SECTION 1 GENERAL

GROUP 1 SAFETY HINTS

FOLLOW SAFE PROCEDURE
Unsafe work practices are dangerous. Understand
service procedure before doing work; Do not
attempt shortcuts.

WEAR PROTECTIVE CLOTHING

Wear close fitting clothing and safety equipment
appropriate to the job.

WARN OTHERS OF SERVICE WORK

Unexpected machine movement can cause
serious injury.
Before performing any work on the wheel loader,
attach aDo Not Operatetag on the right side
controller lever.

WARN
DO
NOT
OPERATE

USE HANDHOLDS AND STEPS

Falling is one of the major causes of personal injury.
When you get on and off the machine, always
maintain a three point contact with the steps and
handrails and face the machine. Do not use any
controls as handholds.
Never jump on or off the machine. Never mount or
dismount a moving machine.
Be careful of slippery conditions on platforms,
steps, and handrails when leaving the machine.
1-1

PREPARE FOR EMERGENCIES

Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors,
ambulance service, hospital, and fire department
near your telephone.

WORK IN CLEAN AREA

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

PROTECT AGAINST FLYING DEBRIS

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

PROTECT AGAINST NOISE

Prolonged exposure to loud noise can cause
impairment or loss of hearing.
Wear a suitable hearing protective device such as
earmuffs or earplugs to protect against
objectionable or uncomfortable loud noises.

1-2

PARK MACHINE SAFELY

Before working on the machine:
Park machine on a level surface.
Lower bucket to the ground.
Turn key switch to OFF to stop engine. Remove
key from switch.
Move pilot control shutoff lever to locked position.
Allow engine to cool.

SUPPORT MACHINE PROPERLY

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

SERVICE COOLING SYSTEM SAFELY

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

HANDLE FLUIDS SAFELY-AVOID FIRES

Handle fuel with care; It is highly flammable. Do
not refuel the machine while smoking or when near
open flame or sparks. Always stop engine before
refueling machine.
Fill fuel tank outdoors.

1-3

Store flammable fluids away from fire hazards. Do

not incinerate or puncture pressurized containers.
Make sure machine is clean of trash, grease,
and debris.
Do not store oily rags ; They can ignite and burn
spontaneously.

BEWARE OF EXHAUST FUMES

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

REMOVE PAINT BEFORE WELDING OR

HEATING
Avoid potentially toxic fumes and dust.
Hazardous fumes can be generated when paint is
heated by welding, soldering, or using a torch.
Do all work outside or in a well ventilated area.
Dispose of paint and solvent properly.
Remove paint before welding or heating:
If you sand or grind paint, avoid breathing the
dust. Wear an approved respirator.
If you use solvent or paint stripper, remove
stripper with soap and water before welding.
Remove solvent or paint stripper containers and
other flammable material from area. Allow
fumes to disperse at least 15 minutes before
welding or heating.

1-4

ILLUMINATE WORK AREA SAFELY

Illuminate your work area adequately but safely.
Use a portable safety light for working inside or
under the machine. Make sure the bulb is
enclosed by a wire cage. The hot filament of an
accidentally broken bulb can ignite spilled fuel or
oil.

SERVICE MACHINE SAFELY

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

STAY CLEAR OF MOVING PARTS

Entanglements in moving parts can cause serious
injury.
To prevent accidents, use care when working
around rotating parts.

1-5

AVOID HIGH PRESSURE FLUIDS

Escaping fluid under pressure can penetrate the
skin causing serious injury.
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten all
connections before applying pressure.
Search for leaks with a piece of cardboard.
Protect hands and body from high pressure fluids.
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be surgically
removed within a few hours or gangrene may
result.

AVOID HEATING NEAR PRESSURIZED FLUID

LINES
Flammable spray can be generated by heating
near pressurized fluid lines, resulting in severe
burns to yourself and bystanders. Do not heat by
welding, soldering, or using a torch near
pressurized fluid lines or other flammable materials.
Pressurized lines can be accidentally cut when
heat goes beyond the immediate flame area.
Install fire resisting guards to protect hoses or other
materials.
PREVENT BATTERY EXPLOSIONS
Keep sparks, lighted matches, and flame away
from the top of battery. Battery gas can explode.
Never check battery charge by placing a metal
object across the posts. Use a volt-meter or
hydrometer.
Do not charge a frozen battery; It may explode.
Warm battery to 16
C(60
F).

1-6

PREVENT ACID BURNS

Sulfuric acid in battery electrolyte is poisonous. It
is strong enough to burn skin, eat holes in clothing,
and cause blindness if splashed into eyes.
Avoid the hazard by:
1. Filling batteries in a well-ventilated area.
2. Wearing eye protection and rubber gloves.
3. Avoiding breathing fumes when electrolyte is
added.
4. Avoiding spilling of dripping electrolyte.
5. Use proper jump start procedure.
If you spill acid on yourself:
1. Flush your skin with water.
2. Apply baking soda or lime to help neutralize
the acid.
3. Flush your eyes with water for 10-15 minutes.
Get medical attention immediately.
If acid is swallowed:
1. Drink large amounts of water or milk.
2. Then drink milk of magnesia, beaten eggs, or
vegetable oil.
3. Get medical attention immediately.

USE TOOLS PROPERLY

Use tools appropriate to the work. Makeshift
tools, parts, and procedures can create safety
hazards.
Use power tools only to loosen threaded tools and
fasteners.
For loosening and tightening hardware, use the
correct size tools. Avoid bodily injury caused by
slipping wrenches.
Use only recommended replacement parts.(See
Parts catalogue.)

1-7

SERVICE TIRES SAFELY

Explosive separation of a tire and rim parts can
cause serious injury or death.
Do not attempt to mount a tire unless you have the
proper equipment and experience to perform the job.
Always maintain the correct tire pressure. Do not
inflate the tires above the recommended pressure.
Never weld or heat a wheel and tire assembly.
The heat can cause an increase in air pressure
resulting in a tire explosion.
Welding can structurally weaken or deform the wheel.
When inflating tires, use a clip-on chuck and
extension hose long enough to allow you to stand
to one side and not in front of or over the tire
assembly. Use a safety cage if available.
Check wheels for low pressure, cuts, bubbles,
damaged rims or missing lug bolts and nuts.
USE PROPER LIFTING EQUIPMENT
Lifting heavy components incorrectly can cause
severe injury or machine damage.
Follow recommended procedure for removal and
installation of components in the manual.

DISPOSE OF FLUIDS PROPERLY

Improperly disposing of fluids can harm the
environment and ecology. Before draining any
fluids, find out the proper way to dispose of waste
from your local environmental agency.
Use proper containers when draining fluids. Do
not use food or beverage containers that may
mislead someone into drinking from them.
DO NOT pour oil into the ground, down a drain, or
into a stream, pond, or lake. Observe relevant
environmental protection regulations when
disposing of oil, fuel, coolant, brake fluid, filters,
batteries, and other harmful waste.

1-8

REPLACE SAFETY SIGNS

Replace missing or damaged safety signs. See
the machine operator's manual for correct safety
sign placement.

LIVE WITH SAFETY

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

KEEP ROPS INSTALLED PROPERLY

Make certain all parts are reinstalled correctly if the
roll-over protective structure(ROPS) is loosened or
removed for any reason. Tighten mounting bolts
to proper torque.
The protection offered by ROPS will be impaired if
ROPS is subjected to structural damage, is
involved in an overturn incident, or is in any way
altered by welding, bending, drilling, or cutting. A
damaged ROPS should be replaced, not reused.

1-9

GROUP 2 SPECIFICATION
1. MAJOR COMPONENT

Bucket

Tire

Main control valve

Boom

Quick coupler

Link

Front axle

Head light

Boom cylinder

Bucket cylinder

Main pump

Cab

Steering cylinder

Hydraulic tank

Precleaner

Step Transmission

1-10

Muffler

Radiator

Air cleaner

Battery

Engine

Rear axle

Counterweight

Fuel tank

2. SPECIFICATIONS
1) WITHOUT CUTTING EDGE TYPE BUCKET

H
2903
C

4 0

F
I
5122
3979
G

50
3
5712 0

Description
Operating weight
Struck

Bucket capacity

1842

E
A

Unit

Specification

kg(lb)

11530(25410)

m3(yd3)

Heaped

1.6(2.1)
1.9(2.5)

Overall length

7125(23' 5")

Overall width

2550( 8' 4")

Overall height

3237(10' 7")

Ground clearance

417( 1' 4")

Wheelbase

Tread

1900( 6' 3")

Dump clearance at 45

2972( 9' 9")

Dump reach

991( 3' 3")

Width over tires

2430( 8' 0")

Dump angle

Roll back angle(Carry position)

56

Lift(With load)

5.6

Cycle time

mm(ft-in)

Degree ()

sec

Dump(With load)

Maximum travel speed

km/hr(mph)

Braking distance

m(ft-in)

Minimum turning radius(Center of outside tire)

Degree ()

39(24.2)
13(42' 8")
30

First gear

6.5(4.0)

Second gear

13.5(8.4)

Third gear

27.1(16.8)

Fourth gear
Reverse

1.4

5.03(16' 6")

Gradability

Travel speed

45

2.7

Lower(Empty)

Forward

2900( 9' 6")

km/hr(mph)

39(24.2)

First gear

6.5(4.0)

Second gear

13.5(8.4)

Third gear

27.1(16.8)

1-11

J
H
K

40

2903
C

F
I
5122
3979
G

2) BOLT-ON CUTTING EDGE TYPE BUCKET

50
5734 30

Description
Operating weight
Struck

Bucket capacity

1842

E
A

Unit

Specification

kg(lb)

11650(25680)

m3(yd3)

Heaped

1.7(2.2)
2.0(2.6)

Overall length

7208(23' 8")

Overall width

2550( 8' 4")

Overall height

3237(10' 7")

Ground clearance

417( 1' 4")

Wheelbase

Tread

1900( 6' 3")

Dump clearance at 45

2911( 9' 7")

Dump reach

1015( 3' 4")

Width over tires

2430( 8' 0")

Dump angle

Roll back angle(Carry position)

56

Lift(With load)

5.6

Cycle time

mm(ft-in)

Degree ()

sec

Dump(With load)

Maximum travel speed

km/hr(mph)

Braking distance

m(ft-in)

Minimum turning radius(Center of outside tire)

Degree ()

39(24.2)
13(42' 8")
30

First gear

6.5(4.0)

Second gear

13.5(8.4)

Third gear

27.1(16.8)

Fourth gear
Reverse

1.4

5.03(16' 6")

Gradability

Travel speed

45

2.7

Lower(Empty)

Forward

2900( 9' 6")

km/hr(mph)

39(24.2)

First gear

6.5(4.0)

Second gear

13.5(8.4)

Third gear

27.1(16.8)

1-12

3. WEIGHT

kg

lb

Front frame assembly

916

2019

Rear frame assembly

1223

2696

Front fender

23

51

Rear fender

34

75

Counterweight

805

1775

Cab assembly

1000

2205

Engine assembly

435

959

Transmission

350

772

Drive shaft(Engine to transmission)

5.9

13

Drive shaft(Front)

14

31

Drive shaft(Center)

11

24

Drive shaft(Rear)

10

22

Front axle(Include differential)

575

1268

Rear axle(Include differential)

560

1235

1320

2910

Hydraulic tank

100

220

Fuel tank

220

485

Main pump assembly

20

44

Main control valve

22

49

638

1407

40

88

Quick coupler assy

210

463

2.0m bucket, with bolt on cutting edge

895

1973

1.9m3 bucket, without cutting edge

775

1709

Boom cylinder assembly(2EA)

132

291

Bucket cylinder assembly(2EA)

94

207

Steering cylinder assembly(2EA)

36

80

Quick coupler cylinder assembly(1EA)

5.5

12

Seat

40

88

Battery

44

97

Item

Tire(4EA)

Boom
Bucket link

1-13

4. SPECIFICATION FOR MAJOR COMPONENTS

1) ENGINE
Item

Specification

Model

Cummins B5.9-C

Type

4-cycle turbocharged diesel engine

Cooling method

Water cooling

Number of cylinders and arrangement

6 cylinders, in-line

Firing order

1-5-3-6-2-4

Combustion chamber type

Direct injection type

Cylinder bore stroke

102120mm(4.02"4.72")

Piston displacement

5880cc(352.8cu in)

Compression ratio

17.5 : 1

Rated gross horse power

137ps at 2200rpm

Maximum gross torque at 1600rpm

58kgfm(419lbfft)

Engine oil quantity

16.4 (4.3 U.S. gal)

Dry weight

400kg(881.8lb)

High idling speed

2370 50rpm

Low idling speed

950 50rpm

Rated fuel consumption

157.3g/ps.h

Starting motor

Delco Remy 37MT(24V)

Alternator

DAC HC60(24V-60AMP)

Battery

212V160Ah

2) MAIN PUMP
Item

Specification

Type

Fixed displacement tandem gear pump

Capacity

41+37cc/rev

Maximum operating pressure

220kgf/cm2(3129psi)

Rated oil quantity

163/ min(43U.S.gpm)

Rated speed

2200rpm

1-14

3) BRAKE PUMP
Item

Specification

Type

Fixed displacement tandem gear pump

Capacity

8cc/rev

Maximum operating pressure

150kgf/cm2(2130psi)

Rated oil quantity

17/ min(4.5U.S.gpm)

4) MAIN CONTROL VALVE

Item

Specification

Type

3 spool

Operating method

Hydraulic pilot assist

Main relief valve pressure

220kgf/cm2(3129psi)

Overload relief valve pressure

240kgf/cm2(3414psi)

5) REMOTE CONTROL VALVE

Specification

Item

Pressure reducing type

Type
Operating
Single operation stroke

Minimum

3.7kgf/cm2(52.6psi)

Maximum

30kgf/cm2(427psi)

Lever

77mm(3.0in)

6) CYLINDER
Specification

Item
Boom cylinder

Bore diaRod dia

12070684mm

Bucket cylinder

Stroke

10050750mm

Steering cylinder

Bore diaRod dia

6540429mm

Quick coupler cylinder

Stroke

502579mm

1-15

7) DYNAMIC POWER TRANSMISSION DEVICES

Specification

Item
Torque converter

Transmission

Axle

Wheels
Brakes

Steering

Model

Clark 13.2 HR24423

Type

Single-stage, single-phase

Type

Semi-automatic power shift

Gear shift

Forward fourth gear, reverse third gear

Adjustment

Electrical single lever type, kick-down system

Drive devices

4-wheel drive

Front

Front fixed location

Rear

Oscillation 13of center pin-loaded

Tires

20.5-25, 16PR(L3)

Travel

Four-wheel, wet-disc type, full hydraulic

Parking

Spring applied, hydraulic released brake on front

axle

Type

Full hydraulic, articulated

Steering angle

40to both right and left angle, respectively

1-16

5. TIGHTENING TORQUE OF MAJOR COMPONENT

Size

Items

No.

kgfm

lbfft

Engine mounting bolt, nut

M202.5

57.9 8.7

419 63

Radiator mounting bolt, nut

M121.75

12.3 2.5

89.0 18

Main pump housing mounting bolt

1/2-13UNC

19.6 2.9

142 21

Main control valve mounting bolt

M121.75

12.8 3

92.6 22

Steering unit mounting bolt

3/8-16UNC

3.3 0.8

23.9 5.8

Priority valve mounting bolt

M 81.25

2.5 0.5

18.1 3.6

Brake valve mounting bolt

M 81.25

2.5 0.5

18.1 3.6

Fuel tank mounting bolt

M162.0

27.9 4.5

202 33

Hydraulic oil tank mounting bolt

M121.75

12.3 2.5

89.0 18

10

Transmission mounting bolt

M202.5

57.9 8.7

419 63

Front axle mounting bolt

M202.0

100 15

723108

Rear axle support mounting bolt, nut

M242.0

100 15

723108

13

Tire mounting nut

M221.5

60 2

434 15

14

Drive shaft joint mounting bolt, nut

3/8-24UNF

6 0.8

43.4 5.8

15

Counterweight mounting bolt

M302.0

199 29.9

1439216

Operator's seat mounting bolt

M 81.25

3.4 0.8

24.6 5.8

ROPS Cab mounting bolt(4EA)

M243.0

28 2.6

203 19

Engine

5
6

Hydraulic
system

11
12

16
17

Power train
system

Others

1-17

6. TORQUE CHART
Use following table for unspecified torque.
1) BOLT AND NUT
(1) Coarse thread
Bolt size

10T

8T
kgfm

lbfft

kgfm

lbfft

M 6 1.0

0.85 ~ 1.25

6.15 ~ 9.04

1.14 ~ 1.74

8.2 ~ 12.6

M 8 1.25

2.0 ~ 3.0

14.5 ~ 21.7

2.73 ~ 4.12

19.7 ~ 29.8

M10 1.5

4.0 ~ 6.0

28.9 ~ 43.4

5.5 ~ 8.3

M12 1.75

7.4 ~ 11.2

53.5 ~ 79.5

9.8 ~ 15.8

71 ~ 114

M14 2.0

12.2 ~ 16.6

88.2 ~ 120

16.7 ~ 22.5

121 ~ 167

M16 2.0

18.6 ~ 25.2

135 ~ 182

25.2 ~ 34.2

182 ~ 247

M18 2.5

25.8 ~ 35.0

187 ~ 253

35.1 ~ 47.5

254 ~ 343

M20 2.5

36.2 ~ 49.0

262 ~ 354

49.2 ~ 66.6

356 ~ 482

M22 2.5

48.3 ~ 63.3

350 ~ 457

65.8 ~ 98.0

476 ~ 709

M24 3.0

62.5 ~ 84.5

452 ~ 611

85.0 ~ 115

615 ~ 832

M30 3.5

124 ~ 168

898 ~ 1214

169 ~ 229

1223 ~ 1655

M36 4.0

174 ~ 236

1261 ~ 1703

250 ~ 310

1808 ~ 2242

39.8 ~ 60

(2) Fine thread

Bolt size

8T
kgfm

10T
lbfft

kgfm

lbfft

M 8 1.0

2.17 ~ 3.37

15.7 ~ 24.3

3.04 ~ 4.44

22.0 ~ 32.0

M10 1.25

4.46 ~ 6.66

32.3 ~ 48.2

5.93 ~ 8.93

42.9 ~ 64.6

M12 1.25

7.78 ~ 11.58

76.3 ~ 83.7

10.6 ~ 16.0

76.6 ~ 115

M14 1.5

13.3 ~ 18.1

96.2 ~ 130

17.9 ~ 24.1

130 ~ 174

M16 1.5

19.9 ~ 26.9

144 ~ 194

26.6 ~ 36.0

193 ~ 260

M18 1.5

28.6 ~ 43.6

207 ~ 315

38.4 ~ 52.0

278 ~ 376

M20 1.5

40.0 ~ 54.0

289 ~ 390

53.4 ~ 72.2

386 ~ 522

M22 1.5

52.7 ~ 71.3

381 ~ 515

70.7 ~ 95.7

512 ~ 692

M24 2.0

67.9 ~ 91.9

491 ~ 664

90.9 ~ 123

658 ~ 890

M30 2.0

137 ~ 185

990 ~ 1338

182 ~ 248

1314 ~ 1795

M36 3.0

192 ~ 260

1389 ~ 1879

262 ~ 354

1893 ~ 2561

1-18

2) PIPE AND HOSE

Thread size

Width across flat'mm(

kgfm

lbfft

1/4"

19

21.7

3/8"

22

28.9

1/2"

27

36.2

3/4"

36

12

86.8

1"

41

14

101

Thread size

Width across flat'mm(

kgfm

lbfft

1/4"

19

28.9

3/8"

22

36.2

1/2"

27

43.4

3/4"

36

13

94.0

1"

41

15

109

3) FITTING

1-19

7. RECOMMENDED LUBRICANTS
Use only oils listed below or equivalent.
Do not mix different brand oil.
Ambient temperature
C(
F)
Service point

Kind of fluid

Capacity
(U.S. gal)

-20
(-4)

-10
(14)

0
(32)

10
(50)

20
(68)

30 40
(86) (104)

SAE 30
SAE 10W
Engine oil pan

Engine oil

16.4(4.3)
SAE 10W-30
SAE 15W-40

Torque converter
Transmission

Oil

25(6.6)

Axle

Gear oil

Front : 40(10.6)
Rear : 40(10.6)

DEXRON

SAE 80W-90LSD/API GL-5

ISO VG 32

Tank:
75(19.8)
Hydraulic tank

ISO VG 46

Hydraulic oil
System:
120(31.7)

ISO VG 68

ASTM D975 NO. 1

Fuel tank

Diesel fuel

200(52.8)
ASTM D975 NO. 2

NLGI NO. 1

Fitting
(Grease nipple)

Grease

Radiator

Mixture of
antifreeze
and water
50 : 50

As required
NLGI NO. 2

Ethylene glycol base permanent type

35(9.2)

1-20

GROUP 3 OPERATIONAL CHECKOUT RECORD SHEET

Owner
Date
Hours
Serial No.
Technician

9
9
9
9
9

Use this sheet to record operational

checkout results.
Perform the operational check before
installing any test equipment.

Item

OK

NOT
OK

1. Monitor indicator and gauge checks(Engine OFF)

Hourmeter and gauge check
Battery check
Monitor indicator circuit check
Monitor turn signals and warning indicator check

2. Transmission, axle and engine linkages, neutral start

switch and reverse warning alarm switch checks
Transmission control lever and neutral
Neutral start and reverse warning
Alarm circuit checks
Engine speed control linkage check

3. Monitor indicator and gauge checks(Engine running)

Monitor display and alternator output checks
Monitor bypass circuit and seat belt indicator check
Monitor primary and secondary level check
Transmission oil warm up procedure
Transmission temperature gauge check

1-21

Comments

4. Brake system and clutch cut off checks

Park brake capacity check
Park brake transmission lockout check
Service brake pump flow check
Service brake capacity check
Brake accumulator precharge check
Brake system leakage check
Service brake pedal check
Service and park brake system drag check
Clutch cut off check

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

6. Hydraulic system checks

Hydraulic system warm up procedure
Hydraulic pump performance check
Pilot control valve boom float check
Boom down solenoid valve check
Control valve lift check
Bucket rollback circuit relief valve check
Bucket dump circuit relief
Low pressure check
High pressure check
Boom and bucket cylinder drift check
Boom down solenoid valve leakage check
Pilot controller check
Return to dig check
Boom height kickout check-if equipped

1-22

7. Steering system checks

Steering valve check
Steering system leakage check

Priority valve
Low check pressure
High check pressure

8. Accessory checks
Operating lights check
Work light check
Brake light check
Cab light check
Horn circuit check
Windshield washer and wiper check
Defroster blower check
Heater/Air conditioner blower check
Heater functional check
Air conditioner functional check
Start aid system check

9. Cab components and vandal protection checks

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

1-23

SECTION 3 POWER TRAIN SYSTEM

GROUP 1 STRUCTURE AND FUNCTION
1. POWER TRAIN COMPONENT OVERVIEW
Transmission

Front axle

Front drive shaft

Upper drive shaft

Center drive shaft

Rear drive shaft

Engine

Rear axle

The power train consists of the following components :

Transmission
Front, upper, center and rear drive shafts
Front and rear axles
Engine power is transmitted to the transmission through the torque converter.
The transmission is a hydraulically engaged four speed forward, three speed reverse countershaft type
power shift transmission. A disk type parking brake is located on the front of the transmission housing.
The transmission outputs through universal joints to three drive shaft assemblies. The front drive shaft
is a telescoping shaft which drives the front axle. The front axle is mounted directly to the loader frame.
The front axle is equipped with limited slip differential.
The rear axle is mounted on an oscillating pivot. The rear axle is equipped with limited slip differential.
The power transmitted to front axle and rear axle is reduced by the pinion gear and ring gear of
differential. It then passes from the differential to the sun gear shaft(Axle shaft) of final drive.
The power of the sun gear is reduced by a planetary mechanism and is transmitted through the
planetary hub to the wheel.

3-1

1) HYDRAULIC SCHEMATIC

1-2-3
Declutch

To transmission
lube
Oil cooler(Option)

FR
From master
cylinder

Filter

Charging
pump
assembly

Vent

Torque
converter

Converter
safety valve

Clutch
regulator
Removable
screen
Oil sump

3-2

2) HYDRAULIC CIRCUIT

Modulation
valve FWD

Torque
converter

Modulation
valve REV

REV
Clutch
regulator valve
FWD,LO

Hose

Oil cooler
(Option)

B
FWD,H/4

Converter
safety
valve

D
1
Filter

E
3

Hose

Pump

Lubrication

Suction screen
Air breather
Oil sump

Speed

Forward
1

Reverse
4

B
C

Neutral

X : Solenoid activated

3-3

2. TRANSMISSION
1) STRUCTURE
6

10

11

7
5

1
2
3
4

Filter
Charging pump
Regulating valve
Impeller

5
6
7
8

Turbine
Stator(Reaction member)
Control valve
Modulator valve

9
10
11

Converter housing
Transmission case
Rear cover

The transmission is a mid-mount torque converter and transmission assembly connected to the engine
by means of a drive shaft.
The control valve assembly(7) mounted directly on the side of the converter housing(9).
The function of the control valve assembly is to direct oil under pressure to the desired directional and
speed clutch. A provision is made to neutralize the transmission when the brakes are applied. This is
accomplished through use of a brake actuated shutoff valve. The speed and direction clutch
assemblies are mounted inside the transmission case(10) and are connected to the output shaft of the
converter either by direct gearing or drive shaft. The purpose of the speed or directional clutches is to
direct the power flow through the gear train to provide the desired speed range and direction.

3-4

2) OPERATION
With the engine running, the converter charging pump(2) draws oil from the transmission sump
through the removable oil suction screen and directs it through the oil filter and the pressure
regulating valve(3).
The pressure regulating valve maintains pressure to the transmission control cover for actuating the
direction and speed clutches. This requires a small portion of the total volume of oil used in the
system. The remaining volume of oil is directed through the torque converter circuit to the oil cooler
and returns to the transmission for positive lubrication. This regulator valve consists of a hardened
valve spool operating in a closely fitted bore. The valve spool is spring loaded to hold the valve in a
closed position. When a specific pressure is achieved, the valve spool works against the spring
until a port is exposed along the side of the bore. This sequence of events provides the proper
system pressure.
After entering the converter housing the oil is directed through the stator support to the converter
blade cavity and exits in the passage between the turbine shaft and converter support. The oil then
flows out of the converter to the oil cooler. After leaving the cooler, the oil is directed to a lubricating
fitting on the transmission and through a series of tubes and passages lubricates the transmission
bearings and clutches. The oil then gravity drains to the transmission sump.
The hydraulic torque converter consists basically of three elements and their related parts to
multiply engine torque. The engine power is transmitted from the engine flywheel to the impeller
element through the impeller cover. This element is the pump portion of the hydraulic torque
converter and is the primary component which starts the oil flowing to the other components which
results in torque multiplication. This element can be compared to a centrifugal pump in that it picks
up fluid at its center and discharges at its outer diameter.
The torque converter turbine(5) is mounted opposite the impeller(4) and is connected to the output
shaft of the torque converter. This element receives fluid at its outer diameter and discharges at its
center. Fluid directed by the impeller out into the particular design of blading in the turbine and
reaction member(6) is the means by which the hydraulic torque converter multiplies torque.
The reaction member of the torque converter is located between and at the center or inner
diameters of the impeller and turbine elements. Its function is to take the fluid which is exhausting
from the inner portion of the turbine and change its direction to allow correct entry for recirculation
into the impeller element.
The torque converter will multiply engine torque to its designed maximum multiplication ratio when
the output shaft is at zero RPM. Therefore, we can say that as the output shaft is decreasing in
speed the torque multiplication is increasing.
The control valve assembly consists of a valve body with selector valve spools. A detent ball and
spring in the selector spool provides one position for each speed range. A detent ball and spring in
the direction spool provides three position, one each for forward, neutral and reverse.
With the engine running and the directional control lever in neutral position, oil pressure from the
regulating valve is blocked at the control valve, and the transmission is in neutral. Movement of the
forward and reverse spool will direct oil, under pressure to either the forward or reverse direction
clutch as desired. When either directional clutch is selected the opposite clutch is relieved of
pressure and vents back through the direction selector spool. The same procedure is used in the
speed selector.

3-5

The direction or speed clutch assembly consists of a drum with internal splines and a bore to
receive a hydraulically actuated piston. The piston is "oil tight" by the use of sealing rings. A steel
disc with external splines is inserted into the drum and rests against the piston. Next, a friction disc
with splines at the inner diameter is inserted. Discs are alternated until the required total is
achieved. A heavy back-up plate is then inserted and secured with a snap ring. A hub with outer
diameter splines is inserted into the splines of discs with teeth on the inner diameter. The discs and
hub are free to increase in speed or rotate in the opposite direction as long as no pressure is
present in that specific clutch.
To engage the clutch, as previously stated, the control valve is placed in the desired position. This
allows oil under pressure to flow from the control valve, through a passageway, to a chosen clutch
shaft. This shaft has a drilled passageway for oil under pressure to enter the shaft. Oil pressure
sealing rings are located on the clutch shaft. These rings direct oil under pressure to a desired
clutch. Pressure of the oil forces the piston and discs against the heavy back-up plate. The discs,
with teeth on the outer diameter, clamping against discs with teeth on the inner diameter, enables
the hub and clutch shaft to be locked together and allows them to drive as a unit.
There are bleed balls or bleed orifices, in the clutch piston which allow quick escape for oil when the
pressure to the piston is released.

3-6

3. TRANSMISSION
1) TYPICAL CROSS SECTION

FWD

REV

4th

2nd

3rd

3-7

1st

2) TRANSMISSION LAYOUT

D
C

B
E

F
H
N
G

L
K
J

A
B
C
D
E

Torque converter
Charge pump assembly
Pump drive idler gear
Pump drive gear
Forward clutch

F
G
H
J

Reverse clutch
1st clutch
2st clutch
Idler shaft

3-8

K
L
M
N

3rd clutch
4th clutch
Output shaft
Solenoid control valve

3) OPERATION OF TRANSMISSION
(1) Forward
Forward 1st
In 1st forward, foreward clutch and 1st clutch are engaged.
Foreward clutch and 1st clutch are actuated by the hydraulic pressure applied to the clutch
piston.

INPUT

FWD

REV

4th

2nd

1st

3rd

Idler

OUTPUT

3-9

 Forward 2nd
In 2nd forward, foreward clutch and 2nd clutch are engaged.
Foreward clutch and 2nd clutch are actuated by the hydraulic pressure applied to the clutch
piston.

INPUT

FWD

REV

4th

2nd

1st

3rd

Idler

OUTPUT

3 - 10

 Forward 3rd
In 3rd forward, foreward clutch and 3rd clutch are engaged.
Foreward clutch and 3rd clutch are actuated by the hydraulic pressure applied to the clutch
piston.

INPUT
FWD

REV

4th

2nd

1st

3rd

Idler

OUTPUT

3 - 11

 Forward 4th
In 4th forward, 4th clutch and 3rd clutch are engaged.
4th clutch and 3rd clutch are actuated by the hydraulic pressure applied to the clutch piston.

INPUT

FWD

REV

4th

2nd

1st

3rd

Idler

OUTPUT

3 - 12

(2) Reverse
Reverse 1st
In 1st reverse, reverse clutch and 1st clutch are engaged.
Reverse clutch and 1st clutch are actuated by the hydraulic pressure applied to the clutch piston.

INPUT

FWD

REV

4th

2nd

1st

3rd

Idler

OUTPUT

3 - 13

 Reverse 2nd
In 2nd reverse, reverse clutch and 2nd clutch are engaged.
Reverse clutch and 2nd clutch are actuated by the hydraulic pressure applied to the clutch
piston.

INPUT

FWD

REV

4th

2nd

1st

3rd

Idler

OUTPUT

3 - 14

 Reverse 3rd
In 3rd reverse, reverse clutch and 3rd clutch are engaged.
Reverse clutch and 3rd clutch are actuated by the hydraulic pressure applied to the clutch piston.

INPUT

FWD

REV

4th

2nd

1st

3rd

Idler

OUTPUT

3 - 15

4) ELECTRIC SOLENOID CONTROL VALVE

Direction
& speed

Solenoids
energized

Clutches
pressurized

Forward 1st

V X Y

Forward & 1st

Forward 2nd

V X

Forward & 2nd

Forward 3rd

Forward & 3rd

Forward 4th

V Z

4th & 3rd

Reverse 1st

W X Y

Reverse & 1st

Reverse 2nd

W X

Reverse & 2nd

Reverse 3rd

Reverse & 3rd

2P
RP

RC

2C
1P

FHP

Pilot and clutch pressure check points

1P
1st pilot
2P
2nd pilot
2C
2nd clutch
4P(FHP) 4th clutch
RP
Reverse pilot
RC
Reverse clutch

V
FWD

Z
4th

W
REV

Energized

Inlet

Pilot pressure
Vent

De-energized

Vent

3 - 16

Y
1st

X
2nd

4. EGS LEVER
1) SHIFT LEVER OPERATION
EGS lever applications share the principle of selecting direction and gear positions.
Direction is selected by placing the lever in one of three detented positions(Neutral, Forward or
Reverse).
Gear shifts are made by bringing the lever either in the upshift position or in the downshift
position. These positions are spring returned.
With the EGS, shifts are made relative to the previous position : The EGS remembers the selected
gear position and shifts either to a higher gear or to a lower gear.
The EGS display always shows the selected shift lever position, the selected direction, the gear
position and the gear direction.
This operating principle accounts for the flexibility of the EGS system : It makes possible to control
any(Electric) powershift transmission with the same shift lever, provided the correct software(A
program for the EGS computer) is installed.
It also facilitates features such as kickdown, automatic powerup in neutral, preset gear selection
after a direction change, etc..

Forward
LOCK

Heatsink
Upshift
SPRING RETURN

Neutral
Downshift
SPRING RETURN

Display - LEDS

Reverse
LOCK

The froward driving direction is selected by pushing the lever away from the driver(This usually
corresponds with pushing it to the normal driving direction).
The reverse driving direction is selected by pulling the lever towards the driver.
The neutral can be selected by placing the lever into its central detented position.
An upshift is requested by rotating the shift lever counter clockwise.
A downshift is requested by rotating the shift lever clockwise.

3 - 17

2) FUNCTIONAL DESCRIPTION
(1) Automatic powerup in neutral
When power is first applied to the EGS, neutral is always selected.
This is regardless of the position of the shift lever(It can be in either forward, neutral or reverse
position).
In order to start driving, the driver first has to place the shift lever into the neutral(Central detented)
position before a specific direction can be selected.
(2) Neutral start protection
Each EGS can have an output signal, which is deactivated whenever the shift lever is in the
neutral position.
This signal can be used to control a normal closed relay preventing engine start up whenever the
shift lever is not in the neutral detented position.
If during powerup the shiftlever is in forward or in reverse, the neutral start protection will not be
activated(Due to the function automatic powerup in neutral). Only after leaving this function
automatic powerup in neutral the neutral start protection will be activated.
(3) Kickdown
This EGS lever is also available with a shift lever integrated push button, which is used for the
kickdown function.
Usually it's used for requesting a downshift from 2nd to 1st gear, which is dropped after a direction
change : F2KickdownF1R2
This is called kickdown.
If however the speed is too high, the kickdown request is stored for a certain time. If during this
time the speed has not slowed down sufficiently, the request is dropped.

3 - 18

3) DISPLAY FUNCTION
The EGS has an internal bicolor LED display for displaying the selected shiftlever position, the
selected shiftlever direction, the transmission position and the transmission direction.
Application specific details are described in a separate document : EGS functional description.
This EGS functional description can be requested for each EGS unit. This description overrules
the below description wherever applicable.
(1) Displayed information
Typically four types of information about the EGS and the transmission can be of interest to the
driver :
Selected shiftlever position and transmission position
Selected shiftlever direction and transmission direction
Application specific information
Diagnostic information
Selected position and direction
The difference between shift lever position and transmission position might not be immediately
clear, but when one remembers that the EGS can protect the transmission(Example : By not
allowing a downshift), it becomes clear that the requested position(The shift lever position) can
be different from the actual engaged position(The position of the transmission).
Both shift lever position and transmission position can be divided in two subcategories:
Gear position
(1st, 2nd, 3rd, 4th)
Driving direction
(Forward, neutral, reverse)
Application specific information
This can be anything(Whatever the customer wants to see).
As an example : On an EGS automatically controlling the lockup clutch, it's interesting to see
whether or not the converter is in lockup. This can be indicated on the EGS
display by using the LED 7-yellow.
Diagnostic information
Two types of diagnostic information are considered :
ON LINE diagnostics
This information is given during normal driving when something special happens.
In most applications, the LED 8 is used to indicate standstill. This helps to spot problems with
the speed sensor in an early stage before the lack of protection resulting from the failure can
produce damaged to the drivetrain.
Which on line diagnostic functions are provided is detailed in the application specific EGS
Functional description.
OFF LINE diagnostics
There are three selftest modes built into the EGS. Details about their function and usage are
described in clause 5), Selftest functions.

3 - 19

(2) Display layout

The EGS uses LED's(Light Emmitting Diodes) to give information to the driver.
It consists of eight multicolor LED's :
Labelled 1 to 8 and can light up in red, green and yellow.

These numbered LED's are used for displaying both the shift lever selection and the transmission
engagement.
They also used to indicate diagnostic information in the different test modes.
The red LED is labelled N and when this lights up it indicates that the transmission is placed in
neutral(This is possible even while the shift lever is not in neutral).
The yellow LED is labelled T which stands for troubleshooting. This LED is ON while working in
one of the three selftest modes described in clause 5), Selftest function.
(3) Display method
Basically the gear position is shown by turning ON the LED that corresponds with the selected
position. In 1st gear, LED 1 is ON, in 2nd gear, LED 2 is ON etc..
The selected direction is shown with the color of the LED :
Red
Indicates
Neutral
Green
Indicates
Forward
Yellow
Indicates
Reverse
Additionally LED N(Red) is ON while the transmission is in neutral.
The position shown is always the selected shiftlever position. Most of the time, the actual
transmission position will be the same as the shown one, and in that case that's all there is.
However if, because of an active protection or because of some internally generated delay, there
is a discrepancy between transmission position and shift lever position, a 2nd LED will indicate the
transmission position(Color indicates direction).
To let the driver know the difference between both indications, the transmission LED blinks while
the shift lever LED stays ON all the time.
While this may seem a bit confusing at first, it's very easy to understand the shown information in
reality.
Example : Driving in 4th gear forward at high speed.

LED 4 - Green

When the driver is making a downshift, but due to a

too high speed the EGS will protect the transmission
and will not allow the requested downshift. Thus the
transmission will stay in 4th gear forward, while the
LED 3 - Green &
shiftlever is in 3rd gear forward.
LED 4 - Blinking green
3 - 20

4) CONNECTOR PIN DESIGNATIONS

Below table lists the function of each EGS connector pin for the transmission :
Pin

Comment

Battery plus

Battery ground

Neutral start signal

CV Solenoid 1

CV Solenoid 2

CV Forward solenoid

CV Reverse solenoid

Null

Speed 5km/hr

10

Speed sensor input HOT

11

Speed sensor input GND

12

Travel speed signal

13

CV High / Low solenoid

14

Declutch

15

Extension kick down

16

Shield ground(Internally connected to wire 2)

CV stands for control valve.

3 - 21

5) SELFTEST FUNCTIONS
The EGS has special circuitry to help verifying its operation.
Three selftest modes are built into the EGS control programs :
Input test
Speed sensor test + Lamptest
Output test
The EGS furthermore has the ability to check for possible problems while driving(On line
diagnostics).
As described in clause(2), Display layout at page 3-18, the T LED is used for identifying different
troubleshooting modes. This is done in combination with the status of the N LED.
(1) Operation of the N and T LED's
Overview
Situation

LED

In normal situations(Driving, no problems)

T LED is always OFF

When error is detected

T LED is ON or BLINKING

In selftest mode

T LED is always ON

Detailed operation
Situation

N LED

T LED

Normal operation

On when transmission neutral

OFF

Internal fault

ON

Blinking SLOWLY

Input test

Blinking SLOWLY

ON

Output test

Blinking FAST

ON

Speed sensor test

OFF

ON

(2) Selftest operation

Selftest modes can only be started while powering up the EGS.
Invocation of a certain mode is done by moving the shift lever to a specific position while switching
on the power of the EGS.
Leaving the selftest mode is done by switching OFF the power of the EGS.
Selftest mode invocation
Below table lists what conditions must be satisfied during powerup to get into a specific selftest
mode :
Selftest mode

To enter mode

Input test

FWD & UP

Speed sensor test

REV & UP

Output test

FWD & DOWN

3 - 22

 Input test
When EGS shiftlever is held in the forward up position while power is applied, input test mode
is activated.
In this mode, driving is not possible, since all EGS outputs remain OFF until the testmode is left.
This test is used to verify operation of the shiftlever and its inputs.
The LED's(Gear position indicators) on the EGS top cover are used to display test information :
Shift lever position

LED Color

LED Number

RED
RED
RED

4
5
3

FWD
FWD & UP
FWD & DOWN

GREEN
GREEN
GREEN

4
5
3

REV
REV & UP
REV & DOWN

YELLOW
YELLOW
YELLOW

4
5
3

Wire 14 = GROUND
Wire 15 = GROUND

RED
GREEN

1 (Together with above LED)

1 (Together with above LED)

Neutral
UP
DOWN

If wire 14 and wire 15 are grounded simultaneously LED 1 lights up yellow.

Speed sensor test

When EGS is held in the reverse up position while power is applied, speed sensor test mode is
activated.
In this mode, driving is possible.
The test begins with a lamp test and then displays the speed sensor information.
Speed display
The LED corresponding with below table burns to indicate converter turbine speed :
Turbine rpm

LED Number(Green)

1 BLINKS

0 - 249

1 ON

250 - 499

2 ON

500 - 749

3 ON

750 - 999

4 ON

1000 -1249

5 ON

1250 - 1499

6 ON

1500 - 1749

7 ON

1750 -1999

8 ON

Above 2000

8 BLINKS

3 - 23

 Output test
When EGS is held in the forward down position while power is applied, output test mode is
activated.
In this mode, driving is not possible, since all EGS outputs remain OFF until the testmode is left.
LED's 1 - 8 light up sequentially during output test :
First LED 1 is switched on shortly, then LED 2 etc..
When LED 8 is switched off, LED 1 is again switched on and so on.
The color of the LED indicates its status :
Color

Status

GREEN

Output OK

YELLOW

Output NOT connected or shorted to battery plus

RED

Output shorted to ground(or to another output)

The LED numbers correspond to output wires as follows :

LED Number

Output wire

13

To find the function of the corresponding output wires - See EGS functional description

3 - 24

6) REPLACING OF EP-ROM
35
25

33

26
31

27

34

38
D

40

39

42

43

(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)

(9)

Remove screw(33).
Remove screw(38).
Remove screw(34).
Remove screw(25).
Remove plate(26) and seal(27).
Slide the PCB's(42, 43) out of the housing, with rear cover connected(31, 35).
Remove plastic cover(40).
Replace EP-ROM(39).
Notice the correct position of the mark on the EP-ROM (See D).
Reassemble the EGS.
Notice the correct slots for the different ports.
See on the right figure.
A : Slots for cover(40)
B : Slots for PCB(42)
C : Slots for PCB(43)

3 - 25

A
B
C

5. AXLE
1) OPERATION
The power from the engine passes through torque converter, transmission and drive shafts, and is
then sent to the front and rear axles.
Inside the axles, the power passes from the bevel pinion to the bevel gear and is sent at right
angles. At the same time, the speed is reduced and passes through the both differentials to the
axle shafts. The power of the axle shafts is further reduced by planetary-gear-type final drives and
is sent to the wheels.
(1) Front axle
3

Final drive

Differential

Axle

Axle

(2) Rear axle

3

Final drive

Differential

3 - 26

2) SECTION OF FRONT AXLE DIFFERENTIAL

1
5

1
2

Bevel pinion
Bevel gear

3
4

Sun gears
Shaft

3-27

Side gear(Differential)

3) SECTION OF REAR AXLE DIFFERENTIAL

1
5

1
2

Bevel pinion
Bevel gear

3
4

Sun gear
Shaft

3 - 28

Side gear(Differential)

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

3
2

(2) When driving straight forward

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

Pinion gear
Side gear

Side gear

Axle gear shaft

Carrier
Pinion gear

(3) When turning

When turning, the rotating speed of the
left and right wheels is different, so the
pinion gear and side gear inside the
differential assembly rotate in accordance
with the difference between the rotating
speed of the left and right wheels.
The power of the carrier is then
transmitted to the axle gear shafts.

Swing
Pinion gear
Side gear

Side gear

Carrier
Pinion gear

3 - 29

Ring gear

5) TORQUE PROPORTIONING DIFFERENTIAL

(1) Function
Because of the nature of their work, 4wheel-drive loaders have to work in
places where the road surface is bad.
In such places, if the tires slip, the ability
to work as a loader is reduced, and also
the life of the tire is reduced.
The torque proportioning differential is
installed to overcome this problem.
In structure it resembles the differential of
an automobile, but the differential pinion
gear has an odd number of teeth.
Because of the difference in the
resistance from the road surface, the
position of meshing of the pinion gear
and side gear changes, and this changes
the traction of the left and right tires.

(2) Operation
When travelling straight(Equal
resistance from road surface to left and
right tires)
Under this condition, the distances
involving the engaging points between
right and left side gears and pinion-a and
b-are equal and the pinion is balanced as
FLa=FRb. Thus, FL=FR, and the
right and left side gears are driven with
the same force.

Spider rotating
direction

FL

Engaging
point

Left side gear

3 - 30

FR
a b

Pinion

Engaging
point

Right side gear

 When travelling on soft ground

(Resistance from road surface to left and
right tires is different)
If the road resistance to the left wheel is
smaller, the left side gear tends to rotate
forward, and this rotation changes the
engaging points between the side gears
and pinion. As a result, the distances
involving the engaging points becomes
a>b. The pinion now is balanced as FL
a=FRb, where FL>FR. The right
side gear is driven with a greater force
than the left side gear. The torque can
be increased by up to about 30% for
either side gear.
The pinion therefore does not run idle
and driving power is transmitted to both
side gears until the difference between
road resistance to the right and left
wheels reaches about 30%.

Spider rotating
direction

Small road
resistance
Engaging
point

FL
FR
a b

Engaging
point

Left side gear

Right side gear

Pinion

3 - 31

Large road
resistance

6) FINAL DRIVE(Front & rear)

1
2

Axle shaft
Planetary gear

Ring gear

Sun gear

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

3 - 32

6. TIRE AND WHEEL

5
4
6

1
2

Wheel rim
Tire

3
4

O-ring
Lock ring

5
6

Side ring
Valve assembly

1) The tire acts to absorb the shock from the ground surface to the machine, and at the same time
they must rotate in contact with the ground to gain the power which drives the machine.
2) Various types of tires are available to suit the purpose. Therefore it is very important to select the
correct tires for the type of work and bucket capacity.

3 - 33

GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING

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

3-34

 Transmission oil must be at operating temperature for these checks.

Item

Description

Service action

Start engine. Apply service OK

brakes and release parking brake. Check completed.

Transmission oil warmup procedure

TRANS

Move EGS lever to 3rd speed.

Move EGS lever to forward "F"
position.
Increase engine speed to high idle
for 30 seconds.
Move EGS lever to neutral "N"
position and run for 15 seconds.
Repeat procedure until
transmission temperature gauge
arrow points to bar above dial.

Transmission noise
check
Engine running.

Run engine at approximately OK

1600rpm.
Check completed.
Drive unit with transmission in NOT OK
each forward and reverse speed. Go to transmission makes
excessive noise group 3.
LISTEN : Transmission must not
make excessive noise in any
range.
Engine rpm must not "lug down"
as unit is shifted between gears.

Transmission"kick
down" check
Engine running.

Release parking brake and shift to OK

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

3-35

Item
Forward, reverse and
4th speed clutch pack
drag check
Transmission must
be warmed up for
this check.
Engine running.

Description
Park unit on level surface.
Apply service brakes.
Move EGS lever to neutral.
Move EGS lever to 1st.

Service action
OK
Check completed.
NOT OK
If unit moves, repair
transmission.

Release parking brake and

service brakes.
Run engine at low idle.
LOOK : Unit must not move in
either direction.
NOTE : If unit moves forward,
either the forward pack or the 4th
speed pack is dragging.

Transmission pressure,
pump flow, and leakage
check
Engine running.

Run engine at low idle.

Release parking brake.

OK
Check completed.

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

3-36

Item
Transmission shift
modulation check
Engine running.

Description

Service action

Run engine at approximately OK

1600rpm.
Check completed.
Put transmission in 1st forward, NOT OK
shift several times from forward to Go to unit shifts too fast,
reverse and reverse to forward. chapter 2 in this group.
Repeat check in 2nd gear.
LOOK : Unit must slow down and
change direction smoothly.

Torque converter check

Start engine. Apply service OK

brakes and release parking brake. Check completed.
Move EGS lever to 3rd speed.

NOT OK
If stall rpm are too low or
Move EGS lever to forward "F"
too high, problem may be
position.
engine power or torque
Increase engine speed to high converter.
idle.
IF OK
LOOK : Torque converter stall Replace transmission
rpm must be within the following torque converter.
range.
Stall rpm : 2300 ~ 2440rpm
Move EGS lever to neutral "N"
position and run for 15 seconds.

3-37

2. TROUBLESHOOTING
1) TRANSMISSION
Diagnose malfunction charts are arranged from most probable and simplest to verify, to least
likely, more difficult to verify. Remember the following steps when troubleshooting a problem :
Step 1. Operational check out procedure(See group 3 in section 1.)
Step 2. Operational checks(In this group.)
Step 3. Troubleshooting
Step 4. Tests and/or adjustments(See group 3.)
Problem
Transmission slippage

Cause

Remedy

Low oil level.

Add oil.

Wrong oil grade.

Change oil.

Restricted transmission pump Remove and clean screen.

suction screen.
Leak in transmission control Remove valve and inspect gaskets.
valve or gasket.
Low transmission pump flow Do transmission pump flow test.
due to worn pump.
Weak or broken pressure Do transmission system pressure test.
regulating valve spring.

3-38

Problem
Machine will not move

Cause

Remedy

Low oil level.

Add oil.

Applied park brake.

Check parking brake fuse.

Check continuity to parking brake switch.

No power to transmission Check transmission controller fuse.

controller.
Malfunctioning parking brake Remove and inspect parking brake solenoid
solenoid valve.
valve.
Check for power to solenoid valve.

Machine does not

engage in low gear

Restricted modulation orifice.

Remove orifice and check for contamination

and/or plugging.
(Do not remove valve housing for this purpose.)

Excessive leakage in
transmission element.

Do transmission element leakage test using

system pressure.

Worn clutch disks.

Repair transmission.

Low or no transmission
pressure.

See transmission pressure is low in this group.

Service brake will not release.

Do brake pedal operational check.

Do service and park system drag checks.

Failed torque converter.

Do torque converter stall test.

If engine pulldown in normal, torque converter is
good.

Broken shafts or gears.

Drain transmission to determine if large pieces of

metal contamination are present.

Broken drive shafts.

Inspect drive shafts and universal joints for

external damage. Repair.

Broken ring or pinion gear.

If drive shaft rotate with transmission in gear but

machine does not move, a differential failure is
indicated. Repair.

Malfunctioning transmission Check solenoid valve.

control solenoid valve.
Stuck spool in transmission Remove and inspect transmission control valve
control valve.
spools.
Stuck modulation valve.

Remove end cover to inspect modulation spool.

Replace if necessary.

Malfunctioning transmission Check speed sensor.

speed sensor.

3-39

Problem

Cause

Remedy

Transmission pressure Low oil level.

is low(All gears)

Check transmission oil level and refill if

necessary.

Failed transmission pressure Verify transmission system pressure. Do

switch.
transmission system pressure test.
Plugged suction strainer.

Transmission pump may be noisy if transmission

suction screen is clogged. Drain transmission.
Remove and clean suction screen.
Also, check condition of transmission filter.

Stuck transmission pressure Remove transmission pressure regulating valve.

regulating valve or broken Inspect for damage(See transmission control
valve).
spring.
Failed control valve gasket.

Inspect transmission control valve for external

leakage. Remove control valve.
Inspect or replace gasket.

Stuck modulation valve.

Remove end cover to inspect modulation spool

and check torque on cap screws retaining control
valve to transmission.

Transmission system Failed transmission pump.

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

Add oil.
Do transmission system pressure test.

Restricted transmission pump Remove and clean screen.

suction screen.
Low transmission pump flow.

Do transmission pump flow test.

Excessive transmission
element leakage.

Do transmission element leakage test using

system pressure.

Stuck modulation valve.

Remove end cover to inspect modulation spool.

Replace if necessary.

Restricted modulation orifice.

Remove orifice and inspect for contamination and

/or plugging.

Malfunctioning two stage piston. Remove and inspect two stage piston.
Restricted oil passages Remove control valve and inspect oil passage.
between control valve and
transmission elements.

3-40

Problem

Cause

Remedy

Transmission direction Wrong transmission controller.

shifts too fast

Check if transmission controller has been

changed

System pressure too high.

Do transmission system pressure test.

Stuck modulation valve.

Remove and inspect modulation valve.

Replace if necessary. Also remove end cover to
inspect modulation spool and control valve
housing.
Replace if necessary.

Malfunctioning two stage piston. Remove and inspect two stage piston.
Stuck or missing check valves.

Inspect transmission control valve.

Missing O-ring from end of Remove orifice and inspect port for O-ring.
modulation orifice.
Broken piston return spring.
Machine "creeps"
in neutral

Disassemble and inspect clutch.

Warped disks and plates in Check transmission.

transmission.

Transmission hydraulic High oil level.

system overheats

Transmission overfilled or hydraulic pump seal

leaking.

Low oil level.

Add oil.

Wrong oil grade.

Change oil.

Park brake dragging.

Check for heat in park brake area.

Pinched, restricted or leaking Check cooler lines.

lube lines.
Machine operated in too high Operate machine in correct gear range.
gear range.
Malfunction in temperature Install temperature sensor the verify temperature.
gauge or sender.
Do tachometer/temperature reader installation
procedure.
Restricted air flow through oil Do radiator air flow test.
cooler or radiator.
Failed oil cooler bypass Disassemble and inspect.
valve(In thermal bypass valve).
Failed thermal bypass valve.

Remove thermal bypass valve and check to see if

machine still overheats. Do transmission oil
cooler thermal bypass valve test.

Internally restricted oil cooler.

Do oil cooler restriction test.

Leakage in transmission Do transmission system pressure, element

hydraulic system.
leakage, and shift modulation test.
Malfunction in converter relief Do converter out pressure test.
valve.
Low transmission pump output. Do transmission pump flow test.

3-41

Problem

Cause

Remedy

Excessive transmission Too low engine low idle.

Check engine low idle speed.
noise(Under load or no
Worn parts or damaged in Remove transmission suction screen.
load)
for metal particles.
transmission.
Repair as necessary.

Inspect

Warped drive line between Inspect drive line.

engine and torque converter.

Foaming oil

Low or no lube.

Do converter-out and lube pressure test.

transmission pump flow test.

Do

Incorrect type of oil.

Change oil.

High oil level.

Transmission overfilled or hydraulic pump seal

leaking.

Low oil level.

Add oil.

Air leak on suction side of Check oil pickup tube on side of transmission.
pump.
Oil ejected from dipstick Plugged breather.

Inspect breather on top of transmission.

Replace.

Machine vibrates

Aerated oil.

Add oil.

Low engine speed.

Check engine speed.

Failed universal joints on Check universal joints.

transmission drive shaft or
differential drive shafts.
Machine lacks power Engine high idle speed set too Check high idle adjustment.
and acceleration
low.
Incorrect transmission oil.

Change oil.

Aerated oil.

Add oil.

Low transmission pressure.

Do transmission system pressure test.

Warped transmission clutch.

Do transmission clutch drag checks.

Torn transmission control valve Inspect gasket.

gasket.
Brake drag.

Do brake drag check.

Failed torque converter.

Do torque converter stall speed test.

Low engine power.

Do engine power test.

Put clear hose on thermal bypass outlet port.
Run machine to check for bubbles in oil.

Torque converter stall Aerated oil.

RPM too high

Stuck open converter relief Do converter-out pressure test.

valve.
Leakage in torque converter Do converter-out pressure test.
seal.
Replace torque converter.
Torque converter not
transferring power(Bent fins,
broken starter).

3-42

Problem

Cause

Remedy

Torque converter stall Low engine power.

RPM too low
Mechanical malfunction.

Do engine power test.

Transmission pressure Low oil level.

light comes ON when
Cold oil.
shifting from forward to
reverse(All other gears Leak in reverse pack.
OK)

Add oil.

Remove and inspect torque converter.

Warm oil to specification.

Do transmission pressure, pump flow, and
leakage check.

Transmission pressure Cold oil.

Warm oil to specification.
light comes ON for each
No time delay in monitor.
Do monitor check.
shift
Restriction in modulation orifice. Remove orifice and inspect for restriction and/or
plugging.
Stuck modulation valve.

Remove and inspect.

Low transmission pressure Do transmission system pressure test.

circuit.
Leak in transmission pressure Do converter out pressure test.
circuit.
Failed transmission pump.

Do transmission pump flow test.

Clogged filter.

Inspect filter. Replace.

3-43

2) DIFFERENTIAL / AXLE
Problem
Differential low on oil

Cause

Remedy
Inspect axle and differential for leaks.

External leakage.

Excessive differential Low oil level in differential.

and/or axle noise

Check oil. Remove drain plug and inspect for

metal particles in differential case.
Disassemble and determine cause.

Incorrect type of oil.

Change oil

Dragging brakes.

Do brake check.

Failed pinion bearing.

Remove and inspect pinion.

Check to ensure pinion housing was indexed.

Incorrect gear mesh pattern Remove pinion gear housing and inspect ring and
between ring and pinion gear. pinion gear.
Failed differential pinion gears Remove differential housing drain plug and
inspect for metal particles. Disassemble and
and/or cross shafts.
inspect.
Failed axle bearing.

Do axle bearing adjustment check.

Mechanical failure in axle Remove differential. Inspect, repair.

planetary.
Oil seeping from outer Excessive end play in axle.
Do axle bearing adjustment check.
axle seal
Worn outer bearing and/or cup. Disassemble and inspect outer axle bearing, cup,
spacer, and seal. Replace, if necessary.

Axle overheats

Overfilled differential.

Check differential oil return system for excessive

internal restriction.

Low differential oil.

Add oil.

Overfilled differential.

See differential overfills with oil in this group.

Brake drag.

See brakes drag in this group.

3) DRIVE LINE
Problem

Cause

Remedy

Excessive drive line Yokes not in line on drive Inspect. Align drive shaft yokes.
vibration or noise
shafts.
Worn front drive line support Inspect, repair.
bearing.
Bent drive shaft.

Inspect all drive shafts. Replace.

Loose yoke retaining nuts(Drive Inspect. Replace.

shafts wobble at high speed).
Rear axle oscillating support.

Inspect, repair.

Lack of lubrication.

Lubricate with proper grade of grease.

3-44

GROUP 3 TESTS AND ADJUSTMENTS

1. CLUTCH CUT-OFF PRESSURE SWITCH TEST
The setting pressure of the clutch cut-off
pressure switch should be suited with the
specification. The rated pressure is 25 kgf/cm2.
For the detailed method for pressure adjusting,
refer to page 4-22.

Clutch cut off

pressure switch

Brake valve

3-45

2. TRANSMISSION PUMP PRESSURE AND FLOW TESTING

1) TEST PORT

B
A

K
D

M
N

Port
G

J
C

3 - 46

Description

Regulated clutch pressure snap

connector(Pressure switch)

Modulated forward clutch pressure

Reverse clutch pressure

2nd clutch pressure

3rd clutch pressure

1st clutch pressure

Converter outlet temperature

Converter outlet pressure

Converter inlet pressure

Port for lube oil from cooler

Port for converter out oil to cooler

Lube in pressure check point

Forward high(4th) clutch pressure

2) TESTING
Before testing is carried out, ensure that the oil is at the correct level and at normal operating
temperature 80~ 95
C(180~ 200
F).
3) TORQUE CONVERTER STALL TEST
Mark the engine crankshaft pulley with chalk or reflective tape and check the maximum no-load
speed of the engine using a stroboscopic tachometer.
Raise the loader arms and set the machine against fixed obstruction. Apply firmly the footbrake.
Select forward 3th and, with the throttle fully open, check engine speed which should be as shown
in technical data. Torque converter stall speed is 227070rpm.
Do not apply the clutch cut off switch during this test as the clutch disconnect will be
activated and a false reading will result.
Repeat the above test whilst simultaneously operating the loader arm raise service to blow off the
main relief valve.
Engine speed should be as shown in technical data.
If engine speeds are appreciably below the stated figures, the engine is losing power and should be
serviced or overhauled. Where the engine speed does not change significantly from the governed
speed, check the transmission for clutch slippage or internal leakage. Above phenomenon is also
indicated an incorrect torque converter.
4) CLUTCH LEAKAGE TEST
Connect a flowmeter between the transmission and oil cooler. With the parking brake firmly
applied, test at 1800rpm transmission input direction spool in forward or reverse and range spool in
1st, 2nd or 3rd. Converter out flow should not exceed 2.5GPM(9.5lpm) less than charging pump
flow or a max difference of 1GPM(3.8lpm) between any two speeds. Record the flow rate. Repeat
the test for each clutch pair.
5) CLUTCH PRESSURE TEST
Connect a pressure gauge to the clutch pressure tapping point A. Run the engine at idling speed,
engage clutches in sequence(As in previous test) and note the gauge readings which should be as
shown in technical data. Clutch pressure should be in 17~20bar(240~280psi).
Clutch pressure should not vary by more than 0.34bar(5psi) from one another. Any clutch showing
a greater variation should be disassembled for servicing.
Never use service brake while making clutch pressure checks.
Units having brake actuated declutching in forward and/or reverse will not give a true
reading.
Always use parking brake when making clutch pressure checks.

3-47

6) PUMP FLOW TEST

Stop the engine and remove transmission filter. Assemble flow test tool by locating adapter K
through center bore of body L and securing with adapter.
Screw body onto filter spigot on transmission and connect a flow meter N as shown.
Start the engine and run at 2000rpm. The flow meter will show the pump flow which should be as
shown in technical data. A low reading indicates a worn pump or blocked suction strainer.

K
M

Specifications
Oil temperature
Pump flow(Minimum)

80~ 95
C(180~200
F)
17.5GPM

Low transmission pump flow can be caused by :

Low oil level.
Cold transmission oil.
Plugged suction screen.
Air leak in pump suction tube.
Pump mounting cap screws loosen.
Worn transmission pump.

3 - 48

2. CONTROL VALVE
1) STRUCTURE
11
1
2

12

13

4
9
5

14

15

16
17

6
10

20
21

22

18

23
24

36
3
35
37

25
26
45
19
44

34
33
32

43

31

27

28
29
30

31

38
42

39
40
41

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

Elbow
Tube assy
Elbow
Valve plug
Shift spool
Spring
Shift spool
Plug
Valve spool
Spring
Plug & O-ring
Spring
Shift spool
Spool stop
Roll pin & plug stop

16
17
18
19
20
21
22
23
24
25
26
27
28
29
30

Spring
Shift spool
Pipe plug
Gasket
Plug
Spool stop
Spool
Spring
Valve body
Pipe plug
Lock washer
Screw
Lock washer
Screw
Shuttle valve solenoid
3-94

31
32
33
34
35
36
37
38
39
40
41
42
43
44
45

Solenoid coil
O-ring
O-ring
O-ring
Control valve housing
Spool stop
Ground wire harness
Screw
Receptacle & wire assy
Lock washer
Nut
Grommet
Dust cover
Dust cover seal
Mounting stud

2) DISASSEMBLY AND ASSEMBLY

The numerical sequence shown on the
illustration is intended as a guide to
disassembling.
For assembly the sequence should be
reversed.

7
6

(1) When disassembly

Depress spool 22 to remove stop 21.
Renew oil seals when spools 5 and 13
are removed.
Depress spool 9 to remove stop 36.

Nm

kgfm

lbfft

27, 29

31-33

3.2-3.4

23-25

2
1

(2) When assembly

Depress spool 9 to fit stop 36.
Take care not to cut lips of oil seals
when refitting spools 5 and 13.
Depress spool 22 to fit stop 21.
Refer to tightening sequence as shown
in the figure.
Torque settings
Item

3-95

10

11

12

SECTION 4 BRAKE SYSTEM

GROUP 1 STRUCTURE AND FUNCTION
1. OUTLINE
The brakes are operated by a pressure compensated, closed center hydraulic system.
Flow is supplied by a fixed displacement, gear type brake pump.
BRAKE SYSTEM
The fixed displacement brake pump supplies flow to service brake circuit and park brake circuits. It
flows to four accumulator. The accumulator has a gas precharge and an inlet check valve to
maintain a pressurized volume of oil for reserve brake applications.
Oil through the accumulator flows to the brake valves. The brake valve is a closed center design,
dual circuit operated by a pedal.
The front and rear brakes will operate simultaneously with only one brake pedal depressed.
The differential contains annular brake piston and double sided disk.
Brake pump flow also goes to the parking brake solenoid valve.
The brake system contains the following components:
Brake pump
Parking brake solenoid valve
Brake valve
Accumulators
Pressure switches

4-1

FULL POWER HYDRAULIC BRAKE

SYSTEM
ADVANTAGES - The full power hydraulic
brake system has several advantages over
traditional brake actuation systems. These
systems are capable of supplying fluid to a
range of very small and large volume
service brakes with actuation that is faster
than air brake systems. Figure represents
a time comparison between a typical
air/hydraulic and full power hydraulic brake
actuation system.

Response time
Full power brake actuation VS
Air/Hydraulic brake actuation
1000
900

Brake torque(lbin)

800

Full power systems can supply significantly

higher brake pressures with relatively low
reactive pedal forces. The reactive pedal
force felt by the operator will be proportional
to the brake line pressure being generated.
This is referred to as brake pressure
modulation.
Another key design feature of full power
systems is the ability to control maximum
brake line pressure. In addition, because
these systems operate with hydraulic oil,
filtration can be utilized to provide long
component life and low maintenance
operation.

Brake pressure
(Full power)

700
600
500

Brake pressure
(Air/hydraulic)
Brake torque
(Air/hydraulic)

400
300

Brake torque
(Full power)

200
100
0

2
Time(Seconds)

Because these systems are closed center,

by using a properly sized accumulator,
emergency power-off braking that is
identical to power-on braking can be
achieved. These systems can be either
dedicated, where the brake system pump
supplies only the demands of the brake
system or non-dedicated, where the pump
supplies the demands of the brake system
as well as some secondary down stream
hydraulic devise.
Another important note is that all seals
within these system must be compatible
with the fluid medium being used.

4-2

2. HYDRAULIC CIRCUIT

33

FRONT

REAR

21
18

Coupler cylinder

17

16

19
16
7

22
BR1

BR2 M2
DS1

S1
DS2

S2

Steering system

RCV

S3

20

P2

13

MCV

Return line
N

3MPa

P
P1

A 1st pump
B 2nd pump
C Brake pump

23
C

24
Return line

25

1
7
8
13
16
17

Pump assy
Brake valve
Check valve
Pilot supply unit
Accumulator
Accumulator

26

27

18
19
20
21
22
23

Solenoid valve
Pressure switch
Pressure switch
Pressure switch
Pressure switch
Line filter

4-3

24
25
26
27
33

Air breather
Hydraulic tank
Return filter
Bypass valve
Axle

1) SERVICE BRAKE RELEASED

33

FRONT

REAR

21
18

Coupler cylinder

17

16

19
16
7

22
BR1

BR2 M2
DS1

S1
DS2

S2

Steering system

RCV

S3

20

P2

13

MCV

Return line

3MPa

P
P1

23
C

A 1st pump
B 2nd pump
C Brake pump

24
Return line

25

26

27

When the pedal of brake valve(7) is released, the operating force is eliminated by the force of the
spring, and the spool is returned.
When the spool removes up, the exhaust port is opened and the hydraulic oil in the piston of axles
return to the tank(25).
Therefore, the service brake is kept released.

4-4

2) SERVICE BRAKE OPERATED

33

FRONT

REAR

21
18

Coupler cylinder

17

16

19
16
7

22
BR1

BR2 M2
DS1

S1
DS2

S2

Steering system

RCV

S3

20

P2

Return line

13

MCV

3MPa

P
P1

23
C

A 1st pump
B 2nd pump
C Brake pump

24
Return line

25

26

27

When the pedal of brake valve(7) is depressed, the operating force overcomes the force of the
spring, and is transmitted to the spool. When the spool moves down, the inlet port is opened, and
at the same time the hydraulic oil controlled the pressure level by the other spool in the brake valve
enters the piston in the front and rear axles. Therefore, the service brake is applied.

4-5

3) PARKING BRAKE RELEASED

33

FRONT

REAR

21
18

Coupler cylinder

17

16

19
16
7

22
BR1

BR2 M2
DS1

S1
DS2

S2

Steering system

RCV

S3

20

P2

13

MCV

Return line
N

3MPa

P
P1

23
C

A 1st pump
B 2nd pump
C Brake pump

24
Return line

25

26

27

When the parking brake switch is pushed, the solenoid valve(18) is energized and the hydraulic oil
enters the front axle. It overcomes the force of the spring and pushes the piston. This releases
the brake.
Therefore, the hydraulic oil pressure is applied to the parking brake piston in front axle through the
solenoid valve(18) and the parking brake is kept released.

4-6

4) PARKING BRAKE OPERATED

33

FRONT

REAR

21
B

18

Coupler cylinder

17

16

19
16
7

22
BR1

BR2 M2
DS1

S1
DS2

S2

Steering system

RCV

S3

20

P2

Return line

13

MCV

3MPa

P
P1

23
C

A 1st pump
B 2nd pump
C Brake pump

24
Return line

25

26

27

When the parking brake switch is pushed once more, the solenoid valve(18) is deenergized and the
valve open the exhaust port.
At the same time, the hydraulic oil return to the tank through the solenoid valve(18). When the
piston is returned by the force of the spring, the parking brake is applied.

4-7

3. BRAKE PUMP
1) STRUCTURE

31

20
21
22
24
27

32
33

25

23

23
22

21
20

35
26

28

24

36
30

29
19

19
20
21
22
23
24

Spacer plate
O-ring
Back up seal
Seal element
Bushing
Bushing

25
26
27
28
29
30

Driven gear
Drive gear
Rear body
O-ring
Splined coupling
Cap screw

31
32
33
35
36

Cover
Spring washer
Bolt
Dowel pin
O-ring

Brake pump used for the brake of this machine is pressure loaded type gear pump. This gear pump
have a maximum delivery pressure of 150kgf/cm2(2130psi).
The pressure loaded type gear pump is designed so that the clearance between the gear and the side
plate can be automatically adjusted according to the delivery pressure. Therefore, the oil leakage from
the side plate is less than that in the case of the fixed side plate type under a high discharge pressure.
Consequently, no significant reduction of the pump delivery occurs, even when the pump is operated
under pressure.

4-8

2) PRINCIPLE OF OPERATION
(1) Mechanism for delivering oil
The drawing at right shows the
operational principle of an external gear
pump in which two gears are rotating in
mesh.
The oil entering through the suction port is
trapped in the space between two gear
teeth, and is delivered to the discharge
port as the gear rotates.
Except for the oil at the bottom of the gear
teeth, the oil trapped between the gear
teeth, is prevented from returning to the
suction side with the gears in mesh.
Since the gears are constantly delivering
oil, the oil delivered to the discharge port
is forced out of the port.
The amount of discharge increases with
the speed of rotation of the gear.
If there is no resistance in the oil passage
into which the discharged oil flows, the oil
merely flows through the passage,
producing no increase in pressure.
If however, the oil passage is blocked with
something like a hydraulic cylinder, there
will be no other place for the oil to flow, so
the oil pressure will rise. But the pressure
which rises in this way will never go
higher, once the hydraulic cylinder piston
starts moving because of the oil pressure.
As described earlier, the pump produces
the oil flow, but not the oil pressure. We
can therefore conclude that pressure is a
consequence of load.
In other words, the pressure depends on
a counterpart.

Suction

4-9

Discharge

(2) Internal oil leakage

Oil leaks from a place under higher
pressure to a place under lower pressure,
provided that a gap or a clearance exists
in between.
In the gear pump, small clearances are
provided between the gear and the case
and between the gear and the side plate
to allow the oil to leak out and to serve as
a lubricant so that the pump will be
protected from seizure and binding.
The drawing at right shows how the
leaked oil flows in the pump. As such,
there is always oil leakage in the pump
from the discharge side(Under higher
pressure) to the suction side. The
delivery of the pump is reduced by an
amount equal to the pump discharge.
In addition, the delivery of the pump will
also decrease as the amount of oil
leakage increases because of expanded
radial clearance resulting from the wear of
pump parts, the lower oil viscosity
resulting from increases in the oil
temperature, and the initial use of low
viscosity oil.

rge
cha
s
i
D

n
ctio
Su

4-10

(3) Forces acting on the gear

The gear, whose outer surface is
subjected to oil pressure, receives forces
jointing towards its center.
Due to the action of the delivery pressure,
the oil pressure in higher on the delivery
side of the pump, and due to suction
pressure, is lower on the suction side. In
the intermediate section, the pressure will
gradually lower as the position moves
from the delivery side to the suction side.
This phenomenon is shown in the
drawing at right.
In addition, the gears in mesh will receive
interacting forces.
These forces pushing the gears toward
the suction side are received by the
bearings. Since the gears are pressed
toward the suction side by these forces,
the radial clearance becomes smaller on
the suction side in the case. In some
pumps, the clearance may become zero,
thus allowing the gear teeth and the case
to come into light contact.
For this reason, an excessive increase in
the delivery pressure must be avoided,
since it will produce a large force which
will act on the gears, placing an overload
on the bearings, and resulting in a
shortened service life of the bearing or
interference of the gear with the case.

Drive gear

Suction
side

Discharge
side

Driven gear

Pressure distribution

4-11

(4) "Trapping" phenomenon of the oil

When a gear pump is rotating with the
gears in mesh as shown in the drawing at
right, in some instances two sets of gear
teeth are in mesh while in other instances
only one set of the gear teeth is in mesh.
When two sets of the teeth are in mesh
simultaneously, the oil in the space
between the meshed gear teeth will be
trapped inside-the front and rear exits will
be completely shut.
This is called the "trapping" phenomenon
of oil.
The space in which the oil is trapped
moves from the suction side to the
delivery side as the gears rotate. The
volume of the space gradually decreases
from the start of trapping until the space
reaches the center section, and then
gradually increases after leaving the
center section until the end of trapping.
Since the oil itself is non-shrinkable, a
reduction of the volume of space will
greatly increase the oil pressure, unless
some plosion in made to relieve oil
pressure. The high pressure oil will
cause the pump to make noise and
vibrate.
To prevent this, relief notches are
provided on the side plates to release the
oil to the delivery side.
As shown in the drawing at right, the relief
notches are provided in such a way that
the oil can be relieved from the tapping
space to the delivery side when the
volume of the space is reduced.
Relief notches are also provided on the
suction side to prevent the formation of a
vacuum in the space by allowing the oil to
enter the space from the suction side
when the space is reduced.

Delivery
side

Suction side

Trapping starts
The space
reaches the
minimum

Trapping ends

Fixed side plate type

Side plate

Relief notch

Pressure loaded type

4-12

Bushing

4. BRAKE VALVE
1) STRUCTURE

72

42

80
26

41

86
27
4
28
5
55
64

14

1.25

82
32

36
21
37
65
1

41
18

43

1.47

1.22
12
30

29
12

1.23

87

31
59
24
115

1
1.22
1.23
1.25
1.47
4
5
9
12
14
18
21

Housing
Spool
Spool
Spool
Spool
Sleeve
Sleeve
Sleeve
Spring retainer
Spring retainer
Unit WVI
Spring retainer

24
26
27
28
29
30
31
32
36
37
41
42

Reducer
Spring
Spring
Spring
Spring
Spring
Spring
Spring
Circlip
Circlip
Locking screw
Locking screw
4-13

43
55
59
64
65
72
80
82
86
87
115

Locking screw
O-ring
O-ring
Thrust ring
Shaft seal
Pedal unit
O-ring
Spring
Unit RV
Sleeve
Locking screw

2) OPERATION

M1
N
S1

BR1

M2

BR2

M2
DS1

BR1
DS2

S1

S3

S2

DS2
S3

BR2

S2
T

VIEW A
Port

Port name

Size

From main pump

M181.5

To hydraulic tank

M181.5

BR1

To service brake in front axle

M161.5

BR2

To service brake in rear axle

M161.5

DS1

Pressure switch stop light

M121.5

DS2

Pressure switch accumulator pressure

M121.5

S1

Accumulator service brake

M181.5

S2

Accumulator service brake

M181.5

S3

Accumulator parking brake

M161.5

M2

Accumulator parking brake

M121.5

To hydraulic tank

M161.5

4-14

(1) Accumulator charging valve

The accumulator loading valve or
pressure switch-off valve has the purpose
to keep a pressure level within certain limit
values(Switch-off pressure, switch-on
pressure) in an accumulator circuit. The
switching pressure difference is approx
18% of the switch-off pressure.

S2

1
S1

If actuators(N) downstream from the

pump produce a higher pressure than the
switch-off pressure of the accumulator
loading valve the accumulator circuit is
raised to this pressure level.

The valve consists mainly of pilot control

with pressure setting element(1), pressure
compensator(2) and check valve(3).
Switching over of pump flow from accumulator load into neutral circulation
The pump delivers into the accumulator circuit via the check valve(3) during the loading
procedure. For this the pressure is passed to the load signal side of the pressure compensator(2)
via the control line and pilot control. This throttles the pump flow until the pressure, which builds
up in the accumulator circuit, overcomes the spring force of the pressure setting element(1).
The pilot control element switches the load signal line of the pressure compensator(2) from S1 to
T. The pressure compensator(2) then switches the pump flow from P to N and the check valve(3)
closes. The loading pressure is complete and the pump flow flows with low p through the
loading valve.
Switching over of pump flow from neutral circulation into accumulator load
If the pressure in the accumulator circuit decreases to the lower switching point(Adding pressure)
P is connected to the load signal chamber of the pressure compensator(2) and the pump delivers
again into the accumulator circuit.

4-15

(2) 2 circuit brake valve

The 2-circuit remotely powered braking
valve is direct controlled pressure relief
valve in 3-way design with infinite
mechanical operation.

BR1

It has a maximum pressure relief of

secondary circuits and infinite adjustability
of pressure in the secondary circuits
(Braking circuits) proportional to the
direction of the operating element(4).

1
BR2

M2
DS1

With failure of one braking circuit the

second braking circuit remains fully
functional because of the mechanical
contact of both spools(2).

SP1

SP2

The operating force at the pedal remains

unchanged.
The 2-circuit remotely powered brake valve consists mainly of housing(1) and control spool(2),
main compression spring(3), operating element(4) and the return springs(5) and (6).
The valve is operated via the operating element(4). It pushes the main control spring(3) against
both control spools(2). First the control edges close at channel T, afterwards the flow from SP and
BR is released in both braking circuits.
The pressure building up in the brake lines pushes simultaneously via the pilot oil drillings(7)
behind the control spool against the main compression spring(3) so that the braking
pressure(Secondary pressure) rises proportional to the operating element kept constant the
control spools(2) moves into control position and holds the controlled pressure in channels BR1
and BR2 constant. The operating force of the operating element is proportional to its deflection.
When the main compression spring(3) is unloaded the pressure springs and the control spools
move in such a way that they close SP towards BR and open BR towards T and thus close the
secondary circuits(Braking circuits).

4-16

5. BRAKE ACCUMULATOR
1) STRUCTURE
Item

A
C

31EC-0219
(Item16)

81L1-0004
(Item15)

Diameter

121mm

121mm

Mounting height

145mm

151mm

Norminal volume

0.75m

0.75m3

Priming pressure

7kgf/cm2

50kgf/cm2

Operating medium

Oil

Operating pressure

Max 56kgf/cm

Max 180kgf/cm2

Thread

M181.5

M181.5

Operating
temperature range

-30 ~ 80
C

-30 ~ 80
C

Priming gas

Nitrogen

Nitrogen

A Fluid portion
B Gas portion

Oil
2

C Diaphragm
D Valve disk

2) OPERATION
(1) Purpose
Fluids are practically incompressible and are thus incapable of accumulating pressure energy. In
hydropneumatic accumulators, the compressibility of a gas is utilized to accumulate fluid. The
compressible medium used in the accumulators is nitrogen.
In braking systems, the purpose of the accumulators is to store the energy supplied by the
hydraulic pump. They are also used as an energy reserve when the pump is not working, as a
compensator for any losses through leakage, and as oscillation dampers.
(2) Operation
The accumulator consists of a fluid portion(A) and a gas portion(B) with a diaphragm(C) as a gastight dividing element. The fluid portion(A) is connected to the hydraulic circuit, causing the
diaphragm accumulator to be filled and the gas volume to be compressed as the pressure rises.
When the pressure falls, the compressed gas volume will expand, thus displacing the
accumulated pressure fluid into the circuit.
The diaphragm bottom contains a valve disk(D) which, if the diaphragm accumulator is
completely empty, closes the hydraulic outlet, thus preventing damage to the diaphragm.
(3) Installation requirements
The accumulators can be fitted in the hydraulic circuit, directly on a component or in blocks on
suitable consoles.
They should be fitted in as cool a location as possible.
Installation can be in any position.

4-17

(4) Maintenance of the accumulator

No special maintenance beyond the legal requirements is necessary.
The accumulator should be checked annually. It should be replaced if the initial gas
pressure has fallen by more than 30%(Please refer to Performance testing and
checking of the accumulator).
(5) Disposal of the accumulator
Before the accumulator is scrapped, its gas filling pressure must be reduced. For this
purpose, drill a hole through gas chamber(B) using a drill approx. 3mm in diameter. The
gas chamber is located on the side opposite the threaded port above the welding seam
around the center of the accumulator.
Wear safety goggles when doing this job.
(6) Performance testing and checking of the accumulator
The accumulator is gradually pressurized via the test pump; until the initial gas pressure is
reached, the hydraulic pressure in the accumulator will rise abruptly. This is apparent
from gauge M. If the initial gas pressure is more than 30% below the prescribed value,
the accumulator needs to be replaced. If the measuring process needs to be repeated,
wait for intervals of 3 minutes between the individual tests. Any accumulator whose initial
gas pressure is insufficient must be scrapped following the instructions under Disposal of
the accumulator.
The amount of initial gas pressure can also be checked from the vehicle. Start the
vehicle's engine. The pump will now supply oil to the accumulators. Until the initial gas
pressure is reached, the hydraulic pressure in the accumulator will rise abruptly. This is
apparent from the gauge in the cab. If the initial gas pressure is more than 30% below the
prescribed value, that initial pressure lies outside the permissible range for at least one of
the accumulators fitted in the vehicle. This accumulator can be traced only by using the
method described above, i.e. all accumulators have to be individually tested. The
accumulator whose initial gas pressure is insufficient must be replaced and scrapped
following the instruction under Disposal of the accumulator.

Accumulator

Safety valve

4-18

(7) Repair work

When working on the braking system, always make sure that there is absolutely no
pressure in the system. Even when the engine in switched off there will be some residual
pressure in the system.
When doing repair work, make sure your environment is very clean.
Immediately close all open ports on the components and on pipes using plugs.
For safety reasons the accumulators need to be replaced as a whole if damaged.

4-19

6. PRESSURE SWITCHES
1) STRUCTURE

Normally closed
H1

Normally open

H2

Technical data
Type

Medium

H1
mm

H2
mm

Adjusting range
kg/cm2

Parking

NC

Oil

M121.5

55

10 ~ 20

13 1

Max 42

Charging

NC

Oil

M121.5

55

20 ~ 50

45 2

Max 42

Brake stop

NO

Oil

M121.5

55

1 ~ 10

51

Max 42

Clutch cut off

NO

Oil

55

20 ~ 50

25 1

Max 42

Item

NC : Normally closed

NO : Normally open

4-20

Adjusting pressure Voltage

kg/cm2
V

2) OPERATION
(1) Purpose
The pressure switches are used to visually or audibly warn the driver of the pressure within the
system.
(2) Make contact / circuit closer
The pressure switch can be fitted in the braking system or directly on one of its components.
The system pressure acts on an absorption area within the switch, making an electrical contact as
the pressure on that area is increased. The resulting current is used to activate a warning facility,
for instance.
(3) Break contact / circuit breaker
The pressure switch can be fitted in the braking system or directly on one of its components.
The system pressure acts on a absorption area within the switch, breaking an electrical contact
as the pressure on that area is increased. The current is now broken, e.g. to deactivate a
warning facility.
(4) Installation requirements
No special measures need to be taken.
(5) Maintenance of the pressure switch
No special maintenance beyond the legal requirements is necessary.
When using high-pressure cleaners on the vehicle, please make sure that the water jet is not
directed at the pressure switch(Corrosion of contacts).
(6) Repair work
When working on the braking system, always make sure that there is absolutely no
pressure in the system. Even when the engine is switched off there will be some residual
pressure in the system.
When doing repair work, make sure your environment is very clean.
Immediately close all open ports on the components and on pipes using plugs.
For safety reasons the pressure switch needs to be replaced as a whole if damaged.

4-21

(7) Adjusting and testing pressure switch

The adjusting screw located between the two contact plugs can be set to the desired value within
a certain range. For adjusting range, please refer to the table Technical data on the previous
page.
After making the adjustment, the adjusting screw should be secured using wax or a similar
material.

(,)
(+)

4-22

Screw

GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING

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

: Troubleshooting
: Tests and adjustments

4-23

Hydraulic oil must be at operating temperature for these checks(Refer to page 6-51).
Item
Parking brake capacity
check
Seat belt must be worn
while doing this check to
prevent possible injury
when machine stops
suddenly.

Description
Start engine.
30

20

20

10

40

10
5

mph

km/h

30

50

Fasten seat belt.

Release parking brake and put
transmission in 2nd gear forward.

Service action
OK
Check completed.
NOT OK
Inspect parking brake. Go
to group 3.

Drive machine at 8 km/hr and

switch parking brake ON.
LOOK/FEEL : Machine must
come to a stop within 2 meters(6
feet) when parking brake is
engaged at 8 km/hr.
Transmission must shift to neutral.

Parking brake
transmission lockout
check
Engine running.

Turn parking brake to ON.

Place transmission in 1st forward.

OK
Check completed.

NOT OK
Slowly increase engine speed to
Go to transmission control
high idle.
circuit in section 3.
LOOK : Machine must not move.

4-24

Item

Description

Service brake pump

flow check
Hydraulic oil must be at
operating temperature
for the check.
Engine OFF.

Stop engine.

Service brake capacity

check
Engine running.

Turn clutch cut-off switch OFF.

Service action
OK
Check completed.

Operate brake pedal approximately 20

NOT OK
times.
Check for brake circuit
Start engine and run at low idle.
leakage.
Record number of seconds
required for low brake pressure Go to next page.
indicator lamp to go out.
IF OK
LOOK : Indicator lamp must go Install a cap on line
out in less than 4 seconds from connected to inlet of
time engine starts.
pressure reducing valve
and repeat pump flow
NOTE : Indicator will not come on
check.
approximately 1 second after
starting engine.
If time does not decrease,
check for worn brake
pump. Go to brake pump
flow test, in section 3.
OK
Check completed.

Apply service brakes, release park

brake and put transmission in 2nd NOT OK
forward.
Check brake pressure in
group 3.
Increase engine speed to high
IF OK
idle.
Inspect brake disk, see
LOOK : Machine may not move
group 3.
or move at a very slow speed.
Repeat check three times to
ensure accurate results.

4-25

Item
Brake accumulator
precharge check
The axles and hydraulic
oil must be at operating
temperature for this
check.

Description

Service action

Start and run engine for 30 OK

seconds.
Check completed.
ON

F
OF

STAR
T

Stop engine and turn key switch to NOT OK

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

Brake system leakage

check
ON

F
OF

STAR
T

Stop engine.
Wait 2 minutes.
Turn key switch to ON and wait 5
seconds.
LOOK : Brake oil pressure
warning lamp must not come on
within 2 minutes after stopping
engine.

OK
Check completed.
NOT OK
If brake leakage is
indicated with brakes
released, check leakage
at accumulator inlet check
valve and brake valve. If
brake leakage is indicated
with brakes applied, check
for leakage at brake valve
and brake pistons.
Check individual
component leakage.

4-26

Item

Description

Service action

Service brake pedal

check

Slowly depress brake pedal.

Service and parking

brake system drag
checks
Engine running

Position machine on gradual OK

slope.
Check completed.

OK
Check completed.

Listen for a hissing noise that

indicates oil is flowing to brake NOT OK
pistons.
Inspect for debris under
brake pedal. Inspect
LISTEN/FEEL : A hissing noise
clutch cut off linkage.
must be heard when pedal is
depressed.

Lower bucket approximately

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

Clutch cut off check

Place clutch cut off switch in ON

position.
Release parking brake.

OK
Check completed.

NOT OK
Adjust clutch cut off
Run engine at half speed in 1st
pressure switch, see page
forward.
4-20.
Firmly depress brake pedal.
FEEL : Transmission must
disengage when brake pedal is
depressed at 30% of pedal stroke.
NOTE : Clutch cut off pressure
switch can be adjusted to operator
preference to match your loading
needs.

4-27

2. TROUBLESHOOTING
1) SERVICE BRAKE
Diagnose malfunction charts are arranged from most probable and simplest to verify, to least likely,
more difficult to verify. Remember the following steps when troubleshooting a problem :
Step 1. Operational check out procedure(See section 1)
Step 2. Operational checks(In this group)
Step 3. Troubleshooting
Step 4. Tests and adjustments(See group 3)

Problem
Poor or no brakes

Cause

Remedy

Brake accumulator charge low.

Do brake accumulator check.

Brake pump standby pressure Do brake pump standby pressure test.

low.

Aggressive brakes

Brakes drag

Brake pressure low.

Do brake valve pressure test.

Air in system.

Bleed brakes.

Worn brake surface material.

Inspect brake surface material.

Leakage in brake valve.

Do brake valve leakage test.

Leakage in brake piston seal.

Check for an over filled differential.

Apply brakes and check for leakage from check
plug.
It is normal for the oil level to be slightly
above the check plug.

Wrong oil in hub.

Drain and refill.

Internal restriction in circuit.

Remove lines and components.

Brake valve malfunction.

Disassemble and inspect.

Low oil level.

Check oil level.

Brake pedal not returning Inspect floor mat and pedal.

properly.
Debris holding valve partially Do brake valve pressure test.
open in brake valve.

Brakes lock up

Warped brake disk.

Inspect brake disk.

Stuck brake piston.

Repair.

Brake valve malfunction.

Clean or replace brake valve.

4-28

Problem
Brakes chatter

Cause

Remedy

Air in brake system.

Do brake bleed procedure.

Worn brake surface material.

Inspect brake surface material.

Wrong oil in differential.

Drain. Refill.

Hissing noise when Leakage in brake valve, or

brake pedal is held with brake piston.
engine stopped

Do brake system leakage test.

Brake pressure warning Malfunction in brake low

light will not go out or pressure warning switch.
stays on excessively
Brake accumulator pressure
long after start-up
too low.

Replace switch.
Recharge accumulator.

Low brake pump standby

pressure setting.

Do brake pump standby pressure test.

Leakage in pressure reducing

manifold block.

Do pressure reducing valve manifold leakage

test.

Leakage in brake system.

Do brake system components leakage tests.

Worn brake pump.

Do brake pump flow test.

Leakage in parking brake

solenoid.

Do parking brake pressure test.

4-29

2) PARKING BRAKE MALFUNCTIONS

Problem
Brake will not hold

Brake disk overheats

Cause

Remedy

Pads not adjusted correctly.

Adjust parking brake.

Malfunctioning parking brake

solenoid.

Inspect and replace.

Worn brake disk and/or brake

pads.

Disassemble, inspect, repair.

Brake piston hangs up in bore.

Remove and inspect. Repair.

Pads out of adjustment.

Adjust parking brake.

Brake not released.

Release parking brake.

Disassemble, inspect brake.
Repair if necessary.
Inspect for loosen or broken lines between brake
pressure switch and indicator on dash.

Parking brake indicator Faulty wiring or switch.

in monitor does not
come on when brake
applied

Inspect for loose or broken lines between brake

pressure switch and indicator on dash.
Inspect for a faulty indicator on dash. Replace if
necessary.

Brake will not apply

Pads out of adjustment.

Adjust parking brake.

Malfunctioning wiring, switch,

or solenoid.

Check electric circuit.

Restriction between brake

valve and brake.

Remove hose and inspect. Replace.

4-30

GROUP 3 TESTS AND ADJUSTMENTS

1. PARKING BRAKE PERFORMANCE
1) MEASUREMENT CONDITION
(1) Tire inflation pressure: Specified pressure
(2) Road surface : Flat, dry, paved surface
20') gradient.
with 1/5(11
(3) Machine : In operating condition
Item
Parking brake
performance

20%
gradient

Standard valve

11
20'

Keep machine on 20%

(11
20') gradient

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

11
20'

2. EXTERNAL BRAKE INSPECTION

Remove axle housing and inspect for wear of
brake disks.
Replace brake disks if oil grooves of facing
material are no longer visible.

4-31

20%
gradient

3. HYDRAULIC BRAKE BLEEDING PROCEDURE

Escaping fluid under pressure can
penetrate the skin causing serious injury.
Avoid the hazard by relieving pressure
before disconnecting hydraulic or other
lines. Tighten all connections before
applying pressure.
Search for leaks with a piece of
cardboard. Protect hands and body from
high pressure fluids.

If an accident occurs, see a doctor

immediately. Any fluid injected into the
skin must be surgically removed within a
few hours or gangrene may result.
Doctors unfamiliar with this type of injury
should reference a knowledgeable
medical source.
Two people are required to bleed brake
system oil, one to operate brake valve and
other to open and close bleed screws.
1) Install frame locking bar.
brake.

Engage parking
A

2) Put a clear plastic tube on bleed screw(B)

to route low to hydraulic reservoir filler tube
or container(A).
3) Start engine and run at low idle.
4) Push and hold brake pedal down until
brake bleeding procedure is complete.
If bubbles continue for more than 2
minutes, stop bleeding procedure.
Check for and correct problem, then
continue.
5) Open on bleed screw on differential and
axle assembly until hydraulic oil starts to
flow. Close bleed screw when oil is free of
air. Release brake pedal.

Frame locking bar

6) Repeat steps 1) ~ 5) for each bleed screw.

7) Push either brake pedal and hold down.
8) Check hydraulic oil level.

4-32

GROUP 4 DISASSEMBLY AND ASSEMBLY

1. BRAKE PUMP
1) STRUCTURE
31

20
21
22
24
27

32
33

25

23

23
22

21
20

35
26

28

24

36
30

29
19

19
20
21
22
23
24

Spacer plate
O-ring
Back up seal
Seal element
Bushing
Bushing

25
26
27
28
29
30

Driven gear
Drive gear
Rear body
O-ring
Splined coupling
Cap screw

4-33

31
32
33
35
36

Cover
Spring washer
Bolt
Dowel pin
O-ring

2) GENERAL
(1) Introduction
Each unit comprises an end cover, body housing, the bush/gear assembly and a mounting flange
bolted together. The gear/bush assembly consists of a pair of meshing gears supported by plain
bearings in the bushes. The drive gear journal extends through the mounting flange to form the
drive shaft. A lip type shaft seal and O-rings provide external sealing whilst special lobe seals and
backing rings are used internally.
(2) Routine maintenance
No maintenance is necessary other than periodic checks for tightness of the mounting bolts and
visual examination for oil leakage. The unit should be kept externally clean, especially in the area
of the shaft seals as dirt can accelerate seal wear and cause leakage.
The unit must be operated only with clean oil and the system manufacturer's directions for
periodic renewal of system oil filter elements must be strictly observed.
(3) Field servicing
Seal kits and spare parts are available to enable units to be serviced.

4-34

3) DISASSEMBLY
31

20
21
22
24
27

32
33

25

23

23
22

21
20

35
26

28

24

36
30

29
19

Before disassembling ensure that the unit itself, bench and tools are thoroughly clean.
(1) Lightly mark the end cover(31), body(27) and spacer plate(19) to ensure reassembly in the
correct position.
(2) Remove the bolts(32) and separate the brake pump unit from the main pump using a soft faced
hammer.
(3) Remove splined coupling(29) and O-rings(28,36) sealing the internal passages between the
pump sections.
(4) Remove the spacer plate(19) from the body(27), free from spacer plate from location dowel(35)
using a soft faced hammer.
(5) Remove the backup seal(21), the seal element(22) and the body O-ring(20).
(6) Remove the end cover(31) from the body(27).
(7) Remove the backup seal(21), the seal element(22) and the body O-ring(20).
Before removing the internal components each bushing(23, 24) must be marked to denote its
location within the body. On the plain area of the bush away from the seal location, lightly mark.
(8) With the unit laying on its side grasp hold of the drive shaft(26) and pull it squarely out of the body
(27) bringing the bushing(23, 24) with it.
(9) Remove the driven gear(25) and the two remaining bushing(23, 24).

4-35

4) INSPECTION AND REPAIR

(1) Assessment
Each components should be thoroughly cleaned, carefully examined and assessed for suitability
re-use. Below is a guide for inspecting the various components.
(2) Body
Inspect the body bore cut-in where both gears wipe into the body.
The body can only be re-used if the cut-in is bright and polished in appearance and the depth
does not exceed 0.15mm(0.006").
The body should be replaced if the surface is scored, has a matt appearance or shows signs that
the tip of the gears have dug in and torn away the surface material.
The body should be inspected to ensure that there is no superficial damage which may
adversely effect performance or sealing. Pay particular attention to the port threads and body Oring seal recesses.
(3) Spacer plate and end cover
The inner surfaces should be inspected to ensure that there is no unusual wear or scoring in the
regions where the body O-rings and backing rings contact, which result in external leakage.
Check the shaft seal recess for scoring or damage that could result in oil leakage around the
outer diameter of the shaft seal. Replacement shaft seals can be refitted with Loctite hydraulic
sealant to overcome slight damage in this area.
(4) Bushing
The side faces which abut the gears should be perfectly flat showing no sign of scoring.
Characteristically there are bright polished areas on this surface caused by loading against the
gear side faces, which is often more pronounced on the low pressure side. The bush should be
replaced if there is any general scoring or fine scoring with a matt appearance or tearing of the
surface material. Often there is a witness where the tips of the opposing gears have wiped an
overlap reassembling a half moon shape. There must be no noticeable wear step as it is critical
that the bush side face is completely flat to the gear side face.
The bearing liners are acceptable providing that they are not scored or show other damage.
The general outside area of the bush should not show any prominent signs of wear.
(5) Gears
The gear side faces should be examined for bruising or scoring. Often operation on
contaminated fluid shows scoring between the root of the gear and the journal undercut, which
leaves a wear step. If a wear step can be felt, coincidental with the root diameter, by drawing a
sharp pointed tool across the surface from the undercut outwards towards the tip of the gear,
then the gear is unserviceable.
The gear teeth should then be carefully examined to ensure that there are no signs of bruising or
pitting.
The journal bearing surfaces should be completely free from scoring or bruising. The surface
should appear highly polished and smooth to touch.
Examine the area where the shaft seal lips run on the drive shaft, this shows up as a polished
ring or rings. If a noticeable groove can be felt or there is scoring the shaft should be replaced.
Provided the drive shaft is not damaged from the drive-coupling and the gears have not been
harmed as described above, then the gears can be re-used. If, however, the gears are
damaged they must be replaced as a matched pair.
As a matter of good practice, when pumps have been disassembled, all the seals should be
replaced. It is most important that only the genuine seals are used.
4-36

5) ASSEMBLY

31

20
21
22
24
27

32
33

25

23

23
22

21
20

35
26

28

24

36
30

29
19

Ensure that all parts are perfectly clean and lightly lubricate the bushes and gears with hydraulic
oil(Ensure body O-ring recess and end faces remain free from oil). This will assist with their
assembly when they are later fitted into the body.
(1) Refit the cover drive shaft bushing(23) and cover driven bushing(24) into the undowelled end of
the body(27) from where they were removed.
(2) Place the end cover(31) against the body(27) and then stand the assembly on the cover so that
the hollow dowels are uppermost, i.e. the bushing should be at the bottom with the bushings
against the cover.
(3) Fit the drive shaft(26) and driven gear(25) back into their original positions in the body(27).
(4) Refit the separate plate drive shaft bushing(24) and the separate plate driven bushing(23) into
their original bores.
(5) Fit the new body O-ring(20).
(6) Fit the new seal element(22) and backup seal(21) to the bushing.
(7) Fit the dowel(35) to the body(27).
(8) Carefully refit the spacer plate(19) to the body(27). If the spacer plate(19) is not fitted squarely
the backup seal(21) may become misplaced and trapped, resulting in internal damage if the unit
is run in this condition.

4-37

ASSEMBLY

31

20
21
22
24
27

32
33

25

23

23
22

21
20

35
26
24

28
36

30

29
19

(9) Fit O-rings(28, 36) and coupling(29) to the spacer plate(19).

(10) Holding the whole unit together carefully turn it over, making sure it is supported on the spacer
plate(19) not the shaft.
(11) Slide off the end over and fit seals as in (5) and (6) above.
(12) Fit the end cover(31), taking care not to dislodge the backup seal(21) and bolt(33) the unit
together. Tighten the bolts to the torque figures stated below.
Tightening torque : 5.00.3kgfm(36.22.2lbfft)
Pour a small amount of oil into a port and check that the shaft can be rotated without undue force
using a smooth jawed hand wrench hooked around the shaft or a suitable half coupling locked
against the key.

4-38

6) RUNNING-IN

Pressure gauge

Test unit

Microbic
filter

Variable
restrictor

Flow
meter
Relief valve
Strainer
Tank

(1) A unit which has been re-assembled with either new gears, bushes or body, must be carefully
run-in before it is subjected to full working conditions.
(2) Ideally this should be done on a test rig(See figure) where pressure can be gradually applied and
any wipings from the body cut-in arrested by filters.
(3) It is recommended that the unit is run-in at 1500rpm, initially, at zero pressure for one minute then
in stages with the pressure increased by 500psi every minute, until maximum rated pressure has
been attained. Frequently check the system temperature, ensuring that it does not exceed the
maximum permissible figure of 80
C. If the temperature exceeds the system or unit specification
the test must be delayed and operated off-load until acceptable temperatures are obtained.

4-39

SECTION 5 STEERING SYSTEM

GROUP 1 STRUCTURE AND FUNCTION
1. OUTLINE
The steering system of this machine consists of a fixed-displacement pump supplying a load sensing
steering system and an open center loader system.
The components of the steering system are :
Steering pump(2nd pump)
Steering unit
Overload valve block
Priority valve
Steering cylinders
The steering pump, the second pump of main pump, draws hydraulic oil from the hydraulic tank.
Outlet flow from the pump flows to the priority valve. The priority valve preferentially supplies flow, on
demand, to the steering unit. When the machine is steered, the steering unit routes flow to the
steering cylinders to articulate the machine.
When the machine is not being steered, or if pump flow is greater than steering flow, the priority valve
supplies flow to the loader system.
That is, output flow from the steering pump enters into the first pump of main pump for the operation
of the attachment.

5-1

2. HYDRAULIC CIRCUIT

10

LH

RH

6
R

MCV

21MPa

RCV lever
LS

20

32
CF

EF

4
A
B
C

LS
P

Brake system
C

Return line

33 32
LS

31

EF

1st pump
2nd pump
Brake pump

24
Return line

21MPa

18
A

25
26

27

1
4
5
6
10

Main pump
Priority valve
Steering unit
Overload valve block
Steering cylinder

18
20
24
25
26

Pressure switch(Option)
Pressure switch(Option)
Air breather
Hydraulic tank
Return filter

5-2

27
31
32
33

Bypass valve
Emergency pump(Option)
Check valve(Option)
Check valve(Option)

1) NEUTRAL

10

LH

RH

6
G
R

MCV

T
P

21MPa

RCV lever
LS

CF

EF

4
LS

D
P

Brake system
B

Return line

24

A
B

1st pump
2nd pump

Return line

25
26

27

Emergency steering system

The steering wheel is not being operated so control spool(G) does not move.
The oil from the steering pump(B) enters port P of the priority valve and the inlet pressure oil moves
the spool(D) to the right.
Oil flow into LS port to the hydraulic tank(25) through orifice and return filter.
So, the pump flow is routed to the loader system(Main control valve) through the EF port.

5-3

2) LEFT TURN

10

RH

LH

6
G
R

E
H

MCV

T
P

21MPa

RCV lever
LS

CF

EF

4
LS

D
P

Brake system
B

Return line

24

A
B

1st pump
2nd pump

Return line

25
26

27

Emergency steering system

When the steering wheel(E) is turned to the left, the spool(G) within the steering unit(5) connected
with steering column turns in left hand direction.
At this time, the oil discharged from the steering pump flows into the spool(G) of the steering unit(5)
through the spool(D) of priority valve and flows into the gerotor(H).
Oil flow from the gerotor flows back into the spool(G) where it is directed out the left work port(L) to
the respective chamber of the steering cylinders(10).
Oil returned from left and right cylinder returns to hydraulic tank through the spool of the steering unit.
When the above operation is completed, the machine turns to the left.
5-4

3) RIGHT TURN

10

RH

LH

6
R

E
H

MCV

T
P

21MPa

RCV lever
LS

CF

EF

4
LS

D
P

Brake system
B

Return line

24

A
B

1st pump
2nd pump

Return line

25
26

27

Emergency steering system

When the steering wheel(E) is turned to the right, the spool(G) within the steering unit(5) connected
with steering column turns in right hand direction.
At this time, the oil discharged from the steering pump flows into the spool(G) of the steering unit(5)
through the spool(D) of priority valve and flows into the gerotor(H).
Oil flow from the gerotor flows back into the spool(G) where it is directed out the right workport to the
respective chamber of the steering cylinders(10).
Oil returned from left and right cylinder returns to hydraulic tank through the spool of the steering unit.
When the above operation is completed, the machine turns to the right.
5-5

3. PRIORITY VALVE
1) STRUCTURE

CF

LS

EF

1
2
3

Plug
O-ring
Spool

4
5
6

Housing
Spring
Plug

5-6

Orifice

2) OPERATION
(1) Neutral

CF

5
CF EF

LS

PP
P

LS

LOADER ACTUATED(D)

EF

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

5-7

(2) Midturn

CF

5
CF EF

LS

PP
P

LS

FULL STEER RATE(D)

EF

When the machine is steered, load sensing pressure from the steering unit flows through the orifices LS
port in the priority valve. Load sensing pressure plus spring(5) force move the spool(3) to the against
the pilot pressure on the left end of the spool. This restricts flow to the loader through the EF port while
the CF port is opened to the steering unit.
The load sensing circuit is control circuit that routes steering workport pressure to the spring side of the
priority valve spool. It allows the priority valve spool to sense the pressure that is required to steer the
unit under varying conditions.
During normal steering conditions, oil is entered into the load sensing circuit through an orifice in the
steering unit. When steering at the full steer rate(D), the orifice opens to an unrestricted passage. At
low engine speed, the spool will shift to the full left position, directing all flow to the steering unit. At high
idle, the steering system can use about one-half of the pump flow. Therefore, the excess oil flows to
the main control valve.
The load-sensing circuit receives the majority of its flow from the load sensing orifice in the steering unit.
Some flow is also supplied from the CF port through orifice(A) in the priority valve spool.

5-8

(3) Full turn

CF

5
CF EF

LS

PP
P

LS

EF

When the machine is steered to a full turn, the frames bottom against the steering stops.
Pressure to the steering unit(Pilot pressure), which is sensed at the left end of the priority valve spool(3),
continues to increase until it can move the spool to the right against the load sensing pressure plus
spring force. At this time, all oil flows out of the EF port to the loader control valve.
If the loader attachment is being operated while steering, the loader function will slow until the machine
reaches the steering stops. At that time, the loader cycle speed will increase until the machine is
steered again.

5-9

4. STEERING UNIT
1) STRUCTURE

1
2
24
5

6
3

7
4
2
8
2

12

10

9
13
14
15
16
14
18
16

21
14
17
18
20

1
2
3
4
5
6
7

Dust seal ring

Housing assy
Ball
Bushing
Roto Glyd ring
Bearing assy
Ring

8
9
10
12
13
14
15

Cross pin
Spring set
Cardan shaft
O-ring
Intermediate plate
O-ring
Distributor plate

5-10

16
17
18
20
21
24

Gearwheel set
End cover
Washer
Pin screw
Screw
Pilot relief valve

2) OPERATION

NEUTRAL

C Anti-cavitation valves
D Load sense port to priority valve
E Gerotor

Spool I
J
Steering shaft

System pressure oil

G Return

Work pressure oil

H
Sleeve

G
Return

F
From priority valve

Trapped oil
Return pressure oil

The steering unit consists of a spool(I) inside a sleeve(H) within a housing. When steering wheel is not
moving, the valve is in the neutral(A) position. In neutral, the spool and sleeve are aligned so that oil
flow through the valve is blocked. The steering cylinder(B) are held stationary by trapped oil in the left
and right workports.
When the steering unit is turned to the right, the spool rotates relative to the sleeve, and opens
passages which allow pump flow through the spool and sleeve assembly. Oil flows to the gerotor(E)
causing the gerotor gear to rotate. Oil flow from the gerotor flows back into the valve where it is
directed out the right workport to the respective ends of the steering cylinders.
A bypass orifice is machined into the spool and sleeve assembly. It is a variable orifice that introduces
a small leak into the pressure side of the steering unit. Its purpose is to dampen the initial pressure
surge when the steering wheel is partially turned. When the steering wheel is fully turned, the leak is
closed off.
Return oil flows back in through the left workport through the spool and sleeve assembly to return. The
load sensing orifice is located between the sleeve and the gerotor. This orifice feeds the load sensing
circuit between the steering unit and the priority valve through the LS port.
When the rotation of the steering wheel stops, the gerotor gear continues to move, turning the sleeve,
until the sleeve stops the flow to the gerotor. At this point, the valve is back in the neutral position and
will remain there until the steering wheel is moved again.
The valve has a variable steering which is proportional to the speed the steering wheel is rotated. A
variable orifice bypasses oil around the gerotor. Turning the steering wheel slowly takes approximately
seven turn(Variable orifice small) lock to lock versus four turns(Variable orifice large) when turning the
steering wheel quickly.

5-11

5. OVERLOAD VALVE

1
2
9
3

8
6

9
P
T

5
6

7
8

R
T
P

P, T, L, R port

3/4-16 UNF

Shock valves

270-290 bar

Screw

M10146

HYDRAULIC CIRCUIT

1
2
3

O-rings set
O-rings set
Rolled pin

4
5
6

Screw
Shock valve
Spring

5-12

7
8
9

O-ring
Plug
Housing assy

6. STEERING CYLINDER
1) STRUCTURE

8,9 12 5,6 7 4 10,11 3

14 15

16

13

17

22,23

18

1
2
3
4
5
6
7
8

Tube assy
Rod assy
Gland
Du bushing
Rod seal
Back up ring
Buffer ring
Dust wiper

9
10
11
12
13
14
15
16

19,20,21

Snap ring
O-ring
Back up ring
O-ring
Piston
O-ring
Piston seal
Wear ring

5-13

17
18
19
20
21
22
23

Nylon nut
Pipe assy
U-bolt
Hexagon nut
Spring washer
Bushing
Dust seal

2) OPERATION

15

13 16 17

This machine use to cross connected cylinder for steering operation.

The steering cylinder use a gland(3) to remove piston and sealed seals. Dust wiper(8) located on the in
side of the gland protects cylinder inner parts from dust. The piston(13) is fastened to the rod(2) by a
nut(17).
The piston uses a single wear ring(16) with a piston seal(15) to seal between the piston and tube. The
gland seals against the tube with two O-rings. The rod is sealed against the gland with a rod seal(5).

5-14

GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING

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

: Troubleshooting
: Tests and adjustments

5-15

Hydraulic oil must be at operating temperature for these checks(Refer to page 6-57).
Item

Description
Run engine at low idle.
A

Steering unit check

Service action
OK
Check completed.

Turn steering wheel until frames

are at maximum right(A) and then NOT OK
left(B) positions.
Go to next check.
LOOK : Frames must move
smoothly in both directions.
When steering wheel is stopped,
frames must stop.
FEEL : Excessive effort must not
be required to turn steering
wheel.
NOTE : It is normal for steering to
drift from stops when steering
wheel is released.

Steering system leakage

check
Heat hydraulic oil to
operating temperature.
Run engine high idle.

Left

Right

Turn steering wheel rapidly until OK

frames are against stops.
Check completed.
Hold approximately 2kg on NOT OK
steering wheel.
Do steering system leakage
Count steering wheel revolutions test in group 3 to isolate the
leakage.
for 1 minute.
Repeat test in opposite direction.
LOOK : Steering wheel should
rotate less than 6rpm.
NOTE : Use good judgment;
Excessive steering wheel rpm
does not mean steering will be
affected.

Priority valve
pressure check

low

Park machine on a hard surface.

Hold brake pedal down.

OK
Check completed.

NOT OK
Do priority valve pressure
Steer machine to the right and left test in group 3.
as far as possible.
Run engine at high idle.

LOOK : Machine must turn at

least half way to the right and left
stops.

5-16

Item
Priority valve high
pressure check
Run engine at high idle.

Description

Service action

Steer to steering stop and release OK

wheel.
Check completed.
Roll bucket back and hold over NOT OK
relief and observe engine rpm.
Priority pressure is set too
high. Do priority valve
Turn wheel to steering stop and
pressure test in group 3.
hold, observe engine rpm.
LOOK : Steering stall engine rpm
must be higher than hydraulic stall
rpm.

5-17

2. TROUBLESHOOTING
Diagnose malfunction charts are arranged from most probable and simplest to verify, to least
likely, more difficult to verify. Remember the following steps when troubleshooting a problem :
Step 1. Operational check out procedure(See group 3 in section 1)
Step 2. Operational checks(In this group)
Step 3. Troubleshooting
Step 4. Tests and adjustments(See group 3)
Problem
No steering

Slow or hard steering

Cause

Remedy

Low oil level.

Add recommended oil.

Restricted suction line.

Check.

Failed hydraulic pump.

Remove and inspect return filter for

metal pump particles.

Failed main hydraulic pump drive.

Remove main hydraulic pump and

inspect drive gear.

Stuck priority valve spool.

Remove and inspect priority valve spool.

Broken priority valve spring.

Remove and inspect spring.

Relief valve in priority valve stuck open.

Do priority valve relief cartridge leakage

test in group 3.

Failed hydraulic lines.

Check.

Too much friction in the mechanical parts Lubricate bearings and joints of frame or
cylinders or repair if necessary.
of the machine.
Check steering column installation.
Cold oil.

Warm the hydraulic oil.

Low steering unit pressure setting.

Do steering unit pressure test in group 3.

Clean or replace cartridge in bottom of
priority valve.

Worn hydraulic pump.

Do hydraulic pump performance check.

Sticking priority valve spool.

Remove and inspect.

Broken priority valve spring.

Remove and inspect.

Pinched or restricted LS line.

Inspect line. Do priority valve LS port

flow test in group 3.

Low system relief valve setting.

Test and adjust if necessary.

Low overload relief valves setting.

Test and adjust if necessary.

5-18

Problem

Cause

Remedy

Constant steering to Air in system.

maintain straight travel
Leakage in steering system.

Check for foamy oil.

Do steering system leakage check.
Do steering unit neutral leakage test in
group 3.

Worn steering unit.

Leaf spring without spring force or broken. Replace leaf springs.

Spring in overload relief valve broken.

Replace overload relief valve.

Gear wheel set worn.

Replace gear wheel set.

Cylinder seized or piston seals worn.

Replace defects parts.

Slow steering wheel Leakage in steering system.

movement will not cause
Worn steering unit gerotor.
any frame movement

Do steering system leakage check.

Steering wheel can be Leakage in steering system.

turned with frames
against steering stop

Do steering system leakage check.

Steering wheel turns Broken steering column or splined of

with no resistance and steering unit.
causes
no
frame
Lack of oil in steering unit.
movement
Leakage in steering system.

Remove and inspect.

Erratic steering

Air in oil.

Check for foamy oil.

Low oil level.

Add recommended oil.

Sticking priority valve spool.

Remove and inspect spool.

Loose cylinder piston.

Remove rod to inspect piston.

Damaged steering unit.

Remove and inspect.

Air in oil.

Check for foamy oil.

Low oil level.

Add recommended oil.

Spongy or soft steering

Free play at steering

Loose steering wheel nut.
wheel
Worn or damaged splines on steering
column or unit.
Steering unit binding or Binding in steering column or
steering wheel does not misalignment of column.
immediately return to
High return pressure.
neutral when released
Contamination in steering unit.

5-19

Do steering unit leakage check.

Start engine and check steering operation.

Do steering system leakage test in group 3.

Tighten.
Inspect.

Inspect.
Check for a pinched or damaged return
line.
Inspect hydraulic filter for contamination.
Repair cause of contamination. Flush
hydraulic system.

Problem
Steering unit locks up

Cause

Remedy

Large particles of contamination in Inspect hydraulic filter for contamination.

steering unit.
Repair cause of contamination. Flush
hydraulic system.
Thermal shock

Do priority valve LS port flow test in

group 3. This oil flow provides a warmup flow to steering unit when not using
the steering.

Worn or damaged steering unit.

Repair or replace steering unit.

Abrupt steering wheel

oscillation

Improperly timed gerotor gear in steering Time gerotor gear.

unit.

Steering wheel turns by

itself

Lines connected to wrong port.

Reconnect lines.

Worn or damaged steering unit.

Repair or replace steering unit.

Vibration in steering
system or hoses jump

High steering unit setting.

Do steering unit pressure test in group

3.

Neutral position of
steering wheel cannot
be obtained, i.e. there is
a tendency towards
"motoring"

Steering column and steering unit out of

line.

Align the steering column with steering

unit.

Too little or no play between steering

column and steering unit input shaft.

Adjust the play and, if necessary,

shorten the splines journal.

Pinching between inner and outer spools.

Contact the nearest service shop.

"Motoring" effect.
The steering wheel can
turn on its own

Leaf springs are stuck or broken and Replace leaf springs.

have therefore reduced spring force.
Inner and outer spools pinch, possibly Clean steering unit or contact the
nearest service shop.
due to dirt.
Reduce return pressure.
Return pressure in connection with the
reaction between differential cylinder and
steering unit too high.

Backlash

Jerky steering

Cardan shaft fork worn or broken.

Replace cardan shaft.

Leaf springs without spring force or broken.

Replace leaf springs.

Worn splines on the steering column.

Replace steering column.

LS port orifice missing.

Inspect orifice.

Orifice in top end of priority valve spool

missing.

Disassemble and inspect.

Thermal shock is caused by a large temperature differential(Approx 30

C, 50
F) between the steering unit and
hydraulic oil. If the steering is not operated for a long period of time and the orifice in the bottom of the priority
valve spool is plugged, the steering unit may bind up when the steering is operated if the hydraulic oil is hot
enough.

5-20

Problem

Cause

Remedy

"Shimmy" effect
Air in the steering cylinder.
The steered wheels
vibrate
(Rough tread on tires
Mechanical connections or wheel
gives vibrations.)
bearings worn.
High priority valve setting pressure.
Steering wheel can be Oil is needed in the tank.
turned the whole time
Steering cylinder worn.
without the steered
wheels moving
Gear wheel set worn.
Spacer across cardan shaft forgotten.
Steering wheel can be
turned slowly in one or
both directions without
the steered wheels
turning

Bleed cylinder.
Find and remove the reason for air
collection.
Replace worn parts.
Set pressure as regular value.
Fill with clean oil and bleed the system.
Replace or repair cylinder.
Replace gear wheel set.
Install spacer.

One or both anticavitation valves are leaky Clean or replace defect or missing
or are missing in overload relief valves.
valves.
One or both overload relief valves are
leaky.

Clean or replace.

Steering is too slow and Insufficient oil supply to steering unit, pump Replace pump or increase number of
heavy when trying to defective or number of revolutions too low. revolutions.
turn quickly
Adjust valve to correct setting.
Relief valve setting too low.
Relief valve sticking owing to dirt.

Clean the valve.

Spool in priority valve sticking owing to dirt..

Clean the valve, check that spool moves

easily without spring.

Too weak spring in priority valve.

Replace spring by a stronger.

"Kick back" in steering Fault in the system.

wheel from system
Kicks from wheels

Contact authorized man or shop.

Heavy kick-back in Wrong setting of cardan shaft and

steering wheel in both gear-wheel set.
directions

Correct setting as shown in group 4.

Turning the steering Hydraulic hoses for the steering Connect lines to correct ports.
wheel activates the cylinders have been switched around.
steered wheels opposite
Hard
point
when Spring force in priority valve too weak.
starting to turn the
Air in LS and / or P line.
steering wheel
Clogged orifices in LS or PP side in
priority valve.

Too little steering force

Replace spring by a stronger.

Bleed LS and P line.
Clean orifices in spool and in connecting
plugs for LS and PP.

Oil is too thick(Cold).

Let machine run until oil is warm.

Pump pressure too low.

Correct pump pressure.

5-21

GROUP 3 TESTS AND ADJUSTMENTS

1. HYDRAULIC OIL CLEAN UP PROCEDURE USING PORTABLE FILTER CADDY
Service equipment and tool
Portable filter caddy
Two 4000mm 1" 100R1 Hoses
Quick disconnect fittings
Discharge wand
Connectors
Brake system and steering system use
oil from hydraulic tank. Flush all lines
in the brake and steering system.
Disassemble and clean major
components for brake and steering
system.
Brake and steering components may fail
if brake, steering system is not cleaned
after hydraulic tank contamination.
1) If hydraulic system is contaminated due to a
major component failure, remove and
disassemble steering cylinders to clean
debris from cylinders.
2) Install a new return filter element. Inspect
filter before installing new element.
For a failure that creates a lot of debris,
remove access cover from hydraulic
tank. Drain and clean hydraulic tank of
fill the specified oil to hydraulic tank
through upper cover.
3) To minimize oil loss, pull a vacuum in
hydraulic tank using a vacuum pump.
Connect filter caddy suction line to drain
port at bottom of hydraulic tank using
connector. Check to be sure debris has not
closed drain port.
4) Put filter caddy discharge line into hydraulic
tank filler hole so end is as far away from
drain port as possible to obtain a thorough
cleaning of oil.

5-22

5) Start the filter caddy. Check to be sure oil

is flowing through the filters.
Operate filter caddy approximately 10
minutes so oil in hydraulic tank is circulated
through filter a minimum of four times.
hydraulic tank capacity : 75
(19.8U.S. gal)
Leave filter caddy operating for the next
steps.
6) Start the engine and run it at high idle.
For the most effective results, cleaning
procedure must start with the smallest
capacity circuit then proceed to the next
largest capacity circuit.
7) Operate all functions, one at a time, through
a complete cycle in the following order:
Clam, steering, bucket, and boom. Also
include all auxiliary hydraulic functions.
Repeat procedure until the total system
capacity has circulated through filter caddy
seven times, approximately 30 minutes.
Each function must go through a minimum
of three complete cycles for a through
cleaning for oil.
Filtering time for machines with auxiliary
hydraulic functions must be increased
because system capacity is larger.
8) Stop the engine. Remove the filter caddy.
9) Install a new return filter element.
10) Check oil level in hydraulic tank ; Add oil if
necessary.

5-23

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

B
D
C

2) DIGITAL THERMOMETER INSTALLATION

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

A
B

3) DISPLAY MONITOR TACHOMETER

The display monitor tachometer is accurate
enough for test work.
30

20

20

10

40

10
5

5-24

mph

km/h

30

50

3. STEERING SYSTEM RESTRICTION TEST

SPECIFICATION
Oil temperature
Engine speed
Maximum pressure
at steering unit

656
C(15010
F)
High idle
2.0Mpa(20bar, 285psi)

GAUGE AND TOOL

Gauge 0~7.0Mpa(0~70bar, 0~1000psi) 1EA
This test will check for restrictions in the
steering system which can cause overheating
of hydraulic oil.
1) Install
temperature
reader.(See
temperature reader installation procedure in
this group.)
2) Heat hydraulic oil to specifications.(See
hydraulic oil warm up procedure at page
6-58.)
3) Connect fitting(A) and gauge to steering
unit.
Do not operate steering or loader
functions or test gauge may be
damaged.

4) Run engine at specification and read

pressure gauges.
If pressure is more than specification at the
steering unit, inspect priority valve for a
stuck spool. Make sure orifice plugs are
installed in ends of priority valve spool.
Check for plugged orifice in priority valve LS
port.

5-25

4. STEERING UNIT LEAKAGE TEST

SPECIFICATION
Oil temperature
Engine speed
Maximum leakage

406
C(10010
F)
High idle
5.7cc/ 10min

GAUGE AND TOOL

Temperature reader
Measuring container(Approx 20)
Stop watch

1) Install frame locking bar to prevent machine

from turning.
temperature
reader.(See
2) Install
temperature reader installation procedure in
this group.)
3) Heat hydraulic oil to specifications.(See
hydraulic oil warm up procedure at page
6-58.)
4) Disconnect return hose from fitting.
Install cap on fitting.
5) Run engine at specifications. Rotate
steering wheel against locking bar using
approximately 1.2kgm of force.
Measure oil flow from return hose for 1
minute.

Frame locking bar

6) Leakage is greater than specifications,

repair or replace steering unit.

5-26

5. STEERING UNIT PRESSURE TEST

SPECIFICATION
Oil temperature
656
C(15010
F)
Engine speed
High idle
Relief pressure
20.5~21.5Mpa
(205~215bar, 3200~3300psi)
GAUGE AND TOOL
Gauge 0~35.0Mpa(0~350bar, 0~5000psi)
Temperature reader

CF

1) Connect test fitting and gauge to CF port on

priority valve.

2) Install temperature reader.(See temperature

installation procedure in this group.)
3) Install frame locking bar.
4) Heat hydraulic oil to specifications.(See
hydraulic oil warm up procedure at page
6-58.)
5) Run engine at specifications and turn
steering wheel rapidly hold approximately
22N(5lb force) pressure on wheel with
frames locked.
If steering wheel is turned slowly, it will
continue to with the frames locked.
This will give an incorrect pressure
reading.

Frame locking bar

If steering wheel continues to turn

rapidly with the frames locked, steering
system leakage is indicated.
6) Read pressure gauge.
valve relief pressure.

Relief valve

This is the priority

7) If pressure in not to specification, remove

the plug(A) from steering unit. Turn
adjusting screw in relief cartridge using a
hex head wrench to adjust pressure.

If pressure cannot be adjusted to

specification, disassemble and inspect
steering unit.

5-27

6. PRIORITY VALVE "LS" PORT FLOW TEST

SPECIFICATION
Oil temperature
Engine speed
LS port flow(Approx)

406
C(10010
F)
Low idle
0.5/min(0.13gpm)
A

GAUGE AND TOOL

Temperature reader
Measuring container
Stop watch

EF
LS
P

Priority valve LS port flow test will check for a

plugged or missing orifice in the priority valve
spool. A plugged orifice will block warm up
flow to the steering unit which can cause
thermal shock.(See for an explanation of
thermal shock, page 5-20.)

A missing orifice can cause the pump to be

loaded to high pressure at all times causing
overheating.
temperature
reader.(See
1) Install
temperature reader installation procedure in
this group.)
2) Heat hydraulic oil to specifications.(See
hydraulic oil warm up procedure at page
6-58.)
3) Disconnect line from LS port and install
plug(A).
4) Connect line(B) to priority valve.
5) Start engine and run at specification.
6) Measure flow from LS port for 1 minute.
If flow is low, low steering system neutral
pressure or a plugged orifice in priority
valve spool is indicated.
If flow is high, remove priority valve spool
and inspect for a missing orifice.
Do hydraulic system restriction test in this
group.

5-28

GROUP 4 DISASSEMBLY AND ASSEMBLY

1. PRIORITY VALVE
1) STRUCTURE

1
2
3
9
4

5
2

6
7

1
2
3

Plug
O-ring
Spool

4
5
6

Housing
Spring
Plug

2) TOOLS
Torque wrench(5kgfm)
Hex socket wrench(1")
Hex socket wrench(7/8")
Hex wrench (7/32")
Pincette
Grease

5-29

7
8
9

Name plate
Drive screw
Orifice

3) DISASSEMBLY
Cleanliness is the primary means of
assuring satisfactory the priority valve life.
Select clean place.
Before removing the piping, clean the
surrounding area of valve ports.

EF

(1) Fix the housing(4) in a vise with copper or

lead sheets.
Do not over tighten jaws.

(2) Loosen plug(6) for LS port.

(3) Remove spring (5).

EF
P

5-30

EF

(4) Remove Plug(1) and separate O-ring(2)

individually.

(6) The priority valve is now dismantled.

5-31

EF

(5) Remove the spool(3).

Can't remove the orifice(9) from spool(3),
because the orifice was locked at the
spool.

4) ASSEMBLY
Clean all metal parts in clean solvent and
blow dry with air and correct any damage,
burrs and rust.
Do not wipe dry with cloth or paper towel.
Replace seals such as O-ring with new
ones as a rule and coat with grease.

P
EF

5-32

EF

(4) Insert the spring(5) into the housing(4).

(3) Install the O-ring(2) onto plug(1) and istall

the plug(1) into the housing(4).
Tighten torque : 6.1kgfm(44.3lbft)

EF

Fix the housing(4) in a vise.

Do not over tighten jaws.
Insert the spool(3) in the housing(4).
Secure the spool(3) remain in their correct
direction as the illustration.
Secure the spool(3) to move smoothly by
finger.
(1)

(2)

This completes assembly.

5-33

EF

(5) Install the O-ring(2) on plug(6) and install

the plug(6) into the housing(4).
Tighten torque : 6.1kgfm(44.3lbft)

5) TROUBLESHOOTING
Problem
Steering wheel
is heavy

Cause

Remedy

1. Relief valve of steering unit is clogged

with dirt.

Disassembly, clean and reassembly.

2. Spool is stuck.

Disassembly, clean and reassembly or

replace.

3. Orifice of plug and spool is clogged.

Disassembly, clean and reassembly.

(Steering wheel
is heavy at
engine low idle)

a. Pump is faulty.

Check pump.

(Steering speed
is not high at
engine high idle)

b. Control pressure is low.

Reset control pressure.

c. Piping is faulty.

Replace piping.

d. Pump is faulty.

Check pump.

Abnormal noise

Leakage

1. Relief valve of steering unit is clogged

with dirt.

Disassembly, clean and reassembly.

2. Spool is stuck.

Disassembly, clean and reassembly or

replace.

1. Loosen the plug.

Retighten the specified torque.

2. O-ring is damaged.

Replace.

5-34

2. STEERING UNIT
1) STRUCTURE

1
2
24
5

6
3

7
4
2
8
2

12

10

9
13
14
15
16
14
18
16

21
14
17
18
20

1
2
3
4
5
6
7

Dust seal ring

Housing assy
Ball
Bushing
Roto Glyd ring
Bearing assy
Ring

8
9
10
12
13
14
15

Cross pin
Spring set
Cardan shaft
O-ring
Intermediate plate
O-ring
Distributor plate

5-35

16
17
18
20
21
24

Gearwheel set
End cover
Washer
Pin screw
Screw
Pilot relief valve

2) TOOLS
(1) Holding tool.

(2) Assembly tool for O-ring and kin-ring.

(3) Assembly tool for dust seal.

(4) Torque wrench 0-7.1kgfm(0-51.6lbft).

13mm socket spanner
12mm screwdriver
6mm screwdriver
2mm screwdriver
Plastic hammer
Ratchet spanner

5-36

3) DISASSEMBLY
(1) Disassemble steering column from
steering unit and place the steering unit in
the holding tool. Screw out the screws in
the end cover(7-off-one rolled pin).

(2) Remove the end cover, sideways.

(3) Lift the gearwheel set with spacer

bushing(and spacer if fitted) off the unit.
Take out the two O-rings.

(4) Remove spacer bushing and spacer(if

fitted) from the gearwheel.

5-37

(5) Remove cardan shaft.

(6) Remove distributor plate.

(7) Remove O-ring.

(8) Lift off intermediate plate.

5-38

(9) Remove O-ring.

(10) Screw out the threaded bushing.

(11) Remove cross pin.

(12) Shake out the ball(8.5mm).

5-39

(13) Pull sleeve and spool out of the housing.

(14) Take ring, bearing races and needle

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

(15) Carefully pull the spool out of the sleeve.

(16) Press the neutral position springs out of

their slots in the spool.

5-40

(17) Remove dust seal and O-ring.

(18) The steering unit is now completely

disassembled.

Cleaning
Clamp all parts carefully in Shellsol K or the
like.
Inspection an replacement
Replace all seals and washer. Check all
parts carefully and make any replacements
necessary.
Lubrication
Before assembly, lubricate all parts with
hydraulic oil.

5-41

4) ASSEMBLY
(1) Assemble spool and sleeve.
The sleeve and spool are correctly
assembled when
The slots-in sleeve and spool-for the
neutral position springs are opposite
each other and
One of the 3 T-shaped grooves(A) in the
spool is opposite one of the sets(B) of
small holes in the sleeve.

(2) Place the two flat neutral position springs

in the slot.

(3) Place the curved springs between the flat

ones and press them into place.

(4) Line up the spring set.

5-42

(5) Guide the spool into the sleeve.

(6) Press the springs together and push the

neutral position springs into place in the
sleeve.

(7) Line up the springs and center them.

(8) Guide the ring down over the sleeve.

The ring should be able to rotate-free of
the springs.

5-43

(9) Fit the cross pin into the spool/sleeve.

(10) Fit bearing races and needle bearing as

shown on below drawing.

1
2
3
4
5

Outer bearing race

Needle bearing
Inner bearing race
Spool
Sleeve
Inside chamfer on inner bearing race
must face inner spool.

1
2
3

*
4
5

(11) Grease O-ring and kin-ring with hydraulic

oil and place them on the tool. See next
page.

5-44

(12) Put the steering unit in the holding tool

keeping the bore vertical. Guide the outer
part of the assembly tool into the bore.
Guide the inner part of the tool right to the
bottom.

(13) Press and turn the O-ring into position in

the housing. Draw the inner and outer
parts of the assembly tool out of the
steering unit bore, leaving the guide in the
bore.

(14) Take the steering unit out of the holding

tool and place it horizontally. With a light
turning movement, guide the spool and
sleeve into the bore.

5-45

(15) The spool set will push out the assembly

tool guide. The O-ring is now in position.

(16) Put the steering unit back into the holding

tool keeping the bore vertical. Place the
cross pin in the spool/sleeve so that it is
parallel to the port flange.

(17) Put the ball into the hole indicated by the

arrow.

(18) Screw the threaded bushing lightly into the

bore. The top of the bushing must lie just
below the surface of the housing.

5-46

(19) Grease the O-ring with mineral oil

approximate viscosity 500 cSt at 20 C
and place it in the groove.

(20) Place the intermediate plate so that the

channel holes match the holes in the
housing.

(21) Grease the O-ring with mineral oil

approximate viscosity 500 cSt at 20 C
and place it in the groove.

(22) Place the distributor plate so that the

channel holes match the holes in the
intermediate plate and the housing.

5-47

(23) Guide the cardan shaft down into the bore

so that the slot is parallel with the
connection flange.

(24) Place the gear wheel(Rotor) so that the

cross pin from item 33 is positioned in
relation to two tooth bases - as the screw
driver indicates.

(25) Grease the two O-rings with mineral oil

approximate viscosity 500 cSt at 20 C
and place them in the two grooves in the
gear rim. Fit the gear rim so that the seven
through holes match the holes in the
distributor plate.
Turn the gear rim so that the smaller
diameter of the holes face the distributor
plate.

(26) Orientate the holes with a single screw.

5-48

(27) Place the end cover in position.

(28) Place the washers over the holes and the

rolled pin in the hole shown.

(29) Fit the other six screws. Cross - tighten all

the screws and the rolled pin with a torque
of 30.6kgfm(224.4lbft). Steering unit
can now be function tested.

(30) Turn the steering unit 180and place the

dust seal ring in the housing.

5-49

(31) Fit the dust seal ring in the housing using

special tool and a plastic hammer.

(32) Press the plastic plugs into the connection

ports. Do not use a hammer.

5-50

3. OVERLOAD VALVE
1) STRUCTURE

1
2
9
3

8
6

9
P
T

5
6

7
8

1
2
3

O-rings set
O-rings set
Rolled pin

4
5
6

Screw
Shock valve
Spring

5-51

7
8
9

O-ring
Plug
Housing assy

2) TOOLS
(1) Hexagon socket spanner, 8mm.

(2) Torque wrench, 0~7.1kgfm(0~51lbft)

with 8mm hexagon socket spanner.

(3) Adjustable wrench.

5-52

3) DISASSEMBLY
(1) Remove the rolled pin.

(2) Remove the plug(8) and O-ring(7).

8
7

(3) Remove the spring(6) and shock valve(5).

6
5

(4) Remove the O-ring set(1, 2).

1,2

5-53

(5) Remove the check valve(9).

9

(6) The overload valve is now disassembled.

5-54

4) ASSEMBLY
Cleaning
Clean all parts carefully in Shellsol K or the
like.
Inspection an replacement
Replace all seals and washers. Check all
parts carefully and make any replacements
necessary.
Lubrication
Before assembly, lubricate all parts with
hydraulic oil.

(1) Fit check valve(9).

9

(2) Fit the shock valve(5) and spring(6).

6
5

(3) Fit the O-ring(7) and screw the plug(8).

8
7

5-55

(4) Fit the rolled pin.

(5) The overload valve is now assembled. It

can be checked for leakage separately or
when mounted on a steering unit.

(6) Locate the four O-rings between overload

valve and steering unit and fit these
components together.

(7) Tighten the hexagon socket screws with a

+3.6
torque of 6.6+0.5
0 kgfm(47.7 0 lbft).

5-56

(8) Press the plastic plugs into the connection

ports. The overload valve is now
assembled.

5) TROUBLESHOOTING
Problem
Steering wheel
is heavy

Cause

Remedy

1. Over tighten mounting torque.

Retighten as specified torque.

2. Over load valve seat side is clogged

with dirt.

Disassembly, clean, reassembly.

Steering cylinder 1. Overload valve seat side is clogged

reaction is bad
with dirt.

Disassembly, clean, reassembly.

2. Anti cavitation check valve seat is

clogged with dirt.

Disassembly, clean, reassembly.

3. Damage of O-ring for adjusting.

Replace.

Abnormal noise

1. Overload valve seat side clogged

with dirt.

Disassembly, clean, reassembly.

Leakage

1. Loosen 2 mounting bolt.

Retighten as specified torque.

2. Damage of O-ring.

Replace.

3. Leakage through plug.

Apply seal tape to thread and retighten

as specified torque.

5-57

4. STEERING CYLINDER
1) STRUCTURE

8,9 12 5,6 7 4 10,11 3

14 15

16

13

17

22,23

18

1
2
3
4
5
6
7
8

Tube assy
Rod assy
Gland
Du bushing
Rod seal
Back up ring
Buffer ring
Dust wiper

9
10
11
12
13
14
15
16

19,20,21

Snap ring
O-ring
Back up ring
O-ring
Piston
O-ring
Piston seal
Wear ring

5-58

17
18
19
20
21
22
23

Nylon nut
Pipe assy
U-bolt
Hexagon nut
Washer spring
Bushing
Dust seal

2) TOOLS AND TIGHTENING TORQUE

(1) Tools
Tool name

Remark
B

17
32

Spanner

41
Steel bar

For gland

(-) Driver

Small and large sizes

Torque wrench

Capable of tightening with the specified torques

(2) Tightening torque

Part name

Item

Size

Torque
kgfm

lbfft

Gland

M70 2

70 7

506 51

Nylon nut

17

M27 2

75 8

542 58

Nut(Pipe assy)

18

M22 1.5

30 3

217 21.7

Nut

20

M10 1.5

3.2 0.3

23.1 2.2

5-59

3) DISASSEMBLY
(1) Remove cylinder head and piston rod
Hold the clevis section of the tube in a
vise.
Use mouth pieces so as not to damage
the machined surface of the cylinder
tube. Do not make use of the outside
piping as a locking means.

m
m

Pull out piston rod(2) about 200mm

'7.1in(-Because the piston rod is rather
heavy, finish extending it with air pressure
after the oil draining operation.

0
20

Loosen and remove the gland(3).

Cover the extracted piston rod(2) with rag

Wrench

to prevent it from being accidentally

damaged during operation.

3
2

Draw out gland(3) and piston rod (2)

assembly together from cylinder tube(1).
Since the piston rod assembly is heavy in
this case, lift the tip of the piston rod(2)
with a crane or some means and draw it
out. However, when piston rod(2) has
been drawn out to approximately two
thirds of its length, lift it in its center to
draw it completely.

Lift

Full straight
sideways

5-60

Oil pan

 Note that the plated surface of piston

rod(2) is to be lifted. For this reason, do
not use a wire sling and others that may
damage it, but use a strong cloth belt or
a rope.
Place the removed piston rod assembly
on a wooden V-block that is set level.
Cover a V-block with soft rag.

Piston assy

Wooden block

(2) Remove piston and cylinder head

Remove the nylon nut(17).
Remove piston assembly(13), and Oring(14).

14 15 16 13 17

Remove the gland(3) assembly from

piston rod(2).
If it is too heavy to move, move it by
striking the flanged part of gland(3) with
a plastic hammer.
Pull it straight with cylinder head
assembly lifted with a crane.
Exercise care so as not to damage the
lip of rod bushing(4) and packing
(5,6,7,8,9) by the threads of piston
rod(2).

Lift with a crane

Plastic
hammer

8,9 5,6
7

4
Full straight

5-61

(3) Disassemble the piston assembly

Remove wear ring(16) and piston seal
(15).
Exercise care in this operation not to
damage the grooves.

15 16

(4) Disassemble gland assembly

Remove back up ring(11), and O-ring
(10).
Remove O-ring(12).
Remove snap ring(9) and dust wiper(8).
Remove back up ring(6), rod seal(5).
Remove buffer ring(7).
Exercise care in this operation not to
damage the grooves.
Do not remove seal and ring, if does not
damaged.

8,9 12 5,6 7 10,11 4

5-62

4) ASSEMBLY
(1) Assemble gland assembly
Check for scratches or rough surfaces if
found smooth with an oil stone.
Coat the inner face of gland(3) with
hydraulic oil.
3

Coat dust wiper(8) with grease and fit

dust wiper(8) to the bottom of the hole of
dust wiper.
At this time, press a pad metal to the
metal ring of dust seal.
Fit snap ring(9) to the stop face.

Press here
(Straight down)
Metal
8

Fit back up ring(6) and rod seal(5) to

corresponding grooves, in that order.
Fit buffer ring(7).
Coat each packing with hydraulic oil
before fitting it.
Insert the backup ring until onside of it is
inserted into groove.

Wrong

Rod seal(5) has its own fitting direction.

Therefore, confirm it before fitting them.
Fitting rod seal(5) and buffer ring(7) up
side down may damage its lip. Therefore
check the correct direction that is shown
in fig.

Right

Push bar

7
5,6

5-63

 Fit back up ring(11) to gland (3).

Put the backup ring in the warm water of
30~50
C Fit O-ring(10) to gland(3).
Fit O-ring(12) to gland(3).

4
10
11
3
12

(2) Assemble piston assembly

Check for scratches or rough surfaces.
If found smooth with an oil stone.
Coat the outer face of piston(13) with
hydraulic oil.

Fit piston seal(15) to piston

Put the piston seal in the warm water of
60~100
C for more than 5 minutes.
After assembling the piston seal, press its
outer diameter to fit in.

15

Fit wear ring(16) to piston(13).

Fit O-ring(14) to piston(13).

14 15 16 13

5-64

(3) Install piston and gland

Fix the piston rod assembly to the work
bench.
Apply hydraulic oil to the outer surface of
piston rod(2), the inner surface of piston
and gland.
Insert gland assembly to piston rod(2).

Gland assembly

Fit piston assembly to piston rod.

Tightening torque : 505kgfm
(36236lbfft)

Piston rod

Piston assembly
Piston rod

Tighten nylon nut(17) to piston rod(2).

Tightening torque : 758kgfm
(54258lbfft)

5-65

17

(4) Overall assemble

Place a V-block on a rigid work bench.
Mount the cylinder tube assembly(1) on it
and fix the assembly by passing a bar
through the clevis pin hole to lock the
assembly.
Insert the piston rod assembly in to the
cylinder tube assembly, while lifting and
moving the piston rod assembly with a
crane.
Be careful not to damage piston seal by
thread of cylinder tube.
Match the bolts holes in the cylinder head
flange to the tapped holes in the cylinder
tube assembly and tighten socket bolts to
a specified torque.
Refer to the table of tightening torque.

Fix with a bar

Lift

Straight

Apply liquid packing

Tube
Piston rod
Wrench

Gland

5-66

SECTION 7 ELECTRICAL SYSTEM

GROUP 1 COMPONENT LOCATION
1. LOCATION 1

17
18
19

11
12
13
14
15
16

Switch panel
20
21
22
23

1
2
3
4
5
6
7
8

9
10

24
25
26

1
2
3
4
5
6
7
8
9

10
Horn button
11
Starting switch
12
Multi function switch
13
Cluster
14
Kick down switch
15
Override switch
Ride control switch(Option) 16
Attachment engage switch 17
Attachment disengage switch 18

EGS lever
19
Emergency steering pilot lamp(Option) 20
Beacon switch(Option)
21
Work lamp switch
22
Main light switch
23
Clutch cut off switch
24
Parking brake switch
25
Cold start switch(Option)
26
Prolix switch

7-1

Buzzer stop switch

Rear wiper/washer switch
Air conditioner switch
Hazard switch
Aircon & heater switch
Check unit
Relay board
Fuse box

2. LOCATION 2

2
3
4
5

14
13
12
11
7

10
9
8

1
2
3
4
5

Head lamp
Horn
Oil temperature sender
Air cleaner switch
Alternator

6
7
8
9
10

Fuel sender
Battery
Tail stop flash lamp
Back up buzzer
Battery relay

7-2

11
12
13
14

Start relay
Brake pressure switch
Clutch oil pressure switch
Front turn lamp

GROUP 2 ELECTRICAL CIRCUIT

7-3

TRANSMISSION HARNESS

CAB SIDE

FRONT SIDE

FRAME SIDE
GAUGE SIDE

7-4

1. ILLUMINATION CIRCUIT
1) OPERATING FLOW
Fuse box (No.20)
Illumination switch [CS-39(1)]
Switch ON, 1st step
[CS-39(7)]
Hazard and illumination switch indicator lamp ON
[CS-39(5)]
Fuse box(11)
I/conn [CN-3(8)]
RH Combi clearance lamp ON [CL-16(4)]
I/conn [CN-10(1)]
LH Head lamp ON [CL-3(4)]
I/conn [CN-7(14)]
All cluster guage lamp ON
Fuse box(12)
I/conn [CN-3(7)]
No. plate lamp ON [CL-21(2)]
LH Combi clearance lamp ON [CL-15(4)]
I/conn [CN-10(2)]
RH Head lamp ON [CL-4(4)]
2) CHECK POINT
Engine

Key switch

Check point

Voltage

- GND (Switch input)

- GND (Switch output)
OFF

ON

- GND (To light)

- GND (To gauge lamp)

GND : Ground

7-5

20~25V

ILLUMINATION CIRCUIT
FUSE BOX

CN-36
LH HEAD LIGHT

CL-3

ILL & HEAD LAMP SW

RH HEAD LIGHT

CN-10
CL-4

3
NUMBERPLATE LAMP
CS-39
CL-21

RH COMBI
CN-8

CL-16
LH COMBI

CN-3
CL-15
SPEED METER

CS-41

CN-127
T/M TEMP

CN-119
WATER TEMP
HAZARD SW

CN-117
VOLT METER
JT-29

CN-104
FUEL METER
CN-7

4
CN-107

7-6

2. HEAD LIGHT CIRCUIT

1) OPERATING FLOW
Fuse box(No.19)
Head light switch [CS-39(4)]
Light switch ON, 2nd step [CS-39(2)]
Multi function switch [CS-11(8)]
Multi function switch MIDDLE [CS-11(7)]
I/conn [CN-10(4)]
LH Head light low beam
ON [CL-3(1)]
RH Head light low beam
ON [CL-4(1)]
Multi function switch DOWN [CS-11(6)]
I/conn [CN-10(3)]
LH Head light high beam
ON [CL-3(2)]
RH Head light high beam
ON [CL-4(2)]
I/conn [CN-7(3)]
Cluster high beam pilot
lamp ON [CL-41(2)]

2) CHECK POINT
Engine

Key switch

Check point

Voltage

- GND (Switch input)

- GND (Switch output)
- GND (Multi function input)
- GND (Multi function output)
OFF

ON

- GND (Multi function output)

- GND (Low beam)
- GND (High beam)
- GND (Passing B+)

GND : Ground

7-7

20~25V

HEAD LIGHT CIRCUIT

FUSE BOX

CN-36

ILL & HEAD LAMP SW

LH HEAD LIGHT

1
CL-3
RH HEAD LIGHT

CS-39
CL-4

2
CN-8

7
HI BEAM PILOT LAMP

6
CL-41
CN-10

EARTH

4
5

CS-11

CN-7

MULTI FUNCTION SW

7-8

JT-28

3. WORK LIGHT SWITCH

1) OPERATING FLOW
Fuse box(No.17)
Work light switch [CS-21(5)]
Work light switch ON [CS-21(1)]
I/conn [CN-5(4)]
LH Front work lamp ON [CL-6(2)]
RH Front work lamp ON [CL-5(2)]
Work light switch [CS-21(6)]
Work light switch ON [CS-21(2)]
I/conn [CN-5(3)]
LH Rear work lamp ON [CL-22(2)]
RH Rear work lamp ON [CL-23(2)]
Work lamp switch indicator lamp ON
2) CHECK POINT
Engine

Key switch

Check point

Voltage

- GND (Switch input)

- GND (Switch output)
OFF

ON

- GND (Front work light)

- GND (Rear work light)

GND : Ground

7-9

20~25V

WORK LIGHT SWITCH

FUSE BOX

CN-36

1
3

WORK LAMP SW

FRONT WORK
LIGHT,LH

CN-5

CL-6
FRONT WORK
LIGHT,RH

CS-21
CL-5

2
3

4
REAR WORK
LIGHT,LH

CL-22
REAR WORK
LIGHT,RH

CL-23

7-10

4. STARTING CIRCUIT
1) OPERATING FLOW
Battery(+) terminal
Battery relay(M8, B+ terminal)
Fusible link [CN-60(1)]
I/conn [CN-1(1)]
Fuse box (No.13)
Start switch [CS-2(1)]
The EGS lever is neutral position. It is necessary condition before the starting.
The EGS has an output signal which is activated whenever the shift lever is in the neutral position.
This signal can be used to control a relay and prevent engine from starting whenever the shift lever is
not in the neutral position.
(1) When start key switch is in ON position
Start switch ON
Start switch [CS-2(2)]
I/conn [CN-2(1)]
Battery relay [CR-1]
Battery relay operating(All power is supplied with the electric component)
Start switch [CS-2(3)]
Fuse box [No.4]
I/conn [CN-2(8)]
I/conn [CN-4(9)]
Engine stop solenoid [CN-79(1)]
(2) When start key switch is in START position
Start switch START [CS-2(5)]
Start safety relay [CR-5(2)]
Start safety relay [CR-5(4)]
I/conn [CN-3(3)]
I/conn [CN-4(7)]
Start relay [CR-23(2)]
+
Starter(Terminal B and M connector of start motor)
2) CHECK POINT
Engine

Key switch

Check point

Voltage

- GND (Battery B+)

- GND (Fusible link)
- GND (Start key B+)
- GND (Start key BR terminal)
- GND (I/conn CN-2(1))
Running

ON

- GND (Start key R2 terminal)

- GND (Start safety relay output)
- GND (Check unit)
- GND (Start key IG terminal)
- GND (Engine stop solenoid)

GND : Ground

7-11

20~25V

STARTING CIRCUIT
CHECK UNIT

EGS

CN-58

CN-111

FUSE BOX

8
SAFETY RY

PROLIX SW

CN-15

CS-7

CR-5

CN-36

1
MASTER SW
BATT RY

60R

60R

60B

60B

NEUTRAL RY
CR-1

CR-38
STARTER
CN-60

2
CN-1

CN-45

DO-2

START RY
DO-1

5
9

3
CN-2

CS-2

CS-43

CR-23

DO-9

ENG STOP SOL

CN-79

START SWITCH
EMERGENCY
TRAVEL SW

10
CN-3
CN-4

7-12

5. ENGINE STOP CIRCUIT

1) OPERATING FLOW
Start key OFF [CS-2(3)]
Fuse box (No.4)
Engine stop solenoid OFF [CN-79(1)]

I/conn [CN-2(8)]

I/conn [CN-4(9)]

2) CHECK POINT
Engine

Key switch

OFF

OFF

Check point

Voltage

- GND (Start key IG terminal)

- GND (Engine stop solenoid)

GND : Ground

3) WIRING DIAGRAM - See page 7-12.

7-13

0V

6. CHARGING CIRCUIT
When the starter is activated and the engine is started, the operator releases the key switch to the
ON position.
Charging current generated by operating alternator flows into the battery through the battery
relay(CR-1).
The current also flows from alternator to each electrical component and controller through the fuse
box.
1) OPERATING FLOW
(1) Warning flow
Altermator [CN-74(I)]
I/conn [CN-6(1)]
JT-27(4)(10)

I/conn [CN-4(3)]
I/conn [CN-2(2)]
Check unit [CN-58(2)(18)]
Cluster charge warning lamp ON [CL-46(1), Below 24V]
Volt meter [CN-104(B)]

(2) Charging flow

Alternator
Starter [CN-45(B+)]
Battery relay [CR-1]
Battery(+) terminal
Charging
I/conn [CN-60(1),(2)]
I/conn [CN-1(1),(2)]
Fuse box
2) CHECK POINT
Engine

Key switch

Check point

Voltage

- GND (Battery)
- GND (Battery relay)
Running

ON

- GND (ALT B+)

- GND (ALT I)

20~28V

- GND (Check unit)

- GND (Fuse box)

Engine

Key switch

Running

ON

Check point
- GND (Cluster)

GND : Ground

7-14

Resistance

CHARGING CIRCUIT

FUSE BOX

6
CHECK UNIT

CN-1

CN-58

CN-60

JT-27

CN-36
24V

5
CHARGE WARNING LAMP

CL-46

1
MASTER SW

DO-5
BATT RY

60R

60R

60B

60B

TO STARTER
CR-1
VOLT METER

STARTER

TO BATT

CN-104
CN-6

CN-45

3
ALTERNATOR

CN-74
CN-4

4
CN-2

7-15

7. ELECTRIC PARKING, DECLUTCH CIRCUIT

1) OPERATING FLOW
(1) Parking OFF
Fuse box (No.6)
Parking switch OFF [CS-17(6)(8)]
I/conn [CN-8(3)]
Parking solenoid ON(Activated)
Parking brake released(By hydraulic pressure)
(2) Parking ON
Fuse box (No.6)

Parking switch ON

(3) Declutch ON
Fuse box (No.6)

Clutch cut-off switch ON

Parking solenoid [CN-71] OFF

Parking brake applied [By spring force]
[CS-17(6)(2)]
Parking switch indicator lamp ON
[CS-17(5)(1)]
I/conn [CN-15(4)]
EGS [CN-111(14)]
T/M declutch
Clutch cut-off switch [CS-42(6)(2)]
Clutch cut-off switch indicator lamp ON
Clutch cut-off switch [CS-42(5) (1)]
Service brake applied
Service brake pressure switch ON [CD-5]
I/conn [CN-15(4)]
Declutch
Clutch oil pressure switch

2) CHECK POINT
Engine

Key switch

Check point

Voltage

- GND (Parking switch input)

- GND (Parking switch output)
- GND (Parking switch input)
Running

ON

- GND (Parking switch output)

- GND (Parking solenoid)
- GND (Clutch cut-off press switch)
- GND (Declutch input signal)

GND : Ground

7-16

20~25V

ELECTRIC PARKING, DECLUTCH CIRCUIT

EGS

FUSE BOX

CN-58

CN-111

CHECK UNIT

CS-7

PROLIX SW

CN-15

CN-36
NEUTRAL RY

7
CR-38

PARKING SW

CS-17

4
CLUTCH CUT-OFF SW

PARK SOL

CD-5

CD-71

DO-9

CS-43

CLUTCH
CUT-OFF
CS-42

CN-8

7-17

EMERGENCY
TRAVEL SW

8. WIPER AND WASHER CIRCUIT

1) OPERATING FLOW
Fuse box (No.7)
Wiper relay [CR-4(1)(3)]

Front wiper motor [CN-21(1)]

Front relay 2 [CR-26(2), (3)]

Multi function switch [CS-12(6)]

Rear wiper & washer switch [CS-3(1)]
Rear wiper motor [CN-102(1)]
(1) Front washer switch ON
Washer switch ON [CS-12(6)(2)]

Washer tank [CN-22(2)]

Washer operating
Check unit [CN-58(21)(15)]
Wiper relay 2
[CR-26(2)(4)]
Wiper motor [CN-21(5)]
Wiper motor operating(Low)

(2) Front wiper switch ON

INT position
Wiper switch ON [CS-12(6)(1)]
Check unit [CN-58(10)(15)]
Wiper relay
[CR-26(4)(1)]
Wiper motor [CN-21(5)]
Wiper motor intermittently operating
Lo position
Wiper switch ON [CS-12(6)(4)]
Wiper relay 2 [CR-26(3)(1)]
Wiper motor [CN-21(5)]
Wiper motor operating (Low)
Hi position
Wiper switch ON [CS-12(6)(3)]
Wiper relay [CR-4(1)(4)]
Wiper motor [CN-21(4)]
Wiper motor operating(High)
(3) Auto-parking(When switch OFF)
Switch OFF
Fuse box (No.7)
Wiper relay Hi [CR-4(1)(3)]
Wiper motor
[CN-21(1)(2)]
Multi function switch [CS-12(5)(4)]
Wiper relay Lo [CR-26(3)(1)]
Front wiper motor [CN-21(5)]
Wiper motor stop
(4) Rear wiper and washer switch
Wiper switch ON(1st step)
Wiper switch ON [CS-3(1)(6)]
Washer switch ON(2nd step)
Washer switch ON [CS-3(1)(3)]

Wiper motor [CN-102(5)]

Wiper motor operating
Rear wiper and washer switch indicator lamp ON
Rear washer tank [CN-103(2)]

Washer operating

2) CHECK POINT
Engine

Stop

Key switch

Check point

Voltage

ON

- GND (Front wiper switch power input)

- GND (Rear wiper switch power input)
- GND (Wiper relay power input)
- GND (Front wiper motor Lo power input)
- GND (Front wiper motor High power input)
- GND (Wiper relay power input)
- GND (Front washer power output)
- GND (Rear washer power output)
- GND (Front wiper motor power output)
- GND (Rear wiper motor power output)

20~25V

GND : Ground

7-18

WIPER AND WASHER CIRCUIT

FUSE BOX

CHECK UNIT

CN-58

CN-102

REAR WIPER

CN-36

6
WIPER RY2

CR-26

3
WIPER RY

CR-4

9
7

5
4

CS-5

CS-11

10

CS-12

CN-103

CN-22

R/WASHER

REAR WIPER & WASHER SW

F/WASHER

CS-3

CN-21

FRONT WIPER

MULTIFUNCTION SWITCH

7-19

MONITORING CIRCUIT

BRK OIL

CHECK UNIT

T/M TEMP

CL-45
AIR FILTER
CN-119
CL-50

WATER TEMP

CN-58

ENG OIL

CL-49
CN-117

OVER HEAT
HYD TEMP

FUEL METER

CL-48
PARKING

CL-47

CL-44

24V

CN-107

CN-8

CN-6

JT-27

T/M OIL TEMP

CD-29

CN-7
CN-9
FUEL SENDER

CD-2
AIR FILTER

CD-10

ENG OIL PRESS

CN-2

CD-3

CD-26

CD-1

CD-18
OVER HEAT SW

CD-9
HYD TEMP SW

PARKING PS

BRAKE OIL PS

WATER TEMP
CN-4
CD-8

7-20

HAZARD, TURN AND ROTARY CIRCUIT

FUSE BOX
COMBI LAMP RH

CL-16

ROTARY LAMP

COMBI LAMP LH

CN-5

CL-7

CN-2
CL-15

FLASHER UNIT

CN-36

CR-11
RH TURN LAMP,RR

CL-43
LH TURN LAMP,RR

CL-42

EARTH

CN-7

CS-5

CS-12

CS-11

LH COMBI LAMP,FR

CL-24
RH COMBI LAMP,FR

CS-23

CS-41

CL-25
CN-8

HAZARD SW

BEACON LAMP SW

MULTI FUNCTION SWITCH

CN-10

7-21

JT-28

3. MONITORING SYSTEM
1. CLUSTER
The gauges panel consists of gauges and monitors as shown below, to warn the operator in case of
abnormal machine operation or conditions for the appropriate operation and inspection.
Gauges
: Indicate operating status of the machine.
Warning lamp : Indicate abnormality of the machine.
Pilot lamp
: Indicate operating status of the machine.
The monitor installed on this machine does not entirely guarantee the condition of the
machine.
Daily inspection should be performed according to chapter 6, Maintenance.
Engine oil pressure warning lamp

T/M oil pressure warning lamp

Hyd oil temp warning lamp
Brake fail warning lamp

Overheat warning lamp

Battery charging warning lamp
Left turning pilot lamp
High beam pilot lamp

Right turning pilot lamp

Parking brake pilot lamp

30

20

20

10

40

10
5

30

mph

50

km/h

FUEL

WATER

BATT

TRANS

T/M oil temperature gauge

Engine coolant temperature gauge
Air cleaner warning lamp

Battery volt meter

Speedometer
Fuel gauge

1) SPEEDOMETER
(1) Specification
30

20

20

10

10
5

mph

km/h

Input(Hz)

Input pulse

40

Vpp = 20V MIN

30

50

1km = 26.2Hz
1.8V MAX

GND

(2) Indicated standard

Standard(km/h)

20

40

Allowable(km/h)

+4.8
0

+4.8
0

7-22

2) FUEL GAUGE
(1) This gauge indicates the amount of fuel in the fuel tank.
Red

White

(2) Fill the fuel when the red range illuminates.

(3) The gauge indicates continuously the current fuel amount
even after turn OFF the starting switch. This does not mean
that the gauge is out of order.
If the gauge illuminates the red range even though the
machine is on the normal condition, check the electric
device as that can be caused by the poor connection of
electricity or sensor.

FUEL

Fuel quantity

Resistance()

Zone

240

Red

33.5

White

3) ENGINE COOLANT TEMPERATURE GAUGE

Red

Green

(1) This indicates the temperature of coolant.

Green range : 37-105
C(99-221
F)
Red range : 105
C(221
F) Above
(2) The green range illuminates when operating.

WATER

(3) Keep idling engine at low speed until the green range
illuminates, before operation of machine.
(4) When the red range illuminates, turn OFF the engine, check
the radiator and engine.
Temperature(
C) Tolerance(
C)

Resistance()

Zone

37

+11.7, -13.9

533.2

Green

105

+1.7, -1.8

73.3

Red

7-23

4) TRANSMISSION OIL TEMPERATURE GAUGE

Red

Green

(1) This range indicates the temperature of transmission oil.

Green range : 37-120
C(99-248
F)
Red range : 120
C(248
F) Above
(2) The green range indicates when operating.

WATER

(3) Keep idling engine at low speed until the green range
indicates, before operation of machine.
(4) If the indicator is in the red range, it means the transmission is
overheated. Be careful that the indicator does not move into
the red range.
Temperature(
C) Tolerance(
C)

Resistance()

Zone

37

+13.9, -16.7

767.7

Green

120

+2.8, -2.8

65.4

Red

5) BATTERY VOLT METER

White

Green

Red

BATT

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

Tolerance(V)

Input voltage(V)

Zone

24

+0.50, -0.50

24

Green

30

+0.25, -0.25

30

Red

6) DIRECTION PILOT LAMP

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

7) HIGH BEAM PILOT LAMP

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

7-24

8) PARKING BRAKE PILOT LAMP

(1) When the parking brake is actuated, the lamp lights ON.
Check the lamp is OFF before driving.

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

10) TRANSMISSION OIL PRESSURE WARNING LAMP

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

11) AIR CLEANER WARNING LAMP

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

12) BATTERY CHARGING WARNING LAMP

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

7-25

13) ENGINE OIL PRESSURE WARNING LAMP

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

14) OVERHEAT WARNING LAMP

(1) This lamp is turned ON when the temperature of cooling water
is over the normal temperature (110
C, 230
F).
(2) Check the cooling system when the lamp is ON.

15) HYDRAULIC OIL TEMP WARNING LAMP

(1) This warning lamp operates and the buzzer sounds when the
temperature of hydraulic oil is over 105
C(221
F).
(2) Check the hydraulic oil level when the lamp is turned ON.
(3) Check for debris between oil cooler and radiator.

7-26

3. SWITCHES

Cold start switch(Option)

Prolix switch
Buzzer stop switch

Emergency steering pilot lamp(Option)

Beacon switch(Option)
Work lamp switch
Main light switch
Clutch cut off switch
Parking brake switch

Switch panel
Horn button
Starting switch
Multi function switch
Kick down switch
Override switch
Ride control switch
(Option)
Attachment
engage switch

Rear wiper/washer switch

Aircon switch
Hazard switch

Attachment
disengage switch

1) STARTING SWITCH
(1) There are three positions, OFF, ON and START.
ON

F
OF

STAR
T

(2) OFF

: None of electrical circuits activate.

(3) ON

: All the systems of machine operate.

(4) START : Use when operating the engine.

Release key immediately after starting.

7-27

2) OVERRIDE SWITCH
(1) This switch is for an emergency in case the EGS(Electronic Gear
Selection) is inoperative.
Forward

(2) The machine can travel with forward 2th or backward 2th at EGS
prolix switch ON.

N
Backward

3) HAZARD SWITCH
(1) Use for parking, or roading machine.
If the switch is left ON for a long time, the battery may be
discharged.
(2) The below indicator lamp is turned ON when operating this switch.

4) CLUTCH CUT OFF SWITCH

(1) This switch is pressed, it will cut off the clutch when brake operates.
Be careful not to use this switch when driving on a slope.
(2) The below indicator lamp is turned ON when operating this switch.

5) PARKING BRAKE SWITCH

(1) This switch is pressed, the parking brake will start to operate and the
gauge panel warning lamp will comes ON.
When operating the gear selector lever, be sure to release the
parking brake. If the machine is operated with the parking
brake engaged, the brake will overheat and may cause the
brake system to go out of order.
(2) The below indicator lamp is turned ON when operating this switch.

7-28

6) MAIN LIGHT SWITCH

(1) This switch use to operates the clearance lamp and head light by two step.
First step
: Clearance lamp and cluster illumination lamp comes
ON. Also, the below indicator lamp comes ON.
Second step : Head light comes ON.

7) WORK LAMP SWITCH

(1) This switch turns ON the working lamps located on the cab and
radiator door.
(2) The below indicator lamp is turned ON when operating this switch.

8) AIR CONDITIONER SWITCH

(1) This switch use to operates the air conditioner.
(2) Refer to the air conditioner and heater for detail operation.
(3) The below indicator lamp is turned ON when operating this switch.

9) REAR WIPER AND WASHER SWITCH

(1) The switch use to operates the rear wiper and washer by two step.
First step
: The rear wiper operates.
Second step : The washer liquid is sprayed and the rear wiper is
operated only while pressing. If release the switch,
return to the first step position.

7-29

10) BUZZER STOP SWITCH

(1) The red lamp on the cluster lights ON and the buzzer sounds when
the machine has a problem.
In this case, if the switch is pressed, the buzzer will be stopped. Be
sure to check machine for problems.
(2) Wait until the lamp is turned OFF, if the red lamp lights ON after the
buzzer stopped.
If not, stop engine and check the system which the lamp is ON.
11) COLD START SWITCH(Option)
(1) This switch is used for starting the engine in cold weather.
If pressed, starting aid fluid is injected for easier engine starting.
(2) The below indicator lamp is turned ON when operating this switch.
Never hold the push button switch in for more than 5 seconds,
as this can damage the electric valve solenoid.

12) CAB LAMP SWITCH

(1) This switch turns ON the cab room lamp.

13) KICK DOWN SWITCH

Kick down switch

(1) The kick-down switch or RCV lever switch is pushed, gear selection
will instantly changes from F2(R2) to F1(R1).
(2) If the switch is pushed or machine speed reaches up to 6km/hr,
the gear selection will automatically change to F2(R2).

7-30

14) EMERGENCY STEERING PILOT LAMP(Option)

Primary
Emergency

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

15) MULTI FUNCTION SWITCH

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

O J

(2) Dimmer switch

Up
M
Down

This switch is used to turn the head lights direction.

Switch positions
Up
: To flash for passing
Middle : Head lights low beam ON
Down : Head lights high beam ON
If you release the switch when it's in up position, the switch will return
to middle.

(3) Turning switch

Left turning

This switch is used to warn or signal the turning direction of the

machine to other vehicles or equipment.
Push the lever up for turning left, pull the lever down for turning right.

Right turning

7-31

16) HORN BUTTON

(1) If you press the button on the top of the multifunction switch, the horn
will sound.

17) BEACON SWITCH(Option)

(1) This switch turns ON the rotary light on the cab.
(2) The below indicator lamp is turned ON when operating this switch.

18) EGS PROLIX SWITCH

(1) When the EGS is inoperative, press this switch at starting switch is
OFF.
(2) Start engine with starting switch when keep override switch is Neutral
position.

19) RIDE CONTROL SWITCH(Option)

(1) This switch is pressed, the ride control system will start to operate.
The ride control system significantly reduces pitching and loping
without slowing down the travel speed.
(2) The below indicator lamp is turned ON when operating this switch.

7-32

20) ATTACHMENT ENGAGE SWITCH

(1) This switch is use to engage the quick coupler pins.
(2) If this switch is pressed for 5 seconds, the quick coupler pins move in
the engaged position.
If the switch is released, the quick coupler pins will remain in the
engaged position.
Check for engagement as followings.
Put down pressure on the attachment.
Back up the machine and make sure that there is no movement
between the quick coupler and attachment.
21) ATTACHMENT DISENGAGE SWITCH
(1) This switch is use to disengage the quick coupler pins.
(2) If this switch is pressed for 5 seconds, the quick coupler pins move in
the disengaged position.
If the switch is released, the quick coupler pins will remain in the
disengaged position.

7-33

GROUP 4 ELECTRICAL COMPONENT SPECIFICATION

Part name

Symbol

Specifications

12V 80Ah
(2EA)

Battery

Rated load :
24V
100A(Continuity)
1000A
(30 Seconds)

Battery relay
CR-1

Fusible link

24V 60A

Start key

CS-2

1.25LW
1.25LB
1.25BW

1.25GY

CN-60

6 5 4 3

2 1

ST
ACC
OFF
HT
C R2 R1 IG BR B OFF

Pa
Pressure switch

Check

Check specific gravity

1.280 Over : Over charged
1.280 ~ 1.250 : Normal
1.250 Below : Recharging

Check coil resistance

Normal : About 50
Check contact
Normal :

Check disconnection
Normal : 0
(Connect ring terminal and
check resistance between
terminal 1 and 2)

Check contact
OFF : (For each terminal)
ON : 0(For terminal 1-3)
(For terminal 1-5)
START : 0(For terminal 1-3
and 1-5)

N.C TYPE

Check contact
Normal : 0(Close)

N.O TYPE

Check contact
Normal : (Open)

CD-3 CD-26
CD-25 CD-39

Pa
Pressure switch
CD-4
CD-5

CD-11
CD-40

7-34

Part name

Symbol

Specifications

Pa

Pressure switch
(For engine oil)

0.5kg/cm2
(N.C TYPE)

Check

Check contact
Normal : 0(Close)

CD-18

Coolant temp
sensor

Check resistance
Normal :
225
F Over : 0

Check resistance
19213.5 at 73.9
C

CD-9

Coolant
temp sensor

CD-8

Pa

Air cleaner
pressure switch

CD-10

Pressure :
635mmH2O
(N.O TYPE)

Check contact
Normal :

24V 1.2A

Check LED lamp

Check Resistance
About 24

Reed switch :
Magnetic type

Check resistance
Full
: About 30
Low level : About 300

Parking
solenoid

CN-71

Fuel sender

CD-2

7-35

Part name

Symbol

Specifications

Transmission
oil temperature
sender

1/2 P.T.F

Check resistance
137.214.5 at 87.8
C

24V 20A

Check resistance
Normal : About 200
(For terminal 1-3)
:
(For terminal 2-4)

24V 20A

Check resistance
Normal : About 160
(For terminal 2-6)
: 0
(For terminal 1-3)
:
(For terminal 1-3)

CD-29

Relay
(4pin)

3
4

CR-2
AC AC
RY1RY1
CR-2CR-7
CR-26
CR-5CR-10 AC AC
CR-5
RY2RY2

Relay
(5pin)

1
2
4
6
3

CR-4
CR-38
CR-4 CR-35
CR-35 CR-38
CR-26

Proximate
switch

Check

24V 400mA

CN-100 CN-101

Hydraulic
temperature

Check resistance
Normal
:
105
C Over : 0

Check contact
Normal : 1.12
(For terminal 2-4)
: 2.07
(For terminal 3-4)
: 3.17
(For terminal 4-1)

CD-1

Air conditioner
resistor

2 Lo
4 Hi
3 ML
1 MH

1
2
3
4

7-36

Part name

Symbol

Specifications

Speaker

4 20W

Check resistance
Normal : 50

24V 8A

Check contact
OFF :
(For terminal 1-5, 2-6)
: 0
(For terminal 5-7, 6-8)

24V 8A

Check contact
OFF :
(For terminal 2-4, 1-7)

CN-23(LH)
CN-24(RH)

10 9 8 7 6 5 4 3 2 1
10

Switch
(Locking type)

8 2 7 1

Check

CS-17 CS-41 CS-50

CS-21 CS-42 CS-54
CS-23

10 9 8 7 6 5 4 3 2 1

Switch
(Non-locking
type)

10

75

CS-3

Work lamp,
Room lamp,
Number plate
lamp

CS-39

Work lamp
24V 70W

1
2

CL-1
CL-5

Number plate lamp

Room lamp
24V 10W

CL-6 CL-22
CL-21 CL-23

24V 70W
(H1 TYPE)

Beacon lamp
CL-7

Hour meter

CN-48

7-37

Check disconnection
Normal : A few

Check disconnection
Normal : A few

Check operation
Supply power(24V) to
terminal No.2 and contact
terminal No.1 and ground

Part name

Symbol

Specifications

Horn
CN-20 CN-25

Pa

22-28V 2A
110dB

Check operation
Supply power(24V) to each
terminal and connect ground

24V 2.5A

Check contact
Normal :

24V 20W+20W

Check resistance
Power ON : 4+4
(For terminal 1-6, 4-8)

Receiver dryer

Check

CN-29

Cassette radio

1
2
3
4
5
6
7
8
9

S.L+
ACC
N.C
S.R+
N.C
S.LB+
S.RN.C

CN-27

24V 0.5A
110dB

Back up buzzer

CN-65

M
Washer pump

24V 2.5A

CN-103 CN-22

24V 1.5A
2-speed
Auto parking

Wiper motor
CN-102, CN-21

7-38

Check contact
Normal : 26.4
(For terminal 1-2)

Part name

Symbol

Specifications

Check

3
2

Cigar lighter

24V 5A

CL-2

Ether

24V 15A

Check contact
Normal : 1.1

24V

Check resistance
Normal : 15-25

20V 60A

Check voltage
Normal : 24-28V

Delco Remy
28MT 24V

Operating or not

24V 79W

Check contact
Normal : 13.4

CN-78

Engine stop
solenoid
CN-79

B+

G
3~

Alternator

I
GND

CN-74

M
Starter

B+

CN-45

Air conditioner
compressor

CN-28

7-39

Part name

Start relay

Symbol

Specifications

2
1

24V 200A

Check

Check contact
Normal : 11.3

CR-23

Blower

Blower switch

24V 9A
2900150rpm

1
2
3

GND
24 5 36
COM
MH

LOW
ML
HI

5
6

Check resistance
Normal : 0(For terminal 1-2,
3, 4, 5, 6)

DC Servo motor
9-16V 300mA Max

CS-58

Mode actuator
and
temperature
actuator

M+

S+

M-

FS

S-

NC

Intake actuator

Thermostat

12V
F

Working
temperature of
contact point
A/C ON : 4.5
C
A/C OFF : 1.5
C

1
2

7-40

Check resistance
Normal : 2.0

Part name

Symbol

Flasher unit

Specifications

24V
85 ~ 190 C/M
50dB

CR-11

Head lamp

Lo

Hi

24V 75W/70W
(H4 TYPE)
24V 4W
(T4W)

CL-3 CL-4

Combi lamp

CL-15 CL-16

Turn lamp

Check

Check disconnection
Normal : A few

24V 5W
(R5W)
224V 21W
(P21W)

24V 21W
(P21W)

CL-24 CL-25

Transmission
speed sensor

m
rp

Internal resistance
14807.5%

CD-27

Continuous
Capacity :
180Amp
Push in capacity :
1000Amp

Master switch

7-41

Part name

Symbol

Specifications

Warning buzzer

Check

24V 200mA
905dB(m)

24V

CN-26

M
Air conditioner
fan

1
2

CN-83

Ether switch
and buzzer
stop switch
(Rocker switch
push button)

24V 8A

Check contact
OFF :
(For terminal 1-5, 2-6)

24V 8A

Check contact
OFF :
(For terminal 1-5, 2-6)
: 0
(For terminal 5-7, 6-8)

Change over
switch

Check contact
OFF :
(For terminal 5-4, 5-6
1-2, 2-3)

CS-30 CS-34

Prolix switch
(Locking type)
CS-7

Emergency
travel switch
CS-43

Joy stick lever

CN-144

7-42

Check contact
Normal : 80~90
(For terminal 1-5, 2-6
3-7, )
:
(For terminal 4-8)

Part name

Symbol

Specifications

Check

10 9 8 7 6 5 4 3 2 1

Switch
(Non-locking
type)

24V 8A
2

CS-52 CS-53

7-43

Check contact
OFF :
(For terminal 2-4, 1-7)

GROUP 5 CONNECTORS
1. CONNECTOR DESTINATION
Connector
number

Type

No. of
pin

CN-1

58

CN-2

SWP

CN-3

Destination

Connector part No.

Female

Male

I/conn(Frame harness-Main harness)

S813-030200

S813-130200

12

I/conn(Frame harness-Main harness)

S814-012000

S814-112000

SWP

I/conn(Frame harness-Main harness)

S814-008000

S814-108000

CN-4

SWP

12

I/conn(Frame harness-Engine harness)

S814-012000

S814-112000

CN-5

SWP

I/conn(Cab harness-Main harness)

S814-008000

S814-108000

CN-6

SWP

12

I/conn(Gauge harness-Main harness)

S814-012000

S814-112000

CN-7

SWP

14

I/conn(Gauge harness-Main harness)

S814-014000

S814-114000

CN-8

SWP

14

I/conn(Front harness-Main harness)

S814-014000

S814-114000

CN-9

SWP

I/conn(T/M check harness-Main harness)

S814-008001

S814-108001

CN-10

SWP

I/conn(Cowl harness-Frame harness)

S814-008000

S814-108000

CN-12

SWP

12

I/conn(Gauge harness-Main harness)

S814-012000

S814-112000

CN-13

Fasten

I/conn(Main harness-AC AVA Assy)

S810-008202

CN-15

12

I/conn(Main harness-T/M harness)

S814-012000

CN-20

Horn

S819-010122

CN-21

Front wiper motor

6189-0133

CN-22

Front washer tank

S814-002000

CN-23

Shur

Speaker(LH)

S822-014000

S822-114004

CN-24

Shur

Speaker(RH)

S822-014000

S822-114004

CN-25

Horn

CN-26

Fasten

Warning buzzer

S810-002202

CN-27

PA

Cassette and radio

S811-009003

CN-28

Compressor(Air conditioner)

0297-3407

CN-29

Grommet

Receiver drier

21L7-12000

CN-30

PA

13

Air conditioner controller

S811-013002

CN-36

20

Fuse box

21L7-10230

CN-45

Ring term

Starter

S820-414000

CN-48

Hour meter

S819-010112

CN-58

36

Check unit

344111-1

CN-60

58

Fusible link

CN-65

Shur

Back up buzzer

S822-014000

CN-71

Parking solenoid

S816-002001

CN-74

Ring term

Alternator

S820-406000

S814-101000

CN-78

Shur

Ether

S822-014000

S822-114000

CN-79

Ring term

Fuel cut off solenoid

S818-020311

CN-83

Air conditioner fan

PH805-02028

CN-100

Boom kick out

S816-003001

CN-101

Bucket leveler

S816-003001

S814-112000

35215-0200

S813-130200

7-44

Connector part No.

Connector
number

Type

No. of
pin

CN-102

Rear wiper motor

6189-0133

CN-103

Rear washer tank

S814-002000

CN-104

Ring term

Volt meter

S821-105000

CN-107

Ring term

Fuel gauge

S821-105000

CN-111

Buchse socket

35

Control unit

6029-199-004

CN-112

Buchse socket

Transmission WG/PW

6029-199-018

CN-114

Fasten

Joystick

CN-117

Ring term

Water temp

S821-105000

CN-119

Ring term

Transmission temp

S821-105000

CN-127

Ring term

Speed meter

S821-105000

CR-1

Ring term

Battery relay

S820-104000

CR-2

Fasten

Horn relay

S810-004202

CR-4

Fasten

Wiper relay

S810-006202

CR-5

Fasten

Safety relay

S810-004202

CR-7

Fasten

Aircon relay

S810-004202

CR-10

Fasten

Bucket leveler relay

S810-006202

CR-11

Fasten

Flasher unit

S810-003702

CR-23

Start relay

S816-002003

CR-26

Fasten

Wiper relay 2

S810-006202

CR-35

Fasten

Ride control relay

S810-006202

CR-38

Fasten

Neutral relay

S810-006202

CS-2

SWP

Start key switch

S814-006000

CS-3

SWF

10

Rear wiper switch

CS-5

Shur

Horn switch

S822-014000

CS-7

SWF

10

Prolix switch

593757

CS-11

SWP

Multi function switch

S814-008000

CS-12

SWP

Multi function switch

S814-006000

CS-17

SWF

10

Parking switch

593757

CS-21

SWF

10

Work lamp switch

593757

CS-23

SWF

10

Beacon switch

593757

CS-30

SWF

10

Ether switch

593757

CS-34

SWF

10

Buzzer stop switch

593757

CS-39

SWF

10

Illumination and head lamp switch

593757

CS-41

SWF

10

Hazard switch

593757

CS-42

SWF

10

Clutch cut off switch

593757

CS-43

Fasten

Emergency travel switch

CS-50

SWF

10

Ride control switch

593757

CS-52

SWF

10

Attachment engage switch

593757

Destination

Female

Male

S816-008002

Relay

Switch
593757

7-45

S810-006202

Connector
number

Connector part No.

Type

No. of
pin

CS-53

SWF

10

Attachment disengage switch

593757

CS-54

SWF

10

Air conditioner switch

593757

CS-58

Fasten

Blower switch

CL-1

Room lamp

MG610392

CL-2

Fasten

Cigar lighter

S810-003202

CL-3

SWP

Head light(LH)

S814-004000

CL-4

SWP

Head light(RH)

S814-004000

CL-5

SWP

Work light(LH)

S814-002000

CL-6

SWP

Work light(RH)

S814-002000

CL-7

Fasten

Beacon lamp

S810-001202

CL-15

SWP

Combi lamp(RR, LH)

S814-004000

CL-16

SWP

Combi lamp(RR, RH)

S814-004000

CL-21

SWP

Numberplate lamp

S814-002000

CL-22

SWP

Work light(LH)

S814-002000

CL-23

SWP

Work light(RH)

S814-002000

CL-24

SWP

Turn lamp(LH)

S814-002000

CL-25

SWP

Turn lamp(RH)

S814-002000

CL-41

SWF

Hi beam lamp(Dash board)

913328

CL-42

SWF

Turn lamp(LH, Dash board)

913328

CL-43

SWF

Turn lamp(RH, Dash board)

913328

CL-44

SWF

Parking lamp(Dash board)

913328

CL-45

SWF

Brake fail lamp(Dash board)

913328

CL-46

SWF

Charge lamp(Dash board)

913328

CL-47

SWF

Hydraulic oil lamp(Dash board)

913328

CL-48

SWF

Over heat lamp(Dash board)

913328

CL-49

SWF

Engine oil lamp(Dash board)

913328

CL-50

SWF

Air cleaner lamp(Dash board)

913328

CL-51

SWF

Transmission oil lamp(Dash board)

913328

CL-52

SWF

Glow lamp(Dash board)

913328

CL-53

SWF

Steering pressure lamp

913328

CL-54

SWF

Steering pump pressure lamp

913328

Destination

Female

Male

S810-006202

Light

Sensor, sender
CD-1

Hyduaulic oil temp sendor

S819-010122

CD-2

SWP

Fuel sendor

S814-002000

CD-3

Rubber cap

Brake fail pressure switch

21EA-00310

CD-4

Rubber cap

Stop lamp pressure switch

21EA-00300

CD-5

Rubber cap

Clutch cut off pressure switch

21EA-00310

CD-8

Ring term

Water temp sendor

CD-9

Over heat switch

CD-10

Ring term

Air cleaner switch

S820-105000
S819-010122
S820-105000

7-46

Connector
number

Connector part No.

Type

No. of
pin

CD-11

Back up pressure switch

CD-18

Engine oil pressure switch

CD-25

Transmission oil pressure switch

S819-010122

CD-26

Rubber cap

Parking oil pressure switch

21EA-00310

CD-27

Rund stecker

Turbine speed sendor

6029-199-002

CD-29

Ring term

Transmission temp sendor

CD-39

Steering pressure switch

S819-010122

CD-40

Steering pump pressure switch

S819-010122

Destination

7-47

Female

Male

S819-010122
S820-105000

S820-105000

2. CONNECTION TABLE FOR CONNECTORS

1) 58-L TYPE CONNECTOR
No. of
pin

Receptacle connector(Female)

Plug connector(Male)

S813-030100

S813-130100

S813-030200

7-48

S813-130200

2) PA TYPE CONNECTOR
No. of
pin

Receptacle connector(Female)

Plug connector(Male)

S811-005002

S811-105002

S811-007002

S811-107002

S811-009002

S811-109002

11

11

11

S811-011002

7-49

S811-111002

No. of
pin

Receptacle connector(Female)

Plug connector(Male)

13

7
S811-013002

17

17
S811-117002

13

13
S811-113002

17

S811-017002
10

21

11

11
S811-021002

10

21

21

7-50

S811-121002

3) 58-X TYPE CONNECTOR

No. of
pin

Receptacle connector(Female)

Plug connector(Male)

S813-060100

S813-160100

S813-060200

7-51

S813-160200

4) J TYPE CONNECTOR
No. of
pin

Receptacle connector(Female)

Plug connector(Male)

S816-002001

S816-102001
3

1
S816-003001

7-52

2
S816-103001

5) SWP TYPE CONNECTOR

No. of
pin

Receptacle connector(Female)

Plug connector(Male)

S814-001000

S814-101000

1
S814-002000

2
S814-102000

2 1

23

S814-003000

S814-103000

3
1
S814-004000

7-53

S814-104000

No. of
pin

Receptacle connector(Female)
3

Plug connector(Male)
6

4
1
S814-006000
4

S814-106000
1

5
1
S814-008000

12

9
S814-012000

12

S814-108000

12

S814-112000

14

1
11
S814-014000

11

14

7-54

14
S814-114000

6) CN TYPE CONNECTOR
No. of
pin

Receptacle connector(Female)

Plug connector(Male)

1
S810-001202

S810-101202

S810-002202

S810-102202
2

2
S810-003202

S810-103202
1

3
S810-004202

7-55

3
2
S810-104202

No. of
pin

Receptacle connector(Female)
3

Plug connector(Male)
1

4
S810-006202

6
S810-106202

5
S810-008202

8
S810-108202

7-56

7) BS TYPE CONNECTOR
No. of
pin

Receptacle connector(Female)

Plug connector(Male)

S812-002001

S812-102001

S812-003001

S812-103001

S812-004001

S812-104001

S812-006001

7-57

S812-106001

8) LC TYPE CONNECTOR
No. of
pin

Receptacle connector(Female)

Plug connector(Male)

10

10

6
S815-010000
12

12

7
S815-012000
16

16

9
S815-016000
18

18

10
S815-018000

7-58

No. of
pin

Receptacle connector(Female)
12

Plug connector(Male)

24

24

13
S815-024000

7-59

9) 375 FASTEN TYPE CONNECTOR

No. of
pin

Receptacle connector(Female)

Plug connector(Male)

2
1

S810-002402

7-60

S810-102402

GROUP 6 TROUBLESHOOTING
1. WHEN STARTING SWITCH IS TURNED ON, CLUSTER LAMP DOES NOT LIGHT UP
Before carrying out below procedure, check all the related connectors are properly inserted and the
fuse No.2 is not blown out and ON/OFF of bulb.
After checking, connect the disconnected connectors again immediately unless otherwise specified.

Cause
YES
YES Check voltage

Remedy

Defective cluster

Replace

Disconnection in
wiring harness or
poor contact
between
CN-58(1) and
fuse No.2

Repair or replace
(After clean)

Disconnection in
wiring harness or
poor contact
between CN-7(4)
and fuse No.2

Repair or replace
(After clean)

between CN-58
(1) and chassis
NO

Check voltage
between CN-7(4)
and chassis

NO

CLUSTER
FUSE
4
No.2
CN-7
1
CN-58

Check voltage
YES

20 ~ 30V

NO

0V

7-61

2.

WHEN COOLANT OVERHEAT LAMP LIGHTS UP(Engine is started)

Before carrying out below procedure, check all the related connectors are properly inserted.
After checking, connect the disconnected connectors again immediately unless otherwise specified.

Cause
YES

YES

Check resistance
between CN-4
(11) and chassis

YES

Does display go
off when
disconnect CD-9
and connector?

Starting switch : OFF NO

Check resistance
between CN-2(4)
and chassis

YES

Starting switch : ON
Engine : start

Starting switch : OFF

Check resistance
between CN-6(4)
NO
and chassis

NO

Starting switch : OFF

Before checking,
disconnect CD-9
NO

Remedy

Coolant overheat
(105
C2
C)

Check engine
system

Defective
overheat switch

Replace

Disconnection in
wiring harness or
poor contact
between CD-9
and CN-2(4)

Repair or replace
(After clean)

Disconnection in
wiring harness or
poor contact
between CN-6(4)
and CN-2(4)

Repair or replace
(After clean)

Defective cluster

Replace

OVERHEAT SWITCH

CLUSTER

T
4
CN-6

11

CN-4

CN-2

CHECK UNIT
24
CN-58

Check resistance
YES

MAX 1

NO

MIN 1M

7-62

CD-9

3.

WHEN AIR CLEANER LAMP LIGHTS UP(Engine is started)

Before carrying out below procedure, check all the related connectors are properly inserted.
After checking, connect the disconnected connectors again immediately unless otherwise specified.

Cause
YES

Does display go
off when
disconnect CD-10
and connector?
Starting switch : ON
Engine : start

YES

Check resistance
between CN-2(6)
NO
and chassis

YES

Defective air
cleaner or air
cleaner switch

Repair air cleaner

or replace air
cleaner switch

Disconnection in
wiring harness or
poor contact
between CN-2(6)
and CD-10

Repair or replace
(After clean)

Disconnection in Repair or replace

wiring harness or (After clean)
poor contact
between CN-4(6)CN-2(6) - CN-6(6)

Starting switch : OFF

Before checking,
disconnect CD-10

Remedy

Check resistance
between CN-6(6)
NO
and chassis
Starting switch : OFF

Defective cluster

NO

CLUSTER

AIR CLEANER SWITCH

6

CN-6

CN-2

Pa

CN-4
CD-10

CHECK UNIT
36
CN-58

Check resistance
YES

MAX 1

NO

MIN 1M

Replace

7-63

4.

WHEN ENGINE OIL PRESSURE LAMP LIGHTS UP(Engine is started)

Before carrying out below procedure, check all the related connectors are properly inserted.
After checking, connect the disconnected connectors again immediately unless otherwise specified.

Cause
YES

Remedy

Engine oil leakage, Check engine oil

or defective switch level or replace
switch
YES

Does display go
off when
disconnect CD-18
and connector?

Check resistance
between CN-4
(10) and chassis

YES

Starting switch : ON
Engine : start

Disconnection in Repair or replace

wiring harness or (After clean)
poor contact
between CN-4(10)
-CD-18

Starting switch : OFF

Disconnection in Replace
wiring harness or
poor contact
between CN-6(5) CN-2(5)- CN-4(10)

NO

Check resistance
between CN-6(5)
NO
and chassis
Starting switch : OFF
Before checking,
disconnect CD-18

Defective cluster

NO

Replace

ENGINE OIL PRESSURE SWITCH

CLUSTER
5
CN-6

10

CN-4

CN-2

CHECK UNIT
23
CN-58

Check resistance
YES

MAX 1

NO

MIN 1M

7-64

Pa
CD-18

5.

WHEN HYDRAULIC OIL TEMPERATURE LAMP LIGHTS UP(Engine is started)

Before carrying out below procedure, check all the related connectors are properly inserted.
After checking, connect the disconnected connectors again immediately unless otherwise specified.

YES

Does display go
off when
disconnect CD-1
and connector?

YES

YES

Starting switch : ON
Engine : start

Check resistance
between CN-2(9)
and chassis
Starting switch : OFF
Before checking,
NO
disconnect CD-1

Check resistance
between CN-6(8)
NO
and chassis
Starting switch : OFF

Before checking,
disconnect CD-1
NO

Cause

Remedy

High temperature
of hydraulic oil or
defective switch

Check hydraulic
oil temperature
(105
C2
C),
hydraulic cooling
or replace switch

Disconnection in
wiring harness or
poor contact
between CN-6(8)
and CN-2(9)
Disconnection in
wiring harness or
poor contact
between CN-2(9)
and CD-1

Repair or replace
(After clean)

Defective cluster

Replace

HYDRAULIC OIL
TEMPERATURE SWITCH

CLUSTER
8
CN-6

T
9
CN-2

CHECK UNIT
12
CN-58

Check resistance
YES

MAX 1

NO

MIN 1M

7-65

CD-1

6. WHEN TORQUE CONVERTER OIL TEMPERATURE GAUGE DOES NOT OPERATE

(Check torque converter oil temperature lamp ON/OFF)
Before carrying out below procedure, check all the related connectors are properly inserted.
After checking, connect the disconnected connectors again immediately unless otherwise specified.

Cause
YES

Defective cluster
YES

Check resistance
between CN-9(6)
NO
and chassis
Starting switch : OFF
See : TABLE

YES

Check resistance
between CD-29
NO
and chassis
Starting switch : OFF
See : TABLE

NO

Disconnection in
wiring harness or
poor contact
between CN-9(6)
and CD-29

Repair or replace
(After clean)

Defective sender

Replace

TRANS

TRANSMISSION OIL
TEMPERATURE SENDER

CLUSTER
10

CN-7

CD-29

CN-9

Check resistance
YES

MAX 1

NO

MIN 1M

Check table
Temperature

50
C

92
C

120
C

130
C

Unit resistance()

168.7

(34)

19.5

12.4

Tolerance

0~ -10

(-)

+10~ 0

Angle

-30

-8

+27

+30

Item

Replace

Disconnection in Repair or replace

wiring harness or (After clean)
poor contact
between CN7(10) and CN-9(6)

Check resistance
between CN-7
(10) and chassis
Starting switch : ON
Engine : start
See : TABLE

Remedy

7-66

7. WHEN COOLANT TEMPERATURE GAUGE DOES NOT OPERATE

(Check coolant temperature lamp ON/OFF)
Before carrying out below procedure, check all the related connectors are properly inserted.
After checking, connect the disconnected connectors again immediately unless otherwise specified.
Cause
YES
YES

Check resistance
between CN-7
(11) and chassis
Starting switch : ON
Engine : start
See : TABLE

Check resistance
between CN-2(3)
NO
and chassis
Starting switch : OFF
Before checking,
disconnect connector
See : TABLE

YES

Check resistance
between CN-4
NO
(12) and chassis

YES

Starting switch : OFF

See : TABLE

Check resistance
between CD-8
NO
and chassis
Starting switch : OFF
See : TABLE

NO
TRANS

Remedy

Defective cluster

Replace

Disconnection in
wiring harness or
poor contact
between CN-7
(11) and CN-2(3)

Repair or replace
(After clean)

Disconnection in
wiring harness or
poor contact
between CN-2(3)
and CN-4(12)

Repair or replace
(After clean)

Disconnection in
wiring harness or
poor contact
between CN-4
(12) and CD-8

Repair or replace
(After clean)

Coolant overheat
or defective
sender

Check coolant
temperature or
replace

WATER TEMPERATURE SENDER

CLUSTER
11

CN-7

CN-2

12

CN-4

CD-8

Check resistance
YES

MAX 1

NO

MIN 1M

Check table
Temperature
Item
Unit resistance()

(40
C)

91
C

105
C

120
C

222

(41.3)

28

19.2

Tolerance

(-)

4.5

(-)

Angle

-30

+13

+30

7-67

8. WHEN FUEL GAUGE DOES NOT OPERATE(Check warning lamp ON/OFF)

Before carrying out below procedure, check all the related connectors are properly inserted.
After checking, connect the disconnected connectors again immediately unless otherwise specified.

Cause
YES

YES

Check resistance
between CN-7
(12) and chassis
Starting switch : OFF
See : TABLE

Check resistance
between CN-2(7)
NO
and chassis

YES

See : TABLE

Check resistance
between CD-2(2)
NO
and chassis
YES

See : TABLE

Check resistance
between CD-2(2)
NO and CD-2(1) with
chassis
See : TABLE
E

NO

Defective cluster

Replace

Disconnection in
wiring harness or
poor contact
between CN-7
(12) and CN-2(7)

Repair or replace
(After clean)

Disconnection in
wiring harness or
poor contact
between CD-2(1)
and CN-2(7)

Repair or replace
(After clean)

Check circuit
between CD-2(2)
and chassis

Repair or replace
(After clean)

Defective sensor

Replace

FUEL

FUEL SENDER
CLUSTER

1
12

CD-2

CN-2

CN-7

Check resistance
YES

MAX 1

NO

MIN 1M

Check table
Temperature

Empty

(1/2)

Full

Unit resistance()

95

(32.5)

Tolerance

2.5

2.5

Angle

-30

+30

Item

7-68

Remedy

9. WHEN GAUGES OF FUEL, HYDRAULIC OIL AND COOLANT INDICATE HIGH OR FULL
Before carrying out below procedure, check all the related connectors are properly inserted.
After checking, connect the disconnected connectors again immediately unless otherwise specified.

Cause
YES

Remedy

Defective cluster

Replace

Disconnection in
wiring harness or
poor contact
between CN-7
(13) and chassis

Repair or replace
(After clean)

Check resistance
between CN-7
(13) and chassis
Starting switch : ON
Voltage : 20~30v

NO

CLUSTER
13
CN-7

Check resistance
YES

MAX 1

NO

MIN 1M

7-69

10.

WHEN BATTERY LAMP LIGHTS UP(Engine is started)

Before carrying out below procedure, check all the related connectors are properly inserted.
After checking, connect the disconnected connectors again immediately unless otherwise specified.
Cause
YES

Check voltage
between CN-6(1)
and chassis

YES

NO

YES

Check voltage
YES
between CN-58
(2) and chassis

Check voltage
Check voltage
YES
between CN-2(2)
between
and chassis
alternator terminal
"I" and chassis
Voltage : 26~30V
Voltage : 26~30V
Starting switch : ON

Defective cluster

Replace

Disconnection in
wiring harness or
poor contact
between CN-6(1)
and CN-58(18)

Repair or replace
(After clean)

Defective check
unit

Replace

Disconnection in Repair or replace

wiring harness or (After clean)
poor contact
between CN-58(2)
and CN-2(2)

NO

Voltage : 27.5~30V

Remedy

YES

Check voltage
between CN-4(3)
NO
and chassis
NO

Disconnection in
wiring harness or
poor contact
between CN-4(3)
and CN-2(2)

Repair or replace
(After clean)

Disconnection in
wiring harness or
poor contact
between CN-4(3)
and alternator
terminal " H "

Repair or replace
(After clean)

Defective alternator Replace

NO

CLUSTER

CHECK UNIT
18

1
CN-6

2
CN-58

CN-2

CN-4

Check valtage
YES

20 ~ 30V

NO

0V

7-70

ALTERNATOR
"I" TERMINAL

11. WHEN PARKING SOLENOID DOES NOT WORK

Before carrying out below procedure, check all the related connectors are properly inserted and the
fuse No.6 is not blown out.
After checking, connect the disconnected connectors again immediately unless otherwise specified.
Cause
YES

YES

Check voltage
between CN-71
(2) and chassis
Starting switch : ON
Parking switch : ON-OFF
Voltage : 20~30V

Check voltage
between CN-8(3)
NO
and chassis

YES

Defective parking
brake solenoid

Replace

Disconnection in
siring harness or
poor contact
between CN-8(3)
and CN-71(2)

Repair or replace
(After clean)

Disconnection in
Repair or replace
wiring harness or (After clean)
poor contact
between CS-17(8)
and CN-8(3)

Voltage : 20~30V

Check voltage
between CS-17
NO
(8) and chassis
Parking switch : OFF
Voltage : 20~30V

Remedy

Check voltage
between CS-17
NO
(6) and chassis
Voltage : 20~30V

Defective parking
switch

Replace

Repair or replace
Disconnection in
wiring harness or (After clean)
poor contact
between CS-17(6)
and CN-36(6)

CN-8

PARKING SWITCH
8

3
FUSE

No.6

2
1

CN-71
2
1

CS-17

PARKING SOLENOID

7-71

12. TRANSMISSION IS NOT RETURNED TO NEUTRAL WHEN PARKING BRAKE IS APPLIED

Before carrying out below procedure, check all the related connectors are properly inserted and the
fuse No.1(Transmission controller) and No.6 are not blown out.
After checking, connect the disconnected connectors again immediately unless otherwise specified.
Cause
YES
YES

Defective T/M
controller

Check voltage
between EN-111
(14) and chassis
Voltage : 20~30V

YES

Check voltage
between CS-17
NO
(1) and chassis
Voltage : 20~30V
Parking switch : ON

YES

Check voltage
between CS-17
NO
(5) and chassis

Disconnection in
wiring harness or
poor contact
between CN-15
(4) and CS-17(1)

Repair or replace
(After clean)

Defective switch

Replace

Disconnection in Repair or replace

wiring harness or (After clean)
poor contact
between CS-17(5)
and fuse No.6

NO

Voltage : 20~30V

1
4

Replace

Disconnection in Repair or replace

wiring harness or (After clean)
poor contact
between CS-17(6)
and fuse No.6

NO

Check voltage
between CN-15
(1) and chassis
Starting switch : ON
Parking switch : ON
Prolix switch : OFF
Voltage : 20~30V

Remedy

PROLIX SWITCH

CN-15

FUSE
5
6

No.1

8
CS-7

PARKING SWITCH

FUSE
6
No.6

5
1
CS-17

7-72

13. MACHINE DOES NOT TRAVEL

Before carrying out below procedure, check all the related connectors are properly inserted and the
fuse No.1(Transmission controller) is not blown out.
After checking, connect the disconnected connectors again immediately unless otherwise specified.
Wiring diagram : See page 7-17.
Cause
YES

Is there continuity
between CN-15
(4) and chassis?

YES

Disconnect parking
switch connector
Clutch cut-off switch
:OFF

Is voltage
YES between CN-15
(4) and chassis
20-30V?
Starting switch : ON
Parking switch : OFF

YES

Is there continuity
between CN-15 (2)
and chassis?
NO

Is voltage between
CN-15(1) and
chassis 20-30V?

NO

Starting switch : ON

NO

YES

Is problem
removed when
EN-111 is
replaced?

YES

Is problem
removed when
NO T/M harness is
replaced?
NO

7-73

NO

Remedy

Disconnection in Repair or replace

wiring harness or (After clean)
poor contact
between CS-42(5)
- CS-42(1) -CD-5 CN-15(4)
Defective parking
switch or
disconnection
wiring harness or
poor contact
between CN-15
(4) and CS-17(1)

Repair or replace
(After clean)

Disconnection in
wiring harness or
poor contact
between CN-15
(2) and chassis

Repair or replace
(After clean)

Disconnection in
wiring harness or
poor contact
between CN-15
(1) and fuse No.1

Repair or replace
(After clean)

Defective T/M
controller(EGS)

Replace

Defective T/M
harness

Replace

Check solenoid

Repair or replace
(After clean)

14. WHEN STARTING SWITCH IS TURNED ON, HEAD LAMP DOES NOT LIGHTS UP
Before carrying out below procedure, check all the related connectors are properly inserted and the
fuse No.19 is not blown out and ON/OFF of bulb.
After checking, connect the disconnected connectors again immediately unless otherwise specified.
Cause
YES

Defective bulb

FUSE BOX

Remedy
Replace

Check voltage
YES
between CL-3(1) (3) and CL-4(1) -(3)
Disconnection in
Repair or replace
wiring harness or
(After clean)
poor contact
between CN-10(4)CL-3(1), 4(1) and
CL-3(3) - CN-8(11),
CL-4(3) - CN-8(12).

Voltage : 20~30V
NO
Starting switch : ON
Head lamp switch : ON

Check voltage
YES between CN-

10(4) and CN8(11), (12)

Voltage : 20~30V
Starting switch : ON
Head lamp switch : ON

ILL & HEAD LAMP SW

Disconnection in
wiring harness or
poor contact
between CN-10(4)
and CS-11(7)

NO

Check voltage
between CS-11
(7) and chassis
Starting switch : ON
Head lamp switch :
ON-OFF

CN-36

LH HEAD LIGHT

Repair or replace
(After clean)

CL-3
RH HEAD LIGHT

CS-39
CL-4

YES

Check voltage
between CS-11
(8) and chassis

YES

Voltage : 20~30V
Starting switch : ON

NO

CN-8

HI BEAM PILOT LAMP

Disconnection in
wiring harness or
poor contact
between CS-11(8)
and CS-39(2)

Check voltage
between CS-39
(2) and chassis

YES Defective head

Repair or replace
(After clean)

CL-41
CN-10

Replace switch

EARTH

lamp switch

Check voltage
between CS-39
NO
(4) and chassis
NO

Disconnection in
wiring harness or
poor contact
between CS-39(4)
and fuse No.19

CS-11

NO

Defective
Replace
multifunction switch

Repair or replace
(After clean)

MULTI FUNCTION SW

7-74

CN-7

JT-28

15. WHEN STARTING SWITCH IS TURNED ON, WIPER MOTOR DOES NOT OPERATE
Before carrying out below procedure, check all the related connectors are properly inserted and the
fuse No.7 is not blown out.
After checking, connect the disconnected connectors again immediately unless otherwise specified.

Check voltage
between CS-12
(6) and chassis
Voltage : 20~30V
Starting switch : ON
Wiper switch : 1st

Voltage : 20~30V
Starting switch : ON
Wiper switch : 1st

Voltage : 20~30V
Starting switch : ON
Wiper switch : OFF

NO

NO

Voltage : 20~30V
Starting switch : ON
Wiper switch : 1st

NO

NO

Poor connection of Replace

chassis

Disconnection in
Repair or replace
wiring harness or (After clean)
poor contact
between CR-26(1)
and CN-21(5)
Defective wiper
switch

CN-36

WIPER RY2

Replace

Disconnection in
Repair or replace
wiring harness or (After clean)
poor contact
between CS-12(6)
and fuse No.7

CR-26

WIPER RY

CR-4

CN-21

Check voltage
YES
between CS-12
(4) and chassis

Check voltage
between CN-21(5)
and chassis

CS-5

YES

CS-12

wiper motor and

chassis

Remedy
Replace

CS-11

Check voltage
YES between front

Defective front
wiper motor

CN-58

Cause
YES

FUSE BOX

CHECK UNIT

FRONT WIPER

MULTIFUNCTION SWITCH

7-75

16. WHEN STARTING SWITCH ON DOES NOT OPERATE

FUSE BOX

Before carrying out below procedure, check all the related connectors are properly inserted and and
the fuse No.15 is not blown out.
After checking, connect the disconnected connectors again immediately unless otherwise specified.
Cause
YES

Check voltage
between CN-60(2)
and chassis

YES

Voltage : 20~30V

Check voltage
YES
between CR-1
(M4) and chassis

NO

Remedy

Defective cable

Repair or replace

assembly

(After clean)

Short circuit or

Replace

defect of fusible
link or defective
battery relay

Voltage : 20~30V

NO

Check voltage
YES between CS-2
(1)[and CS-2(2)]
and chassis

Disconnection in

Replace

wiring harness or
poor contact
between CS-2(2) -

Voltage : 20~30V

CN-36

CN-2(1)-CR-1
(M4)

NO

Check voltage
and specific
gravity of battery

Disconnection in

Replace
MASTER SW

wiring harness or

BATT RY

60R

60R

poor contact
between fuse No.

Specific gravity : MIN 1.28

Voltage : MIN 24V

CR-1

13 and CS-2(1) or
defect of start

TO STARTER

switch
CN-1
CN-60

Battery capacity

Repair or replace

too low

(After clean)

DO-2

CN-2

CS-2

NO

START SWITCH

7-76

60B

60B

17. WHEN STARTING SWITCH IS TURNED ON, WORK LAMP DOES NOT LIGHTS UP
Before carrying out below procedure, check all the related connectors are properly inserted, and the
fuse No.16 is not blown out.
After checking, connect the disconnected connectors again immediately unless otherwise specified.

Cause
Check voltage
YES between each
lamp(2) and
chassis
Check voltage
between CN-5(3),
(4) and chassis

YES

Voltage : 20~30V
Starting switch : ON

Voltage : 20~30V
Starting switch : ON

YES

Check voltage
between CS-21
(2) and chassis

NO

Voltage : 20~30V
Starting switch : ON

Check voltage
between CS-21
(6) and chassis

NO
YES

Voltage : 20~30V
Starting switch : ON

NO

Check voltage
between fuse No.
16 and chassis
Voltage : 20~30V
Starting switch : ON

NO

YES

NO

Defective lamp

Remedy
Replace

Disconnection in
Repair or replace
wiring harness or (After clean)
poor contact
between CN-5(3) CL-22(2), CL23(2)
and CN-5(4) - CL5(2), CL-6(2)
Disconnection in
Repair or replace
wiring harness or (After clean)
poor contact
between CN-5(3) CS-21(2) and CN5(4) - CS-21(1)
Defective work
lamp switch

Replace switch

Disconnection in
Repair or replace
wiring harness or (After clean)
poor contact
between CS--21(6)
and fuse No.16

Short circuit of fuse Replace

7-77

18. WHEN ENGINE DOES NOT START

EGS

Check supply of the power at engine stop solenoid while starting switch is ON.
Before carrying out below procedure, check all the related connectors are properly inserted.
After checking, connect the disconnected connectors again immediately unless other wise specified.
Check forward reverse switch at neutral position.

Defective battery

YES

Defective magnet
of start motor

YES between starter

magnet coil and

chassis

Starting switch : Start

Defective start
relay

NO

Starting switch : Start

YES

Check operation
NO of starter relay

YES

Starting switch : Start

STARTER

Check switch : Neutral

YES

Disconnection in
wiring harness or
poor contact
between CN-3(3)
and CR-5(4)

Replace

Defective relay

Replace

CN-45
START RY

CR-23

ENG STOP SOL

YES

Check voltage
between CR-23
(2) and chassis
Voltage : 20~30V
Starting switch : ON

TO BATT

CR-5

Check voltage
between CR-5(3)
and chassis
Starting switch : OFF NO

NO

YES

CN-111

Check voltage
between CR-5(4)
and chassis

Check operation
of start safety
NO
relay

CN-36

SAFETY RY

Starting switch : OFF NO

NO

Replace

Check voltage
between CN-15
(2) and chassis

Defective start
relay

CN-79

Replace

Disconnection in
Repair or replace
wiring harness or
poor contact
between CN-3(3)CR-23(2)
CN-2

CS-2

Check voltage

Check operation
of start motor

Remedy
Check engine
system charge or
replace (After
checking specific
gravity of battery)
Replace

CN-15

Cause
YES

FUSE BOX

Disconnection in
Repair or replace
wiring harness or
poor contact
between CN-15(3)
and CR-5(3)

CN-4
START SWITCH

CN-3

Starting switch : OFF

NO

Defective EGS

Replace

7-78