maintenance Procedures ...................................................... SP000097
Standard Torques ................................................................................ SP000813
Drive Train
Transmission and Torque Converter.................................................. SP000867
Transmission Error Codes (ZF).......................................................... SP001056
Front Axle (ZF-MT-L 3085)................................................................. SP000868
Rear Axle (ZF-MT-L 3075) ................................................................. SP000869
Drive Shaft ........................................................................................... SP000870
Brake
Service Brake....................................................................................... SP001359
Brake Supply Valve............................................................................. SP001360
Parking Brake ...................................................................................... SP000873
Brake Pedal Valve............................................................................... SP000874
Accumulator.......................................................................................... SP000875
Steering
Steering ................................................................................................ SP001361
Cushion Valve...................................................................................... SP000328
Emergency Steering ............................................................................ SP000877
Table of Contents
Page I
Frame
Articulation Center ............................................................................... SP000878
Counterweight....................................................................................... SP000130
Tank
Oil Tank................................................................................................ SP000879
Fuel Tank ............................................................................................. SP001362
Hydraulics
Cylinders............................................................................................... SP001027
Main Pump........................................................................................... SP001035
Main Control Valve.............................................................................. SP000881
Load Isolation System......................................................................... SP000882
Cooling System.................................................................................... SP001374
Pilot System ......................................................................................... SP000884
Hydraulic Schematic (DL250) ............................................................. SP000886
Electrical System
Air Conditioner ..................................................................................... SP000172
Electrical System ................................................................................. SP000924
Electrical Schematic (DL250).............................................................. SP000925
Table of Contents
Page II
1Safety
SP000865
WHEEL LOADER SAFETYSP000865
Wheel Loader
Safety
Edition 1
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
DANGER!
Unsafe use of the wheel loader could lead to serious injury
or death. Operating procedures, maintenance and
equipment practices or traveling or shipping methods that
do not follow the safety guidelines on the following pages
could cause serious, potentially fatal injuries or extensive
damage to the machine or nearby property.
CAUTION!
This word is used on safety messages and safety labels and
indicates potential of a hazardous situation that, if not
avoided, could result in minor or moderate injury. It may
also be used to alert against a generally unsafe practice.
WARNING!
This word is used on safety messages and safety labels and
indicates potential of a hazardous situation that, if not
avoided, could result in serious injury or death. It may also
be used to alert against a highly unsafe practice.
DANGER!
This word is used on safety messages and safety labels and
indicates an imminent hazard of a situation that, if not
avoided, is very likely to cause death or extremely serious
injury. It may also be used to alert against equipment that
may explode or detonate if handled or treated carelessly.
Accessory Applications
This wheel loader has been designed primarily for moving earth
with a bucket. For use as a grapple or for other object handling,
contact DOOSAN. Lifting-work applications are permitted in
approved lift configuration, to rated capacity only, with no
side-loading (unless prohibited by local regulation). Do not use
machine for activities for which it was not intended. Do not use
bucket for lifting work, unless lift slings are used in approved
configuration.
GENERAL HAZARD
INFORMATION
Safety Rules
Only trained and authorized personnel can operate and maintain
the machine.
Follow all safety rules, precautions and instructions when
operating or performing maintenance on the machine.
Do not operate the machine if you are not feeling well, if you are
taking medication that makes you feel sleepy, if you have been
drinking, or if you are suffering from emotional problems. These
problems will interfere with your sense of judgement in
emergencies and may cause accidents.
When working with another operator or with a person on work
site traffic duty, be sure that all personnel know the nature of the
work and understand all hand signals that are to be used.
Always observe strictly any other rules related to safety.
Safety Features
Be sure that all guards and covers are installed in their proper
position. Have guards and covers repaired immediately if
damaged.
Be sure that you understand the method of use of safety
features such as transmission lever neutral lock and the seat
belt, and use them properly.
Never remove any safety features. Always keep them in good
operating condition.
Failure to use safety features according to the instructions in the
Operation and Maintenance Manual could result in serious
bodily injury.
To prevent hot coolant from spurting out, shut down engine, wait
for the coolant to cool, then loosen the cap slowly to relieve the
pressure.
To prevent hot oil from spurting out, shut down engine, wait for
the oil to cool, then loosen the cap slowly to relieve the pressure.
HAOA060L
Figure 6
Accumulator
The pilot control system is equipped with an accumulator. For a
brief period of time after the engine has been shut down, the
accumulator will store a pressure charge that may enable
hydraulic controls to be activated. Activation of any controls may
enable the selected function to operate under force of gravity.
When performing maintenance on the pilot control system, the
hydraulic pressure in the system must be released as describe
in Operation and Maintenance Manual.
The accumulator is charged with high-pressure nitrogen gas, so
it is extremely dangerous if it is handled in the wrong way.
Always observe the following precautions;
• Do not drill or make any holes in the accumulator or
expose it any flame, fire or heat source.
• Do not weld on the accumulator, or try attaching
anything to it.
• When carrying out disassembly or maintenance of
the accumulator, or when disposing of the
accumulator, the charged gas must be properly
released. Contact your DOOSAN distributor.
• Wear safety goggles and protective gloves when
working on an accumulator. Hydraulic oil under
pressure can penetrate the skin and cause serious
injuries.
Engine Ventilation
Engine exhaust gases can cause loss of judgment, loss of
alertness, and loss of motor control. These gases can also
cause unconsciousness, serious injury and fatal accidents.
Make sure of adequate ventilation before starting engine in any
enclosed area.
You should also be aware of open windows, doors or ductwork
into which exhaust may be carried, or blown by wind, exposing
others to danger.
ARO1770L
Figure 11
IMPORTANT
If you need more information or have any questions or
concerns about safe operating procedures or working the
wheel loader correctly in a particular application or in the
specific conditions of your individual operating
environment, please consult your local DOOSAN
representative.
Figure 14
Movement Alarms
If wheel loader is equipped with an audible travel movement
alarm, test alarm on a daily basis. Audible alarm should sound
as soon as travel system is engaged.
gradually level any existing slope. If it's not possible to level area
or avoid working on a slope, reducing size and cycling rate m(16''
)
workload is recommended. 400 m
TURBO-II
HDO1042L
Figure 17
Figure 19
IMPORTANT
When hydraulic system maintenance or service work must
be performed, be aware that accumulators in system store
fluid under pressure after system has been shut down. To
release hydraulic pressure in accumulators, operate control
with engine "OFF" until accumulator pressure is completely
dissipated.
HAAD4050
Figure 21
HAOC920L
Figure 22
HDO1037L
Figure 24
Use of Lighting
When checking fuel, oil, battery electrolyte, or window washing
fluid, always use lighting with anti-explosion specifications. If
such lighting equipment is not used, there is danger of
explosion.
If work is carried out in dark places without using lighting, it may
lead to injury, so always use proper lighting.
Even if the place is dark, never use a lighter or flame instead of
lighting. There is danger of fire. There is also danger that the
HDO1040L
battery gas may catch fire and cause and explosion.
Figure 25
Burn Prevention
When checking the radiator coolant level, shut down engine, let
the engine and radiator cool down, then check the coolant
recovery tank. If the coolant level in the coolant recovery tank is
near the upper limit, there is enough coolant in the radiator.
Loosen the radiator cap gradually to release the internal
pressure before removing the radiator cap.
If the coolant level in the coolant recovery tank is below the
lower limit, add coolant.
Cooling system conditioner contains alkali. Alkali can cause
personal injury. Do not allow alkali to contact the skin, the eyes,
or the mouth.
Allow cooling system components to cool before you drain the
cooling system.
Hot oil and hot components can cause personal injury. Do not
allow hot oil or hot components to contact the skin.
Remove the hydraulic tank filter plug only after the engine has
been stopped. Make sure that the hydraulic tank filter plug is
cool before you remove it with your bare hand. Remove the
hydraulic tank filter plug slowly to relieve pressure.
Relieve all pressure in the hydraulic oil system, in the fuel
system, or in the cooling system before you disconnect any
lines, fittings, or related items.
Batteries give off flammable fumes that can explode. HAAE1980
Figure 26
Do not smoke while you are checking the battery electrolyte
levels.
Electrolyte is an acid. Electrolyte can cause personal injury. Do
not allow electrolyte to contact the skin or the eyes.
Always wear protective glasses when you work on batteries.
WARNING!
When you connect or disconnect connectors between ECU
and Engine or connector between ECU and the machine,
always disconnect the source power to protect damage of
the ECU.
If you don't observe this procedure, the ECU would be
gamaged or the engine would operate abnormally.
WARNING!
Failure to obtain prompt medical assistance could result in
gangrene or other serious damage to tissue.
WARNING!
Improper lifting can allow load to shift and cause personal
injury or damage to the machine.
Specification
for DL250/
DL250TC
Edition 1
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
DL250
1 2 3 4
5 6 7
18 17 11 20 19 10 22 23 24
45
26 8 25
13 14 15
44 12
30 28 27
43 42 39 40 36 38 37 16 41 35 34 33 32 31 21 29 FG012273
Figure 1
1 2 3 4
5 6 7
47 18 17 17 11 20 19 10 22
12 44 15 1 23 24 26 8 25
46 45 14
E SIDE
29 27 30 28
43 39 42 41 40 37 36 35 34 33 32 31 21
FG012275
Figure 2
14,230kg 14,520 kg
Vehicle Weight
(31,372 lb) (32,015 lb)
Engine
Type DOOSAN DL06 (Tier-lll)
Rated power (SAE J 1995 gross) 165 ps @ 2,100 rpm (121 kw @ 2,100 rpm)
Max. Torque (SAE J 1995 gross) 82 kg•m / 1,400 rpm (593 ft lb @ 1,400 rpm)
Transmission
Full Automatic Power -Shift Full Automatic Power Shift
Speeds 4 Forward, 3 Reverse
Brake Systems
Service Brakes 4 Wheel, Wet Multi Disks, Dual Pedal
Parking Brake Dry Disk on Transmission
Performance
Forward: 6.6 (4.1) / 11.5 (7.1) / 22.5 (14.0) / 34.0 (21.0) km/h
Travel Speed (1 / 2 / 3 / 4) km/h (MPH)
Reverse: 7.0 (4.3) / 12.5 (7.8) / 23.5 (14.6) km/h (MPH)
Steering Angle ± 40°
Min. Tire Turning Radius 20.5-25-
5,450 mm (17' 10")
(Out-Tire Edge) 16PR (L3)
Max Tractive Effort 14,500 kg (31,967 lb)
Max. Breakout Force 10,500 kg (23,149 lb) 10,300 kg (22,708 lb)
Boom Up 5.4± 0.5 Seconds 5.8± 0.5 Seconds
Boom Down 3.3± 0.4 Seconds 3.9± 0.4 Seconds
Bucket Crowd 1.7± 0.3 Seconds 2.4± 0.3 Seconds
Bucket Dump 1.3± 0.3 Seconds 2.2± 0.3 Seconds
Maximum Gradeability 58% (30°)
Working Range
Dump Height at 45° (w / teeth) 2,549 mm (8' 4") 2,556 mm (8' 5")
Dump Reach at 45° (w / teeth) 1,367 mm (4' 6") 1,434 mm (4' 8")
Max Dump Angle at Fully Raised 46° 50°
Max Tilt Angle at Carry 47° 48°
Travel Dimension
Overall Length (W / BOT) 7,929 mm (26') 8,137mm (26')
Overall Width 2,740 mm (9')
Overall Height 3,260 mm (10' 8")
Wheel Base 3,020 mm (9' 11")
Tread 2,040 mm (6' 8")
Ground Clearance 410 mm (1' 4")
80
70
TORQUE (kg.m)
60
POWER OUTPUT (ps)
150
100
160
150
140
DL250
Figure 4, illustrates exterior machine dimensions and working
range of machine when it is equipped with a standard
bucket.
O
P
B(D)
F
40
Q
M
45
I"
I
K
C
H"
H
L
E
J
FG006688
Figure 4
7,694 mm 7,928 mm
Overall Length (A)
(25' 3") (26')
2,740 mm
Overall Width (B)
(9')
3,290 mm 3,260 mm
Overall Height (C)
(10' 10") (10' 8")
2,740 mm
Bucket Width (D)
(9')
3,020 mm
Wheel Base (E)
(9' 11")
2,040 mm
Tread (F)
(6' 8")
440 mm 410 mm
Ground Clearance (G)
(1' 5") (1' 4")
60 mm 90 mm 161 mm
Digging Depth (J)
(2") (4") (6")
5,450 mm 5,477 mm
(Out Tire Edge) (O)
(17' 10") (17' 11")
Turning 5,430 mm
(C/Weight Edge) (P)
Radius (17' 10")
6,010 mm 6,335 mm
(Bucket Edge) (Q)
(19' 9") (20' 9")
O
P
B(D)
F
40
Q
M
45
"I"
I
K
C
"H"
H
L
E
J
FG012279
Figure 5
7,929 mm
Overall Length (A)
(26')
2,740 mm
Overall Width (B)
(9')
3,260 mm
Overall Height (C)
(10' 8")
2,740 mm
Bucket Width (D)
(9')
3,020 mm
Wheel Base (E)
(9' 11")
2,040 mm
Tread (F)
(6' 8")
410 mm
Ground Clearance (G)
(1' 4")
2,549 mm
Dump Height, at 45° (with teeth) (H)
(8' 4")
1,367 mm
Dump Reach, at 45° (with teeth) (I)
(4' 6")
60 mm
Digging Depth (J)
(2")
3,856mm
Bucket Hinge Height (K)
(12' 8")
5,477 mm
(Out Tire Edge) (O)
(18'")
Turning 5,430 mm
(C/Weight Edge) (P)
Radius (17 12"')
6,220 mm
(Bucket Edge) (Q)
(20' 5")
R
S
40
T
P
C
O
B (D) E F
L
A
45
J
K
M
H
I
N
15
FG008114
Figure 6
7,995 mm
Overall Length (A)
(26' 2")
2,740 mm
Overall Width (B)
(9' 0")
3,290 mm
Overall Height (C)
(10' 8")
2,740 mm
Bucket Width (D)
(9' 0")
3,020 mm
Wheel Base (E)
(9' 9")
2,040 mm
Tread (F)
(6' 7")
410 mm
Ground Clearance (G)
(1' 3")
2,700 mm
Dump Height, at 45° (with teeth) (I)
(8' 9")
1,330 mm
Dump Reach, at 45° (with teeth) (K)
(4' 4")
50 mm
Digging Depth (L)
(2")
3,962mm
Max. Bucket Hinge Height (M)
(12' 5")
5,477 mm
(Out Tire Edge) (R)
(18')
5,430 mm
Turning Radius (C/Weight Edge) (S)
(17' 8")
6,250 mm
(Bucket Edge) (T)
(20' 5")
O
P
B(D)
F
40
Q
M
45
"I"
I
K
C
"H"
H
L
E
J
FG012280
Figure 7
8,137 mm
Overall Length (A)
(26')
2,740 mm
Overall Width (B)
(9')
3,260 mm
Overall Height (C)
(10' 8")
2,740 mm
Bucket Width (D)
(9')
3,020 mm
Wheel Base (E)
(9' 11")
2,040 mm
Tread (F)
(6' 8")
410 mm
Ground Clearance (G)
(1' 4")
2,556 mm
Dump Height, at 45° (with teeth) (H)
(8' 5")
1,434 mm
Dump Reach, at 45° (with teeth) (I)
(4' 8")
80 mm
Digging Depth (J)
(3")
3,962mm
Bucket Hinge Height (K)
(13')
5,477 mm
(Out Tire Edge) (O)
(18')
5,430 mm
Turning Radius (C/Weight Edge) (P)
(17' 10")
6,345 mm
(Bucket Edge) (Q)
(20' 10")
E F
A
C
B
D
FG006689
Figure 8
Reference Reference
Description Description
Number Number
A 1,566 mm (5' 2") E 1,500 mm (4' 11")
B 2,406 mm (7' 11") F 753 mm (2' 6")
C 3,692 mm (12' 1") a 46°
D 8,135 mm (26' 8") b 43°
Bucket Capacity
Standard toothed bucket has a capacity of 2.5 m3 (3.25 yd3). An
optional bucket equipped with a cutting edge and no teeth has a
capacity of 2.6 m3 (3.38 yd3).
Tipping Load
Static Tipping Load with bucket in Over Front position is 12,200
kg (26,895 lb). With bucket in Fully Turned position, Static
Tipping Load is 10,200 kg (22,486 lb).
MATERIAL WEIGHT
The data below describes weight of a cubic meter (cubic yard) of
many types of workload materials.
401 kg/m3
Charcoal --------------------- ---------------------
(695 lb/yd3)
449 kg/m3
Coke, foundry size --------------------- ---------------------
(756 lb/yd3)
897 kg/m3
Coal, anthracite --------------------- ---------------------
(1,512 lb/yd3)
1,522 kg/m3
Dolomite, crushed --------------------- ---------------------
(2,565 lb/yd3)
1,522 kg/m3
Earth, DRY, packed --------------------- ---------------------
(2,565 lb/yd3)
1,762 kg/m3
Earth, WET, muddy --------------------- ---------------------
(2,970 lb/yd3)
1,522 kg/m3
Limestone, crushed --------------------- ---------------------
(2,565 lb/yd3)
1,602 kg/m3
Limestone, fine --------------------- ---------------------
(2,705 lb/yd3)
1,282 kg/m3
Phosphate, rock --------------------- ---------------------
(2,160 lb/yd3)
929 kg/m3
Salt --------------------- ---------------------
(1,566 lb/yd3)
529 kg/m3
Snow, light density --------------------- ---------------------
(891 lb/yd3)
1,522 kg/m3
Sand, DRY, loose --------------------- ---------------------
(2,565 lb/yd3)
1,922 kg/m3
Sand, WET, packed --------------------- ---------------------
(3,240 lb/yd3)
1,362 kg/m3
Shale, broken --------------------- ---------------------
(2,295 lb/yd3)
529 kg/m3
Sulphur, broken --------------------- ---------------------
(1,620 lb/yd3)
IMPORTANT
Weights are approximations of estimated average volume
and mass. Exposure to rain, snow or ground water; settling
or compaction due to overhead weight and chemical or
industrial processing or changes due to thermal or
chemical transformations could all increase value of
weights listed in table.
General
Maintenance
Procedures
Edition 1
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
WARNING!
Structural elements of the machine may be built from a
variety of steels. These could contain unique alloys or may
have been heat treated to obtain particular strength
characteristics. It is extremely important that welding
repairs on these types of steel are performed with the
proper procedures and equipment. If repairs are performed
incorrectly, structural weakening or other damage to the
machine (that is not always readily visible) could be
caused. Always consult DOOSAN After Sales Service
before welding on integral components (loader arm, frames,
car body, track frames, turntable, attachment, etc.) of the
machine. It is possible that some types of structurally
critical repairs may require Magnetic Particle or Liquid
Penetrant testing, to make sure there are no hidden cracks
or damage, before the machine can be returned to service.
CAUTION!
Always perform welding procedures with the proper safety
equipment on hand. Adequate ventilation and a dry work
area are absolutely essential. Keep a fire extinguisher
nearby and always wear protective clothing and the
recommended type of eye protection.
HYDRAULIC SYSTEM -
GENERAL PRECAUTIONS
Always maintain oil level in the system at recommended levels.
Assemblies that operate under heavy loads, at high speed, with
extremely precise dimensional tolerances between moving parts
- pistons and cylinders, or shoes and swash plates, for example
- can be severely damaged if oil supply runs dry.
Assemblies can be run dry and damaged severely in a very
short time when piping or hoses are disconnected to repair leaks
and/or replace damaged components. Hoses that are
inadvertently switched during disassembly (inlet for outlet and
vice versa), air introduced into the system or assemblies that are
low on oil due to neglect or careless maintenance, could all
produce sufficient fluid loss to cause damage.
IMPORTANT
Hydraulic system operating conditions (repetitive cycling,
heavy work loads, fluid circulating under high-pressure)
make it extremely critical that dust, grit or any other type of
contamination be kept out of the system. Observe fluid and
filter change maintenance interval recommendations and
always preclean any exterior surface of the system before it
is exposed to air. For example, the reservoir fill cap and
neck area, hoses that have to be disassembled, and the
covers and external surfaces of filter canisters should all be
cleaned before disassembly.
General Precautions
Fluid level and condition should always be checked whenever
any other type of maintenance service or repair is being
performed.
NOTE: If the unit is being used in an extreme temperature
environment (in sub-freezing climates or in high
temperature, high humidity tropical conditions),
frequent purging of moisture condensation from the
hydraulic reservoir drain tap should be a regular and
frequent part of the operating routine. In more
moderate, temperate climates, draining reservoir
sediment and moisture may not be required more
than once or twice every few months.
Inspect drained oil and used filters for signs of abnormal coloring
or visible fluid contamination at every oil change. Abrasive grit or
dust particles will cause discoloration and darkening of the fluid.
Visible accumulations of dirt or grit could be an indication that
filter elements are overloaded (and will require more frequent
replacement) or that disintegrating bearings or other component
failures in the hydraulic circuit may be imminent or have already
occurred. Open the drain plugs on the main pump casings and
check and compare drain oil in the pumps. Look for evidence of
grit or metallic particles.
Vibration or unusual noise during operation could be an
indication of air leaking into the circuit (Refer to the appropriate
Troubleshooting section for component or unit for procedures.),
or it may be evidence of a defective pump. The gear type pilot
pump could be defective, causing low pilot pressure, or a main
pump broken shoe or piston could be responsible.
NOTE: If equipped, indicated operating pressure, as shown
on the multidisplay digital gauge on the Instrument
Panel ("F-Pump" and "R-Pump") will be reduced as a
result of a mechanical problem inside the pump.
However, pressure loss could also be due to
cavitation or air leakage, or other faults in the
hydraulic system.
Check the exterior case drain oil in the main pumps. If no
metallic particles are found, make sure there is no air in the
system. Unbolt and remove the tank return drain line from the
top part of the swing motor, both travel motors and each main
pump. If there is air in any one of the drain lines, carefully prefill
the assembly before bolting together the drain line piping
connections. Run the system at low rpm.
IMPORTANT
Make sure that cleaning solvents will be compatible with
rubber materials used in the hydraulic system. Many
petroleum based compounds can cause swelling,
softening, or other deterioration of system sealing
elements, such as O-rings, caps and other seals.
Figure 1
General Guidelines
All parts must be clean to permit an effective inspection. During
assembly, it is very important that no dirt or foreign material
enters unit being assembled. Even minute particles can cause
malfunction of close fitting parts such as thrust bearing, matched
parts, etc.
WARNING!
Care should be exercised to avoid inhalation of vapors,
exposure to skin and creating fire hazards when using
solvent type cleaners.
Bearing inspection
The conditions of the bearing are vital to the smooth and
efficient operation of the machinery. When any component
containing bearings is disassembled, always carefully examine
the condition of the bearings and all of its components for wear
and damage.
Once the bearing is removed, clean all parts thoroughly using a
suitable cleaning solution. If the bearing is excessively dirty soak
the bearing assembly in a light solution and move the bearing
around until all lubricants and or foreign materials are dissolved
and the parts are thoroughly clean.
When drying bearings, moisture free compressed air can be
used. Be careful not to direct the air in a direction which will
force the bearing to dry spin while not being properly lubricated.
Normal Bearing
Smooth even surfaces with no discoloration or marks.
Figure 2
Bent Cage
Cage damage due to improper handling or tool usage.
Figure 3
Figure 4
Galling
Metal smears on roller ends due to overheat, lubricant failure or
overload.
Replace bearing - check seals and check for proper lubrication.
Figure 5
Figure 6
Figure 7
Misalignment
Outer race misalignment due to foreign object.
Clean related parts and replace bearing. Make sure races are
properly seated.
Figure 8
Indentations
Surface depressions on race and rollers caused by hard
particles of foreign materials.
Clean all parts and housings, check seals and replace bearings
if rough or noisy.
Figure 9
Figure 10
Brinelling
Surface indentations in raceway caused by rollers either under
impact loading or vibration while the bearing is not rotating.
Replace bearing if rough or noisy.
Figure 11
Cage Wear
Wear around outside diameter of cage and roller pockets
caused by abrasive material and inefficient lubrication.
Replace bearings - check seals.
Figure 12
Figure 13
Figure 14
Smears
Smearing of metal due to slippage caused by poor fitting,
lubrication, overheating, overloads or handling damage.
Replace bearings, clean related parts and check for proper fit
and lubrication.
Replace shaft if damaged.
Figure 15
Figure 16
Heat Discoloration
Heat discoloration can range from faint yellow to dark blue
resulting from overload or incorrect lubrication.
Excessive heat can cause softening of races or rollers.
To check for loss of temper on races or rollers, a simple file test
may be made. A file drawn over a tempered part will grab and
cut metal, whereas a file drawn over a hard part will glide readily
with no metal cutting.
Replace bearing if over heating damage is indicated. Check
seals and other related parts for damage.
Figure 17
Stain Discoloration
Discoloration can range from light brown to black caused by
incorrect lubrication or moisture.
if the stain can be removed by light polishing or if no evidence of
overheating is visible, the bearing can be reused.
Check seals and other related parts for damage.
Figure 18
Standard
Torques
Edition 1
Standard Torques
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
Grade
Dia. x Pitch
(mm)
3.6 4.6 4.8 5.6 5.8 6.6 6.8 6.9 8.8 10.9 12.9
(4A) (4D) (4S) (5D) (5S) (6D) (6S) (6G) (8G) (10K) (12K)
0.15 0.16 0.25 0.22 0.31 0.28 0.43 0.48 0.50 0.75 0.90
M5 x Std.
(1.08) (1.15) (1.80) (1.59) (2.24) (2.02) (3.11) (3.47) (3.61) (5.42) (6.50)
0.28 0.30 0.45 0.40 0.55 0.47 0.77 0.85 0.90 1.25 1.50
M6 x Std.
(2.02) (2.16) (3.25) (2.89) (3.97) (3.39) (5.56) (6.14) (6.50) (9.04) (10.84)
0.43 0.46 0.70 0.63 0.83 0.78 1.20 1.30 1.40 1.95 2.35
M7 x Std.
(3.11) (3.32) (5.06) (4.55) (6.00) (5.64) (8.67) (9.40) (10.12) (14.10) (16.99)
0.70 0.75 1.10 1.00 1.40 1.25 1.90 2.10 2.20 3.10 3.80
M8 x Std.
(5.06) (5.42) (7.95) (7.23) (10.12) (9.04) (13.74) (15.18) (15.91) (22.42) (27.48)
0.73 0.80 1.20 1.00 1.50 1.35 2.10 2.30 2.40 3.35 4.10
M8 x 1
(5.28) (5.78) (8.67) (7.23) (10.84) (9.76) (15.18) (16.63) (17.35) (24.23) (29.65)
1.35 1.40 2.20 1.90 2.70 2.35 3.70 4.20 4.40 6.20 7.20
M10 x Std.
(9.76) (10.12) (15.91) (13.74) (19.52) (19.99) (26.76) (30.37) (31.18) (44.84) (52.07)
1.50 1.60 2.50 2.10 3.10 2.80 4.30 4.90 5.00 7.00 8.40
M10 x 1.25
(10.84) (11.57) (18.08) (15.18) (22.42) (20.25) (31.10) (35.44) (36.16) (50.63) (60.75)
2.40 2.50 3.70 3.30 4.70 4.20 6.30 7.20 7.50 10.50 12.50
M12 x Std.
(17.35) (18.08) (26.76) (23.86) (33.99) (30.37) (45.56) (52.07) (54.24) (75.94) (90.41)
2.55 2.70 4.00 3.50 5.00 4.50 6.80 7.70 8.00 11.20 13.40
M12 x 1.25
(18.44) (19.52) (28.93) (25.31) (36.16) (32.54) (49.18) (55.69) (57.86) (81.00) (96.92)
3.70 3.90 6.00 5.20 7.50 7.00 10.00 11.50 12.00 17.00 20.00
M14 x Std.
(26.76) (28.20) (13.23) (37.61) (54.24) (50.63) (72.33) (83.17) (86.79) (122.96) (144.66)
4.10 4.30 6.60 5.70 8.30 7.50 11.10 12.50 13.00 18.50 22.00
M14 x 1.5
(29.65) (31.10) (47.73) (41.22) (60.03) (54.24) (80.28) (90.41) (94.02) (133.81) (159.12)
5.60 6.00 9.00 8.00 11.50 10.50 15.50 17.90 18.50 26.00 31.00
M16 x Std.
(40.50) (43.39) (65.09) (57.86) (83.17) (75.94) (112.11) (129.47) (133.81) (188.05) (224.22)
6.20 6.50 9.70 8.60 12.50 11.30 17.00 19.50 20.00 28.00 35.50
M16 x 1.5
(44.84) (47.01) (70.16) (62.20) (90.41) (81.73) (122.96) (141.04) (144.66) (202.52) (256.77)
7.80 8.30 12.50 11.00 16.00 14.50 21.00 27.50 28.50 41.00 43.00
M18 x Std.
(56.41) (60.03) (90.41) (79.56) (115.72) (104.87) (151.89) (198.90) (206.14) (296.55) (311.01)
9.10 9.50 14.40 12.50 18.50 16.70 24.50 27.50 28.50 41.00 49.00
M18 x 1.5
(65.82) (68.71) (104.15) (90.41) (133.81) (120.79) (177.20) (198.90) (206.14) (296.55) (354.41)
11.50 12.00 18.00 16.00 22.00 19.00 31.50 35.00 36.00 51.00 60.00
M20 x Std.
(83.17) (86.79) (130.19) (115.72) (159.12) (137.42) (227.83) (253.15) (260.38) (368.88) (433.98)
12.80 13.50 20.50 18.00 25.00 22.50 35.00 39.50 41.00 58.00 68.00
M20 x 1.5
(92.58) (97.64) (148.27) (130.19) (180.82) (162.74) (253.15) (285.70) (296.55) (419.51) (491.84)
15.50 16.00 24.50 21.00 30.00 26.00 42.00 46.00 49.00 67.00 75.00
M22 x Std.
(112.11) (115.72) (177.20) (151.89) (216.99) (188.05) (303.78) (332.71) (354.41) (484.61) (542.47)
17.00 18.50 28.00 24.00 34.00 29.00 47.00 52.00 56.00 75.00 85.00
M22 x 1.5
(122.96) (133.81) (202.52) (173.59) (245.92) (209.75) (339.95) (44.76) (405.04) (542.47) (614.80)
20.50 21.50 33.00 27.00 40.00 34.00 55.00 58.00 63.00 82.00 92.00
M24 x Std.
(148.27) (155.50) (238.68) (195.29) (289.32) (245.92) (397.81) (419.51) (455.67) (593.10) (655.43)
23.00 35.00 37.00 31.00 45.00 38.00 61.00 67.00 74.00 93.00 103.00
M24 x 2.0
(166.35) (253.15) (267.62) (224.22) (325.48) (202.52) (441.21) (484.61) (535.24) (672.66) (744.99)
NOTE: Torque values listed throughout this manual are lubricated (wet) threads; values should be
increased 1/3 for nonlubricated (dry) threads.
Heat Treated Material Grade 5 and Grade 8
Grade 5 Grade 8
Thread Size (3 Radial Dashes On Head) (6 Radial Dashes On Head)
Foot Pounds Newton Meter Foot Pounds Newton Meter
(ft lb) (Nm) (ft lb) (Nm)
1/4" - 20 6 8 9 12
1/4" - 28 7 9 11 15
5/16" - 18 13 18 18 24
5/16" - 24 15 20 21 28
3/8" - 16 24 33 34 46
3/8" - 24 27 37 38 52
7/16" - 14 38 52 54 73
7/16" - 20 42 57 60 81
1/2" - 13 58 79 82 111
1/2" - 20 65 88 90 122
9/16" - 12 84 114 120 163
9/16" - 18 93 126 132 179
5/8" - 11 115 156 165 224
5/8" - 18 130 176 185 251
3/4" - 10 205 278 290 393
3/4" - 16 240 312 320 434
7/8" - 9 305 414 455 617
7/8" - 14 334 454 515 698
1" - 8 455 617 695 942
1" - 14 510 691 785 1064
1 1/8" - 7 610 827 990 1342
1 1/8" - 12 685 929 1110 1505
1 1/4" - 7 860 1166 1400 1898
1 1/4" - 12 955 1295 1550 2102
1 3/8" - 6 1130 1532 1830 2481
1 3/8" - 12 1290 1749 2085 2827
1 1/2" - 6 1400 2034 2430 3295
1 1/2" - 12 1690 2291 2730 3701
1 3/4" - 5 2370 3213 3810 5166
2" - 4 1/2 3550 4813 5760 7810
NOTE: If any bolts and nuts are found loose or at
values less than what the chart states, it is
recommended that the loose bolt and/or nut be
replaced with a new one.
Torque
Radiator, Air Cleaner, Boots, Etc. Hydraulic System
Clamp Type And Size
Kilogram Meter Inch Pounds Kilogram Meter Inch Pounds
(kg•m) (in lb) (kg•m) (in lb)
"T" Bolt (Any Diameter) 0.68 - 0.72 59 - 63 ------- ------
Worm Drive - Under
44 mm (1-3/4 in) Open 0.2 - 0.3 20 - 30 0.5 - 0.6 40 - 50
Diameter
Worm Drive - Over 44 mm
0.5 - 0.6 40 - 50 ------- ------
(1-3/4 in) Open Diameter
Worm Drive - All
0.6 - 0.7 50 - 60 0.5 - 0.6 40 - 50
"Ultra-Tite"
Bolt Torque
Flange Bolt
Kilogram Meter Foot Pounds
Size (*) Size
(kg•m) (ft lb)
1/2" 5/16" 2.1 - 2.5 15 - 18
3/4" 3/8" 3.0 - 3.7 22 - 27
1" 3/8" 3.7 - 4.8 27 - 35
1 - 1/4" 7/16" 4.8 - 6.2 35 - 45
1 - 1/2" 1/2" 6.4 - 8.0 46 - 58
2" 1/2" 7.6 - 9.0 55 - 65
2 - 1/2" 1/2" 10.9 - 12.6 79 - 91
3" 5/8" 19.1 - 20.7 138 - 150
3 - 1/2" 5/8" 16.2 - 18.4 117 - 133
Torque Multiplication
A wrench extension tool can be used to increase the tightening
force on a high capacity nut or bolt.
For example, doubling the distance between the bolt and the
back (handle) end of the torque wrench doubles the tightening
force on the bolt. It also halves the indicated reading on the
scale or dial of the torque wrench. To accurately adjust or
convert indicated scale or dial readings, use the following
formula:
I = A x T / A + B where:
I = Indicated force shown on the torque wrench scale or dial.
T = Tightening force applied to the nut or bolt (actual Torque). Figure 1
CAUTION!
Disassembly, overhaul and replacement of components on
the machine, installation of new or replacement parts and/
or other service-related maintenance may require the use of
thread or flange sealing assembly compound.
Use the information on this page as a general guide in
selecting specific formulas that will meet the particular
requirements of individual assembly installations. DOOSAN
does not specifically endorse a specific manufacturer or
brand name but the following table of "Loctite" applications
is included for which cross-references to other makers'
products should also be widely available.
IMPORTANT
Use primer "T" or "N" for all cold weather assembly of
fastener adhesives, with Thread locker sealers 222, 242/243,
262, 271, 272, or 277.
Breakaway Cure
Product Application Color Removal Strength (in lb) of
Sealer Alone
Low strength for 6 mm (1/4") or
222 Purple Hand tools 45
smaller fasteners.
Medium strength for 6 mm (1/4") and
242 or 243 Blue Hand tools 80
larger fasteners.
Heat/260°C (500°F)
High strength for high grade fasteners Remove HOT
262 Red 160
subject to shock, stress and vibration.
(NO solvent)
Extra high strength for fine thread Heat/260°C (500°F)
271 Red 160
fasteners up to 25 mm (1") diameter. Remove HOT
High temperature/high strength for
Heat/316°C (600°F)
272 hostile environments to 232°C Red 180
Remove HOT
(450°F).
Extra high strength for coarse thread
Heat/260°C (500°F)
277 fasteners 25 mm (1") diameter and Red 210
Remove HOT
larger.
V. "Loctite" Adhesives
Transmission
and Torque
Converter
Edition 1
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
11
1
10 3 2
12
7 4
13
11
10
8 5
6
9 10
FG008077
Figure 1
Item DL250
Model 4WG-190 (Full Auto)
Type 3-Element, 1-Stage, Single-phase,
E/G mounted with flexible plate
Oil Cooler Water-cooled (multi-plate) and Air-cooled
Torque Converter Charging Pump 105 lpm at 2,000 rpm
Hydraulic Pump P.T.O 1:1
T/C Size ∅ 340 mm (13.39 in)
Stall Ratio 3.06
Safety Relief 11 Bar (160 psi)
Type Full Power Shift, Counter shaft
Speeds 4 Forward / 3 Reverse
Ratio F: 3.745 / 2.184 / 1.072 / 0.636
Transmission R: 3.555 / 1.981 / 1.017
Power Shift Control 16 - 18 bar (232 - 261 psi)
Pressure
Shift Control Electric Shift with Proportional Valve
Oil Capacity 45 l (11.8 U.S. gal)
Dry Weight 505 kg (1,113 lb)
Front 7 C Mechanics
Output Flange
Rear 6 C Mechanics
Transmission Control
Transmission control, See “The Chart of Measuring Points and
Connection 4 WG-190” on page -13., Electrohydraulic unit on
page -14 and “Oil Circuit Diagram 4WG-190” on page 1-15.
The transmission pump, necessary for the oil supply of
converter, and the transmission control, is input-side mounted
from outside, together with stator shaft and oil supply flange, on
transmission. The drive is realized by the pump-wheel flange of
converter.
The feed rate of pump is Q = 105 lpm at nEngine = 2000 min-1.
This pump is sucking the oil through the coarse filter out of oil
sump and delivers it through the ZF-Fine filter can be fitted also
externally from transmission - to system pressure valve.
ZF-Fine filter
Grade of filtration according to ISO 4572: β30 ≥ 75 β15 = 25 β10 =
5.0
Filter area at least: 3,900 cm2
Dust capacity according to ISO 4572 at least: 40 g
The six clutches of transmission are selected via the 6
proportional valves P1 to P6.
The proportional valve (pressure regulator unit) consist of
pressure regulator (e.g. Y1). follow-on slide and oscillation
damper.
The pilot pressure of 9 bar (130.54 psi) for the control of
follow-on slides is created by the reducing valve. The pressure
oil (16 +2 bar (230 +29 psi)) is directed through the follow-on
slide to corresponding clutch.
Marking on
No. Denomination of Position Connection
Valve Block
Measuring Points for Pressure Oil and Temperature
51 Converter Inlet - Opening pressure 9 bar (130 psi) M10 x 1 H
52 Converter Exit - Opening pressure 3.5 bar (51 psi) M14 x 1.5
53 Clutch Forward 16+2 bar (230 - 260 psi) KV M10 x 1 B
55 Clutch Reverse 16 +2 bar (230 +29 psi) KR M10 x 1 E
56 Clutch 16 +2 bar (230 +29 psi) K1 M10 x 1 D
57 Clutch 16 +2 bar (230 +29 psi) K2 M10 x 1 A
58 Clutch 16 +2 bar (230 +29 psi) K3 M10 x 1 C
60 Clutch 16 +2 bar (230 +29 psi) K4 M10 x 1 F
63 Converter Exit
M14 x 1.5
Temperature 100°C, Short-time 120°C
65 System Pressure 16 +2 bar (230 +29 psi) K4 M10 x 1 K
Measuring points for Delivery Rates
15 Connection to Heat Exchanger 1 5/16" - 12UNF-2B
16 Connection from Heat Exchanger 1 5/16" - 12UNF-2B
Inductive Transmitters and Speed Sensor
21 Inductive Transmitter n Turbine M18 x 1.5
34 Speed Sensor n Output and Speedometer -------
47 Inductive Transmitter n Central Gear Train M18 x 1.5
48 Inductive Transmitter n Engine M18 x 1.5
Connections
49 Plug Connection on Hydraulic Control Unit
68 Pilot Pressure (Optional) M16 x 1.5 J
69 System Pressure (Optional) M16 x 1.5 G
CODE
FG008638
Figure 3
LEGEND:
= System Pressure
= Pilot Pressure
AMS1111L
SP000867
Transmission and Torque Converter SP000867
Page 17
TRANSMISSION ELECTRICAL
COMPONENTS
20
30
13
21 10
40
50
0 km/h
10 18
19
17
14
20
15
3 2 1
1
16
1-4 A
MAN 2-4
3
9
2
11
12 4
6 7
FG004369
Figure 5
AJS0200L
Figure 6
2 2
• Pressure: 0.8 kg/cm → 8.3 kg/cm (11 - 118 psi)
FG005184
3. The contained temperature sensor detects the temperature Figure 7
of control valve and transmits the electrical signal to TCU,
and serves TCU determines gears to change.
• Neutral: At temperature less than -30°C
• 1st or 2nd gear: At temperature less than -10°C
• Normal Operation: At temperature greater than -10°C
• N: Neutral
• R: Reverse KD
N
• 1,2,3,4: Shift Step
SHIFT SWITCH
* Forward shift range: 1 - 4
LEVER LOCK KEY
* Reverse shift range: 1 - 3 R (N/D)
2. Kick-down (Down Shift) Switch AJS0270L
Figure 13
• KD: Kick-down Switch
3. Lever Lock Key
• N: Neutral (The lever is not moved.)
• D: Driving (The lever is released.)
4. Switch Circuit
B A AD3 (B3)
1 2 G B AD2 (B2)
1 2 L X1
C AD1 (B1)
1 2 V
D AD7 (KD)
R A ED1 (+/VP)
2 Gr
1 D AD6 (N)
3 2
1
3 Y B AD4 (F) X2
1 2
3 P C AD5 (R)
AJS0280L
Figure 14
D C B A
(AD5) PINK
X2
(AD4) YELLOW
(VP) RED
(AD7) VIOLET
D C B A
(AD1) BLUE
X1
(AD2) GREEN
(AD3) BLACK
AJS0290L
Figure 15
6. Switch Connection
ED1 VP
AD1 B1
AD2 B2
AD3 B3
AD4 V
AD5 R
AD6 AS
AD7 KD
AJS0300L
Figure 16
12 11 10 9 8 7
DEUTSCH
1 2 3 4 5 6
FG004371
Figure 18
3-Lever (Optional)
AUX. BUCKET BOOM
1. Horn Switch
H KD
• H: Horn Switch
2. Kick-down (Down Shift) Switch
• KD: Kick-down Switch
12 11 10 9 8 7
DEUTSCH
1 2 3 4 5 6
FG004372
Figure 19
1
12 1
RETURN TO DIG
12 MAGNET
2
11 2
FLOAT
11 MAGNET
3
10 3
RAISE
10 MAGNET
4
HORN
9
5
DOWN SHIFT
8
FG004373
Figure 20
7 6
8 5
DEUTSCH
9 4
10 3
11 2
12 1
FG004374
Figure 21
Fault Display h
left right
g
character character
BAR
CAN - Message FG004442
The TCU sends the fault code of a detected fault in the specified Figure 23
CAN - message, while the fault is active.
If more than one fault is detected, the fault code scrolls.
Abbreviations
O.C. Open Circuit
S.C. Short Circuit
OP-Mode OPeration Mode
TCU Transmission Control Unit
ABS Anti Blocking System
ASR Anti Slipping Regulation
EEC Electronic Engine Controller
PTO Power Take Off
CCO Clutch Cut Off
Normal
There is no failure detected in transmission system or failure has
no or slight effects on transmission control. TCU will work
without or in special cases with little limitations. (see following
table)
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.
Actuator
open circuit:R12 ≈ R1G ≈ R2G ≈ ∞
1
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) R
short cut to battery:R12 ≈ R;R1G ≈ 0, R2G ≈ R or R 1G ≈ R, R2G ≈
0 (for S.C. to battery, G is connected to battery voltage). 2
G
HBOE640I
Figure 24
Cable
UBat
open circuit:
R12 ≈ R1P ≈ R1C ≈ R2P ≈ R2C ≈ ∞ P (power supply)
TCU
short cut to ground: Actuator /
1 2
Sensor
R12 ≈ 0;R 1C ≈ R2C ≈ 0,R1P ≈ R2P ≈ ∞
C (chassis)
short cut to battery:
R12 ≈ 0,R 1C ≈ R2C ≈ ∞,R1P ≈ R2P ≈ 0 Gnd
HBOE650I
Figure 25
1 II KR Y2
9 14 BATT
10 K1 Y3
K2 Y6
17
(8)
10 20 K3 Y4
(N) 87a 87a K4 Y1
18 87
30 30
87 +
85 86 86 85 - 21
11
1-4 2-4 1
23 5
22 68 14 2-1 2-3
87a
30 52
87 30
8 16
85 86 8 36 (CN1-4) SIG. 15
53 21 2 4
57
3
12 62 2
11
+ VPS1
Y2
7
2
13
10
4 1 9
Y1 1 56
Y3 3 32
Y4 4 55 15 2 1
3 Y5 5 9 18 4 26 3
KICK 1 2 3 4
Y6 6 51 DOWN STEP STEP STEP STEP F N R
TEMP 8 39 45 X2-A VP
TEMP 9 46 67 X2-D AD6
X1-A
23 49 AD3
22
63
X1-D
X1-C
AD7 2
AD1
17 65 X1-B AD2
43 X2-B AD4
64 X2-C AD5
A 25
26 CC-TV
B
C
27 59
4P CONN(4) 9
28
12 19 7
27 (ENGINE)
44
35
F
N 5
0
I
3
41 31 R II
(TURBINE) 10 9
42
(CENTRAL 29
GEAR CHAIN) 3
EST-37A
3 28
1
AUTO(1-4) 29
AUTO(2-4) 20 2 F 2-LEVER (OPT)
5
TML 1 2 3 1 4 N
PST
MANUAL 2 7
AUTO(1-4) R
AUTO(2-4)
MONO-LEVER (OPT)
25 66 1
F/R SELECT 7 5
L11 7
ELEC. STEERING 7 10 9
L14
1 6
7 0
NC 3
1
30 NO
C 3 5 I
1 II
2 9
31 19
10
3
87a 28
30
3 87 87a 87a
2 30 30
85 86 87 87
1
85 86 86 85
PVED
7
34 33
4
5 8 32
6
35 ELECTRIC STEERING (OPT) 9
FG008639
Figure 26
Traveling Circuits
Shift Lever Position TCU Input TCU Output T/M Control Valve
Neutral 45, 67, 20 (12, 13) -
1st Gear 45, 20, 43, 63 (12, 13) - 32, 9 Y3, Y5
2nd Gear 45, 20, 43 (12, 13) - 9, 51 Y5, Y6
Forward
3rd Gear 45, 20, 43, 65 (12, 13) - 55, 9 Y4, Y5
4th Gear 45, 20, 43, 63, 65 (12, 13) - 56, 55 Y2, Y4
1st Gear 45, 20, 64, 63 (12, 13) - 10, 32 Y1, Y3
Reverse 2nd Gear 45, 20, 64 (12, 13) - 10, 51 Y1, Y6
3rd Gear 45, 20, 64, 65 (12, 13) - 32, 9 Y1, Y4
(8)
17 10 4
(N) 87a
18 87
30 11
85 86 1 8
1-4 2-4 1
52 14 2-1 2-3
19
BATT 14 23
36 16
68
(CN1-4) SIG. 15
21 2
12
VPS1 7 13 3
+
62 2
Y2 2 10 11
Y1 1 56
4 1 9
Y3 3 32
Y4 4 55
3 Y5 5 9 EST-37A
KICK 1 2 3 4
Y6 6 51 DOWN STEP STEP STEP STEP F N R
TEMP 8 39 45 X2-A VP
TEMP 9 46 67 X2-D AD6
49 X1-A AD3
23 22 X1-D
17 63 X1-C
AD7 2
AD1
65 X1-B AD2
19 43 X2-B AD4
(ENGINE) 64 X2-C AD5
41
12 (TURBINE)
42
(CENTRAL
3
GEAR CHAIN)
7 6
AUTO(1-4) 29 66 1
5
AUTO(2-4) 20 7
10 9
PST TML 1 2 3 1
MANUAL 2
5 AUTO(1-4)
AUTO(2-4)
FG005186
Figure 27
(8)
17 10 4
(N) 87a
18 87
30 11
85 86 1 8
1-4 2-4 1
52 14 2-1 2-3
19
BATT 14 23
36 (CN1-4) SIG. 15 16
68
21 2
12
VPS1 7 13 3
+
62 2
Y2 2 10 11
Y1 1 56
4 1 9
Y3 3 32
Y4 4 55
3 Y5 5 9 EST-37A
KICK 1 2 3 4
Y6 6 51 DOWN STEP STEP STEP STEP F N R
TEMP 8 39 45 X2-A VP
TEMP 9 46 67 X2-D AD6
49 X1-A AD3
23 22 X1-D
17 63 X1-C
AD7 2
AD1
65 X1-B AD2
19 43 X2-B AD4
(ENGINE) 64 X2-C AD5
41
12 (TURBINE)
42
(CENTRAL
3
GEAR CHAIN)
7 6
AUTO(1-4) 29 66 1
5
AUTO(2-4) 20 7
10 9
PST TML 1 2 3 1
MANUAL 2
5 AUTO(1-4)
AUTO(2-4)
FG005187
Figure 28
17 10 4
(N) 87a
18 87
30 11
85 86 1 8
1-4 2-4 1
52 14 2-1 2-3
19
BATT 14 23
36 (CN1-4) SIG. 15 16
68
21 2
12
VPS1 7 13 3
+
62 2
Y2 2 10 11
Y1 1 56
4 1 9
Y3 3 32
Y4 4 55
3 Y5 5 9 EST-37A
KICK 1 2 3 4
Y6 6 51 DOWN STEP STEP STEP STEP F N R
TEMP 8 39 45 X2-A VP
TEMP 9 46 67 X2-D AD6
49 X1-A AD3
23 22 X1-D
17 63 X1-C
AD7 2
AD1
65 X1-B AD2
19 43 X2-B AD4
(ENGINE) 64 X2-C AD5
41
12 (TURBINE)
42
(CENTRAL
3
GEAR CHAIN)
7 6
AUTO(1-4) 29 66 1
5
AUTO(2-4) 20 7
10 9
PST TML 1 2 3 1
MANUAL 2
5 AUTO(1-4)
AUTO(2-4)
FG005188
Figure 29
(8)
17 10 4
(N) 87a
18 87
30 11
85 86 1 8
1-4 2-4 1
52 14 2-1 2-3
19
BATT 14 23
36 (CN1-4) SIG. 15 16
68
21 2
12
VPS1 7 13 3
+
62 2
Y2 2 10 11
Y1 1 56
4 1 9
Y3 3 32
Y4 4 55
3 Y5 5 9 EST-37A
KICK 1 2 3 4
Y6 6 51 DOWN STEP STEP STEP STEP F N R
TEMP 8 39 45 X2-A VP
TEMP 9 46 67 X2-D AD6
49 X1-A AD3
23 22 X1-D
17 63 X1-C
AD7 2
AD1
65 X1-B AD2
19 43 X2-B AD4
(ENGINE) 64 X2-C AD5
41
12 (TURBINE)
42
(CENTRAL
3
GEAR CHAIN)
7 6
AUTO(1-4) 29 66 1
5
AUTO(2-4) 20 7
10 9
PST TML 1 2 3 1
MANUAL 2
5 AUTO(1-4)
AUTO(2-4)
FG005189
Figure 30
17 10 4
(N) 87a
18 87
30 11
85 86 1 8
1-4 2-4 1
52 14 2-1 2-3
19
BATT 14 23
36 (CN1-4) SIG. 15 16
68
21 2
12
VPS1 7 13 3
+
62 2
Y2 2 10 11
Y1 1 56
4 1 9
Y3 3 32
Y4 4 55
3 Y5 5 9 EST-37A
KICK 1 2 3 4
Y6 6 51 DOWN STEP STEP STEP STEP F N R
TEMP 8 39 45 X2-A VP
TEMP 9 46 67 X2-D AD6
49 X1-A AD3
23 22 X1-D
17 63 X1-C
AD7 2
AD1
65 X1-B AD2
19 43 X2-B AD4
(ENGINE) 64 X2-C AD5
41
12 (TURBINE)
42
(CENTRAL
3
GEAR CHAIN)
7 6
AUTO(1-4) 29 66 1
5
AUTO(2-4) 20 7
10 9
PST TML 1 2 3 1
MANUAL 2
5 AUTO(1-4)
AUTO(2-4)
FG005190
Figure 31
(8)
17 10 4
(N) 87a
18 87
30 11
85 86 1 8
1-4 2-4 1
52 14 2-1 2-3
19
BATT 14 23
36 (CN1-4) SIG. 15 16
68
21 2
12
VPS1 7 13 3
+
62 2
Y2 2 10 11
Y1 1 56
4 1 9
Y3 3 32
Y4 4 55
3 Y5 5 9 EST-37A
KICK 1 2 3 4
Y6 6 51 DOWN STEP STEP STEP STEP F N R
TEMP 8 39 45 X2-A VP
TEMP 9 46 67 X2-D AD6
49 X1-A AD3
23 22 X1-D
17 63 X1-C
AD7 2
AD1
65 X1-B AD2
19 43 X2-B AD4
(ENGINE) 64 X2-C AD5
41
12 (TURBINE)
42
(CENTRAL
3
GEAR CHAIN)
7 6
AUTO(1-4) 29 66 1
5
AUTO(2-4) 20 7
10 9
PST TML 1 2 3 1
MANUAL 2
5 AUTO(1-4)
AUTO(2-4)
FG005191
Figure 32
17 10 4
(N) 87a
18 87
30 11
85 86 1 8
1-4 2-4 1
52 14 2-1 2-3
19
BATT 14 23
36 (CN1-4) SIG. 15 16
68
21 2
12
VPS1 7 13 3
+
62 2
Y2 2 10 11
Y1 1 56
4 1 9
Y3 3 32
Y4 4 55
3 Y5 5 9 EST-37A
KICK 1 2 3 4
Y6 6 51 DOWN STEP STEP STEP STEP F N R
TEMP 8 39 45 X2-A VP
TEMP 9 46 67 X2-D AD6
49 X1-A AD3
23 22 X1-D
17 63 X1-C
AD7 2
AD1
65 X1-B AD2
19 43 X2-B AD4
(ENGINE) 64 X2-C AD5
41
12 (TURBINE)
42
(CENTRAL
3
GEAR CHAIN)
7 6
AUTO(1-4) 29 66 1
5
AUTO(2-4) 20 7
10 9
PST TML 1 2 3 1
MANUAL 2
5 AUTO(1-4)
AUTO(2-4)
FG005192
Figure 33
(8)
17 10 4
(N) 87a
18 87
30 11
85 86 1 8
1-4 2-4 1
52 14 2-1 2-3
19
BATT 14 23
36 (CN1-4) SIG. 15 16
68
21 2
12
VPS1 7 13 3
+
62 2
Y2 2 10 11
Y1 1 56
4 1 9
Y3 3 32
Y4 4 55
3 Y5 5 9 EST-37A
KICK 1 2 3 4
Y6 6 51 DOWN STEP STEP STEP STEP F N R
TEMP 8 39 45 X2-A VP
TEMP 9 46 67 X2-D AD6
49 X1-A AD3
23 22 X1-D
17 63 X1-C
AD7 2
AD1
65 X1-B AD2
19 43 X2-B AD4
(ENGINE) 64 X2-C AD5
41
12 (TURBINE)
42
(CENTRAL
3
GEAR CHAIN)
7 6
AUTO(1-4) 29 66 1
5
AUTO(2-4) 20 7
10 9
PST TML 1 2 3 1
MANUAL 2
5 AUTO(1-4)
AUTO(2-4)
FG005193
Figure 34
Downshift
Overview
1. There are two downshift switches down Figure 35, and it is
possible for operators to select one of them according to
the condition.
2. If the downshift switch is depressed during the machine
moving, downshifting takes place automatically. As a
result, fast digging and moving is possible. But at the
manual mode the kick-down can only be activated.
3. If a change or traveling direction takes place or the
downshift switch is depressed a second time, downshifting FG004391
is released automatically. Figure 35
11
1 8
1-4 2-4 1
52 14 2-1 2-3
19
BATT 14 23
36 (CN1-4) SIG. 15 16
68
21 2
12
VPS1 7 13 3
+
62 2 4
Y2 2 10 11
Y1 1 56
4 1 9
Y3 3 32
Y4 4 55
3 Y5 5 9 EST-37A
KICK 1 2 3 4
Y6 6 51 DOWN STEP STEP STEP STEP F N R
TEMP 8 39 45 X2-A VP
TEMP 9 46 67 X2-D AD6
49 X1-A AD3
23 22 X1-D
17 63 X1-C
AD7 2
AD1
65 X1-B AD2
19 43 X2-B AD4
(ENGINE) 64 X2-C AD5
41
12 (TURBINE)
42
(CENTRAL
3
GEAR CHAIN)
7 6
AUTO(1-4) 29 66 1
5
AUTO(2-4) 20 7
10 9
PST TML 1 2 3 1
MANUAL 2
5 AUTO(1-4)
AUTO(2-4)
FG005194
Figure 36
With the auto selector switch (Figure 37) is in the "O" and the
forward second gear is selected, if either downshift switch 1-4 A
(Figure 35) is activated, a pulse is sent to the "22" transmission
controller. This signal energizes solenoid valves, (Y3 and Y5),
MAN 2-4
which shifts the transmission to the forward first gear. When
either switch (Figure 35) is selected a second time, the
transmission pulse signal of the "22" terminal is interrupted and
solenoid valve, Y5 and Y6, are energized and the transmission
returns to the forward second gear.
FG004375
Figure 37
11
1 8
1-4 2-4 1
52 14 2-1 2-3
19
BATT 14 23
36 (CN1-4) SIG. 15 16
68
21 2
12
VPS1 7 13 3
+
62 2 4
Y2 2 10 11
Y1 1 56
4 1 9
Y3 3 32
Y4 4 55
3 Y5 5 9 EST-37A
KICK 1 2 3 4
Y6 6 51 DOWN STEP STEP STEP STEP F N R
TEMP 8 39 45 X2-A VP
TEMP 9 46 67 X2-D AD6
49 X1-A AD3
23 22 X1-D
17 63 X1-C
AD7 2
AD1
65 X1-B AD2
19 43 X2-B AD4
(ENGINE) 64 X2-C AD5
41
12 (TURBINE)
42
(CENTRAL
3
GEAR CHAIN)
7 6
AUTO(1-4) 29 66 1
5
AUTO(2-4) 20 7
10 9
PST TML 1 2 3 1
MANUAL 2
5 AUTO(1-4)
AUTO(2-4)
FG005195
Figure 38
When the auto selector switch (Figure 38) is in the "I" position, the
"29" terminal of transmission controller is energized. This allows
the transmission to automatically upshift and downshift gears
depending on the load and on the engine speed.
If either downshift switch (Figure 35) is activated, a pulse signal
is sent to the "22" terminal of transmission controller. This signal
shifts the transmission to the next lowest gear.
Automatic
Downshift Switch "Activated"
Gear Selection
Fourth Gear Downshift to Third Gear
Third Gear Downshift to Second Gear
Second Gear Downshift to First Gear
First Gear Remains in First Gear
11
1 8
1-4 2-4 1
52 14 2-1 2-3
19
BATT 14 23
36 (CN1-4) SIG. 15 16
68
21 2
12
VPS1 7 13 3
+
62 2 4
Y2 2 10 11
Y1 1 56
4 1 9
Y3 3 32
Y4 4 55
3 Y5 5 9 EST-37A
KICK 1 2 3 4
Y6 6 51 DOWN STEP STEP STEP STEP F N R
TEMP 8 39 45 X2-A VP
TEMP 9 46 67 X2-D AD6
49 X1-A AD3
23 22 X1-D
17 63 X1-C
AD7 2
AD1
65 X1-B AD2
19 43 X2-B AD4
(ENGINE) 64 X2-C AD5
41
12 (TURBINE)
42
(CENTRAL
3
GEAR CHAIN)
7 6
AUTO(1-4) 29 66 1
5
AUTO(2-4) 20 7
10 9
PST TML 1 2 3 1
MANUAL 2
5 AUTO(1-4)
AUTO(2-4)
FG005196
Figure 39
When the auto selector switch (Figure 39) is in the "I" position,
the "20" terminal of transmission controller is energized. This
allows the transmission to automatically upshift and downshift
gears depending on the load and on the engine speed.
If either downshift switch (Figure 35) is activated, a pulse signal
is sent to the "22" terminal of transmission controller. This signal
shifts the transmission to the next lowest gear.
Automatic
Downshift Switch "Activated"
Gear Selection
Fourth Gear Downshift to Third Gear
Third Gear Downshift to Second Gear
Second Gear Downshift to First Gear
First Gear Remains in First Gear
HA3O2018
CAUTION! Figure 40
17 10 4
(N) 87a
18 87
30 11
85 86 1 8
1-4 2-4 1
52 14 2-1 2-3
19
BATT 14 23
36 (CN1-4) SIG. 15 16
68
21 2
12
VPS1 7 13 3
+
62 2
Y2 2 10 11
Y1 1 56
4 1 9
Y3 3 32
Y4 4 55
3 Y5 5 9 EST-37A
KICK 1 2 3 4
Y6 6 51 DOWN STEP STEP STEP STEP F N R
TEMP 8 39 45 X2-A VP
TEMP 9 46 67 X2-D AD6
49 X1-A AD3
23 22 X1-D
17 63 X1-C
AD7 2
AD1
65 X1-B AD2
19 43 X2-B AD4
(ENGINE) 64 X2-C AD5
41
12 (TURBINE)
42
(CENTRAL
3
GEAR CHAIN)
7 6
AUTO(1-4) 29 66 1
5
AUTO(2-4) 20 7
10 9
PST TML 1 2 3 1
MANUAL 2
5 AUTO(1-4)
AUTO(2-4)
FG005197
Figure 41
19
6
13
0
14 5 I
3
1 II
9 14 BATT
10
11
1-4 2-4 1
23 5
22 68 14 2-1 2-3
87a
30 52
87 30
86 36
8 16
85 8 (CN1-4) SIG. 15
53 21 2 4
57
3
62 2
11
4 1 9
KICK 1 2 3 4
DOWN STEP STEP STEP STEP F N R
45 X2-A VP
67 X2-D AD6
X1-A AD3
22 X1-D
63 X1-C
AD7 2
AD1
65 X1-B AD2
19 43 X2-B AD4
(ENGINE) 64 X2-C AD5
41
12 (TURBINE)
42
(CENTRAL
GEAR CHAIN) 3
AUTO(1-4) 29
AUTO(2-4) 20
PST TML 1 2 3 1
MANUAL 2
5 AUTO(1-4)
AUTO(2-4)
FG004390
Figure 43
Introduction
AEB Starter
Start
BOS0360L
Figure 44
Figure 45
Inner Section
Figure 46
Reference Reference
Description Description
Number Number
1 Clutch Shaft "KR" 9 Transmission Pump
2 Power Take-off; Coaxial; 10 Flexible Plate
Engine-dependent 11 Converter
3 Clutch Shaft "KV" 12 Input Transmitter for Engine
4 Clutch Shaft "K2" Speed
5 Clutch Shaft "K3" 13 Clutch Shaft "K4"
6 Output Flange - Rear 14 Converter Relief Valve
7 Output Flange - Converter Side 15 Clutch Shaft "K1"
8 Output Shaft
3
3
4
3
8
5
7 6
FG008067
Figure 47
Reference Reference
Description Description
Number Number
1 Lifting Lugs 5 Model Identification Plate
2 Flexible Plate 6 output Flange - Converter Side
3 Transmission Suspension Bores 7 Oil Drain Plug with Magnetic
M20 Insert M38x1.5
4 Attachment Possibility for 8 Attachment Possibility for Oil
Emergency Steering Pump (Not Filter Pipe with Oil Dipstick
Used) (Converter Side)
1 2 3 4 5
12
11 9
10
BZS0060L
Figure 48
Reference Reference
Description Description
Number Number
1 Flexible Plate 8 Parking Brake
2 Converter 9 Output Flange - Rear
3 Converter Bell Housing 10 Oil Drain Plug with Magnetic
4 Breather Insert M38x1.5
5 Transmission - Case Cover 11 Output Flange - Converter Side
6 Filter Head 12 Transmission Case
7 Box Filter (Fine Filter)
1 2
6
4
HOT
BZS0070L
Figure 49
Reference Reference
Description Description
Number Number
1 Lifting Lugs 6 Output Flange - Rear
2 Power Take-off; Coaxial; 7 Parking Brake
Engine-dependent 8 Box Filter (Fine Filter)
3 Electrohydraulic Control 9 Filter Head
4 Oil Filter Pipe
5 Transmission Suspension Bores
M20
Gearshift System
Figure 50
Figure 52
Figure 53
Figure 54
Figure 56
Clutch KV
Figure 57
Figure 58
Figure 59
Figure 60
Figure 61
Figure 62
Figure 63
Figure 64
IMPORTANT
Different versions in relation to position of cable harness
are possible.
In this connection, pay attention to Specifications of
Vehicle Manufacturer.
Figure 65
Figure 66
Figure 67
Figure 68
Figure 69
Figure 70
Figure 71
Figure 72
Figure 73
Figure 74
Figure 75
Figure 76
Figure 77
Figure 78
Reference
Description
Number
1 Vibration Damper (3x
Spool and
Compression Spring)
2 Follow On Site (3x
Spool and
Compression Spring)
3 Pressure Reducing
Valve (1x Spool and Figure 79
Compression Spring)
Figure 80
Figure 83
Figure 84
Reference
Description
Number
1 Main Pressure Valve
(1x Spool and
Compression Spring.)
2 Follow On Slide (3x
Spool and
Compression Spring)
Figure 85
3 Vibration Damper (3x
Spool and
Compression Spring)
Figure 87
Figure 88
Figure 89
Figure 90
Figure 91
Figure 92
Figure 93
Figure 94
Figure 95
Figure 96
Figure 97
Figure 98
Figure 99
Figure 100
Figure 101
Figure 102
Figure 103
Figure 104
Figure 105
Figure 106
Figure 107
Figure 108
Figure 109
Figure 110
2. AInstall device (S) on gear teeth run out of stator shaft and
remove (compl.) using two-armed puller carefully out of
housing bores.
(S) Separating device - 5870 300 024
(S) Two-armed puller - 5870 970 004
Figure 111
Figure 112
Figure 113
Figure 114
Figure 115
Figure 116
Figure 117
Figure 118
Figure 119
Figure 120
Figure 121
Figure 122
13. Remove socket head screws, output shaft and two oil
collecting plate.
Figure 123
Figure 124
Reference
Description
Number
AN Input
KV Clutch - Forward
KR Clutch - Reverse
K1 Clutch - 1st Speed
K2 Clutch - 2nd Speed Figure 125
K3 Clutch - 3rd Speed
K4 Clutch - 4th Speed
Figure 126
Figure 127
Figure 128
Figure 129
Figure 130
IMPORTANT
If contrary to ZF-Recommendation the tapered roller
bearing of clutches and of input and output are not
replaced, the allocation (inner bearing races to outer
bearing races) must at least be maintained.
Figure 131
Mark inner bearing races and outer bearing races
accordingly to each other.
Figure 132
Figure 133
Figure 134
Figure 135
Figure 136
Figure 137
Figure 138
Figure 139
Figure 140
Figure 141
Figure 142
Figure 143
Figure 144
Figure 146
Figure 147
Figure 148
Figure 149
Figure 150
Figure 151
Figure 152
Figure 153
Figure 154
Figure 155
Figure 156
Figure 157
Figure 158
Figure 159
Figure 160
IMPORTANT
To ensure the correct installation of the oil tubes, the use of
the indicated special tool (S) is imperative.
Figure 161
IMPORTANT
The pipe end must be maximally plane with the
housing face. If necessary, equalize projection of pipe.
Figure 163
Figure 164
IMPORTANT
The pipe end must be maximally plane with the
housing face. If necessary, equalize projection of pipe.
Figure 165
Figure 166
Figure 167
Figure 169
Figure 170
Figure 171
Reference
Description
Number
1 Plate Carrier
2 Piston
3 Outer Plate - One Sided
Coated (1 Piece)
4 Inner Plates (10 Pieces)
5 Outer Plate - Coated On
Figure 172
Both Sides (10 Pieces)
6 Retaining Ring (Optional
S = 2.1 - 4.2 mm
{0.08 - 0.17 in})
7 End Shim
IMPORTANT
Install outer plate (3) with the uncoated side facing the
piston.
Figure 173
Figure 174
4. Press on end shim with about 100 N {10 kg (22 lb)}, apply
dial indicator and set it at zero (Figure 175).
Figure 175
IMPORTANT
Use oil according to the list of lubricants TE-ML 03.
Figure 177
Figure 178
10. Insert ball bearing until seated and attach using retaining
ring.
Figure 179
Figure 180
Figure 181
Figure 182
Figure 183
Figure 184
Figure 185
Figure 186
Figure 187
Figure 188
Figure 189
Figure 190
Figure 191
Figure 192
Figure 193
Figure 194
IMPORTANT
The plate arrangement of Clutch-K1is not identical
with Clutch-K2 and K3. In this connection see Figure
195.
Reference
Description
Number
1 Plate Carrier
2 Piston
Figure 195
3 Outer Plate - One Sided
Coated (1 Piece)
4 Inner Plates (9 Pieces)
5 Outer Plate - Coated on
Both Sides (9 Pieces)
6 Retaining Ring (Optional
s = 2.1 - 4.2 mm
(0.08 - 0.17 in))
7 End Shim
Reference
Description
Number
1 Plate Carrier
2 Piston
3 Outer Plate - One Sided
Coated (1 Piece)
4 Inner Plates (7 Pieces)
5 Outer Plate - Coated on
Both Sides (7 Pieces)
6 Retaining Ring (Optional
s = 2.1 - 4.2 mm
(0.08 - 0.17 in))
7 End Shim
IMPORTANT
Install outer plate (3) with the uncoated side facing the
piston.
Figure 197
10. Lay on the end shim and squeeze retaining ring in (e.g. s =
3.1 mm (0.12 in)).
Figure 198
11. Press on end shim with about 100 N (10 kg {22 lb}), apply
dial indicator and set it at zero (Figure 199).
12. Push end shim using screwdriver against retaining ring
until seated (upward) and read plate clearance on dial
indicator (Figure 200).
NOTE: In case of a deviation from required plate
clearance, correct with corresponding retaining
ring (s= 2.1 - 4.2 mm (0.08 - 0.17 in)).
Figure 199
IMPORTANT
Use oil according to the list of lubricants TE-ML 03
Figure 201
Figure 202
16. Install idler gear until all inner plates are accommodated.
Figure 203
17. Assemble axial washer (3) (55 x 78 x), axial needle cage
(2) and running disk (1) (55 x 78 x 5).
NOTE: Install running disk (1), with the chamber facing
the axle needle cage.
IMPORTANT
Only if the running disk is overlapping with the shaft
collar is ensured that all inner plates are
accommodated.
Figure 204
Figure 205
Figure 206
Figure 207
Figure 208
Figure 209
Figure 210
Figure 211
Figure 212
Figure 213
Figure 214
Reference
Description
Number
1 Plate Carrier
2 Piston
3 Outer Plate - One Sided
Coated (1 Piece)
4 Inner Plates (9 Pieces)
5 Outer Plate - Coated on
Both Sides (9 Pieces)
6 Retaining Ring (Optional
s = 2.1 - 4.2 mm
(0.08 - 0.17 in)) Figure 215
7 End Shim
IMPORTANT
Install outer plate (3) with the uncoated side facing the
piston.
Figure 216
Figure 217
Figure 218
IMPORTANT
Use oil according to the list of lubricants TE-ML 03.
15. Install idler gear until all inner plates are accommodated.
NOTE: This step makes the later assembling of the
idler gear easier.
16. Remove idler gear again.
Figure 220
Figure 221
Figure 222
Figure 223
20. Assemble axial washer (3) (55 x 78 x 1), needle cage (2)
and running disk (1) (55 x 78 x 5).
NOTE: Install running disk (1), with the chamber facing
the needle cage.
Figure 224
CAUTION!
Use safety gloves.
Figure 225
Figure 226
Figure 227
Figure 228
Figure 229
Figure 230
Figure 231
Figure 232
Figure 233
Figure 234
Figure 235
Figure 236
Reference
Description
Number
AN Input
KV Clutch - Forward
KR Clutch - Reverse
K1 Clutch - 1st Speed
K2 Clutch - 2nd Speed Figure 237
K3 Clutch - 3rd Speed
K4 Clutch - 4th Speed
AB Output
Figure 238
Figure 239
Reference
Description
Number
AN Input
KV Clutch - Forward
KR Clutch - Reverse
K1 Clutch - 1st Speed
K2 Clutch - 2nd Speed
K3 Clutch - 3rd Speed
K4 Clutch - 4th Speed
AB Output Figure 240
IMPORTANT
Before the installation of the clutches and the drive
shaft, grease rectangular rings and align them
centrally.
Figure 241
Figure 242
Figure 243
5. Position Clutch-K2.
Figure 244
Figure 245
Figure 246
Figure 247
Figure 248
12. Grease O-rings on two oil tubes (see also Figure 163). Wet
mounting face with sealing compound Loctite #574.
13. Position preassembled housing cover using lifting device
carefully on gearbox housing until seated (Figure 249).
NOTE: Pay attention to overlapping of the oil tubes with
the bores in housing cover.
(S) Lifting chain - 5870 281 047
Figure 249
Figure 250
Figure 251
Figure 252
Figure 253
Figure 254
Figure 255
Figure 256
Figure 257
Figure 258
Figure 259
Figure 260
Figure 261
Reference
Description
Number
1 Piston
2 Compression Spring
3 Pressure Plate
4 Lock Plate
Figure 262
NOTE: Install pressure plate with spigot (∅6 mm
(0.24 in)) facing lock plate.
2. Install components according to Figure 262, preload and
attach using lock plate.
3. Install new O-ring on plug (Arrow) and install it.
NOTE: Torque limit (M14 x 1.5) 2.55 kg•m (18.44 ft lb).
Figure 263
Figure 264
Figure 265
Figure 266
4. Insert O-ring (Arrow) into the annular groove and oil it.
Figure 267
Figure 268
Figure 269
Figure 270
9. Fasten oil feed housing using socket head screws and hex
head screws (2 pieces).
NOTE: Torque limit (Socket head screws) 2.35 kg•m
(16.96 ft lb).
NOTE: Torque limit (Hex head screws) 4.69 kg•m
(33.93 ft lb).
NOTE: Pay attention to the position of fixing plate, see
Arrow.
(S) Box spanner (Torx, TX-40) - 5870 042 004
Figure 271
Figure 272
Figure 273
Figure 274
Figure 275
Figure 277
Figure 278
Figure 279
Figure 280
10. Mount gasket and fasten cover using hex head screws.
NOTE: Torque limit (M8/8.8) 2.35 kg•m (16.96 ft lb).
Figure 281
Figure 282
Reference
Description
Number
1 Gasket
2 Duct Plate
3 Gasket Figure 283
4 Intermediate Plate
5 Gasket
Figure 284
Figure 285
Figure 286
Figure 287
Figure 288
Reference
Description
Number
34 Speed Sensor
N-Output and
Speedometer
21 Inductive Transmitter
N-Turbine
Figure 289
47 Inductive Transmitter
N-Central Gear Train
48 Inductive Transmitter
N-Engine
Figure 290
Figure 291
IMPORTANT
Pay attention to different setting dimensions. Setting
dimension corresponds to distance between contact
face-inductive transmitter and tooth tip, see Figure 292.
Figure 292
Figure 293
Figure 294
EXAMPLE L:
EXAMPLE L:
Figure 295
Reference
Description
Number
1 Speed Sensor
2 Plate
3 O-ring
Figure 297
IMPORTANT
Before putting transmission into service, carry out oil
filling according to Operation and Maintenance
Manual.
Figure 298
Figure 299
Transmission
Error Codes (ZF)
Edition 1
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
ABBREVIATIONS
Throughout this section the following abbreviations are used to
indicate various conditions.
Abbreviations
O.C. Open Circuit
S.C. Short Circuit
Op-Mode OPeration Mode
TCU Transmission Control Unit
EEC Electronic Engine Controller
PTO Power Take Off
Reference Description
BAR
Letter
FG004442
a, f Automatic Range (Upshifting
and Downshifting) Figure 1
b, c, d, e Preselected Gear
g EST-37 has detected an
error and is flashing.
h This character will not be
used at the EST-37.
Normal
There is no failure detected in transmission system or failure has
no or slight effects on transmission control. TCU will work
without or in special cases with little limitations. (See “Table of
Fault Codes” on page -14.)
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.
Fault Meaning of the Fault Code Reaction of the TCU Possible Steps to Remarks
Code (Possible reason for fault Repair
(hex) detection.)
11 Logical error at gear range signal. TCU shifts Check cables from Failure cannot be
transmission to neutral. TCU to shift lever. detected in systems
TCU detected a wrong signal
with DW2/DW3 shift
combination for gear range. Op-Mode: transmission Check signal
lever.
shut down. combinations of shift
• Cable from shift lever to TCU is
lever positions for gear Fault is taken back if
broken.
range. TCU detects a valid
• Cable is defective and is signal for position.
contacted to battery voltage or
vehicle ground.
• Shift lever is defective.
12 Logical error at direction select TCU shifts Check cables from Fault is taken back if
signal. transmission to neutral. TCU to shift lever. TCU detects a valid
signal for direction at
TCU detected a wrong signal Op-Mode: transmission Check signal
shift lever.
combination for direction. shut down. combinations of shift
lever positions F-N-R.
• Cable from shift lever to TCU is
broken.
• Cable is defective and is
contacted to battery voltage or
vehicle ground.
• Shift lever is defective.
13 Logical error at engine derating After selcting neutral, Check engine derating This fault is reset after
device. TCU changes to OP- device. power up of TCU.
Mode limp home.
TCU detected no reaction of Only DL500
engine while derating device activ.
15 Logical error at direction select TCU shifts Check the cables from Fault is taken if TCU
signal 2. shift lever. transmission to neutral TCU to shift lever2. detects a valid neutral
if selector activ signal for the direction
TCU detected a wrong signal Check signal
at the shift lever.
combination for the direction. OP-Mode: transmission combinations of shift
shutdown if selector lever positions F-N-R
• Cable from shift lever 2 to TCU is
activ.
broken.
• Cable is defective and is
contacted to battery voltage or
vehicle ground.
• Shift lever is defective.
B7 Overtemp sump.
BC Overspeed output.
F2 Configuration lost.
F3 Application error.
F5 Clutch failure
Actuator
Open circuit:R12 ≈ R 1G ≈ R2G ≈ ∞ 1
HBOE640I
Figure 2
Cable
UBat
open circuit:
R12 ≈ R1P ≈ R 1C ≈ R2P ≈ R2C ≈ ∞ P (power supply)
TCU
Actuator /
short cut to ground: 1 2
Sensor
Front Axle
(ZF-MT-L 3085)
Edition 1
Front Axle
(ZF-MT-L 3085)
Safety Precautions ............................................... 6
Applicable Models ................................................ 6
General Description .............................................. 7
Outline ............................................................................. 7
DL250......................................................................... 8
Lubrication Instructions ................................................. 10
Oil drain .................................................................... 11
Oil filling.................................................................... 11
Check ....................................................................... 11
Oil change intervals.................................................. 11
Oil level check .......................................................... 11
Bleeders ................................................................... 11
Brake ........................................................................ 11
Brake bleeding at the vehicle ................................... 11
Make Wear Measurement on Multidisk Brake............... 13
Wear measurement - Multidisk brake....................... 13
Inscriptions On Model Identification Plate ..................... 14
Torque Limits for Screws............................................... 15
Torque Limits for Screws (In Nm) According
to ZF Standards 148................................................. 15
Examples of Gear Tooth Contact Patterns for the
Gleason Gear-tooth System.......................................... 16
Special Tool ........................................................ 19
List of Special Tools for Disassembly and Reassembly ....
...................................................................................... 19
ZF Multitrac Rigid Axle MT-L 3085 ..................... 28
Disassembly of Output and Brake ................................. 28
Reassembly of Output and Brake ................................. 38
Disassembly of Differential Carrier and Brake Tubes ... 51
Disassembly of Differential Carrier........................... 51
Disassembly of Limited Slip Differential ................... 55
Disassembly of Drive Pinion..................................... 56
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
Outline
Front Axle
Frame-Fixed
Type
Semifloating
26,900 kg
Max. Static Load
(59,200 lb)
Drive Flange 6C
FG006692
Figure 1 DRIVE AXLE ASSEMBLY
Reference
Description 4 6
Number 5
6 4
1 Oil Drain Hole M24x1.5
Axle Casing
2 Oil Drain Hole M24x1.5
Outputs
3 Oil Filler Hole M36x1.5
4 Brake Bleeder 2
1 3
5 Bleeder 2
FG006694
6 Check Hole
(Wear for Multidisk Brake) Figure 2
4 6
6 4 5
2
2 3 1
FG006696
Figure 3
Oil drain
Remove drain plugs 1 and 2 and drain oil.
Oil filling
Provide drain plugs (M24x1.5) with new O-ring and install
them.
Tightening torque MA = 7.14 kg•m (51.63 ft lb).
Bleeders
At initial operation and during the oil change intervals,
clean Bleeder 3 and 5 and make a functional check.
Brake
For the pneumatic-hydraulic or via an accumulator system
-operated brake actuation following oils are permissible:
1.Motor oils SAE 10W according to specification MIL-L
2104 C, MIL-L 46152, API-CC, CD, SC, SD, SE
2.ATF-Oils Type A, Suffix A, Dexron of II D
Figure 4
Following to this provide level plug with a new O-ring and install "X"
it!
Tightening torque MA = 7.14 kg•m (51.63 ft lb)
FG008078
Figure 5
Figure 6
Reference
Description
Number
1 Axle Type
2 Axle Serial No.
3 ZF Parts - List No.
4 Total-ratio of Axle / Version With or Without
ZF multidisk Self Locking Differential
5 Type of Lubricant
6 Lubricant Specifications
Figure 7
Figure 8
Figure 9
Figure 11
Figure 12
Figure 13
Figure 22
2. Remove plugs (3x, Figure 23 and Figure 24) and drain oil
from axle casing.
Figure 23
Figure 24
Figure 25
Figure 26
Figure 27
Figure 28
Figure 29
Figure 30
Figure 31
Figure 32
Figure 33
Figure 34
Figure 35
Figure 36
Figure 37
Figure 38
Figure 39
Figure 40
Figure 41
Figure 42
Figure 43
Figure 44
Figure 45
Figure 46
25. Remove pin from support shim and remove released cup
springs.
Figure 47
Figure 48
Figure 49
28. Remove guide ring, support rings and U-rings from annular
grooves of brake housing.
NOTE: See Figure 51, for installation position of single
parts.
Figure 50
Reference
Description
Number
1 Brake Housing
2 Guide Ring
3 Support Ring
4 U-ring
5 U-ring
6 Support Ring
7 Output Shaft
Figure 51
Figure 52
30. Remove brake housing with lifting tackle (S) from output
shaft.
(S) Lifting chain 5870 281 047
(S) Eyebolts 5870 204 071
Figure 53
Figure 54
Figure 55
Figure 56
Figure 57
Figure 58
Figure 59
Figure 60
Figure 61
Figure 62
6. Install shaft seal with the sealing lip visible to oil chamber
(See Figure 64).
(S) Driver 5870 051 052
NOTE: The exact installation position of shaft seal will
be obtained by using specified driver (S).
NOTE: Just before installation, wet outer diameter of
shaft seal with mineral spirits.
Figure 63
Reference
Description
Number
1 Brake Housing
2 Shaft Seal
* Grease Filling
Figure 64
Figure 65
Figure 66
Figure 67
Reference
Description
Number
1 Brake Housing
2 Guide Ring
3 Support Ring
4 U-ring
5 U-ring
6 Support Ring
7 Output Shaft
Figure 68
Figure 69
Figure 70
Figure 71
13. Press gripping rings (4x, see arrows) onto pins until seated
on assembly fixture (S).
NOTE: The exact installation dimension (see Figure 74)
of gripping rings is obtained when using
specified assembly fixture.
NOTE: Pay attention to installation position, install
gripping rings with orifices offset by 180° to
each other.
Figure 72
Figure 73
Reference
Description
Number
1 Pin
2 Gripping Rings
3 Cup Springs
4 Support Shim
5 Retaining Ring
X Installation Dimension
Gripping Rings 10.5
+0.3 mm
Figure 74
Figure 75
Figure 76
Figure 77
18. Drive slotted pins (6x) into bores of support shim to lock
retaining ring.
(S) Drive mandrel 5870 705 011
NOTE: Pay attention to installation position, see Figure
78.
Figure 78
Reference
Description
Number
1 Brake Housing
2 Retaining Ring
3 Slotted Pin
4 Support Shim
5 Piston
X Installation Dimension
4.0 - 0.5 mm
Figure 79
Figure 80
Figure 81
21. Install outer and inner clutch disks alternately starting with
an outer clutch disk.
NOTE: Oil clutch disks according to ZF List of
Lubricants TE-ML 05.
Figure 82
Figure 83
23. Grease both O-rings (see arrows) and insert them into
annular grooves of ring gear.
Figure 84
Figure 85
25. Heat inner bearing races and install them until seated with
big radius showing to planet carrier (downwards).
NOTE: Subsequently install inner bearing races after
cooling down.
Figure 86
Figure 87
27. Heat inner bearing races and install them on planet gears
until seated.
NOTE: Subsequently install inner bearing races after
cooling down.
Figure 88
Figure 89
30. Insert stub shaft into spline of axle bevel gear until seated.
Figure 91
Figure 92
Figure 93
EXAMPLE
Figure 94
34. Install determined shim(s), e.g. s = 2.20 mm, into sun gear
shaft using grease.
Figure 95
Figure 96
Figure 97
Figure 98
Figure 99
Figure 100
Figure 101
2. Remove plugs (3x, Figure 104, Figure 105) and drain oil
from axle casing.
Figure 104
Figure 105
Figure 106
Figure 107
Figure 108
Figure 109
Figure 110
Figure 111
Figure 112
Figure 113
Figure 114
Figure 115
Figure 116
Figure 117
Figure 118
Figure 119
Figure 120
Figure 121
Figure 122
Figure 123
Figure 124
Figure 125
Figure 126
Figure 127
6. Take off spacer ring and remove inner bearing race from
drive pinion.
(S) Gripping insert 5873 002 032
(S) Basic set 5873 002 001
Figure 128
Figure 129
Figure 130
Figure 131
Figure 132
Figure 133
Figure 134
Figure 135
Reference
Description
Number
1 Vent Valve
2 Connection Part
3 O-ring
4 Rectangular Ring
Figure 137
Figure 138
Figure 139
Figure 140
6. Fasten brake tube using hexagon nut and union nut (see
below figure).
Tightening torque MA = 10.20 kg•m (73.76 ft lb)
Figure 141
Figure 142
Reference
Description
Number
1 O-ring
2 Screw Plug
3 Vent Valve
Figure 143
9. Install plug.
Tightening torque MA = 7.14 kg•m (51.63 ft lb)
Figure 144
Figure 145
Figure 146
EXAMPLE "A"
Figure 147
Figure 148
EXAMPLE "B"
Figure 149
Figure 150
Figure 151
Figure 152
Figure 153
Figure 154
Figure 155
Figure 156
9. Assemble washer.
Figure 157
Figure 158
11. Check rolling moment 0.15 - 0.31 kg•m (1.11 - 2.21 ft lb)
NOTE: For new bearings it should be tried to achieve
the max. value of rolling moment.
NOTE: If required rolling moment is not obtained,
correct it with an adequate spacer ring (Figure
153), according to following indications:
Rolling moment too low - install a thinner spacer
ring
Rolling moment too high - install a thicker
spacer ring.
Then remove slotted nut again and remove input flange Figure 159
from drive pinion.
Figure 160
Figure 161
Figure 162
Figure 163
Figure 164
4. Insert axle bevel gear until seated and at the same time,
assemble all inner clutch disks with splines.
Figure 165
Figure 166
Figure 167
Figure 168
Figure 169
Figure 170
Figure 171
EXAMPLE "D"
Figure 172
Figure 173
Figure 174
Figure 175
Figure 176
Figure 177
Figure 178
Figure 179
Figure 180
Figure 181
Figure 183
Figure 184
Figure 185
Figure 187
7. Insert stub shaft into spline of axle bevel gear until seated.
Then fix O-ring (see arrow) using grease into recess of
axle casing.
NOTE: Step (Figure 188 thru Figure 191) is to be made
on both output sides.
Figure 188
Figure 189
Figure 190
Figure 191
Rear Axle
(ZF-MT-L 3075)
Edition 1
Rear Axle
(ZF-MT-L 3075)
Safety Precautions ............................................... 6
Applicable Models ................................................ 6
General Description .............................................. 7
Outline ............................................................................. 7
DL250......................................................................... 8
Lubrication Instructions ................................................. 10
Oil drain .................................................................... 10
Oil filling.................................................................... 10
Check ....................................................................... 11
Oil change intervals.................................................. 11
Oil level check .......................................................... 11
Bleeders ................................................................... 11
Brake ........................................................................ 11
Brake bleeding at the vehicle ................................... 11
Make Wear Measurement on Multidisk Brake............... 13
Wear measurement - Multidisk brake....................... 13
Inscriptions On Model Identification Plate ..................... 14
Torque Limits for Screws............................................... 15
Torque Limits for Screws (In Nm) According to
ZF-Standards 148 .................................................... 15
Examples of Gear Tooth Contact Patterns
for the Gleason Gear-tooth System............................... 17
Special Tool ........................................................ 20
List of Special Tools for Disassembly and Reassembly ....
...................................................................................... 20
ZF Multitrac Rigid Axle MT-L 3075 ..................... 30
Disassembly of Output and Brake ................................. 30
Reassembly of Output and Brake ................................. 40
Disassembly of Differential Carrier and Brake Tubes ... 53
Disassembly of Differential Carrier........................... 53
Disassembly of Limited Slip Differential ................... 57
Disassembly of Drive Pinion..................................... 59
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
Outline
Rear Axle
Trunnion Mounting
Type
Semifloating
20,800 kg
Max. Static Load
(45,800 lb)
Drive Flange 6C
FG006692
Figure 1 DRIVE AXLE ASSEMBLY
Reference
Description 4 6
Number 5
6 4
1 Oil Drain Hole M24x1.5
Axle Casing
2 Oil Drain Hole M24x1.5
Outputs
3 Oil Filler Hole M36x1.5
4 Brake Bleeder 2
1 3
5 Bleeder 2
FG006694
6 Check Hole
(Wear for Multidisk Brake) Figure 2
4 6
6 4 5
2
2 3 1
FG006696
Figure 3
Oil drain
Remove drain plugs 1 and 2 and drain oil.
Oil filling
Provide drain plugs (M24x1.5) with new O-ring and install
them.
Tightening torque MA = 7.14 kg•m (51.63 ft lb).
Bleeders
At initial operation and during the oil change intervals,
clean Bleeder 3 and 5 and make a functional check.
Brake
For the pneumatic-hydraulic or via an accumulator
system-operated brake actuation following oils are
permissible:
1.Motor oils SAE 10W according to specification MIL-L
2104 C, MIL-L 46152, API-CC, CD, SC, SD, SE
2.ATF-Oils Type A, Suffix A, Dexron of II D
Figure 4
Following to this provide level plug with a new O-ring and install "X"
it!
Tightening torque MA = 7.14 kg•m (51.63 ft lb)
FG008078
Figure 5
Figure 6
Reference
Description
Number
1 Axle Type
2 Axle Serial No.
3 ZF Parts - List No.
4 Total-ratio of Axle / Version With or Without
ZF multidisk Self Locking Differential
5 Type of Lubricant
6 Lubricant Specifications
Figure 7
Figure 8
Figure 9
Figure 11
Figure 12
Figure 13
Figure 22
2. Remove plugs (3x, Figure 23 and Figure 24) and drain oil
from axle casing.
Figure 23
Figure 24
Figure 25
Figure 26
Figure 27
Figure 28
Figure 29
Figure 30
Figure 31
Figure 32
Figure 33
Figure 34
Figure 35
Figure 36
Figure 37
Figure 38
Figure 39
Figure 40
Figure 41
Figure 42
Figure 43
Figure 44
Figure 45
Figure 46
25. Remove pin from support shim and remove released cup
springs.
Figure 47
Figure 48
Figure 49
28. Remove guide ring, support rings and U-rings from annular
grooves of brake housing.
NOTE: See Figure 51, for installation position of single
parts.
Figure 50
Reference
Description
Number
1 Brake Housing
2 Guide Ring
3 Support Ring
4 U-ring
5 U-ring
6 Support Ring
7 Output Shaft
Figure 51
Figure 52
Figure 53
Figure 54
Figure 55
Figure 56
Figure 57
Figure 58
Figure 59
Figure 60
Figure 61
Figure 62
6. Install shaft seal with sealing lip visible to oil chamber, see
Figure 64.
(S) Driver 5870 051 052
NOTE: The exact installation position of shaft seal will
be obtained by using specified driver (S).
NOTE: Just before installation, wet outer diameter of
shaft seal with mineral spirits.
Figure 63
Reference
Description
Number
1 Brake housing
2 Shaft seal
* Grease filling
Figure 64
Figure 65
Figure 66
Figure 67
Reference
Description
Number
1 Brake Housing
2 Guide Ring
3 Support Ring
4 U-ring
5 U-ring
6 Support Ring
7 Output Shaft
Figure 68
Figure 69
Figure 70
Figure 71
13. Press gripping rings (4x, see arrows) onto pins until seated
on assembly fixture (S).
NOTE: The exact installation dimension (see Figure 74)
of gripping rings is obtained when using
specified assembly fixture.
NOTE: Observe installation position, install gripping
rings with orifices offset by 180° to each other.
Figure 72
Figure 73
Reference
Description
Number
1 Pin
2 Gripping Rings
3 Cup Springs
4 Support Shim
5 Retaining Ring
X Installation Dimension
Gripping Rings 10.5
+0.3 mm
Figure 74
Figure 75
Figure 76
Figure 77
18. Drive slotted pins (6x) into bores of support shim to lock
retaining ring.
(S) Drive mandrel 5870 705 011
NOTE: Pay attention to installation position, see Figure
79.
Figure 78
Reference
Description
Number
1 Brake Housing
2 Retaining Ring
3 Slotted Pin
4 Support Shim
5 Piston
X Installation Dimension
4.0 - 0.5 mm
Figure 79
Figure 80
Figure 81
21. Install outer and inner clutch disks alternately starting with
an outer clutch disk.
NOTE: Oil clutch disks according to ZF List of
Lubricants TE-ML 05.
Figure 82
Figure 83
23. Grease both O-rings (see arrows) and insert them into
annular grooves of ring gear.
Figure 84
Figure 85
25. Heat inner bearing races and install them until seated with
the big radius showing to planet carrier (downwards).
NOTE: Subsequently install inner bearing races after
cooling down.
Figure 86
Figure 87
27. Heat inner bearing races and install them on planet gears
until seated.
NOTE: Subsequently install inner bearing races after
cooling down.
Figure 88
Figure 89
30. Insert stub shaft into spline of axle bevel gear until seated.
Figure 91
Figure 92
Figure 93
EXAMPLE
Figure 94
34. Install determined shim(s), e.g. s = 2.20 mm, into sun gear
shaft using grease.
Figure 95
Figure 96
Figure 97
Figure 98
Figure 99
Figure 100
Figure 101
Figure 103
2. Remove plugs (3x, Figure 104, Figure 105) and drain oil
from axle casing.
Figure 104
Figure 105
Figure 106
Figure 107
Figure 108
Figure 109
Figure 110
Figure 111
Figure 112
Figure 113
Figure 114
Figure 115
Figure 116
Figure 117
Figure 118
Figure 119
Figure 120
Figure 121
Figure 122
Figure 123
Figure 124
Figure 125
Figure 126
Figure 127
Figure 128
6. Take off spacer ring and remove inner bearing race from
drive pinion.
(S) Gripping insert 5873 012 013
(S) Basic set 5873 002 001
Figure 129
Figure 130
Figure 131
Figure 132
Figure 133
Figure 134
Figure 135
Figure 136
Reference
Description
Number
1 Vent Valve
2 Connection Part
3 O-ring
4 Rectangular Ring
Figure 138
Figure 139
Figure 140
Figure 141
6. Fasten brake tube using hexagon nut and union nut (see
below figure).
Tightening torque MA = 10.20 kg•m (73.76 ft lb)
Figure 142
Figure 143
Reference
Description
Number
1 O-ring
2 Screw Plug
3 Vent Valve
Figure 144
9. Install plug.
Tightening torque MA = 7.14 kg•m (51.63 ft lb)
Figure 145
Figure 146
Figure 147
EXAMPLE "A"
Figure 148
Figure 149
EXAMPLE "B"
EXAMPLE "C"
Figure 150
Figure 151
Figure 152
Figure 153
Figure 154
Figure 155
Figure 156
Figure 157
Figure 158
Figure 159
11. Check rolling moment (0.11 - 0.23 kg•m (0.81 - 1.70 ft lb)).
NOTE: For new bearings it should be tried to achieve
the max. value of rolling moment.
NOTE: If required rolling moment is not obtained,
correct it with an adequate spacer ring (Figure
154), according to following indications:
Rolling moment too low - install a thinner spacer
ring
Rolling moment too high - install a thicker
spacer ring.
Figure 160
Then remove slotted nut again and remove input flange
from drive pinion.
12. Install shaft seal with sealing lip visible to oil chamber
(downwards).
(S) Driver 5870 048 225
NOTE: The exact installation position of shaft seal will
be obtained by using exact driver (S).
NOTE: Just before installation, wet outer diameter of
shaft seal with mineral spirits. and fill space
between sealing and dust lip with grease.
Figure 161
Figure 162
Figure 163
Reference
Description
Number
1 Differential housing
2 Sealing cover
3 Installation dimension
2.0 ± 0.5 mm
Figure 164
Figure 165
Figure 166
Figure 167
Figure 168
Figure 169
Figure 170
Figure 171
Figure 172
Figure 173
Figure 174
Figure 175
Figure 176
Figure 177
Figure 178
Figure 179
Figure 180
Figure 181
Figure 182
Figure 183
Figure 184
Figure 185
Figure 187
Figure 188
Figure 189
Figure 191
7. Insert stub shaft into spline of axle bevel gear until seated.
Then install O-ring (see arrow) using grease into recess of
axle casing.
NOTE: Step (Figure 192 thru Figure 195) is to be made
on both output sides.
Figure 192
Figure 193
Figure 194
Figure 195
Drive Shaft
Edition 1
Drive Shaft
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
REAR AXLE
2 3
FRONT AXLE FG006697
Figure 1
Service Brake
Edition 1
Service Brake
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
2 1
6
5
7
9 FG008070
Figure 1
CLOSES 3 Bar
S TOP
FRONT AXLE
L.H Brake valve BR1 BR2 2
OPENS 25 Bar
T/M DISCONNECT
REAR AXLE
T/M
P1 T1 P2 T2
E/G 7
5 8
R.H Brake pedal 12
0.46 BAR
30B 30B
15B
0.75L 65bar 0.75L 0.32L
parking brake
(PFO1/4) (PFO3/8) (PFO3/8) (PFO3/8)
TP1
(PFO3/8)
A1 LPWS P1 P2 A2 A3 (PFO1/4)
1.5 BAR
15
C3-1 C3-2
4.0 C2 C3-3
TP2 PILOT
(PFO3/8)
TANK (PFO1/4)
2
0.5" 28 kgf/cm
C4
0.5"
20 abs.
FO
(PFO1/2)
SAFETY 13
C3 PARK
(PFO3/8)
C1
(PFO1/2)
C6 C5
LPWS 11
14
2
T 160 kgf/cm
OIL COOLER PK
10 1" 3/4" 3/4" M
(PFO1/2)
(PFO1/4)
23ccr A4 T1 T2
(PFO3/8)
(PFO3/8) (PFO1/4)
30B
BRAKE/FAN/PILOT P
3/4"
* TUV only 0.75L
PUMP
3
19.8 cm/rev L
7/16" 90±5 Bar
STEER PUMP 1200±50 rpm BRAKE & PILOT & FAN MOTER SUPP LY VALVE
3
63.8 cm/rev
FAN MO TOR
LOADER PUMP
3
58.3 cm/rev
PUMP
FG009904
Figure 2
Reference Reference
Description Description
Number Number
1 Rear Axle 9 Brake Valve
2 Transmission Cutoff Switch 10 Brake Pump
3 Front Axle 11 Pilot Supply Line
4 Brake 12 Low Pressure Warning Switch
5 Brake Pedal 13 Parking Brake Valve
6 Stop Light Switch 14 Low Pressure Warning Switch
7 Parking Brake 15 Brake and Pilot Filter
8 Accumulators : Brake
Brake Supply
Valve
Edition 1
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
TP1 PA
C3-1 A1 A1-1
A4
4
3 10
4
P1
5 5
PI
C3-4
TP2
6 LP
PK 6
C2 F0
T1
C4
C1 C6
C5
P2 A3
7
1
2 4
4
T2
C3-2 A2 A2-2
M F1 C3-3
PART NO.
LOT NO.
AOS0560L
Figure 1 Brake & Fan Motor Supply Valve
Reference Reference
Description Description
Number Number
1 Body (200*127*79) 6 Coil (C4, C5)
2 Sequence (C1) 7 Relief (C6)
3 Reducing (C2) 8 Plug
4 Check (C3-1, C3-2, C3-3, C3-4) 9 Plug
5 Solenoid (C4, C5) 10 Orifice (∅4.0-M8*1.25)
C3-1 C3-2
A4 4.0 C2 C3-3
TP2 PI
28 kgf/cm
C4
SAFETY
FO
C1 C3-4
PA
120 kgf/cm
F1
C5 PK
C6
M 160 kgf/cm
T1 T2
FG009905
Figure 2 Hydraulic Circuit
Specifications
Item Specifications
Max. Operating Pressure 210 kg/cm2 (3,000 psi)
Rated Flow 57 l/min (15.05 gpm)
Setting Pressure C1 120 ± 2 kg/cm2 (1,710 ± 28 psi)
(Input P:180 kg/cm2(2,560 psi),
Q:40 l/min (10.5 gpm)
C2 28 ± 2 kg/cm2 (398 ± 28 psi)
(Input P:120 kg/cm2(1,710 psi),
Q:20 l/min (5.3 gpm)
C6 160 ± 2 kg/cm2 @ 40 lpm
(2,130 ± 2 psi @ 10.5 gpm
C3 Cracking Pressure 2.40 kg/cm2 (34.1 psi)
Port Size F0, F1, M PF 1/2 O-ring
TP1, TP2, T2 PF 1/4 O-ring
LP, LK ∅30 PF 1/4 BSP
All other ports PF 3/8 O-ring
Parking Brake
Edition 1
Parking Brake
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
1 2 3
FG006707
Figure 1
Reference Reference
Description Description
Number Number
1 Transmission 3 Parking Brake Disk
2 Parking Brake
16
20 4 3 13 14 8 10 15 7 11 12 FG008072
Figure 2
Figure 3
6. General
Any discovered defects or damage to parts not listed here must
naturally be repaired or replaced using original parts.
For any other information not contained in these instructions or
for more detailed instructions, please contact the vehicle or
brake manufacturer.
Brake Pedal
Valve
Edition 1
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
Theory of Operation
The brake pedal valve is attached to, and operated by, the brake
pedal. See Figure 1. The valve contains two spools. See Figure
2. One spool ports fluid to the brake pistons in the front axle, and
the other spool ports fluid to the brake pistons in the rear axle.
Maximum system operating pressure is 60 ±3 bars (870 ±44
psi). If something in one of the circuits should fail, the other
circuit will continue to operate.
18 1.5
0
24
40
LOCK PLATE
T1
BL1
P1
BR1
T2
BL2
P2
BR2
BR2 BR1
P2 T2 P1 T1
FG008844
Figure 1
4
1 5
P2 T2 P1 T1
3
6
BR BR BL
BL
2 BR2 BR1
P2 T2 P1 T1
AJS0740L
Figure 2
Reference Reference
Description Description
Number Number
1 Primary Control Spool 4 Upper Spring
2 Secondary Control Spool 5 Main Control Spring
3 Lower Spring 6 Working Element
Accumulator
Edition 1
Accumulator SP000875
Page 1
MEMO
Accumulator SP000875
Page 2
Table of Contents
Accumulator
Accumulator SP000875
Page 3
MEMO
Accumulator SP000875
Page 4
SAFETY PRECAUTIONS
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
Accumulator SP000875
Page 5
GENERAL DESCRIPTION
1
FG006708
Figure 1
Reference Reference
Description Description
Number Number
1 Brake Accumulator - 2ea 2 Pilot Accumulator
Reference
Description
Number
1 Shell
2 Diaphragm
3 Poppet
4 Fluid Port
Figure 2
Accumulator SP000875
Page 6
Accumulators are solidly constructed to resist the high operating
pressures of the fluids they contain. There are only three main
moving parts: a valve assembly at the top allows adding or
expelling gas from the compressible, precharged upper
chamber; a valve assembly at the bottom of the accumulator for
passing hydraulic fluid in and out, and an elastic diaphragm to
separate the two chambers. The flexible diaphragm changes
shape to conform to the changing pressures and volumes of the
two fluids in the upper and lower chambers.
There are six possible positions the diaphragm can be in and
they are as follows: Pressure Fluid Nitrogen
Accumulator SP000875
Page 7
The highest working pressure is sometimes referred to as
the "P3" pressure and can also be referenced on the
manufacturer's data label on the exterior of the
accumulator.
5. If system oil pressure begins to fall off or is momentarily
checked or interrupted, the energy stored on the other side
of the diaphragm, in the form of compressed gas, pushes
oil back out of the lower chamber, maintaining oil pressure
of the circuit.
6. With minimal system pressure, an equilibrium point may be
reached in which accumulator precharge pressure and
hydraulic system oil pressure achieve a rough balance. In
this condition a minimal amount of oil is stored in the
accumulator.
Specifications
System Charge Pressure Volume
30 kg/cm2 750 cc
Brake
(430 psi) (45.77 in3)
15 kg/cm2 320 cc
Pilot
(210 psi) (19.53 in3)
Accumulator SP000875
Page 8
1Steering
SP001361
STEERING SP001361
Steering
Edition 1
Steering SP001361
Page 1
MEMO
Steering SP001361
Page 2
Table of Contents
Steering
Steering SP001361
Page 3
MEMO
Steering SP001361
Page 4
SAFETY PRECAUTIONS
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
Steering SP001361
Page 5
GENERAL DESCRIPTION
2 3
6
FG006709
Figure 1
Reference Reference
Description Description
Number Number
1 Cushion Valve 4 Main Pump
2 Steering Unit 5 EHPS Valve
3 Main Block Valve 6 Steering Cylnder
Steering SP001361
Page 6
3
L R
BRAKE/PILOT/FAN PUM P
3
19.8 cm /rev
TPU EF
0.75 STEER
O.25"
C1 UNIT
PUMP C2
P T
160
ELECTRIC STEER
1"
P-controller
HT
0.75
2 4
LE
RE
PE
1 3
EF
TE (PF3/4) 12 BAR
Ps
30 BAR (PF1/2)
190 BAR
Ts
TPS (PF1/2)
O.25" P(PF3/4) T(PF1/2)
6
70X 35X430
STEERING CYL.
15BAR 15BAR CUSHION V/V
1
FG009906
Reference Reference
Description Description
Number Number
1 Cushion Valve 4 Main Pump
2 Steering Unit 5 EHPS Valve
3 Main Block Valve 6 Steering Cylnder
Steering SP001361
Page 7
EHPS Valve
Figure 1
Steering SP001361
Page 8
Reference Reference
Description Description
Number Number
1 To Tank 10 To Steering Cylinder
2 To Emergency System (Right Side)
3 To Main Pump 11 Shock and Suction Valve
(Right Side)
4 From Main Pump
12 From Steering Unit R-port
5 To Steering Unit P-port
13 Relief Valve
6 From Steering Unit T-port
14 Check Valve
7 From Steering Unit L-port
15 Main Steering Spool
8 Shock and Suction Valve
(Left Side) 16 Pressure Reducing Valve
9 To Steering Cylinder (Left Side) 17 Metering Spool
18 Priority Spool
Steering SP001361
Page 9
Parts List
Figure 2
Reference Reference
Description Description
Number Number
1 Valve Block 51 Threaded Plug
2 Spool W. Spring 52 Threaded Plug
3 Spool W. Spring, 60 Cover, Spring Housing
Reduction Valve 61 O-ring
4 Spool, Metering 62 O-ring
5 Compress Spring 63 Screw
7 Spool, Dynamic / Intern PP 65 Plug
8 Throttle Screw 66 Cover
9 Compress Spring 67 Screw
15 Pipe W. O-ring 80 Shock Valve PVLP
16 Plug W. O-ring, Pipe 81 Spring Conically
20 Plug W. O-ring 82 Plug with. O-ring
21 Bush W. Plug, Reduction Valve 85 Check Valve
22 Plug W. O-ring, LS 90 Valve Seat
23 Plug W. O-ring, PP 91 Pilot Cone
25 Plug W. O-ring, Shuttle 92 Spring OSV
26 Ball, 1/2 94 Adjustment Screw, PVB/PVP
37 Label 95 Plug OSV
40 Plug 150 Packing,
50 Threaded Plug EHPS Type 1&2 M/ELAKTIV
Steering SP001361
Page 10
Description of operation of EHPS with integrated priority
valve
Figure 3 shows a diagram of the steering system.
The system includes the following Sauer-Danfoss components:
One steering unit, type OSPCX CN and one steering valve, type
0 EHPS valve
The following valves are integrated in the EHPS (position
numbers refer to numbers on drawing Figure 1)
Figure 3
Steering SP001361
Page 11
Steering Spool at Neutral Position
Figure 4
In neutral position, the oil will pass from the pump across the
integrated priority valve (18) in the EHPS valve for discharge
through the EF port. When the steering unit is in neutral, flow
through it is blocked and all flow through the priority valve (18) in
EHPS valve is directed out the EF port and passed to the main
control valve.
When the engine is turned off, the priority valve spool (18) is
pushed to the right by the spring.
The passage to the EF port is blocked while the passage to the
CF port is open.
When the machine is started, EF port of the EHPS valve may be
connected to the working hydraulic. Maximum pressure on the
EF port = 270 bar.
The operating pressure in the loader system has not effected on
the operation of the priority valve (18) of EHPS valve.
Independently of operation of the loader actuated in relief, the priority
valve (18) will not shift until the machine is steered.
A part of flow through the priority valve spool (18) will flow to P
port of steering unit through the pressure reducing valve. Also,
flow as pilot signal of steering through the priority valve spool
(18) passes from the P port through the Dynamic orifice and into
the LS line. It flows to the tank through the LS orifice in main
spool.
In neutral position, the main spool will be in its center position.
This means that knocks and impacts from the cylinder are not
transmitted to the steering unit. The EHPS valve is thus of the
nonreactive type.
Steering SP001361
Page 12
Steering Spool Operated
1. Turning Left
Figure 5
When the steering wheel is turned to the left, the pressure oil
from the steering unit will fill the left side chamber of main
steering spool (15), and the main steering spool (15) moves to
the right.
At the same time of moving of the main steering spool (15), LS
signal will be blocked.
If LS signal of main steering spool (15) is blocked, it cause the to
pressure increase in the left chamber of the priority valve (18A) and
then the priority valve (18) will be pushed to the right side.
Consequently, oil will flow via CF from the priority valve to the
main spool.
Oil will now push steering cylinder rod out and it will cause wheel
loader to be steered to left side.
The rate of movement of main steering spool (15) is concluded
as flow rate, which is kept in left chamber from steering unit.
Furthermore, the rate controls speed of movement for cylinder.
When the cylinder reaches to end position, pressure of oil
flowing through main steering spool (15) will increase. If the oil
pressure increase up to the setting of relief valve, the relief valve
will be activated. This results in decreasing pressure in the left
chamber of priority valve (18A), and will push the priority valve
(18) to right side. The oil flow to cylinder will be blocked.
Steering SP001361
Page 13
2. Turning Right
Figure 6
When the steering wheel is turned to the right, the pressure oil
from the steering unit will fill the right side chamber of main
steering spool (15), and main steering spool (15) moves to the
left.
At the same time as the main spool (15) is moving the LS signal
will be blocked.
If LS signal of main steering spool (15) is blocked, it cause the
pressure to increase in the left chamber of priority valve (18A)
and then the priority valve (18) will be pushed to the right side.
Consequently, oil will flow via CF of priority valve to main spool.
This oil will push the steering cylinder rod out and it will cause
wheel loader to be steered to right side.
The rate of movement of main steering spool (15) is concluded
as flow rate, which is kept in right chamber from steering unit.
Furthermore, the rate controls speed of movement for cylinder.
When the cylinder reaches the end position, pressure of oil
flowing through main steering spool (15) will increase. If the oil
pressure increase up to relief valve setting, the relief valve will
be activated. It results in decreasing pressure on the left
chamber of priority valve (18A), and will push the priority valve
(18) to right side. Then, oil flow to cylinder will be blocked.
Steering SP001361
Page 14
Pressure Reducing Valves
Figure 7
Steering SP001361
Page 15
Pilot Relief Valve
Figure 8
Reference Reference
Description Description
Number Number
1 Plastic Plug 4 Thrust Pad
2 Adjustment Screw 5 Valve Seat
3 Spring
Steering SP001361
Page 16
Steering Unit
Figure 9
Reference Reference
Description Description
Number Number
1 Bearing 7 Sleeve
2 Neutral Position Spring 8 Cardan Shaft
3 Cross Pin 9 Spool
4 Housing 10 Check Valve
5 Gear Wheel 11 Distributor Plate
6 Gear Rim 12 End Cover
Function
The steering unit consists of a rotary valve and a rotary metering
unit.
Via a steering column the steering unit is connected to the
steering wheel of the vehicle.
When the steering wheel is turned, oil is directed from the
steering system pump via the rotary valve (spool and sleeve)
and rotary metering (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 rotation of the
steering wheel.
Steering SP001361
Page 17
Exploded View of a Steering Unit
Figure 10
Steering SP001361
Page 18
FUNCTION
The main relief valve is inside the EHPS valve, and set the
maximum circuit pressure of the steering circuit. When the
EHPS valve is being actuated, and the steering circuit goes up
above the set pressure of this valve, oil will be relieved, and the
priority valve spool will be actuated, and the oil will be drained to
EF port.
Figure 11
Priority spool.
Position 18.
Figure 12
Metering spool.
Position 17.
Figure 13
Steering SP001361
Page 19
Relief valve.
Position 13.
Figure 14
Shock valve
Position 10.
Figure 15
Pressure reducing valve
Position 16.
Figure 16
Shuttle valve
Figure 17
Figure 18
Steering SP001361
Page 20
EHPS house.
Reference
Description
Number
1 Metering Spool Position 17
2 Main Spool Position 15 (Behind
End Cover)
3 Pressure Reduction Valve
Position 16
(Behind End Cover)
4 Priority Spool Position 18
Figure 19
Steering SP001361
Page 21
Steering SP001361
Page 22
SP000328
CUSHION VALVE SP000328
Cushion Valve
Edition 1
Cushion Valve
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
Function
The cushion valve absorbs any excessive peak pressure that
maybe generated during initial movement of the steering wheel
or during a change in steering direction. The cushion valve also
prevents excessive high-pressure and shock that can result from
steering load inertia.
Working Principle
If a high-pressure oil is fed back to port R, it pushes spring (3)
and opens poppet (2). This operation directs the high-pressure
oil to port L through the center hole in spool (12) and the check
valve poppet in port L part. At the same time, oil reaches the
pressure room of the plug through orifice (8). This operation
closes the passage from port R to port L. This releases the
pressure and prevents machine shock by intercepting oil. If a
low-pressure oil flows, the cushion operation is not necessary. It
is due to the speed of closing spool (12) is faster than the speed
of opening poppet (2), therefore, the cushion valve does not
work.
Specifications
General
Max. Pressure 210 bar (3,046 psi)
Main Relief Pressure 15 bar (218 psi)
Hydraulic Oil ISO VG 46 WR or SIMILAR
Hydraulic Oil Temperature -20 - +90 °C
Environments
Atmospheric Temperature -30 - +45 °C
Vibration 3 - 5G/ 30 Hz
Shock 10G
Figure 1
Reference Reference
Description Description
Number Number
1 Body 10 Spring
2 Seat Valve 11 Back up Ring
3 Poppet 12 O-ring
4 Spring 13 O-ring
5 Plug 14 O-ring
6 Spring 15 Plug
7 Spool 16 Plug
8 Plug 17 Orifice
9 Poppet
Emergency
Steering
Edition 1
Emergency Steering
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
7 8
10 9
1
FG006710
Figure 1
Reference Reference
Description Description
Number Number
1 Pump & DC Motor 6 Oil Tank
2 Steering Pump 7 Steering Unit
3 Check Valve 8 Block Valve
4 Pressure Sensor 9 Steer Cylinder
5 Pump 10 Cushion Valve
B 62 Bar
R2 6B BR
M 10ccr
EMR.STEERING S/W
AJO0011L
30 15
20 20
10
40
10 25
5
50 30
0 0
km/h x100r/min
CHECK
STOP
F/R
1 FG006741
Figure 4
18.00 450
16.00 400
14.00 350
12.00 300
AMPS
GPM
10.00 250
8.00 200
6.00 150
4.00 100
2.00 50
0.00 0
0 500 1000 1500 2000 2500 3000 3500
PSI
Flow, 10 cc Amps, 10 cc
FG005128
Figure 5
Figure 6
Reference Reference
Description Description
Number Number
1 Retaining Ring 7 DC Motor
2 Shaft Seal 8 Start Sw Kit
3 Backup Ring 9 Gasket
4 Seal 10 Lock Washer
5 O-ring 11 Mounting Screw
6 Valve Assembly 12 Pump Assembly
Articulation
Center
Edition 1
Articulation Center
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
CAUTION!
When the loader is steered, the area near the center hinge
pins becomes so narrow that you might get caught between
the front and rear frames. Before trying to service the
loader, make sure to set the frame lock plate.
Before moving (traveling) the loader, make sure the frame
lock plate is set to the original position.
FG006713
Figure 1
DETAIL B
S=1/2
(LOWER HINGE BEARING)
DETAIL A
S=1/2
(UPPER HINGE BEARING)
AOS0170L
Figure 2
Counterweight
Edition 1
Counterweight SP000130
Page 1
MEMO
Counterweight SP000130
Page 2
Table of Contents
Counterweight
Counterweight SP000130
Page 3
MEMO
Counterweight SP000130
Page 4
SAFETY PRECAUTIONS
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
Counterweight SP000130
Page 5
SPECIFICATIONS
NOTE: Weight.
COUNTERWEIGHT
AJS0620L
Figure 1
Counterweight SP000130
Page 6
1Tank
SP000879
OIL TANK SP000879
Oil Tank
Edition 1
Oil Tank
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
Parts List
1 7
2 8
3 9
10
4
5 11
6
12
13
14
16 15
FG006714
Figure 1
Specifications
Oil Tank
Type Pressurized Sealing
Capacity (System) 158 liters (42 U.S. gal.)
Air Breather
Open Pressure 0.40 kg/cm2 (5.7 psi)
Vacuum pressure 0.035 kg/cm2 (0.5 psi) at 900 liters/min. (238 U.S. gal./min.)
Return Filter
Filtration Rating 10 μ
Pressure Drop 0.25 kg/cm2 (3 psi) at 600 liters (159 U.S. gal.), 20 cSt
Filtration Efficiency Over 99.5 %
Suction Filter
Filtration Rating 177 μ
Bypass Valve
Cracking Pressure 1.5 kg/cm2 (21 psi) at 40 liters (10.5 U.S. gal.), 20 cSt
Pressure Drop 2.0 kg/cm2 (28 psi) at 40 liters (10.5 U.S. gal.), 20 cSt
Fuel Tank
Edition 1
Fuel Tank
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
Parts List
2
4
3
5
1
12 11 10
FG008845
Figure 1
Reference Reference
Description Description
Number Number
1 Fuel Tank 7 Hose; Engine Oil Drain
2 Fuel Pipe 8 O-ring
3 Packing 9 Cover
4 Fuel Cap 10 Sender Cover
5 Fuel Strainer 11 Fuel Sender
6 Drain Cock 12 Step
Figure 2
Cylinders
Edition 1
Cylinders SP001027
Page 1
MEMO
Cylinders SP001027
Page 2
Table of Contents
Cylinders
Cylinders SP001027
Page 3
MEMO
Cylinders SP001027
Page 4
SAFETY PRECAUTIONS
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
Cylinders SP001027
Page 5
GENERAL DESCRIPTION
The machine contains boom cylinders, buckets cylinders and
steering cylinders. Each cylinder contains a cylinder tube, piston
rod, piston, and cylinder head. See Figure 1. The piston is held
to piston rod by a nut. A dust seal protects the U-ring and oil seal
from dirt and also prevents oil from leaking out of the cylinder.
Figure 1
Reference Reference
Description Description
Number Number
1 Retaining Ring 10 Seal O-ring
2 Dust Seal 11 Piston
3 U-ring 12 Spring
4 Seat O-ring 13 Cylinder Tube
5 Port (A) 14 O-ring, Backup Ring
6 Cushion Plate 15 Bushing
7 Wear Ring 16 Cylinder Head
8 Piston Nut 17 Bolt
9 Port (B) 18 Piston Rod
Cylinders SP001027
Page 6
Theory of Operation
1. Piston 1
2. Oil Path A
3. Oil Path B
F1 = P x πB2
4
4. Rod Diameter
When the cylinder rod is retracted, oil flow through the circuit
from the pump to the front side of the cylinder generates a force 2
(F2) that can be expressed by the formula in which the diameter 3
of the piston rod is expressed by R, and the other two terms are
the same as in the preceding expression. 0331
2
π(B -R )2 Figure 3
F2 = P x
4
Q1 = S x π(B2)
4
Q2 = S x π(B2-R2)
4
Q1 > Q 2 0332
Figure 4
Cylinders SP001027
Page 7
Parts List
29
23
25 24
20
19
22
26
27
14
28
16
15
17
18
11
12
13
7
21 6
9 5
8
10
29
BAS0170L
Figure 5
Cylinders SP001027
Page 8
Reference Reference
Description Description
Number Number
1 Tube Assembly 16 Wear Ring
2 Steel Bushing 17 Dust Ring
3 Rod Assembly 18 O-ring
4 Steel Bushing 19 Piston Nut
5 Rod Cover 20 Lock Ring
6 DU-bushing 21 Socket Hex Bolt
7 Retaining Ring 22 Pipe Assembly
8 U-packing 23 O-ring
9 Backup Ring 24 Spring Washer
10 Dust wiper 25 Hex Bolt
11 O-ring 26 Pipe Clamp
12 Backup Ring 27 Spring Washer
13 O-ring 28 Hex Bolt
14 Piston 29 Grease Fitting Seal Kit
15 Glyd Ring
Cylinders SP001027
Page 9
Lift Hydraulic Cylinder
33 2
22
23
21
30 24
32
29
30
31
26 25
27
28
19
18
13
15
14
17 7
20 10
12 11
6
5
8 4
7
9
BAS0180L
Figure 6
Cylinders SP001027
Page 10
Reference Reference
Description Description
Number Number
1 Tube Assembly 18 Piston Nut
2 Steel Bushing 19 Lock Ring
3 Rod Assembly 20 Socket Hex Bolt
4 Rod Cover 21 Pipe Assembly
5 DU-bushing 22 O-ring
6 Retaining Ring 23 Spring Washer
7 U-packing 24 Hex Bolt
8 Backup Ring 25 Pipe Assembly
9 Dust wiper 26 O-ring
10 O-ring 27 Spring Washer
11 Backup Ring 28 Socket Hex Bolt
12 O-ring 29 Pipe Clamp
13 Piston 30 Spring Washer
14 Glyd Ring 31 Hex Bolt
15 Wear Ring 32 Hex Bolt
16 Dust Ring 33 Grease Fitting Seal Kit
17 O-ring
Cylinders SP001027
Page 11
Steering Hydraulic Cylinder
27
27
23
24
26
1
25
21
22
20
19
14
16
15
18 17
10
11
6
12
13
5
7
8
9
27
BAS0190L
Figure 7
Cylinders SP001027
Page 12
Reference Reference
Description Description
Number Number
1 Tube Assembly 15 Glyd Ring
2 Steel Bushing 16 Wear Ring
3 Rod Assembly 17 Dust Ring
4 Steel Bushing 18 O-ring
5 Rod Cover 19 Piston Nut
6 DU-bushing 20 Lock Ring
7 U-packing 21 Cushion Plunger
8 Backup Ring 22 Stop Ring
9 Dust wiper 23 Check Valve
10 O-ring 24 Spring
11 Backup Ring 25 Plug
12 O-ring 26 O-ring
13 Washer 27 Grease Fitting Seal Kit
14 Piston
Cylinders SP001027
Page 13
TROUBLESHOOTING, TESTING
AND ADJUSTMENT
Problem Possible Cause Remedy
Oil leaking between cylinder head Foreign material in U-ring (3). Remove foreign material.
(16) and piston rod (18). (Index nos. Scratches in U-ring (3). Replace U-ring (3).
refer to Figure 1)
Damage to U-ring (3). Replace U-ring (3).
Foreign material in dust seal (2). Remove foreign material.
Scratches to dust seal (2). Replace dust seal.
Damage to dust seal (2). Replace dust seal.
Foreign material in seal O-ring (4). Remove foreign material.
Scratches in seal O-ring (4). Replace O-ring (4).
Damage to seal O-ring (4). Replace O-ring (4).
Scratches on sealing surface of If scratches are not deep, hone
piston rod (18). with an oil stone and lubricate. If
scratches are deep, replace
piston rod (18).
Deep scratches on inner surface of Replace bushing.
bushing (15).
Oil leaking between cylinder head Damage to O-rings (14). Replace O-rings (14).
(16) and cylinder tube (13).
Oil leaking from welded area of Damage to welded area. Replace cylinder tube (13).
cylinder tube (13).
Oil leaking between cylinder head Foreign material in U-ring (3, Remove foreign material.
(16) and piston rod (18). (Index nos. Figure 1)
refer to Figure 1). Scratches in U-ring (3, Figure 1). Replace U-ring (3).
Damage to U-ring (3, Figure 1). Replace U-ring (3).
Foreign material in dust seal (2, Remove foreign material.
Figure 1).
Scratches in dust seal (2, Figure 1). Replace dust seal (2).
Damage to dust seal (2, Figure 1). Replace dust seal (2).
Foreign material in seal O-ring (4, Remove foreign material.
Figure 1).
Scratches in seal O-ring (4, Figure Replace O-ring (4).
1).
Damage to seal O-ring (4, Figure Replace O-ring (4).
1).
Scratch on sealing surface of If scratches are not deep, hone
piston rod (18, Figure 1). with an oil stone and lubricate. If
scratches are deep, replace
piston rod (18).
Deep scratches on inner surface of Replace bushing.
bushing (15, Figure 1).
Oil leaking between cylinder head Damage to O-rings (14, Figure 1). Replace O-rings (14).
(16) and cylinder tube (13).
Oil leaking from welded area of Damage to welded area. Replace cylinder tube (13).
cylinder tube (13).
Cylinders SP001027
Page 14
Problem Possible Cause Remedy
Cylinder drops from pull of gravity. Light scratches on sealing surface Hone out scratches with oil
of cylinder tube (13, Figure 1). stone.
Deep scratches on sealing surface Replace cylinder tube (13).
of cylinder tube (13, Figure 1).
Deep scratches on sealing surface Replace O-rings (10).
of piston O-rings (10, Figure 1).
Foreign material in U-ring (3, Remove foreign material.
Figure 1).
Scratches in U-ring (3, Figure 1). Replace U-ring (3).
Damage to U-ring (3, Figure 1). Replace U-ring (3).
Nylon wear rings (7, Figure 1) Replace nylon wear rings (7).
twisted.
Nylon wear rings (7, Figure 1) Replace nylon wear rings (7).
scratched.
Nylon wear rings (7, Figure 1) have Replace nylon wear rings (7).
other damage.
Slow bucket and boom movements. Reduced oil flow due to dirty filter Disassemble and clean parts.
or dirty intake line.
Air drawn into circuit through loose Tighten intake connections.
connections.
Reservoir oil level too low. Fill reservoir to correct level.
Relief valve pressure setting Adjust relief valve pressure.
incorrect.
Damaged pump shaft or pump Replace damaged parts.
drive sleeve.
Pump worn or damaged internally. Replace worn or damaged parts.
Relief valve sticking. Disassemble and inspect
cartridge. Clean or replace
cartridge.
Air in pressure line. Perform cylinder bleeding
procedure to remove air. Tighten
or replace pressure line.
Damaged pipe or hose. Replace pipe or hose.
Worn cylinder seals. Replace worn parts.
Low-pressure, shown by weak Reduced oil flow due to dirty filter Disassemble and clean parts.
upward movement of boom and or dirty intake line.
bucket. Reservoir oil level too low. Fill reservoir to correct level.
Relief valve pressure setting Adjust relief valve pressure.
incorrect.
Pump worn or damaged internally. Replace worn or damaged parts.
Relief valve sticking. Disassemble and inspect
cartridge. Clean or replace
cartridge.
Worn cylinder seals. Replace worn parts.
Low pump output due to dirty Remove and clean pump
discharge pipes. discharge pipes.
Relief valve spring is weak. Relief Replace worn parts.
valve poppet worn.
Cylinders SP001027
Page 15
Problem Possible Cause Remedy
Cylinder drops when control valve is Worn plunger in control valve. Replace plunger.
in neutral. Stuck overload relief valve due to Replace worn parts.
worn seat surface.
Loose pipes or joints. Tighten parts.
Worn piston seal on hydraulic Replace seal.
cylinder.
Vibration or excessive noise. Excessive resistance in pump Inspect intake line and clean or
intake line. replace as necessary.
Air being drawn into intake line. Inspect pipe joints and tighten.
Chattering relief valve. Change oil, replace valve.
Air bubbles in oil. Wrong type of operating oil. Drain and fill with proper type of
oil.
Oil level too low. Raise to proper level.
Air trapped in system. Perform cylinder bleeding
procedure to remove air.
Frequent rubber hose damage. System pressure too high. Adjust relief valve pressure.
Hoses breaking due to contact with Restrain hoses to prevent
another machine parts. contact.
Cylinders SP001027
Page 16
DISASSEMBLY
NOTE: Keep on hand a container large enough to hold all of
the oil in cylinder being repaired. When cylinder rod
and head are removed, oil will run out of cylinder.
NOTE: Dispose of drained fluids according to local
regulations.
1. Use an allen wrench to remove bolts that hold cylinder
head to cylinder tube. See Figure 8.
Figure 8
Figure 9
Figure 10
Cylinders SP001027
Page 17
4. Remove piston nut (1, Figure 11), piston assembly (2),
cushion flange (3), and cylinder head assembly (4).
Reference
Description
Number
1 Piston Nut
2 Piston Assembly
3 Cushion Flange
Cylinder Head
4
Assembly
Figure 11
Figure 12
Reference
Description
Number
1 Retaining Ring
2 Dust Seal
Figure 13
Reference
Description
Number
1 U-Packing
2 O-ring
3 Ring
Figure 14
Cylinders SP001027
Page 18
CLEANING AND INSPECTION
(WEAR LIMITS AND
TOLERANCES)
For general cleaning and inspection procedures, refer to
"General Maintenance Procedures" section.
REASSEMBLY
NOTE: Check cylinder head grooves for U-packing and dust
seal. If edges of grooves are sharp or have burns,
use an oil stone to smooth surface. See Figure 15.
Figure 15
Figure 16
Cylinders SP001027
Page 19
2. Install split backup ring into its groove by compressing ring.
See Figure 17. Make sure that ends of ring do not overlap.
NOTE: The U-packing can be installed by hand or by
using a seal installing jig. The jig should be
made of copper, aluminum, or plastic. If a jig is
used, be sure that jig does not have sharp
edges that could damage U-packing.
Figure 17
Figure 18
Figure 19
Cylinders SP001027
Page 20
5. Check to be sure that U-packing and backup ring are
correctly installed by pushing with your hand on inner
diameter of U-packing. See Figure 20.
NOTE: There are 2 backup rings used on outside of
cylinder head. One backup ring is continuous.
The other backup ring is open, split by an
angled cut.
Figure 20
Reference
Description
Number
1 Split Backup Ring
Continuous Backup
2
Ring
Figure 21
Figure 22
Figure 23
Cylinders SP001027
Page 21
9. Use a seal installing jig to install dust seal into cylinder
head. See Figure 24. Install retaining ring.
Figure 24
Figure 25
Figure 26
Cylinders SP001027
Page 22
12. Insert one end of backup ring into its groove. See Figure
27. Use your hand to slide other end of ring into groove.
Figure 27
13. Use warm water to expand slipper seal. See Figure 28.
This will make seal easier to install. Set slipper seal in 60
-100° C (140 - 212° F) water for 5 minutes or longer.
Figure 28
14. Insert one end of slipper seal, (1, Figure 29) into its groove.
Use your hand to slide other end of slipper seal into
groove.
WARNING!
Before piston is inserted into cylinder tube, make sure
that slipper seal is no longer expanded. If seal is still
expanded, it could catch on threaded portion of
cylinder tube. An expanded seal could also jam inside
cylinder tube. Figure 29
Cylinders SP001027
Page 23
15. Install two backup rings, (1, Figure 30). One ring fits on
either side of slipper seal (2).
Reference
Description
Number
1 Backup Ring
2 Slipper Seal
Figure 30
Figure 31
17. Set cylinder rod (1, Figure 32) into a repair fixture (2).
Securely clamp rod to fixture. Exercise caution to prevent
nicks or scratches to chrome plated areas of rod. chrome
plated area is oil sealing surface of rod.
Reference
Description
Number
1 Cylinder Rod
2 Repair Fixture
Figure 32
Cylinders SP001027
Page 24
18. Slide cylinder head assembly (1, Figure 33) onto cylinder
rod (2). Use caution to prevent threads on rod from
damaging seal inside cylinder head.
Reference
Description
Number
1 Cylinder Head
2 Cylinder Rod
Figure 33
19. Install cushion flange (1, Figure 34) on cylinder rod (2).
Slide piston assembly (3) onto cylinder rod (2).
Reference
Description
Number
1 Cushion Flange
2 Cylinder Rod
3 Piston Assembly
Figure 34
20. Install piston nut (1, Figure 35) and tighten it with an impact
wrench. Then use a torque wrench to tighten nut (1) to
specified torque.
After nut has been tightened, check to see that cushion
flange moves.
Figure 35
21. Slide rod assembly into cylinder tube. Align punch mark (1,
Figure 36) with port (2) in cylinder tube. This will align hole
(3) in cylinder head with port (2).
Reference
Description
Number
1 Punch Mark
2 Port
3 Hole
Figure 36
Cylinders SP001027
Page 25
22. Install bolts in cylinder head and tighten them to torque
specified in bolt torque chart. See Figure 37. Double check
to make sure that hole in cylinder head is align with port in
cylinder tube.
NOTE: After rebuilding a cylinder, or after loosening a
cylinder hydraulic line, air must be bled from
hydraulic system. To bleed air from system, first
extend and retract a cylinder (or pair of
cylinders) about 5 times at low engine rpm. Stop
cylinder about 100 mm (4 in) short of full
extension and full retraction. Then fully extend
and retract cylinder about 5 times, also at low Figure 37
engine rpm.
Cylinders SP001027
Page 26
SP001035
MAIN PUMP SP001035
Main Pump
Edition 1
Main Pump
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
Theory Of Operation
The hydraulic pump is a triple vane pump which contains three
pumping sections. The first pumping section supplies oil for the
front attachment. The second pumping section supplies oil for
the steering cylinders. Surplus oil which is not necessary for the
steering function is directed into control valve to join the first
pump's oil by the priority valve. The third pump section, is the
pilot pump, used for brakes and pilot line operation.
Figure 1
Figure 2
Figure 3
Reference
Kit Code Number Remark
Number
1 P1 Cartridge (B17) S24-40164-0 Rotor, vane, holdout pins, port-plates
2 P2 Cartridge (B20) S24-77212
3 P3 Cartridge (B20) S24-94162
- Seal Kit S24-76934 All seals included: shaft seal,
(S1-0.7bar) square-rings, O-rings
4 Shaft and Bearing S24-76933 Shaft, bearing, retaining ring
Assembly (Code 3)
Main Pump
70.6 105.9 101.8 38.1 12.45
R 73,8
Figure 4
7.9
6.35 MAX
Dimensions
38
76.7
82.7
106.4
127,00
126,95
64,3
147.4
17,5
80.7
2.3×45°
1.3×45°
87.1
181
211
22.25
30.2 SHAFT CODE 3
SAE C splined shaft
Class 1 - J498 b
12/24 d.p. - 14 teeth
30° pressure angle
flat root side fit
47.65
58.7
147.4
PRESSURE SAE#8
PRESSURE 19.1
PRESSURE 31.75
FG005325
Page 11
SP001035
Specification
Reference Reference
Description Description
Number Number
1 Modification 6 Type of Shaft
2 Seal Class 7 Cam Ring for "P3"
3 Design Letter 8 Cam Ring for "P2"
4 Porting Combination 9 Cam Ring for "P1"
5 Direction of Rotation 10 Series
Specifications
Specification
Item
Main Pump Steering Pump Pilot Pump
Model Number T67CCAY-B17-B20-B20-3R41-B1MY
Type Vane
58.3 cc/rev 63.8 cc/rev 19.8 cc/rev
Displacement
(3.56 in3/rev) (3.89 in3/rev) (1.208 in3/rev)
Seal Driver
A seal driver is required to install shaft seal in the pump
mounting cap.
NOTE: 1. Material: 4140 or equivalent.
2. Remove all burrs and break sharp edges: 0.25/
0.13R.
3. Length 19 mm ("A" dia) to be heat treated Rc 50/
55.
NOTE: A dia: 34.90 - 34.75
B dia: 57.10 - 56.92
C: 145
Figure 6
Tool ref.: SS2
Protective Cone
A protective cone is to be used when installing shaft assembly in
the mounting cap. The protective cone prevents damaging the
lips of the shaft seal during insertion.
NOTE: 1. Material: TEFLON preferred.
2. Remove all burrs and break sharp edges: 0.25/
0.13 R.
NOTE: A: 60
B dia: 35.00 - 34.95
C dia: 31.33 - 31.25
Tool ref.: CP14
Figure 7
Figure 8
Figure 9
Figure 10
Figure 11
Figure 12
Figure 13
Figure 14
Figure 15
Figure 16
Figure 17
Figure 18
Figure 19
Figure 20
WARNING!
Replace all seals and backup rings with new ones.
Make sure the dowel pin(s) (10) are properly inserted
in corresponding hole in housing (13).
Figure 21
Figure 22
WARNING!
When inserting P1 cartridge in mounting cap, make
sure the white teflon backup ring is not damaged and
securely in place.
5. Use screws (38) to ensure mounting cap (19) goes down Figure 23
straight and does not tilt.
NOTE: Tighten screws (38) to 110 Nm (80 ft lb).
6. Turn pump vertically 180°. Then securely hold it in vise on
mounting cap, making sure it is level.
WARNING!
Make sure the dowel pin is properly inserted in the
corresponding hole in housing (13).
Figure 24
Figure 25
Figure 26
10. Position rotor (32), with vanes (31), on splines of shaft (17).
Figure 27
WARNING!
Make sure rotation is as per required.
Figure 28
Figure 29
Figure 30
Figure 31
Figure 32
Main Control
Valve
Edition 1
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
(2)
(2)
T1
P1
(3)
Pb1 (2) Pa1
B1 A1
Pb2 Pa2
(2) B2 A2 (2)
Pb3 Pa3
B3 A3
FG006715
Figure 1
(1)
P
200 BAR
(2)
BUCKET
a1 b1
BUCKET CYLINDER
BOOM
a2
b2
BOOM CYLINDER
A2 275 BAR
(RAISE)
B2
(LOWER)
OPTION
a3 b3
Figure 3
Types Description
A Must replaced when Disassembly / Reassembly, supplied in repair kit.
B Supplied as spare parts for quality warranty or assembly.
C Supplied as single item.
D Cannot be supplied.
Order of Replacement
Reference numbers are those shown in Figure 3.
1. Remove overload relief valves (27, 28, and 29) from valve
housing.
2. Remove main relief valve (30) from valve housing.
3. Remove anticavatation valve (31) from valve housing.
NOTE: Do not disassemble relief valve and
anticavatation valve unless problems are found
in them, because they should be replaced as
assemblies. They should be removed according
to “Valve Maintenance” on page 1-18, and
“Anticavatation Valve” on page 1-21. Provided,
that overload relief valve whose setting
pressure is higher than that of main relief valve
should not be removed because its adjustment
is impossible. Match mark parts, for proper
orientation and location during reassembly.
4. Loosen socket head bolt (13) and remove long caps (9 and
10) along with O-rings (12) on flange (of bucket and boom
spools).
5. Remove bucket spool (2) and boom spool, as assemblies,
from valve housing (1).
NOTE: Take care to prevent any dent or scratches on
surface of spool when taking it out.
Disassembly
1. Remove plug (2), spring (7), poppet (4) and sleeve (3) from
relief valve cartridge housing (1).
2. Remove adjustment lock nut assembly (13) and remove
pilot poppet (6) and spring (8).
3. Remove O-rings and backup rings from all pieces.
NOTE: Do not remove pilot seat (5) that is attached to
the plug body by crimping.
Figure 6
Reassembly
1. Install O-ring (9) and backup ring (10) on pilot seat (5).
2. Install O-ring (11) on plug (2).
3. Install O-ring (11) on relief valve cartridge housing (1).
4. Install sleeve (3), main poppet (4), spring (7) and pilot seat
(5) (with plug) in relief valve cartridge housing (1). Tighten
plug (2) to a torque of 10 - 11 kg•m (69 - 80 ft lb).
5. Insert pilot poppet (6) and spring (8) in plug (2). Position
O-ring (14) on plug (2). Install adjustment lock nut
assembly (13) in plug. Temporarily tighten lock nut.
6. Insert main relief valve assembly in valve housing and
tighten to a torque of 9 - 11 kg•m (69 - 80 ft lb).
NOTE: Adjust pressure as described in “Main Relief
Valve Adjustment” on page 1-23.
Disassembly
1. Remove plug (2), springs (7 and 8), piston (5), main poppet
(4), and sleeve (3) from relief valve cartridge housing (1).
2. Loosen adjustment lock nut assembly (10) and remove
spring (9) and pilot poppet (6).
3. Remove O-rings and backup rings from all pieces.
Figure 7
Anticavatation Valve
Disassembly
1. Remove plug (6) from poppet sleeve (1).
NOTE: Do not disassemble main poppet (2). It is
connected to spring seat (4) and by C-pin (5)
which keeps it assembled to other parts.
2. Remove O-ring (7) and backup ring (8) from poppet sleeve
(1).
3. Remove O-ring (9) from plug (6)
Reassembly
1. Install O-ring (7) and backup ring (8) on poppet sleeve (1).
2. Install O-ring (9) on plug (6)
3. Slide poppet sleeve (1) in plug (6).
4. Install anticavataton valve in valve housing. Tighten it to a
torque of 8 - 9 kg•m (58 - 65 ft lb).
OPERATION
1. First, check if valve arrangement is correct and oil is clean.
Check for leakage by increasing pressure gradually
(inching device with low idle).
2. Use hydraulic oil specified in the Operation and
Maintenance Manual.
3. Do not increase pressure of relief valve above its nominal
pressure value.
4. Start normal work cycle operations only after sufficiently
warming up the pilot circuit.
NOTE: When operating at low temperatures, use the
following procedures to prevent the valve from
sticking, due to heat shock of spool:
5. Do not move main relief valve or overload relief valve
abruptly and successively in case of pilot operation, but
operate the system slowly so that the oil in hydraulic
actuators flows smoothly and increases its temperature
evenly.
6. Do not try minute or composite operation at low
temperatures which may cause heat in some parts.
Load Isolation
System
Edition 1
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
7 8
1 6
FG006718
Figure 1
T X2
MX
3 4
Lifting cylinder
7 2
3
4 1 2
1
B A
8
Control block
FG008846
Figure 2
Reference Reference
Description Description
Number Number
1 LIS Valve (RSM2) 5 Emergency Drain Screw
2 Valve spool 6 Accumulator
3 3/2-way Directional Valve, 7 Lift Cylinder
Solenoid Operated 8 Control Valve
4 Pressure Relief Valve
(EC Design Tested)
CAUTION!
The safety technical requirements of the vehicle have to be
taken into account!
Before carrying out any maintenance work the
accumulators must be unloaded. (zero pressure).
Specification
General
Installation Optional
Ambient Temperature Range - 20 ~ + 80 °C
Weight 15 kg
Hydraulic
Ports A, B 420 bar
Max. Operating Pressure Port X2 350 bar
Port T 30 bar
Max. Nominal Flow Ports A, X2 150 l/min
Pressure Fluid Mineral Oil (HL, HLP) to DIN 51524
Viscosity range 10 ~ 380 mm2/s
Degree of Contamination
ISO 4406 (C) class 20/18/15
(Max. Permissible)
Electrical
Control Voltage 12V , 24V
Power Consumption (Solenoid) 14.4 W
Characteristic Curve
(measured with HLP 68, Oil = 40 ± 5°C)
Figure 3
Figure 4
Reference Reference
Description Description
Number Number
10 Housing 130 Compression Spring
20 Piston 140 Compression Spring
40 Socket 160 Plug
70 Spring Disc 170 Plug
80 Valve Seat 190 Plug
90 Valve Seat 230 Cheese Head Screw
100 Throttle Pin 260 FTWE
110 Grubscrew 270 DBDS
Specification
General
Ambient Temperature
- 53 ~ + 204 °C
Range
Weight 28.7 kg
Hydraulic
Max. Operating Pressure 280 bar
Capacity (Oil) 4 liters
Parts List
Figure 5
Reference Reference
Description Description
Number Number
01 Accumulator Body 08 Gas Valve Body
02 Hydraulic Cap 8A Gas Valve O-ring
03 Gas Cap 09 Protective Strap
04 Piston 9A Protective Screw
05 V O-ring 10 Name Plate
5A Backup Washer 13 Port Protector
07 End Seal O-ring 15 Mounting Bracket Assembly
7A Backup Washer
Cooling
System
Edition 1
Cooling System
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
10 5 9
2
4
6 7 8
FG006719
Figure 1
Reference Reference
Description Description
Number Number
1 Radiator Assembly 6 Transmission
2 Fan Guard 7 Transmission Oil Filter
3 Fan Motor (Rear Side) 8 Block Valve
4 Cooling Fan (Rear Side) 9 Oil Tank
5 Engine 10 Radiator Cap
Figure 2
Reference Reference
Description Description
Number Number
1 Engine 6 Cooling Fan
2 Cooling Pump 7 Temperature Sensor
3 Cooler 8 Temperature Sensor
4 Electronic Unit (ECU) 9 Transmission
5 Fan Motor
Figure 3
1
FG009993
Figure 4
Reference Reference
Description Description
Number Number
1 Fan Motor 4 Drain Line
2 Fan Guard 5 Outlet Line
3 Inlet Line 6 Pressure Check Port
WARNING
A modifying program of the control unit is permitted by an
authorized person.
3 2 1
T
3/4"
19ccr
4
P
1/2"
L
7/16" FG009989
Figure 5
Reference Reference
Description Description
Number Number
1 Motor 3 Prop. Pressure Relief Cartridge
2 Solenoid Operated Spool Valve 4 Check Valve
Figure 6
Reference Reference
Description Qty. Description Qty.
Number Number
1 Front Bearing 1 9 Idler Gear 1
2 Seal 2 10 Valve Cover 1
3 Bearing Block 2 11 Bolt 4
4 O-ring 2 Prop. Relief Valve
12 1
5 Dowel Pin 4 Catridge
6 Gear Housing 1 Solenoid Operated
13 1
Spool Valve
7 Coupling 1
14 Check Valve Catridge 1
8 Drive Gear 1
ON
REVERSE
FAN S/V
OFF
FG005765
Figure 7 Time Chart
Function
The principal function of the pilot operated PRV is controls the
motor speed from idle to max. speed by infinitely adjusting the
applied solenoid current. Further, the PRV protects the motor
from over pressurization. Due to the fail safe function, maximum
PRV pressure is automatically set when solenoid de-energized
(motor runs at max. speed = max. cooling power). Increasing
solenoid current results in decreasing induced spring force,
thereby reducing valve opening pressure (motor speed
decreases). The nominal pressure is factory set, not adjustable.
Because of the pilot operation, the minimal adjustable pressure
drop across the valve is slightly higher than for direct operated
RV at the same flow.
NOTE: In the case of bidirectional motor with pressurized
outlet port, the back pressure is added to the nominal
PRV setting (due to the internal PRV drain).
Screw-in cartridge
• Pilot operated
• Nominal pressure adjustable + 20 % / - 30 %
• Qmax = 100 l/min
• Pmax = 400 bar
• PN max = 200 bar
General Specifications
Hydraulic Specifications
Electrical Control
Figure 8
Figure 9
Reference Reference
Description Description
Number Number
10 Coil KJ35/16 - G24 40 O-ring Viton ID 18.77x1.78
20 Retaining Nut M16x1x9.2 50 O-ring Viton ID 15.60x1.78
25 Hexagon Nut M8x1 60 Backup Ring RD 14.6x17.5x1.4
30 O-ring Viton ID 14.00x1.78
WARNING!
A modifying pressure of the proportional relief valve is
permitted by an authorized person.
Check Valve
The AC check valve prevents cavitation and erosion during
motor speed deceleration and spin-down.
Figure 10
TANK
T
3/4"
19ccr
4
P
1/2"
L
7/16"
FAN MOTOR
5
3
FG009990
Figure 11
Reference Reference
Description Description
Number Number
1 Motor 4 Check Valve
2 Solenoid Operated Spool Valve 5 Cooler Pump
3 Pressure Relief Cartridge
Reference Reference
Description Qty. Description Qty.
Number Number
1 Front Bearing 1 9 Idler Gear 1
2 Seal 2 10 Valve Cover 1
3 Bearing Block 2 11 Bolt 4
4 O-ring 2 12 Relief Valve Catridge 1
5 Dowel Pin 4 13 Solenoid Operated 1
6 Gear Housing 1 Spool Valve
7 Coupling 1 14 Check Valve Catridge 1
8 Drive Gear 1
Pilot System
Edition 1
Pilot System
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
8 1
6 5
7
FG006724
Figure 1
Reference Reference
Description Description
Number Number
1 Oil Tank 5 Main Control Valve
2 Pilot Control Valve 6 Aux. Control Valve
3 Brake & Pilot Supply Valve 7 Pilot Accumulator
4 Pilot Plate 8 Brake & Pilot Filter
Figure 2
Figure 3
Specification
Hydraulic Fluid ISO VG #46 or SIMILAR
Ambient Temperature -29 ~ +93 °C
Hyd. Oil Temperature -20 ~ +100 °C
Vibration 3 -5G/ 30Hz
Shock 10G
Supply Pressure 28 kg/cm2 (398 psi)
Supply Flow 42 lpm
Contamination NAS 9 Grade after Flushing
Reference
Description
Number
P Brake & Pilot Supply Valve
(PL port)
T Tank Return
1 Boom Up
2 Bucket Crowd
3 Boom Down
4 Bucket Dump
5 Option
6 Option
Figure 4
Figure 5
OIL TANK
T B1 B2 a1 a2
P A1 A2 b1 b2
PL
FG006726
Figure 6
Figure 7
Specification
Supply Pressure Max. 100 bar (1450 psi)
Control Pressure Max. 28 kg/cm2 (398 psi)
Breakaway Pressure 4.5 bar
Return-line Pressure Max. 3 bar (44 psi)
Control Flow Max. 15 l/min (4 USgpm)
Hysteresis Max. 0.5 bar (7.3 psi)
Ambient Temperature -40 ~ +60 °C
Hyd. Oil Temperature -20 ~ +70 °C
Leakage Max. 20 cm3/min
(From pump connection to tank with the spool in neutral position and a supply pressure of 40 bar)
System Voltage 24V
Reference
Description
Number
P Brake & Pilot Supply Valve
(’PL’ port)
T Tank Return
A1 Bucket Dump
A2 Boom Down
A3 Aux. (A port)
B1 Bucket Crowd
B2 Boom Up
B3 Aux. (B port)
Figure 8
Figure 9
1Hydraulic
Schematic
(DL250)
Edition 1
Hydraulic Schematic
(DL250)
Safety Precautions ............................................... 5
Applicable Models ................................................ 5
DL250 ................................................................... 7
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
P
2
3/8", Brake P=60–3kgf/cm
T 3/8", Brake P=60–3kgf/cm 2
CLOSES 3 Bar
S TOP
* JOYSTICK VALVE * OPTIONAL EQUIPMENT
(3-SPOOL OPT) Kick-down Horn
OPENS 25 Bar
T/M DISCONNECT
REAR AXLE DUMP CROWD AUTO RETUR N RAISE LOWER OPT OPT
PILOT
TO DI G
T/M D.C D.R D.F
P1 T1 P2 T2
E/G
T
P
R.H Brake pedal
4 3 2 1 5 6
0.46 BAR
30B 30B
15B
0.75L 65bar 0.75L
parking brake
0.32L
(PFO1/4) (PFO3/8) (PFO3/8) (PFO3/8)
TP1 JOYSTICK VALVE
(PFO3/8) A1 LPWS P1 P2 A2 A3 (PFO1/4)
1.5 BAR (STD) Kick-down Horn
C3-1 C3-2
0.5" 28 kgf/cm 2 C4
0.5"
FO SAFETY
20 abs. (PFO1/2)
T
C3 PARK P
(PFO3/8)
2 4 3 1
100 L/MIN FI 120 kgf/cm 2
C1
(PFO1/2)
LPWS
C6 C5
T 160 kgf/cm 2
OIL COOLER 3/4" 3/4" M
PK
1" (PFO1/2)
(PFO1/4)
P
19ccr A4 T1 T2
(PFO3/8) (PFO3/8) (PFO1/4)
30B
P 200 BAR
BRAKE/FAN/PILOT * TUV only 0.75L
PUMP 3/4"
3
19.8 cm/rev L
7/16"
STEER PUMP BRAKE & PILOT & FAN MOTER SUPP LY VALVE
3
63.8 cm/rev
FAN MO TOR BUCKET
LOADER PUMP a1 b1
3
58.3 cm/rev
BUCKET CYL.
BLOCK (DUMP)
VALVE
P1 P3 BOOM
a2 b2
1.25 1.25"
C3 TPM BOOM CYL.
0.25"
<
TPU EF
STEER
O.25" 0.75
UNIT 275 BAR
C1 (LOWER/FLOAT)
C2 A2
P T
140x 80X777 (RAISE)
160 B2
<
(LOWER)
C 4L
PRE CHARGER: 20 BAR
1"
P-controller
HT 0.75 X2 T
B 62 Bar
R2 6B BR
M 10ccr
EMR.STEERING S/W
15BAR 15BAR
CUSHION V/V
< <
FG009991
Figure 1
Air Conditioner
Edition 1
Air Conditioner
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
FG004488
Figure 1
The heater and air conditioner are combined into one blower unit
in the right control stand of operator's seat. If necessary, the
operator can control inner temperature using the operation panel
installed in the top of the right side door.
WARNING!
All service and inspection of the air-conditioning system
should be performed with the starter switch in the "O" AJS0530L
(OFF) position. Figure 2
4
7
3
HBOI020L
Figure 3
Reference Reference
Description Description
Number Number
1 Evaporator 5 Compressor
2 Expansion Valve 6 Blower Fan
3 Condenser 7 Receiver Dryer
4 Condenser Fan
WARNING!
Refrigerant gas is pressurized and sealed in the
air-conditioning system. Special precautions are required
for the proper recharging or release of refrigerant. Release
of refrigerant into the atmosphere is strictly regulated by
law. Make sure that you are in compliance with all mandated
federal, state and municipality requirements, before starting
any service or repair of the air conditioner. Refrigerant gas
used in the system must meet or exceed specifications for
R134a refrigerant, or any subsequently issued
environmentally mandated standard.
FG004455
Figure 4
INPUT
OFF SW
A / C SW
VENT SW
DEF. SW
HEAT SW
FRE SW
REC SW
LOW SW
MID SW
HI SW
COOL SW
WARM SW
HDA6048L
Figure 5
50%
MAX HOT
0%
HDA6049L
Figure 6
LOW RELAY
HDA6050L
Figure 7
COMP OFF
1.5 C 4.0 C
HDA6051L
Figure 8
FG004481
Figure 9
Foot + Rear
FG004482
Figure 10
FG004483
Figure 11
3
5 2
B A
3 II
10 9
15-1 15-2
15 + -
M
14
LED 1~12
7
8 87a
30
3 11 HIGH
5 12 MID
- + 87
M 8 13 LOW
85 86 18 9 REC
19 10 FRE
10 M
15-6
MODE SELECT
23 7 VENT
9 AIR MODE 21 17 DEF
87a
RECIRCLE/FRESH 20 8 FOOT 15-7
30 BLOWER SPEED
M
87 TEMP. CONTROL
85 86 14 3 (WARM)
15 2 (COOL) M
9
2
16
4
5
15-8
4 1
DEF 2 7 1 6
10 M FOOT
3 6
15-9
26 16
CN7 HRS 26P
CN1 AMP MIC 13P + 250 4P
14
11 15
HRS NO.GT7A-26PD-DS 26P AMP MIC 13P
13 13 12 11 10 9 8 7 6 5 4 3 2 1
6 5 4 3 2 1
12 26 25 24 23 22 21 20 19 18 17 16 15 14
13 12 11 10 9 8 7
(CN7) (CN1)
FG004394
Figure 12
Figure 13
WARNING!
Always wear protective glasses and gloves when handling
refrigerant. If refrigerant comes in contact with the skin or
eyes, immediately flush with clean, running water and
consult a physician.
Select a clean and well ventilated area to work.
The refrigerant container is under high-pressure and
should be stored below 40°C (104°F). Be careful not to drop
the container from a high location
The contents are under high-pressure and should not be
used with compressed air or near an open flame.
UNION NUT
TORQUE WRENCH
CORRECT WRONG
WRONG
WRONG
CORRECT
O - RING POSITION
HDA6066L
Figure 14
RECOVER REFRIGERANT
RUN SYSTEM
3. When the manifold gauge dial falls below 3.5 kg/cm2 (50
psi), slowly open the low-pressure valve.
4. Open both the high and low-pressure valves slowly until
the manifold gauge dials indicates 0 kg/cm2 (0 psi).
Reference
Description
Number
1 Handle
2 Hose Connection
3 Mounting Disk
Reference
Description
Number
Refrigerant Leak
1
Detection Device
WARNING!
For accurate refrigerant leak detection, perform leak
detection procedure in a well ventilated area.
Refrigerant Charging
1. Perform the vacuuming procedure, vacuum holding and
leaking tests as described in the proceeding headings.
NOTE: First charge the refrigerant system with 100 g
(3.5 ounces) of refrigerant with the engine off.
Then using the manifold gauges as a guide fully
charge the system with the engine running.
When exchanging refrigerant containers, press
the manifold gauge low side valve to eliminate
air from the charging hose.
Reference
Description 2 3
Number
1 To Compressor 1 4
2 Low-pressure Side
3 High-pressure Side
4 From Receiver
5 Refrigerant Supply
Container
5
2. Charge the system by opening the manifold gauge low HDA6072L
side valve. Figure 21
Initial charge amount: 100 g (3.5 ounces).
WARNING!
When charging refrigerant system with the engine running;
• Always keep refrigerant supply container in the
upright position.
Never open the high side pressure valve.
WARNING!
• When outside temperature is low, warm the
refrigerant supply container with warm water not
exceeding 40°C (104°F). Do not allow water to
come in contact with the charging adapter valve
handle.
• When outside temperature is high, cool off
refrigerant supply container and condenser to aid
the refrigerant charging process.
Reference
Description
Number Figure 22
1 Pressure
2 High-pressure
3 Low-pressure
4 Compressor Stop
Inspection Procedure
1. High-pressure side.
Compressor outlet → condenser inlet → receiver dryer
inlet → air conditioner unit inlet
2. Low-pressure side.
Compressor inlet → air conditioner unit outlet
3. Compressor.
Compressor shaft area, bolt hole area and magnetic clutch
area.
4. Receiver dryer.
Pressure switch and plug area.
5. Connection valve area.
Inspect all valve areas.
Verify all valves are capped to prevent leaking.
Check for foreign material inside of valve cap.
6. Interior of air conditioner unit.
After stopping engine, insert detector probe into drain
hose. (Leave inserted for 10 seconds minimum.)
NOTE: When inspecting leakage from the air
conditioner unit, perform the inspection in a well
ventilated area.
Electrical
System
Edition 1
Electrical System
CAUTION!
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
Symbol Color
W White
G Green
Or Orange
B Black
L Blue
Lg Light green
R Red
Gr Gray
P Pink
Y Yellow
Br Brown
V Violet
BR
E
8
R B+ I
B+
I(L)
REG. - + - +
7
FIELD F+
F-
1
E
GND
FG006702
Reference Reference
Description Description
Number Number
1 Battery 5 Starter Switch
2 Battery Relay 6 Fuse Box
3 Fusible Link 7 Alternator
4 Circuit Breaker 8 Diode
67
11
F ACC
N C
R B
R2
BR
5 R1
3
6
2
4
B A
BR
E
12
R B+ I
12
B+
I(L) - + - +
REG. 10
1
FIELD F+
F-
E
#6
#4
(CONN.1) (CONN.3)
FG006703
Figure 2 STARTER CIRCUIT (1) - WHILE STARTING
67
11
F ACC
N C
R B
R2
BR
5 R1
3
6
2
4
B A
BR
E
12
R B+ I
12
B+
I(L) - + - +
REG. 10
1
FIELD F+
F-
E
#6
#4
(CONN.1) (CONN.3)
FG008325
Figure 3
6
4
2
ACC C B A
B 5
R2 BR
9
R1 BR E
12
CN2-1
7 1
STARTER SWITCH CONNECTION
-
TML D H
PST B BR R1 R2 C ACC
OFF
PREHEAT 10
ON
START +
FG008326
Figure 4 ENGINE PREHEAT CIRCUIT
Reference Reference
Description Description
Number Number
1 Battery 7 Air Heater Relay
2 Battery Relay 8 Engine Control Unit (ECU)
3 Fusible Link 9 Preheat Indicator Light
4 Circuit Breaker 10 Air Heater
5 Starter Switch 11 Engine Thermo Sensor
6 Fuse Box 12 Diode
ACC C
6 B 5 4 2
R2 B A
BR
R1 7
BR
E
1-40
1-05
1-06
1-10
- + - +
1-11 8
1-02
1-03
STARTER SWITCH CONNECTION
1-08
1
TML 1-09 #1~#6
PST B BR R1 R2 C ACC
OFF
PREHEAT 9
ON
START
FG008327
Reference Reference
Description Description
Number Number
1 Battery 6 Fuse Box
2 Battery Relay 5 Diode
3 Fusible Link 8 Engine Control Unit (ECU)
4 Circuit Breaker 9 Injector Solenoid
5 Starter Switch
6
3
9
8
CN1-1
4 2
B A
1
CHARGE CN2-5 4 2 BR
L5
E
6
BUZZER CIRCUIT
8
R B+ I
8
7
B+
10 9 I(L)
13
REG. 7 - + - +
FIELD
10
F+
F-
1
E
GND
FG008328
Figure 6 CHARGING CIRCUIT
Reference Reference
Description Description
Number Number
1 Battery 6 Fuse Box
2 Battery Relay 7 Alternator
3 Fusible Link 8 Diode
4 Circuit Breaker 9 Gauge Panel
5 Starter Switch 10 Control Unit
17 2
+
3
-
B+
16
E
D+C
15 5
20
30 15
20
6
10
40
10 25
5
50 30
0 0
km/h x100r/min
CHECK
STOP
F/R
7
J O
I II
12 10 11 9 8
FG006500
Figure 7
Reference Reference
Description Description
Number Number
1 Instrument Panel 10 Turn Signal Light Switch
2 Battery 11 High Beam Switch
3 Alternator 12 Working Light Switch
4 Speed Sensor 13 Brake Oil Pressure Switch
5 Coolant Temperature Sensor 14 Parking Brake Pressure Switch
6 Fuel Sensor 15 Transmission Cutoff Switch
7 Transmission Oil Temperature 16 Control unit
Sensor 17 Engine Control Unit (ECU)
8 Air Cleaner Indicator
9 Hazard Warning Light Switch
9 8 1 7 2 16 17
30 15
20 20
10 10 18
40
10 25
5
11 19
50 30
0 0
km/h x100r/min
12 20
13 F/R
21
14 15 4 5 6 22
HOURS
1
10 3
Figure 8
1 25 24
R B+ I B A
CN1 AMP MIC 13P
+ SIG CN1-4
SPEED -
B+ BR
I(L) E
+ S CN1-3
TACHO -
REG. 9
+ S CN1-6
WATER - 11 FIELD F+
TEMP F-
+ S CN1-7 E - + - +
FUEL - 12 12V 150AH 23 12V 150AH
+ S CN1-8 GND
T/M OIL
TEMP
- CN1-13 13
10 27
2-3 1-4 CN3-8 3
HOUR 1
26
2
2-4 2-1 CN3-1
CN3-4
CN3-3 21
2
ILLUMINATION
CN1-9
CN1 AMP MIC 13P
CN1-1
CHARGE CN2-5 3 1
L5
SPARE CN2-4 4 2
L4
MIRROR HEATING CN2-12
L12 BUZZER CIRCUIT
BRAKE OIL PRESS
L10
CN2-10 6
8
3
PARK BRAKE
L16
CN2-16 7 22
AIR CLEANER CN2-2 87a
L2 4 30
SPARE CN2-3 10 9 87
L3
F/R SELECT CN2-11 13 85 86
L11
REVERSE FAN CN2-13
L13
CN1-10 20
WORKING
L9
CN2-9 8
TURN SIGNAL (R)
L8
CN2-8 7
TURN SIGNAL (L)
L6
CN2-6 6
HI BEAM
L7
CN2-7 5
ELEC. STEERING CN2-14
L14 36
EMG STEERING CN2-15 14
L15
CN1-2 7 19
PREHEAT CN2-1
L1
CN1-5
E/G DIAGNOSTIC CN2-17
L17 1-13
CN1-11
1-56
CN2 AMP MIC 17P
1-22
15
14 1-56
1-33
18
17 FG008329
Figure 9
Instruments
Sensor Specification
Function Display Input
Input Specification
Terminal
10 km/h- 704 Hz
20 km/h- 1407 Hz
30 30 km/h- 2111 Hz
20
40 CN1-4 40 km/h- 2814 Hz
Speedometer 10
CN1-5 *ƒ = 70.36 V [Hz]
50
0 km/h ƒ : Frequency of T/M
Controller
v : Speed [km/h]
500 rpm - 100 Hz
1000 rpm - 200 Hz
15
20 1500 rpm - 300 Hz
10
2000 rpm - 400 Hz
Tachometer 25 CN1-3
5
2500 rpm - 500 Hz
30
0 *ƒ = 0.2 N [Hz]
x100r/min
ƒ: Frequency
N : Engine rpm
ALTERNATOR "I"
Hour Meter
Terminal voltage (24V)
HAOA601L
(1/2)
EMPTY FULL
EMPTY - Above 90 Ohm
Fuel Level
CN1-7 1/2 - 38 Ohm
Gauge
FULL - Below 10 Ohm
120 C
50 C 150 C
50°C - Above 188 Ohm
Transmission Oil
Temperature CN1-8 120°C - 21 Ohm
Gauge
150°C - Below 0.7 Ohm
Input
Description Symbol Operation Remarks
Terminal
Lights up while the
air heater is heated.
Forward /
Reverse F/R CN2 - 11
Initial Operation
Input
Item Output (Operation and initial setting mode)
(Terminal)
Initial Operation CN 1-1 • All warning lights are turned "ON" and turned "OFF" after 2
seconds.
(Except for turn signal indicator, high beam indicator,
working light indicator and transmission cutoff indicator and
emergency steering indicator.
• Warning buzzer is activated and turned "OFF" after 2
seconds.
• Monitoring system displays present condition.
5
1
2
MIRROR HEATING
L12 6
AIR CLEANER
L2 7 8
F/R SELECT 3 1
L11
REVERSE FAN 4 2 I
L13
CHARGE
L4
6
BUZZER CIRCUIT 3
L5
7 8
87a
BRAKE OIL PRESS
L10 30 4
PARK BRAKE 10 9 87
L16
13 85 86
13 12 11 10 9 8 7
FG008076
Figure 10
Reference Reference
Description Description
Number Number
1 Instrument Panel 7 Pilot Buzzer
2 Starter Switch 8 Alternator
3 Forward Lever Switch 9 Brake Oil Pressure Switch
4 Reverse Lever Switch 10 Parking Brake Pressure Switch
5 Fuse Box 11 Alarm Relay 2
6 Control Unit
Characteristic of Operation
Input Output
All warning lights are turned
1 When the starter switch is "ON." "ON" and turned "OFF"
after 2 - 2.5 seconds.
Battery warning light turns
is below 12 ±1 V
When "I" terminal voltage of "ON," L5
2
alternator Battery warning light turns
is above 12 ±1 V
"OFF," L5
Warning buzzer sounds
Brake oil pressure switch is "ON."
immediately
When "I" terminal voltage of
3 Forward or Reverse lever switch is "ON"
alternator is above 12 ±1 V Warning buzzer sounds
and Parking brake pressure switch is
immediately
"ON."
6
+ (R) -
P
+ (F) -
P
1
7
2
CN5-6 15(53a)
CN5-8 53c
CN4-2 H
CN5-7 J
H CN5-3 53b
L CN5-1 53
87a CN5-4 31b
S
5 LO 30
TML J 0 I II OFF ON OFF ON
HI 87
M SW WIPER WASHER HORN
STOP B 86 85
- RUN
E
3
4 1
2
5 4 3
FG004463
Figure 11
Reference Reference
Description Description
Number Number
1 Fuse Box 2 5 Wiper Motor
2 Wiper Washer Switch 6 Washer Tank
3 Wiper Relay 7 Diode
4 Wiper Timer
3
B
+
STOP RUN E
2
M L 2
4 II
-
S 6 0
5 I 7
10 9
5 5
5
+ (R) -
P
+ (F)
P
- 4
FG004464
Figure 12 REAR WINDSHIELD WIPER 1ST ACTION CIRCUIT
Reference Reference
Description Description
Number Number
1 Fuse Box 1 4 Washer Tank
2 Wiper/washer Switch 5 Diode
3 Wiper Motor
3
B
2
+
STOP RUN E
M L 2
4 II
-
S 6 0
5 I 7
10 9
5 5
5
+ (R) -
P
+ (F) - 4
P
FG004465
Figure 13 REAR WINDSHIELD WIPER STOP CIRCUIT
Reference Reference
Description Description
Number Number
1 Fuse Box 1 4 Washer Tank
2 Wiper/washer Switch 5 Diode
3 Wiper Motor
Light Circuit
22
87a
30 28
87 87a 29
30 87a
(RR) 85 86 87 30
87
(FR) 23 85 86
85 86
19 (RL) 21
20 1
5 0
(FL) 7 6 I 2
(CR)
10 9 3 II
24 9 10 27 -
18 (CL)
18 +
17
1
CN2-9 L9 WORKING
CN2-7 HI BEAM
L7
CN2-6 TURN SIGNAL (L)
L6
CN2-8 TURN SIGNAL (R)
L8 B 26
CN1-2
2 E B ACC
7
L
1 8 3
10 11 5 87a
30
7 87 0
6 I 2
2 85 86
6 3 II
1 5 4 6 3 2 2 3 6 4 5 1 8 9 10
10 9
(clearanc)
(turn sig)
(turn sig)
18 TML N
(high)
(high)
(low)
(low)
CN4-8
49a
CN4-4 R
CN4-1 L
CN4-5
56
4
CN4-6
56b
CN4-7
56a
CN4-9
15/1
25
(clearanc)
(clearanc)
(back up)
(back up)
(turn sig)
(turn sig)
(stop)
(stop)
9
C A B E F D D F E B A C 87a
30
87
F
14 16 15 85 86
R
5
FG004467
Figure 14 LIGHT CIRCUIT
30
20
40
7 10
0 50
Km/h
e-doctor
ECU
1
14P
10
3 2 1
7 6 5 4
11 10 9 8
14 13 12
FG005280
Figure 15
Reference Reference
Description Description
Number Number
1 ECU (Engine Control Unit) 7 Tacho Meter
3 Electronic Accelerator Pedal 8 Transmission Controller
4 Engine Diagnostic Connector 10 Fuse Box
5 Engine Check Warning Light
36 53
3 2 1
7 11 54 71
7 6 5 4
1 6 72 89
11 10 9 8
14 13 12
ECU
ENGINE VEHICLE
CONN CONN
GAUGE PANEL
3 2-32 1-30 0.5BW DIAGNOSTIC LAMP (-)
OIL PRESSURE P& 4 2-27
SENSOR 1-22 0.5YB DIAGNOSTIC LAMP (+)
(ODFT)
t 1 2-42 PREHEAT LAMP (- )
1-56 0.5LB
(0 281 002 420) 2 2-28
V CIRCUIT BREAKER
+ FUSE 2 (1)
1-33 0.5WG TACHO S
- TACHO
3 2-33 10A
BOOST PRESSURE P& 4 2-34
SENSOR 1-65 0.85YR
(LDFT)
t 1 2-25
(0 281 002 576) 2 2-36
V
ECONOMIC-MODE SW
1 2-23 1-62 0.85YL 1
5
CRANKSHAFT SPEED SENSOR N 2 2-19 7
(TONE WHEEL WITH SLOTS ) ACCELERATOR PEDA L
(0 281 002 662)
V 1-77 0.5R A 10 9
0.5B
1-79 0.5G B PT POSITION
2 2-09 SENSOR
1-78 0.5B C
CAMSHAFT SPEED SENSOR N 1 2-10 1-48 0.5Or E IDLE
(TONE WHEEL WITH PINS ) VALIDATION
(0 281 002 662) V F
0.5BL D
1 2-15
COOLANT TEMPER ATURE t 1-29 0.5BL 0.5BL
2 2-26
SENSOR V
FUEL TEMPER ATURE 2 E/G EMERGENCY S TOP S W
SENSOR
t 2 3
1 2-35 1-87 0.5R
(0 281 002 209) V
DIAGNOSTIC SW
3 2-13 0.5BL
1-85 0.5WB 1
RAIL PRESSURE SENSOR P 2 2-14 5
(RGS3) 7
(0 281 002 534) V 1 2-12
0.5B 10 9
(CONN.2)
1-35 0.5Y CAN B H
(CONN.3) (CONN.1)
GROUND TO FRAM E
FG006729
Figure 16
14P
3 2 1
7 6 5 4
11 10 9 8
FG005201
14 13 12
Figure 18
Figure 19
FG004339
Figure 23
ACCELERATOR ASS’Y
A 0.5R
POSITION PT B 0.5B
SENSOR
C 0.5W
IDLE E 0.5G
VALIDATION
F 0.5L
D 0.85Or
FOOT PEDAL
DETAIL "A"
D A
E B
"A"
F C
HI
Sig 3 LO
Sig 2 HI LO
PEDAL SENSOR IDLE VALIDATION SW. 100%
Diagnostic
Region
WHITE BLACK RED BLUE ORANGE GREEN 91%
OV C B A +VE F D E
C.W. C.W. 73%
70.63%
E
C THROTTLE POSITION RETURN WHITE 3%
F 0%
Diagnostic
D COMMON 48.3 W.O.T
0 Datum -2.7
ORANGE
-15.2
-11.9
-7.4
45.8%
53.3 MIN
58.3
D Region
-5.2 C.T
Degrees Travel
44
Outline
It controls the speed of cooling fan according to temperature of
coolant or transmission oil.
Its reverse rotation function can be used for cleaning.
Information on temperature of coolant and transmission oil are
sent to the cooling fan controller via communication line (CAN).
9 10
3
1
4
ECU
5
6 3 1
4 2
7
11
FG005241
Figure 25
Reference Reference
Description Description
Number Number
1 Cooling Fan Controller 8 ECU
2 Reverse Rotation Lamp 9 Transmission Controller (TCU)
3 Cooling Fan Reverse Switch 10 Transmission Oil Temperature
4 Cooling Fan Proportional Valve Sensor
5 Reverse Rotation Solenoid 11 Coolant Temperature Sensor
6 Fuse Box
7 Fan Check Connector
14
6
15 13
ACC C B A
B
AMP 040 36P R2 BR
R1 BR E
10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11 16 15 14 13 12 11 10 9 16 17
(CN12) (CN11)
- + - +
2 12
CN1-1
CN2-13
L13
9
10
8
1-35 J1939 (+) 25
1-34 J1939 (-) 26 120 OHM
1-33 27
1-53 28
1-52
1-51
11
1
CN11
CN12-1
CN12-4
CN11-1 CN12-2
4
CN11-2
5
CN11-3 CN12-11
6
7 11
CN12-12
BATTERY (+) CN11-4
1
12 CN11-5
BATTERY (-) 2
13
18 3
CN11-6 3
CN11-7 CN11-13 1
4
5
CN12-13 7
4 CN12-14
10 9
CN12-19
5 CN12
FG005183
Figure 26
Reference Reference
Description Description
Number Number
1 Cooling Fan Controller 10 Transmission Oil Temperature
2 Reverse Rotation Lamp Sensor
3 Cooling Fan Reverse Rotation 11 Coolant Temperature Sensor
Switch 12 Battery
4 Cooling Fan Proportional Valve 13 Battery Relay
5 Reverse Rotation Solenoid 14 Fuse Lamp Link
6 Fuse Box 15 Circuit Braker
7 Engine Diagnostic Connector 16 Start Switch
8 ECU 17 Diode
9 Transmission Controller (TCU) 18 Fan Check Connector
Figure 28
FG004939
Figure 29
Figure 30
FG004492
Figure 31
Communication Monitoring
1. Communication port
A. SAE J1939 datalink
B. CAN H, CAN L, SHIELD
2. Communication failure
A. E0, E1, or E2 is shown on the controller display.
B. If there shows no error message, it means normal
operation.
Current Current
< Transmission Oil Temperature vs. current > < Coolant Temperature vs. current >
FG008075
Figure 32
Rotation
LED
All the segments light up for one second when power is first
supplied to the controller.
Block Diagram
3
5
6
8
4
FG004925
Figure 33 EMERGENCY STEERING SYSTEM BLOCK DIAGRAM
Reference Reference
Description Description
Number Number
1 Fuse Box 6 Emergency Steering Indicator
2 Emergency Steering Switch 7 Transmission Controller
3 Emergency Steering Timer 8 Battery
4 Emergency Steering Pressure 9 Main Steering Pressure Switch
Switch
5 Emergency Steering Pump
When the speed of the vehicle exceeds 5 km/h and the main
steering pressure is less than 3 kg/cm2, an electrically powered
hydraulic pump will be operated for a time limited 60 seconds
and thus the emergency steering is possible.
This system includes the electrically powered hydraulic pump,
which is controlled by the emergency steering timer (3). The
emergency steering timer (3) obtains signals from the main
steering pressure switch (9) and the transmission controller (7).
When the emergency steering is activated, the emergency
steering indicator (6) light turns "ON."
operation is following.
FG004921
Figure 34
4
A B
5 C
1 4 D
S0
6 S3
8
7 S1 3
2
7
1
8 S2 6
E1 (28V) 9 S4 9 5
SPEED
3
FG004923
Figure 36
Reference Reference
Description Description
Number Number
1 Emergency Steering Timer 6 Starter Switch "START"
2 Emergency Steering Indicator 7 Main Steering Pressure Switch
3 Transmission Controller (TCU) 8 Emergency Steering Pressure
4 Emergency Steering Pump Switch
5 Starter Switch "ON" 9 Emergency Steering Switch
AJS0480L
Figure 37 EMERGENCY STEERING PUMP
I
WARNING
AJO0011L
Make sure that no persons are near the machine when Figure 38 EMERGENCY STEERING
testing the function of the emergency steering system, SWITCH
there is a risk that someone may be crushed between the
front and the rear frame.
A
11
C
5
- + D P
8
E
2
1 10 5 1
0
2 I 6 9 10
II 3
10 9
4
9 3
4 3bar
1 7
6
8
10bar
3
C 7
ACC 36 2
B 9 5 6
12
FG004924
Figure 39 EMERGENCY STEERING SYSTEM CIRCUIT
Reference Reference
Description Description
Number Number
1 Fuse Box 8 Diode
2 Emergency Steering Switch 9 Transmission Controller
3 Emergency Steering Timer 10 Headlight Switch
4 Main Steering Pressure Switch 11 Battery
5 Emergency Steering Pump 12 Starter Switch
6 Emergency Steering Indicator 13 Emergency Steering Pressure
7 Emergency Steering Pressure Switch
Switch
Electric Circuit
7 2 87a
11 30
87
10
+ 2 85 86
O 1
-
5 12
7
10 9 4
8
1 6
12
87a 3 87a
30 10 30
87
11 87
+ 85 86 86
O
12 85
- 12
1
9 5 3
+
O
-
FG004461
Figure 40 ELECTRIC DETENT CIRCUIT
Reference Reference
Description Description
Number Number
1 Fuse Box 2 7 Float Magnetic
2 Float Kick-out Switch 8 Return to Dig Magnetic
3 Raise Relay 9 Raise Proximity Switch
4 Float Relay 10 Float Proximity Switch
5 Return to Dig Relay 11 Return to Dig Proximity Switch
6 Raise Magnetic 12 Diode 3ea
HA0O2027
Figure 41
MAIN POWER
CIRCUIT
AJS0510L
Figure 42
1Electrical
Schematic
(DL250)
Edition 1
Electrical Schematic
(DL250)
Safety Precautions ............................................... 5
Applicable Models ................................................ 5
DL250 ................................................................... 7
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
DIODE 3
L4 B 23D 18B
0.85L CIGAR LIGHTER 11C 4C
AMP 040 36P REAR WIPER SW
P E
+
CHARGE CN2-5 107A 0.5W 0.5W 107B 3 1 26B 0.85R STOP RUN E 0.85B (2549-9129 ) (545-00001) 1.25WG
L5 2RW 0.85BY
+(2190-2036D18) 11B
10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 ECU CON.3 (16-PIN) ECU CON.2 ( PIN) (ENG MAINTENANCE) CN2-3 4 2 9C 0.5RW M L 24A 0.85LW 1.25B 0.85B
TIME DELAY 0.85LW 24C 4 II 2 0.85B 0.85WL 209B CC-TV - 0.85BY
20 19 18 17 16 15 14 13 12 11 16 15 14 13 12 11 10 9 CYLINDER
CONN. ENGINECONN. L3
- DA2-1 4P CONN(1)
BRAKE OIL PRESS CN2-10 110A 0.5YL 0.5YL 110B 6 S 181B 0.85Y 1.25W 1.25W + 3W
5 1 0.85YB 25A 6 0
L10 BUZZER CIRCUIT
1.25WR
0.85WL
(CN12) (CN11)
1.25RB
1.25RY
0.85RY
1.25W
181A 25B 7 0.85B
0.85L
32D 5 151B
2RG
2RW
111A 111B 7 I
2RY
PARK BRAKE CN2-16 0.5Lg 0.5Lg
0.85RG
L16 24B 10 1.25WR 1.25WR
REAR WIPER MOTOR 9
CN1-10 115A 0.85LR 8 57B 0.5BrW (2538-9005 ) 2 60E 0.5WR 3Y
197A 143A 152A 20A 106A 14A 23A 41A 114A 209A 151A 81A 6A
EMG STEERING (OPTION) ELEC. STEERING CN2-14 187F 0.5LY 0.85B 13
DA2-2
6 0.5B EMG STEERING
11D STARTER
(65.26201-7044)
L14 DA2-3 9 10 11 12 13 14 1 2 3 4 5 6 7 8 8
B 0.85L 23C 32B 0.85BR 32C 0.85BR TIMER
7 3 5B C 24V 4.5KW
EMG STEERING CN2-15 205B 0.5RW 0.85LR 115B 10 9 183B 0.85LB 30A 20A 15A 15A 15A 15A 10A 10A 10A 10A 10A 10A 10A 10A
L15 2WR 2WR 2WR
A 60R B
STARTER 149C WINDOW WASHER 17 18 2C 15 16
WORKING CN2-9 0.5RL 0.5RL 0.5RL 123B 0.85RY 4G 5W 5W 4D 2B B
C 13G 0.85LR L9 (4916-9006 ) 15R 157A
EMG STEERING PUMP 0.5GR 0.5GR HORN (H)
13H TURN SIGNAL (R) CN2-8 84C 0.5GR H.F 0.85B 0.85RG
(401-00127A) P D 207A L8 0.85L 23B + (R) - 32A 0.85BR (516-00014 ) FUSE BOX 2 FUSE BOX 1
0.85W 0.5GL 0.5GL P 5W 5W BLINKER 60R
1.25WR
(K1006678 ) (K1006678 )
0.85LR
0.85BY
DIODE 5 TURN SIGNAL (L) CN2-6 85C 0.5GL UNIT
EMG STEERING SW L6 0.5R 0.5R 81B
4F 60BC 4E B (2525-1011 )
60B E 0.85BR 96B + (F) - 0.85B 123C 0.85RY 11A
(2549-9110 ) 207B 15 16 0.85WR 17 18 15B 3WR
HI BEAM CN2-7 87B 0.5R 110C P HORN (L) ACC
+(2190-2036D21) L7 0.85YL 0.85B L.F 0.85B E 0.85B C A
BRAKE OIL PRESS SW (516-00015 )
65bar 10A 10A 10A 10A 10A 10A 10A 10A 30A 20A 15A 15A 15A 15A 13A
CN1-2 0.85B (2549-9093 )
0.85B 1 5 206B 0.85BR 111C 0.85BR 96C 8 4 0.85B B
0.85Lg 0.85B 1 2 3 4 5 6 7 8 9 10 11 12 13 14
PARK BRAKE PRESS SW L 10A BR 60B
PREHEAT CN2-1 153C 0.5WL 65bar 82A 6B 0.85Br
10 9 60M 0.5WR L1 (2549-9093 ) DA2-4 26A 89A 33A 184A 92A 16A 17A 63A 59A 45A 105A 19B 19A R2
0.85BR 0.85BR 0.85GY 7A
0.5B CN1-5 113A 0.5LB
0.85WR
0.5G
0.85WL
1.25R 1.25R
0.85LB
R1 FUSIBLE LINK 2
0.85RW
0.85LR
0.85BR
1.25LR
E/G DIAGNOSTIC CN2-17 108B 0.5YB 1.25RB 1.25RB 2RW STARTER SWITCH (2527-1023A)
2RG
2RW
2RW
2RL
2RL
9 206A L17
MAIN STEERING 0.85YB 0.85YB 0.85YB (K1001654A) 3WR 3R
2RW
PRESS SW 208B 0.85WB 208A 3 4 207C 0.85W CN1-11 156A
0.85B 0.85LR 0.85LR 0.85LR 5W 5W 5W 15A 1C
(2549-1135D11) EMG STEERING 0.5BW 0.5G
3bar 1 13F 0.85LR CN2 AMP MIC 17P 2WR 0.5RW 0.85Br
TIMER FLOAT RELAY FUSIBLE LINK 1
EMG STEERING 0.85B 204B 0.85WG 204A 6 8 11D 0.85BY C
(537-00039B) STARTER SW (2544-9033 ) 2LR 2LR (2527-1023A)
PRESS SW 10bar 7 205A 0.5RW 0.5RW
0.85B 5 34C 87a 0.85RW 0.85RW 0.5RW 2WR 2R
(K1018277) 0.85RY 0.85RY 30 33B 0.85RB 0.85Br
2 27C 0.5G 0.5G 34A 87 2RL 2RL 2RL 1.25LR 7B 60R 2A 1B
7
ELECTRIC STEERING 0.5LY DA1-3 2 0.5G
3 0.85RY 85 86 33C 0.85RB STOP LAMP SW (L) 0.85WL 0.85WL
EMG STEERING 0.85LR 11 3W
34B 0.85GW 88A 89B 0.85GY 1.25RG DIODE 2 CIRCUIT BREAKER BATTERY RELAY
174A 2R 3R
DIAGNOSTIC(-) 0.5BW 34B’ 5bar (2527-9004 ) (2544-9024 )
0.85WR 0.85WR 0.85WR
FLOAT 8A
ELECTRIC STEERING (OPTION) 1/2 DIAGNOSTIC(+) 0.5YB
MAGNET
(549-00010)
0.85GY 5W 8W 8W
B A
HEAD LAMP(L) HEAD LAMP(R) HORN RELAY
0.85RG
PREHEAT(-) 0.5LB 1
1.25LR
0.85LY 83A HEAD LAMP RELAY LAMP SWITCH
0.5RW
0.5RW
0.5LY 0.5LY (K1005906 ) (K1005907 ) (2544-9033 ) 4B 3B 3A
2RW
2RW
5 82B
2LR
PREHEAT(+) 0.5WL 0.85GY (2544-9033 ) (2549-9109 ) 1A
21W 3W 70W 70W 70W 70W 3W 21W 0.85RY 0.85LB 1.25BrW
SAUER-DANFOSS SUPPLY PART
ELEC. STEERING RELAY 1
NC
C ELECTRIC STEERING 0.85YB
FLOAT KICK-OUT ASSEMBLY (OPTION) 87a
30 92B
7
87a 1.25RG +(2190-2036D4) 1.25BrW 8C BR
0.5WL
0.85YL O 173B 0.85W 60B 9 10
0.85LY
187C 60B 60R
0.85B
0.85B
190A 3 85 86 187A 87 5 174B 0.85RY 0.5B 10 9
0.85WR
185D
0.85WR
0.85WL
0.85WL
0.85GR
0.85GL
- 0.85B
0.85RW
0.85RW
7 0.5WR DIODE 1
0.85R
0.85R
187B 85 86 0.85LgB 185B 0.85LB 196B
0.85WR
0.85WR
CC-TV
0.85WL
0.85WL
60U
0.85BR
0.5BrW
0.5B
0.85RW
0.5GR
0.5BrY
0.85G
0.5GL
0.5GL
7 0.5B 186E 186B 10 9 60 HAZARD SWITCH
0.5R
PROXIMITY SW 0.5B 4P CONN(2)
2RL
0.5WR 9B
(clearanc)
0.85Lg 3 190B (4549-1148 ) (2549-9138 )
(clearanc)
(turn sig)
ELEC. STEERING SW - + - +
(turn sig)
187G 0.5B 83C 83D SW TURN SIGNAL HEAD LAMP
(high)
(high)
(low)
+(2190-2036D2)
(low)
0.85LgR 2 189B 8 0.85LY (RAISE) 1 2 12V 100AH 12V 100AH
0.85B 0.85LgB DA3-1 TML N
0.85LgW 1 188B + 33K 0.85RB 0.85RB 3 4 DA3-2
0.85GY 82C CN4-8
0.85LY 0.85LY 0.85RY 49a BATTERY
PVED O 38B 0.85RY 85B 84B
0.5GR 0.85GR 0.85GR 84A CN4-4 (2506-1104 )x2
4 163B J1939 (+) 0.5Y R
- 0.85B
RETURN TO DIG RAISE 0.85GL 0.85GL 0.85GL 85A CN4-1 AVX 8W
5 164B J1939 (-) 0.5YB RETURN TO DIG RELAY L COMBINATION
MAGNET RAISE RELAY MAGNET
0.85RW 0.85RW 1.25WY 62B CN4-5 SWITCH (R) AVX 1.25WG
6 165B J1939 DATALINK SHIELD (2544-9033 ) (2544-9033 ) 37A 56
(RETURN TO DIG) 1 0.85G 87a 33F 33D 87a 0.85R 3 0.85R 0.85R 0.85RW 86A CN4-6 (4549-9418) 0.5RW AVX 2RW
12 30 0.85RB 30 56b
+ 33L 0.85RB 0.85B 0.85RB 10 0.85R 87A CN4-7
35B 37B 0.85WR
35A 87 87 56a 9A 4A 18A
ECU O 36B 0.85WG 35B’ 37B’ 0.85RG 59C CN4-9 0.85WL
0.85GW I B+ R
(539-000 ) 85 86 0.85RB 0.85RB 86 85 15/1
- 0.85B 0.85LB 92F CN5-6 15B
1.25LR
2 6 0.85RY 0.5LB 0.5 uF
0.5RW
36A 33G 33E 38A 5 1 15(53a)
0.5Br
2RW
2RW
2LR
(clearanc)
ENGINE VEHICLE 35C 96A CN5-8 153B 157B
(turn sig)
37C 0.85BR 0.85BR B+
(stop)
DA1-2 53c
0.85WL (clearanc)
CONN CONN DA1-1
(back up)
PROXIMITY SW C B
(stop)
0.5BrY 0.85BrY 95B CN4-2 -
3 2-32 0.85WG 0.85B H
156B 1-30 0.5BW DIAGNOSTIC (-) (4549-1148 )x2 0.85RB 0.85B 0.85B I(L)
OIL PRESSURE P& 4
0.85WR
HORN SWITCH 2 0.5BL 94A CN5-7
200A
2-27 108A 1-22 0.5YB DIAGNOSTIC (+) J
0.85GW
0.85GR
0.85WR
SENSOR 0.5WR 0.5WR
0.85GW
t 0.5WR H 97B 97A CN5-3
0.85RY
92D 95A 0.85BrY 0.85RY
(ODFT) 1 2-42 113B 1-56 0.5LB PREAEAT (-) 53b REG.
0.5BrW 0.5BrW 0.85B TRIO DIODE
(0 281 002 420) 2 2-28 28B 1-33 0.5WG TACHO
LIS ASSEMBLY (OPTION) 85E 88B 16B 58C 60X 58D 17B 88C 84E 0.85LB 4 9
43A
L 98B 0.85YB 98A CN5-1
53
V SAFETY START RELAY BACK UP RELAY
C A B E F D D F E B A C 0.85W 0.85BrL 100B CN5-4 FIELD
LIS SELECT SW (2544-9033 ) (2544-9033 ) (ON JOYSTICK)-L S 101A 0.85Y 31b F+
LIS SOL-VALVE (549-00083 ) LO
0.5BrW 57A 87a 87a TML J 0 I II OFF ON OFF ON 154A D H
+ F-
3 2-33 (K ) 0.85LY +(2190-2036D3) 30 45B 0.5RL 45D 30 HI
DOWN SHIFT SW 15L E
BOOST PRESSURE P& 4 2-34 127C
87 87 58A 0.85RY
21W 21W 5W 21W 21W
M STOP SW WIPER WASHER HORN 0.85BG
SENSOR 0 92E
t 3 33J 85 86 45C 0.5RL 0.85WL 41B 46A 0.85V B 0.85L 172A 172B
127B 0.85RB 0.5Gr 145A 0.5P 85 86 45E 0.5RL LICENCE LAMP RUN
-
(LDFT) 1 2-25 5 I REAR COMBI LAMP REAR COMBI LAMP 1 GND
(K1005717 ) 5 8 0.5BL 94B PREHEAT RELAY ALTERNATOR 99
(0 281 002 576) ACCELERATOR PEDAL 146A (K1003561 ) (K1003561 ) E 0.85B AIR HEATER
2 2-36 124A 1 II (544-00007 ) 8B
V 0.85LY (ON JOYSTICK)-R (2502-9007B)
2RL
9 60 0.5BL 94C 2
0.5B 10 0.5WR 0.85RL 0.85RY 58B 101B 87a WIPER TIMER 24V 60A
160A 1-77 0.5R 160B A + PILOT CUT OFF SW
LIS RELAY WIPER MOTOR 30 100A 0.85BrL 94D ALTERNATOR 80A(OPTION)
1 2-23 0.85B - (2549-9098 ) 0.5BL 3 (2537-9002 )
161B 1-79 0.5G 161A B (2544-9033 ) 0.85WG (4538-9017 ) 0.85LB 92C 87 (502-00003)
CRANKSHAFT SPEED SENSOR N 2 2-19
PT POSITION
SENSOR
0.5P +(2190-2036D17)
162B 1-78 0.5B 162A C 87a 0.85RY 146B 5 14 56A PILOT CUT OFF 0.85W AIRCONINIT
(TONE WHEEL WITH) SLOTS BACK BUZZER 44B 0.85BW 44A 1 1 85 86 93B
SOL-VALVE 0.5B 0.5L 93A 4 (4920-9050A)
(0 281 002 662)
V 158A 1-48 0.5Or 158B E IDLE
30 33H 0.85RB 0.85RB
0.5Gr 145B 52 23 14C 0.85RW (2516-1124 ) 5 41C 0.85WL 0.85WL 41D 5
127A 87
VALIDATION DA5-1 7 7 42A 0.85Or 0.85Or PARKING BRAKE 0.5B 5 BLOWER
F 0.85RY 124B 30 68 14D 0.85RW WIPER RELAY 15
126A 85 86 125B 0.85LR 1 3 44C RELEASE SOL-VALVE 2LR 63D + -
2 42B (2544-9033 ) M
2-09 0.5BL 169A D 0.85LR 125A 8 36 27B 0.85G 0.85B 10 9 60F 0.5WR 0.5WR 60G 9 10 0.5B
N 2RW 0.85LR 63E 14
CAMSHAFT SPEED SENSOR 1 0.5B
2-10 0.85LR 125C 53 45P 3 DA5-2
(TONE WHEEL WITH PINS
) 169D 0.85RL 2RW
1-29 0.5BL 0.5BL 0.85BL 0.85BL 42C
(0 281 002 662) V 0.85BL 126B 57 TRANSMISSION 62 141A 0.85YR 0.85YR 141B 2 SPEED SENSOR PARKING BRAKE SW
4 2
FG006730
Figure 1