Professional Documents
Culture Documents
SECTION 1 GENERAL
SECTION 2 ENGINE
1. STRUCTURE
This service manual has been prepared as an aid to improve the quality of repairs by giving the
serviceman an accurate understanding of the product and by showing him the correct way to
perform repairs and make judgements. Make sure you understand the contents of this manual and
use it to full effect at every opportunity.
This service manual mainly contains the necessary technical information for operations performed in
a service workshop.
For ease of understanding, the manual is divided into the following sections.
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Contact your Hyundai distributor for the latest information.
0-1
2. HOW TO READ THE SERVICE MANUAL
Distribution and updating Revised edition mark (①②③…)
Any additions, amendments or other changes When a manual is revised, an edition mark is
will be sent to HYUNDAI distributors. recorded on the bottom outside corner of the
Get the most up-to-date information before you pages.
start any work.
Revisions
Filing method Revised pages are shown at the list of revised
1. See the page number on the bottom of the pages on the between the contents page and
page. section 1 page.
File the pages in correct order.
2. Following examples shows how to read the Symbols
page number. So that the shop manual can be of ample
Example 1 practical use, important places for safety and
3-3 quality are marked with the following symbols.
Section number (3. Power train
system)
Consecutive page number for Symbol Item Remarks
each section.
Special safety precautions are
3. Additional pages : Additional pages are necessary when performing the
indicated by a hyphen(-) and number after the work.
Safety
page number. File as in the example. Extra special safety precautions
10 - 4 are necessary when performing
10 - 4 - 1 the work because it is under
Added pages internal pressure.
10 - 4 - 2
10 - 5 Special technical precautions or
※ Caution
other precautions for preserving
standards are necessary when
performing the work.
0-2
3. CONVERSION TABLE
Method of using the Conversion Table
The Conversion Table in this section is provided to enable simple conversion of figures. For details of
the method of using the Conversion Table, see the example given below.
Example
1. Method of using the Conversion Table to convert from millimeters to inches
Convert 55 mm into inches.
(1) Locate the number 50 in the vertical column at the left side, take this as ⓐ, then draw a horizontal
line from ⓐ.
(2) Locate the number 5in the row across the top, take this as ⓑ, then draw a perpendicular line
down from ⓑ.
(3) Take the point where the two lines cross as ⓒ. This point ⓒ gives the value when converting
from millimeters to inches. Therefore, 55 mm = 2.165 inches.
Millimeters to inches ⓑ
1mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0-3
Millimeters to inches 1mm = 0.03937in
0 1 2 3 4 5 6 7 8 9
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
0 1 2 3 4 5 6 7 8 9
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
0-4
Liter to U.S. Gallon 1ℓ = 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.631 25.625 25.889 26.153
0 1 2 3 4 5 6 7 8 9
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
0-5
kgf·m to lbf
kgf lbf·ftft 1kgf·m = 7.233lbf·ft
0 1 2 3 4 5 6 7 8 9
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 10005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
0-6
kgf/cm2 to lbf/in2 1kgf / cm2 = 14.2233lbf / in2
0 1 2 3 4 5 6 7 8 9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 2863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 5603 2617 2631 2646 2660 2674 2688
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
0-7
TEMPERATURE
Fahrenheit-Centigrade Conversion.
A simple way to convert a fahrenheit temperature reading into a centigrade temperature reading or vice verse
is to enter the accompanying table in the center or boldface column of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
˚C ˚F ˚C ˚F ˚C ˚F ˚C ˚F
-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 117.8
-37.2 -35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
0-8
SECTION 1 GENERAL
73031GE01
7579S1GE01
1-1
PREPARE FOR EMERGENCIES
Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors,
ambulance ser vice, hospital, and fire
department near your telephone.
73031GE03
73031GE04
73031GE05
1-2
PARK MACHINE SAFELY
Before working on the machine:
· Park machine on a level surface.
· Lower bucket to the ground.
· Turn key switch to OFF to stop engine.
Remove key from switch.
· Move pilot control shutoff lever to locked
position.
· Allow engine to cool. 73031GE23
73031GE07
73031GE08
1-3
Store flammable fluids away from fire hazards.
Do not incinerate or puncture pressurized
containers.
Make sure machine is clean of trash,
grease, and debris.
Do not store oily rags ; They can ignite and
burn spontaneously.
73031GE09
1-4
ILLUMINATE WORK AREA SAFELY
Illuminate your work area adequately but safely.
Use a portable safety light for working inside or
under the machine. Make sure the bulb is
enclosed by a wire cage. The hot filament of an
accidentally broken bulb can ignite spilled fuel
or oil.
73031GE11
73031GE13
1-5
AVOID HIGH PRESSURE FLUIDS
Escaping fluid under pressure can penetrate the
skin causing serious injury.
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten
all connections before applying pressure.
Search for leaks with a piece of cardboard.
Protect hands and body from high pressure
73031GE14
fluids.
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be
surgically removed within a few hours or
gangrene may result.
73031GE15
other materials.
1-6
PREVENT ACID BURNS
Sulfuric acid in battery electrolyte is poisonous. It
is strong enough to burn skin, eat holes in
clothing, and cause blindness if splashed into
eyes.
1. Avoid the hazard by:
2. Filling batteries in a well-ventilated area.
3. Wearing eye protection and rubber gloves.
Avoiding breathing fumes when electrolyte
is added.
4. Avoiding spilling of dripping electrolyte.
5. Use proper jump start procedure.
1. If you spill acid on yourself:
2. Flush your skin with water.
Apply baking soda or lime to help neutralize
the acid.
3. Flush your eyes with water for 10-15 minutes.
Get medical attention immediately.
1. If acid is swallowed:
2. Drink large amounts of water or milk.
Then drink milk of magnesia, beaten eggs,
or vegetable oil.
73031GE18
3. Get medical attention immediately.
1-7
SERVICE TIRES SAFELY
Explosive separation of a tire and rim parts can
cause serious injury or death.
Do not attempt to mount a tire unless you have the
proper equipment and experience to perform the job.
Always maintain the correct tire pressure. Do not
inflate the tires above the recommended pressure.
Never weld or heat a wheel and tire assembly.
The heat can cause an increase in air pressure
resulting in a tire explosion.
Welding can structurally weaken or deform the
wheel.
When inflating tires, use a clip-on chuck and
extension hose long enough to allow you to stand
to one side and not in front of or over the tire
assembly. Use a safety cage if available.
Check wheels for low pressure, cuts, bubbles, 73031GE24
73031GE25
1-8
REPLACE SAFETY SIGNS
Replace missing or damaged safety signs.
See the machine operator's manual for correct
safety sign placement.
73031GE21
K E E P RO P S I N S TA L L E D P RO P E R LY
(option)
Make certain all parts are reinstalled correctly if
the roll-over protective structure (ROPS) is
loosened or removed for any reason. Tighten
mounting bolts to proper torque.
The protection offered by ROPS will be
impaired if ROPS is subjected to structural
damage, is involved in an overturn incident, or is
in any way altered by welding, bending, drilling, 73031GE22
or cutting. A damaged ROPS should be
replaced, not reused.
1-9
GROUP 2 SPECIFICATION
1. MAJOR COMPONENT
Precleaner(option)
Bell crank Bucket cylinder Cab Main pump Rain cap(std) Muffler Engine
Bucket link Front axle Steering cylinder Transmission Rear axle Fuel tank
7609S2SE01
1-10
2. SPECIFICATIONS
1) WITH BOLT-ON CUTTING EDGE TYPE BUCKET (HL757-9S)
5250
B
F
I
H
3910
C
K
G
40
52
D
0
617 0
5
E
A
7579S2SE03
1-11
WITH BOLT-ON CUTTING EDGE TYPE BUCKET (HL757XTD-9S)
5650
B
F
I
4320
H
C
K
G
40
52
D
0
636 0
0 E
A
7579S2SE03-1
1-12
2) WITH TOOTH TYPE BUCKET (HL757-9S)
5250
B
F
I
H
3910
C
K
G
40
52
D
0
623 0
5
E
A
7579S2SE02
1-13
WITH TOOTH TYPE BUCKET (HL757XTD-9S)
5650
B
F
I
H
4320
C
K
G
40
52
D
0
642 0
0 E
A
7579S2SE02-1
1-14
3. WEIGHT
Item kg lb
Front frame assembly 1139 2510
Rear frame assembly 1667 3680
Front fender (LH & RH) 31 68
HL757-9S 550 1210
Counterweight
HL757XTD-9S 840 1850
Cab assembly 780 1720
Engine assembly 485 1070
Transmission assembly 518 1140
Drive shaft (front) 26 57
Drive shaft (center) 22 49
Drive shaft (rear) 13 29
Front axle (include differential) 970 2140
Rear axle (include differential) 760 1680
Tire (20.5-25, 16PR, L3) 203 448
Hydraulic tank assembly 230 507
Fuel tank assembly 219 483
Main pump assembly 40 88
Fan & brake pump assembly 6.5 14.3
Main control valve (2 / 3 spool) 45 / 65 99 / 143
Steering valve (EHPS) 10 22
HL757-9S 980 2160
Boom assembly
HL757XTD-9S 1145 2520
Bell crank assembly 264 580
Bucket link 48 110
2.8 m3 bucket, with bolt on cutting edge 1075 2370
2.6 m3 bucket, with tooth 1060 2340
Boom cylinder assembly 108 238
Bucket cylinder assembly 122 269
Steering cylinder assembly 29 64
Seat 40 88
Battery 44 97
1-15
4. SPECIFICATION FOR MAJOR COMPONENTS
1) ENGINE
Item Specification
Model Cummins QSB6.7
Type 4-cycle turbocharged and charge air-cooled diesel engine
Control type Electronic control
Cooling method Water cooling
Number of cylinders and arrangement 6 cylinders, in-line
Firing order 1-5-3-6-2-4
Combustion chamber type Direct injection type
Cylinder bore × stroke 107×124 mm (4.2"×4.9")
Piston displacement 6730 cc (410cu in)
Compression ratio 17.2 : 1
Rated horse power (Net) 170 hp at 2100 rpm
Maximum torque at 1400 rpm (Net) 82 kgf·m (593 lbf·ft)
Engine oil quantity 18ℓ (4.8 U.S. gal)
Wet weight 485 kg(1069 lb)
High idling speed 2230 ± 50 rpm
Low idling speed 800± 25 rpm
Rated fuel consumption 252 g/kW·hr
Starting motor Nippondenso 228000-7902 (24V-3.7kW)
Alternator Delco Remy 24SI (24V-70Amp)
Battery 2×12V×160Ah
1-16
2) MAIN PUMP
Item Specification
Type Gear pump
Capacity 56+56 cc/rev
Maximum operating pressure 210 kgf/cm2 (2990 psi)
Rated oil quantity 225ℓ/min (59.4 U.S.gpm)
Rated speed 2100 rpm
1-17
6) CYLINDER
Item Specification
Boom cylinder Bore dia×Rod dia×Stroke Ø140×Ø75×750 mm
Bucket cylinder Bore dia×Rod dia×Stroke Ø160×Ø80×475 mm
Steering cylinder Bore dia×Rod dia×Stroke Ø 70×Ø45×436 mm
Item Specification
Model 4WG190
Converter Single-stage, single-phase
Type
Transmission Full-automatic power shift
Transmission Converter stall ratio 2.542 : 1
Gear shift Forward fourth gear, reverse third gear
Control Electrical single lever type, kick-down system
Pump rated flow 105ℓ/min (27.7 U.S.gpm) at 2000 rpm
Drive devices 4-wheel drive
Axle Front Front fixed location
Rear Oscillation ±13˚ of center pin-loaded
Wheels Tires 20.5-25, 16PR (L3)
Travel Four-wheel, wet-disc type, full hydraulic
Brakes
Parking Spring applied, hydraulic released brake on transmission
Type Full hydraulic, articulated
Steering
Steering angle 40˚ to both right and left angle, respectively
1-18
5. TIGHTENING TORQUE OF MAJOR COMPONENT
Torque
No. Descriptions Bolt size
kgf·m lbf·ft
1 Engine mounting bolt, nut (rubber, 2EA) M20×2.5 57.9 ± 8.7 419 ± 63
2 Engine mounting bolt (bracket, 8EA) M12×1.75 10.7 ± 1.6 77.4 ± 11.6
3 Engine mounting bolt (flywheel housing, 12EA) M10×1.5 4.6 ± 0.9 33.3 ± 6.5
Engine
4 Engine mounting bolt (flywheel housing, 4EA) M10×1.5 4.5 ± 0.6 32.5 ± 4.3
5 Radiator mounting bolt M16×2.0 29.7 ± 4.5 215 ± 32.5
6 Fuel tank mounting bolt, nut M16×2.0 29.7 ± 4.5 215 ± 32.5
7 Main pump housing mounting bolt M12×1.75 12.8 ± 3.0 92.6 ± 21.7
8 Fan & brake pump housing mounting bolt M10×1.5 6.9 ± 1.4 50 ± 10.1
9 Main control valve mounting bolt M12×1.75 12.8 ± 3.0 92.6 ± 21.7
10 Steering unit mounting bolt M10×1.5 6.9 ± 1.4 50 ± 10.1
11 Pilot supply unit M8×1.25 2.5 ± 0.5 18.1 ± 3.6
12 Hydraulic Steering valve (EHPS) mounting bolt M8×1.25 2.5 ± 0.5 18.1 ± 3.6
13 system Cushion valve M8×1.25 2.5 ± 0.5 18.1 ± 3.6
14 Brake valve mounting bolt M8×1.25 2.5 ± 0.5 18.1 ± 3.6
15 Cut-off valve mounting bolt M8×1.25 2.5 ± 0.5 18.1 ± 3.6
16 Remote control lever mounting bolt M6×1.0 1.1 ± 0.2 8.0 ± 1.4
17 Safety valve M8×1.25 2.5 ± 0.5 18.1 ± 3.6
18 Hydraulic oil tank mounting bolt M16×2.0 29.7 ± 4.5 215 ± 32.5
19 Transmission mounting bolt, nut (rubber, 2EA) M24×3.0 100 ± 15 723 ± 108
20 Transmission mounting bolt (bracket) M20×2.5 46.3 ± 7.0 335 ± 50.6
21 Power Front axle mounting bolt, nut M27×2.0 135 ± 15 976 ± 108
train
22 system Rear axle support mounting bolt, nut M27×2.0 135 ± 15 976 ± 108
23 Tire mounting nut M22×1.5 79 ± 2.5 571 ± 18.1
24 Drive shaft joint mounting bolt, nut 1/2-20UNF 6.0 ± 0.8 43.4 ± 5.8
25 Counterweight mounting bolt M30×3.5 199 ± 30 1439 ± 216
26 Operator's seat mounting bolt M8×1.25 3.4 ± 0.8 24.6 ± 5
Others
27 Cab mounting bolt (4EA) M30×3.5 199 ± 30 1440 ± 217
28 Cab mounting nut (4EA) M16×2.0 20.5 ± 4.7 148 ± 40
1-19
6. TORQUE CHART
1-20
2) PIPE AND HOSE (FLARE type)
Thread size Width across flat (mm) kgf·m lbf·ft
1/4" 19 4 28.9
3/8" 22 5 36.2
1/2" 27 9.5 68.7
3/4" 36 18 130
1" 41 21 152
1-1/4" 50 35 253
9/16-18 19 4 28.9
11/16-16 22 5 36.2
13/16-16 27 9.5 68.7
1-3/16-12 36 18 130
1-7/16-12 41 21 152
1-11/16-12 50 35 253
4) FITTING
1/4" 19 4 28.9
3/8" 22 5 36.2
1/2" 27 9.5 68.7
3/4" 36 18 130
1" 41 21 152
1-1/4" 50 35 253
1-21
7. RECOMMENDED LUBRICANTS
Use only oils listed below or equivalent.
Do not mix different brand oil.
Ambient temperature˚C (˚F)
Capacity
Service point Kind of fluid -20 -10 0 10 20 30 40
ℓ (U.S. gal)
(-4) (14) (32) (50) (68) (86) (104)
SAE 30
SAE 10W
Engine oil pan Engine oil 18 (4.8)
SAE 10W-30
SAE 15W-40
SAE 10W-30
Transmission Engine oil 43 (11.4)
SAE 15W-40
Front : 32 (8.5) ★
Axle UTTO Refer to below list
Rear : 24 (6.3)
ISO VG 32
Tank:
124 (32.7)
Hydraulic tank Hydraulic oil ISO VG 46
System:
175 (46)
ISO VG 68
NLGI NO.1
Fitting
Grease As required
(grease nipple) NLGI NO.2
Mixture of
antifreeze Ethylene glycol base permanent type
Radiator 36 (9.5)
and water
50 : 50
★
·SAE : Society of Automotive Engineers Recommended oil list
·API : American Petroleum Institute - BP TERRAC SUPER TRANSMISSION 10W-30
·ISO : International Organization for Standardization - CASTROL AGRI TRANS PLUS 10W-30
·NLGI : National Lubricating Grease Institute - MOBILFLUID 426
·ASTM : American Society of Testing and Material - SHELL DONAX TD 10W-30
·UTTO : Universal Tractor Transmission Oil - TOTAL DYNATRANS MPV
1-22
GROUP 3 OPERATIONAL CHECKOUT RECORD SHEET
·Owner :
·Date :
·Hours :
·Serial No. :
·Technician :
OK NOT
Item Comments
OK
1-23
4. Brake system and clutch cut off checks
5. Driving checks
1-24
7. Steering system checks
8. Accessory checks
1-25
SECTION 2 ENGINE
1. STRUCTURE
Crankcase
breather
Belt tensioner
Flywheel housing
Water outlet
Fan drive
Oil pan
7577AEG01
· Direct 4-stroke, 6-cylinders, water-cooling and charge air cooled diesel engine in installed, cylinder
block and cylinder head are made of case iron and turbocharger is attached.
2-1
2. SYSTEM DIAGRAMS
The following drawings show the flow through the engine systems.
1) FUEL SYSTEM
7607AEG02
2-2
2) LUBRICATING OIL SYSTEM
7607AEG03
7607AEG04
2-3
(2) Lubrication for the power components
7607AEG05
7607AEG06
2-4
3) COOLING SYSTEM
7607AEG07
7607AEG08
2-5
5) EXHAUST SYSTEM
7607AEG09
2-6
GROUP 2 F
FUEL
UEL WARMER SYSTEM
1. S
SPECIFICATION
PECIFICATION
1) Operating voltage : 24±4V
2) Power : 350±50W
3) Current : 15A
2. O
OPERATION
PERATION
1) T h e c u r r e n t o f f u e l w a r m e r s y s t e m i s Fuel warmer
automatically controlled without thermostat
according to fuel temperature.
2) At the first state, the 15A current flows to the fuel
warmer and engine may be started in 1~2 Prefilter
minutes.
3) If the fuel starts to flow, ceramic-disk in the fuel
warmer heater senses the fuel temperature to
reduce the current as low as 1.5A.
So, fuel is protected from overheating by this
2507A5MS12
mechanism.
3. E
ELECTRIC
LECTRIC CIRCUIT
CN-60
MASTER SW 40A
3R 104 104 3R 105 FUSE MAXI
3R 102 111 15R 106
80A
3R
15R
CN-95
CS-74 BATT. RY
80R 107 108
80R 109
BATTERY
CR-1
TO STARTER
MCU
AC COMP. OFF SIG_REVERSE FAN
AUDIO/ROOM LAMP
HORN/CONVERTER
WORK LAMP_REAR
AIR-CON/HEATER 1
AIR-CON/HEATER 2
JOYSTICK-DETENT
SPARE_HIGH SOURCE
BACK.STOP LAMP
JOYSTIC_SWITCH
RIDE CONTROL
CIGARLIGHTER
FAN REVERSE
FUEL WARMER
TURN LAMP
HEAD LAMP
FUEL WARMER
WIPER INT SIG
ILL.LAMP
BEACON
SPARE
WIPER
CAN2 LOW
PARK
FUSE BOX
WASH SIG
CAN2 HI
CN-36
10A
20A
20A
20A
20A
10A
20A
30A
20A
30A
20A
20A
20A
20A
20A
10A
20A
20A
10A
10A
20A
30A
10A
20A
20A
20A
10A
5A
A38
B14
B15
A16
A24
B40
B30
A05
A18
A08
A23
A31
A35
A26
24
25
26
27
28
29
30
31
32
33
34
15
16
17
18
19
20
21
22
23
1
2
3
4
5
6
7
8
L 380
CN-58B
CN-5
20
21
22
CR-25 23
86 30 87a 24
B G01A
85 25
87
RW 531
ECM POWER IG 26
86 27
85 87 87a R 530
30 28
ECM POWER RY 29
40
CR-35 31
86 30 87a 32 CN-13 FUEL WARMER
B G01
85 33 1 B
Gr 550
87 MCU POWER IG 30 2 A
RW 531
86 35 3
85 87 87a R 530 CN-96
30 4
POWER RY 5
6
LW 381
Y 370A
Y 370B
H BR ACC ST C
6 7
Y 370
L 380
5 CS-2
8
6
3 5
CR-46
CR-36
2
87
30
87a
85
85 8787a 86
4
B
1
1
5
3
2
4
RW 531
4 3
R 530
0, I
1 5 4
1
H 0 I II
86 30
2 3
RW 531
2
2-7
GROUP 3 ENGINE SPEED & STALL RPM
1. TEST
TEST CONDITION
1) Normal temperature of the whole system
- Coolant : Approx 80˚C (176˚F)
- Hydraulic oil : 45 ± 5˚C (113 ± 10˚F)
- Transmission oil : 75 ± 5˚C (167 ± 10˚F)
2) Normal operating pressure : See page 6-50.
2. SPECIFICATION
SPECIFICATION
Engine speed, rpm (P mode)
Remark
Low idle High idle Pump stall Converter stall Full stall Fan motor
800±25 2230±50 2000±70 2040±70 1620±100 1150±20
3. ENGINE
ENGINE RPM CHECK
Remark : If the checked data is not normal, it indicates that the related system is not working properly.
Therefore, it is required to check the related system pressure : See page 6-50.
1) Pump stall rpm
- Start the engine and raise the bucket
approx 45 cm (1.5 ft) as the figure.
- Press the accelerator pedal fully and
operate the bucket control lever to the
45cm
M H
- Set the clutch cut off mode switch at the Clutch cut off mode switch
OFF position.
- Press the brake pedal and accelerator
pedal fully.
- Shift the transmission lever to the 4th
forward position.
- Check the engine rpm at the above 75792EG02
condition.
3) Full stall rpm
- Start the engine and raise the bucket
OFF
L
- Set the clutch cut off mode switch at the Clutch cut off mode switch
OFF position.
- Press the brake pedal and accelerator
45cm
pedal fully .
- Shift the transmission lever to the 4th
forward position and operate the bucket
lever to the retract position fully. 75792EG03
Transmission Engine
Front axle
Front drive shaft Center drive shaft Rear drive shaft Rear axle
75793PT01
3-1
HYDRAULIC CIRCUIT
K4 KR K1 K3 KV K2
P1 F 60 P2 E 55 P3 D 56 P4 C 58 P5 B 53 P6 A 57
B D B D B D B D B D B D
Pressure
Temp reducing
sensor valve
9+0.5 bar
System
pressure
Valve block control circuit valve
16+2 bar
Filter pressure
differential valve
Converter
Relief Filter
valve
11+2 bar
Oil sump
Lubrication Main oil circuit
7607APT18
Current
Forward Reverse Positions
Engaged No. of the
Speed Neutral on the
clutch measuring
1 2 3 4 1 2 3 valve block
points
Y1 X K4 F 60
Y2 X X X KR E 55
Y3 X X K1 D 56
Y4 X X X K3 C 58
Y5 X X X KV B 53
Y6 X X K2 A 57
Engaged
K1,KV KV,K2 K3,KV K4,K3 KR,K1 KR,K2 KR, K3 - - -
clutch
X : Pressure regulator under voltage
3-2
2. TORQUE CONVERTER
5 1 2 3 4
73033TM00
The converter is working according to the Trilok-system, i.e. it assumes at high turbine speed the
characteristics, and with it the favorable efficiency of a fluid clutch.
The converter is designed according to the engine power so that the most favorable operating
conditions are obtained for each installation case.
The Torque converter is composed of 3 main components :
Pump wheel - turbine wheel - stator (reaction member)
These 3 impeller wheels are arranged in such a ring-shape system that the fluid is streaming through
the circuit components in the indicated order.
Pressure oil from the transmission pump is constantly streaming through the converter. In this way, the
converter can fulfill its task to multiply the torque of the engine and at the same time, the heat created in
the converter is dissipated via the escaping oil.
The oil which is streaming out of the pump wheel, enters the turbine wheel and is there inversed in the
direction of flow.
According to the rate of reversion, the turbine wheel and with it also the output shaft is receiving a more
or less high reaction torque. The stator (reaction member), following the turbine, has the task to reverse
the oil streaming out of the turbine once more and to deliver it under the suitable discharge direction to
the pump wheel.
Due to the reversion, the stator receiving a reaction torque.
The relation turbine torque/pump torque is called torque multiplication. This is the higher, the greater
the speed difference of pump wheel and turbine wheel will be.
Therefore, the maximum torque multiplication is created at stationary turbine wheel.
With increasing output speed, the torque multiplication is decreasing. The adaption of the output speed
to a certain required output torque will be infinitely variable and automatically achieved by the torque
converter.
3-3
when the turbine speed is reaching about 80% of the pump speed, the torque multiplication becomes
1.0 i.e. the turbine torque becomes equal to that of the pump torque.
From this point on, the converter is working similar to a fluid clutch.
A stator freewheel serves to improve the efficiency in the upper driving range, in the torque
multiplication range it is backing-up the torque upon the housing, and is released in the clutch range.
In this way, the stator can rotate freely.
Turbine wheel
From the engine
TT
TP
To the gearbox
Starting nT = 0
condition 1 1.5 Reaction member 2.5
(stator) Machine standing
still
Intermediate
condition 1 <1.5 <2.5 nT < n engine
Condition in the
coupling point 1 0 1 nT = 0.8n engine
7577APT100
3-4
3. TRANSMISSION
1) LAYOUT
12
11
10
3
15
14
13
8
6
7
16
7577APT03
3-5
2) INSTALLATION VIEW
6 8 3
11
15
14
7
4
2
5 1
12
10 9 13
7577APT02
3-6
3) OPERATION OF TRANSMISSION
(1) Forward
① Forward 1st
In 1st forward, forward clutch (KV) and 1st clutch (K1) are engaged.
Forward clutch and 1st clutch are actuated by the hydraulic pressure applied to the clutch piston.
KR KR
KV IN
K4
K2
INPUT
K3 K1
KV
OUT
GEAR PATTERN
K2
K1 K3
K4
OUTPUT OUTPUT
7577APT04 F1
3-7
② Forward 2nd
In 2nd forward, forward clutch (KV) and 2nd clutch (K2) are engaged.
Forward clutch and 2nd clutch are actuated by the hydraulic pressure applied to the clutch
piston.
KR KR
KV IN
K4
K2
INPUT
K3 K1
KV
OUT
GEAR PATTERN
K2
K1 K3
K4
OUTPUT OUTPUT
7577APT05 F2
3-8
③ Forward 3rd
In 3rd forward, forward clutch (KV) and 3rd clutch (K3) are engaged.
Forward clutch and 3rd clutch are actuated by the hydraulic pressure applied to the clutch piston.
KR KR
KV IN
K4
K2
INPUT
K3 K1
KV
OUT
GEAR PATTERN
K2
K1 K3
K4
OUTPUT OUTPUT
7577APT06 F3
3-9
④ Forward 4th
In 4th forward, 4th clutch (K4) and 3rd clutch (K3) are engaged.
4th clutch and 3rd clutch are actuated by the hydraulic pressure applied to the clutch piston.
KR KR
KV IN
K4
K2
INPUT
K3 K1
KV
OUT
GEAR PATTERN
K2
K1 K3
K4
OUTPUT OUTPUT
7577APT07 F4
3-10
(2) Reverse
① Reverse 1st
In 1st reverse, reverse clutch (KR) and 1st clutch (K1) are engaged.
Reverse clutch and 1st clutch are actuated by the hydraulic pressure applied to the clutch piston.
KR KR
KV IN
K4
K2
INPUT
K3 K1
KV
OUT
GEAR PATTERN
K2
K1 K3
K4
OUTPUT OUTPUT
7577APT08 R1
3-11
② Reverse 2nd
In 2nd reverse, reverse clutch (KR) and 2nd clutch (K2) are engaged.
Reverse clutch and 2nd clutch are actuated by the hydraulic pressure applied to the clutch
piston.
KR KR
KV IN
K4
K2
INPUT
K3 K1
KV
OUT
GEAR PATTERN
K2
K1 K3
K4
OUTPUT OUTPUT
7577APT09 R2
3-12
③ Reverse 3rd
In 3rd reverse, reverse clutch (KR) and 3rd clutch (K3) are engaged.
Reverse clutch and 3rd clutch are actuated by the hydraulic pressure applied to the clutch piston.
KR KR
KV IN
K4
K2
INPUT
K3 K1
KV
OUT
GEAR PATTERN
K2
K1 K3
K4
OUTPUT OUTPUT
7577APT10 R3
3-13
4) ELECTRO-HYDRAULIC SHIFT CONTROL WITH PROPORTIONAL VALVE
2 1 3
A A
Y6 Y1
Y5 Y2
B
Y4 Y3
3 6
2 6 1 4 11 9 10
Y5
Transmission control, see schedule of hydraulic circuit, electro-hydraulic control unit and measuring
points at page 3-2, 3-14 and 3-64.
The six clutches of the transmission are selected via the 6 proportional valves P1 to P6. The
proportional valve (pressure regulator unit) is composed of pressure regulator (e.g. Y1), follow-on
slide and vibration damper.
The control pressure of 9 bar for the actuation of the follow-on slides is created by the pressure
reducing valve. The pressure oil (16+2bar) is directed via the follow-on slide to the respective
clutch.
3-14
Due to the direct proportional selection with separated pressure modulation for each clutch, the
pressures to the clutches, which are engaged in the gear change, will be controlled. In this way, a
hydraulic intersection of the clutches to be engaged and disengaged becomes possible.
This is creating spontaneous shiftings without traction force interruption.
At the shifting, the following criteria are considered:
- Speed of engine, turbine, central gear train and output.
- Transmission temperature.
- Shifting mode (Up-, down-, reverse shifting and speed engagement out of neutral).
- Load condition (full and part load, traction, overrun inclusive consideration of load cycles during
the shifting).
The main pressure valve is limiting the maximum control pressure to 16+2 bar and releases the
main stream to the converter and lubricating circuit.
In the inlet to the converter, a converter satety valve is installed which protects the converter from
high internal pressures (opening pressure 11+2bar).
Within the converter, the oil serves to transmit the power according to the well-known
hydrodynamic principle (see torque converter, page 3-3).
To avoid cavitation, the converter must be always completely filled with oil.
This is achieved by a converter back pressure back-up valve, rear-mounted to the converter, with
an opening pressure of at least 4.3bar.
The oil, escaping out of the converter, is directed to a oil cooler.
The oil is directed from the oil cooler to the transmission and from there to the lubricating oil circuit,
so that all lubricating points are supplied with cooled oil.
In the electro-hydraulic control unit are 6 pressure regulators installed.
R
direction Forward (F)-Neutral (N)-Reverse
(R) by tilting the gear selector lever.
The gear selector is also available with
integrated kickdown push button.
For the protection from unintended start off,
a neutral interlock is installed.
N D
Position N - Gear selector lever blocked in
this position.
Position D - Driving. 73033TM17
3-15
6) ELECTRIC CONTROL UNIT
(1) Complete system
1
2
14 12
5
10
4 15 9
3
7
13
2
6
11
8 7609S3PT33
3-16
·Protection from operating errors as far as necessary, is possible via electronic protection
(programming).
·Protection from over-speeds (On the basis of engine and turbine speed).
·Automatic reversing (Driving speed-dependent).
·Pressure cut-off possible(Disconnecting of the drive train for maximum power on the power
take-off).
·Change-over possibility for Auto-/Manual mode.
·Kick down functions possible.
(3) Driving and shifting
- Neutral position :
Neutral position will be selected via the controller.
After the ignition is switched on, the electronics remains in the waiting state. By the position
NEUTRAL of the controller, resp. by pressing the pushbutton NEUTRAL, the EST-37A becomes
ready for operation.
Now, a gear can be engaged.
- Starting :
The starting of the engine has always to be carried out in the NEUTRAL POSITION of the
controller.
For safety reasons it is to recommend to brake the machine securely in position with the parking
brake prior to start the engine.
After the starting of the engine and the preselection of the driving direction and the gear, the
machine can be set in motion by acceleration.
At the start off, the converter takes over the function of a master clutch.
On a level road it is possible to start off also in higher gears.
- Upshifting under load
Upshifting under load will be then realized if the machine can still accelerate by it.
- Downshifting under load
Downshifting under load will be realized if more traction force is needed.
- Upshifting in overrunning condition
In the overrunning mode, the upshifting will be suppressed by accelerator pedal idling position, if
the speed of the machine on a downgrade should not be further increased.
- Downshifting in overrunning condition
Downshiftings in overrunning mode will be then carried out if the machine should be retarded.
If the machine will be stopped and is standing with running engine and engaged transmission,
the engine cannot be stalled. On a level and horizontal roadway it is possible that the machine
begins to crawl, because the engine is creating at idling speed a slight drag torque via the
converter.
It is convenient to brake the machine at every stop securely in position with the parking brake.
At longer stops, the controller has to be shifted to the NEUTRAL POSITION.
At the start off, the parking brake has to be released. We know from experience that at a
converter transmission it might not immediately be noted to have forgotten this quite normal
operating step because a converter, due to its high ratio, can easily overcome the braking
torque of the parking brake.
3-17
Temperature increases in the converter oil as well as overheated brakes will be the
consequences to be find out later.
Neutral position of the selector switch at higher machine speeds (above stepping speed) is not
admissible.
Either a suitable gear is to be shifted immediately, or the machine must be stopped at once.
(4) Independent calibration of the shifting elements (AEB)
The AEB has the task to compensate tolerances (plate clearance and pressure level) which are
influencing the filling procedure of the clutches. For each clutch, the correct filling parameters are
determined in one test cycle for :
·Period of the quick-filling time
·Level of the filling compensating pressure
The filling parameters are stored, together with the AEB-program and the driving program in the
transmission electronics. Because the electronics will be separately supplied, the AEB-cycle
must be started only after the installation of both components in the machine, thus ensuring the
correct mating (Transmission and electronics).
※ It is imperative, to respect the following test conditions :
- Shifting position neutral
- Engine in idling speed
- Parking brake actuated
- Transmission in operating temperature
※ After a replacement of the transmission, the electrohydraulic control or the TCU in the machine,
the AEB-cycle must be as well carried out again.
The AEB-cylcle continues for about 3 to 4 minutes. The determined filling parameters are stored
in the EEProm of the electronics. In this way, the error message F6 shown on the display will be
cancelled also at non-performed AEB.
(5) Pressure cut-off
In order to provide the full engine power for the hydraulic system, the control can be enlarged for
the function of a pressure cut-off in the 1st and 2nd speed. In this way, the pressure in the
powershift clutches will be cut-off, and the torque transmission in the drive train will be eliminated
by it. This function will be released at the actuation of a switch, arranged on the brake pedal.
For a soft restart, the pressure will be build-up via a freely programmable characteristic line.
3-18
4. FAULT CODE
1) MACHINE FAULT CODE
HCESPN FMI Description
Hydraulic oil temperature sensor circuit - Voltage above normal, or shorted to high source (or
3
101 open circuit)
4 Hydraulic oil temperature sensor circuit - Voltage below normal, or shorted to low source
5 Engine cooling fan EPPR valve circuit - Current below normal, or open circuit
145
6 Engine cooling fan EPPR valve bircuit - Current above normal
Boom up lever detent solenoid circuit - Voltage below normal, or shorted to low source (or
4
172 open circuit)
6 Boom up lever detent solenoid circuit - Current above normal
Boom down lever detent solenoid circuit - Voltage below normal, or shorted to low source (or
4
173 open circuit)
6 Boom down lever detent solenoid circuit - Current above normal
Bucket lever detent solenoid circuit - Voltage below normal, or shorted to low source (or open
4
174 circuit)
6 Bucket lever detent solenoid circuit - Current above normal
Engine cooling fan reverse solenoid circuit - Voltage below normal, or shorted to low source (or
4
181 open circuit)
6 Engine cooling fan reverse solenoid circuit - Current above normal
Engine cooling fan reverse driving status signal circuit - Voltage below normal, or shorted to
4
183 low source (or open circuit)
6 Engine cooling fan reverse driving status signal circuit - Current above normal
Emergency steering pump relay circuit - Voltage below normal, or shorted to low source (or
4
187 open circuit)
6 Emergency steering pump relay circuit – Current above normal
0 Steering main pump pressure sensor data above normal range (or open circuit)
1 Steering main pump pressure sensor data below normal range
202
2 Steering main pump pressure sensor data error
4 Steering main pump pressure sensor circuit - Voltage below normal, or shorted to low source
0 Emergency steering pump pressure sensor data above normal range (or open circuit)
1 Emergency steering pump pressure sensor data below normal range
203 2 Emergency steering pump pressure sensor data error
Emergency steering pump pressure sensor circuit - Voltage below normal, or shorted to low
4
source
0 Boom cylinder pressure sensor data above normal range (or open circuit)
1 Boom cylinder pressure sensor data below normal range
204
2 Boom cylinder pressure sensor data error
4 Boom cylinder pressure sensor circuit - Voltage below normal, or shorted to low source
0 Bucket cylinder pressure sensor data above normal range (or open circuit)
1 Bucket cylinder pressure sensor data below normal tange
205
2 Bucket cylinder pressure sensor data error
4 Bucket cylinder pressure sensor circuit - Voltage below normal, or shorted to low source
3-19
HCESPN FMI Description
3 Fuel level sensor circuit - Voltage above normal, or shorted to high source (or open circuit)
301
4 Fuel level sensor circuit - Voltage below normal, or shorted to low source
Engine coolant temperature sensor circuit - Voltage above normal, or shorted to high source
3
304 (or open circuit)
4 Engine coolant temperature sensor circuit - Voltage below normal, or shorted to low source
310 8 Engine speed signal error – Abnormal frequency or pulse width
318 8 Engine cooling fan speed signal error – Abnormal frequency or pulse width
4 Engine preheat relay circuit – Voltage below normal, or shorted to low source (or open circuit)
322
6 Engine preheat relay circuit - Current above normal
4 Fuel warmer relay circuit - Voltage below normal, or shorted to low source (or open circuit)
325
6 Fuel warmer relay circuit – Current above normal
4 Anti-restart relay circuit - Voltage below normal, or shorted to low source (or open circuit)
327
6 Anti-restart relay circuit – Current above normal
Engine power mode selector circuit – Voltage above normal, or shorted to high source (or
3
346 open circuit)
4 Engine power mode selector circuit – Voltage below normal, or shorted to low source
0 Brake oil pressure sensor data above normal range (or open circuit)
1 Brake oil pressure sensor data below normal range
503
2 Brake oil pressure sensor data error
4 Brake oil pressure sensor circuit – Voltage below normal, or shorted to Low Source
0 Parking oil pressure sensor data above normal range (or open circuit)
1 Parking oil pressure sensor data below normal range
507
2 Parking oil pressure sensor data error
4 Parking oil pressure sensor circuit - Voltage below normal, or shorted to low source
Clutch cut off mode selector circuit – Voltage above normal, or shorted to high source (or
3
551 open circuit)
4 Clutch cut off mode selector circuit – Voltage below normal, or shorted to low source
Transmission shift mode selector circuit – Voltage above normal, or shorted to high source (or
3
552 open circuit)
4 Transmission shift mode selector circuit – Voltage below normal, or shorted to low source
0 Differential lock pressure sensor data above normal range (or open circuit)
1 Differential lock pressure sensor data below normal range
558
2 Differential lock pressure sensor data error
4 Differential lock pressure sensor circuit - Voltage below normal, or shorted to low source
701 4 Hourmeter circuit - Voltage below normal, or shorted to low source
0 Battery voltage high
705
1 Battery voltage low
3-20
HCESPN FMI Description
707 1 Alternator node I voltage low (or open circuit)
3 Buzzer circuit - Voltage above normal, or shorted to high source
723
4 Buzzer circuit - Voltage below normal, or shorted to low source (or open circuit)
4 Wiper relay circuit - Voltage below normal, or shorted to low source (or open circuit)
727
6 Wiper relay circuit – Current above normal
Boom position sensor signal circuit – Voltage above normal, or shorted to high
3
728 source (or open circuit)
4 Boom position sensor signal circuit – Voltage below normal, or shorted to low source
Bucket position sensor signal circuit – Voltage above normal, or shorted to high
3
source (or open circuit)
729
Bucket position sensor signal circuit – Voltage below normal, or shorted to low
4
source
730 19 APTC heater PWM output duty operation error
830 12 MCU internal memory error
840 2 Cluster communication error
841 2 ECM communication error
842 2 TCU communication error
843 2 APTC communication error
844 2 Monitor communication error
850 2 RCM communication error
3-21
2) ENGINE FAULT CODES
Fault code
J1939 SPN Reason Effect (only when fault code is active)
J1939 FMI
Engine control module critical internal failure - Possible no noticeable performance effects,
111
Bad intelligent device or component. Error engine dying, or hard starting.
629
internal to the ECM related to memory hardware
12
failures or internal ECM voltage supply circuits.
Engine magnetic crankshaft speed/position lost Fueling to injectors is disabled and the engine
115 both of two signals - Data erratic, intermittent, or can not be started.
612 incorrect. The ECM has detected that the
2 primary engine speed sensor and the backup
engine speed sensor signals are reversed.
Intake manifold 1 pressure sensor circuit - Engine power derate.
122 Voltage above normal, or shorted to high source.
102 High signal voltage detected at the intake
3 manifold pressure circuit.
Intake manifold 1 pressure sensor circuit - Engine power derate.
123 Voltage below normal, or shorted to low Source.
102 Low signal voltage or open circuit detected at the
4 intake manifold pressure circuit.
Intake manifold 1 pressure - Data valid but above Engine power derate.
124 normal operational range - Moderately severe
102 level. Intake manifold pressure has exceeded the
16 maximum limit for the given engine rating.
Accelerator pedal or lever position sensor 1 Severe derate in power output of the engine.
131 circuit - Voltage above normal, or shorted to high Limp home power only.
91 source. High voltage detected at accelerator
3 pedal position circuit.
Accelerator pedal or lever position sensor 1 Severe derate in power output of the engine.
132 circuit - Voltage below normal, or shorted to low Limp home power only.
91 source. Low voltage detected at accelerator
4 pedal position signal circuit.
Remote accelerator pedal or lever position Remote accelerator will not operate. Remote
133 sensor 1 circuit - Voltage above normal, or accelerator position will be set to zero percent.
974 shorted to high source. High voltage detected at
3 remote accelerator pedal position circuit.
Remote accelerator pedal or lever position Remote accelerator will not operate. Remote
134 sensor 1 circuit - Voltage below normal, or accelerator position will be set to zero percent.
974 shorted to low source. Low voltage detected at
4 remote accelerator pedal position signal circuit.
Engine oil rifle pressure 1 sensor circuit - Voltage None on performance. No engine protection
135 above normal, or shorted to high source. High for oil pressure.
100 signal voltage detected at the engine oil pressure
3 circuit.
Engine oil rifle pressure 1 sensor circuit - Voltage None on performance. No engine protection
141 below normal, or shorted to low source. Low for oil pressure.
100 signal voltage detected at engine oil pressure
4 circuit.
143 Engine oil rifle pressure - Data valid but below None on performance.
100 normal operational range - Moderately severe
18 level.
Engine coolant temperature 1 sensor circuit - Possible white smoke. Fan will stay ON if
144
Voltage above normal, or shorted to high source. controlled by ECM. No engine protection for
110
High signal voltage or open circuit detected at engine coolant temperature.
3
engine coolant temperature circuit.
3-22
Fault code
J1939 SPN Reason Effect (only when fault code is active)
J1939 FMI
Engine Coolant Temperature 1 Sensor Circuit - Possible white smoke. Fan will stay ON if
145
Voltage Below Normal, or Shorted to Low controlled by ECM. No engine protection for
110
Source. Low signal voltage detected at engine engine coolant temperature.
4
coolant temperature circuit.
Engine Coolant Temperature - Data Valid but Progressive power derate increasing in
146 Above Normal Operational Range - Moderately severity from time of alert.
110 Severe Level. Engine coolant temperature signal
16 indicates engine coolant temperature is above
engine protection warning limit.
Accelerator Pedal or Lever Position 1 Sensor Severe derate in power output of the engine.
Circuit Frequency - Data Valid but Below Normal Limp home power only.
147
Operational Range - Most Severe Level. A
91
frequency of less than 100 Hz has been
1
detected at the frequency throttle input to the
ECM.
Accelerator Pedal or Lever Position Sensor 1 - Severe derate in power output of the engine.
148 Data Valid but Above Normal Operational Limp home power only.
91 Range - Most Severe Level. A frequency of
0 more than 1500 Hz has been detected at the
frequency throttle input to the ECM.
Engine Coolant Temperature - Data Valid but Progressive power derate increasing in
151 Above Normal Operational Range - Most severity from time of alert. If Engine Protection
110 Severe Level. Engine coolant temperature signal Shutdown feature is enabled, engine will shut
0 indicates engine coolant temperature above down 30 seconds after Red Stop Lamp starts
engine protection critical limit. flashing.
Intake Manifold 1 Temperature Sensor Circuit - Possible white smoke. Fan will stay ON if
153 Voltage Above Normal, or Shorted to High controlled by ECM. No engine protection for
105 Source. High signal voltage detected at intake intake manifold air temperature.
3 manifold air temperature circuit.
Intake Manifold 1 Temperature Sensor Circuit - Possible white smoke. Fan will stay ON if
154 Voltage Below Normal, or Shorted to Low controlled by ECM. No engine protection for
105 Source. Low signal voltage detected at intake intake manifold air temperature.
4 manifold air temperature circuit.
Intake Manifold 1 Temperature - Data Valid but Progressive power derate increasing in
155 Above Normal Operational Range - Most severity from time of alert. If Engine Protection
105 Severe Level. Intake manifold air temperature Shutdown feature is enabled, engine will shut
0 signal indicates intake manifold air temperature down 30 seconds after Red Stop Lamp starts
above engine protection critical limit. flashing.
187 Sensor Supply 2 Circuit - Voltage Below Normal, Engine power derate.
520195 or Shorted to Low Source. Low voltage detected
4 at the sensor supply number 2 circuit.
195 Coolant Level Sensor 1 Circuit - Voltage Above None on performance.
111 Normal, or Shorted to High Source. High signal
3 voltage detected at engine coolant level circuit.
196 Coolant Level Sensor 1 Circuit - Voltage Below None on performance.
111 Normal, or Shorted to Low Source. Low signal
4 voltage detected at engine coolant level circuit.
197 Coolant Level - Data Valid but Below Normal None on performance.
111 Operational Range - Moderately Severe Level.
18 Low coolant level has been detected.
Barometric Pressure Sensor Circuit - Voltage Engine power derate.
221
Above Normal, or Shorted to High Source. High
108
signal voltage detected at barometric pressure
3
circuit.
3-23
Fault code
J1939 SPN Reason Effect (only when fault code is active)
J1939 FMI
Barometric Pressure Sensor Circuit - Voltage Engine power derate.
222
Below Normal, or Shorted to Low Source. Low
108
signal voltage detected at barometric pressure
4
circuit.
227 Sensor Supply 2 Circuit - Voltage Above Normal, Engine power derate.
520195 or Shorted to High Source. High voltage
3 detected at sensor supply number 2 circuit.
Engine Crankshaft Speed/Position - Data Valid Fuel injection disabled until engine speed falls
234
but Above Normal Operational Range - Most below the overspeed limit.
190
Severe Level. Engine speed signal indicates
0
engine speed above engine protection limit.
Coolant Level - Data Valid but Below Normal Progressive power derate increasing in
235 Operational Range - Most Severe Level. Low severity from time of alert. If Engine Protection
111 engine coolant level detected. Shutdown feature is enabled, engine will shut
1 down 30 seconds after Red Stop Lamp starts
flashing.
237 External Speed Command Input (Multiple Unit
644 Synchronization) - Data Erratic, Intermittent, or
2 Incorrect. Communication between multiple
engines may be intermittent.
238 Sensor Supply 3 Circuit - Voltage Below Normal, Possible hard starting and rough running.
520196 or Shorted to Low Source. Low voltage detected
4 on the +5 volt sensor supply circuit to the engine
speed sensor.
241 Wheel-based vehicle speed - Data erratic, Engine speed limited to ,maximum engine
84 intermittent, or incorrect. The ECM lost the speed without VSS parameter value. Cruise
2 vehicle speed signal. control, gear-down protection, and road speed
governor will not work.
242 Wheel-based vehicle speed sensor circuit Engine speed limited to maximum engine
84 tampering has been detected - Abnormal rate of speed without VSS parameter value. Cruise
10 change. Signal indicates an intermittent control, gear-down protection, and road speed
connection or VSS tampering. g+H53overnor will not work.
245 Fan control circuit - Voltage below normal, or The fan may stay on continuously or not run at
647 shorted to low source. Low signal voltage all.
4 detected at the fan control circuit when
commanded on.
271 Fuel pump pressurizing assembly 1 circuit - Engine will run poorly at idle. Engine will have
1347 Voltage below normal, or shorted to low source. low power. Fuel pressure will be higher than
4 Low signal voltage detected at the fuel pump commanded.
actuator circuit.
Fuel pump pressurizing assembly 1 circuit - Engine will not run or engine will run poorly.
272
Voltage above normal, or shorted to high source.
1347
High signal voltage or open circuit detected at
3
the fuel pump actuator circuit.
281 Fuel pump pressur izing assembly 1 - Engine will not run or possible low power.
1347 Mechanical system not responding properly or
7 out of adjustment.
SAE J1939 multiplexing PGN timeout error - At least one multiplexed device will not
285
Abnormal update rate. The ECM expected operate properly.
639
information from a multiplexed device but did not
9
receive it soon enough or did not receive it at all.
SAE J1939 multiplexing configuration error - At least one multiplexed device will not
286
Out of calibration. The ECM expected operate properly.
639
information from a multiplexed device but only
13
received a portion of the necessary information.
3-24
Fault code
J1939 SPN Reason Effect (only when fault code is active)
J1939 FMI
SAE J1939 multiplexed accelerator pedal or Engine may only idle or engine will not
287 lever sensor system - received network data In accelerate to full speed.
91 error. The OEM vehicle electronic control unit
19 (VECM) detected a fault with its accelerator
pedal.
SAE J1939 Multiplexing Remote Accelerator The engine will not respond to the remote
288 Pedal or Lever Position Sensor Circuit - throttle. Engine may only idle. The primary or
974 Received Network Data In Error. The OEM cab accelerator may be able to be used.
19 vehicle electronic control unit (VECM) detected
a fault with the remote accelerator.
292 Auxiliary temperature Sensor Input 1 - Special Possible engine power derate.
441 instructions.
14
Auxiliary temperature sensor input 1 circuit - None on performance.
293 Voltage above normal, or shorted to high
441 source. High signal voltage or open circuit
3 detected at the OEM auxiliary temperature
circuit.
Auxiliary temperature sensor input 1 circuit - None on performance.
294 Voltage below normal, or shorted to low source.
441 Low signal voltage detected at the OEM
4 auxiliary temperature circuit.
296 Auxiliary pressure sensor input 1 - Special Possible engine power derate.
1388 instructions.
14
Auxiliary pressure sensor input 1 circuit - None on performance.
297
Voltage above normal, or shorted to high
1388
source. High signal voltage detected at the OEM
3
pressure circuit.
Auxiliary pressure sensor input 1 circuit - None on performance.
298 Voltage below normal, or shorted to low source.
1388 Low signal voltage or open circuit detected at
4 the OEM pressure circuit.
319 Real time clock power interrupt - Data erratic, None on performance. Data in the ECM will
251 intermittent, or incorrect. Real time clock lost not have accurate time and date information.
2 power.
Injector solenoid driver cylinder 1 circuit - Engine can possibly misfire or run rough.
Current below normal, or open circuit. High
322 resistance detected on injector number 1 circuit
651 or no current detected at number 1 injector
5 driver or return pin when the voltage supply at
the harness is on.
Injector solenoid driver cylinder 5 circuit - Engine can possibly misfire or run rough.
Current below normal, or open circuit. High
323 resistance detected on injector number 5 circuit
655 or no current detected at number 5 injector
5 driver or return pin when the voltage supply at
the harness is on.
Injector solenoid driver cylinder 3 circuit - Engine can possibly misfire or run rough.
Current below normal, or open circuit. High
324 resistance detected on injector number 3 circuit
653 or no current detected at number 3 injector
5 driver or return pin when the voltage supply at
the harness is on.
Injector solenoid driver cylinder 6 circuit - Engine can possibly misfire or run rough.
Current below normal, or open circuit. High
325 resistance detected on injector number 6 circuit
656 or no current detected at number 6 injector
5 driver or return pin when the voltage supply at
the harness is on.
3-25
Fault code
J1939 SPN Reason Effect (only when fault code is active)
J1939 FMI
Injector solenoid driver cylinder 2 circuit - Engine can possibly misfire or run rough.
Current below normal, or open circuit. High
331
resistance detected on injector number 2 circuit
652
or no current detected at number 2 injector
5
driver or return pin when the voltage supply at
the harness is on.
Injector solenoid driver cylinder 4 circuit - Engine can possibly misfire or run rough.
Current below normal, or open circuit. High
332
resistance detected on injector number 4 circuit
654
or no current detected at number 4 injector
5
driver or return pin when the voltage supply at
the harness is on.
Engine coolant temperature - Data erratic, The ECM will estimate engine coolant
334
intermittent, or incorrect. The engine coolant temperature.
110
temperature reading is not changing with engine
2
operating conditions.
342 Electronic calibration code incompatibility - Out Possible no noticeable performance effects,
630 of calibration. An incompatible calibration has engine dying, or hard starting.
13 been detected in the ECM.
343 Engine control module warning internal No performance effects or possible severe
620 hardware failure - Bad intelligent device or power derate.
12 component. Internal ECM failure.
351 Injector power supply - Bad intelligent device or Possible smoke, low power, engine misfire,
627 component. The ECM measured injector boost and/or engine will not start.
12 voltage is low.
352 Sensor supply 1 circuit - Voltage below normal, Engine power derate.
1079 or shorted to low source. Low voltage detected
4 at sensor supply number 1 circuit.
386 Sensor supply 1 circuit - Voltage above normal, Engine power derate.
1079 or shorted to high source. High voltage detected
3 at sensor supply number 1 circuit.
Engine oil rifle pressure - Data valid but below Progressive power derate increasing in
415 normal operational range - Most severe level. Oil severity from time of alert. If engine protection
100 pressure signal indicates oil pressure below the shutdown feature is enabled, engine will shut
1 engine protection critical limit. down 30 seconds after red stop lamp starts
flashing.
418 Water in fuel indicator - Data valid but above Possible white smoke, loss of power, or hard
97 normal operational range - Least severe level. starting.
15 water has been detected in the fuel filter.
428 Water in fuel indicator sensor circuit - Voltage None on performance. No water in fuel
97 above normal, or shorted to high source. High warning available.
3 voltage detected at the water in fuel circuit.
429 Water in fuel indicator sensor circuit - Voltage None on performance. No water in fuel
97 below normal, or shorted to low source. Low warning available.
4 voltage detected at the water in fuel circuit.
Accelerator pedal or lever idle validation switch - Engine will only idle.
431 Data erratic, intermittent, or incorrect. Voltage
558 detected simultaneously on both idle validation
2 and off-idle validation switches.
Accelerator pedal or lever idle validation circuit - Engine will only idle.
432 Out of calibration. Voltage at idle validation
558 on-idle and off-idle circuit does not match
13 accelerator pedal position.
3-26
Fault code
J1939 SPN Reason Effect (only when fault code is active)
J1939 FMI
Engine oil rifle pressure - Data erratic, None on performance. No engine protection
435
intermittent, or incorrect. An error in the engine for oil pressure.
100
oil pressure switch signal was detected by the
2
ECM.
Battery 1 voltage - Data valid but below normal Engine may stop running or be difficult to start.
441
operational range - Moderately severe level.
168
ECM supply voltage is below the minimum
18
system voltage level.
Battery 1 Voltage - Data valid but above normal Possible electrical damage to all electrical
442
operational range - Moderately severe level. components.
168
ECM supply voltage is above the maximum
16
system voltage level.
449 Injector metering rail 1 pressure - Data valid but None or possible engine noise associated with
157 above normal operational range - Most severe higher injection pressures (especially at idle or
0 level. light load). Engine power is reduced.
Injector metering rail 1 pressure sensor circuit - Power and or speed derate.
451
Voltage above normal, or shorted to high source.
157
High signal voltage detected at the rail fuel
3
pressure sensor circuit.
Injector metering rail 1 pressure sensor circuit - Power and or speed derate.
452
Voltage below normal, or shorted to low source.
157
Low signal voltage detected at the rail fuel
4
pressure sensor circuit.
Intake manifold 1 temperature - Data valid but Progressive power derate increasing in
488 above normal operational range - Moderately severity from time of alert.
157 severe level. Intake manifold air temperature
16 signal indicates intake manifold air temperature
is above the engine protection warning limit.
497 Multiple unit synchronization switch - Data
1377 erratic, intermittent, or incorrect.
2
523 Auxiliary intermediate (PTO) speed switch None on performance.
611 validation - Data erratic, intermittent, or
2 incorrect.
Auxiliary input/output 2 circuit - Voltage above None on performance.
527 normal, or shorted to high source. High signal
702 voltage or open circuit has been detected at the
3 auxiliary input/output 2 circuit.
528 Auxiliary alternate torque validation switch - None on performance.
93 Data erratic, intermittent, or incorrect.
2
Auxiliary input/output 3 circuit - Voltage above
529
normal, or shorted to high source. Low signal
703
voltage has been detected at the auxiliary input/
3
output 2 circuit.
Injector metering rail 1 pressure - Data valid but The ECM will estimate fuel pressure and
553 above normal operational range - Moderately power is reduced.
157 severe level. The ECM has detected that fuel
16 pressure is higher than commanded pressure.
Injector metering rail 1 pressure - Data erratic, Possibly hard to start, low power, or engine
554 Intermittent, or incorrect. The ECM has smoke.
157 detected that the fuel pressure signal is not
2 changing.
3-27
Fault code
J1939 SPN Reason Effect (only when fault code is active)
J1939 FMI
Injector metering rail 1 pressure - Data Valid Either the engine will not start or the engine
559 but Below Normal Operational Range - will not have starter lockout protection.
157 Moderately Severe Level. The ECM has
18 detected that fuel pressure is lower than
commanded pressure.
Starter relay driver circuit - Voltage above The engine will not have starter lockout
584
normal, or shorted to high source. Open circuit protection.
677
or high voltage detected at starter lockout
3
circuit.
585 Starter relay driver circuit - Voltage below Engine power derate. The ECM uses an
677 normal, or shorted to low source. Low voltage estimated turbocharger speed.
4 detected at starter lockout circuit.
Turbocharger 1 speed - Data valid but above Amber lamp will light until high battery voltage
595
normal operational range - Moderately severe condition is corrected.
103
level. High turbocharger speed has been
16
detected.
599 Auxiliary commanded dual output shutdown - None or possible engine noise associated with
640 Special instructions. higher injection pressures (especially at idle or
14 light load). Engine power is reduced.
Turbocharger 1 speed - Data valid but below Engine can run rough. Possibly poor starting
687
normal operational range - Moderately severe capability. Engine runs using backup speed
103
level. Low turbocharger speed detected by the sensor. Engine power is reduced.
18
ECM.
689 Engine crankshaft speed/position - Data Engine power derate.
190 erratic, intermittent, or incorrect. Loss of signal
2 from crankshaft sensor.
Turbocharger 1 compressor inlet temperature Engine power derate.
691 circuit - Voltage above normal, or shorted to
1172 high source. High signal voltage detected at
3 turbocharger compressor inlet air temperature
circuit.
Turbocharger 1 compressor inlet temperature Engine will run derated. Excessive black
692
circuit - Voltage below normal, or shorted to low smoke, hard start, and rough idle possible.
1172
source. Low signal voltage detected at
4
turbocharger compressor inlet air tempera
Engine speed / position camshaft and Possible no noticeable performance effects,
crankshaft misalignment - Mechanical system engine dying, or hard starting.
731
not responding properly or out of adjustment.
723
mechanical misalignment between the
7
crankshaft and camshaft engine speed
sensors.
757 Electronic control module data lost - Condition Possible poor starting. Engine power derate.
611 exists. Severe loss of data from the ECM.
31
Engine camshaft speed / position sensor - Possible engine power derate.
778
Data erratic, intermittent, or incorrect. The ECM
723
has detected an error in the camshaft position
2
sensor signal.
Auxiliary equipment sensor input 3 - Root Possible no noticeable performance effects or
779 cause not known. e n g i n e d y i n g o r h a r d s t a r t i n g . Fa u l t
703 information, trip information, and maintenance
11 monitor data may be inaccurate.
3-28
Fault code
J1939 SPN Reason Effect (only when fault code is active)
J1939 FMI
Power supply lost with ignition on - Data erratic, Engine will shut down.
intermittent, or incorrect. Supply voltage to the
1117 ECM fell below 6.2 volts momentarily, or the
627 ECM was not allowed to power down correctly
2 (retain battery voltage for 30 seconds after key
OFF).
1633 OEM datalink cannot transmit - Data erratic, Engine will only idle.
625 intermittent, or incorrect. Communications
2 within the OEM datalink network is intermittent.
Sensor supply 4 circuit - Voltage above normal, Engine will only idle.
2185 or shor ted to high source. High voltage
520197 detected at +5 volt sensor supply circuit to the
3 accelerator pedal position sensor.
Sensor supply 4 circuit - Voltage below normal, Possibly hard to start, low power, or engine
2186 or shorted to low source. Low voltage detected smoke.
520197 at +5 volt sensor supply circuit to the
4 accelerator pedal position sensor.
Injector metering rail 1 pressure - Data valid but Engine may be difficult to start.
2249 below normal operational range - Most severe
157 level. The ECM has detected that fuel pressure
1 is lower than commanded pressure.
Electric lift pump for engine fuel supply circuit - Engine may be difficult to start.
2265 Voltage above normal, or shorted to high
1075 source. High voltage or open detected at the
3 fuel lift pump signal circuit.
Electric lift pump for engine fuel supply circuit - Possible low power.
2266 Voltage below normal, or shorted to low source.
1075 Low signal voltage detected at the fuel lift pump
4 circuit.
Electronic fuel injection control valve circuit -Engine may exhibit misfire as control switches
2311 Condition exists. Fuel pump actuator circuit from the primary to the backup speed sensor.
633 resistance too high or too low. Engine power is reduced while the engine
31 operates on the backup speed sensor.
2321 Engine crankshaft speed/position - Data erratic, Possible low power.
190 intermittent, or incorrect. crankshaft engine
2 speed sensor intermittent synchronization.
Engine camshaft speed / position sensor - Data Engine power derate.
2322
erratic, intermittent, or incorrect. Camshaft
723
engine speed sensor intermittent
2
synchronization.
2345 Turbocharger 1 Speed - Abnormal rate of Engine power derate.
103 change. The turbocharger speed sensor has
10 detected an erroneous speed value.
Turbocharger turbine inlet temperature Engine power derate.
2346 (Calculated) - Data valid but above normal
2789 operational range - Least severe level.
15 Turbocharger turbine inlet temperature has
exceeded the engine protection limit.
2347 Turbocharger compressor outlet temperature Engine brake on cylinders 1, 2, and 3 can not
2790 (Calculated) - Data valid but above normal be activated or exhaust brake will not operate.
15 operational range - Least severe level.
2377 Fan control circuit - Voltage above normal, or Variable geometry turbocharger will go to the
647 shorted to high source. Open circuit or high open position.
3 voltage detected at the fan control circuit.
3-29
Fault code
J1939 SPN Reason Effect (only when fault code is active)
J1939 FMI
2384 VGT actuator driver circuit - Voltage below Variable geometry turbocharger may be in
641 normal, or shorted to low source. Low voltage either the open or closed position.
4 detected at turbocharger control valve circuit.
VGT actuator driver circuit - Voltage above The intake air heaters may be ON or OFF all
2385
normal, or shorted to high source. Open circuit the time.
641
or high voltage detected at turbocharger
3
control valve circuit.
2555 Intake air heater 1 circuit - Voltage above The intake air heaters may be ON or OFF all
729 normal, or shorted to high source. High voltage the time.
3 detected at the intake air heater signal circuit.
2556 Intake air heater 1 circuit - Voltage below Can not control transmission.
729 normal, or shorted to low source. Low voltage
4 detected at the intake air heater signal circuit.
2557 Auxiliary PWM driver 1 circuit - Voltage above Can not control transmission.
697 normal, or shorted to high source. High signal
3 voltage detected at the analog torque circuit.
2558 Auxiliary PWM driver 1 circuit - Voltage below Power derate and possible engine shutdown if
697 normal, or shorted to low source. Low signal engine protection shutdown feature is enabled.
4 voltage detected at the analog torque circuit.
Intake manifold 1 pressure - Data erratic,
2973 intermittent, or incorrect. The ECM has
102 detected an intake manifold pressure signal
2 that is too high or low for current engine
operating conditions.
3-30
3) DEFINITION OF OPERATING MODES
(1) Normal
There's no failure detected in the transmission system or the failure has no or slight effects on
transmission control. TCU will work without or in special cases with little limitations. (See
following table)
(2) Substitute clutch control
TCU can't change the gears or the direction under the control of the normal clutch modulation.
TCU uses the substitute strategy for clutch control. All modulations are only time controlled.
(Comparable with EST 25)
(3) Limp-home
The detected failure in the system has strong limitations to transmission control. TCU can
engage only one gear in each direction. In some cases only one direction will be possible.
TCU will shift the transmission into neutral at the first occurrence of the failure. First, the operator
must shift the gear selector into neutral position.
If output speed is less than a threshold for neutral to gear and the operator shifts the gear selector
into forward or reverse, the TCU will select the limp-home gear.
If output speed is less than a threshold for reversal speed and TCU has changed into the limp-
home gear and the operator selects a shuttle shift, TCU will shift immediately into the limp-home
gear of the selected direction.
If output speed is greater than the threshold, TCU will shift the transmission into neutral. The
operator has to slow down the vehicle and must shift the gear selector into neutral position.
(4) Transmission-shutdown
TCU has detected a severe failure that disables control of the transmission.
TCU will shut off the solenoid valves for the clutches and also the common power supply (VPS1).
Transmission shifts to neutral. The park brake will operate normally, also the other functions
which use ADM1 to ADM8.
The operator has to slow down the vehicle. The transmission will stay in neutral.
(5) TCU-shutdown
TCU has detected a severe failure that disables control of system.
TCU will shut off all solenoid valves and also both common power supplies (VPS1, VPS2). The
park brake will engage, also functions are disabled which use ADM 1 to ADM 8.
The transmission will stay in neutral.
※ Abbreviations
OC : Open circuit
SC : Short circuit
OP mode : Operating mode
TCU : Transmission control unit
EEC : Electronic engine controller
PTO : Power take off
3-31
4) TRANSMISSION FAULT CODES
Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair
(Hex) possible reason for fault detection
10 Logical error at direction select signal TCU shifts transmission to · Check the cables from TCU to shift
3rd shift lever neutral if selector active lever 3
T C U d e t e c t e d a w r o n g s i g n a l OP mode : Transmission · Check signal combinations of shift
combination for the direction shutdown if lever positions F-N-R
·Cable from shift lever 3 to TCU is broken selector active · If shift lever is a CAN shift lever
·Cable is defective and is contacted to check CAN cable/shifter/device
battery voltage or vehicle ground ※ Fault is cleared if TCU detects a
·Shift lever is defective valid neutral signal for the direction
at the shift lever
11 Logical error at gear range signal TCU shifts transmission to · Check the cables from TCU to shift
TCU detected a wrong signal combination neutral lever
for the gear range OP mode : Transmission · Check signal combinations of shift
·Cable from shift lever to TCU is broken shutdown lever positions for gear range
·Cable is defective and is contacted to ※ Failure cannot be detected in
battery voltage or vehicle ground systems with DW2/DW3 shift lever.
·Shift lever is defective Fault is taken back if TCU detects a
valid signal for the position
12 Logical error at direction select signal TCU shifts transmission to · Check the cables from TCU to shift
TCU detected a wrong signal combination neutral lever
for the direction OP mode : Transmission · Check signal combinations of shift
·Cable from shift lever to TCU is broken shutdown lever positions F-N-R
·Cable is defective and is contacted to ※ Fault is taken back if TCU detects a
battery voltage or vehicle ground valid signal for the direction at the
·Shift lever is defective shift lever
13 Logical error at engine derating device After selecting neutral, · Check engine derating device
TCU detected no reaction of engine while TCU change to OP mode ※ This fault is reset after power up of
derating device active limp home TCU
15 Logical error at direction select signal 2 TCU shifts transmission to · Check the cables from TCU to shift
shift lever neutral if selector active lever 2
TCU detected a wrong signal combination OP mode : Transmission · Check signal combinations of shift
for the direction shutdown if lever positions F-N-R
·Cable from shift lever 2 to TCU is broken elector active ※ Fault is taken back if TCU detects a
·Cable is defective and is contacted to valid neutral signal for the direction
battery voltage or vehicle ground at the shift lever
·Shift lever is defective
17 S.C. to ground at customer specific Customer specific · Check the cable from TCU to
function No. 1 (ride control) customer specific function No. 1
TCU detected a wrong voltage at the device
output pin, that looks like a S.C. to vehicle · C h e ck t h e c o n n e c t o r s f r o m
ground customer specific function No. 1 to
·Cable is defective and is contacted to TCU
vehicle ground · Check the resistance of customer
·Customer specific function No. 1 device specific function No. 1 device
has an internal defect
·Connector pin is contacted to vehicle
ground
※ Some fault codes are not applied to this machine.
3-32
Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair
(Hex) possible reason for fault detection
18 S.C. to battery voltage at customer specific Customer specific · Check the cable from TCU to
function No. 1 (ride control) customer specific function No. 1
TCU detected a wrong voltage at the device
output pin, that looks like a S.C. to battery · C h e ck t h e c o n n e c t o r s f r o m
voltage customer specific function No. 1 to
·Cable is defective and is contacted to TCU
battery voltage · Check the resistance of customer
·Customer specific function No. 1 device specific function No. 1 device
has an internal defect
·Connector pin is contacted to battery
voltage
19 O.C. at customer specific function No. 1 Customer specific · Check the cable from TCU to
(ride control) customer specific function No. 1
TCU detected a wrong voltage at the device
output pin, that looks like a O.C. for this · C h e ck t h e c o n n e c t o r s f r o m
output pin customer specific function No. 1
·C a b l e i s d e fe c t i ve a n d h a s n o device to TCU
connection to TCU · Check the resistance of customer
·Customer specific function No. 1 device specific function No. 1 device
has an internal defect
·Connector has no connection to TCU
21 S.C. to battery voltage at clutch cut off Clutch cut off function is · Check the cable from TCU to the
input disabled sensor
The measured voltage is too high: OP mode : Normal · Check the connectors
·Cable is defective and is contacted to · Check the clutch cut off sensor
battery voltage
·Clutch cut off sensor has an internal
defect
·Connector pin is contacted to battery
voltage
22 S.C. to ground or O.C. at clutch cut off Clutch cut off function is · Check the cable from TCU to the
input disabled sensor
The measured voltage is too low: OP mode : Normal · Check the connectors
·Cable is defective and is contacted to · Check the clutch cut off sensor
vehicle ground
·Cable has no connection to TCU
·Clutch cut off sensor has an internal
defect
·Connector pin is contacted to vehicle
ground or is broken
25 S.C. to batter y voltage or O.C. at No reaction, TCU use · Check the cable from TCU to the
transmission sump temperature sensor default temperature sensor
input OP mode : Normal · Check the connectors
The measured voltage is too high: · Check the temperature sensor
·Cable is defective and is contacted to
battery voltage
·Cable has no connection to TCU
·Temperature sensor has an internal
defect
·Connector pin is contacted to battery
voltage or is broken
※ Some fault codes are not applied to this machine.
3-33
Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair
(Hex) possible reason for fault detection
26 S.C. to batter y voltage or O.C. at No reaction, TCU uses · Check the cable from TCU to the
transmission sump temperature sensor default temperature sensor
input OP mode : Normal · Check the connectors
The measured voltage is too low: · Check the temperature sensor
·Cable is defective and is contacted to
vehicle ground
·Temperature sensor has an internal
defect
·Connector pin is contacted to vehicle
ground
27 S.C. to batter y voltage or O.C. at No reaction, TCU uses · Check the cable from TCU to the
retarder temperature sensor input default temperature sensor
The measured voltage is too high: OP mode : Normal · Check the connectors
·Cable is defective and is contacted to · Check the temperature sensor
battery voltage
·Cable has no connection to TCU
·Temperature sensor has an internal
defect
·Connector pin is contacted to battery
voltage or is broken
28 S.C. to ground at retarder temperature No reaction, TCU uses · Check the cable from TCU to the
sensor input default temperature sensor
The measured voltage is too low: OP mode : Normal · Check the connectors
·Cable is defective and is contacted to · Check the temperature sensor
vehicle ground
·Temperature sensor has an internal
defect
·Connector pin is contacted to vehicle
ground
31 S.C. to battery voltage or O.C. at engine OP mode : Substitute clutch · Check the cable from TCU to the
speed input control sensor
TCU measures a voltage higher than · Check the connectors
7.00V at speed input pin · Check the speed sensor
·Cable is defective and is contacted to
battery voltage
·Cable has no connection to TCU
·Speed sensor has an internal defect
·Connector pin is contacted to battery
voltage or has no contact
32 S.C. to ground at engine speed input OP mode : Substitute clutch · Check the cable from TCU to the
TCU measures a voltage less than 0.45V control sensor
at speed input pin · Check the connectors
·Cable/connector is defective and is · Check the speed sensor
contacted to vehicle ground
·Speed sensor has an internal defect
33 Logical error at engine speed input OP mode : Substitute clutch · Check the cable from TCU to the
TCU measures a engine speed over a control sensor
threshold and the next moment the · Check the connectors
measured speed is zero · Check the speed sensor
·Cable/connector is defective and has · Check the sensor gap
bad contact ※ This fault is reset after power up of
·Speed sensor has an internal defect TCU
·Sensor gap has the wrong size
※ Some fault codes are not applied to this machine.
3-34
Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair
(Hex) possible reason for fault detection
34 S.C. to battery voltage or O.C. at turbine OP mode : Substitute clutch · Check the cable from TCU to the
speed input control sensor
TCU measures a voltage higher than If a failure is existing at · Check the connectors
7.00V at speed input pin output speed, · Check the speed sensor
·Cable is defective and is contacted to TCU shifts to neutral
vehicle battery voltage OP mode : Limp home
·Cable has no connection to TCU
·Speed sensor has an internal defect
·Connector pin is contacted to battery
voltage or has no contact
35 S.C. to ground at turbine speed input OP mode : Substitute clutch · Check the cable from TCU to the
TCU measures a voltage less than 0.45V control sensor
at speed input pin If a failure is existing at · Check the connectors
·Cable/connector is defective and is output speed, · Check the speed sensor
contacted to vehicle ground TCU shifts to neutral ※ This fault is reset after power up of
·Speed sensor has an internal defect OP mode : Limp home TCU
36 Logical error at turbine speed input OP mode : Substitute clutch · Check the cable from TCU to the
TCU measures a turbine speed over a control sensor
threshold and at the next moment the If a failure is existing at · Check the connectors
measured speed is zero output speed, · Check the speed sensor
·Cable/connector is defective and has TCU shifts to neutral · Check the sensor gap
bad contact OP mode : Limp home
·Speed sensor has an internal defect
·Sensor gap has the wrong size
37 S.C. to battery voltage or O.C. at internal OP mode : Substitute clutch · Check the cable from TCU to the
speed input control sensor
TCU measures a voltage higher than · Check the connectors
7.00V at speed input pin · Check the speed sensor
·Cable is defective and is contacted to
vehicle battery voltage
·Cable has no connection to TCU
·Speed sensor has an internal defect
·Connector pin is contacted to battery
voltage or has no contact
38 S.C. to ground at turbine speed input OP mode : Substitute clutch · Check the cable from TCU to the
TCU measures a voltage less than 0.45V control sensor
at speed input pin · Check the connectors
·Cable/connector is defective and is · Check the speed sensor
contacted to vehicle ground
·Speed sensor has an internal defect
39 Logical error at internal speed input OP mode : Substitute clutch · Check the cable from TCU to the
TCU measures a internal speed over a control sensor
threshold and at the next moment the · Check the connectors
measured speed is zero · Check the speed sensor
·Cable/connector is defective and has · Check the sensor gap
bad contact ※ This fault is reset after power up of
·Speed sensor has an internal defect TCU
·Sensor gap has the wrong size
3A S.C. to battery voltage or O.C. at output Special mode for gear · Check the cable from TCU to the
speed input selection sensor
TCU measures a voltage higher than OP mode : S u b s t i t u t e · Check the connectors
12.5V at speed input pin clutch control · Check the speed sensor
·Cable is defective and is contacted to If a failure is existing at
battery voltage turbine speed,
·Cable has no connection to TCU TCU shifts to neutral
·Speed sensor has an internal defect OP mode : Limp home
·Connector pin is contacted to battery
voltage or has no contact
※ Some fault codes are not applied to this machine.
3-35
Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair
(Hex) possible reason for fault detection
3B S.C. to ground at output speed input Special mode for gear · Check the cable from TCU to the
TCU measures a voltage less than 1.00V selection sensor
at speed input pin OP mode : Substitute clutch · Check the connectors
·Cable/connector is defective and is control · Check the speed sensor
contacted to vehicle ground If a failure is existing at
·Speed sensor has an internal defect turbine speed,
TCU shifts to neutral
OP mode : Limp home
3C Logical error at output speed input Special mode for gear · Check the cable from TCU to the
TCU measures a turbine speed over a selection sensor
threshold and at the next moment the OP mode : Substitute clutch · Check the connectors
measured speed is zero control · Check the speed sensor
·Cable/connector is defective and has If a failure is existing at · Check the sensor gap
bad contact turbine speed, ※ This fault is reset after power up of
·Speed sensor has an internal defect TCU shifts to neutral TCU
·Sensor gap has the wrong size OP mode : Limp home
3D Turbine speed zero doesn't fit to other - · Not used
speed signals
3E Output speed zero doesn't fit to other Special mode for gear · Check the sensor signal of output
speed signals selection speed sensor
If transmission is not neutral and the OP mode : Substitute clutch · Check the sensor gap of output
shifting has finished, control speed sensor
TCU measures output speed zero and If a failure is existing at · Check the cable from TCU to the
turbine speed or internal speed not equal turbine speed, sensor
to zero. TCU shifts to neutral ※ This fault is reset after power up of
·Speed sensor has an internal defect OP mode : Limp home TCU
·Sensor gap has the wrong size
54 DCT1 timeout OP mode : Normal · Check display computer
Timeout of CAN-message DCT1 from · Check wire of CAN-Bus
display computer · Check cable to display computer
·Interference on CAN-Bus
·CAN wire/connector is broken
·CAN wire/connector is defective and
has contact to vehicle ground or battery
voltage
55 JSS timeout TCU shifts to neutral while · Check joystick steering controller
Timeout of CAN-message JSS from joystick steering is active · Check wire of CAN-Bus
joystick steering controller OP mode : Normal · Check cable to joystick steering
·Interference on CAN-Bus controller
·CAN wire/connector is broken
·CAN wire/connector is defective and
has contact to vehicle ground or battery
voltage
56 Engine CONF timeout OP mode : Substitute · Check engine controller
Timeout of CAN-message engine CONF clutch control · Check wire of CAN-Bus
from engine controller · Check cable to engine controller
·Interference on CAN-Bus
·CAN wire/connector is broken
·CAN wire/connector is defective and
has contact to vehicle ground or battery
voltage
※ Some fault codes are not applied to this machine.
3-36
Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair
(Hex) possible reason for fault detection
57 EEC1 timeout OP mode : Substitute · Check EEC controller
Timeout of CAN-message EEC1 from clutch control · Check wire of CAN-Bus
EEC controller · Check cable to EEC controller
·Interference on CAN-Bus
·CAN wire/connector is broken
·CAN wire/connector is defective and
has contact to vehicle ground or battery
voltage
58 EEC3 timeout OP mode : Substitute · Check EEC controller
Timeout of CAN-message EEC3 from clutch control · Check wire of CAN-Bus
EEC controller · Check cable to EEC controller
·Interference on CAN-Bus
·CAN wire/connector is broken
·CAN wire/connector is defective an has
contact to vehicle ground or battery
voltage
5C Auto downshift signal No reaction · Check cluster controller
CAN signal for automatic downshift is · Check wire of CAN-Bus
defective · Check cable to cluster controller
·Cluster controller is defective
·Interference on CAN-Bus
5D Manual downshift signal No reaction · Check cluster controller
CAN signal for manual downshift is · Check wire of CAN-Bus
defective · Check cable to controller
·Cluster controller is defective
·Interference on CAN-Bus
5E CCO request signal No reaction · Check cluster controller
CAN signal for CCO request is defective · Check wire of CAN-Bus
·Cluster controller is defective · Check cable to controller
·Interference on CAN-Bus
61 AEB request signal No reaction · Check I/O controller, Omron master
CAN signal for AEB request is defective OP mode : Normal · Check wire of CAN-Bus
·I/O controller is defective · Check cable to I/O controller,
·Interference on CAN-Bus Omron master
64 Sarting gear signal No reaction. · Check I/O controller
CAN signal for starting gear is defective TCU uses default starting · Check wire of CAN-Bus
·I/O controller is defective gear · Check cable to I/O controller
(illegal starting gear) OP mode : Normal
·Interference on CAN-Bus
65 Engine torque signal OP mode : Substitute · Check engine controller
CAN signal for engine torque is defective clutch control · Check wire of CAN-Bus
·Engine controller is defective · Check cable to engine controller
·Interference on CAN-Bus
69 Reference engine torque signal OP mode : Substitute · Check engine controller
CAN signal for reference of engine torque clutch control · Check wire of CAN-Bus
is defective · Check cable to engine controller
·Engine controller is defective
·Interference on CAN-Bus
6A Actual engine torque signal OP mode : Substitute · Check engine controller
CAN signal for actual engine torque is clutch control · Check wire of CAN-Bus
defective · Check cable to engine controller
·Engine controller is defective
·Interference on CAN-Bus
※ Some fault codes are not applied to this machine.
3-37
Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair
(Hex) possible reason for fault detection
6E EEC2 timeout No reaction, TCU uses · Check EEC controller
Timeout of CAN-message EEC2 from default signal accelerator · Check wire of CAN-Bus
EEC controller pedal in idle position · Check cable to EEC controller
·Interference on CAN-Bus OP mode : Normal
·CAN wire/connector is broken
·CAN wire/connector is defective and
has contact to vehicle ground or battery
voltage
71 S.C. to battery voltage at clutch K1 TCU shifts to neutral · Check the cable from TCU to the
The measured resistance value of the valve OP mode : Limp home gearbox
is out of limit, the voltage at K1 valve is too If failure at another clutch · Check the connectors from TCU to
high is pending the gearbox
·Cable/connector is defective and has TCU shifts to neutral · Check the regulator resistance*
contact to battery voltage OP mode : TCU shutdown · Check internal wire harness of the
·Cable/connector is defective and has gearbox
contact to another regulator output of * See page 3-49
the TCU
·Regulator has an internal defect
72 S.C. to ground at clutch K1 TCU shifts to neutral · Check the cable from TCU to the
The measured resistance value of the valve OP mode : Limp home gearbox
is out of limit, the voltage at K1 valve is too If failure at another clutch · Check the connectors from gearbox
low is pending to TCU
·Cable/connector is defective and has TCU shifts to neutral · Check the regulator resistance*
contact to vehicle ground OP mode : TCU shutdown · Check internal wire harness of the
·Regulator has an internal defect gearbox
* See page 3-49
73 O.C. at clutch K1 TCU shifts to neutral · Check the cable from TCU to the
The measured resistance value of the OP mode : Limp home gearbox
valve is out of limit If failure at another clutch · Check the connectors from gearbox
·Cable/connector is defective and has no is pending to TCU
contact to TCU TCU shifts to neutral · Check the regulator resistance*
·Regulator has an internal defect OP mode : TCU shutdown · Check internal wire harness of the
gearbox
* See page 3-49
74 S.C. to battery voltage at clutch K2 TCU shifts to neutral · Check the cable from TCU to the
The measured resistance value of the OP mode : Limp home gearbox
valve is out of limit, the voltage at K2 valve If failure at another clutch · Check the connectors from gearbox
is too high is pending to TCU
·Cable/connector is defective and has TCU shifts to neutral · Check the regulator resistance*
contact to battery voltage OP mode : TCU shutdown · Check internal wire harness of the
·Cable/connector is defective and has gearbox
contact to another regulator output of * See page 3-49
the TCU
·Regulator has an internal defect
75 S.C. to ground at clutch K2 TCU shifts to neutral · Check the cable from TCU to the
The measured resistance value of the valve OP mode : Limp home gearbox
is out of limit, the voltage at K2 valve is too If failure at another clutch · Check the connectors from gearbox
low is pending to TCU
·Cable/connector is defective and has TCU shifts to neutral · Check the regulator resistance*
contact to vehicle ground OP mode : TCU shutdown · Check internal wire harness of the
·Regulator has an internal defect gearbox
* See page 3-49
※ Some fault codes are not applied to this machine.
3-38
Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair
(Hex) possible reason for fault detection
76 O.C. at clutch K2 TCU shifts to neutral · Check the cable from TCU to the
The measured resistance value of the OP mode : Limp home gearbox
valve is out of limit If failure at another clutch · Check the connectors from gearbox
·Cable/connector is defective and has no is pending to TCU
contact to TCU TCU shifts to neutral · Check the regulator resistance*
·Regulator has an internal defect OP mode : TCU shutdown · Check internal wire harness of the
gearbox
* See page 3-49
77 S.C. to battery voltage at clutch K3 TCU shifts to neutral · Check the cable from TCU to the
The measured resistance value of the OP mode : Limp home gearbox
valve is out of limit, the voltage at K3 valve If failure at another clutch · Check the connectors from gearbox
is too high is pending to TCU
·Cable/connector is defective and has TCU shifts to neutral · Check the regulator resistance*
contact to battery voltage OP mode : TCU shutdown · Check internal wire harness of the
·Cable/connector is defective and has gearbox
contact to another regulator output of * See page 3-49
the TCU
·Regulator has an internal defect
78 S.C. to ground at clutch K3 TCU shifts to neutral · Check the cable from TCU to the
The measured resistance value of the valve OP mode : Limp home gearbox
is out of limit, the voltage at K3 valve is too If failure at another clutch · Check the connectors from gearbox
low is pending to TCU
·Cable/connector is defective and has TCU shifts to neutral · Check the regulator resistance*
contact to vehicle ground OP mode : TCU shutdown · Check internal wire harness of the
·Regulator has an internal defect gearbox
* See page 3-49
79 O.C. at clutch K2 TCU shifts to neutral · Check the cable from TCU to the
The measured resistance value of the OP mode : Limp home gearbox
valve is out of limit If failure at another clutch · Check the connectors from gearbox
·Cable/connector is defective and has no is pending to TCU
contact to TCU TCU shifts to neutral · Check the regulator resistance*
·Regulator has an internal defect OP mode : TCU shutdown · Check internal wire harness of the
gearbox
* See page 3-49
7D S.C. ground at engine derating device Engine derating will be on · Check the cable from TCU to the
·Cable is defective and is contacted to until engine derating device
vehicle ground TCU power down even if · Check the connectors from engine
·Engine derating device has an internal fault vanishes (Loose derating device to TCU
defect connection) · Check the resistance* of engine
·Connector pin is contacted to vehicle OP mode : Normal derating device
ground ※ Not used
* See page 3-49
7E S.C. battery voltage at engine derating No reaction · Check the cable from TCU to the
device OP mode : Normal engine derating device
·Cable/connector is defective and is · Check the connectors from backup
contacted to battery voltage alarm device to TCU
·Engine derating device has an internal · Check the resistance* of backup
defect alarm device
* See page 3-49
※ Some fault codes are not applied to this machine.
3-39
Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair
(Hex) possible reason for fault detection
7F O.C. at engine derating device No reaction · Check the cable from TCU to the
TCU detected a wrong voltage at the OP mode : Normal engine derating device
output pin, that looks like a O.C. for this · Check the connectors from engine
output pin derating device to TCU
·C a b l e i s d e fe c t i ve a n d h a s n o · Check the resistance* of engine
connection to TCU derating device
·Engine derating device has an internal * See page 3-49
defect
·Connector has no connection to TCU
81 S.C. to battery voltage at clutch K4 TCU shifts to neutral · Check the cable from TCU to the
The measured resistance value of the OP mode : Limp home gearbox
valve is out of limit, the voltage at K4 valve If failure at another clutch · Check the connectors from gearbox
is too high is pending to TCU
·Cable/connector is defective and has TCU shifts to neutral · Check the regulator resistance*
contact to battery voltage OP mode : TCU shutdown · Check internal wire harness of the
·Cable/connector is defective and has gearbox
contact to another regulator output of * See page 3-49
the TCU
·Regulator has an internal defect
82 S.C. to ground at clutch K4 TCU shifts to neutral · Check the cable from TCU to the
The measured resistance value of the valve OP mode : Limp home engine derating device
is out of limit, the voltage at K4 valve is too If failure at another clutch · Check the connectors from gearbox
low is pending to TCU
·Cable/connector is defective and has TCU shifts to neutral · Check the regulator resistance*
contact to vehicle ground OP mode : TCU shutdown · Check internal wire harness of the
·Regulator has an internal defect gearbox
* See page 3-49
83 O.C. at clutch K4 · Check the cable from TCU to the
The measured resistance value of the TCU shifts to neutral gearbox
valve is out of limit OP mode : Limp home · Check the connectors from gearbox
·Cable/connector is defective and has If failure at another clutch to TCU
contact to TCU is pending · Check the regulator resistance*
·Regulator has an internal defect TCU shifts to neutral · Check internal wire harness of the
OP mode : TCU shutdown gearbox
* See page 3-49
84 S.C. to battery voltage at clutch K4 TCU shifts to neutral · Check the cable from TCU to the
The measured resistance value of the OP mode : Limp home gearbox
valve is out of limit, the voltage at K4 valve If failure at another clutch · Check the connectors from gearbox
is too high is pending to TCU
·Cable/connector is defective and has TCU shifts to neutral · Check the regulator resistance*
contact to battery voltage OP mode : TCU shutdown · Check internal wire harness of the
·Cable/connector is defective and has gearbox
contact to another regulator output of * See page 3-49
the TCU
·Regulator has an internal defect
85 S.C. to ground at clutch KV TCU shifts to neutral · Check the cable from TCU to the
The measured resistance value of the valve OP mode : Limp home gearbox
is out of limit, the voltage at K4 valve is too If failure at another clutch · Check the connectors from gearbox
low is pending to TCU
·Cable/connector is defective and has TCU shifts to neutral · Check the regulator resistance*
contact to vehicle ground OP mode : TCU shutdown · Check internal wire harness of the
·Regulator has an internal defect gearbox
* See page 3-49
※ Some fault codes are not applied to this machine.
3-40
Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair
(Hex) possible reason for fault detection
86 O.C. at clutch KV TCU shifts to neutral · Check the cable from TCU to the
The measured resistance value of the OP mode : Limp home gearbox
valve is out of limit If failure at another clutch · Check the connectors from gearbox
·Cable/connector is defective and has is pending to TCU
contact to TCU TCU shifts to neutral · Check the regulator resistance*
·Regulator has an internal defect OP mode : TCU shutdown · Check internal wire harness of the
gearbox
* See page 3-49
87 S.C. to battery voltage at clutch KR TCU shifts to neutral · Check the cable from TCU to the
The measured resistance value of the OP mode : Limp home gearbox
valve is out of limit, the voltage at KR valve is If failure at another clutch · Check the connectors from gearbox
too high is pending to TCU
·Cable/connector is defective and has TCU shifts to neutral · Check the regulator resistance*
contact to battery voltage OP mode : TCU shutdown · Check internal wire harness of the
·Cable/connector is defective and has gearbox
contact to another regulator output of the * See page 3-49
TCU
·Regulator has an internal defect
88 S.C. to ground at clutch KR TCU shifts to neutral · Check the cable from TCU to the
The measured resistance value of the valve OP mode : Limp home gearbox
is out of limit, the voltage at KR valve is too If failure at another clutch · Check the connectors from gearbox
low is pending to TCU
·Cable/connector is defective and has TCU shifts to neutral · Check the regulator resistance*
contact to vehicle ground OP mode : TCU shutdown · Check internal wire harness of the
·Regulator has an internal defect gearbox
* See page 3-49
89 O.C. at clutch KR TCU shifts to neutral · Check the cable from TCU to the
The measured resistance value of the OP mode : Limp home gearbox
valve is out of limit If failure at another clutch · Check the connectors from gearbox
·Cable/connector is defective and has no is pending to TCU
contact to TCU TCU shifts to neutral · Check the regulator resistance*
·Regulator has an internal defect OP mode : TCU shutdown · Check internal wire harness of the
gearbox
* See page 3-49
91 S.C. to ground at relay reverse warning Backup alarm will be on · Check the cable from TCU to the
alarm until backup alarm device
TCU detected a wrong voltage at the TCU power down even if · Check the connectors from backup
output pin, that looks like a S.C. to vehicle fa u l t va n i s h e s ( L o o s e alarm device to TCU
ground connection) · Check the resistance* of backup
·Cable is defective and is contact to OP mode : Normal alarm device
vehicle ground * See page 3-49
·Backup alarm device has an internal
defect
·Connector pin is contacted to vehicle
ground
92 S.C. to battery voltage at relay reverse No reaction · Check the cable from TCU to the
warning alarm OP mode : Normal backup alarm device
TCU detected a wrong voltage at the · Check the connectors from backup
output pin, that looks like a S.C. to battery alarm device to TCU
voltage · Check the resistance* of backup
·Cable is defective and is contacted to alarm device
battery voltage * See page 3-49
·Backup alarm device has an internal
defect
·Connector pin is contacted to battery
voltage
※ Some fault codes are not applied to this machine.
3-41
Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair
(Hex) possible reason for fault detection
93 O.C. at relay reverse warning alarm No reaction · Check the cable from TCU to the
TCU detected a wrong voltage at the OP mode : Normal backup alarm device
output pin, that looks like a O.C. for this · Check the connectors from backup
output pin alarm device to TCU
·C a b l e i s d e fe c t i ve a n d h a s n o · Check the resistance* of backup
connection to TCU alarm device
·Backup alarm device has an internal * See page 3-49
defect
·Connector has no connection to TCU
94 S.C. to ground at relay starter interlock No reaction · Check the cable from TCU to the
TCU detected a wrong voltage at the OP mode : Normal stater interlock relay
output pin, that looks like a S.C. to vehicle · Check the connectors from starter
ground interlock relay to TCU
·Cable is defective and is connection to · Check the resistance* of starter
vehicle ground interlock relay
·Starter interlock relay has an internal * See page 3-49
defect
·Connector pin is contacted to vehicle
ground
95 S.C. to battery voltage at relay starter No reaction · Check the cable from TCU to the
interlock OP mode : Normal starter interlock relay
TCU detected a wrong voltage at the · Check the connectors from starter
output pin, that looks like a S.C. to battery interlock relay to TCU
voltage · Check the resistance* of starter
·C a b l e i s d e fe c t i ve a n d h a s n o interlock relay
connection to battery voltage * See page 3-49
·Starter interlock relay has an internal
defect
·Connector pin is contacted to battery
voltage
96 O.C. at relay starter interlock No reaction · Check the cable from TCU to the
TCU detected a wrong voltage at the OP mode : Normal starter interlock relay
output pin, that looks like a O.C. for this · Check the connectors from starter
output pin interlock relay to TCU
·C a b l e i s d e fe c t i ve a n d h a s n o · Check the resistance* of starter
connection to TCU interlock relay
·Starter interlock relay has an internal * See page 3-49
defect
·Connector has no connection to TCU
9A S.C. to ground at conver ter lock up No reaction · Check the cable from TCU to the
clutch solenoid OP mode : Normal converter clutch solenoid
TCU detected a wrong voltage at the · C h e ck t h e c o n n e c t o r s f r o m
output pin, that looks like a S.C. to vehicle converter clutch solenoid to TCU
ground · Check the resistance* of converter
·Cable is defective and is contacted to clutch solenoid
vehicle ground * See page 3-49
·Conver ter clutch solenoid has an
internal defect
·Connector pin is contacted to vehicle
ground
※ Some fault codes are not applied to this machine.
3-42
Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair
(Hex) possible reason for fault detection
9B O.C. at converter lock up clutch solenoid Converter clutch always · Check the cable from TCU to the
TCU detected a wrong voltage at the open, retarder not converter clutch solenoid
output pin, that looks like a O.C. for this available · C h e ck t h e c o n n e c t o r s f r o m
output pin OP mode : Normal converter clutch solenoid to TCU
·C a b l e i s d e fe c t i ve a n d h a s n o · Check the resistance* of converter
connection to TCU clutch solenoid
·Conver ter clutch solenoid has an * See page 3-49
internal defect
·Connector has no connection to TCU
9C S.C. to battery voltage at converter lock No reaction · Check the cable from TCU to the
up clutch solenoid OP mode : Normal converter clutch solenoid
TCU detected a wrong voltage at the · C h e ck t h e c o n n e c t o r s f r o m
output pin, that looks like a S.C. to battery converter clutch solenoid to TCU
voltage · Check the resistance* of converter
·Cable is defective and has no contacted clutch solenoid
to battery voltage * See page 3-49
·Conver ter clutch solenoid has an
internal defect
·Connector pin is contacted to battery
voltage
A1 S.C. to ground at difflock or axle No reaction · Check the cable from TCU to the
connection solenoid OP mode : Normal difflock solenoid
TCU detected a wrong voltage at the · Check the connectors from difflock
output pin, that looks like a S.C. to vehicle solenoid to TCU
ground · Check the resistance* of difflock
·Cable is defective and is contacted to solenoid
vehicle ground * See page 3-49
·Difflock solenoid has an internal defect
·Connector pin is contacted to vehicle
ground
A2 S.C. to battery voltage at difflock or axle No reaction · Check the cable from TCU to the
connection solenoid OP mode : Normal difflock solenoid
TCU detected a wrong voltage at the · Check the connectors from difflock
output pin, that looks like a S.C. to battery solenoid to TCU
voltage · Check the resistance* of difflock
·C a b l e i s d e fe c t i ve a n d h a s n o solenoid
connection to battery voltage * See page 3-49
·Difflock solenoid has an internal defect
·Connector pin is contacted to battery
voltage
A3 O.C. at difflock or axle connection No reaction · Check the cable from TCU to the
solenoid OP mode : Normal difflock solenoid
TCU detected a wrong voltage at the · Check the connectors from difflock
output pin, that looks like a O.C. for this solenoid to TCU
output pin · Check the resistance* of difflock
·C a b l e i s d e fe c t i ve a n d h a s n o solenoid
connection to TCU * See page 3-49
·Difflock solenoid has an internal defect
·Connector has no connection to TCU
※ Some fault codes are not applied to this machine.
3-43
Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair
(Hex) possible reason for fault detection
A4 S.C. to ground at warning signal output No reaction · Check the cable from TCU to the
TCU detected a wrong voltage at the OP mode : Normal warning device
output pin, that looks like a S.C. to vehicle · Check the connectors from warning
ground device to TCU
·Cable is defective and is contacted to · Check the resistance* of warning
vehicle ground device
·Warning device has an internal defect * See page 3-49
·Connector pin is contacted to vehicle
ground
A5 O.C. voltage at warning signal output No reaction · Check the cable from TCU to the
TCU detected a wrong voltage at the OP mode : Normal warning device
output pin, that looks like a O.C. for this · Check the connectors from warning
output pin device to TCU
·C a b l e i s d e fe c t i ve a n d h a s n o · Check the resistance* of warning
connection to TCU device
·Warning device has an internal defect * See page 3-49
·Connector has no connection to TCU
A6 S.C. to battery voltage at warning signal No reaction · Check the cable from TCU to the
output OP mode : Normal warning device
TCU detected a wrong voltage at the · Check the connectors from warning
output pin, that looks like a S.C. to battery device to TCU
voltage · Check the resistance* of warning
·Cable is defective and has is contacted device
to battery voltage * See page 3-49
·Warning device has an internal defect
·Connector pin is contacted to battery
voltage
B1 Slippage at clutch K1 TCU shifts to neutral · Check pressure at clutch K1
TCU calculates a differential speed at OP mode : Limp home · Check main pressure in the system
closed clutch K1. If this calculated value If failure at another clutch · Check sensor gap at internal speed
is out of range, TCU interprets this as is pending sensor
slipping clutch TCU shifts to neutral · Check sensor gap at output speed
·Low pressure at clutch K1 OP mode : TCU shutdown sensor
·Low main pressure · Check signal at internal speed
·Wrong signal at internal speed sensor sensor
·Wrong signal at output speed sensor · Check signal at output speed
·Wrong size of the sensor gap sensor
·Clutch is defective · Replace clutch
B2 Slippage at clutch K2 TCU shifts to neutral · Check pressure at clutch K2
TCU calculates a differential speed at OP mode : Limp home Check main pressure in the system
closed clutch K2. If this calculated value If failure at another clutch · Check sensor gap at internal speed
is out of range, TCU interprets this as is pending sensor
slipping clutch TCU shifts to neutral · Check sensor gap at output speed
·Low pressure at clutch K2 OP mode : TCU shutdown sensor
·Low main pressure · Check signal at internal speed
·Wrong signal at internal speed sensor sensor
·Wrong signal at output speed sensor · Check signal at output speed
·Wrong size of the sensor gap sensor
·Clutch is defective · Replace clutch
※ Some fault codes are not applied to this machine.
3-44
Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair
(Hex) possible reason for fault detection
B3 Slippage at clutch K3 TCU shifts to neutral · Check pressure at clutch K3
TCU calculates a differential speed at OP mode : Limp home · Check main pressure in the system
closed clutch K3. If this calculated value If failure at another clutch · Check sensor gap at internal speed
is out of range, TCU interprets this as is pending sensor
slipping clutch TCU shifts to neutral · Check sensor gap at output speed
·Low pressure at clutch K3 OP mode : TCU shutdown sensor
·Low main pressure · Check signal at internal speed
·Wrong signal at internal speed sensor sensor
·Wrong signal at output speed sensor · Check signal at output speed
·Wrong size of the sensor gap sensor
·Clutch is defective Replace clutch
B4 Slippage at clutch K4 TCU shifts to neutral · Check pressure at clutch K4
TCU calculates a differential speed at OP mode : Limp home Check main pressure in the system
closed clutch K4. If this calculated value If failure at another clutch · Check sensor gap at internal speed
is out of range, TCU interprets this as is pending sensor
slipping clutch TCU shifts to neutral · Check sensor gap at turbine speed
·Low pressure at clutch K4 OP mode : TCU shutdown sensor
·Low main pressure · Check signal at internal speed
·Wrong signal at internal speed sensor sensor
·Wrong signal at turbine speed sensor · Check signal at turbine speed
·Wrong size of the sensor gap sensor
·Clutch is defective Replace clutch
B5 Slippage at clutch KV TCU shifts to neutral · Check pressure at clutch KV
TCU calculates a differential speed at OP mode : Limp home · Check main pressure in the system
closed clutch KV. If this calculated value If failure at another clutch · Check sensor gap at internal speed
is out of range, TCU interprets this as is pending sensor
slipping clutch TCU shifts to neutral · Check sensor gap at turbine speed
·Low pressure at clutch KV OP mode : TCU shutdown sensor
·Low main pressure · Check signal at internal speed
·Wrong signal at internal speed sensor sensor
·Wrong signal at turbine speed sensor · Check signal at turbine speed
·Wrong size of the sensor gap sensor
·Clutch is defective · Replace clutch
B6 Slippage at clutch KR TCU shifts to neutral · Check pressure at clutch KR
TCU calculates a differential speed at OP mode : Limp home Check main pressure in the system
closed clutch KR. If this calculated value If failure at another clutch · Check sensor gap at internal speed
is out of range, TCU interprets this as is pending sensor
slipping clutch TCU shifts to neutral · Check sensor gap at turbine speed
·Low pressure at clutch KR OP mode : TCU shutdown sensor
·Low main pressure · Check signal at internal speed
·Wrong signal at internal speed sensor sensor
·Wrong signal at turbine speed sensor · Check signal at turbine speed
·Wrong size of the sensor gap sensor
·Clutch is defective · Replace clutch
B7 Overtemp sump No reaction · Cool down machine
TCU measured a temperature in the oil OP mode : Normal · Check oil level
sump that is over the allowed threshold. · Check temperature sensor
B9 Overspend engine Retarder applies
-
OP mode : Normal
BA Differential pressure oil filter No reaction · Check oil filter
TCU measured a voltage at differential OP mode : Normal · Check wiring from TCU to
pressure switch out of the allowed range differential pressure switch
·Oil filter is polluted · C h e ck d i f fe r e n t i a l p r e s s u r e
·Cable/connector is broken or cable/ switch(Measure resistance)
connector is contacted to battery voltage
or vehicle ground
·Differential pressure switch is defective
※ Some fault codes are not applied to this machine.
3-45
Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair
(Hex) possible reason for fault detection
BB Slippage at converter lockup clutch No reaction · Check pressure at converter lockup
TCU calculates a differential speed at OP mode : Normal clutch
closed converter lockup clutch. If this · Check main pressure in the system
calculated value is out of range, TCU · Check sensor gap at engine speed
interprets this as slipping clutch sensor
·Low pressure at converter lockup clutch · Check sensor gap at turbine speed
·Low main pressure sensor
·Wrong signal at engine speed sensor · Check signal at engine speed
·Wrong signal at turbine speed sensor sensor
·Wrong size of the sensor gap · Check signal at turbine speed
·Clutch is defective sensor
· Replace clutch
C0 Engine torque or engine power overload OP mode : Normal
TCU calculates an engine torque or
e n g i n e p o w e r a b o ve t h e d e f i n e d
thresholds
C1 Transmission output torque overload OP mode : Normal
TCU calculates an transmission output
torque above the defined threshold
C2 Transmission input torque overload programmable :
TCU calculates an transmission input No reaction or shift to
torque above the defined threshold neutral
OP mode : Normal
C3 Overtemp converter output No reaction · Cool down machine
TCU measured a oil temperature at the OP mode : Normal · Check oil level
converter output that is the allowed · Check temperature sensor
threshold
C4 S. C. t o g r o u n d a t j oy s t i ck s t a t u s No reaction · Check the cable from TCU to
indicator OP mode : Normal joystick status indicator
TCU detected a wrong voltage at the · Check the connectors from joystick
output pin, that looks like a S.C. to vehicle status indicator to TCU
ground · Check the resistance* of joystick
·Cable is defective and is contacted to status indicator
vehicle ground * See page 3-49
·Joystick status indicator has an internal
defect
·Connector pin is contacted to vehicle
ground
C5 S.C. to battery voltage at joystick status No reaction · Check the cable from TCU to
indicator OP mode : Normal joystick status indicator
TCU detected a wrong voltage at the · Check the connectors from joystick
output pin, that looks like a S.C. to battery status indicator to TCU
voltage · Check the resistance* of joystick
·Cable is defective and is contacted to status indicator
battery voltage * See page 3-49
·Joystick status indicator has an internal
defect
·Connector pin is contacted to battery
voltage
※ Some fault codes are not applied to this machine.
3-46
Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair
(Hex) possible reason for fault detection
C6 O.C. at joystick status indicator No reaction · Check the cable from TCU to
TCU detected a wrong voltage at the OP mode : Normal joystick status indicator
output pin, that looks like a O.C. for this · Check the connectors from joystick
output pin status indicator to TCU
·C a b l e i s d e fe c t i ve a n d h a s n o · Check the resistance* of joystick
connection to TCU status indicator
·Joystick status indicator has an internal * See page 3-49
defect
·Connector pin has no connection to
TCU
D1 S.C. to battery voltage at power supply See fault codes No.21 to · Check cables and connectors to
for sensors 2C sensors, which are supplied from
TCU measures more than 6V at the pin AU1
AU1 (5V sensor supply) · Check the power supply at the pin
AU1(Should be appx. 5V)
· Fault codes No.21 to No.2C may be
reaction of this fault
D2 S.C. to ground at power supply for See fault codes No.21 to · Check cables and connectors to
sensors 2C sensors, which are supplied from
TCU measures less than 4V at the pin AU1
AU1 (5V sensor supply) · Check the power supply at the pin
AU1(Should be appx. 5V)
· Fault codes No.21 to No.2C may be
reaction of this fault
D3 Low voltage at battery Shift to neutral · Check power supply battery
Measured voltage at power supply is lower OP mode : TCU shutdown · Check cables from batteries to TCU
than 18V(24V device) · Check connectors from batteries to
TCU
D4 High voltage at battery Shift to neutral · Check power supply battery
Measured voltage at power supply is OP mode : TCU shutdown · Check cables from batteries to TCU
higher than 32.5V(24V device) · Check connectors from batteries to
TCU
D5 Error at valve power supply VPS1 Shift to neutral · Check fuse
TCU switched on VPS1 and measured OP mode : TCU shutdown · Check cables from gearbox to TCU
VPS1 is off or TCU switched off VPS1 and · Check connectors from gearbox to
measured VPS1 is still on TCU
·Cable or connectors are defect and are · Replace TCU
contacted to battery voltage
·Cable or connectors are defect and are
contacted to vehicle ground
·Permanent power supply KL30 missing
·TCU has an internal defect
D6 Error at valve power supply VPS2 Shift to neutral · Check fuse
TCU switched on VPS2 and measured OP mode : TCU shutdown · Check cables from gearbox to TCU
VPS2 is off or TCU switched off VPS2 and · Check connectors from gearbox to
measured VPS2 is still on TCU
·Cable or connectors are defect and are · Replace TCU
contacted to battery voltage
·Cable or connectors are defect and are
contacted to vehicle ground
·Permanent power supply KL30 missing
·TCU has an internal defect
※ Some fault codes are not applied to this machine.
3-47
Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair
(Hex) possible reason for fault detection
E3 S.C. to battery voltage at display output No reaction · Check the cable from TCU to the
TCU sends data to the display and OP mode : Normal display
measures always a high voltage level on · Check the connectors at the display
the connector · Change display
·Cable or connectors are defective and
are contacted to battery voltage
·Display has an internal defect
E4 S.C. to ground at display output No reaction · Check the cable from TCU to the
TCU sends data to the display and OP mode : Normal display
measures always a high voltage level on · Check the connectors at the display
the connector · Change display
·Cable or connectors are defective and
are contacted to battery voltage
·Display has an internal defect
E5 Communication failure on DeviceNet Shift to neutral · Check Omron master
OP mode : TCU shutdown · Check wire of DeviceNet-Bus
· Check cable to Omron master
F1 General EEPROM fault No reaction · Replace TCU
TCU can't read non volatile memory OP mode : Normal ※ Often shown together with fault
·TCU is defective code F2
F2 Configuration lost Transmission stay neutral · Reprogram the correct configurat-
TCU has lost the correct configuration and OP mode : TCU shutdown ion for the vehicle (e.g. with cluster
can't control the transmission controller,...)
·Interference during saving data on non
volatile memory
·TCU is brand new or from another
vehicle
F3 Application error Transmission stay neutral · Replace TCU
Something of this application is wrong OP mode : TCU shutdown ※ This fault occurs only if an test
engineer did something wrong in
the application of the vehicle
F5 Clutch failure Transmission stay neutral · Check clutch
AEB was not able to adjust clutch filling OP mode : TCU shutdown ※ TCU shows also the affected clutch
parameters on the display
·One of the AEB-Values is out of limit
F6 Clutch adjustment data lost No reaction, · Execute AEB
TCU was not able to read correct clutch Default values : 0 for AEB
adjustment parameters Offsets used
·Interference during saving data on non OP mode : Normal
volatile memory
·TCU is brand new
F7 Substitute clutch control OP mode : Substitute · Check engine retarder torque
·Transmission input torque wrong clutch control · Check speed sensors
·Engine retarder torque wrong
·Speed signal (s) defective
※ Some fault codes are not applied to this machine.
3-48
5) MEASURING OF RESISTANCE AT ACTUATOR/SENSOR AND CABLE
(1) Actuator
2 G
76043PT19
(2) Cable
UBat
P(Power supply)
TCU
1 2 Actuator/
Sensor
C(Chassis)
Ground
76043PT20
3-49
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
2
3
3
2
7609A3PT15
2
3
1
3
2
7609A3PT16
3-50
2) DIFFERENTIAL
(1) Description 3
When the machine makes a turn, the
2 4
outside wheel must rotate faster than the
inside wheel. A differential is a device
which continuously transmits power to the
right and left wheels while allowing them
to turn a different speeds, during a turn.
The power from the drive shaft passes
through bevel pinion (1) and is transmitted
to the bevel gear (2). The bevel gear
changes the direction of the motive force
by 90 degree, and at the same time
reduces the speed. 1
It then transmits the motive force through
the differential (3) to the axle gear shaft 770-3 [3-26(1)]
(4).
770-3 [3-26(2)]
770-3 [3-26(3)]
3-51
6. TIRE AND WHEEL
7407APT10
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.
3-52
GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING
Chapter 2 : Troubleshooting
Group 3 : Tests and adjustments
3-53
※ Transmission oil must be at operating temperature for these checks.
for 30 seconds.
AN AH
A
Move gear selector lever to neutral
"N" position and r un for 15
seconds.
1
4
2
3
Repeat procedure until
transmission temperature gauge
arrow points to bar above dial.
Gear selector lever and Move gear selector lever to each OK
neutral lock latch checks position. Check completed.
Engine OFF. 1
NOT OK
changes slightly as steer ing
Repair lock or replace
column is tilted.
switch.
FEEL : Lever must move freely
through all positions.
Engage neutral lock.
Apply slight effort to move lever into
forward (F) and reverse (R).
LOOK : Neutral lock must stay
engaged.
Automatic shifting check Start engine. OK
Check completed.
1
2
3
F
N
Move gear selector lever to 4th
4
R
speed.
NOT OK
Turn T/M shift mode switch to AL Go to transmission error
(auto light) mode. code group at page 3-32~
3-48.
Auotmatic sign LOOK : Automatic sign on monitor.
Repair or replace the
Move gear selector lever to forward monitor or harness.
or reverse position.
Increase engine rpm.
LOOK : Speed on monitor must
vary with machine speed.
3-54
Item Description Service action
Transmission noise Run engine at approximately 1600 OK
check 1
2
rpm. Check completed.
3
Engine running.
4
4
2
3
LOOK/FEEL : Transmission must
shift back to 2nd gear.
Shift to (3rd or 4th) gear and press
gear selector lever kick down
switch once.
LOOK/FEEL : Transmission must
not shift down.
Select T/M shift mode switch to AL
(auto light) mode.
Drive machine at approximately
90% speed of max speed in each
gear (2nd or 3rd or 4th).
Shift to (2nd or 3rd or 4th) gear in
each forward and reverse speed
and press gear selector kick down
lever switch or RCV lever switch
once.
LOOK/FEEL : It shift down quickly
from current gear to one step lower
speed and recover to original
speed quickly when push the
switch one more time. (mode 1)
3-55
Item Description Service action
LOOK/FEEL : If shifts down from
current gear to one step lower
speed when push the switch
everytime and recover when push
the switch in 1st gear. (mode 2)
Forward, reverse and 4th Park unit on level surface. OK
speed clutch pack drag 1
2
3 Check completed.
Apply service brakes.
4
check
NOT OK
※ Transmission must Move gear selector lever to neutral.
I f u n i t m ove s, r e p a i r
be warmed up for Release
Move gear selector lever to 1st. transmission.
this check.
Engine running. Release parking brake and service
P
brakes.
Run engine at low idle.
LOOK : Unit must not move in
either direction.
NOTE : If unit moves forward,
either the forward pack or the 4th
speed pack is dragging.
Transmission shift Run engine at approximately 1300 OK
modulation check 1
4
2
3 rpm. Check completed.
Engine running.
Put transmission in 1st forward, NOT OK
shift several times from forward to Go to unit shifts too fast,
reverse and reverse to forward. chapter 2 in this group.
Repeat check in 2nd gear.
LOOK : Unit must slow down and
change direction smoothly.
Torque converter check Start engine. Apply service brakes OK
1
4
2
3
and release parking brake. Check completed.
Move gear selector lever to 3rd NOT OK
speed. If stall rpm are too low or
too high, problem may be
Move gear selector control lever to
engine power or torque
forward "F" position.
converter.
Increase engine speed to high idle.
IF OK
LOOK : Torque converter stall rpm Replace transmission
must be within the following range. torque converter.
Stall rpm : 2040±70 rpm
Move gear selector control lever to
neutral "N" position and run for 15
seconds.
3-56
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.)
3-57
Problem Cause Remedy
Machine will not move Low oil level. Add oil.
Applied park brake. Check parking brake fuse.
Check continuity to parking brake switch.
No power to transmission contro- Check transmission controller fuse.
ller.
Malfunctioning parking brake Remove and inspect parking brake solenoid
solenoid valve. valve.
Check for power to solenoid valve.
Restricted orifice of PPC valve. Remove orifice and check for contamination
and/or plugging.
(Do not remove valve housing for this purpose.)
Excessive leakage in Do transmission element leakage test using
transmission element. system pressure.
Worn clutch disks. Repair transmission.
Low or no transmission See transmission pressure is low in this group.
pressure.
Service brake will not release. Do brake pedal operational check.
Do service and park system drag checks.
Failed torque converter. Do torque converter stall test.
If engine pulldown in normal, torque converter is
good.
Broken shafts or gears. Drain transmission to determine if large pieces
of metal contamination are present.
Broken drive shafts. Inspect drive shafts and universal joints for
external damage. Repair.
Broken ring or pinion gear. If drive shaft rotate with transmission in gear but
machine does not move, a differential failure is
indicated. Repair.
Machine does not Malfunctioning transmission Check solenoid valve.
engage in low gear control solenoid valve.
Stuck spool in transmission Remove and inspect transmission control valve
control valve. spools.
Stuck PPC valve. Remove end cover to inspect PPC valve.
Replace if necessary.
Malfunctioning transmission Check speed sensor.
speed sensor.
3-58
Problem Cause Remedy
Transmission pressure is Low oil level. Check transmission oil level and refill if
low (all gears) necessary.
Failed transmission pressure Verify transmission system pressure. Do
switch. transmission system pressure test.
Plugged suction strainer. Transmission pump may be noisy if transmission
suction screen is clogged. Drain transmission.
Remove and clean suction screen.
Also, check condition of transmission filter.
Stuck transmission pressure Remove transmission pressure regulating valve.
regulating valve or broken spring. Inspect for damage (See transmission control
valve).
Failed control valve gasket. Inspect transmission control valve for external
leakage. Remove control valve.
Inspect or replace gasket.
Stuck PPC valve. Remove end cover to inspect modulation spool
and check torque on cap screws retaining
control valve to transmission.
Tr a n s m i s s i o n s y s t e m Failed transmission pump. Do pump flow test.
pressure is low (one or
Failed transmission control valve Inspect transmission control valve for external
two gears)
gasket. leakage. Remove control valve.
Inspect or replace gasket.
Leakage in clutch piston or seal Disassemble and repair.
ring.
Transmission shifts too Low oil level (aeration of oil). Add oil.
low
Low transmission pressure. Do transmission system pressure test.
Restricted transmission pump Remove and clean screen.
suction screen.
Low transmission pump flow. Do transmission pump flow test.
Excessive transmission Do transmission element leakage test using
element leakage. system pressure.
Stuck PPC valve. Remove end cover to inspect modulation spool.
Replace if necessary.
Restricted PPC valve orifice. Remove orifice and inspect for contamination
and /or plugging.
Restricted oil passages between Remove control valve and inspect oil passage.
control valve and transmission
elements.
Incorrect transmission oil. Change oil (SAE 10W-30/15W-40)
3-59
Problem Cause Remedy
Transmission shifts too Wrong transmission controller. Check if transmission controller has been
fast changed
System pressure too high. Do transmission system pressure test.
Stuck PPC valve. Remove and inspect PPC valve.
Replace if necessary. Also remove end cover
to inspect PPC valve and control valve housing.
Replace if necessary.
Stuck or missing check valves. Inspect transmission control valve.
Missing O-r ing from end of Remove orifice and inspect port for O-ring.
modulation orifice.
Broken piston return spring. Disassemble and inspect clutch.
Incorrect transmission oil. Change oil (SAE 10W-30/15W-40).
Machine "creeps" War ped disks and plates in Check transmission.
in neutral transmission.
Transmission hydraulic High oil level. Transmission overfilled or hydraulic pump seal
system overheats leaking.
Low oil level. Add oil.
Wrong oil grade. Change oil.
Park brake dragging. Check for heat in park brake area.
Pinched, restricted or leaking lube Check cooler lines.
lines.
Machine operated in too high Operate machine in correct gear range.
gear range.
Malfunction in temperature gauge I n s t a l l t e m p e ra t u r e s e n s o r t h e ve r i f y
or sensor. temperature.
Do tachometer/temperature reader installation
procedure.
Restricted air flow through oil Do radiator air flow test.
cooler or radiator.
Failed oil cooler bypass valve (In Disassemble and inspect.
thermal bypass valve).
Failed thermal bypass valve. Remove thermal bypass valve and check to see
if machine still overheats. Do transmission oil
cooler thermal bypass valve test.
Internally restricted oil cooler. Do oil cooler restriction test.
Leakage in transmission hydraulic Do transmission system pressure, element
system. leakage test.
Malfunction in converter relief Do converter out pressure test.
valve.
Low transmission pump output. Do transmission pump flow test.
3-60
Problem Cause Remedy
Excessive transmission Too low engine low idle. Check engine low idle speed.
noise (Under load or no
Wo r n p a r t s o r d a m a g e d i n Remove transmission suction screen. Inspect
load)
transmission. for metal particles.
Repair as necessary.
Warped drive line between engine Inspect drive line.
and torque converter.
Low or no lube. Do converter-out and lube pressure test. Do
transmission pump flow test.
Foaming oil Incorrect type of oil. Change oil.
High oil level. Transmission overfilled or hydraulic pump seal
leaking.
Low oil level. Add oil.
Air leak on suction side of pump. Check oil pickup tube on side of transmission.
Oil ejected from dipstick Plugged breather. Inspect breather on top of transmission.
Replace.
Machine vibrates Aerated oil. Add oil.
Low engine speed. Check engine speed.
Fa i l e d u n i ve r s a l j o i n t s o n Check universal joints.
transmission dr ive shaft or
differential drive shafts.
Machine lacks power and Engine high idle speed set too Check high idle adjustment.
acceleration low.
Incorrect transmission oil. Change oil.
Aerated oil. Add oil.
Low transmission pressure. Do transmission system pressure test.
Warped transmission clutch. Do transmission clutch drag checks.
Torn transmission control valve Inspect gasket.
gasket.
Brake drag. Do brake drag check.
Failed torque converter. Do torque converter stall speed test.
Low engine power. Do engine power test.
Torque conver ter stall Aerated oil. Put clear hose on thermal bypass outlet port.
RPM too high Run machine to check for bubbles in oil.
Stuck open converter relief valve. Do converter-out pressure test.
Leakage in torque converter seal. Do converter-out pressure test.
Torque converter not Replace torque converter.
transferring power (Bent fins,
broken starter).
3-61
Problem Cause Remedy
Torque conver ter stall Low engine power. Do engine power test.
RPM too low
Mechanical malfunction. Remove and inspect torque converter.
Transmission pressure Low oil level. Add oil.
light comes ON when
Cold oil. Warm oil to specification.
shifting from forward to
reverse (all other gears Leak in reverse pack. Do transmission pressure, pump flow, and
OK) leakage check.
Transmission pressure Cold oil. Warm oil to specification.
light comes ON for each
No time delay in monitor. Do monitor check.
shift
Restriction in modulation orifice. Remove orifice and inspect for restriction and/or
plugging.
Stuck PPC valve. Remove and inspect.
Low transmission pressure circuit. Do transmission system pressure test.
3-62
2) DIFFERENTIAL / AXLE
Problem Cause Remedy
Differential low on oil External leakage. Inspect axle and differential for leaks.
Excessive differential Low oil level in differential. Check oil. Remove drain plug and inspect for
and/or axle noise metal particles in differential case.
Disassemble and determine cause.
Incorrect type of oil. Change oil
Dragging brakes. Do brake check.
Failed pinion bearing. Remove and inspect pinion.
Check to ensure pinion housing was indexed.
Incorrect gear mesh pattern Remove pinion gear housing and inspect ring
between ring and pinion gear. and pinion gear.
Failed differential pinion gears Remove differential housing drain plug and
and/or cross shafts. inspect for metal particles. Disassemble and
inspect.
Failed axle bearing. Do axle bearing adjustment check.
M e c h a n i c a l fa i l u r e i n a x l e Remove differential. Inspect, repair.
planetary.
Oil seeping from outer Excessive end play in axle. Do axle bearing adjustment check.
axle seal
Worn outer bearing and/or cup. Disassemble and inspect outer axle bearing,
cup, spacer, and seal. Replace, if necessary.
Overfilled differential. Check differential oil return system for
excessive internal restriction.
Axle overheats Low differential oil. Add oil.
Overfilled differential. See differential overfills with oil in this group.
Brake drag. See brakes drag in this group.
3) DRIVE LINE
Problem Cause Remedy
E x c e s s i v e d r i v e l i n e Yokes not in line on drive shafts. Inspect. Align drive shaft yokes.
vibration or noise
Worn front drive line support Inspect, repair.
bearing.
Bent drive shaft. Inspect all drive shafts. Replace.
Loose yoke retaining nuts (drive Inspect. Replace.
shafts wobble at high speed).
Rear axle oscillating support. Inspect, repair.
Lack of lubrication. Lubricate with proper grade of grease.
3-63
GROUP 3 TESTS AND ADJUSTMENTS
48 47 21
16
15
52,63 54
34
65 51 68
69 49
H J
K G
57 A F
60
B E
53 55
C D
58 56
VIEW X
7607APT14
3 - 64
2) DELIVERY RATES
Port Description Size
15 Connection to the oil cooler 1 5/6″-12UNF-2B
16 Connection from the oil cooler 1 5/6″-12UNF-2B
4) CONNECTIONS
Port Description Size
49 Plug connection on the hydraulic control unit -
68 Pilot pressure (option) J M16×1.5
69 System pressure (option) G M16×1.5
3-65
GROUP 4 DISASSEMBLY AND ASSEMBLY
1. CONTROL VALVE
1) DISASSEMBLY
(1) Illustration on the right shows the comple-
te control unit.
73073CV001
73073CV002
73073CV003
73073CV004
3-66
(5) Loosen socket head screws.
Separate cover from housing and cable
harness.
Box spanner 5873 042 002
73073CV005
73073CV006
73073CV007
73073CV008
3-67
(9) Separate housing from valve housing by
loosening the adjusting screws uniformly.
Adjusting screws 5870 204 036
73073CV009
73073CV010
73073CV011
3-68
2) ASSEMBLY
※ Check all components for damage and
renew if necessary.
Prior to the installation, check free travel of
all moving parts in the housing.
Spools can be exchanged individually.
Oil the components prior to the assembly.
Insert diaphragms with the concave side
showing upward until contact is obtained.
※ Installation position, see arrows.
73073CV015
73073CV016
73073CV017
3-69
73073CV019
73073CV020
73073CV022
3-70
(7) Install components according to figure (6).
Preload compression springs of the
follow-on slides and locate spool
provisionally by means of cylindrical pins
Ø5.0 mm (assembly aid), see arrows.
Install two adjusting screws.
Assemble gasket (arrow 1) and housing
cover, and position them uniformly against
shoulder, using adjusting screws.
※ Pay attention to the different housing 73073CV023
covers-install the recess Ø19 mm (arrow
2), facing the main pressure valve.
Now, fasten housing cover by means of
socket head screws.
·Torque limit : 0.56 kgf·m (4.06 lbf·ft)
Remove cylindrical pins (assembly aid)
again.
Adjusting screws 5870 204 036
Box spanner 5873 042 002
73073CV025
3-71
(10) Introduce female connector against
shoulder, with the groove facing the guide
nose of the cover.
Install gasket (arrow) and fasten cover by
means of socket head screws.
·Torque limit : 0.56 kgf·m (4.06 lbf·ft)
Box spanner 5873 042 002
73073CV026
73073CV027
73073CV028
73073CV029
3-72
(14) Mount intermediate plate, with the
screens showing upward.
73073CV030
73073CV031
73073CV032
73073CV033
3-73
2. POWERSHIFT TRANSMISSION
Fasten transmission of the assembly car.
Assembly car 5870 350 000
Strips 5870 350 063
Support 5870 350 090
75773TM050
1) DISASSEMBLY
(1) Separate hydraulic control unit and duct
plate from gearbox housing
① Loosen two socket head screws and
install adjusting screws.
Now, loosen remaining socket head
screws and separate valve housing from
duct plate.
Adjusting screws (M6) 5870 204 063
Box spanner 5873 042 002 75773TM051
75773TM052
75773TM053
3-74
(2) Converter
① Loosen hexagon head screws and
separate diaphragm from the converter.
75773TM060
75773TM061
75773TM062
75773TM063
3-75
(3) Hydraulic pump
① Loosen socket head screws.
75773TM064
75773TM065
75773TM067
3-76
(4) Converter back pressure valve
① Preload compression spring and remove
lock plate.
Remove released components.
75773TM068
75773TM069
75773TM076
3-77
③ Loosen hexagon nuts and remove both
covers (arrows).
Loosen screw connection (housing/
housing cover).
75773TM077
75773TM078
device.
Handle (6 pieces needed) 5870 260 010
Eye bolt (M20, 2EA) 0636 804 003
Eye bolt (M16, 1EA) 0636 804 001
Puller device 5870 000 017
Lifting chain 5870 281 047
3-78
⑥ Separate housing cover along with
clutches from the gearbox housing, using
lifting device.
75773TM081
75773TM082
75773TM083
75773TM084
3-79
⑩ Tilt housing cover 180。.
Illustration on the right shows the
arrangement of the single clutches and
the input in the housing cover.
AN Input
KV Clutch-Forward
KR Clutch-Reverse
K1 Clutch-1st speed
K2 Clutch-2nd speed
K3 Clutch-3rd speed
75773TM085
K4 Clutch-4th speed
75773TM086
75773TM087
75773TM088
3-80
⑭ Remove clutch K3.
75773TM089
75773TM090
75773TM092
3-81
18 Squeeze rectangular ring out (arrow)
and press ball bearing from the shaft.
75773TM093
75773TM095
75773TM096
75773TM097
3-82
④ Separate plate carrier from the shaft.
Three leg puller 5870 971 003
75773TM098
75773TM099
75773TM100
75773TM101
3-83
⑧ Remove both O-rings (arrows).
75773TM102
75773TM103
75773TM104
75773TM105
3-84
(7) Disassemble clutch K1, K2 and K3
※ The following figures show the disassem-
bly of clutch K3.
The disassembly of the clutches K1 and
K2 is similar.
75773TM110
75773TM111
75773TM112
3-85
④ Remove both needle bearings as well as
the axial bearing (complete).
75773TM113
75773TM114
75773TM115
75773TM116
3-86
(8) Disassemble clutch K4
① Squeeze rectangular ring out (arrow).
75773TM120
75773TM121
75773TM122
75773TM123
3-87
⑤ Preload cup-spring pack and squeeze
snap ring out.
Remove released components.
Remove piston.
Assembly aid 5870 345 008
75773TM124
75773TM125
75773TM126
3-88
(9) Disassemble drive shaft
① Squeeze rectangular ring out.
Pull off tapered roller bearing.
Remove opposite tapered roller bearing
accordingly.
Grab sleeve 5873 002 045
Basic set 5873 002 001
Basic set 5873 002 006
75773TM130
75773TM131
3-89
2) REASSEMBLY
(1) Install oil tubes
※ To ensure the correct installation of the oil
tubes, the use of the indicated special tool
is imperative.
75773TM140
75773TM142
3-90
④ Assemble both oil tubes (arrows) until
contact is obtained.
Equip screw plug with new O-ring and
install it.
·Torque limit : 14.3 kgf·m (103 lbf·ft)
75773TM143
75773TM144
75773TM146
3-91
(2) Reassemble clutch KV and KR
※ The following figure show the reassembly
of the clutch KV. The reassembly of the
clutch KR has to be carried out
accordingly.
Preassemble plate carrier
① Check function of the purge valve.
※ Ball must not stick, if necessary, clean
with compressed air.
75773TM150
75773TM151
75773TM152
75773TM153
3-92
Plate pack KV, KR
※ The plate arrangement respectively
stacking of clutch KV and KR is identical.
⑤ The following draft shows the installation
position of the components. 2.7
+0.2
mm
1 Plate carrier 5
3
2 Piston
3 Outer plate-one sided coated (1 piece) 6 2
4 Inner plates (10 pieces)
5 Outer plates-coated on both sides
7
(10 pieces)
1
6 Snap ring (optional s = 2.1~4.2 mm) 4
7 End shim
Effective number of friction surfaces = 20
※ Install outer plate 3 with the uncoated
side facing the piston.
Install on the end-shim side two outer 76043PT07
and inner plates each.
75773TM155
75773TM156
3-93
⑧ Press on end shim with about 100N (10
kg), apply dial indicator and set it at zero.
75773TM157
again.
※ Use oil SAE 10W-30/15W-40.
Magnetic stand 5870 200 055
Dial indicator 5870 200 057
75773TM159
3-94
⑪ Mount stud (arrow).
Wet screw-in thread with loctite (type
No.241).
·Torque limit (M10) : 1.7 kgf·m
(12.5 lbf·ft)
75773TM160
75773TM161
75773TM162
75773TM163
3-95
⑮ Heat inner diameter of plate carrier
(about 120˚C).
Hot air blower 220V 5870 221 500
Hot air blower 110V 5870 221 501
75773TM164
75773TM165
75773TM166
75773TM167
3-96
Press tapered roller bearing against
shoulder.
Install opposite tapered roller bearing
accordingly.
75773TM168
75773TM169
75773TM176
3-97
③ Assemble plate carrier until contact is
obtained.
Hot air blower 220V 5870 221 500
Hot air blower 110V 5870 221 501
75773TM177
75773TM178
75773TM179
75773TM180
3-98
⑦ Preload cup spring pack and fix it by
means of snap ring.
Assembly aid 5870 345 088
75773TM181
Plate pack K1
1 Plate carrier +0.2
2 Piston 2.4 mm
3 Outer plate-one side coated (1 piece)
5
4 Inner plates (9 pieces) 3
5 Outer plates-on both sides coated
2 6
(9 pieces)
6 Snap ring (optional s=2.1~4.2 mm)
7
7 End shim
Effective number of friction surfaces = 18 1 4
3-99
Adjust plate clearance
Plate clearance clutch K1 2.4+0.2 mm
Plate clearance clutch K2 and K3
1.8+0.2 mm
※ For the adjustment of the plate clearance
are snap rings with different thickness
available.
To ensure a faultless measuring result,
install the plates for the moment without
oil. 75773TM185
75773TM186
75773TM187
3-100
⑩ Now, push the end shim by means of
screw driver against snap ring until
contacts is obtained (upward) and read
plate clearance on the dial indicator.
※ In case of a deviation from the required
plate clearance, correct with correspond-
ing snap ring (s = 2.1~4.2 mm).
After the adjustment of the plate
clearance has been carried out, remove
the plate pack, oil plates and install it 75773TM188
again.
Use oil SAE 10W-30/15W-40.
Magnetic stand 5870 200 055
Dial indicator 5870 200 057
75773TM189
75773TM190
3-101
⑬ Introduce idler gear until all inner plates
are accommodated.
75773TM191
75773TM192
75773TM193
75773TM194
3-102
17 Squeeze rectangular ring in(Arrow) and
let it snap in.
Install opposite rectangular r ing
accordingly.
75773TM195
75773TM200
75773TM201
75773TM202
3-103
④ Check function of the purge valve.
※ Ball must not stick, if necessary clean
with compressed air.
Insert both O-ring (arrow) scrollfree into
the grooves of the piston and oil them.
75773TM203
75773TM204
75773TM205
75773TM206
3-104
Plate pack K4
※ The following draft shows the installation
position of the components. +0.2
1.2 mm
1 Plate carrier
2 Piston 5
3
3 Outer plate-one side coated (1 piece)
4 Inner plates (5 pieces) 6 2
5 Outer plates-coated on both sides
(5 pieces) 7
6 Snap ring (optional s = 2.1~4.2 mm) 4 1
7 End shim
Effective number of friction surfaces = 10
※ Install outer plate 3 with the uncoated
76043PT14
side facing the piston.
75773TM210
75773TM211
3-105
⑩ Press on the end shim with about 100N
(10 kg), apply dial indicator and set it at
zero.
75773TM212
75773TM214
3-106
⑬ Assemble both axial washers as well as
needle case.
※ Upper and lower axial washer have the
same thickness (55×78×1).
75773TM215
75773TM216
75773TM217
75773TM218
3-107
17Heat inner diameter of the plate carrier
(about 120˚C).
Assemble preassembled plate carrier
until all inner plates are accommodated.
※ Use safety gloves.
75773TM219
75773TM220
75773TM221
75773TM222
3-108
Squeeze rectangular ring in (arrow) and
let it snap in.
Install opposite rectangular ring.
75773TM223
75773TM225
75773TM226
75773TM227
3-109
④ Introduce turbine shaft until the snap ring
snaps into the groove of the drive shaft
turbine shaft is axially fixed.
75773TM228
75773TM229
75773TM230
75773TM231
3-110
③ Insert all bearing outer races into the
bearing bores of the housing.
Install O-ring (arrows).
※ At the use of already run bearings, pay
attention to the allocation of the bearing
outer races, see also note/page 3-81.
AN Input
KV Clutch-Forward
KR Clutch-Reverse
K1 Clutch-1st speed
K2 Clutch-2nd speed 75773TM232
K3 Clutch-3rd speed
K4 Clutch-4th speed
AB Output
75773TM233
75773TM234
3-111
(7) Install preassembled drive shaft and
clutches
① Insert all bearing outer races into the
bearing bores of the housing cover.
※ At the use of already run bearings, pay
attention to the allocation of the bearing
outer races, see also note/page 3-81.
AN Input
KV Clutch-Forward
KR Clutch-Reverse
K1 Clutch-1st speed
K2 Clutch-2nd speed
K3 Clutch-3rd speed
K4 Clutch-4th speed
AB Output 75773TM235
75773TM236
75773TM237
3-112
④ Install clutch K3.
75773TM238
75773TM239
75773TM240
75773TM241
3-113
⑧ Fix all clutches by means of handles.
Handle (6 pieces needed) 5870 260 010
75773TM242
75773TM243
75773TM245
3-114
⑫ Install both cylindrical pins centrally to
the housing face.
75773TM246
75773TM247
75773TM248
75773TM249
3-115
③ Fix pump shaft by means of circlip.
75773TM250
75773TM251
75773TM252
3-116
② Assemble output flange.
Insert O-ring (arrow) into the gap of drive
flange and shaft.
75773TM256
75773TM257
75773TM258
3-117
② Introduce components according to
figure (10) ①, preload and fix by means
of lock plate.
Equip plug(Arrow) with new O-ring and
install it.
·Torque limit (M14×1.5) : 2.5 kgf·m
(18.4 lbf·ft)
75773TM261
75773TM262
75773TM263
75773TM264
3-118
④ Insert O-ring (arrow) into the annular
groove and oil it.
75773TM265
75773TM266
75773TM267
75773TM268
3-119
⑧ Fasten oil feed housing by means of
socket head screws and hexagon head
screws (2 pieces).
·Torque limit
- Socket head screw : 2.3 kgf·m
(16.6 lbf·ft)
- Hexagon head screw : 4.7 kgf·m
(33.9 lbf·ft)
※ Pay attention to the position of the fixing
plate, see Arrow. 75773TM269
75773TM270
75773TM271
75773TM272
3-120
④ Introduce converter until contact is
obtained.
※ Pulse disk of the converter must be
positioned centrally to the bore of the
inductive transmitter, see Arrow.
Only in this way will be ensured that the
converter is perfectly introduced.
75773TM273
75773TM274
75773TM275
75773TM276
3-121
⑦ Fix hexagon head screws by means of
lock plate.
Driver 5870 057 010
Handle 5870 260 002
75773TM277
75773TM278
75773TM279
75773TM280
3-122
(14) Mount duct plate and hydraulic control
unit
① Install components according to the
following draft.
·Torque limit (M8) : 2.3 kgf·m
(17.0 lbf·ft)
5
※ Pay attention to the installation position 3 4
of the different gaskets, see draft.
2
1 Gasket 1
2 Duct plate
3 Gasket
4 Intermediate plate
5 Gasket
Adjusting screws 5870 204 063
76043PT21
Box spanne 5873 042 004
75773TM282
75773TM283
3-123
(15) Install plugs and oil level tube
① Equip both plugs (arrows) with new
O-rings and install them.
·Torque limit (M18×1.5) : 5.1 kgf·m
(36.9 lbf·ft)
·Torque limit (M26×1.5) : 8.2 kgf·m
(59.0 lbf·ft)
75773TM284
75773TM285
75773TM286
3-124
(16) Speed sensor and inductive transmitters
① The figures show the installation position
of the single inductive transmitters and
the speed sensor.
34 Speed sensor
n-Output and speedometer
21 Inductive transmitter
n-Turbine
47 Inductive transmitter
n-Central gear train 75773TM290
48 Inductive transmitter
n-Engine
75773TM291
75773TM292
3-125
3. FRONT AXLE
1) DISASSEMBLY
(1) Disassembly output and brake
① Fix axle to assembly truck.
Assembly truck 5870 350 000
Fixtures 5870 350 077
Clamping brackets 5870 350 075
Support 5870 350 125
※ Before clamping the axle fully turn in the 7609AAX001
7609AAX002
7609AAX003
3-126
③ Remove the breather valve (see arrow).
※ To avoid any damage, the breather valve
must be removed when separating the
output.
7609AAX004
7609AAX006
7609AAX007
3-127
⑦ Use a lever to remove the cover from the
output shaft.
7609AAX008
7609AAX009
7609AAX010
3-128
⑪ Pull the tapered roller bearing from the
planetary carrier.
Rapid grip 5873 014 016
Basic tool 5873 004 001
7609AAX012
7609AAX013
7609AAX014
7609AAX015
3-129
⑮ Lift the disk package out of the brake
housing.
7609AAX016
7609AAX017
7609AAX018
7609AAX019
3-130
1 Brake housing
2 Guide ring
3 Back-up ring
4 Grooved ring
5 Grooved ring
6 Back-up ring
7 Slide ring seal
8 Output shaft
7609AAX020
7609AAX021
7609AAX022
3-131
21 Use a lever to remove the slide ring seal
from the output shaft.
Resetting device 5870 400 001
7609AAX023
7609AAX024
3-132
(2) Disassembly axle housing
① Secure axle housing with the lifting
device and loosen the hexagon screws.
Then separate the axle housing from the
axle drive housing.
※ Pay attention to releasing differential.
7609AAX025
7609AAX026
7609AAX027
7609AAX028
3-133
(3) Disassembly input
① Use the lifting device to lift the differential
out of the axle drive housing.
Load carrying fixture 5870 281 083
※ Disassembly of the differential is
described as of page 3-137.
7609AAX029
7609AAX030
7609AAX031
7609AAX032
3-134
④ Heat slotted nut by means of hot air
blower.
※ Slotted nut is secured with loctite (type
No. : 262).
7609AAX033
7609AAX034
7609AAX035
7609AAX036
3-135
⑧ Remove spacer ring and pull the tapered
roller bearing from the input pinion.
Gripping device AA00 684 425
Basic tool 5873 002 000
7609AAX037
7609AAX038
3-136
(4) Disassembly differentials
Disassembly hydraulic lock differential
(option)
① Remove axial roller cage (arrow).
7609AAX039
7609AAX041
7609AAX042
3-137
⑤ Remove single parts.
2 3
1
1 Pressure piece 4
2 Cage
5
3 Lever (12EA)
4 Disk carrier
5 Disk package
7609AAX043
7609AAX044
7609AAX045
7609AAX046
3-138
⑨ Force out both differential axles (short)
and remove the releasing spider gears
with thrust washers from the differential
housing.
7609AAX047
7609AAX048
7609AAX049
7609AAX050
3-139
Disassembly conventional differential
(standard)
① Pull both tapered roller bearings from the
differential.
Grab sleeve 5873 012 016
Basic tool 5873 002 001
7609AAX051
7609AAX052
7609AAX053
7609AAX054
3-140
⑤ Force out both slotted pins.
7609AAX055
7609AAX056
7609AAX057
7609AAX058
3-141
⑨ Press crown wheel from the differential
carrier.
7609AAX059
7609AAX060
7609AAX061
7609AAX062
3-142
④ Remove spider shafts and axle bevel
gears (see figure) out of the differential
housing.
7609AAX063
7609AAX064
7609AAX065
7609AAX066
3-143
(5) Reassembly differentials
Reassembly hydraulic lock differential
(option)
① Mount two locating pins and press the
heated crown wheel onto the differential
housing until contact is obtained.
Locating pins 5870 204 040
7609AAX067
7609AAX068
7609AAX069
7609AAX070
3-144
⑤ Insert spider gears with thrust washers
into the differential housing and fix them
with the two spider shafts (short).
1 2
※ Thrust washers must be positioned with
the tabs (see arrow 1) being located in
the recesses of the differential housing.
※ Pay attention to radial installation position
of the spider shafts (fixing holes, arrow
7609AAX071
2).
7609AAX072
7609AAX073
7609AAX074
3-145
⑨ Mount two adjusting screws and insert
the housing cover until contact with the
differential housing is obtained.
Locating pins 5870 204 040
Preload the differential by means of the
press and bolt with new locking screws.
7609AAX076
7609AAX077
9 Snap ring
※ For the number of disks and the disk
arrangement please refer to the relating
parts manual.
3-146
⑬ Preload disk package with an axial force
of F = 50+30 kN.
Then check the setting dimension "A" =
1.05±0.1 mm from the collar of the
differential cover to the plane face of the
outer disk (see also below sketch).
Pressure piece 5870 100 069
Load cell 5870 700 004
※ Any deviation from the specified setting 7609AAX079
7609AAX081
7609AAX082
3-147
17 Preload the differential by means of the
press and the pressure piece.
Then finally tighten the housing cover
with hexagon screws.
·Tightening torque (M14/10.9) :
18.9 kgf·m (136 lbf·ft)
Pressure piece 5870 100 075
7609AAX083
7609AAX084
7609AAX085
3-148
Reassembly conventional differential
(standard)
① Mount two locating pins and press the
heated crown wheel onto the differential
housing until contact is obtained.
Locating pins 5870 204 040
7609AAX086
7609AAX087
7609AAX088
7609AAX089
3-149
⑤ Insert spider gears with thrust washers
into the differential housing and fix them
with the two spider shafts (short).
1 2
※ Thrust washers must be positioned with
the tabs (see arrow 1) being located in
the recesses of the differential housing.
※ Pay attention to radial installation position
of the spider shafts (fixing holes, arrow
7609AAX090
2).
7609AAX091
7609AAX092
7609AAX093
3-150
⑨ Mount two adjusting screws and insert
the housing cover until contact with the
differential housing is obtained.
Locating pins 5870 204 040
Preload the differential by means of the
press and bolt with new locking screws.
7609AAX095
7609AAX096
3-151
Reassembly limited slip differential
(option)
① Mount two locating pins and press the
heated crown wheel onto the differential
housing until contact is obtained.
Locating pins 5870 204 040
7609AAX097
7609AAX098
7609AAX100
3-152
⑤ Insert the axle bevel gear until contact is
obtained and install the inner disks with
the teeth.
7609AAX101
7609AAX102
7609AAX103
7609AAX104
3-153
⑨ Mount outer and inner disks in
alternating order, starting with an inner
disk.
The installation clearance of the internal
parts is corrected by mounting outer
disks with different thicknesses.
The difference in thickness between
the left and the right disk package
7609AAX105
must only be 0.1 mm at maximum.
7609AAX106
3-154
⑫ Fix the thrust washers into the housing
cover by means of grease.
7609AAX108
7609AAX110
3-155
(6) Reassembly input
※ If crown wheel or input pinion are
damaged, both parts must be jointly
replaced.
In case of a new installation of a
complete bevel gear set pay attention to
an identical mating number of input
pinion and crown wheel.
7609AAX111
7609AAX112
3-156
③ Determine dimension III (bearing width).
Dimension III e.g. . . . . . . . . . . . . 39.10 mm
CALCULATION EXAMPLE “A„ :
Dimension I . . . . . . . . . . . . . . . 221.10 mm
Dimension II . . . . . . . . . . . . . . - 181.00 mm
Dimension III . . . . . . . . . . . . . - 39.10 mm
Difference = shim s = 1.00 mm
7609AAX113
7609AAX114
7609AAX115
7609AAX116
3-157
⑦ Heat the tapered roller bearing and insert
it into the input pinion until contact is
obtained.
7609AAX117
7609AAX119
7609AAX120
3-158
⑪ Insert input flange and fix it by means of
disk and slotted nut.
·Tightening torque :
122 kgf·m (885 lbf·ft)
Slotted nut wrench 5870 401 139
Clamping device 5870 240 002
※ Preliminarily mount slotted nut without
loctite. 7609AAX121
7609AAX123
7609AAX124
3-159
Determination of shims for setting of
b e a r i n g r o l l i n g t o r q u e ( d i f fe r e n t i a l
housing) and backlash (bevel gear set)
※ Determine the required shims on the
basis of the read value (deviation/test
dimension) and the corresponding
specifications of the table below :
(KRS – SET – RIGHT)
(KRS = bevel gear set) 7609AAX125
3-160
16 Insert the determined shim (e.g. s =
0.9 mm) into the hole of the axle housing
and adjust the bearing outer ring (see
arrow) until contact is obtained.
7609AAX127
7609AAX128
7609AAX129
3-161
Leakage test of lock
20 Pressurize the lock (p = 1 bar), close
shut-off valve and remove air line.
No noticeable pressure loss is allowed
to occur within 10 sec.
※ This operation is only necessary for
hydraulic lock diferential (option).
7609AAX131
7609AAX133
3-162
Reassembly of shaft seal (figure
AX134~136)
23 Loosen the slotted nut and pull the input
flange from the input pinion.
Slotted nut wrench 5870 401 139
Clamping device 5870 240 002
7609AAX134
3-163
(7) Reassembly axle housing
① Grease O-ring (see arrow) and insert it
into the axle housing.
7609AAX137
③ Mount fitting.
·Tightening torque :
3.67 kgf·m (26.6 lbf·ft)
7609AAX139
7609AAX140
3-164
⑤ M o u n t b ra ke t u b e w i t h t h r e a d e d
connection and hexagon nut (see arrow).
·Tightening torque :
10.2 kgf·m (73.8 lbf·ft)
7609AAX141
7609AAX142
3-165
(8) Reassembly output and brake
① Pull in wheel stud into the output shaft
until contact is obtained.
Wheel stud puller-basic tool
5870 610 001
Insert (M22×1.5) 5870 610 002
Special tool may only be used for repair
solution when exchanging individual 7609AAX143
wheel studs with mounted output shaft.
When using a new output shaft, mount
the wheel studs with the press.
7609AAX144
3-166
④ Insert both bearing outer rings (see
arrows) into the brake housing until
contact is obtained.
7609AAX147
7609AAX149
3-167
1 Brake housing
2 Guide ring
3 Back-up ring
4 Grooved ring
5 Grooved ring
6 Back-up ring
7 Slide ring seal
8 Output shaft
7609AAX151
7609AAX152
7609AAX153
3-168
⑩ Insert disk and cup spring with the
convex side showing upwards into the
piston.
7609AAX154
7609AAX155
7609AAX156
7609AAX157
3-169
⑭ Press stop bolt into the planetary carrier
until contact is obtained.
1 Stop bolt
2 Planetary carrier
7609AAX158
7609AAX161
3-170
18 Wet front face (contact face bearing
inner ring, arrow 1) and profile (teeth,
arrow 2) in the output shaft with anti-
corrosive agent.
7609AAX162
7609AAX165
3-171
1 Planetary carrier
2 Output shaft
X Gap width
7609AAX166
7609AAX169
3-172
25 Insert the cover into the output shaft until
contact is obtained.
7609AAX170
7609AAX172
7609AAX173
3-173
29 Measure dimension II, from the front face
of the sun gear shaft to the mounting
surface of the axle housing.
Dimension II e.g. . . . . . . . . . . . . 17.15 mm
Straightedge 5870 200 022
7609AAX174
CALCULATION EXAMPLE :
Dimension I . . . . . . . . . . . . . . . 19.75 mm
Dimension II . . . . . . . . . . . . . . - 17.15 mm
Difference . . . . . . . . . . . . . . . . . 2.60 mm
Required axial play e.g. . . . . - 1.00 mm
Difference = shim e.g. s = 1.60 mm
7609AAX175
7609AAX176
3-174
32 Fix O-ring (see arrow) with grease into
the countersink of the brake housing.
7609AAX177
7609AAX178
7609AAX180
3-175
Check brake hydraulics for leakages
※ Before starting the test, completely breathe
the brake hydraulics.
Then pressurize the brake temporarily (5EA)
with p = 100 bar max.
High-pressure test :
Build up test pressure p = 100-10 bar max
and close connection to HP pump via shut- 7609AAX181
off valve.
A pressure drop of max 2 % (2 bar) is
permissible during a 5-minute testing time.
Low-pressure test :
Reduce test pressure p = 5 bar and close
shut-off valve.
No pressure drop is allowed during a
5-minute testing time.
Test media :
Engine oil SAE 10W
HP pump 5870 287 007
Clutch 0501 207 939
Reduction (M18×1.5) 5870 950 161
Oil collector bottle 5870 286 072
C h e ck o p e ra b i l i t y o f hy d ra u l i c l o ck
differential (opt)
Build up pressure p = 20 bar max and close
connection to HP pump via shut-off valve.
Lock on :
When rotating the input flange, both outputs
must have the same direction of rotation.
Lock off :
7609AAX182
When rotating the input flange, one side has
no movement or has the opposite direction of
rotation.
Prior to putting the axle into operation, fill it
with oil according to the related lubrication
and maintenance instructions.
3-176
4. REAR AXLE
1) DISASSEMBLY - OUTPUT/BRAKE 4
5
1 Input 2 3 4
2 Output
3 Brake
1 3 2
4 Axle housing
5 Axle drive housing
7577AAXR001
7577AAXR002
7577AAXR003
7577AAXR004
3-177
(1) Disassembly output assy/brake :
For any replacement of components you
can remove the output assy (with brake)
as one unit.
- In this context refer to work steps on
page 3-178~186.
- Figure 7577AAXR007~009 and
assembly steps on page 3-192~196.
Please consider, however, that multi discs
of the brake must be replaced on both 7577AAXR005
outputs each.
(3) Output/brake :
① Disassemble brake tube.
7577AAXR007
3-178
③ Remove stub shaft and sun gear shaft.
※ Pay attention to shim (placed in sun gear
shaft) and mark allocation of shim to sun
gear shaft and output side-assembly aid.
※ In certain cases the stub shaft/sun gear
shaft could get stuck in the axle housing
(gearing of axle bevel gear/differential).
7577AAXR009
7577AAXR010
7577AAXR011
7577AAXR012
3-179
⑦ Lift compl. planetary carrier out of brake
housing.
※ Special tool
Inner extractor 5870 300 019
Eye nut 5870 204 073
7577AAXR013
7577AAXR014
7577AAXR015
3-180
⑩ Pull bearing inner ring off the planetary
carrier.
※ Special tool
Grab sleeve 5870 003 033
Basic tool 5870 003 001
7577AAXR016
7577AAXR017
7577AAXR018
7577AAXR019
3-181
⑭ Lift piston off with lever.
※ Special tool
Adjusting device 5870 400
001
7577AAXR020
7577AAXR021
To the sketch :
1 Brake housing
2 Guide ring 1
3 Support ring 2
4 Grooved ring 3
5 Grooved ring 4
5
6 Support ring
6
7577AAXR022
3-182
16 Lift brake housing off the output shaft by
means of lifting device.
※ Special tool
Lifting chain 5870 281 047
Eyebolts 5870 204 071
7577AAXR023
7577AAXR024
7577AAXR025
3-183
19 Pull bearing inner ring from output shaft.
※ Special tool
Rapid grip 5873 014 016
Basic tool 5873 004 001
7577AAXR026
7577AAXR027
3-184
2) REASSEMBLY - OUTPUT/BRAKE 3
1
1 Planetary carrier
2 Brake housing
3 Disc package 4 2
4 Piston 4
5 Combi seal ring
6 Output shaft
※ Special tool 6
5
Assembly truck 5870 350 000
7577AAXR028
Fixture 5870 350 112
1 Brake housing
2 Output shaft
3 Shaft seal (part I) 1
combi seal ring
4 Wear sleeve (part II)
3
X = installation dimension/shaft seal Detail Z :
4.1 + 0.2 mm 3
Y = installation dimen./wear sleeve
2.6 + 0.2 mm
4
2
4
7577AAXR031
3-185
② Apply sealing agent (Loctite no. 574) on
contact faces of wear sleeve/output shaft
and mount wear sleeve (part I/combi
seal ring) considering installation
dimension Y - see detailed sketch figure
7577AAXR031.
※ Special tool
Pressing device 5870 506 172
7577AAXR032
7577AAXR033
7577AAXR034
7577AAXR035
3-186
④ Position preassembled brake housing on
the output shaft.
※ Special tool
Lifting chain 5870 281 047
Eyebolts 5870 204 071
7577AAXR036
1 Brake housing
1
2 Guide ring
3 Support ring
4 Grooved ring 2
5 Grooved ring 3
6 Support ring 4
5
6
7577AAXR038
3-187
⑥ Flush - mount slotted pins (for installation
position refer to arrow) into the piston if
not disassembled, adjust adequately
(flush-fitting).
7577AAXR039
7577AAXR040
7577AAXR042
3-188
⑩ Mount heated bearing inner ring until
contact.
※ Adjust bearing inner ring after cooling
down.
7577AAXR043
1
7577AAXR044
※ Special tool
Lifting chain 5870 281 047
Lifting device 5870 281 082
7577AAXR045
7577AAXR046
3-189
⑭ Evenly tighten locking screws crosswise
- while rotating the brake housing in both
directions several times (roller setting).
·Tightening torque (M18/12.9) :
51 kgf·m (369 lbf·ft)
7577AAXR047
7577AAXR048
7577AAXR049
7577AAXR050
3-190
(3) Brake
4
1 Outer disc s = 2.0 mm
2 Outer disc s = 4.0 mm
1
3 Inner disc (lined disc)
4 End plate
※ Possible other versions could have a 3
2
deviating equipment (number and
arrangement of single discs), the
illustration in the relating spare parts list
fo r m s t h e b a s i s fo r t h e r e q u i r e d 1
equipment. 7577AAXR051
7577AAXR052
3-191
Only for assembly of new parts :
Install cylindrical roller bearing into 3
planetary gear by pressing roller bearing
into planetar y gear by means of
assembly sleeve (arrow) until snap ring 2
engages into annular groove of planetary
gear. 1
1 Planetary gear
2 Roller bearing (with bearing inner ring
7577AAXR054
/cylindical rollers/axial discs and snap
ring)
3 Assembly sleeve
7577AAXR056
3-192
① Determine dimension I from mounting
face (brake housing/axle housing) to stop
pin.
Dimension I e. g . . . . . . . . . . . 21.25 mm
※ Special tool
Digital-depth gauge 5870 200 072
Gauge blocks 5870 200 066
Straightedge 5870 200 022
7577AAXR059
7577AAXR060
- 1.25mm
Result = shim required e.g . . . . ........
s = 1.00mm
7577AAXR062
3-193
(5) Reassemble output assy
① Fix disc package by means of locating
screw - assembly aid.
※ Special tool
Locating screw 5870 204 078
7577AAXR063
7577AAXR064
7577AAXR065
7577AAXR066
3-194
⑤ Connect output with axle housing evenly
by means of hex screws.
·Tightening torque (M18x1.5/10.9) :
39.8 kgf·m (288 lbf·ft)
7577AAXR067
·Tightening torque : 1
Screw nut (2) : 10.2 kgf·m (73.8 lbf·ft)
Cylindrical screw (3) (M8/8.8) :
2. 3 kgf·m (17.0 lbf·ft)
7577AAXR069
3-195
(6) Make leakage test on brake hydraulics
Prior to starting the test, completely
breathe brake hydraulics.
High-pressure test :
Build up testing pressure p = 100-10 bar
max and close connection to HP pump by
means of a shutoff valve. A pressure drop
by max 3% (3 bar) is permissible during a
5 minute test duration.
7577AAXR070
Low-pressure test :
Reduce testing pressure to p = 5 bar and
close shut-off valve again.
No pressure drop is permitted during a 5
minute test duration!
※ Special tool
HP-pump 5870 287 007
Straight screw-in connection
0637 842 518
Measuring fitting (M18x1.5) 5870 950 139
Oil collector bottle 5870 286 072
3-196
3) DISASSEMBLY - DIFFERENTIAL/INPUT
(1) Differential
① Mount axle on assembly truck.
※ Special tool
Assembly truck 5870 350 000
Supporting bracket (2EA) 5870 350 106
7577AAXR002
※ Special tool
Lifting chain 5870 281 047
Eyebolts 5870 204 071
3-197
(2) Input :
For axle version with pivot bearing only
(figure 7577AAXR073) :
① Loosen bolted connection and pull off
bearing flange.
7577AAXR073
7577AAXR074
7577AAXR075
7577AAXR076
3-198
⑤ Lift shaft seal off.
※ Special tool
Pry bar 5870 345 071
7577AAXR077
※ Special tool
Press-off tool 5870 280 044
7577AAXR078
7577AAXR079
7577AAXR080
3-199
⑨ Pull-off outside bearing outer ring.
※ Special tool
Internal extractor 5870 300 019
Counter support 5870 300 020
7577AAXR081
7577AAXR082
3-200
4) REASSEMBLY
EASSEMBLY - INPUT / DIFFERENTIAL
14 2 13
(1) Input
1 Axle drive housing 1 3
2 Input pinion
3 Tapered roller bearing
4
4 Shim for contact pattern (bevel gear set)
5
5 Spacer ring (bearing roll.torque/pinion
bearing) 12 6
6 Tapered roller bearing 10 8 7
7 Shaft seal 11 9
8 Protection plate
9 Input flange
7577AAXR083
10 Disc
11 Hex nut
12 Bearing flange (only for axle version with pivot bearing)
13 Axle housing/part I
14 Axle housing/part II (crown-wheel side)
※Depending on the version - crown wheel and bevel pinion may be mounted as a bevel gear set
(for production reasons, crown wheel and pinion are paired and show an identical pairing number
- see figure 7577AAXR086) or as single parts - the respective version has to be taken from the
specification of the corresponding spare parts list.
If a bevel gear set is specified, the crown wheel must only be replaced together with the pinion.
7577AAXR084
3-201
Determine shim for pinion position
required to obtain an optimum contact
pattern on the bevel gear set (crown
wheel/pinion) :
② We recommend to reinstall the shim
found during disassembly (e.g. S = 1.20
mm see disassembly instructions, page
3-200, figure 7577AAXR082.) into the
inner bearing hole/pinion bearing.
7577AAXR085
※ The contact pattern required on the bevel gear set, however, is decisive. If this is not achieved -
see contact pattern check on page 3-209, correct the pinion position with a corresponding shim.
※ As an alternative, a basic setting of the required pinion position can be made, e.g. when
assembling a new part - as shown below (figure 7577AAXR086 ~ 088).
7577AAXR086
3-202
⑤ Determine dimension III bearing width,
ensure here that the rollers are located
without any play (rotate bearing inner
ring in both directions several times -
roller setting).
Since the installed roller bearing is
subject to a pre-load in installation
position, deduct an experience value of
-0.05 mm.
Dimension III = e.g. . . . . . . . . . . . . . .
33.67 mm - 0.05 mm = 33.62 mm
CALCULATION EXAMPLE e.g. :
Dimension I . . . . . . . . . . . . . 182.81 mm
Dimension II + III (148.00 + 33.62) . . . . . 7577AAXR088
- 181.62 mm
Result . . . . . . . . . . . . . . . . . . = 1.19 mm
Required shim S = 1.20 mm
⑥ Insert determined shim into the hole of
the axle drive housing - see figure
7577AAXR085.
※ Special tool
Digital-depth gauge 5870 200 072
Gauge blocks 5870 200 066
⑦ Undercool bearing outer ring (see arrow)
and bring it into contact position in the
inner bearing hole/pinion bearing by
means of the fixture.
※ Special tool
Assembly fixture 5870 345
049
7577AAXR089
7577AAXR090
3-203
⑨ Mount heated bearing inner ring until
contact position and adjust after cooling-
down.
7577AAXR091
7577AAXR092
3-204
⑫ Mount flange, fix with disc and hex nut.
※ While tightening - rotate pinion in both
directions several times (roller setting).
·Tightening torque (M36×1.5) :
71.4 kgf·m (516 lbf·ft)
※ Special tool
Clamping fork 5870 240 025
7577AAXR093
※ Special tool
Torque wrench 5870 203 031
Reducing adapter ¼" to ½"
5870 656 056
Reducing adapter ½" to ¾"
5870 656 057
3-205
Contact pattern check of bevel gear
set
⑭ Cover some tooth flanks of crown wheel
with marking ink (contact pattern check).
7577AAXR095
7577AAXR096
7577AAXR097
7577AAXR098
3-206
18 Roll input pinion over crown wheel in
both directions (coast - drive flank
meshing - contact pattern).
※ Special tool
Clamping fork 5870 240 025
7577AAXR099
19 Disassemble differential.
Compare contact pattern to examples –
page 3-209.
※ If contact pattern differs considerably,
use a suitable shim for correction (see
figure 7577AAXR085, page 3-202).
7577AAXR100
20 If disassembled :
Insert shim(s) (2) into sun gear shaft (1)
and mount stub shaft (3).
※ If position was not allocated, as specified 1
7577AAXR102
3-207
22 Remount differential - by mounting stub
shaft into gearing of axle bevel gear
(differential).
※ Special tool
Lifting bracket 5870 281 033
7577AAXR103
7577AAXR104
7577AAXR098
3-208
※ BACKLASH
ACKLASH CHECK
- Applied the paint (or red lead) on the surface of several bevel gear teeth.
- Turn the pinioin gear and check the contact pattern.
Correct pattern
WTHAX16 WTHAX17
※ ADJUSTMENT
DJUSTMENT
Incorrect pattern : high contact
WTHAX18 WTHAX19
(-)
WTHAX20
3-209
Incorrect pattern, low contact
WTHAX21 WTHAX22
(+)
WTHAX23
3-210
SECTION 4 BRAKE SYSTEM
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 the cut-off valve for service brake circuit and
park brake circuits. It flows to three accumulator. The accumulator has a gas precharge and an
inlet check valve to maintain a pressurized volume of oil for reserve brake applications.
Oil through the accumulator flows to the brake valves. The brake valve is a closed center design,
dual circuit operated by a pedal.
The front and rear brakes will operate simultaneously with only one brake pedal depressed.
The differential contains annular brake piston and double sided disk.
Brake pump flow also goes to the parking brake solenoid valve in cut-off valve.
The brake system contains the following components:
·Brake pump
·Parking brake solenoid valve in cut-off valve
·Cut-off valve
·Brake valve
·Accumulators
·Pressure switches
4-1
FULL POWER HYDRAULIC BRAKE
SYSTEM
ADVANTAGES - The full power hydraulic Response time
brake system has several advantages over Full power brake actuation VS
Air/Hydraulic brake actuation
traditional brake actuation systems. These
systems are capable of supplying fluid to a 1000
range of very small and large volume
service brakes with actuation that is faster 900
than air brake systems. Figure represents 800
a time comparison between a typical air/ Brake pressure
700 (Full power)
Brake torque(lb·in)
hydraulic and full power hydraulic brake
actuation system. 600
Brake pressure
Full power systems can supply significantly 500 (Air/hydraulic)
higher brake pressures with relatively low Brake torque
400
reactive pedal forces. The reactive pedal (Air/hydraulic)
force felt by the operator will be proportional 300
Brake torque
to the brake line pressure being generated. 200 (Full power)
This is referred to as brake pressure
modulation. 100
Another key design feature of full power
0 1 2 3 4
systems is the ability to control maximum
brake line pressure. In addition, because Time(seconds)
these systems operate with hydraulic oil,
filtration can be utilized to provide long
component life and low maintenance
operation.
Because these systems are closed center,
by using a properly sized accumulator,
emergency power-off braking that is
identical to power-on braking can be
achieved. These systems can be either
dedicated, where the brake system pump
supplies only the demands of the brake
system or non-dedicated, where the pump
supplies the demands of the brake system
as well as some secondary down stream
hydraulic device.
Another important note is that all seals
within these system must be compatible
with the fluid medium being used.
4-2
2. HYDRAULIC CIRCUIT
FRONT 39 REAR
18 PS
T1 P1 T2 P2
40
T/M
17 17
16 7 B1 A1 B2 A2
A3
19
PS T1
PS
PS1
PS
19
T
Parking brake
P
Return line MCV
solenoid
20
Steering system RCV lever
Fan drive moter
2
23
Return line
24 Return line
26 21
25
7579S4BS01
4-3
1) SERVICE BRAKE RELEASED
FRONT
39 REAR
18 PS
40 T1 P1 T2 P2
T/M
17 17
16 7 B1 A1 B2 A2
A3
19
PS T1
PS
PS1
PS
19
P T Return line MCV
20
Steering system RCV lever
Fan drive moter
2 1
23
Return line
24 Return line
26 21
25
7579S4BS02
When the pedal of brake valve (8) is released, the operating force is eliminated by the force of the
spring, and the spool is returned.
When the spool removes up, the drain port is opened and the hydraulic oil in the piston of axles
return to the tank (24).
Therefore, the service brake is kept released.
4-4
2) SERVICE BRAKE OPERATED
FRONT 39 REAR
18 PS
BL1 BR1 BL2 BR2
8
T1 P1 T2 P2
40
T/M
17 17
16 7 B1 A1 B2 A2
A3
19
PS T1
PS
PS1
PS
19
P T Return line MCV
20
Steering system RCV lever
Fan drive moter
2 1
23
Return line
24 Return line
26 21
25
7579S4BS03
When the pedal of brake valve (8) is depressed, the operating force overcomes the force of the
spring, and is transmitted to the spool. When the spool moves down, the inlet port is opened, and
at the same time the hydraulic oil controlled the pressure level by the cut-off valve (7) enters the
piston in the front and rear axles. Therefore, the service brake is applied.
4-5
3) PARKING BRAKE RELEASED
FRONT 39 REAR
18 PS
T1 P1 T2 P2
40
T/M
B
17 17 A
P
16 7 B1 A1 B2 A2
Parking brake switch
A3
19
PS
PS
T1
PS1
PS
19
Parking brake
P T Return line MCV
solenoid
20
Steering system RCV lever
Fan drive moter
2 1
23
Return line
24 Return line
26 21
25
7579S4BS04
When the parking brake switch is pressed A position, the solenoid valve is energized and the
hydraulic oil controlled the pressure level by the cut-off valve enters the parking brake. It overcomes
the force of the spring and pushes the piston rod. This releases the brake.
Therefore, the hydraulic oil pressure is applied to the parking brake piston through the solenoid
valve and the parking brake is kept released.
4-6
4) PARKING BRAKE OPERATED
FRONT 39 REAR
18 PS
T1 P1 T2 P2
40
T/M
B
17 17 A
P
16 7 B1 A1 B2 A2
Parking brake switch
A3
19
PS T1
PS
PS1
PS
19
Parking brake
P T Return line MCV
solenoid
20
Steering system RCV lever
Fan drive moter
2 1
23
Return line
24 Return line
26 21
25
7579S4BS05
When the parking brake switch is pressed B position, the solenoid valve is deenergized and the
valve open the drain port.
At the same time, the hydraulic oil in the parking brake return to the tank through the solenoid
valve. When the piston rod is returned by the force of the spring, the parking brake is applied.
4-7
3. BRAKE PUMP (+FAN PUMP)
1) STRUCTURE
5
9
12
13
14
11
1
Brake pump
11
14
13
12
18
19 7
20
2 17
10 18
17
18 6
8 15
16
23
22 18
12
13
14
11
3
11
14
13
Fan pump 12
7609S4BS06
(770-3ATM) 4-9
4-9
(2) Internal oil leakage
Oil leaks from a place under higher
pressure to a place under lower pressure,
provided that a gap or a clearance exists
in between.
In the gear pump, small clearances are
provided between the gear and the case
and between the gear and the side plate
to allow the oil to leak out and to serve as
a lubricant so that the pump will be rge
protected from seizure and binding. ischa
D
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
n
of the pump is reduced by an amount uctio
S
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 par ts, the lower oil viscosity
resulting from increases in the oil
temperature, and the initial use of low
(770-3ATM) 4-10
viscosity oil.
4-10
(3) Forces acting on the gear
The gear, whose outer surface is
subjected to oil pressure, receives forces
jointing towards its center.
Due to the action of the delivery pressure,
the oil pressure in higher on the delivery
side of the pump, and due to suction
pressure, is lower on the suction side. In
the intermediate section, the pressure will
gradually lower as the position moves
from the delivery side to the suction side. Drive gear
This phenomenon is shown in the
drawing at right.
In addition, the gears in mesh will receive Suction Discharge
interacting forces. side side
These forces pushing the gears toward
the suction side are received by the
bearings. Since the gears are pressed Driven gear
toward the suction side by these forces,
the radial clearance becomes smaller on
the suction side in the case. In some
pumps, the clearance may become zero, Pressure distribution
thus allowing the gear teeth and the case
to come into light contact.
For this reason, an excessive increase in
the delivery pressure must be avoided,
since it will produce a large force which
will act on the gears, placing an overload
on the bearings, and resulting in a
shortened service life of the bearing or
(770-3ATM) 4-11
interference of the gear with the case.
4-11
4. BRAKE VALVE
1) STRUCTURE
17-2
18
17-3,17-4
17-1,17
19
23 22
24
21
2
33
20 8,31,32
9
25 29
25
16 14
15 7
5 13
30
12 6
10
26
11
3
1 4
7607B4BS07
4-12
2) OPERATION
T1 P1 T2 P2
Hydraulic circuit
P2
BR2
7607B4BS08
4-13
(1) Purpose
The purpose of the brake valve is to sensitively increase and decrease the braking pressure
when the brake pedal is actuated.
(2)
2) Ready position
When the braking system is ready for operation, its accumulator pressure acts directly on ports
(P1, P2) of the brake valve. A connection is established between ports (BR1, BR2) and ports (T1,
T2) so that the wheel brakes ports (BR1, BR2) are pressureless via the returns ports (T1, T2).
(3) Partial braking
(3
When the brake valve is actuated, an amount of hydraulic pressure is output as a ratio of the foot
force applied.
The spring assembly (8) beneath pedal plate (16) is designed in such a way that the braking
pressure changes depending on the angle. In the lower braking pressure range, the machine can
be slowed sensitively.
When the braking process is commenced, the upper spool is mechanically actuated via spring
assembly (8), and the lower spool is actuated hydraulically by spool. As spools (3) move
downward, they will first close returns (T1, T2) via the control edges, thus establishing a
connection between accumulator ports (P1, P2) and ports (BR1, BR2) for the wheel brake
cylinders. The foot force applied now determines the output braking pressure. The control spools
(3) are held in the control position by the force applied (spring assembly above the spools and the
hydraulic pressure below the spool (balance of forces).
After output of the braking pressure, spools (3) are in a partial braking position, causing ports (P1,
P2) and ports (T1, T2) to close and holding the pressure in ports (BR1, BR2).
(4) Full braking position
(4
When pedal is fully actuated, end position of the brakes is reached and a connection established
between accumulator ports (P1, P2) and brake cylinder ports (BR1, BR2). Returns (T1, T2) are
closed at this point.
When the braking process is ended, a connection is once again established between brake
cylinder ports (BR1, BR2) and return ports (T1, T2), closing accumulator ports (P1, P2).
The arrangement of spools in the valve ensures that even if one braking circuit fails the other
remains fully operational. This is achieved by means of the mechanical actuation of both spools
and requires slightly more pedal travel.
(5) Limiting the braking pressure
Pedal restriction bolt (23) on pedal plate (16) is used to limit the braking pressure.
(6) Failure of a circuit
In the event of the lower circuit failing, the upper circuit will remain operational. Spring assembly
(8) will mechanically actuate spool. In the event of the upper circuit failing, the lower circuit will
remain operational since the lower spool (3) is mechanically actuated by spring assembly (8) and
spool (3).
(7) Installation requirements
Return lines (T1, T2) must be connected directly to the tank.
The connecting lines must be installed is such a way as to permit proper bleeding.
4-14
(8) Maintenance of the brake valve
No special maintenance beyond the legal requirements is necessary.
When using high-pressure cleaners on the machine, please make sure that the water jet is not
aimed directly at the brake valve (to prevent damaging the bellows).
For safety reasons the whole of the brake valve must be replaced if parts other than those
listed above are damaged.
(9) Repair work
(9
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.
(10) Replacing the complete actuating mechanism
Carefully clamp the unit vertically in a fixture. The actuating mechanism can be removed by taking
out the three bolts. Make sure that spring assembly (8) does not fall out. When installing the new
actuating mechanism, make sure that spring assembly (8) is fitted in the right order. Tighten the
four bolts (25).
(11) Replacing the pedal cover
Pedal cover (18) is simply pulled of by hand. The new pedal cover is pushed over pedal (17) and
tightened manually. Fasten the bellows with the strap retainers.
(12) Replacing the bellows
To change bellows (19) it is advisable to remove pedal (17). For this purpose, loosen snap ring
(22) and knock out pin (20) using a mandrill. When knocking out the bolt, make sure that the
mandrill is applied to the side of the bolt without a knurl. Remove pedal (17) and bellows (19).
Now fit the new bellows and proceed in reverse order as described above. The upper portion of
bellows is fastened to piston, its lower portion to pedal plate (16) secure the bellows using clamps.
4-15
5. CUT-OFF VALVE
1) STRUCTURE
3 4
5 C B
D D
P PS1
A A
C B
SECTION A - A SECTION B - B
1 2
2
B1 A1 A2 B2
A3
PS
A1 A2 T1
B
PS T1
PS1
B1 B2
P T
A3
B 5 1
2) OPERATION
When the pump works, the oil under the pressure flows into P port.
The oil in P port is stored in the accumulator on A3 port.
As the pressure on P line rises to 150 bar, the cut off valve (1) starts cut-offing and the oil in the P
port is unloaded. The pressure on P line goes down 120 bar by the minute leakage from valve and
other factors.
At this pressure, the cut-off valve starts cut-ining.
This process is repeated in the regular period of 30~40 seconds.
4-16
6. BRAKE ACCUMULATOR
1) STRUCTURE
81L1-0003 81L1-0004
Item
(item16) (item17)
Diameter 138 mm 110 mm
Mounting height 187 mm 164 mm
Norminal volume 1.0ℓ 0.75ℓ
75794BS09
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
(2
The accumulator consists of a fluid portion (A) and a gas portion (B) with a diaphragm (C) as a
gas-tight dividing element. The fluid portion (A) is connected to the hydraulic circuit, causing the
diaphragm accumulator to be filled and the gas volume to be compressed as the pressure rises.
When the pressure falls, the compressed gas volume will expand, thus displacing the
accumulated pressure fluid into the circuit.
The diaphragm bottom contains a valve disk (D) which, if the diaphragm accumulator is
completely empty, closes the hydraulic outlet, thus preventing damage to the diaphragm.
3) Installation requirements
(3)
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
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
Accumulator
Pressure gauge(M)
4-18
7. PRESSURE SENSORS
1) STRUCTURE
Connector
Connector
H1
H1
H2 H2
G G
PARKING, CHARGING BRAKE STOP & CLUTCH CUT OFF
7579S4BS15
2) TECHNICAL DATA
H1 H2 Adjusting range Actuating pressure Voltage
Item Medium G
mm mm kgf/cm2 kgf/cm2 V
Parking pressure
Oil PF 1/4" 46.5 11 0 ~ 200 100 ± 5 Max 30
sensor
Charging pressure
Oil PF 1/4" 46.5 11 0 ~ 200 100 ± 5 Max 30
sensor
Brake stop & clutch cut
Oil PF 1/4" 46.5 11 1 ~ 100 5±1 Max 30
off pressure sensor
4-19
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.
4-20
8. PARKING BRAKE SYSTEM
1) STRUCTURE
12
9 1
13
10
11
9 2
8
7
3
5
6 4
7609A4BS21
4-21
2) OPERATION
The two identical lining pads (7, 8) slide on the guide surfaces on the top of the housing and are
held in position by a lining spring (12). The brake itself is directly fixed on the gearbox with the two
guide pins (9).
The brake is positioned axially using the rubber buffers (10) between the brake housing (1) and the
guide pins (9), and the setting screw (11).
When the brake is actuated (= closed) a clamping force is created on the lining pads (7, 8) which is
transmitted to the brake disc. Under the force of the plate spring pack (5), the piston (6), together
with the adjusting screw (4), the pressure bolt (3) and the lining pad (7) are moved towards the
brake disc. When the lining pad (7) comes into contact with the brake disc, the reaction force
displaces the brake on the guide pins (9), against the spring force of the rubber buffers (10), until
the second lining pad (8) is also pressed against the brake disc.
The braking effect (braking torque) is dependent upon the frictional values of the brake linings.
The brake is released by complete pretensioning of the plate spring pack (5). The piston (6) is
moved back by the required minimum release pressure to the stop on the pressure ring (2).
During this process the brake positions itself, depending upon the setting, by the two rubber buffers
(10) up to contact with the setting screw (11). An equal air gap must be guaranteed on both sides
of the brake disc when set correctly.
The clamping force is reduced by wear of the lining pads (7, 8) and the brake disc.
The brake must then be readjusted.
4-22
3) FITTING AND SETTING INSTRUCTIONS
7
8
4
9
10
7 1
2
5
7609A4BS22
※ The fitting or adjusting must always be carried out when the brake is cold.
(1) Fitting the brake
① Rotate the screw cap (5) in a counter-clockwise direction and unscrew it.
② Release the lock nut (1) and turn the adjusting screw (2) counter-clockwise until the pressure
bolt (6) contacts the piston (9) with the flat surface.
③ Slide the brake over the brake disc in this condition.
④ Screw the two guide pins (7) into the gearbox.
⑤ Connect the pressure.
⑥ Apply the required release pressure (min. 130 bar) to the brake in order to pre-tension the plate
spring pack (10) completely, up to the stop.
⑦ Carry out bleeding of the brake using the bleed valve (8) .
4-23
(2) Clearance adjusting
① Insert a setting gauge on both sides between the brake lining carrier and brake disc and hold
them in position.
※ The thickness of the setting gauge must be adjusted to the desired air gap.
② Turn the adjusting screw (2) in a clockwise direction until the two setting gauges are clamped
between the brake lining carriers and the brake disc.
③ Hold the adjusting screw (2) in position and lock using the lock nut (1).
※ The application pressure for clamping the setting gauges must be selected so that both gauges
can be removed using a small amount of force after locking in position.
④ Release the counter nut (4) and then turn the setting screw (3) in a clockwise direction until the
end surface of the setting screw (3) is in contact with the surface provided for setting.
⑤ Hold the setting screw (3) in position and lock using the counter nut (4).
⑥ Remove the setting gauges from both sides of the brake disc.
※ The fitting procedure for the brake and the setting of the desired air gap is now complete.
The brake is ready for use.
⑦ Turn the screw cap (5) in a clockwise direction and tighten hand-tight.
※ The brake should be actuated and released several times to check that it is functioning properly.
7
8
4
9
10
7 1
2
5
7609A4BS22
4-24
(3) Adjusting instructions
① Place the machine on flat ground and secure against rolling away.
② Release the parking brake by application of the required release pressure (min. 130 bar).
③ Rotate the screw cap (5) in a counter-clockwise direction and unscrew it.
④ Release the lock nut (1) of the setting screw (2).
⑤ Insert a setting gauge on both sides between the brake lining carrier and brake disc and hold
them in position.
※ The setting gauge must be selected in accordance with the table under (2) "Clearance adjusting".
⑥ Turn the setting screw (2) in a clockwise direction until the two setting gauges are clamped
between the brake lining carriers and the brake disc.
⑦ Apply the lock nut (1) to the setting screw (2).
※ The application pressure for clamping the setting gauges must be selected so that both gauges
can be removed using a small amount of force after locking in position.
⑧ Release the counter nut (4) and then turn the adjusting screw (3) in a clockwise direction until
the end surface of the adjusting screw (3) is in contact with the surface provided for setting.
⑨ Hold the adjusting screw (3) in position and lock using the counter nut (4).
⑩ Remove the setting gauge from both sides of the brake disc.
※ The adjustment of the desired air gap is now complete. The brake is ready for use.
⑪ Turn the screw cap (5) in a clockwise direction and tighten hand-tight.
※ Actuate the brake valve several times and check the holding effect of the parking brake on a
suitable incline or a suitable gradient.
7
8
4
9
10
7 1
2
5
7609A4BS22
4-25
4) EMERGENCY RELEASE OF THE PARKING BRAKE
In the event of a failure in pressure supply the parking brake can be released mechanically in the
following way :
G
2
5
7609A4BS23
4-26
5) MAINTENANCE AND REPAIR WORK
(1) Maintenance and replacement of the lining pads
The brake, particularly the brake lining carriers, must be visually inspected at regular intervals.
If the remaining lining thickness is too thin, these intervals must be reduced accordingly to
prevent extensive damage to the brake or the brake disc.
Once the minimum remaining lining thickness of 1.0~1.5 mm per brake lining carrier is reached,
the brake lining carrier must be replaced in accordance with the following instructions :
3 1
S1
4 2
S
5
7609A4BS24
① Place the machine on flat ground and secure against rolling away.
② Release the parking brake by application of the required release pressure (min. 130 bar).
③ Rotate the screw cap (5) in a counter-clockwise direction and unscrew it.
④ Release the lock nut (1) of the setting screw (2).
⑤ Rotate the setting screw (2) in an counter-clockwise direction until the pressure bolt (3) can be
pushed completely into the piston (4) .
⑥ Unscrew (lever) the pressure bolt (3) with a suitable screwdriver until it contacts the piston (4).
4-27
5
1
7609A4BS25
⑦ Release the counter nut (1) and unscrew the adjusting screw (2) from the brake housing.
※ The lining spring (5) is pre-tensioned. The lining spring (5) must be held in position with a
suitable tool whilst removing the adjusting screw (2).
⑧ Remove the lining spring (5).
⑨ Remove the two lining pads (3, 4) from the lining compartment in the brake housing.
※ If there is no possibility of changing the brake lining carriers (3, 4) as described above (not
enough space), the brake must be removed completely.
※ Check the pressure line. A pressure line which is too short must be unscrewed in order to permit
removal of the brake.
An emergency release of the parking brake must be carried out before releasing the pressure
line.
⑩ Replace the lining pads (3, 4).
⑪ The lining spring (5) must be pushed in position with a suitable tool whilst screwing in the
adjusting screw (2).
※ If you removed the brake completely because of a lack of space you must carry out fitting of the
brake.
※ After changing the lining pads (3, 4), or repair to them, the brake must be adjusted in
accordance with 3) FITTING AND SETTING INSTRUCTION.
4-28
(2) Replacing the seals
B
3
10
2
1
8 4
9 5
7
6
7609A4BS26
4-29
※ Observe the fitting direction of the grooved rings and use a suitable fitting needle with rounded
edges to fit the new grooved rings. Take care - there is a danger of injury.
※ Carry out re-fitting of the individual parts into the brake in reverse order. Apply a light coat of
fitting fluid lubricant to the sliding and sealing surfaces of the piston when fitting.
⑫ If necessary, also replace the dust protection cap (10).
※ The dust protection cap (10) has a vulcanised-in steel ring which is used to press it into the
opening in the brake housing (4).
In order to replace this you will need to "lever it out" with a suitable tool and then replace with a
fitting fixture by pressing it into the housing (4).
⑬ Fit the brake onto gearbox.
(3) General instructions
Any faults or damage detected on parts not listed here must, of course, be rectified or replaced
by genuine parts.
B
3
10
2
1
8 4
9 5
7
6
7609A4BS26
4-30
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
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
4-31
※Hydraulic oil must be at operating temperature for these checks (refer to page 6-48).
engaged at 8 km/hr.
Transmission must shift to neutral.
Parking brake Turn parking brake to ON. OK
transmission lockout Check completed.
Place transmission in 1st forward.
check
P
NOT OK
Engine running. Slowly increase engine speed to
Go to transmission control
high idle.
circuit in section 3.
LOOK : Machine must not move.
4-32
Item Description Service action
Service brake pump flow Stop engine. OK
check Check completed.
Operate brake pedal approximately
※ Hydraulic oil must be at
20 times. NOT OK
operating temperature
Start engine and run at low idle. Check for brake circuit
for the check.
leakage.
Engine OFF. Record number of seconds
required for low brake pressure Go to next page.
indicator lamp to go out.
IF OK
LOOK : Indicator lamp must go out I n s t a l l a c a p o n l i n e
in less than 4 seconds from time connected to inlet of brake
engine starts. valve and repeat pump
flow check.
NOTE : Indicator will not come on
approximately 1 second after If time does not decrease,
starting engine. check for wor n brake
pump.
Service brake capacity Turn clutch cut-off mode switch OK
check OFF. Check completed.
OFF
Engine running.
Apply service brakes, release park NOT OK
L
M H
brake and put transmission in 2nd Check brake pressure.
forward.
IF OK
Increase engine speed to high idle. Inspect brake disk.
LOOK : Machine may not move or
P
4-33
Item Description Service action
Brake accumulator S t a r t a n d r u n e n g i n e fo r 3 0 OK
precharge check seconds. Check completed.
※The axles and hydraulic
Stop engine and turn start switch to NOT OK
oil must be at operating
ON and wait 5 seconds. Make sure brake pedal is
temperature for this
not binding and keeping
check. NOTE : Engine oil pressure lamp
brakes partially engaged.
will be on due to no engine oil
pressure. Bleed brakes in group 3.
Count the number of times the C h e c k b r a k e s y s t e m
brake pedal can be fully depressed pressure.
before the low brake pressure
NOT OK
warning lamp comes ON.
If light comes ON with
LOOK : Warning lamp must come e n g i n e r u n n i n g ,
ON in 1~5 applications. accumulator has lost it's
charge. Inspect and
Start engine and operate at low
recharge accumulator.
idle.
Observe cluster while applying
brake pedal with maximum force.
LOOK/LISTEN : Brake pressure
indicator must not come ON.
Brake system leakage Start engine and wait 30 seconds. OK
check Check completed.
Stop engine.
NOT OK
Wait 2 minutes.
If brake leakage is
Turn start switch to ON and wait 5 indicated with brakes
seconds. released, check leakage at
accumulator inlet check
LOOK : Brake oil pressure warning
valve and brake valve. If
lamp must not come ON within 2
brake leakage is indicated
minutes after stopping engine.
with brakes applied, check
for leakage at brake valve
and brake pistons.
Check individual
component leakage.
4-34
Item Description Service action
S e r v i c e b ra ke p e d a l Slowly depress brake pedal. OK
check Check completed.
Listen for a hissing noise that
indicates oil is flowing to brake NOT OK
pistons. Inspect for debris under
brake pedal.
LISTEN/FEEL : A hissing noise
must be heard when pedal is
depressed.
Service and parking Position machine on gradual slope. OK
brake system drag Check completed.
Lower bucket approximately 50 mm
checks
(2 in) from ground.
Engine running NOT OK
Release parking and ser vice Adjust park brake.
brakes.
NOT OK
LOOK : Machine must move or
Check floor mat interfer-
coast.
P
M H
can be selected to operator
preference to match your loading
needs.
4-35
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)
4-36
Problem Cause Remedy
Brakes chatter Air in brake system. Do brake bleed procedure.
Worn brake surface material. Inspect brake surface material.
Wrong oil in differential. Drain.Refill.
H i s s i n g n o i s e w h e n Leakage in brake valve, or brake Do brake system leakage test.
brake pedal is held with piston.
engine stopped
Brake pressure warning M a l f u n c t i o n i n b r a k e l o w Replace switch.
light will not go out or pressure warning switch.
stays on excessively long
Brake accumulator pressure too Recharge accumulator.
after start-up
low.
L ow b r a ke p u m p s t a n d by Do brake pump standby pressure test.
pressure setting.
Leakage in pressure reducing Do pressure reducing valve manifold leakage
manifold block. test.
Leakage in brake system. Do brake system components leakage tests.
Worn brake pump. Do brake pump flow test.
Leakage in par king brake Do parking brake pressure test.
solenoid.
4-37
GROUP 3 TESTS AND ADJUSTMENTS
2) MEASURING PROCEDURE
(1) Start the engine and drive the machine
straight up a 1/5 gradient with the bucket
unloaded.
(2) Depress the service brake, place the gear
selector lever in neutral, then stop the
engine.
(3) Turn the parking brake switch ON, then 20%
11 20' gradient
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
75794BS18
the slope.
Setting screw
7609A4BS27
4-38
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 Breather vent
Air breather
immediately. Any fluid injected into the skin
must be surgically removed within a few
hours or gangrene may result. Breather vent
Doctors unfamiliar with this type of injury
should reference a knowledgeable medical
source.
Two people are required to bleed brake A
system oil, one to operate brake valve and
other to open and close bleed screws.
1) Install frame locking bar. Engage parking
brake.
2) Put a clear plastic tube on bleed screw to
route low to hydraulic oil tank 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. Safety lock bar
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.
6) Repeat steps 1)~5) for each bleed screw.
7) Push either brake pedal and hold down.
7579S4BS19
8) Check hydraulic oil level.
4-39
GROUP 4 DISASSEMBLY AND ASSEMBLY
1. BRAKE PUMP
1) MAIN
AIN ASSEMBLY
Inlet
2
Brake pump
3
6
Outlet A
B
2
1 C
5
D
4
13
Inlet
A 12
7
8 11
Outlet
7
10
Fan pump
14
7609S4BS07
4-40
(1) Prepare all parts and clean it.
(2) Prepare M10 torque wrench, oil pump and 1, 2, 5, 7, 10 sub assembly status.
(3) When you assemble, front cover sub assy (5) is based on a front view.
(4) Main assembly order
① Front cover sub assy (5) is based on a front view in drawing, check sense of rotation (CW) and
assembling shaft gear's upper direction.
② At first, one of bushing block sub assy (2) point to same position of figure. After you assemble
drive gear (3) and driven gear (4), you assemble bushing block sub assy (2).
③ Put oil on the assembled parts (2, 3, 4), lubrication for the gear to rotate and assemble front
cover sub assy (5) to A direction.
④ Check the outlet port based on housing sub assy (1) drawing and contamination of part's inside.
Coated oil parts are assembled in the direction vertical and horizontal.
⑤ Assemble multi spacer(6) as shown in the figure and connector (14) put in joint drive gear's(8)
hole.
⑥ One of bush block sub assy(7) point to same position of figure.
After you assemble joint drive gear(8) and driven gear(9), you assemble bush block sub assy.
⑦ Put oil on the assembled parts (7,8,9), lubrication for the gear to rotate assemble multi
spacer(6) to A axis direction.
⑧ Check the outlet port based on housing sub assy(10) drawing and contamination of part's inside.
Coated oil parts are assembled in the direction verticcal and horizontal.
⑨ Assemble rear cover(11) as shown in the figure.
⑩ Washer(12) put in bolt(13), assemble in order of A-D-B-C and tighten bolts same order using
toque wrench
·Tightening torque : 5.1±0.5 kgf·m (36.9±3.7 lbf·ft)
(5) Complete assembly.
(6) Dissembly is assembly's order in reverse.
(7) You proceed running-in using performance test device.
(8) Install it, and use.
4-41
2) SUB ASSEMNLY
※ Beware of scratches, damages and foreign
materials.
※ Grease must have good lubricity and
viscosity.
※ You must prepare snap ring tool and
retainal seal special tool.
(1) Fron
Frontt cover assy
1
① After enough grease on the surface of Direction B
retainal seal (2). It is assembled front
cover (1) using retainal seal special tool. 2
3
※ Lip's direction toward A direction should
be assembled and because of the risk of
Direction A
damage should be used only special tool.
② After you put snap ring tool in 2 holes of Direction A Lip
closely.
2
※ A side of D-ring (2) should be assembled
side of housing (1) closely.
Face A
7407B4BS21
4-42
3) RUNNING-IN
Pressure gauge
Flow
meter
Relief valve
Strainer
Tank
(730TM-3C)4-48
(1) A unit which has been re-assembled with either new gears, bushes or body, must be carefully
run-in before it is subjected to full working conditions.
(2) Ideally this should be done on a test rig (see figure) where pressure can be gradually applied and
any wipings from the body cut-in arrested by filters.
(3) It is recommended that the unit is run-in at 1500 rpm, initially, at zero pressure for one minute then
in stages with the pressure increased by 500 psi 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.
4-43
SECTION 5 STEERING SYSTEM
1. OUTLINE
The steering system of this machine consists of a variable displacement piston pump supplying a
load sensing steering system and an closed center loader system.
The components of the steering system are :
·Steering pump
·Steering valve (EHPS)
·Steering unit
·Cushion valve
·Steering cylinders
The steering pump, the first pump of main pump, draws hydraulic oil from the hydraulic tank.
Outlet flow from the pump flows to the priority valve of steering valve. The priority valve of steering
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 main control valve for the operation of the
attachment.
5-1
2. HYDRAULIC CIRCUIT
10
33
6 CL CR
Ts
EF P LS T
L R
5
MCV
P T
RCV lever
Brake system Fan drive moter
1
Return line
23
29 PS Return line
28 M1
A P1
24 Return line
29
M2 26 21
PS
25
P2
27
M
7579S5SE01
5-2
1) NEUTRAL
10
33
6 CL CR
D Ts
EF P LS T
L R
5
MCV
P T
RCV lever
Brake system Fan drive moter
2 1 A
Return line
23
Return line
24 Return line
26 21
25
7609S5SE02
· The steering wheel is not being operated so control spool (G) does not move.
· The oil from the steering pump (A) enters port P of the priority valve in steering valve (EHPS) and the
inlet pressure oil moves the spool (D) to the right.
· Almost all of pump flow goes to the loader system (main control valve) through the EF port and partly
flows into the hydraulic tank (24) through the spool (M).
5-3
2) LEFT TURN
10
33
6 CL CR
Ts
EF P LS T
·
L R
5
·
·
MCV
P T ·
RCV lever
Brake system Fan drive moter
2 1
Return line
23
Return line
24 Return line
26 21
25
7609S5SE03
When the steering wheel is turned to the left, the pressure oil from the steering unit fill on the left side
chamber of main steering spool (M), and main steering spool moves to the right in the direction.
At the same time of moving of main steering spool, LS signal will be blocked. Refer to page 5-8.
If LS signal of main steering spool is blocked, it cause to increase pressure of right chamber of priority
valve and then priority valve to be pushed to left side.
Consequently, oil will flow via CF of priority valve to main spool. That oil will push steering cylinder rod
out and it will cause wheel loader to be steered to left side.
The rate of movement of main steering spool is concluded as flow rate, which is kept in left chamber
from steering unit. Furthermore the rate controls speed of movement for cylinder.
5-4
3) RIGHT TURN
10
33
6 CL CR
Ts
EF P LS T
L R
5
MCV
P T
RCV lever
Brake system Fan drive moter
2 1
Return line
23
Return line
24 Return line
26 21
25
7609S5SE04
· When the steering wheel is turned to the right, the pressure oil from the steering unit fill on the right
side chamber of main steering spool (M), and main steering spool moves to the left in the direction.
· At the same time of moving of main steering spool, LS signal will be blocked. Refer to page 5-9.
· If LS signal of main steering spool is blocked, it cause to increase pressure of right chamber of priori-
ty valve and then priority valve to be pushed to left side. Consequently, oil will flow via CF of priority
valve to main spool. That oil will push steering cylinder rod out and it will cause wheel loader to be
steered to right side.
· The rate of movement of main steering spool is concluded as flow rate, which is kept in right cham-
ber from steering unit. Furthermore the rate controls speed of movement for cylinder.
5-5
3. STEERING VALVE (EHPS ; Electro Hydraulic Power Steering)
1) STRUCTURE
1 6
L CL CR R
CL CR
T TS Steering
valve Shock valves
block
LS EF P PS Suction valves
L
Main spool
R
S3
KV2
KV1
7 2 8 3 9 4 10 11 5 12
EF 12bar
CF Ps
Pressure
30bar reducing
valve Ts
EF P LS T
Hydraulic circuit
13 14
15 17
18
16
7607SE11
5-6
2) OPERATION
(1) Neutral
CL CR
Shock valves
Suction valves 15
KV1 S3 KV2 17
16
18A CF Ps
Pressure L R
reducing
valve
Ts P T
LS P EF T
18
7607SE12
· In neutral position, the oil will pass from the pump across the integrated priority valve (18) in the
steering valve for discharge through the EF port. When the steering unit is in neutral, flow through
it is blocked and all flow through the priority valve (18) in steering valve is directed out the EF port
and passed to the main control valve.
· When the engine is turned off, the priority valve spool (18) is pushed to the right by the spring. The
passage to the EF port is blocked while the passage to the CF port is open.
· When the machine is started, EF port of the steering valve may be connected to the working
hydraulic. Maximum pressure on the EF port = 210 bar.
· The operating pressure in the loader system has not effected on the operation of the priority
valve(18) of steering valve. Independently of operation of the loader actuated in relief, the priority
valve(18) will not shift until the machine is steered.
· A part of flow through the priority valve spool (18) will flow to P port of steering unit through pres-
sure reducing valve. Also flow as pilot signal of steering through the priority valve spool (18) pass-
es from the P port through the dynamic orifice and into the LS line. It flows to the tank through the
LS orifice in main spool.
· In neutral position, the main spool will be in its center position. This means that knocks and
impacts from the cylinder are not transmitted to the steering unit. The steering valve is thus of the
non-reaction type.
5-7
(2) Turning left
CL CR
Shock valves
Suction valves 15
KV1 S3 KV2 17
16
18A CF Ps
Pressure L R
reducing
valve
P T
Ts
LS P EF T
18
7607SE13
· When the steering wheel is turned to the left, the pressure oil from the steering unit fill on the left
side chamber of main steering spool (15), and main steering spool (15) moves to the right in the
direction.
· At the same time of moving of main steering spool (15), LS signal will be blocked.
· If LS signal of main steering spool (15) is blocked, it cause to increase pressure of left chamber of
priority valve (18A) and then priority valve (18) to be pushed to right side.
Consequently, oil will flow via CF of priority valve to main spool. That oil will push steering cylinder
rod out and it will cause wheel loader to be steered to left side.
· The rate of movement of main steering spool (15) is concluded as flow rate, which is kept in left
chamber from steering unit. Furthermore the rate controls speed of movement for cylinder.
· When the cylinder reaches to end position, pressure of oil flowing through main steering spool (15)
will get to be increased. If the oil pressure increase up to relief pressure to be set, relief valve will
be activated. It result in decreasing pressure of left chamber of priority valve (18A), and will push
priority valve(18) to right side. Then, oil flow to cylinder will be blocked.
5-8
(3) Turning right
CL CR
Shock valves
Suction valves 15
KV1 S3 KV2 17
16
18A CF Ps
Pressure L R
reducing
valve
P T
Ts
LS P EF T
18
7607SE14
· When the steering wheel is turned to the right, the pressure oil from the steering unit fill on the right
side chamber of main steering spool (15), and main steering spool (15) moves to the left in the
direction.
· At the same time of moving of main steering spool (15), LS signal will be blocked.
· If LS signal of main steering spool (15) is blocked, it cause to increase pressure of left chamber of
priority valve (18A) and then priority valve (18) to be pushed to right side. Consequently, oil will
flow via CF of priority valve to main spool. that oil will push steering cylinder rod out and it will
cause wheel loader to be steered to right side.
· The rate of movement of main steering spool (15) is concluded as flow rate, which is kept in right
chamber from steering unit. Furthermore the rate controls speed of movement for cylinder.
· When the cylinder reaches to end position, pressure of oil flowing through main steering spool (15)
will get to be increased. If the oil pressure increase up to relief pressure to be set, relief valve will
be activated. It result in decreasing pressure of left chamber of priority valve (18A), and will push
priority valve (18) to right side. Then, oil flow to cylinder will be blocked.
5-9
(4) Pressure reducing valves
1 2 3
7607SE15
· Pressure reducing valve is a valve, which is supplying pilot oil to steering unit.
That is one of advantage of steering system adopting steering valve.
· Pressure reducing valves are pressure-limiting devices that limit pressure in one portion of a circuit
while leaving system pressure unaffected.
Pressure reducing valves allow flow to pass from (1) to (2) until the pressure at (1) reaches the pre-
determined setting, at which point the spool shifts to restrict input flow from (1) (reducing mode) or
to open flow from (2) to (3) (relieving mode) as needed to maintain the regulated pressure at (2).
1 2 3 4 5
7607SE16
The relief valve is inside the steering valve, and set the maximum circuit pressure of the steering
circuit.
When the steering valve is being actuated, if the steering circuit goes up above the set pressure of
this valve, oil will be relieved, the priority valve spool will be actuated, and the oil will be flow to EF
port.
5-10
4. STEERING UNIT
1) STRUCTURE
1 7
2 8
3 9
4 10
A A
5
11
6
12
SECTION A - A
7607SE17
2) OPERATION
The steering unit consists of a rotary valve and a rotary meter.
Via a steering column the steering unit is connected to the steering wheel of the machine.
When the steering wheel is turned, oil is directed from the steering system pump via the rotary
valve (spool and sleeve) and rotary meter (gear wheel set) to the cylinder ports L or R, depending
on the direction of turn. The rotary meter meters the oil flow to the steering cylinder in proportion to
the angular rotation of the steering wheel.
Spool (9) is connected directly to the drive shaft of steering wheel. It is connected to sleeve (7) by
cross pin (3) (not in contact with the spool when the steering wheel is at neutral) and neutral posi-
tion spring (2).
Cardan shaft(8) is meshed at the top with cross pin (3) and forms one unit with sleeve (7).
At the same time, it is meshed with gear rim (5) of the gerotor set by spline.
There are four ports in valve body. They are connected to the pump circuit, tank circuit, and the
head, and left and right steering cylinder. In addition, the pump port and tank port are connected
inside the body by the check valve. Therefore, if there is any failure in the pump of engine, oil can
be sucked in directly from the tank through the check valve.
5-11
5. CUSHION VALVE
1) STRUCTURE
B A
B A
13
16 15 5 14 8 1 2 3 6 7 5 4
17 13 12 11 10 9
SECTION B - B SECTION A - A
7607SE18
5-12
2) OPERATION
L R
B A
B A
16 8 2 3
Main valve
section
SECTION B - B SECTION A - A
12 11 9
7607SE19
The cushion valve is a valve that eliminates steering jerk motion. It makes a higher pressurized oil to
flow into another line in order to prevent the shock on steering system.
The pressure by rapid supplied pressurized oil from R port is higher than the spring (3) force, so it press
and open the poppet (2). Then the oil flows to the central groove of the spool (12), and flows to L port
through the poppet of the check valve (16) on L port side.
At this time, this pressurized oil flows to the pressure area of the plug (9) through the orifice (8), and this
force is higher than the spring (11) force plus the oil pressure on L port side, so the spool (12) is shifted
to the right. The flow of the supplied oil to L port side through the poppet (2) from R port side is trapped.
The flow of this instant oil makes the function of the cushion. After this operation, the normal steering
operation is not affected because this valve is not operated any longer.
Also, for the response of the pressure when the operation is slow as a cushion effect is not required, the
spool (12) is closed before the poppet (2) is opened, so this valve is not operated.
5-13
6. STEERING CYLINDER
1) STRUCTURE
7579S5SE05
2) OPERATION
This machine use to cross connected cylinder for steering operation.
The steering cylinder use a gland(3) to remove piston and sealed seals. Dust wiper (4) located on
the in side of the gland protects cylinder inner parts from dust. The piston (13) is fastened to the rod
(2).
The piston uses a single wear ring (15) with a piston seal (14) 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 (6).
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 give repair required and group location. If
verification is needed, you will be give next best source of information :
·Chapter 2 : Troubleshooting
·Group 3 : Tests and adjustments
5-15
※Hydraulic oil must be at operating temperature for these checks (refer to page 6-48).
Item Description Service action
Steering unit check Run engine at low idle. OK
Check completed.
A
Turn steering wheel until frames are
at maximum right (A) and then left NOT OK
B
(B) positions. Go to next check.
L O O K : Fra m e s mu s t m ove
smoothly in both directions.
When steering wheel is stopped,
frames must stop.
FEEL : Excessive effort must not be
required to turn steering wheel.
NOTE : It is normal for steering to
drift from stops when steering
wheel is released.
Steering system leakage Turn steering wheel rapidly until OK
check frames are against stop. Check completed.
Heat hydraulic oil to Left Right
Hold approximately 2 kg on steer- NOT OK
operating temperature.
ing wheel. Do steering system leakage
Run engine at high idle.
test in group 3 to isolate the
Count steering wheel revolutions
leakage.
for 1 minute.
Repeat test in opposite direction.
LOOK : Steering wheel should
rotate less than 7 rpm.
NOTE : Use good judgment;
Excessive steering wheel rpm does
not mean steering will be affected.
Priority valve (in steering Park machine on a hard surface. OK
valve) low pressure Check completed.
Hold brake pedal down.
check
NOT OK
Run engine at high idle.
Do steering valve (EHPS)
Steer machine to the right and left pressure test in group 3.
as far as possible.
LOOK : Machine must turn at least
half way to the right and left stops.
Priority valve (in steering Steer to steering stop and release OK
valve) high pressure steering wheel. Check completed.
check
Roll bucket back and hold over NOT OK
relief and observe engine rpm. Priority pressure is set too
Run engine at high idle.
high. Do steering valve
Turn steering wheel to steering
(EHPS) pressure test in
stop and hold, observe engine rpm.
group 3.
LOOK : Steering stall engine rpm
must be higher than hydraulic stall
rpm.
5-16
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)
5-17
Problem Cause Remedy
Slow or hard steering Too much friction in the mechanical parts of Lubricate bearings and joints of steering
the machine. column or repair if necessary.
Check steering column installation.
Cold oil. Warm the hydraulic oil.
Low priority valve pressure setting. Do priority valve pressure test.
Clean or replace cartridge in steering valve.
Worn hydraulic pump. Do hydraulic pump performance check .
Sticking priority valve spool. Remove and inspect.
Broken priority valve spring. Remove and inspect.
C o n s t a n t s t e e r i n g t o Air in system. Check for foamy oil.
maintain straight travel
Leakage in steering system. Do steering system leakage check.
Worn steering unit. Do steering system leakage check.
Do steering unit neutral leakage test in
group 3.
Leaf spring without spring force or broken. Replace leaf springs.
Spring in double shock valve broken. Replace shock valve.
Gear wheel set worn. Replace gear wheel set.
Cylinder seized or piston seals worn. Replace defects parts.
S l o w s t e e r i n g w h e e l Leakage in steering unit gerotor. Do steering system leakage check.
movement will not cause
Worn steering unit gerotor. Do steering leakage check.
any frame movement
Steering wheel can be Leakage in steering system. Do steering system leakage check.
turned with frames
against steering stop
Steering wheel turns with Broken steering column or splined cou- Remove and inspect.
n o r e s i s t a n c e a n d pling.
causes no frame move-
Lack of oil in steering unit. Start engine and check steering operation.
ment
Leakage in steering system. Do steering system leakage test in group 3.
5-18
Problem Cause Remedy
Erratic steering Air in oil. Check for foamy oil.
Low oil level. Add recommended oil.
Sticking priority valve spool. Remove and inspect spool.
Loose cylinder piston. Remove rod to inspect piston.
Damaged steering unit. Remove and inspect.
Spongy or soft steering Air in oil. Check for foamy oil.
Low oil level. Add recommended oil.
Free play at steer ing Loose steering wheel nut. Tighten.
wheel
Worn or damaged splines on steering col- Inspect.
umn or unit.
Steering unit binding or Binding in steering column or misalignment Inspect.
steering wheel does not of column.
immediately retur n to
High return pressure. Check for a pinched or damaged return
neutral when released
line.
Contamination in steering unit. Inspect hydraulic filter for contamination.
Repair cause of contamination. Flush
hydraulic system.
Large particles of contamination in steering Inspect hydraulic filter for contamination.
unit. Repair cause of contamination. Flush
hydraulic system.
Steering unit locks up Worn or damaged steering unit. Repair or replace steering unit.
Abrupt steering wheel Improperly timed gerotor gear in steering Time gerotor gear.
oscillation unit.
Steering wheel turns by Lines connected to wrong port. Reconnect lines.
itself
Vibration in steering sys- High priority valve setting. Do priority valve pressure test.
tem or hoses jump
Neutral position of steer- Steering column and steering unit out of Align the steering column with steering unit.
ing wheel cannot be line.
obtained, i.e. there is a
Too little or no play between steering col- Adjust the play and, if necessary, shorten
tendency towards
umn and steering unit input shaft. the splines journal.
"motoring"
Pinching between inner and outer spools. Contact the nearest service shop.
5-19
Problem Cause Remedy
"Motoring" effect. Leaf springs are stuck or broken and have Replace leaf springs.
The steering wheel can therefore reduced spring force.
turn on its own.
Inner and outer spools pinch, possibly due Clean steering unit or contact the nearest
to dirt. service shop.
Return pressure in connection with the Reduce return pressure.
reaction between differential cylinder and
steering unit too high.
Oil is needed in the tank. Fill with clean oil and bleed the system.
Steering cylinder worn. Replace or repair cylinder.
Gear wheel set worn. Replace gear wheel set.
Spacer across cardan shaft forgotten. Install spacer.
5-20
Problem Cause Remedy
Backlash 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.
"Shimmy" effect. The Air in the steering cylinder. Bleed cylinder.
steered wheels vibrate. Find and remove the reason for air collec-
(Rough tread on tires tion.
gives vibrations)
Mechanical connections or wheel bearings Replace worn parts.
worn.
High priority valve setting pressure. Set pressure as regular value.
Steering wheel can be One or both shock valves are leaky or are Clean or replace defective of missing
turned slowly in one or missing in steering valve. valves.
both directions without
the steered wheels turn-
ing.
Steering is too slow and Insufficient oil supply to steering unit, pump Replace pump or increase number of revo-
heavy when trying to turn defective or number of revolutions too low. lutions.
quickly.
Relief valve setting too low. Adjust valve to correct setting.
Relief valve sticking owing to dirt. Clean the valve.
Spool in priority valve sticking owing to 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. Contact authorized man or shop.
wheel from system. Kicks
from wheels.
5-21
Problem Cause Remedy
Heavy kick-back in steer- Wrong setting of cardan shaft and gear- Correct setting as shown in this manual.
ing wheel in both direc- wheel set.
tions.
urning the steering wheel Hydraulic hoses for the steering cylinders Connect lines to correct ports.
activates the steered have been switched around.
wheels opposite.
Hard point when starting Spring force in priority valve too weak. Replace spring by a stronger.
to turn the steering wheel
Oil is too thick (cold). Let motor run until oil is warm.
Too little steering force Pump pressure too low. Correct pump pressure.
(possibly to one side
Too little steering cylinder. Fit a larger cylinder.
only).
Piston rod area of the differential cylinder Fit cylinder with thinner piston rod or 2 dif-
too large compared with piston diameter. ferential cylinders.
Leakage at either input Shaft defective. Replace shaft seal.
shaft, end cover, gear-
Screws loose. Tighten screws.
wheel set, housing or top
part. Washers or O-rings defective. Replace.
5-22
GROUP 3 TESTS AND ADJUSTMENTS
5-23
5) Start the filter caddy. Check to be sure oil
is flowing through the filters.
Operate filter caddy approximately 10 min-
utes so oil in hydraulic oil tank is circulated
through filter a minimum of four times.
※ Hydraulic oil tank capacity 175ℓ(46 U.S.
gal).
Leave filter caddy operating for the next
steps.
6) Start the engine and run it at high idle.
※ For the most effective results, cleaning
procedure must start with the smallest
capacity circuit then proceed to the next
largest capacity circuit.
7) Operate all functions, one at a time, through
a complete cycle in the following order:
clam, steering, bucket, and boom. Also
include all auxiliary hydraulic functions.
Repeat procedure until the total system
capacity has circulated through filter caddy
seven times, approximately 30 minutes.
Each function must go through a minimum
of three complete cycles for a through
cleaning for oil.
※ Filtering time for machines with auxiliary
hydraulic functions must be increased
because system capacity is larger.
8) Stop the engine. Remove the filter caddy.
9) Install a new return filter element.
10) Check oil level in hydraulic oil tank ; Add oil
if necessary.
5-24
2. TEST TOOLS
1) CLAMP-ON ELECTRONIC TACHOMET-
ER INSTALLATION
· Service equipment and tools
B
Tachometer
A : Clamp on tachometer.
Remove paint using emery cloth and
C
connect to a straight section of injec-
tion line within 100 mm (4in) of pump.
Finger tighten only-do not over tighten. D
B : Black clip (-). Connect to main
frame. A
C : Red clip (+). Connect to transducer.
D : Tachometer readout. Install cable. 75795SE32
75795SE33
75793CD03
5-25
3. STEERING SYSTEM RESTRICTION TEST
· SPECIFICATION
Oil temperature 45±5˚C (113±9˚F)
Engine speed High idle
Maximum pressure 4.5MPa (45 bar, 640psi)
at steering valve (EHPS)
· GAUGE AND TOOL
Gauge 0~7 MPa (0~70 bar, 0~1000 psi) 2EA
· This test will check for restrictions in the
steering system which can cause overheat-
Steering pump
ing of hydraulic oil.
1) Install temperature reader.
(see temperature reader installation proce- Fitting
dure in this group).
2) Heat hydraulic oil to specifications.
(see hydraulic oil warm up procedure at
P
page 6-48).
3) Connect fitting and install gauge.
Do not operate steering or loader funct-
ions or test gauge may be damaged.
4) Run engine at specification and read pres-
sure gauges.
If pressure is more than specification at the
steering valve, inspect steering valve for a
priority valve spool. Make sure orifice
plugs installed in ends of priority valve spool. 7607SE24
5-26
4. STEERING UNIT LEAKAGE TEST
· SPECIFICATION
Oil temperature 45±5˚C (113±9˚F)
Engine speed High idle
Maximum leakage 7.5ℓ/min (2 gpm)
· GAUGE AND TOOL Cap fitting
Temperature reader
T
Measuring container (approx. 20ℓ) L
R
Stop watch
1) Install frame locking bar to prevent machine
from turning.
2) Install temperature reader.
(see temperature reader installation proce-
dure in this group).
3) Heat hydraulic oil to specifications.
(see hydraulic oil warm up procedure at
page 6-48).
4) Disconnect return hose from fitting.
Install cap fitting.
5) Run engine at specifications. Rotate
steering wheel against locking bar using
approximately 1.2 kgf·m of force.
Measure oil flow from return hose for 1
minute.
Safety lock bar
6) Leakage is greater than specifications,
repair or replace steering unit.
75795SE11
5-27
5. STEERING VALVE (EHPS) PRESSURE TEST
· SPECIFICATION
Oil temperature 45±5˚C (113±9˚F)
Engine speed High idle
Oil pressure 21±0.5 MPa
(210±5 bar, 3050±72 psi)
· GAUGE AND TOOL Relief valve
Gauge 0~35 MPa (0~350 bar, 0~5000 psi)
CL
CR
Temperature reader
1) Connect gauge to test port.
2) Install temperature reader (see installation
procedure in this group).
3) Install frame locking bar.
4) Heat hydraulic oil to specifications (see
hydraulic oil warm up procedure at page
Test port
6-48).
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 read-
ing.
If steering wheel continues to turn rapidly
with the frames locked, steering system
leakage is indicated.
6) Read pressure gauge. This is the steering Safety lock bar
valve relief pressure.
7) If pressure in not to specification, turn
adjusting screw in relief cartridge using a
hex head wrench (6 mm) to adjust pressure.
If pressure cannot be adjusted to specifica-
tion, disassemble and inspect steering 75795SE12
valve.
5-28
6. STEERING VALVE (EHPS) RELIEF
CARTRIDGE LEAKAGE TEST
· SPECIFICATION
Oil temperature 45±5˚C (113±9˚F)
Engine speed High idle Relief valve
Maximum leakage 1mℓ/min (16 drops per min)
A
· GAUGE AND TOOL
Temperature reader T B
Ts
Measuring container
Stop watch
1) Install temperature reader.
(see temperature reader installation proce-
dure in this group).
2) Heat hydraulic oil to specifications.
(see hydraulic oil warm up procedure at
page 6-48).
3) Install plug (A) in Ts port.
Disconnect line from T port on steering
valve. Install plug in line.
4) Connect line (B) to steering valve.
5) Start engine and run at specification.
6) Measure oil leakage from T port.
7607SE21
7) If leakage is more than specification, disas-
semble and inspect relief cartridge for dam-
age or debris.
5-29
GROUP 4 DISASSEMBLY AND ASSEMBLY
1. STEERING UNIT
1) STRUCTURE
3 8
11
4
9
2
13
14
12
15
13
17
18
21
20
7607SE10
5-30
2) TOOLS
(1) Holding tool + Guide ring
7607SE08
7607SE09
(780-3A) 5-69(3)
(780-3A) 5-69(4)
5-31
(5) Assembly tool for dust seal.
(780-3A) 5-70(1)
5-32
3) TIGHTENING TORQUE AND HYDRAULIC CONNECTIONS
(1) Hydraulic connections
L: Left port
R: Right port
T: Tank
TLPR
P: Pump
(780-3A) 5-71
5-33
4) DISASSEMBLY
(1) Disassemble steering column from
steering unit and place the steering unit in
the holding tool.
Screw out the screws in the end cover (6-
off plus one special screw).
(780-3A) 5-72(1)
(780-3A) 5-72(2)
(780-3A) 5-72(3)
(780-3A) 5-72(4)
5-34
(5) Remove distributor plate.
(780-3A) 5-73(1)
(780-3A) 5-73(2)
(780-3A) 5-73(3)
(780-3A) 5-73(4)
5-35
(9) 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.
(780-3A) 5-74(1)
(780-3A) 5-74(2)
(780-3A) 5-74(3)
(780-3A) 5-74(4)
5-36
(12) Press the neutral position springs out of
their slots in the spool.
(780-3A) 5-75(1)
(780-3A) 5-75(2)
(780-3A) 5-75(3)
※ Cleaning
Clean all parts carefully in Shellsol K or
the like.
※ Inspection and replacement
Replace all seals and washers. Check all
par ts carefully and make any
replacements necessary.
※ Lubrication
Before assembly, lubricate all parts with
hydraulic oil.
5-37
(1) Place the two flat neutral position springs
in the slot.
Place the curved springs between the flat
ones and press them into place.
7607SE06
(780-3A) 5-76(4)
(780-3A) 5-76(1)
(780-3A) 5-77(2)
5-38
(5) Line up the springs and center them.
(780-3A) 5-77(3)
(780-3A) 5-77(4)
(780-3A) 5-78(1)
(780-3A) 5-78(2)
5-39
※ Assembly pattern for standard bearings
1
1 Outer bearing race 2
2 Needle bearing 3
3 Inner bearing race
4 Spool
5 Sleeve * 4
(780-3A) 5-78(4)
(780-3A) 5-79(1)
(780-3A) 5-79(2)
5-40
(11) Hold the outer part of the assembly tool in
the bottom of the steering unit housing
and guide the inner part of the tool right to
the bottom.
(780-3A) 5-79(3)
(780-3A) 5-79(4)
(780-3A) 5-80(1)
(780-3A) 5-80(2)
5-41
(780-3A) 5-80(3)
(780-3A) 5-80(4)
(780-3A) 5-81(1)
(780-3A) 5-81(2)
5-42
(18) The spool set will push out the assembly
tool guide. The O-ring are now in position.
(780-3A) 5-81(3)
(780-3A) 5-81(4)
(780-3A) 5-82(1)
(780-3A) 5-82(2)
5-43
(22) Place the distributor plate so that the
channel holes match the holes in the
housing.
(780-3A) 5-82(3)
(780-3A) 5-82(4)
(780-3A) 5-83(1)
(780-3A) 5-83(2)
5-44
(26) Important
Fit the gearwheel (rotor) and cardan shaft
so that a tooth base in the rotor is
positioned in relation to the shaft slot as
shown.
Turn the gear rim so that the seven
through holes match the holes in the
housing.
(780-3A) 5-83(3)
(780-3A) 5-83(4)
(780-3A) 5-84(1)
(780-3A) 5-84(2)
5-45
(30) Fit the six screws with washers and insert
them. Cross-tighten all the screws and
the rolled pin.
·Tightening torque : 3.1±0.6 kgf·m
(22.4±4.3 lbf·ft)
(780-3A) 5-84(3)
(780-3A) 5-84(4)
(780-3A) 5-85(1)
(780-3A) 5-85(2)
5-46
2. STEERING CYLINDER
1) STRUCTURE
7579S5SE05
5-47
2) TOOLS AND TIGHTENING TORQUE
(1) Tools
Tool name Remark
Wrench For gland
(-) Driver Small and large sizes
Torque wrench Capable of tightening with the specified torques
5-48
3) DISASSEMBLY
(1) Remove cylinder head and piston rod
① 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.
7577ASE30
3
2
7577ASE31
5-49
※ 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.
Wooden block
75795SE40
7577S5SE20
5-50
(3) Disassemble the piston assembly
① Remove wear ring (15) and piston seal 17 14 15
(14).
Remove O-ring (17).
※ Exercise care in this operation not to
damage the grooves.
7577S5SE22
5-51
4) ASSEMBLY
(1) Assemble gland assembly
※ Check for scratches or rough surfaces if
found smooth with an oil stone.
① Coat the inner face of gland (3) with
hydraulic oil.
7607B5SE34
7607B5SE24
7577ASE42
7577ASE43
5-52
⑤ Fit back up ring (11) to gland (3).
※ Put the back up ring in the warm water of 12 3 11,10 9
30~50˚C.
⑥ Fit O-ring (10, 12) to gland (3).
⑦ Fit bushing (9) to gland (3).
7607B5SE26
13
7577S5SE27
7577S5SE28
13
7577S5SE36
5-53
(3) Install piston and gland assembly
① Fix the piston rod assembly to the work Grand assembly
bench. Piston rod
② Apply hydraulic oil to the outer surface of
piston rod (2), the inner surface of piston
and gland (3).
③ Insert gland assembly to piston rod (2).
7577S5SE37
7577S5SE26
Wrench
Gland
7577ASE38
5-54
3. CENTER PIVOT PIN
1) CONSTRUCTION
Figure shows the construction of the center pivot pin assembly. This assembly serves to connect
the front frame with the rear frame; two sets of assemblies are provided, one each for the upper
and lower parts. The numbers in parentheses following the parts name denote the item numbers
shown in the figure in the disassembly and assembly procedures.
8 12,13 11 6 5 21
10
16
18,13
2
1
3,4 20
20 17
1
3,4
8 7
14,15
21 9 16 12,13
UPPER LOWER
7579S5SE15
5-55
2) DISASSEMBLY
After supporting the front frame and the
rear frame as horizontally as possible using
wood blocks and jacks, disassemble as
fo l l o w s : I n o r d e r t o fa c i l i t a t e t h e
disassembly/assembly of the center pivot
pins, remove the drive shaft, hydraulic line
and steering cylinder first.
(1) Maintain the horizontal level of front frame
(20) and rear frame (21), and then 12
8
remove hexagon bolt (12) and plate (8).
(2) Take out upper pin (9) to the downside
using a metal punch. 20
21
7579S5SE16
5-56
(8) Remove bolt (18) and then take out cover
(2) and shims (3, 4). 18 11 2
(9) Take out dust seal (11) from the cover (2).
3,4
(10) Remove the bearing (1), and dust seal
(11).
1
11
7579S5SE18
(17).
(13) Remove the bearing (1), collar (6) and
dust seal (10). 3,4
17 10 18
7579S5SE19
3) INSPECTION
(1) Check the bearing sliding surface for excessive wear, scorching or scratches; replace if
necessary.
(2) Replace all dust seals (10, 11) with new ones.
(3) Grind any pins (5, 9) dented with an oilstone or replace any pins abrasive excessively.
(4) Check inside cover (2, 17) and collar (6, 7) for dents or scratches; if any damage is found, correct
with a grinder or replace.
(5) The serviceable limit of pins and bushings is shown in the table below.
Unit : mm
Std Serviceable limit
Item No. Name Remedy
dimension Outer dia Inner dia Clearance
6, 10 Pin 74.5
1 Tapered roller bearing 75 75.5 0.8 Replace
7, 8 Collar 75.5
12, 13 Dust seal When removed Replace
5-57
4) ASSEMBLY
8 12,13 11 6 5 21
10
16
18,13
2
1
20
3,4
Clearance A
3,4
1 20
17
8 7
14,15
21 9 16 12,13
UPPER LOWER
7579S5SE20
Assemble the center pivot group by reversing the order of disassembly while paying close attention
to the following.
(1) Put the dust seal (10, 11) into cover (2, 17) and front frame (20).
※ Apply grease to the lip of the dust seal. Insert the dust seal so that the dust seal lip faces out and
punch four places on the outer circumference of the seal to lock it.
(2) Lower the temperature of the lower bearing cup to -75±5˚C (-103±9˚F ) and install it to front
frame until it contacts the bottom of the frame.
(3) Coat lightly with oil and install lower bearing in bore in front frame. Coat lightly with oil and install
upper bearing in bore in upper front frame.
(4) Position the cover (2, 17) and hold in place with bolt (12). At this time, adjust shims (3, 4) to press
the shoulder of bearing (1) against retainer.
ㆍ Adjustment method of clearance A
① Install bearing and cover without shim (3, 4)
Install four of bolt (12) so that each bolt is seperated by 90 degrees.
ㆍTightenig torque : 0.8~1.0 kgfㆍm (5.8~7.2 lbfㆍft)
② Adjust shims in order to control the clearance A.
ㆍClearance A : Below 0.1 mm
ㆍShim thickness : 0.1 mm, 0.5 mm
5-58
(5) Apply grease to lower collar (7) and insert it to the lower of roller bearing.
(6) After setting the bearing so that its upper surface is horizontal, tighten the all the bolt (14).
After tightening, confirm that tapered roller bearing moves lightly ; if does not move smoothly, add
shims (3, 4).
ㆍTightening Torque : 9.8~15.8 kgfㆍm (70.9~114lbfㆍft)
ㆍApply loctite #243.
(7) Move the front frame and join it to the rear frame so that match the pin hole at the center.
(8) Apply grease to pin (9), bushing (16) and insert it into tapered roller bearing (1).
(9) Apply grease to lower collar (7) and insert it to the lower of roller bearing through rear frame (21).
(10) Apply grease to pin (5) and insert it into tapered roller bearing (1).
(11) Before tightening bolt (12), adjust shims (14, 15) in order to control the clearance between the
plate (8) and rear frame (21).
ㆍAdjustment method of clearance B
① Install pin (5) and plate (8) without shim (14, 15).
Install four of bolt (14) so that each bolt is seperated by 90 degrees.
ㆍTighting torque : 0.8~1.0 kgfㆍm (5.8~7.2 lbfㆍft)
② Adjust shims in order to control the clearance B.
ㆍClearance B : 0.1~0.2 mm
ㆍShim thickness : 0.1 mm, 0.5 mm
(12) Tighten the all the bolts (12).
ㆍTightening Torque : 9.8~15.8 kgfㆍm (70.9~114 lbfㆍft)
ㆍApply loctite #243.
5) TROUBLESHOOTING
Trouble Probable cause Remed
Shock is felt when steering Capscrew for fixing steering valve is loose Retighten
Faulty center pivot pin mounting bolts Retighten
Center pivot pins have worn out Readjust or replace
Faulty hydraulic system See hydraulic system
Shock is felt when moving Fault fixing of connecting capscrews Retighten
backward or forward
Center pins have worn out Readjust or replace
Bearings of support unit have worn out Retighten
Drive shaft damaged See drive system
Faulty transmission See transmission system
5-59
SECTION 6 WORK EQUIPMENT
The pilot supply unit consists of the pressure reducing valve, relief valve and accumulator.
Flow from the main hydraulic pump not used by the steering system leaves the steering valve EF
port.
It flows to the inlet port plate of mono block type main control valve.
The main control valve is open center system which routes flow to the boom, bucket or auxiliary
cylinders (not shown) when the respective spools are shifted.
Flow from the steering pump is routed to the pilot supply unit where the steering pump outlet
pressure is reduced to pilot circuit pressure. The pilot supply unit control valve flow to the remote
control valve.
The remote control valve routed flow to either end of each spool valve section in the main control
valve to control spool stroke.
A accumulator mounted on pilot supply unit supplies a secondary pressure source to operated
remote control valve so the boom can be lowered if the engine is off.
The return circuit for the main hydraulic system have return filter inside the hydraulic tank. The return
filter uses a filter element and a bypass valve. The bypass valve is located in the upside of filter.
6-1
2. HYDRAULIC CIRCUIT
FRONT
AXLE
LH
10 RH
11 12 30
REAR
31
33
LH RH
Sp
4 T P
18 PS 6 CL CR
T
A B
BL1 BR1 BL2 BR2
8
32 PS 1 3 4 2 1.1 2.1
L
40 T1 P1 T2 P2
R 3 T
T/M
B3
17 17 Ps
a3
B2 15
Ts
A3 L R
19 5
F2
PS
14
PS
T1 B1
A1 AUX
B b1
a1 F1
PS1
PS
19 U 13
P T
P
20 P T
T
P1 P2
2 1
29 23
PS
28 M1
A
29 M2
P1
24 T P
26 21 C
PS
25
P2
27 22
M
7579S6WE01
6-2
3. WORK EQUIPMENT HYDRAULIC CIRCUIT
11 12 4 T P
LH RH
1 3 4 2 1.1 2.1
3 T
B3
B2
15
A2 ROLL BACK DUMP A
b2
a2
F2
B1 14
A1 AUX.
b1
a1 F1
U 13
P
T
Steering valve(EHPS) EF port
P1 P2
Steering system
Brake system
1
Return line
23
24 T P
26 21 C
25
22
7579S6WE02
6-3
1) WHEN THE RCV LEVER IS IN THE RAISE POSITION
11 12 4 T P
LH RH
1 3 4 2 1.1 2.1
3 T
B3
B2
15
A2 ROLL BACK DUMP A
b2
a2
F2
B1 14
A1 AUX.
b1
a1 F1
U 13
P
T
Steering valve(EHPS) EF port
P1 P2
Steering system
Brake system
1
Return line
23
24 T P
26 21 C
25
7579S6WE03
· When the RCV lever (4) is pulled back, the boom spool is moved to raise position by pilot oil
pressure from port 3 of RCV.
· The oil from main pump (1) flows into main control valve (3) and then goes to the large chamber of
boom cylinder (12) by pushing the load check valve of the boom spool.
· The oil from the small chamber of boom cylinder (12) returns to hydraulic oil tank (24) through the
boom spool at the same time.
· When this happens, the boom goes up.
6-4
2) WHEN THE RCV LEVER IS IN THE LOWER POSITION
11 12 4 T P
LH RH
1 3 4 2 1.1 2.1
Make up valve
3 T
B3
B2
15
A2 ROLL BACK DUMP A
b2
a2
F2
B1 14
A1 AUX.
b1
a1 F1
U 13
P
T
Steering valve(EHPS) EF port
P1 P2
Steering system
Brake system
1
Return line
23
24 T P
26 21 C
25
7579S6WE04
· When the RCV lever (4) is pushed forward, the boom spool is moved to lower position by pilot
pressure.
· The oil from main pump (1) flows into main control valve (3) and then goes to small chamber of
boom cylinder (12) by pushing the load check valve of the boom spool.
· The oil returned from large chamber of boom cylinder (12) returns to hydraulic tank (24) through
the boom spool at the same time.
· When the lowering speed of boom is faster, the return oil from the large chamber of boom cylinder
combines with the oil from the pump through the make up valve, and flows into the small chamber
of the cylinder.
This prevents cylinder cavitation by the negative pressure when the pump flow cannot match the
boom down speed.
6-5
3) WHEN THE RCV LEVER IS IN THE FLOAT POSITION
11 12 4 T P
LH RH
1 3 4 2 1.1 2.1
3 T
B3
B2
15
A2 ROLL BACK DUMP A
b2
a2
F2
B1 14
A1 AUX.
b1
a1 F1
U 13
P
T
Steering valve(EHPS) EF port
P1 P2
Steering system
Brake system
1
Return line
23
24 T P
26 21 C
25
7579S6WE05
· When the RCV lever (4) is pushed further forward from the lower position, the pilot pressure
reaches to 13~15bar, then the boom spool is moved to floating position.
· The work ports (A3), (B3) and the small chamber and the large chamber are connected to the
return passage, so the boom will be lowered due to it's own weight.
· In this condition, when the bucket is in contact with the ground, it can be move up and down in
accordance with the shape of the ground.
6-6
4) WHEN THE RCV LEVER IS IN THE DUMP POSITION
11 12 4 T P
LH RH
1 3 4 2 1.1 2.1
3 T
B3
B2
15
A2 ROLL BACK DUMP A
b2
a2
F2
B1 14
A1 AUX.
b1
a1 F1
U 13
P
T
Steering valve(EHPS) EF port
P1 P2
Steering system
Brake system
1
Return line
23
24 T P
26 21 C
25
7579S6WE06
· If the RCV lever (4) is pushed right, the bucket spool is moved to dump position by pilot oil pressure
from port 2 of RCV.
· The oil from main pump (1) flows into main control valve (3) and then goes to the small chamber of
bucket cylinder (11) by pushing the load check valve of the bucket spool.
· The oil at the large chamber of bucket cylinder (11) returns to hydraulic tank (24).
· When this happens, the bucket is dumped.
· When the dumping speed of bucket is faster, the oil returned from the large chamber of bucket
cylinder combines with the oil from the pump, and flows into the small chamber of the cylinder.
This prevents cylinder cavitation by the negative pressure when the pump flow cannot match the
bucket dump speed.
6-7
5) WHEN THE RCV LEVER IS IN THE ROLL BACK (retract) POSITION
11 12 4 T P
LH RH
1 3 4 2 1.1 2.1
3 T
B3
B2
15
A2 ROLL BACK DUMP A
b2
a2
F2
B1 14
A1 AUX.
b1
a1 F1
U 13
P
T
Steering valve(EHPS) EF port
P1 P2
Steering system
Brake system
1
Return line
23
24 T P
26 21 C
25
7579S6WE07
· If the RCV lever (4) is pulled left, the bucket spool is moved to roll back position by pilot oil pressure
from port 4 of RCV.
· The oil from main pump (1) flows into main control valve (3) and then goes to the large chamber of
bucket cylinder by pushing the load check valve of the bucket spool.
· The oil at the chamber of bucket cylinder (11) returns to hydraulic tank (24).
· When this happens, the bucket roll back.
6-8
6) WHEN THE RCV LEVER IS IN THE HOLD POSITION
11 12 4 T P
LH RH
1 3 4 2 1.1 2.1
3 T
B3
B2
15
A2 ROLL BACK DUMP A
b2
a2
F2
B1 14
A1 AUX.
b1
a1 F1
U 13
P
T
Steering valve(EHPS) EF port
P1 P2
Steering system
Brake system
1
Return line
23
24 T P
26 21 C
25
7579S6WE08
· The oil from main pump (1) flows into main control valve (3)
In this time, the bucket spool, the boom spool and the boom float spool are in neutral position, then
· the oil supplied to main control valve (3) returns into hydraulic tank (24) through center bypass
circuit of each spool.
· In this condition, each cylinder keeps the neutral position, so the boom and the bucket is holded.
6-9
4. MAIN PUMP
1) STRUCTURE
21
20
4
3 5
23
13
11 12 P2
22
19
15
8
7 14
6
S
17
18
P1
9
16
8 15
7 14
6 13
12
11
Port Port name Port size
10
S Inlet 2 1/2" SAE
P1, P2 Outlet 1" SAE
1
2 7607S6WE29
6-10
2) OPERATION
The main hydraulic pump is a fixed displacement gear type pump. The pump is drive at engine
speed by the transmission. The pump shafts are supported by shaft seal (1) adapter (2), front body
(16) and rear body (22). The wearplate (8, 11) are located between the gear surface and adapter
(1), rear body (22) and front body (16).
As the drive gear (9) and (19) turns the idler gears (10, 18), the gear teeth come out of mesh. Oil
flows from the hydraulic tank through the inlet into the cavity between the gear teeth. As the gears
continue to rotate, the oil becomes trapped between the gear teeth and front body (16).
The trapped oil is then carried to the pump outlet. Oil is forced out the outlet to supply the hydraulic
function. As the gears re-mesh, they form a seal to prevent oil from flowing between the gears and
back to the inlet.
The pump uses outlet pressure oil to load the wearplate (8, 11) against the gear faces. This
controls internal leakage to maintain pump displacement.
Outlet pressure fills the area bounded by the pressure balance moulded seals (6, 7) to force the
wearplate against the high pressure area or the gear faces.
6-11
5. REMOTE CONTROL VALVE
1) STRUCTURE
33 34 30 31
29
20 32
24 25
23 27
22 26
21 28
18 17
19 16
14 15
9 13
5 11
4 12
8 10
7 3
6 2
44
43 1,35
42 45
38,39,40,41 36,37,38,39
7607B6WE28
6-12
2) OPERATION
T P
33
1 34 2
HYDRAULIC CIRCUIT
(3 Electromagnetic locks)
32
Electromagnetic lock
21
17
18
13
(1) Hydraulic functional principle 8
Pilot devices with end position locks operate as
direct operated pressure reducing valves. 4
They basically comprise of handle (33), four
pressure reducing valves, body (1) and locks. 6
Each pressure reducing valve comprises of a
control spool (6), a control spring (8), a return 1
spring (4), push rod (13) and rod (17).
At rest, handle (33) is held in its neutral position by
return springs (4). Ports (1, 2, 3, 4) are connected 7607B6WE27
6-13
(2) End position lock
Only those control ports, for which it is necessary to hold the handle in a deflected position are
equipped with end position locks.
Electromagnetic lock
When this threshold is overcome, a joint assy (21) contacts the magnet (18); if the magnet (18) is
energized, then handle (33) is held in its end position by magnetic force.
This lock is released automatically when the solenoid is deenergized.
6-14
6. MAIN CONTROL VALVE
1) STRUCTURE
16
17
24
19
18
30
3
19
15
20
24
2
1
20
20
21
22
23
14 16
19 17
21
22
37 23
32 20
25
26 31 19
28 33
25
36 27 28 26
7607B6WE45
29 27
6-15
STRUCTURE
a3 A3 B3 b3
a2 A2 B2 b2
a1 A1 B1 b1
B3
A3 Boom up Boom down
b3
a3 Floating
B2
A2 Roll back Dump
b2
a2
B1
A1 Aux
b1
a1
21MPa
P
Hydraulic circuit
7607B6WE10
6-16
2) BOOM SECTION OPERATION
(1) Spool in neutral
T
LH RH
B3
A3 Boom up Boom down
b3
a3
B2
A2 Roll back Dump
b2
a2
T
Center bypass passage Tank passage
a3 Boom b3
7607WE11
When the boom plunger is in neutral position, oil from the pump flows to the tank through the
center bypass line.
The cylinder port (A3, B3) are shut off from the high pressure feed passage and tank passage by
the boom plunger.
6-17
(2) Boom raise position
T
LH RH
B3
A3 Boom up
b3
a3 Load
check
valve
B2
A2 Roll back Dump
b2
a2
a3 b3
7607WE12
When the pilot pressure is led to the port (a3), the boom plunger is switched, and shut off center
bypass passage.
Oil from the pump flows to the cylinder port (A3) through the load check valve and oil from the
cylinder flows into the tank passage through the cylinder port (B3).
※ Load check valve
When the load pressure is higher than the pump pressure, the load check shuts off the passage
between the high pressure feed passage and the center bypass passage and prevents the reverse
flow from the cylinder.
6-18
(3) Boom lower position
T
LH RH
B3
A3 Boom down
b3
a3 Load
check
valve
B2
A2 Roll back Dump
b2
a2
a3 b3
7607WE13
When the pilot pressure is led to the port (b3), the boom plunger is switched, and shut off center
bypass passage. Oil from the pump flows to the cylinder port (B3), through the load check valve
and oil from the cylinder flows into the tank passage through the cylinder port (A3).
6-19
(4) Boom float position
T
LH RH
B3
A3 Boom float
b3
a3
B2
A2 Roll back Dump
b2
a2
Tank passage
Center bypass passage
7607WE14
When the boom plunger is located in float position, the oil from the pump flows to the tank through
the center bypass line.
The cylinder port (A3) is connected to the tank passage, and the cylinder port (B3) is connected to
the tank passage, and the cylinder port (B3) is connected to the tank passage through the bridge
line. And then the both cylinder port is in float condition.
6-20
3) BUCKET SECTION OPERATION
(1) Spool in neutral
B3
A3 Boom up Boom down
b3
a3
B2
A2 Roll back Dump
b2
a2
T
Center bypass passage Tank passage
a2 Bucket b2
7607WE15
When the bucket plunger is in neutral position, oil from the pump flows to the tank through the
center bypass line.
To cylinder port (A2, B2) are shut off from the high pressure feed passage and tank passage by the
bucket plunger.
6-21
(2) Bucket rollback position
B3
A3 Boom up Boom down
b3
a3
B2
A2 Roll back
b2
a2 Load
check
valve
a2 b2
7607WE16
When the pilot pressure is led to the port (a2), the bucket plunger is switched, and shut off center
bypass passage.
Oil from the pump flows to the cylinder port (A2) through the load check valve and oil from the
cylinder flows into the tank passage through the cylinder port (B2).
※ Load check valve
When the load pressure is higher than the pump pressure, the load check shuts off the passage
between the high pressure feed passage and the center bypass passage and prevents the reverse
flow from the cylinder.
6-22
(3) Bucket dump position
B3
A3 Boom up Boom down
b3
a3
B2
A2 Dump
b2
a2 Load
check
valve
a2 b2
7607WE17
When the pilot pressure is led to the port (b2), the bucket plunger is switched, and shut off center
bypass passage.
Oil from the pump flows to the cylinder port (B2) through the load check valve and oil from the
cylinder flows into the tank passage through the cylinder port (A2).
6-23
4) Main relief valve
Main poppet(A)
· The relief valve is installed between pump
Pilot poppet(B) d1
circuit and tank circuit in the main control Spring(C) d2
valve housing and keeps system pressure
to setting pressure.
· Oil from the pump port (P) enters into the P
seated.
T
4
7607WE18
6-24
5) Port relief valve
The port relief valve is installed between
cylinder port and tank passage. Main poppet(B) Pilot poppet(D)
It protects the actuator from abnormal Piston(A) d1 Spring(C)
d2
pressure, due to outer force or sudden
block of cylinder pressure. Cylinder
The port relief valve is the type of built-in port
make-up function.
1 2 T 3 Circular 4
passage
7607WE19
T Circular 4
passage
7607WE20
6-25
7. PILOT OIL SUPPLY UNIT
1) STRUCTURE
5
1
P
2
U
T
6
P2 2
7607B6WE46
3MPa
Port Port name Port size
U
P1 From steering pump 3/4-16UNF
(2) OPERATION
The pilot supply manifold reduces the pressure from the high pressure circuit to a low pressure
circuit in order to supply the remote control valve.
The accumulator satisfies short term peak power demands and is a source of emergency power
in case of main circuit pressure failures.
The unit consists of the housing, the accumulator(4), the relief valve (6), the check valve and the
reducing valve (2).
The flow path is from the high pressure circuit through port P2 to the pressure reducing valve (2).
The pressure is reduced in the reducing valve (2) and oil passes the check valve into the
accumulator (4) and to the port U, which is connected with the remote control valve.
The pressure relief valve (6) protects the pilot circuit in case of the reducing valve (2) failures or
external increase of pressure.
6-26
8. BOOM AND BUCKET CYLINDER
The boom cylinders are two unit and the bucket cylinder is one unit. They use a bolt on rod guide.
The piston (12) threads on to the rod (2) and is retained by a nut (18) and set screw (19).
The piston seals against the tube (1) with piston seal (15). Two wear rings (16) are located on each
side of the piston seal.
The gland (3, the rod guide) seals against the tube with an O-ring (10). The cylinder thread seals
against the rod with a lip type buffer ring (7) and a rod seal (5). A dust wiper (8) cleans the rod when
it is retracted.
1) BOOM CYLINDER
13,14 28,29
20 1
7579S6WE26
6-27
2) BUCKET CYLINDER
26,28 20 21 1 22 24 23
7577S6WE20
6-28
9. HYDRAULIC OIL TANK
1) STRUCTURE
· The oil from the hydraulic tank is sent from the pump through main control valve to the cylinders.
In the return circuit, the oil from various parts merges.
· A part of oil is cooled in the oil cooler, passes through the hydraulic filter and returns to the
hydraulic tank (1).
· If the hydraulic return oil filter becomes clogged, return filter bypass valve (6) acts to allow the oil
to return directly to the hydraulic tank (1). This prevents damage to the hydraulic filter (5). The
bypass valve (6) is also actuated when negative pressure is generated in the circuit.
15 11,13 4 9
A
7
A
3 6
5
SECTION A - A
2,8
12,14 15 10
7579S6WE22
6-29
2) RETURN OIL FILTER BYPASS VALVE
From MCV
7607B6WE47
6-30
3) AIR BREATHER
The air breather is equipped with the
capacity to perform three functions
simultaneously-as an air filter, breathing
valve, and as a lubrication opening.
(1) Preventing negative pressure inside the
Air breather
tank
The tank is a pressurized sealed type, so
negative pressure is formed inside the
hydraulic tank when the oil level drops
during operations. When this happens,
the difference in pressure between the
tank and the outside atmospheric
pressure opens the poppet in the
breather, and air from the outside is let
into the tank or prevent negative pressure.
(2) Preventing excessive pressure inside
the tank
When the hydraulic cylinder is being
used, the oil level in the hydraulic system
increases and as temperature rises. If
the hydraulic pressure rises above the set
pressure, breather is actuated to release
the hydraulic pressure inside the tank. 7579S6WE27
6-31
10. ACCUMULATOR
The accumulator is installed at the pilot oil
supply unit. When the boom is left the
raised position, and the control levers are
operated with the engine stopped the
pressure of the compressed nitrogen gas
inside the accumulator sends pilot pressure
to the control valve to actuate it and allow 1
the boom and bucket to come down under 2
their own weight. 3
6-32
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 : Troubleshooting
·Group 3 : Tests and adjustments
6-33
※Hydraulic oil must be at operating temperature for these checks (refer to page 6-48).
6-34
Item Description Service action
Bucket rollback circuit relief Position bucket at a 45˚ angle OK
valve check against an immovable object. Check complete.
Engage transmission in 3rd speed NOT OK
forward. Replace boom lower
check valve.
LOOK : Bucket angle must not
change.
Bucket dump circuit relief Raise front of machine which OK
valve low pressure check bucket at 45˚ angle. Go to next check.
Backdrag with bucket while NOT OK
observing bucket angle. Do loader system and
circuit relief valve test at
LOOK : Bucket must not rollback
page 6-50.
Pilot control valve float With the bucket partially dumped, OK
check lower boom to raise front of Check complete.
machine.
Run engine at low idle. NOT OK
Push control lever to the float
Do pilot control valve
detent position and release lever.
pressure test in group 3.
LOOK : Front of machine lower to
the ground and valve must remain
in float position when lever is
released.
6-35
Item Description Service action
Boom cylinder leakage Dump bucket until teeth or cutting OK
check edge is per pendicular to the Drift is approximately the
ground. same between first and
Heat hydraulic oil to
second measurement.
operating temperature. Raise boom until cutting edge is
about 1 m (3 ft) above ground.
Repair loader control valve
Stop engine. Measure drift from or circuit relief valve.
tooth or cutting edge to ground for
1 minute. NOT OK
If drift is considerably less
Wait 10 minutes.
on second measurement,
Measure drift from tooth or cutting repair cylinder.
edge to ground for 1 minute.
LOOK : Compare the drift rate
between the first measurement
and the second measurement.
Bucket cylinder leakage Raise bucket about 1 m (3 ft) off OK
check ground with bucket level. Drift is approximately the
same between first and
Heat hydraulic oil to Stop engine. Place a support
second measurement.
operating temperature. under boom.
Measure drift from tooth or cutting Repair loader control valve
edge to ground for 1 minute. or circuit relief valve at
page 6-57.
Wait 10 minutes.
Measure drift from tooth or cutting NOT OK
edge to ground for 1 minute. Drift is considerably less
on second measurement.
LOOK : Compare the drift rates
between the first measurement
Repair cylinder.
and the second measurement.
Check valve of safety Put bucket level and position about OK
valve leakage check 1.2 m (4 ft) above ground. Check complete.
Heat hydraulic oil to Place a piece of tape on cylinder
NOT OK
operating temperature. rod at least 51 mm (2 in) from rod
Check or replace safety
guide.
valve.
Run engine at low idle in safety-
release position.
LOOK : Bucket must not drift up.
Pilot control valve Stop engine. Turn key switch to OK
OFF position. Check completed.
(RCV lever) check
Move control lever to all positions
NOT OK
and then release.
Repair pilot control valve.
LOOK : Lever must return to
neutral when released from all
positions.
6-36
Item Description Service action
Bucket leveler Position bucket fully dumped just OK
(positioner) check above ground level. Check complete.
Run engine at low idle. Move control lever to bucket NOT OK
leveler detent position and release. Do bucket leveler checks.
LOOK : Bucket must rollback to
the level position and control lever
must return to neutral.
If bucket is in a rolled back position
when key is turned ON, control
lever must be returned to neutral
manually if placed in the bucket
leveler detent position.
After bucket is dumped once,
bucket leveler will work normally.
Boom height kickout Position bucket flat on ground. OK
check Check complete.
Move control lever to boom raise
Run engine at low idle. detent position and release. NOT OK
Do boom height kickout
LOOK : Boom must raise to the
check.
set height and stop.
Control lever must return to
neutral.
Cycle time check Function Operating condition. Maximum cycle time
H e a t h y d r a u l i c o i l t o Boom raise Bucket flat on ground to full height. 6.0sec
operating temperature.
Boom lower Full height to level ground. 3.1sec
Run engine at high idle.
Bucket dump Boom at full height. 1.2sec
Bucket rollback Boom at full height. 1.6sec
Steering [No. of Frame stop to frame stop. 4.0 turns
turns]
OK
Check complete.
NOT OK
Go to slow hydraulic
functions in group 2.
6-37
※MEASURING BOOM AND BUCKET CYCLE TIME
1) MEASUREMENT CONDITION
·Coolant temperature : Inside operating range
·Steering position : Neutral
·Hydraulic temperature : 40~50˚C
·Bucket : Unloaded
·Engine speed : High idling
2) MEASURING TOOL
· Stop watch (1EA)
3) MEASURING PROCEDURE
(1) LIFTING TIME OF BOOM Lifting time of boom
75796WE25
75796WE26
6-38
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 :
Faulty pilot control valve (RCV). Do pilot control valve (RCV) pressure
test in group 3.
Binding loader control valve (MCV) Inspect valve.
spool.
Faulty steering valve (EHPS). Check priority valve, orifice of steering
valve (EHPS) specification.
6-39
Problem Cause Remedy
No steering or hydraulic Low oil level. Add recommended oil.
function
Failed hydraulic pump. Remove and inspect return filter for
metal pump particles.
No hydraulic functions Failed hydraulic pump. Remove and inspect return filter for
steering normal metal pump particles, or replace the
pump.
Failed line filter. Remove and inspect line filter for RCV.
Faulty safety valve. Safety valve leakage test or ON, OFF
function test.
Stuck open port relief valve. Replace relief valve.
Boom float function Low pilot control pressure. Do pressure reducing valve pressure
does not work test in group 3.
Faulty pilot control valve (RCV). Replace relief valve.
Loader control valve (MCV) spool Do pressure reducing valve pressure
binding in bore. test in group 3.
One hydraulic function Faulty pilot control valve (RCV). Do pilot control valve pressure test.
does not work. Inspect and repair valve.
Stuck open port relief valve. Replace relief valve.
Oil leaking past cylinder packings. Do boom and bucket cylinder leakage
test in group 3.
Blockage in oil lines or valve. Inspect lines for damage.
Disconnect and inspect lines for internal
blockage.
Loader control valve (MCV) spool stuck Inspect and repair valve.
in bore.
Low hydraulic power Leakage within work circuit. Do cylinder drift check in group 2.
Low system relief valve (main relief Do loader system and port relief valve
valve) setting. pressure test in group 3.
Low port relief valve setting. Do loader system and port relief valve
pressure test in group 3.
6-40
Problem Cause Remedy
Function drifts down Leaking cylinders. Do cylinder leakage checks in group 3.
Leaking seals in circuit relief valve (port Inspect seals. Replace relief valve.
relief valve) or valve stuck open.
Leaking loader control valve (MCV). Repair or replace valve section.
Boom drifts up Leakage in boom down spool. Remove and inspect boom down spool.
Boom down does not Safety valve not operated. Operate valve.
work (engine off)
Stuck pilot control valve. Inspect.
Faulty line filter. Remove and inspect filter.
Accumulation not operated. Inspect.
MCV spool stuck. Inspect and repair valve.
Oil overheats Low oil viscosity in hot weather. Use recommended oil.
Excessive load. Reduce load.
Holding hydraulic system over relief. Reduce load.
Leakage in work circuit. Do boom and bucket cylinder leakage
test in group 3.
Plugged fins in oil cooler. Inspect and clean oil cooler.
Internally plugged oil cooler. Do hydraulic oil cooler restriction test.
Incorrect system or circuit relief valve Do loader system and circuit relief valve
setting. pressure test in group 3.
Restriction in oil lines or loader control Inspect for dented or kinked lines.
valve (MCV).
Malfunctioning steering valve. Do hydraulic system restriction test in
group 3.
Leaking system main relief valve. Do hydraulic system restriction test in
group 3.
Remove and inspect valve and seals.
Worn hydraulic pump (internal leakage). Do hydraulic pump performance check
in group 2.
Function drops before Stuck open lift check valve. Do control valve lift check in group 2.
raising when valve is
activated
6-41
Problem Cause Remedy
Hydraulic oil foams Low oil level. Add recommended oil.
Wrong oil. Change to recommended oil.
Water in oil. Change oil.
Loose or faulty suction lines (air leak in Tighten or install new lines.
system).
Remote control valve Leaking plunger seals. Remove, inspect and replace plunger
(RCV) leaking seals.
※ Followings are general precautions for the hydraulic system and equipment.
1) Every structure has its limit of strength and durability. The relief valve is installed to limit the
pressure on the hydraulic equipment and protect various parts of the wheel loader from possible
damage. Therefore, never change the preset pressure of the relief valve unless absolutely
necessary.
2) Since the hydraulic equipment is built with precision, the presence of only the slightest amount of
dust and / or other particles in the hydraulic circuit might cause wear and/or damage, resulting in
unstable functions and/or damage, resulting in unstable functions and/or unexpected accidents.
Therefore, always keep hydraulic oil clean. Periodically, check the filter in the return circuit and
replace the element as necessary.
3) Extract about 200cc of hydraulic oil from the tank as a sample every 6 months. If possible, have it
analyzed by a specialist to confirm that the oil can still be used. Never extract the oil for sampling
until the oil temperature has become the normal operating temperature. Since the replacement
period varies depending on operating conditions, refer to Operator's Manual and change oil.
4) Should the equipment get damaged due to the presence of metal particles and/or foreign matter in
the circuit drain out the hydraulic oil and carry out flushing. Also, replace the filter element and
clean the hydraulic tank. Change the hydraulic oil entirely.
5) When checking the filter, if found metal particles in the element, drain out the hydraulic oil entirely,
flush the whole circuit, and then fill with new oil. The presence of metal particles may indicate
internal damage to the equipment. In such a case, check carefully before flushing, and repair or
replace as required.
6) To add and/or change the hydraulic oil, always use recommended oil. (Refer to the list of
recommended oils and lubricants at page 1-22, Recommended lubricants.
lubricants.) Never mix oil of
different makes of kinds.
7) To change the hydraulic oil, use a clean vessel and funnel for pouring it into the tank. Never use
cloth because it might cause the presence of lint in the circuit.
8) When removing the hydraulic equipment, be sure to put plugs or caps on hoses, tube lines and
ports. Also, enter mating marks for later identification.
6-42
9) Disassemble and/or assemble the hydraulic equipment only in a clean place free of dust. When
disassembling, be careful about the interchangeability of parts, and clean the disassembled parts
with pure and clean mineral cleansing oil. Clean the internal passages as well. After the parts
have dried, wipe them off with a clean lint-free cloth.
10) When overhauling the hydraulic equipment replace all O-rings, backup rings, etc. with new ones.
Assemble O-rings with grease or vaseline applied.
11) After installing the equipment, add more hydraulic oil to make up for that lost during disassembly.
12) Tighten joints correctly. Loose joints will cause the hydraulic oil to leak. If the oil leaks, the tank oil
level drops and air gets sucked in, so the pump will break down. Also loose joints in suction lines
will take air in and might cause abnormal noise, malfunction or damage to pumps.
6-43
GROUP 3 TESTS AND ADJUSTMENTS
6-44
5) Start the filter caddy. Check to be sure oil is
flowing through the filters.
Operate filter caddy approximately 10
minutes so oil in hydraulic oil tank is
circulated through filter a minimum of four
times.
※ Hydraulic oil tank capacity : 175 ℓ(46
U.S. gal)
Leave filter caddy operation for the next
steps.
6) Start the engine and run it at high idle.
※ For the most effective results, cleaning
procedure must start with the smallest
capacity circuit then proceed to the next
largest capacity circuit.
7) Operate all functions, one at a time,
through a complete cycle in the following
order: 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 reservoir; Add oil if
necessary.
6-45
2. BOOM HEIGHT KICKOUT ADJUSTMENT
1) Lift the boom up to a desired height, set the
boom control lever at hold, then stop the
engine.
Be careful lest work equipment fall down.
Put the hydraulic safety lock lever in the Boom
LOCK position.
Proximate switch
7707WE20
Plate
7707WE21
Boom
7707WE22
7609S4OP26
6-46
3. TEST TOOLS
1) CLAMP-ON ELECTRONIC TACHOMETER
INSTALLATION
·Service equipment and tools
B
Tachometer
A : Clamp on tachometer.
Remove paint using emery cloth and
C
connect to a straight section of injection
line within 100 mm (4 in) of pump. Finger
Tighten only-do not over tighten. D
B : Black clip ( - ). Connect to main frame.
C : Red clip (+). Connect to transducer. A
D : Tachometer readout. Install cable.
75795SE32
75795SE33
75795SE35
6-47
4. HYDRAULIC OIL WARM UP PROCEDURE
1) Install temperature reader (see temperature
reader installation procedure in this group).
6-48
5. MAIN HYDRAULIC PUMP FLOW TEST
· SPECIFICATION
Oil temperature 45±5˚C (113±9˚F)
Engine speed 2100±25 rpm
Test pressure 210±5 bar (2990 psi)
Maximum pump flow 225ℓ/min (59.4 U.S.gpm)
· FLOW METER GAUGE AND TOOL
Gauge 0~35 MPa (0~350 bar, 0~5000 psi) Flow meter
Temperature reader
To MCV
1) Make test connections.
2) Install temperature reader.
(see temperature reader installation procedure
in this group)
3) Heat hydraulic oil to specifications.
(see hydraulic oil warm up procedure in this
group)
4) Run engine at test specifications.
5) Close flow meter loading valve to increase
pressure to test specifications.
6) Read flow meter.
7) If flow is below specifications, check suction
line and suction pressure for abnormality
before removing pump. 7607WE29
6-49
6. LOADER
L ADER SYSTEM AND PORT RELIEF
VALVE PRESSURE TEST
· SPECIFICATION
Oil temperature (40~50˚C)
Relief valve Engine speed Relief pressure
210±10 kg/cm2 U
System (M) High T
(2990±140 psi)
Boom 240±10 kg/cm2
Low Boom
raise (U) (3410±140 psi)
Bucket
Bucket 240±10 kg/cm2
Low
rollback (R) (3410±140 psi) P
R
Bucket 240±10 kg/cm2
Low
dump (D) (3410±140 psi)
M D
· Gauge and tool
Gauge 0~35 MPa (0~350 bar, 0~5000 psi)
M : System (main) relief valve
R : Bucket rollback relief
D : Bucket dump relief
U : Boom raise relief
1) Install fitting and pressure gauge to test
port in pump delivery line.
2) Install temperature reader.
P
(see temperature reader installation
procedure in this group)
3) Heat hydraulic oil to specifications.
T
(see hydraulic oil warm up procedure in this
group)
4) To check the system relief (M), run engine
at high idle. Lower boom to bottomed Main pump
position.
Slowly activate boom down function while
watching pressure gauge. If pressure is not
to specification, loosen lock nut on system
relief valve (M) and adjust to specification. 7607WE30
6-50
※ Do not adjust the system relief valve
above 210 kg/cm2 (2990 psi). Damage to
the pump will result from excessive
pressure settings.
6-51
7. HYDRAULIC SYSTEM RESTRICTION
TEST
· SPECIFICATION
Oil temperature 45±5˚C (113±9˚F)
Engine speed High idle
Maximum pressure 2 MPa (20 bar, 285 psi)
at steering valve (EHPS).
Maximum pressure at main control valve
1 MPa (10 bar, 145 psi)
· GAUGE AND TOOL
Gauge 0~7 MPa (0~70 bar, 0~1000 psi) 2EA
This test will check for restrictions in the
hydraulic system which can cause
overheating of hydraulic oil.
P
1) Install temperature reader.
(see temperature reader installation
procedure in this group)
2) Heat hydraulic oil to specifications.
(see hydraulic oil warm up procedure in this
group)
3) Connect fitting and gauge to steering valve.
4) Connect fitting and gauge to main control
valve.
Do not operate steering or loader funct-
ions or test gauge may be damaged.
5) Run engine at specification and read
pressure gauges.
If pressure is more than specification at the
T
loader control valve, check for a kinked,
dented or obstructed hydraulic line. Check
loader control valve for a binding spool.
If pressure is more than specification at the
steering unit, inspect neutral condition of
the steering unit and steering valve for a
stuck spool. Make sure orifice plugs are
installed in ends of priority valve spool.
Check for plugged orifice in priority valve
and dynamic signal orifice on steering valve
body. 7607WE31
6-52
8. LOADER CYLINDER DRIFT TEST
· SPECIFICATION B
Oil temperature 45±5˚C (113±9˚F)
Boom horizontal
Bucket horizontal
Bucket loaded A
Item Standard value
Retraction of boom
15 mm
cylinder rod A : Retraction of bucket cylinder rod
Retraction of bucket B : Retraction of boom cylinder rod
23 mm
cylinder rod
· GAUGE AND TOOL
Stop watch
Temperature reader
Put the hydraulic safety lock lever in the
lock position.
Do not go under the work equipment.
1) Set the boom and bucket horizontal, then
stop the engine.
2) Stop the engine, wait for 5 minutes, then
start measuring.
3) Measure the amount the boom and bucket
cylinder rods retract during 15 minutes.
7577AWE31
6-53
9. BOOM AND BUCKET CYLINDER LEAKAGE TEST
· SPECIFICATION
Oil temperature 45±5˚C (113±9˚F)
Engine speed Low idle
Maximum leakage 15 mℓ/min (1/2 oz/min)
· GAUGE AND TOOL
Temperature reader
Stop watch
Measuring container
1) Fasten temperature sensor to head end
port of cylinder to be tested. Cover sensor
with a shop towel.
2) Heat hydraulic oil to specifications (see
hydraulic oil warm up procedure in this
group).
Never work under raised equipment
unless it is supported with a hoist or
support stands.
3) Full extend the cylinder to be tested. If
testing the boom cylinders, restrain boom in
the fully raised position using a hoist or a
stand.
※ Check cylinders for leakage in the fully
extended position only. In the retracted
position contacts the end of the cylinder
and seals off piston seal leakage.
4) Remove and plug cylinder rod end hose or
line.
5) Run engine at slow idle. Activate control
lever to extend cylinder for 1 minute over
relief while measuring leakage for open
port.
If leakage is within specification, excessive
cylinder drift is caused by leakage in the
(770-3ATM) 6-56
loader control valve or circuit relief valve.
6-54
10. PILOT CONTROL VALVE P
PRESSURE
RESSURE TEST
· SPECIFICATION
Oil temperature 45±5˚C (113±9˚F)
Engine speed Low idle
Begin metering 1/4" of lever travel
Pressure in detent :
Boom float detent 1.9 MPa (19 bar)
Pressure at detent position :
Boom power down 19~22bar
Boom raise 19~22bar
Bucket rollback 19~22bar
Bucket dump 19~22bar
· GAUGE AND TOOL
Gauge 0~7 MPa (0~70 bar, 0~1000 psi)
As the control lever is moved from neutral,
the pilot pressure will suddenly jump up to
approximately 5.8bar at 1/4in. travel. The
pressure should then increase smoothly to
the specification at the FEEL position (or
3/4 lever travel), and then jump up about
430psi as the lever is moved into detent.
This test will determine if adequate pilot
pressure is available to move the loader
control valve spools.
※ The FEEL position is when lever is
moved to feel the ramp of the detent
before lever passes into detent position.
1) Lower boom to ground.
2) Connect gauge to the pilot pressure port of
function to be checked.
3) Install temperature reader (see temperature
reader installation procedure in this group).
4) Heat hydraulic oil to specification (see
hydraulic oil warm up procedure in this
7607B6WE41
group).
6-55
11. PILOT OIL SUPPLY UNIT P
PRESSURE
RESSURE TEST
· SPECIFICATION
Oil temperature 45±5˚C (113±9˚F)
Engine speed Low idle and stop
Pilot pressure setting
30~35 bar (430~500 psi)
Relief valve setting pressure 45 bar
Accumulator precharging pressure 16 bar
· GAUGE AND TOOL
Gauge 0~7 MPa (0~70 bar, 0~1000 psi)
The pilot supply unit consist of the pressure
reducing valve, the relief valve and an
accumulator. This regulates pressure to the
pilot control circuit.
1) Connect gauge to test port on the screw
coupling.
2) I n s t a l l t e m p e r a t u r e r e a d e r ( S e e
temperature reader instakkation procedure
in this group).
3) Heat hydraulic oil to specification (see
U
hydraulic oil warm up procedure in this T P2
group).
4) Run engine at loe idle for 1 minute and stop
engine, wait for 5 minutes, Then start
measuring.
5) If pressure in not within specifiactions,
replace valve.
7707WE26
6-56
12. CYCLE TIME TEST
· SPECIFICATION
Oil temperature 45±5˚C (113±9˚F)
Engine speed High idle
Function Operating conditions Maximum cycle time (seconds)
Boom raise Bucket flat on ground to full height 6.0
Boom lower (float) Full height to ground level 3.1
Bucket dump Boom at full height 1.2
Bucket rollback Boom at full height 1.6
Steering (number of turns) Frame stop to stop 4.0 turns
6-57
13. HYDRAULIC OIL FILTER INSPECTION
PROCEDURE
1) Lower the bucket to the ground, stop the
engine, move the control lever back and
forth several times, and clean all over the
upper surface of the hydraulic oil tank.
2) Remove the bolts and take out the filter
case cover and O-ring.
3) Remove the spring and bypass valve.
4) Remove the filter element from the tank. Cover
O-ring
5) Check the element and the filter case Spring
bottom for debris. Excessive amounts of By-pass valve
brass and steel particles can indicate a Return filter
failed hydraulic pump or a pump failure in
process. A rubber type of material can
indicated cylinder packing or other packing
failure.
※ The hydraulic oil filter in the filter case of
the hydraulic oil tank should be replaced
every 250 operating hours or more often.
When the filter element is replaced,
please keep as follows.
(1) Clean the inside of the filter case.
(2) Place new element in the proper positions
inside the filter case.
(3) Install the bypass valve and spring.
Make sure the element stand upright, and
check for complete contact of the element
bottom with the filter case bottom.
(4) Install the O-ring and filter case covers.
Tighten them with bolt. Replace the
7579S6WE60
O-ring with new one if damaged.sa
6-58
GROUP 4 DISASSEMBLY AND ASSEMBLY
1. MAIN PUMP
1) STRUCTURE
21
20
4
3 5
23
13
11 12
22
19
15
8
7 14
6
17
18
9
16
8 15
7 14
6 13
12
11
10
1
2
7607WE33
6-59
2) DISASSEMBLY
21
20
4
3 5
23
13
11 12
22
19
15
8
7 14
6
17
18
9
16
8 15
7 14
6 13
12
11
10
1
2
7607WE33
※ Plug all ports prior to cleaning and disassembling pump to prevent ingress of debris or
contamination.
※ Clean the pump thoroughly with a solvent, ensuring no loose debris or contamination remains on
the unit.
※ Mark each interface and then separate into individual pump sections.
(1) Securely clamp pump horizontally on one port face, ensuring that no damage is sustained to the
port face and remove the stud (20) and nut (21).
(2) Remove the front adaptor (2) from the body (16) using a pulling tool centred on the drive shaft (9).
※ Under NO circumstances attempt to prise or chisel cover from body as such action could
damage the machined sealing faces.
(3) Remove and discard the shaft seal (1) from adaptor making sure that no damage is sustained to
the surface of the seal bore.
(4) Unclamp pump and place it vertically with drive shaft up.
(5) Before removing wearplate from the body mark it using a soft pencil or a felt-tip pen to ensure
correct reassembly. Remove wearplate (8) complete with O-ring seal (7) and back up seal (6).
6-60
DISASSEMBLY
21
20
4
3 5
23
13
11 12
22
19
15
8
7 14
6
17
18
9
16
8 15
7 14
6 13
12
11
10
1
2
7607WE33
6-61
3) MANDATORY REPLACEMENT PARTS
Discard all seals including interface seals, shaft seals, wear plate seals and back up seals. Fit new
seals on reassembly. Wearplates should also be replaced with new items from seal kit.
4) HANDLING/STORAGE
HANDLING/STORAGE
While disassembling pump, ensure no surfaces are scored or marked in any way. A rubber
surfaced table will be beneficial. All components must be placed in a clean, dry and safe area.
Leakage will be created by scratches on components. If parts are to be left for any period ensure
they are not exposed to dirt, dust and corrosion. Keep gears separate from each other in protective
boxes.
5) INSPECTION
INSPECTION OF PARTS
Wash all parts in a solvent and dry.
(1) Adaptor housing and cover
The pump must be replaced if the damage listed is present.
Feature Damage
Corrosion, nicks or burrs (slight burrs can be removed using and
Surfaces
india stone)
Machined sealing lnterfaces Scores, cracks or corrosion
Bearing Loose
(2) Gears
The pump must be replaced if the damage listed is present.
Feature Damage
Corrosion, nicks or burrs (slight burrs can be removed using an
Surfaces lndia stone).
Wear due to seal (s)
Journals Pitting, wear, sufficient wear to change outside diameter
Tooth Cracks or heavy scoring or chipped
Splines/keyways Distortion of wear
End faces Wear, cracks
6-62
(3) Floating wear plates
The pump must be replaced if the damage listed is present.
Feature Damage
Corrosion, nicks or burrs, amounts of scoring,erosion
Surfaces
or any cracks, discoloration caused by overheating
(4) Bolts/Studs
The pump should be replaced if the damage listed is present.
Feature Damage
Corrosion, nicks or burrs (slight burrs can be removed
Surfaces using an lndia stone), cracks or scoring,
distortion or damage to thread form
(6) Coupling
This must be replaced if damage listed is present.
Feature Damage
Surfaces Corrosion, nicks or burrs, erosion, cracks or pitting
Splines Distorted or badly worn
6-63
6) ASSEMBLY
21
20
4
3 5
23
13
11 12
22
19
15
8
7 14
6
17
18
9
16
8 15
7 14
6 13
12
11
10
1
2
7607WE33
※ It is critical that the wearplates are assembled into the pump with regard to the following:
-The seal side of the wearplate must be adjacent to the adaptor or body.
-The high pressure side of the wearplate must be adjacent to the outlet port.
※ This must take place in a clean dry area, ensuring that all parts are clean and free from
contamination or loose particles. Lightly oil all surfaces.
(1) Place body vertically with gear pockets upper most.
(2) Slide wearplate (11) complete with O-ring seal (12) and back up seal (13) down through the
housing to the bottom of the gear pockets.
※ Be sure to refit the wearplate the same as that marked from this position during disassembly.
(3) Fit the gears (18,19) within the housing taking care to replace as marked, with the teeth
reassembled to their original related position.
(4) Fit the wearplate (8) complete with O-ring seal (7) and back up seal (6).
※ Be sure to refit the wearplate the same as that marked from this position during disassembly.
6-64
ASSEMBLY
21
20
4
3 5
23
13
11 12
22
19
15
8
7 14
6
17
18
9
16
8 15
7 14
6 13
12
11
10
1
2
7607WE33
6-65
2. MAIN CONTROL VALVE
1) STRUCTURE
89
11
37
32
33
34 24
23 22
7 35 22
17 23
24
36 21
20 17
19
18 3 24
11 17 23
22
2 12
16
5 1
4 12
12
13
6 1514
21
11 9
8
31 13
25 1514
26 12
27 25
26 11
28 27 39
30 28 38
29 40
7607WE35
6-66
2) GENERAL PRECAUTIONS
(1) Clean room with no dust is recommended for maintenance. Because hydraulic components are
precision, and have minute clearance. Tool and wash-oil must be clean, too. Handle them
carefully.
(2) At removing control valve from the machine, wash around the piping port, and neither dust nor
water should go into inside with plugging. It is same at attaching the machine.
(3) Prepare the required parts by checking structure figure before assembly. There are parts which
are supplied with only sub-assembly part, so check the parts list before assembly.
3) PRECAU
PRECAUTIONS
TIONS FOR DISASSEMBLY
(1) Handle the components carefully not to drop them or bump them with each other as they are
made with precision.
(2) Do not force the work by hitting or twisting as burred or damaged component may not be
assembled or result in oil leakage or low performance.
(3) When disassembled, tag the components for identification so that they can be reassembled
correctly.
(4) Once disassembled, O-ring and back-up rings are usually not to be used again (remove them
using a wire with its end made like a shoe-horn. Be careful not to damage the slot).
(5) If the components are left disassembled or half-disassembled, they may get rust from moisture or
dust. If the work has to be interrupted, take care to prevent rust and dust.
4) PREC
PRECAUTIONS
AUTIONS FOR REASSEMBLY
(1) Take the same precautions as for disassembly.
(2) When assembling the components, remove any metal chips or foreign objects and check them
for any burrs or dents. Remove burrs and dents with oil-stone, if any.
(3) O-rings and back-up rings are to be replaced with new ones, as a rule.
(4) When installing O-rings and back-up rings, be careful not to damage them (apply a little amount
of grease for smoothness).
(5) Tighten the bolts and caps with specified torque.
5) SPEC
SPECIAL
IAL TOOL
· HOLDER
Material : copper
41 Hex : Division
100
28.2
7607WE36
6-67
※ Regarding to change the main plunger
We can not supply the main plunger,
because the plunger is fit for valve
housing.
So, do not change the plunger at the field.
If changing plunger must be needed, then
tell us model name of control valve and Name plate
serial number written at its nameplate.
7607WE37
7607WE39
6-68
(4) Remove the plunger cap (3), spring guide
(4), spring (6) and sleeve (5).
※ Spring is different from boom section
spring. 3
4
5
6
4
7607WE41
7) BOOM PLUNGER
(1) Remove hexagon socket bolts (1) then
remove cover (2).
·Hexagon socket bolt
Width across flat : 8 mm
Tightening torque : 5.1 kgf·m (36.8 lbf·ft)
※ Reassembly
Install cover (2), after making sure that 2 1
O-ring is placed on the edge of the housing 7607WE43
hole.
7607WE44
6-69
(3) Set the spool between holders and
Holder
loosen plunger cap (3) by using vise.
·Plunger cap
Width across flat : 8 mm
Tightening torque : 6.1 kgf·m (44.2 lbf·ft)
※ Set the spool between holders and clamp 3
them by a vise after degreasing the spool
and holders as a special tool.
7607WE45
6
7
7607WE46
housing.
3 4 5
7607WE48
6-70
(2) Loosen hex nut (2), and remove adjust
screw (3), spring (4) and pilot poppet (5).
·Hex nut (2)
Width across flat : 19 mm
2 5
Tightening torque : 3.3 kgf·m (23.6 lbf·ft)
·Adjust screw (3) 4
Width across flat : 22 mm
3
7607WE49
7
6
9
8
7607WE50
Pilot seat
7607WE51
6-71
(5) RESETTING THE RELIEF PRESSURE
7607WE52
※ If setting pressure is mistaken, hydraulic unit may be destroyed and danger may be caused.
Do not raise by any means more than the pressure decided for every model.
Tempolary assembly and setting
① Check the position of setting pressure 0 MPa.
Set adjusting screw (A) temporarily in the position that pilot poppet (B) contacts to pilot seat.
Then pressure adjusting spring (C) begins to be effective.
② Install the main relief valve which is set temporarily to main body.
Tighten cap with torque wrench.
·Tightning torque : 10.2 kgf·m (73.8 lbf·ft)
To set pressure
① Attach exact pressure gauge at exit of pump or gauge port of control valve.
② Operate the pump with rated speed.
③ Operate plunger either boom or bucket at full stroke and check the pressure.
④ Turn adjusting screw (A) (right turn) and set pressure with checking pressure gauge.
·One quarter turn of adjusting screw (A) equals about 4 MPa.
·Setting pressure 20.6 MPa (210 kgf/cm2) at 220ℓ/min.
·Relief is very sensitivity. So, do not turn adjusting screw (A) suddenly.
⑤ Tighten lock nut with torque wrench holding adjusting screw.
·Tightning torque : 3.3 kgf·m (23.6 lbf·ft)
※ Operate plunger and check the setting pressure, again.
6-72
9) PORT RELIEF VALVE
Adjusting screw
※ Do not disassemble adjusting screw.
It’s impossible to readjust setting pressure
exactly on the machine.
(1) Loosen sleeve (1) and remove relief valve.
·Sleeve (1)
Width across flat : 41 mm
Tightening torque : 10.2 kgf·m (73.8 lbf·ft)
6 5 4 3 1 2
※ Install to original position. 7607WE53
7607WE54
4 3 1 2
7607WE55
6-73
11) LOAD CHECK VALVE
2
2 1 1
3 4 3
6-74
3. REMOTE CONTROL VALVE
1) STRUCTURE
33
10
42 12
34 11
30 13
9
31 5
38,39,40,41
6
32
29
24 4
23
25
1,3,4 1
4
22 3 2 7
26
3
21 27
28 2
2
1,3,4 4 1
3 2
20
1
4 1
19
3 2
17 35
44 44
16 16
18 15 43
1,3,4
43
2
36,37,38,39
14 45
45
7607B6WE48
6-75
2) DISASSEMBLY
(1) Remove the boots (32) and loosen nut
(31).
· Tool : spanner 19 mm
7607BRCV01
7607BRCV02
7607BRCV03
6-76
(3) Disassemble plate kit.
7607BRCV04
7607BRCV05
7607BRCV06
7607BRCV07
6-77
(7) Disassemble magnet (18) and rod stopper
(15).
7607BRCV08
7607BRCV09
7607BRCV10
7607BRCV11
6-78
(11) Disassemble plug (2).
· Tool : Wrench 10 mm
7607BRCV12
6-79
3) ASSEMBLY
(1) Coat oil on O-ring and mount plug (3) into
body assembly (1).
7607BRCV13
7607BRCV14
7607BRCV15
7607BRCV16
6-80
(5) Assemble plug kit.
7607BRCV17
7607BRCV09
Important
7607BRCV19
7607BRCV20
6-81
(9) Assemble plate (19).
7607BRCV21
7607BRCV22
7607BRCV23
7607BRCV24
6-82
(12) Assemble plate kit.
Put a bit of grease on rod (17) and Joint
(21).
7607BRCV04
7607BRCV03
7607BRCV02
6-83
(14) Assembled nut (31).
· Tool : spanner 19 mm
· Tightening torque (M12) :
40±4 kgf·cm (28±28.9 lbf·ft)
7607BRCV01
7607BRCV25
6-84
SECTION 7 ELECTRICAL SYSTEM
1. LOCATION 1
15
3
12
24 23
5
4 21
22
14 16
6 7 8 9 10 11 12 13 17 18 19 20
7579S7EL02
7-1
2. LOCATION 2
3 3 2 4
OFF
11 12 5
13
6 7 8 9 10
7609S7EL02-1
7-2
CAB ROOF HARNESS
·ELECTRICAL
PTC
AC HARNESS
1
2
3
HI
OPTION
WIPER
RELAY
REAR
CN-244A
STEER
WITH PTC
LOW
AC
HORN
HEAT
RELAY
WIPER
RELAY
WIPER
RELAY
TIMER
DIFF.
LAMP
LOCK
LAMP
REAR
WORK
MIRROR
RELAY
UNIT
WORK
FRONT
RELAY
EMERGENCY
A
B
C
M
AC SYSTEM GND
FLASHER
BLOWER RELAY
SW2
2
2
2
2
2
2
1
1
1
1
1
1
GND 1
86
86
85
85
AC 24V
ILLUMINATION
WIPER SWITCH
WIPER SWITCH
WIPER SWITCH
Pf
NC
NC
B
E
MIRROR HEAT
MIRROR HEAT SWITCH
AC CONTROLLER B+
BEACON LAMP
NC
NC
NC
NC
NC
EMERGENCY TEST SW
AC OPERATE SIGNAL
3
3
3
3
3
3
SWITCH ATT. LOCK
5
5
5
5
5
5
SWITCH ATT. UNLOCK
BOOM POSITION SELECT
WIPER SWITCH
NC
REVERCE SW_AUTO
REVERCE SW_ON
CASSETTE_ILLUMINATION
PTC POWER
30
30
AC COMP
G
IG
A
Hi 4
2
3
Lo 5
4
4
4
4
4
4
4
3
OUT
87 87a
87 87a
1
3
2
4
4
4
2
2
2
2
2
2
6
1
1
1
1
1
1
5
3
3
3
3
3
3
14
7
13
5
10
10
1
87a
87a
4
3
2
1
5
5
5
5
5
5
15
13
14
15
2
4
4
4
4
4
4
9
5
3
6
8
3
12
11
12
11
B 85
86
86
8
1
6
9
7
1
85
85
30
30
L 87
E 86
87
87
A
2
2
1
B
7
4
6
C
2
5
8
3
CN-7
CR-79
CN-102
CR-4
CR-2
CR-3
CR-55
CN-244
CR-26
CR-7
CR-37
CN-245
CR-11
CN-11
CN-9
CR-56
L
L
L
L
L
L
B
Y
V
B
B
Y
Y
Y
B
B
V
Y
B
Y
B
Y
B
V
B
V
R
R
R
R
R
G
G
G
W
W
W
W
W
W
W
W
Br
Br
Br
Br
Gr
Gr
Gr
Gr
Gr
Or
5L
5B
WITHOUT PTC
BW
VW
BW
RW
RW
RW
RW
YOr
BrW
OrW
300
314
315
310
307
306
311
YW 214
211
462
467
460
230
245
242
140
144
141
GW 130
134
131
436
435
GW 500
RW 501
251
250
254
460
WOr 120
254
251
293
333
332
335
GOr 771
RW 770
520
LW 590
YOr 160
332
333
790
791
114
233
234
235
160
237
G02
G02
G01
G01
G08
G09
310B
310A
ROr 210A
230A
WOr 420A
426A
300A
300B
440D
WOr 690C
G01F
G01E
G01C
G01D
G01G
ELECTRICAL CIRCUIT (1/2) :
240 2.0
G11 2.0
141 1.25
131 1.25
131 1.25
230 0.85
2.0
2.0
2.0
2.0
2.0
0.85
314
315
307
310
311
211
462
245
242
144
134
GROUP 2 ELECTRICAL CIRCUIT
W 307
440A
1 WIPER MOTOR-LOW
R 315
2 WIPER MOTOR-HI
G 311
43 WIPER RY_LOW
Y 310
4 WIPER SW_LOW
520
590
160
Br 314
42 WIPER SW_HI
Y 629
9 RS232 RX 2-MONITOR
L 623
10 RS232 TX 2-MONITOR
GBr 624
37 PROGRAM DUMP-MONITOR
Y 625
CR-59 38 RS232 RX-CLUSTER
Br 422 L 626
86 30 87a 39 RS232 TX-CLUSTER
B G01 RY 627
85 50 PROGRAM DUMP-CLUSTER
RIDE-
87
OrW 216
86
85 87 87a
CONTROL
Br 217 L 251A
SPEED RY
30 13 MIRROR HEATED
Gr 650
14 CLUSTER_BATT. 24V
Or 570C
CR-60 18 SHIFT LEVER_IG
V 580
86 30 87a 27 CLUSTER_ IG
L 425 RW 935
85 6 LAMP-JOYSTICK STR
RIDE-
Br 217 GOr 930
87 15 TCU_ED6-NEU.
W 426 LW 920
86 16 TCU_ED5-REV.
85 87 87a
CONTROL
LOr 421 BrW 910
30 17 TCU_ED4-FWD.
435 WOr 451A
21 SHIFT LEVER_KD
425 ROr 915
CR-58 22 TCU_ED1
426 GrW 925
2 3 4 23 TCU_ED2
G 193 193 VOr 905
1 24 TCU_ED3
BrW 191 540
5
RELAY
Or 190
2
BACK-UP
1 5 4 190A OrW 150 1.25
3
Or MAIN SWITCH_ILL
33
G 180 2.0
TO SHEET 2 OF 2
34 MAIN SWITCH_HEAD
CR-63 LOr 154
35 MAIN SWITCH_ILL
191 YW 214
2 3 4 19 HORN RY
B G01B 436 YOr 184 1.25
1 31 MULTI_HEAD LAMP_LOW
LOr 200 200 R 187 1.25
RELAY
5 32 MULTI_HEAD LAMP_HI
GW 202 202
2
1 5 4 Or 190B
3
STOP LAMP
CR-25
RW 501
86 30 87a 30 FLASHER_L
B G01A B 795
85 12 GROUND_SHIELD
Y 620 L 790
87 7 CAN2 LOW
RELAY
RW 531 Y 791
86 8 CAN2 HI
85 87 87a R 530B LOr 303
30 40 MCU_INT
Gr 305 305
ECM POWER
41 MCU & WASHER
Gr 305A
CR-35
Br 300C
86 30 87a 45 FUSE BOX
B G01 Y 134
85 46 WORK LAMP SWITCH
Gr 550 2.0 VW 144
87 47 WORK LAMP SWITCH
RELAY
RW 531 531 Or 505
POWER
86 28 RH TURN
85 87 87a R 530 2.0 530A GOr 506
30 29 LH TURN
534 BrW 740
57 5V_POWER
WOr 690
CR-38 58 GND_SENSOR
LOr 754
2 3 4 59 TM MODE
R 540 BW 755
CAN2 BUS
1 60 CLUTCH_MODE
335
305
LW 538A
G02A
G02B
5
Or 570 G16
RELAY
2 1
1 5 4 Or 570 RY 627
1
1
2
2
4
NEUTRAL
3
CN-22
L 626
PUMP
3
CN-103
M
M
538 Y 625
CN-127C
WASHER
CR-5 2
86 30 87a
VW 539 539 G16
85 1
G 535 GBr 624
87 4
RELAY
LW 538 L
SAFETY
86
623 3
85 87 87a GOr 534
CN-127B
Y 629 CN-126
30 2
G16
D BATTERY(-)
BW 560
CR-46 J BATTERY(+)
G 993E
86 30 87a E CAN_Hi
L 380 V 994E
85 F CAN_Lo
FUEL
2LW 381 Y 791
87 G CAN2_Hi
RELAY
SERVICE TOLL
Y 370A L 790
86 H CAN2_Lo
WARMER
85 87 87a 2Y 370
30
G16 1
R 781 786
2 B MCU_RS232_RX
Br 782 787
CR-36 3 C MCU_RS232_TX
CONNECTOR_MCU & CAN
W 780 785
2 3 4 4 A MCU_RS232 P_DUMP
CAN BUS
RELAY
5
RW 372 372
2
CN-127
1 5 4
PRE-HEAT
CN-127A
Y 373 373
3
CN-58A
G16B
A13 GND(MAIN)
CN-36 G16A
A14 GND(MAIN)
10A BEACON WOr 120 Or 660
15 B38 ELEC. STEER MAIN PUMP PS
20A WORK LAMP_FRONT GW 130 2.0 V 661
MCU
7-3
A08 CAN2 HI
LOr 303
A23 WIPER INT SIG
610 Gr 305
A31 WASH SIG
621
A38 SPARE_DIGITAL INPUT_LOW
L 380
B14 FUEL WARMER
Y 620 Gr 235
A35 AC CONDENSOR FAN SIGNAL
20A ECM_IG Br 621 W 234
9 B15 AC COMP. OFF SIG_REVERSE FAN
Gr 550 630 Or 233
A16 BLOWER RUN SIGNAL_DINP
10A MCU BW 560 560
10 A24 SPARE_HIGH SOURCE
A26 SPARE_LOW_ENGINE OIL LOW
10A TCU Or 570 570B
11 B40 BOOM POSITION SENSOR
570C
B30 BUCKET POSITION SENSOR
10A CLUSTER V 580 580 BrW 740
12 A01 REF. POWER +5V
650
A37 MECHANICAL ENGINE SELECT
10A CASSETTE LW 590 BW 560
13 A11 POWER IG(+24V)
A12 BATTERY POWER(+24V)
10A SPARE GW 630
14 A02 BATTERY POWER(+24V)
LOr 154
B09 DETENT CONTROL_BUCKET
5A ILLUMINATION 1 YOr 160 160A
35 B08 DETENT CONTROL_BOOM UP
390
B19 DETENT CONTROL_BOOM DOWN
5A ILLUMINATION 2 Or 170 170
36 A30 COUNT_WEIGHT_SET SWITCH
A39 SPARE_ENGINE SPEED SENSOR
BrW 740
A29 SPARE-DIGITAL INPUT-LOW
WOr 690B
A40 SPARE_SPEED PULSE
CS-55 LOr 754
B31 TM MODE SELECT SIG
B G21 BW 755
12 B28 CLUTCH CUT OFF_SLT SIG
2 1 BW 261
2 B32 ENGINE POWER MODE SELEET
Y 423 BrW 740
10 B22 SPARE_PR SIGNAL
4 Br 217 WOr 690
8 9 B05 SPARE_HOUR METER
10 8 B06 SPARE_D_OUT_HIGH
3 WOr 690C
7 A28 SPARE-DIGITAL INPUT-LOW
7 6 WOr 420
6 B33 SPARE-DIGITAL INPUT-LOW
9 423 RW 770
B23 REVERSE FAN MODE-ON
BrW 424 424 GOr 771
4 B34 REVERSE FAN MODE-AUTO
LOr 421
3 A15 BOOM POSITION SELECT SIGNAL
RIDE CONTROL SW
Or 170F
1 A25 BUCKET POSITION SELECT SIGNAL
12 11 W 780
11 A27 PROGRAM DUMP
R 781
A19 RS-232(1) RX
CS-17 Br 782
A09 RS-232(1) TX
B G21B WOr 757
12 A21 RS-232 GND
12
Or 170B Br 758
11 A10 RS-232(2) TX
R 759
10 A20 RS-232(2) RX
10
8
9 CN-134 A06 SPARE-DIGITAL INPUT-HIGH
4
ROr 340C Or 570A
8 1
9
ROr 340B Or 800
7
7 2
3
W 801 CN-58B
4
3
LW 350 CN-157
PARKING SW
6
DIAGNOSTIC
4
Y 352 B G17
3 1 VM1-GND
G17A
1 2 VM2-GND 14
11
12
Or 800
15 SDDK-DIAGNOSTIC 16
W 801
18 EUPR-DIAGNOSTIC 33
TCU
CS-79 Or 570A
6 NC 34
12
B G21A Y 352
21 ED10-PARKING BRAKE SW(+) 35
1
12
10 25 CANF_H 48
0,2
Or 570D V 994
5 26 CANF_L 50
4
B 995 995
6 28 VGS-CAN SHIELD 53
6
9: AUTO
GW 671
7 36 SD4-SPEED METER CLUSTER 54
600A
3: MANUAL
10 3
8 23 VPE1-CONTINUANCE 24V 58
5
DIFF. LOCK SW
Or 570 570
4 45 VPI-POWER IG 61
Or 170 B 810 810
11 3 VMG1-SPEED PICK-UP COM 27
11
12
W 820
19 EF1-SPEED PICK-UP ENG
B 810A
27 CANF_T
RW 825
CN-125 41 EF2-SPEED PICK-UP TURBIN
GW 630 B 810B 850A
BATTERY(+) 1 12 VPS1-GEAR BOX VPS1(+)
BW 560 WOr 830
KEY IG(24V) 2 42 EF3-SPEED PICK-UP GEAR
G 840
NC 3 4 VMG2-SPEED SENSOR OUTPUT
UNIT
R 759 V 845
SERIAL "1"_L(RX) 4 62 EF4-SPEED SENSOR(SIG)
Br 758 VW 850 850
REMOTE
VOr 905
20 ED3-SHIFT LEVER-X1A-B3
CR-40 BrW 910
43 ED4-SHIFT LEVER X2B-FWD
86 30 87a ROr 915
OrW 746 746 63 ED1-SHIFT LEVER X1C-B1
85 LW 920
B G19 64 ED5-SHIFT LEVER X2C-REV
87 GrW 925
V 360 65 ED2-SHIFT LEVER X1B-B2
86 GOr 930
85 87 87a 67 ED6-SHIFT LEVER X2D-NEU
GrW 365
BUCKET RY
31 ED13-REV-JOYSTICK
2
V 360 DO-4 LOr 447
30 ED12-NEU-JOYSTICK
366 VOr 1 GrW 448
44 ED8-FWD-JOYSTICK
360 V 2 VOr 450
NC 14 59 ED15-JOYSTICK SELLECTER(+)
WOr 451
NC 15
V 360 360 W 426
24V(DETEND) 1 8 VPS2-RIDE CONT. RY(+)
Gr 440 440 R 540
24V(HANDLE) 9 52 ADM1-START INTERLOCK RY(-)
WOr 449 449 G 193
REV 2 5 ADM4-REVERSE DRIVE RY(-)
GrW 448 448 700 L 425
FWD 3 57 ADM5-RY RIDE CONT.(-)
LOr 447 447 945 Y 435
CN-246
COUNT_WEIGHT SW16
YW 214B
HORN SWITCH 11
Or 170D
ILLUMINATION 12
B G19
FNR SWITCH 13
CN-160
8.0
8.0
5.0
L
Y
W
280
270
210
260
B G21
L
B
Y
B
B
B
V
V
V
V
B
V
Y
B
V
R
R
R
R
R
R
R
G
G
G
G
G
W
W
W
W
W
W
W
W
W
W
W
Br
Br
Br
Gr
Or
Or
Gr
Or
Or
Gr
LW
LW
LW
LW
YW
VW
VW
YW
RW
RW
LOr
RW
RW
RW
RW
RW
LOr
GW
VOr
YOr
YOr
YOr
ROr
ROr
GOr
GOr
GOr
BrW
BrW
BrW
OrW
WOr
WOr
OrW
WOr
OrW
B G19
EARTH
GOr 534
531
530
531
531
2LW 381
350
112
112
112
112
103
202
610
621
945
940
746
743
360
211
462
394
141
506
505
170
390
184
187
191
200
535
216
422
237
245
242
373
371
372
890
900
865
885
895
880
850
870
860
855
875
112
112
675
672
700
830
825
820
810
845
840
660
661
715
705
725
710
721
720
730
680
358
740
436
656
655
570B
440A
160A
426A
810B
810A
690A
995C
994C
993C
B G22
B
B
B
B
B
R
R
R
2.0
G
Or
3.0
3.0
3.0
3.0
3.0
3.0
3.0
RW
B G20
3
3
9
8
7
6
9
8
7
6
4
1
4
1
5
5
2
2
220
ROr 210
260
220
280
270
WOr 690
BW 261
BrW 740
G22
G20
G20
48
47
46
45
44
43
36
41
40
39
38
37
32
35
34
33
42
31
30
29
28
27
26
25
24
23
22
21
20
14
13
15
17
16
19
18
12
11
10
13
60
20
44
26
56
55
54
53
52
51
50
49
48
47
46
45
43
42
41
36
29
37
22
21
23
24
33
35
34
32
31
30
58
28
27
57
25
38
40
39
59
19
18
17
16
15
14
12
11
10
CN-5
CN-6
170E
G22B
G22A
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
NC
1
HORN
2 2
2
2
1 1
1
5
4
2
6
1
3
A
B
C
SHIELD
CL-2
CS-2
PARKING
AC R/DRY
AC R/DRY
TUU_GND
AC COMP.
CN-139
TCU_(5V+)
CN-172
CN-171
CS-80
B
FUSE MAXI
FUSE MAXI
FUSE MAXI
FUSE MAXI
FUSE MAXI
FUSE MAXI
FUSE MAXI
CN-138
ECM-J1939-
STOP LAMP
REAR LAMP
ECM-J1939+
1
SENSOR_24V
0, I
12V
24V
START RELAY
TUN LAMP_LH
2.5
FUEL SENDER
BACK BUZZER
TUN LAMP_RH
GND
SERVICE
MAIN PUMP PS
ALTERNATOR I
GROUND_MCU
HEAD LIGHT HI
SERVICE
GEAR BOX - Y1
GEAR BOX - Y2
GEAR BOX - Y3
GEAR BOX - Y4
GEAR BOX - Y5
GEAR BOX - Y6
FUEL WARMER
ATT. LOCK SOL
PILOT CUT-OFF
ECM POWER IG
DIFF. LOCK SOL
REF. POWER 5V
SOCKET SOCKET
HEAD LIGHT LOW
PRE-HEAT RELAY
12V
STEERING PUMP PS
4
RIDE CONTROL SOL.
SPEED SENSOR_24V
FILTER RESTRICTION
SENSOR_STOP LAMP
JUMP WIRE-JOYSTICK
AIR CLEANER SWITCH
BOOM UP PR SENSOR
ECM-AIR HEATER OUT
H0 I
BATTERY RELAY(DO-1)
SEERING PUMP RELAY
SEERING PUMP RELAY
3
2
6
5
V
SPEED SENSOR_EF4(2)
24V
PRO-PORTIONAL VALVE
PRO-PORTIONAL VALVE
PRO-PORTIONAL VALVE
H
PROXIMITY SWITCH_24V
C BR ACC
BOOM POSITION SWITCH
PRESSURE SENSOR_JOYSTICK
CLUTCHBRAKE PEDALSENSING
24V_SENSOR-CLUTCH CUT-OFF
CIGAR
BRAKE OIL PRESSURE SENSING
DIFFERENTIAL SHIFT PR SENSOR
12V SOCKET
SWITCH
SWITCH
START KEY
FRAME HARNESS
DC/DC CONVERTER
ECONO MODE
7579S7EL01
·ELECTRICAL
ELECTRICAL CIRCUIT (2/2)
OFF IDLE
5
CN-99 USB PLAYER(WITH H./FREE) POWER CONNECT SUB CONNECTOR
LINEAR THROTTLE
3 990A A A
AUTO REVERSE FAN SW EMERGENCY TEST SW
991A
REMOCON GND
CN-162
12
12
12
5
B RESISTOR 4 3
REMOCON+
6 C B CN-20 0,2
BACK UP+
TEL MUTE
AUX_GND
ASSEMBLY
USB GND
YOr 646 G56
ANT 12V
CN-93
USB D+
1
USB 5V
5 2
USB D-
AUX_R
AUX_L
Or 645 YOr 646 213
GND
ACC
ILL+
4 1 OFF IDLE SW 1 2 0 1
ILL-
CN-27A
NC
NC
NC
NC
CS-73
CS-75
GW 644 Or 645
11
4 11
3
4
6 10
CN-27
9
3 11 ON IDLE SW 8 7
ON IDLE L 643 W 642 HORN
10
11
12
11
10
12
10
11
12
13
14
15
16
2 CN-25
9
4
8
1
2
3
4
5
6
7
1
2
3
4
5
6
7
1
3
3
1
23 ACCEL POSITION RETURN
6 W 642 L 643 G56A
1 9 ACCEL POSITION SIGNAL 2
WOr
OrW
GW 644 213A
GOr
YOr
RW
LW
RW
22 ACCEL POSITION SUPPLY 1
WOr
Or
BW
GOr
W
Gr
R
B
B
G 647
CN-6 34 SWITCH RETURN
G 990 G 990 213 CL-3
ECM-J1939+ 7 46 J1939(+)
V 991 V 991 179
G60D
G60C
Lo
G60E
ECM-J1939- 8 47 J1939(-) 6
163C
163B
163A
B 992 B 992 189A
G60
G60
774
696
775
461
591
523
524
521
163
525
526
513
514
515
516
517
518
519
ECM-J1939 SHIELD 9 37 J1939 SHIELD 4 Hi
RW 375 RW 375
PRE-HEAT RELAY 10 40 AIR-HEATER OUTPUT 5
GOr 374 GOr 374 172 172 SPEAKER
PRE-HEAT RELAY 11 42 AIR-HEATER RETURN 3 C
G56B
1 2 E CN-23
ABL
31 ALTERNATE TORQUE
LH
510 510 T
526 WOr
2 1 1
262 524
3 32 COOLANT LEVEL RETURN 2
262 G CL-4
4 28 COOLANT LEVEL
622 CN-10 179 179 CS-1
5 39 POWER IG 6 Lo CN-24
RH
6 23
189 189
4 Hi
HEAD R 522 525 W 1
ECU LIGHT 523
774
696
775
22 5 2
NC 13
Br 622
CN-94 21
162 162
3 C
-RH
W 611 2.0 611 W G56C DOOR S.W
2 E CN-7
ABL
NC 57 4 BATT (+) 20
2.0 611A W 509 509 T CL-1 163 YOr 1
3 BATT (+) 19 1 FUSE_ILLUMINATION
5B G55 2.0 G55B 591 LW
2 BATT (-) 18 3 3 FUSE-CASSETTE
2.0 G55A Gr 521A 521 Gr
1 BATT (-) 17 2 4 FUSE_ROOM LAMP
WOr 694 G60I 696 WOr
7 CN-100 1 5 MCU_RETURN
Gr 466 CN-29 2
GOr 510 742 742 BrW MG651032 774 RW
SEERING PUMP RELAY 52 2 1 B 7 MCU_REVERSE_MANUAL
R 463 R 243 Or 172 694A ROOM LAMP 775 GOr
SEERING PUMP RELAY 53 3 2 Pa 3 3 E 8 MCU_REVERSE_AUTO
V 663 V 238 R/DRY OrW 509 745 745 LW LH W 132
STEERING PUMP PS 55 1 1 4 4 S 1 9 NC
Or 662 YOr 179 G61
MAIN PUMP PS 56 5 CD-1 5
BOOM KICK OUT WORK 2 10 NC
684 W 711 711 R 189 694
4 2 C
HYD. TEMP
6
LAMP CL-5 11 NC
693A 693C YOr 162 CN-101
6 1 1 12 NC
W 213 742 FRONT W 132A
CD-10 8 1 B 1 13 NC
CN-19 YW 726 726 BrW 742 694 G61A
Pa 9 3 E 2 15 NC
WOr 693 693 AIR-CLEANER LW 745 748 748 RH
10 4 S CL-6 2 NC-NC
OrW 748 W 132 1.25 142 RW
CD-2 11
BUCKET LEVELER 6 WORK LAMP RELAY
B 657 693D B G56 1.25 1.25 132 W
FAN SPEED SENSOR_MCU 24 1 12 14 WORK LAMP RELAY
G57
AC RELAY 14 14 1 Pa 2
RIDE
S S + -
V 238 OrW 646 433
AC RELAY 16 CN-154(GRAY) 16 CONTROL 2 BOOM DOWN CL-35
W 711 G 722 722 Br 432 645 P./SWITCH
MCU_HYD TEMP SENSER 46 2 15 3
1.25
YW 726 V 723 723 FAN PROPORTIONAL V/V CN-141 W 133A
MCU_AIR CLEANER SWITCH 47 1 4 1
B 731 432 Or 433 G62A
CN-155(BLACK) 1 2
OPTION
LW 706 LW 391 391 646 OrW 645 CN-136
MCU_FUEL SENDER 48 2
FAN REVERSE SOL
2 CL-36
G 722 R 393 393 432 Br 432 432
MCU_FAN PROPORTIONAL VALVE 42 1 3 2 RIDE SOL
V 723 G57 G58 G58 RW 142 RW 142
CAMERA
FUSE_ILLUMINATION 31 2 1 1 1 SHD 5 REAR WIPER MOTOR
GOr 508 V 609 607 B 612 612 334 G
TURN LAMP_LH 35 4 2 2 2 GND 7 REAR WIPER MOTOR
Or 171 B 606 608 W 615 615 L 252
FUSE_ILLUMINATION 32 1 3 3 3 SIG 9 MIRROR HEAT CONT.
OrW 507 W 608 609 V 614 614
TURN LAMP_RH 34 3 4 4 4 24V 6 NC
5 5 14 NC
253 V
6 6 10 MIRROR HEAT CONT.
WOr 693
GROUND_MCU 45 CN-10 CL-23 11 NC
336
253
330
334
331
Br 684 161A RW 143 143 RW 146 146A 121 WOr
MCU_24V 36 1 12 12 1 12 FUSE_BEACON
508A 2
G71B
2 13 NC
171A
3 CL-22 WORK LAMP RH CL-7 15 NC
507A 146 R 122
YOr 185 185
4
B G70 1.25 G70 B G71A
1
WORK LAMP LH BEACON M
2
G64B
8 NC
G71
MULTI_HEAD LIGHT LOW 28
R 188 188
5 11 11 2 LAMP 1
MULTI_HEAD LIGHT HI 27 6 B G54 2.0 CL-21
693B 171B Or 174 174 CR-39
7 10 10 2 FROM BATT. RY
519
513
518
517
516
515
514
W 212 212 G71 465 L 252
G60M
G60N
HORN 54 8 1 2
G60L
G60J
YOr 163H
YOr 163K
RH
YOr 163J
BrW 741 741 CN-65 464 G64
334
331
OrW 336
330
253
122
WOr 121
MCU_REF. POWER 5V 26 9 1
MCU_BOOM POSITION SENSOR 44
LW 744 744
10
G54
1
BACK BUZZER
NUMBER PLATE LAMP CN-19 M MIRROR CN-150
OrW
OrW 747 747 BrW 192 192 374
GOr
Or
RW
RW
LW
MCU_BUCKET POSITION SENSOR 20 11 2 5 MOTOR RY
Or
HEATER
Br
W
G
R
B
B
Gr 465 L 252A
50 12 2 2
CN-27B
R 464 LH G64A
CL-16
CS-35
CS-76
CS-23
13 CD-40
3
1
3
1
3
1
2
1
ATT. UNLOCK SWITCH 3
5
4
3
1
10
10
9
10
9
8
51
12
12
12
11
11
11
10
571 Or 171 687 687
G62
G61
G64
G60
14
171 Br
A
- S+
4 C 4 Pa CN-149 8 7 8 7
Br 430 430 OrW 507 507 REAR V 664 664 1 10 3 I 0 11 1 11 1 11
RIDE CONTROL RELAY 17 15 3 T COMBI 1 B ELEC. STR PUMP PS
USB +(5V)
OrW 647 647 G54D 695 695
AUX GND
USB GND
WOr
RIDE CONTROL RELAY 18 16 RH 6 C
USD D+
2 E
AUX S2
AUX S1
USD D-
LOr 201 201 G63
17 1 S CD-39
687A 0,I
18 CL-15 A
- S+
YOr 161 161 374 Pa 12 5 8 12 12 10 4 9 3 12 12 10 4 9 3 12
NC 38 19 4 C B MAIN PUMP PS
20
GOr 508 508 REAR 695A REAR WIPER SW MIRROR HEATER SW BEACON SW USB PORT
NC 37 3 T C
G54E COMBI
BOOM UP SENSOR_MCU 21 21 2 E
201A LH
BOOM DOWN SENSOR_MCU 22 22 1 S EMERGENCY STEERING
23 THER_ AMBIENT RELAY(HI)
INCAR FET
NC 59 MISTER(+) TEMP ACT'R
CN-13 CN-96 MODE-1 ACT'R MODE-1 ACT'R INTAKE ACT'R SENSOR SENSOR
BLOWER
L 384 2.0 2.0 384 L
3
1
NC 58 1 B 2 7 2 7 2 7 2 7
1 4 1 4 1 4 1 4
L 384A 2.0 B G53 2.0 1.25 G53 B M M M M
4
2
2
A
5 5 5 5
3
FUEL HEATER CN-28
1
1
5
6
7
5
6
7
5
6
7
5
6
7
4
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
2
3
2
12
CN-13 Gr 247 1.25 247 AC-2 AC-22
5 2
Gr 246 246 Y 377 1.25 G53B AC COMP.
RY
BY
BW
BY
AC COMP. 15 5 6 1 NC 10 10
Y 376 376 G 537 1.25
PRE-HEAT RELAY 12 6 7 CN-80 NC 5 5
G 536 536 ROr 717 1.25 CR-24
2.0
2.0
2.0
2.0
START RELAY 19 7 8 15W 707 NC 14 14
ROr 716 716 RS-1 377
MCU_ALTERNATOR I 49 8 NC 6 6 CN-11
ROr 717A 961 B BW 2.0 BW
3 2 15R 709 PREHEATER GND 1 1 1 1 1 GND(CONTROLLER)
RESISTOR 3W/300 RW 718 1.25 964 YOr 4
RY RY
12 1 TAIL(+) 4 4 4 8 ILLUMINATION
382B L 963 RW RW 2.0 RW
1 PREHEATER BATTERY(+) 3 3 3 3 5 FUSE(Battery)
382A L RELAY 988 W L L
2 ALTERNATOR CN-74 REVERSE FAN 13 13 13 13 4 REVERSE_MCU
CR-23 CN-45 962 R R R
NC 4 5W 727 IG2 2 2 2 2 3 FUSE(IG)
G53A M 965 G RG LY
U
FI 3
ROr 717 537 5R 728
M ACT'R REF 7 7
968 BW
7 7
GB YW
6 DPS(COMPRESSOR)
L 2 SENSOR GND 8 8 8 8 7 CONDENSOR FAN
969 GW Y BR
~3 P 1
B+
THERMISTER(+) 9 9 9 9 2 BLOWER_SIGNAL
G 718 START RELAY 708 966 R 11
YL
B+ INCAR SENSOR 11 11 11
AIR CON
3 3 Pa MODE-1 ACT'R_PBR 9 9 9 9
674 978 BW 8
LgB
B MODE-1 ACT'R_FOOT 8 8 8
693 WOr WOr 692 692A 977 Gr 7
LgR
5 5 C MODE-1 ACT'R_VENT 7 7 7
L 941 941 L L 942 976 Y 6
BrW
TCU_VMGA1(24) 60 6 6 TEMP ACT'R_PBR 6 6 6
G 946 946 G W 947 975 G 5
BrB
TCU_AU1(37) 25 9 9 TEMP ACT'R_WARM 5 5 5
974 BOr 4
BrR
TEMP ACT'R_COOL 4 4 4
673 R R 674 973 L 3
LW
1 1 INTAKE ACT'R_PBR 3 3 3
CD-26 972 BW 2
LB
INTAKE ACT'R_REC 2 2 2
CN-5 682 971 WOr 1
LR
A
- S+
Pa INTAKE ACT'R_FRE 1 1 1
676 VW VW 677 677 PARKING
4 4 B NC 13 13 13 13
CN-160
Br 662 2.0 692 PS
JOYSTICK SELECT 10
16
11
13
14
15
12
4
6
5
1
3
2
C
8
FUSE_JOYSTIC SW 9
7
FUSE BOX_IG 16
W 611 2.0 AC-1 AC-11
FUSE BOX_IG 17 CD-4
3L 382 942
RELAY_BUCKET
FUEL WARMER REALY 33 7 7 1 Pa
ILLUMINATION
S S + -
RELAY_BOOM
HORN RELAY
947
KICK DOWN
2 STOP LAMP
R 673 203 GW GW 204 204
NEUTRAL
MCU_BRAKE OIL LOW PRESSURE 13 8 8 3 CLUTCH CUT-OFF
VW 676 701 Y Y 702 702
FWD
GND
MCU_PARKING PRESSURE 14 2 2 4
REV
24V
NC
NC
NC
NC
Y 701
TCU_EU1(38) 15 10 10 STOP LAMP &
G50B B B G51
363 GrW
442 WOr
11 11 CLUTCH CUT-OFF PS
362 VOr
441 Gr
G19 B
12 12
369 V
GW 359 LW LW 351 CN-71
STOP LAMP RELAY 20 13 13
G51
14 14 1
351
SWITCH PILOT CUT OFF 29 15 15 2
LW 359
SWITCH PARKING 30 PARKING SOL
CN-12
NC 31 SHIFT LEVER
NC 42
AD7
AD6
AD5
AD4
AD3
AD2
AD1
CD-46 MONITOR CLUSTER
VM
VP
CN-110
ED
841 G
B1
AS
B3
B2
1
R
V
846 V SPEED SENSOR OUTPUT MULTI FUNCTION SWITCH 1
2 2 1 442
LAMP_JOYSTICK STR SELECTED
2 1
571 Or 2
Y 7
F
NC 34 3
B 5
WB 8
BG 3
BW 2
NC 35 CD-17 G19
4 3
811 B 6
CAMERA 0_INPUT_SIDE
Lo
CAMERA SIGNAL SHILD
OUTPUT SIGNAL
O
363
L
2
2 1
L
CAMERA 0_INPUT
CAMERA 3_INPUT
CAMERA 2_INPUT
CAMERA 1_INPUT
4
PROGRAM DUMP
MIRROR HEATED
5 BO- BO+ 2
PROGRAM DUMP
Lo Hi F
RS232 PC SHILD
B+
C
X1
RS232_SHILED
X2
ILLUMINATION
ILLUMINATION
AD5(R) C
D
A
D
C
B
4 3
FUSE_TCU 1 369
CAN2-SHILD
CAN2-SHILD
6 FL- FL+ 1
HIGH BEAM
RS232 RXD
RS232 TXD
G 841 812 BW 2
CAN2 LOW
CAN2 LOW
BATT. 24V
BATT. 24V
BATT. 24V
RS232 RX
RS232 TX
O
RH TURN
TCU_VMG2(04) 2
LH TURN
AD6(N)
1
AD4(F)
O J
TURBIN PICK-UP
I
GND_B+
CAN2 HI
CAN2 HI
GND_IG
AD1
AD2
AD3
V 846 826 RW 1
BWG C
IG 24V
IG 24V
ED1(VP)
2 1
Hi
TCU_EF4(62)
J
3
AD7(KD)
HO
2
STANDARD
I
GND
N
GND
B 811 CN-114
NC
NC
NC
NC
TCU_VMG1(03)
RW
4
BVi
BY
FRONT WIPER
Gr
W 821
W
CN-57
CN-56
G
4 3
L
TCU_EF1(19) 5 CD-47(BLACK)
BW 812 813 BOr
6
2
6
1
3
5
4
INTER
14
18
16
14
11
12
13
16
19
17
13
12
11
17
18
10
19
15
20
10
15
20
TCU_VMG1(03) 6 2
8
6
6
2
1
1
7
4
5
4
3
2
D
9
K
RW 826 831 WOr
TCU_EF2(41) 7 1 GEAR PICK-UP
BOr 813
GOr
GBr
CS-5A
CS-11
RW
SHIFT CLUTCH
CS-12
RY
B G50 1.25
4
5
2
TCU_VMG1(03)
5
8
1
3
Or
Or
4
1
3
2
7
Or
R
R
Y
Y
B
WOr 831
L
L
V
GOr
YOr
YOr
LOr
RW
YW
SWITCH SWITCH
LW
B
CS-74 3R
Pf
Gr
Or
Gr
Or
5 Lo
153E
251A
Br
Br
4 Hi
G
105
R
V
Y
104 104 3R
G15
G15
G15
G15
FUSE MAXI
187
790
791
624
596
594
592
650
650
580
790
791
935
625
626
627
505
506
650
580
153
629
623
JOYSTICK STEERING 11
2
3
1
M10 3R 102 111 15R 106 HAZARD SW ILL. HEAD LAMP SW WORK LAMP SW
JOYSTICK STEERING 12
CN-158
12
12
12
CN-159
X1
182
184
187
180
214
303
305
314
311
317
300
501
505
506
X2
12
12
12
3R
10
D
D
B
A
B
A
15R
0.5
0.5
4
9
80A
V
4
4
RW 532
4
CONT_JOYSTICK_INTPU1 18
M5 CN-95
WOr
GrW
BrW
RW 541
GOr
ROr
VOr
LW
3
CONT_JOYSTICK_SENSOR(-) 19
570C Or
G
R
3W 111F
L
CR-1
2
FUSE 21
3W 111A 532 80R 107 108 CS-41
1
11
11
451A
11
CS-42
CS-36
CS-59
CS-21
1
7
9
7
9
7
FUSE 22
930
920
910
915
925
905
10
11
11
11
12
12
12
C
CN-21
B
A
A
9
9
6
2
1
6
5
1
3
1
3
1
3
7
3W 111B G50 80R 109
FUSE 25
B
BATTERY
OrW
WOr
WOr
BrW
BrW
3W 111C
GOr
YOr
RW
LOr
LOr
LOr
LOr
VW
BW
LW
FUSE 26
Or
W
BATT. RY
G
R
R
B
B
3W 111D
G15
596
594
592
580
FUSE 27
3W 111E 15R 111 532A
FUSE 28 2
TO STARTER
153D
153A
153B
G50A
G14
G14
G14
G14
307
315
317
310
505
506
501
501
150
182
180
154
153
134
144
154
154
740
754
690
740
755
690
1
NC 23 DO-2
G14 1.25
B G15 1.25
RW 541
START KEY SWITCH 37
3R 102
FUSE 24
CD-48
ROr 856 856
TCU_ER3(17) 39 1
B
795 0.5
790 0.5
791 0.5
935 0.5
625 0.5
626 0.5
251A 0.5
NC 32 2 Pa
570C
WOr 451A
307
315
310
623
GBr 624
627
650
580
GOr 930
LW 920
BrW 910
ROr 915
GrW 925
VOr 905
505
GOr 506
501
214
LOr 303
305
314
311
300
YOr 184
187
OrW 150
180
154
134
144
LOr 754
BrW 740
BW 755
WOr 690
CD-49
876A
G15
G15
2 C
580
592
596
580
592
594
RW
LOr
YW
VW
RY
TCU_ER2(49) 40 1
Or
Or
Or
Gr
Br
Br
W
G
R
R
Y
Y
L
CN-112
9
7
8
6
1
4
2
10
37
12
38
39
50
13
14
27
15
16
17
18
21
22
23
24
28
29
30
19
40
41
42
43
45
31
32
33
34
35
46
47
59
57
60
58
W
B
V
B
B
V
B
L
16
WOr 876 876
CN-250A
TCU_VMGA2(46) 38 9 VMGA2
CN-250
CLUTCH_MODE
FUSE BOX_ILL
TCU_ED4-FWD.
WIPER MOTOR-HI&LOW
TCU_ED1
TCU_ED2
TCU_ED3
FUSE BOX_HEAD
RH TURN
SHIELD_GROUND
HEAD LAMP_LOW
TCU_JOYSTCIK STR
MCU-SERIAL_H
TCU_ED6-NEU.
MCU-SERIAL_L
TCU_ED5-REV.
PROGRAM DUMP 2
WIPER RY_LOW
LH TURN
RS232_TX
TM_SHIFT_MODE
FLASHER_L
RS232 RX 2
GND_SENSOR
MIRROR HEATED
5V_POWER
1
1
2
4
2
4
ILL
RS232 TX 2
RS232 RX
FUSE BOX_TCU
FUSE BOX_BATT. 24V
FUSE BOX_BATT. IG
RS232 P_DUMP
HORN RY
TCU_KD
HEAD LAMP_HI
MCU_INT
TCU_ER1(39) 41
WIPER RY_HI
TEMP
MCU & WASHER
FUSE BOX
8
VW 851 851 FWD REV
TCU_VPS1(12,13) 36 7 VPS1(+)
BrW 881 881 1 2 3 4 1 2 3
TCU_AIP6(51) 43 6 Y6
LOr 896 896 Y5
TCU_AIP5(09) 44 5 Y5
Gr 886 886 Y2
TCU_AIP4(55) 45 4 Y4 Y3
OrW 866 866
TCU_AIP3(32) 46 3 Y3 Y6
VOr 901 901 VOr
TCU_AIP2(10) 47 2 Y2 Y4
TCU_AIP1(56) 48
YW 891 891 YW
1 Y1 Y1 TO SHEET 1 OF 2
GEARBOX
7579S7EL01-1
7-4
MEMORANDUM
7-5
1. ILLUMINATION CIRCUIT
1) OPERATING FLOW
Fuse box [CN-36 (18)] Illumination switch [CS-21 (3)] Switch ON, 1st step
[CS-21 (9)] Work and hazard switch, cluster, monitor indicator lamp ON
[CS-21 (7)] Fuse box [CN-36 (35)] Switch indicator lamp
I/conn [CN-6 (31)]
LH Combi clearance lamp ON [CL-15 (4)]
I/conn [CN-10 (1)] RH Head lamp ON [CN-4 (3)]
Fuse box [CN-36 (36)] Switch indicator lamp
I/conn [CN-6 (32)]
RH Combi clearance lamp ON [CL-16 (4)]
I/conn [CN-10 (3)] LH Head lamp ON [CL-3 (3)]
2) CHECK POINT
Engine Key switch Check point Voltage
① - GND (switch input)
OFF ON ② - GND (switch output) 20~25V
③ - GND (to light)
※ GND : Ground
7-6
ILLUMINATION CIRCUIT
CLUSTER
R
ILLUMINATION 17
CN-56
MONITOR
R
ILLUMINATION 18
LOr
6
6 LOr 7
3
7 7
4 9
8
4
9 9 9 8
3 10
7 10
R R
11 11
12 1 B 1 12
12 12
CS-36 CS-41
CN-6
1
2
3
4
26
27
HEAD LIGHT-LH
Lo 6 3 28
Hi 4
5
29
Or
C 3
B 30
E 2
ABL
YOr YOr
T 1 1 31
CL-3 Or Or
2 32
HEAD LIGHT-RH 3 33
Lo 6 3 4 34
Hi 4
5
YOr 5 35
C 3
E
B CN-10 59
2
ABL
T 1
60 ALL SWITCH INDICATOR LAMP ON
CL-4
3 CN-14
1
REAR COMBI-LH
C 4
YOr 2
T 3
B 3
E 2
S 1
4
CL-15 3 5
REAR COMBI-RH 11
Or
CL-21
NUMBER
C 4 10 2
PLATE
T 3 1
B LAMP
E 2
S 1
CL-16
7579S7EL03
7-7
2. HEAD LIGHT CIRCUIT
1) OPERATING FLOW
Fuse box [CN-36 (19)] Head light switch [CS-21 (6)] Light switch ON, 2nd step [CS-21 (4)]
Multi function switch [CS-11 (8)]
Multi function switch MIDDLE [CS-11(7)] I/conn [CN-6 (28)] I/conn [CN-10 (5)]
LH Head light low beam ON [CL-3 (6)]
RH Head light low beam ON [CL-4 (6)]
Multi function switch DOWN [CS-11(6)] I/conn [CN-6 (27)] I/conn [CN-10 (6)]
LH Head light high beam ON [CL-3 (4)]
RH Head light high beam ON [CL-4 (4)]
Cluster high beam pilot lamp ON [CN-56 (5)]
2) CHECK POINT
7-8
HEAD LIGHT CIRCUIT
FUSE BOX
ILL & HEAD LAMP SW BEACON 10A
15
12 11
2 WORK LAMP_FRONT 20A
1 16
MIRROR,SER.SOCKET2 20A
3 17
YOr
4 ILL.LAMP 20A
18
G G HEAD LAMP 20A
6 19
6 7 BACK.STOP LAMP 10A
4 20
HORN/CONVERTER 20A
9 9 21
3 AIR-CON/HEATER 1 30A
7
22
12
11 1 FUEL WARMER 20A
1 23
12
CIGARLIGHTER 30A
CS-21 24
YOr ILLUMINATION 1 5A
35
1
Or ILLUMINATION 2 5A
2 36
1 3 CN-36
6 2 4
3 26
R R
HEAD LIGHT-LH 4 27
YOr YOr YOr
Lo 6 5 28
R
Hi 4
5
6 29
Or
C 3
B 7 30
E 2
ABL
YOr YOr
T 1 8 31
CL-3 7 9
Or 32 Or
10 33
11 34
HEAD LIGHT-RH
YOr 12 35
Lo 6
R
Hi 4
13 59
5
YOr
C 3
B
14 60
E 2
ABL
T 1 15 CN-6
CL-4 16
CN-10
4
YOr
YOr
R
G
5
3 8
R
CS-11
CN-56
16
14
19
18
17
13
12
11
10
20
15
8
7
6
5
4
3
2
1
9
8
6
7
1
4
3
2
LAMP_JOYSTICK STR SELECTED
4BWG
W
6
Hi
C
MIRROR HEATED
PROGRAM DUMP
RS232 PC SHILD
ILLUMINATION
Hi Lo
CAN2-SHILD
HIGH BEAM
CAN2 LOW
BATT. 24V
RS232 RX
RS232 TX
B+
RH TURN
LH TURN
C
CAN2 HI
F
IG 24V
L
R
GND
O
GND
L
R
NC
NC
NC
Y 7 Lo
B 5
WB 8
CLUSTER
BG 3
BW 2
7579S7EL04
7-9
3. WORK LIGHT SWITCH
1) OPERATING FLOW
※ Illumination switch : ON position (1st step)
(1) Work lamp switch ON (1st step)
ILL & head lamp switch [CS-21 (9)] Work lamp switch indicate lamp ON
Work lamp switch [CS-36 (7)→(3)]
Front work lamp relay [CR-3 (2)→(5)] I/conn [CN-7 (14)]
LH Front work lamp ON [CL-5 (1)]
RH Front work lamp ON [CL-6 (1)]
(2) Work lamp switch (2nd step)
Work lamp switch [CS-36 (6) → (4)] Rear work lamp relay [CR-55 (2)→(5)]
I/conn [CN-6 (33)] I/conn [CN-14 (12)] LH Rear work lamp ON [CL-22 (1)]
RH Rear work lamp ON [CL-23 (1)]
2) CHECK POINT
Engine Key switch Check point Voltage
① - GND (work lamp power input)
② - GND (work lamp power output)
OFF ON 20~25V
③ - GND (front work lamp)
④ - GND (rear work lamp)
※ GND : Ground
7-10
WORK LIGHT SWITCH
FUSE BOX
1
BEACON 10A
15
2 GW WORK LAMP_FRONT 20A
16
3 MIRROR,SER.SOCKET2 20A
17
4 ILL.LAMP 20A
18
HEAD LAMP 20A
5 19
RW RW BACK.STOP LAMP 10A
6 20
HORN/CONVERTER 20A
7 21
AIR-CON/HEATER 1 30A
8 22
FUEL WARMER 20A
23
9 CIGARLIGHTER 30A
24
10
3 11
SERVICE SOCKET 1 20A
12 25
SPARE 20A
13 26
W W W Y WORK LAMP_REAR 20A
27
FR WORK 1 14
B WIPER 20A
LAMP-LH 2 28
CL-5 15 PARK 20A
29
W CN-7 JOYSTICK-DETENT 10A
30
FR WORK 1 PRE-HEAT, FUEL WARMER 30A
B
LAMP-RH 2 31
FAN REVERSE, ATT 20A
CL-6 32
RIDE CONTROL 10A
33
OPTION JOYSTIC_SWITCH 10A
1 34
CL-35
W W W
1 2 CN-36
B
2
3
FR WORK LAMP
4
W FUSE BOX
1
B 5 LOr
2
5A
CL-36 6 ILLUMINATION 1
35
7
CL-32
RW ILLUMINATION 2 5A
1 8 36
B
2
9 CN-36
RR WORK LAMP
10
RW
1
2
B 11 2 FR WORK LAMP RY
CL-33 12 4 3 2
B
1
13 W
5
4 14
Y
2
GW 4 5 1
3
8 15
CR-3
RW 9 CN-9
RR WORK 1
B
1
LAMP-LH 2 10 31 RR WORK LAMP RY
CL-22 B B 4 3 2
11 32 B
1
RW RW RW RW RW RW
RR WORK 1 12 33 5
B VW
LAMP-RH 2 2
CN-14 34 Y
CL-23 3 4 5 1
35 CR-55
59
2
60
WORK LAMP SW 1
CN-6
12 11
1
3
Y
4
VW
6
LOr
6 7
LOr
4
9 9
3
7
R
11
12 1
12
B
CS-36
12 11
1
3
4 CLUSTER
R 17 ILLUMINATION
6
6 LOr CN-56
7
4
MONITOR
R R
9 9 18 ILLUMINATION
3
7 CN-57
R
11
12 1
12
B
CS-21 7579S7EL05
7-11
4. STARTING CIRCUIT
1) OPERATING FLOW
Battery(+) terminal Fusible link [CN-60] Master switch [CS-74]
I/conn [CN-5 (24)] Fuse box [CN-36] Start switch [CS-2(1)]
ECM power relay [CR-25(30)]
Power relay [CR-35(30)]
※ The gear selector lever is neutral position. It is necessary condition before the starting.
The gear selector has an output signal which is activated whenever the shift lever is in the neutral
position. This signal can be used to control a relay and prevent engine from starting whenever the shift
lever is not in the neutral position.
(1) When start key switch is in ON position
Start switch ON Start switch [CS-2(2)] I/conn [CN-5(37)] Master switch [CS-74]
Battery relay [CR-1]
Battery relay operating (All power is supplied with the electric component)
Start switch [CS-2 (3)] ECM power relay [CR-25 (30)→(87)]
Fuse box [CN-36 (9)] I/conn [CN-5 (16)]
ECM [CN-93(39)]
Power relay [CR-35(30)→(87)]
Fuse box [CN-36 (10)] MCU [CN-58A (A11)]
Fuse box [CN-36 (11)] TCU [CN-157 (45)]
2) CHECK POINT
※ GND : Ground
※ ECM : Electronic control module
※ MCU : Machine control unit
7-12
STARTING CIRCUIT
2
MASTER SW CN-60
3R 104 3R 105
MONITOR CLUSTER 3R 15R 106
CN-95
RW
FUSIBLE LINK
RW
CAMERA 0_INPUT_SIDE
FUSE BOX USB PLAYER
10A BEACON CS-74 BATTERY RY
CAMERA 0_INPUT
15 RW 80R
REMOCON GND
20A WORK LAMP_FRONT
REMOCON+
BATT. 24V
BATT. 24V
BATT. 24V
20A MIRROR,SER.SOCKET2
RH TURN
BACK UP+
TEL MUTE
LH TURN
17 1 B 80R BATTERY
ANT 12V
IG 24V
IG 24V
20A ILL.LAMP
18
GND
ACC
2
ILL+
CR-1
ILL-
CN-127
NC
NC
NC
20A HEAD LAMP
CN-250A
CN-57
CN-56
CN-250
19
3 DO-2 1
10A BACK.STOP LAMP RW
10
11
12
13
14
15
16
8
5
1
2
3
4
5
6
7
9
2
4
3
2
3
1
1
4
3
2
4
4
20 2
20A HORN/CONVERTER 14 B
21 1
30A AIR-CON/HEATER 1 15
LW
22
V
V
20A
STARTER
FUEL WARMER 16
23
M
24
30A CIGARLIGHTER
17 M
W START RY
21 5W
B B+
22
20A SERVICE SOCKET 1 G CN-45
25 5R
20A SPARE 23
26
20A WORK LAMP_REAR 24 CR-23
27
20A WIPER 25 R ALTERNATOR
28
20A PARK, PILOT CUT
29 26 1 B+
~ G
10A JOYSTICK-DETENT 2
27 Or 1 P
30
30A PRE-HEAT, FUEL WARMER 3 ROr L 3
2
31 28
20A FAN REVERSE, ATT CD-46 3 FI U
32 36
10A RIDE CONTROL 4 NC
33
10A JOYSTIC_SWITCH 37 CN-74
34
38 RESISTOR
Y RW
CN-5 5 1
CN-7
ROr 3W/300
3
1
4
2
2
RS-1
20A TURN LAMP
1 CN-13
5A CASSETTE/ROOM LAMP
2 1 1
30A START KEY SWITCH R 32 COOLANT LEVEL RETURN
3 G
2 2
10A TCU 24V BATTERY 28 COOLANT LEVEL
4
20A ECM 24V BATTERY 3 3 39 POWER IG
5
20A MCU 24V BATTERY 4 12 CN-93
6 ECM
10A AIR-CON/HEATER 2
7 5 5
10A
CN-94
CLUSTER 24V BATTERY 6 W
8 6 4 BATT (+)
W
19 7 3 BATT (+)
3R
20 2 BATT (-)
8
1 BATT (-)
21
22
CD-41
23
CN-10 CN-141 1
24
1 1 2 Pa
25
9
20A ECM_IG Br 2 2 3
26
Gr 3 3 4
46
10A MCU BW 4 4 S S + -
10
47
12 5
10A TCU Or 48
11 13 6
49
14
10A CLUSTER V
12 59 15 X2
60
V AD5(R) C
10A CASSETTE LW D
13 AD4(F) B
CN-6 C
B AD6(N) D
10A SPARE B
14 A A
ED1(VP)
CN-159 X1
5A ILLUMINATION 1 AD7(KD) D
35
8 3 AD1 C
5A AD2 B
ILLUMINATION 2
36
GOr
ROr
4
VW
BW
RW
LW
GOr
RW
Or
Or
6 AD3 A
BW
R
R
CN-36
RW
RW
GOr
AD7
VW
LW
Gr
LW
G
R
R
Y
B
Or
Or
CN-134
CN-157
CN-125
CS-2
R
68
45
7 AS AD6
3
8
7
A11
A34
ANTI-RESTART RLY B03
B36
12
1
3
4
5
2
9
1
2
3
4
5
6
3
2
6
5
4
R AD5
CR-5
CR-35
CR-25
SERIAL "1"_H(TX)
ED2-SHIFT LEVER X1B-B2
VPE2-CONTINUANCE 24V
SERIAL "1"_L(RX)
B DIAGNO- V AD4
87a 85 87 86 30 87a 85 87 86 30 4 1 5 2 3 87a 85 87 86 30
VPS2-RIDE CONT.RT(+)
POWER IG(24V)
0, I
1
B3 AD3
BATTERY(+)
STIC
KEY IG(24V)
NETURAL SIG
GROUND
GROUND
B2 AD2
ALT LEVEL
VPI-POWER IG
30 87 30 87 2 5 30 87 B1 AD1
NC
NC
86 85 86 85 3 1 86 85
H 0 I II
4 3 2 1 4 3 2 1 4 3 2 1 ED
4
6
5
3
2
H
C ST ACC BR REMOTE N R F
K VP
POWER RY ECM POWER RY NETURAL RY SAFETY RY START SWITCH MANAGEMENT D VM
OUTPUT SIGNAL
MCU
TCU UNIT GEAR SELECTOR LEVER
7579S7EL06
7-13
5. CHARGING CIRCUIT
When the starter is activated and the engine is started, the operator releases the key switch to the
ON position.
Charging current generated by operating alternator flows into the battery through the battery relay
(CR-1).
The current also flows from alternator to each electrical component and controller through the fuse
box.
1) OPERATING FLOW
(1) Warning flow
Altermator [CN-74 (2)] I/conn [CN-13 (8)] I/conn [CN-6 (49)] MCU [CN-58A (B36)]
Cluster charge warning lamp ON
(2) Charging flow
Alternator Starter [CN-45 (B+)] Battery relay [CR-1]
Battery(+) terminal Charging
Fusible link [CN-60] Master switch [CS-74] I/conn [CN-5 (24)]
Fuse box [CN-30)]
Fusible link [CN-95] I/conn [CN-5 (21, 22, 25~28)] Fuse box [CN-36]
2) CHECK POINT
※ GND : Ground
※ MCU : Machine control unit
7-14
CHARGING CIRCUIT
6
MASTER SW CN-60
3R 104 3R 105
3R 8W 106
CN-95
RW FUSIBLE LINK
FUSE BOX
10A BEACON
15
20A WORK LAMP_FRONT CS-74
16
20A MIRROR,SER.SOCKET2
17
20A ILL.LAMP
18
20A HEAD LAMP
19
10A BACK.STOP LAMP BATTERY
20 BATTERT RY
20A HORN/CONVERTER 1 RW
21 80R
30A AIR-CON/HEATER 1 2
22
20A FUEL WARMER B 80R
3
23
30A CIGARLIGHTER
1
24 4 CR-1
W 2
21
20A
22
SERVICE SOCKET 1
25
20A
23
SEAT HEAT/AIR
26
20A WORK LAMP_REAR 24
27
20A WIPER 25 RW
28 2
20A PARK
B
29
26 1
10A JOYSTICK-DETENT
27 DO-2
30
30A PRE-HEAT, FUEL WARMER
31 28
20A FAN REVERSE, ATT
32 36
10A RIDE CONTROL
33
10A JOYSTIC_SWITCH
37
34
38
Y 47
48
20A
CN-5
TURN LAMP
1
5A AUDIO/ROOM LAMP STARTER
2
30A START KEY SWITCH M
3
10A TCU 24V BATTERY
M
4 START RY
20A ECM 24V BATTERY 5W
5
20A
B+
MCU 24V BATTERY
6 CN-45
10A AIR-CON/HEATER 2 5R
7
8
10A CLUSTER 24V BATTERY
CR-23 3
3R
R ALTERNATOR
1 1 B+
~ G
2 2 1 P
ROr L 3
2
3 3
3 FI U
4 4
46
4 4 NC
5 CN-74
20A ECM_IG
9 47 6
RESISTOR
48 7 RW
10A MCU 1
10 ROr 3W/300
49 8 2
RS-1
11
10A TCU 50 CN-13
59
10A CLUSTER
12 60
10A
CN-6
CASSETTE
13
ROr
14
10A SPARE 5
CN-58A
5A ILLUMINATION 1
B36
35
5A ILLUMINATION 2
36
CN-36
ALT LEVEL
MCU
7579S7EL07
7-15
6. ELECTRIC PARKING CIR
CIRCUIT
CUIT
1) OPERATING FLOW
(1) Parking OFF
Fuse box[CN-36 (29)] Parking switch OFF [CS-17 (8)→(4)] I/conn [CN-5 (30)]
I/conn [CN-12 (13)]
OFF ON
Parking solenoid [CN-71] ON (activated)
P
Parking brake released (by hydraulic pressure)
[CS-17 (7)→(3)] T/M control unit[CN-157 (21)]
(2) Parking ON
Fuse box [CN-36 (29)] Parking switch ON Parking solenoid [CN-71] OFF
Parking brake applied [By spring force]
2) CHECK POINT
Engine Key switch Check point Voltage
① - GND (parking switch input)
Running ON ② - GND (parking switch output) 20~25V
③ - GND (parking solenoid)
※ GND : Ground
7-16
ELECTRIC PARKING CIRCU
CIRCUIT
IT
FUSE BOX
ILLUMINATION 1 5A
35
Or ILLUMINATION 2 5A
36
PARKING SW 1
B
12
12
Or
1
10 25
10
9
ROr
4
7 WIPER 20A
7
28
3
32
RIDE CONTROL 10A
CS-17 2 10A
33
JOYSTIC_SWITCH
34
BOOM UP RY
B
86 30 87a CN-36
LW
85
87
V
86
85 87 87a VOr
30 TCU
CR-41 1 VM1-GND
BUCKET RY 2 VM2-GND
86 30 87a 15 SDDK-DIAGNOSTIC
OrW 18 EUPR-DIAGNOSTIC
85
B Y
6 NC
87 21 ED10-PARKING BRAKE SW(+)
V
86 66 ED9 DIFF. LOCK SWITCH
85 87 87a GrW
30
Y 37 AU1-+5V SUPPLY_BRAKE PEDAL
CR-40 38 EU1-SIGNAL SENSOR_BRAKE PEDAL
DO-5 CN-157
GrW
1
V
2
DO-4
VOr
1
V
OrW
2
BrW
LW
LW
Y
JOYSTICK LEVER
CN-5
CN-6
16
20
21
25
26
44
45
33
47
48
30
31
32
14
29
13
3
15
1
1
2
NC 14
NC 15
V
24V(DETEND) 1
LW
Y
24V(HANDLE) 9
REV 2
FWD 3
LW
NEUTRAL 4
Y
JOYSTICK SELECT 10
CN-12
CN-10
KICK DOWN 8
10
10
11
12
13
14
15
11
12
7
3
8
9
6
1
7
8
9
2
2
4
5
BOOM DOWN(-) 7
GrW
BUCKET(-) 6
VOr
5
OrW
BOOM UP(-)
BrW
LW
LW
COUNT_WEIGHT SW 16
Y
HORN SWITCH 11
Or
ILLUMINATION 12
B
FNR SWITCH 13
CN-160
CIGAR LIGHTER
3
Or
Y
B
LW
CD-4
CN-71 B
BUCKET LEVELER
CL-2
1
2
3
4
CN-101
CN-100
1
1
3
4
1
3
4
2
Pa
B
E
S
B
E
S
SS + -
STOP LAMP & PARKING SOL
CLUTCH CUT-OFF PS
7579S7EL08
7-17
7. WIPER AND WASHER CIRCUIT
1) OPERATING FLOW
Fuse box[CN-36 (28)] Wiper relay Hi [CR-4 (3)→(4)] I/conn [CN-4 (4)]
Front wiper motor [CN-21 (1)]
Wiper relay Lo [CR-26 (5), (2)]
Multi function switch [CS-12 (6)]
I/conn [CN-9 (3)] Rear wiper & washer switch [CS-35 (3)]
Rear wiper motor [CN-102 (1)]
(1) Front washer switch ON
① Washer switch ON [CS-12(6)→(2)] Front washer [CN-22 (1)] Washer operating
MCU [CN-58A (A31)→(B02)] Front wiper relay Lo
[CR-26 (5)→(3)] Front wiper motor [CN-21 (5)]
Wiper motor operating (low)
(2) Front wiper switch ON
① INT position
Wiper switch ON [CS-12 (6)→(1)] MCU [CN-58A (A23)→(B02)] Wiper relay Lo [CR-26 (5)→(3)]
Front wiper motor [CN-21(5)] Front wiper motor intermittently operating
② Lo position
Wiper switch ON [CS-12 (6)→(4)] Wiper relay Lo [CR-26 (4)→(3)] Front wiper motor [CN-21 (5)]
Front wiper motor operating (low)
③ Hi position
Wiper switch ON [CS-12 (6)→(3)] Wiper relay Hi [CR-4(3)→(5)] Front wiper motor [CN-21 (4)]
Front wiper motor operating (high)
(3) Auto-parking (when switch OFF)
Switch OFF Fuse box [CN-36 (28)] Wiper relay Hi [CR-4 (3)→(4)] Front wiper motor
[CN-21 (1)→(2)] Multi function switch [CS-12 (5)→(4)] Wiper relay Lo [CR-26 (4)→(3)]
Front wiper motor [CN-21 (5)] Wiper motor stop
(4) Rear wiper and washer switch
① Wiper switch ON (1st step)
Wiper switch ON [CS-35 (3)→(8)] I/conn [CN-9 (5)] Rear wiper motor [CN-102(5)]
Rear wiper motor operating
② Washer switch ON (2nd step)
Washer switch ON [CS-35 (3)→(5)] I/conn [CN-9 (4)] Rear washer tank [CN-103(1)]
Washer operating
2) CHECK POINT
Condition Check point
① - GND (front wiper switch power input) ⑥ - GND (wiper relay power input)
Engine : Stop ② - GND (rear wiper switch power input) ⑦ - GND (front washer power output)
Key switch : ON ③ - GND (wiper relay power input) ⑧ - GND (rear washer power output)
Voltage : 20~25V ④ - GND (front wiper motor Lo power input) ⑨ - GND (front wiper motor power output)
⑤ - GND (front wiper motor High power input) ⑩ - GND (rear wiper motor power output)
※ GND : Ground
7-18
WIPER AND WASHER CIRCUIT
WASHER
PUMP
CN-103
CN-22
2
1
1
2
OrW
FUSE BOX
Gr
B
B
SERVICE SOCKET 1 20A
25
20A
1 SPARE
26
WORK LAMP_REAR 20A
2 27
Br Br Br WIPER 20A
3 28
OrW OrW PARK 20A
4 29
JOYSTICK-DETENT 10A
RW RW 30
REAR WIPER 5 PRE-HEAT, FUEL WARMER 30A
B 31
12
6
12
11 G G 32
G
10 7 RIDE CONTROL 10A
33
5
JOYSTIC_SWITCH 10A
RW 8
10 3
8 34
8
9
10 CN-36
OrW
0,I
5 10
I 0
Br 11
3
1 12
11
12
8 13 Y
WIPER RY HI
CS-35 4
B 3 2
2 14
R
1
5
15 Br
2
Br
CN-9 3 4 5 1
CR-4
3
WIPER RY LO
G
4 3 2
W
1
Y
FRONT WIPER 5
Y Y Y
3E 1 2
G LW W
2Pf 2 3 4 5 1
B B
1B 3
L R B CR-26
R 4 W
4 Hi 5
M
5 Lo 6
CN-21
6
5
4
REAR WIPER
Br
1 3E
G
2 2Pf
B
9 3 1B
4
LOr
LW
RW
Gr
Br
Br
G
5 4 Hi
7 6 5 Lo
M
1 CN-102
CS-11
CS-12
CS-5
CN-58A
WIPER INT SIG A23
A31
B02
1
2
3
4
5
6
8
7
6
5
4
3
2
1
HO
RW
BVi
BY
4BWG
Gr
W
G
L
WIPER RLY
Y
6
2
6
1
3
5
WASH SIG
C
Hi
J
C
W
II
II
J
Hi Lo
I
O
B+
C
MCU
F
L
R
O
L
R
Y 7 Lo
B 5
WB 8
BG 3
BW 2
7579S7EL09
7-19
HAZARD, TURN AND ROTARY CIRCUIT
11 FUSE BOX
WOr WOr WOr BEACON 10A
12 15
WORK LAMP_FRONT 20A
13 20A
16
MIRROR,SER.SOCKET2
17
14 ILL.LAMP 20A
18
15 HEAD LAMP 20A
19
CN-9 BACK.STOP LAMP 10A
20
HORN/CONVERTER 20A
21
AIR-CON/HEATER 1 30A
22
1 FUEL WARMER 20A
23
2 CIGARLIGHTER 30A
24
3
4
CL-16 33 GW TURN LAMP 20A
C 4 1
OrW CASSETTE/ROOM LAMP 5A
T 3
B
34 2
E 2 START KEY SWITCH 30A
S 1
35 10A
3
TCU 24V BATTERY
36 4
REAR COMBI,RH ECU 24V BATTERY 20A
5
59 MCU 24V BATTERY 20A
6
60 AIR-CON/HEATER 2 10A
7
10A
CL-15 CN-6 CLUSTER 24V BATTERY
8
C 4
GOr
T 3
B
E 2 CN-36
S 1
REAR COMBI,LH
FLASHER UNIT
RW
87 L
GW
85 B G
B
86 E
CR-11
CLUSTER
8 PROGRAM DUMP
7 NC
6 MIRROR HEATED
5 HIGH BEAM
Or
4 RH TURN
GOr
3 LH TURN
2 BATT. 24V
ILL & HEAD LAMP 1 IG 24V
SW : ON(1st step) CN-56
GOr
RW
Or
CS-11
8
7
6
5
4
3
2
1
WOr
GOr
RW
RW
YOr
YOr
4BWG
Or
W
R
B
R
B
6
CL-7
CS-23
CS-41
7
3
1
3
1
8
4
9
9
10
10
12
12
11
11
1
2
Hi
C
1 8 7 11 1 8 7 11
Hi Lo
BEACON
B+
C
LAMP
F
L
R
O
L
R
12 10 4 9 3 12 12 10 4 9 3 12
Y 7 Lo
BW 2
7579S7EL10
7-20
GROUP 3 MONITORING SYSTEM
1. CLUSTER
1) STRUCTURE
The cluster consists of gauges, lamps and LCD 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 lamps : Indicate abnormality of the machine.
· Pilot lamps : Indicate operating status of the machine.
· LCD : Indicates selected the driving speed and direction.
※ The cluster installed on this machine does not entirely guarantee the condition of the
machine. Daily inspection should be performed according to chapter 6, M MAINTENANCE.
AINTENANCE.
※ When the cluster provides a warning immediately check the problem, and perform the
required action.
7579S7EL20
2) GAUGE
(1) Speedometer
Unit ① The speedometer displays the speed of machine in mph and
km/h.
※ The unit ((km/h
km/h or mph
mph)) can be set by the display set up menu
of the monitor and selected unit is displayed.
Refer to page 7-40.
75793CD03
7-21
(2) Fuel gauge
① This gauge indicates the amount of fuel in the fuel tank.
② Fill the fuel when the indicator moves red range or lamp blinks
in red, refuel as soon as possible to avoid running out of fuel.
※ If the gauge indicates below red range even though the
machine is on the normal condition, check the electric device
Red
75793CD04 as that can be caused by the poor connection of electricity or
sensor.
7-22
3) WARNING LAMPS
75793CD95
77073CD17
75793CD35
7-23
(4) Hydraulic oil temperature 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.
77073CD21
77073CD23
77073CD20
77073CD18
7-24
(9) Steering warning lamp
① Primary
This lamp indicates that the primary steering has failed. When
the indicator comes on and the action alarm sounds, steer the
machine immediately to a convenient location and stop the
machine. Stop the engine and investigate the cause.
※ Do not operate the machine until the cause has been cor-
77073CD66
rected.
② Emergency
This lamp indicates the emergency steering system is active.
※ Immediately pull the machine to a convenient stop and stop
the engine.
※ The emergency steering system can be manually tested.
77073CD15
Refer to page 7-45.
77073CD22
77073CD16
7-25
4) PILOT LAMPS
7609S3CD10
75793CD17
7807A3CD11
7-26
(4) High beam pilot lamp
① This lamp works when the illuminating direction is upward.
② This lamp comes ON when the dimmer switch is operated, e.g.,
when passing another vehicle.
77073CD12
77073CD13
77073CD65
7-27
(9) Ride control pilot lamp (option)
① Auto ride control
This lamp lights ON when push in the bottom of the ride control
switch (auto position).
※ Refer to page 7-44.
75793CD33
75793CD34
7707A3CD40
5) LCD
Type 1 (1) The LCD can be used with the gear selector.
It indicates speed and driving direction.
2
3 No Symbol Meaning Remark
2
Forward, reverse, neutral
1 1 1, 2, 3, 4 Actual gear display Actual gear
75793CD39
P Parking brake mode active
7-28
2. MONITOR
Vertical
Main display
Horizonta
l
1) BUTTONS
(1) Menu button
① Main display to main menu, main menu to main display.
② AEB cancel button in AEB setting.
75793CD90
75793CD91
75793CD92
75793CD93
75793CD94
7-29
2) MAIN MENU
Main display
1 3
6
7
4 Main menu
5
8
10 Press
9
TYPE A (default)
2 8
9
5
10
6
7
TYPE B 75793CD11
(1) Structure
No Main menu Sub menu Description
Engine speed Engine warming up, Engine speed
Kick down Mode 1 (down/up), Mode 2 (down only)
Wiper speed 4 steps
1
Fan-auto mode Interval and time setting
MODE AEB AEB setting
75793CD12
Speed meter Pulse setting
Fault code Active, logged fault (machine, ECU, TCU)
Machine monitoring Hyd temp, Battery, Coolant temp
T/M oil temp
2
Monitoring history Hour meter, ODO meter
MONITORING
75793CD13
Clock Clock
Display Brightness setting (Manual/Automatic)
Type display (A or B type)
4
Unit Temp (˚F/˚C), Distance (km/mile), Pressure (bar, Mpa, kgf/m2, psi)
DISPLAY SET UP Rear camera Reverse mode, Active camera, Display order
75793CD13
Language 12 languages
7-30
(2) Mode
① Engine speed
75793CD16
75793CD16A 75793CD16B
75793CD16C 75793CD16D
② Kick down
75793CD17
75793CD17A
· Mode 1 (down/up) : Press kick down button once, shift down and press button again, shift up.
· Mode 2 (down only) : Press kick down button every time, shift to lower gear respectively.
※ Refer to page 7-46.
③ Wiper speed
75793CD18
· Setting wipe speed 1 to 4.
75793CD18A
④ Fan-auto mode
75793CD110
75793CD111 75793CD112
7-31
⑤ AEB
Actual gear window
75793CD19
75793CD19A
* : Transmission stays in neutral, you have to restart the TCU (ignition off/on).
⑥ Speed meter
75793CD20
75793CD20B 75793CD20A
7-32
(3) Monitoring
① Fault code
75793CD23
75793CD23C 7709S3CD23D
75793CD23E 7709S3CD23
7709S3CD23G
75793CD23H 75793CD23I
75793CD23J
7-33
② Machine monitoring
75793CD24
7709S3CD24A 7709S3CD24B
③ Record monitoring
75793CD25
75793CD25A 75793CD25C
· Hour meter
- Total : total hour meter
To show the item in the main display, select "ON"
and press (this item could not reset).
- Latest : the latest hour meter after reset.
To show the item in the main display, select "ON"
and press . 75793CD25D
75793CD25F 75793CD25H
· ODO meter
- Total : total ODO meter
To show the item in the main display, select "ON"
and press (this item could not reset).
- Latest : the latest ODO meter after reset.
To show the item in the main display, select "ON"
and press .
75793CD25J
To reset the latest odometer, select "initializing" and
press .
7-34
(4) Management
① Machine security
75793CD26
75793CD26A 75793CD26B
· Interval setting
- If set interval setting to 5 minutes,
ESL system is activated after 5
minutes.
Therefore, the password does not
need to restart engine within 5
minutes. 75793CD26J 75793CD26K
7-35
· Change password
- Input 5 to 10 digits and press *.
75793CD26G 75793CD26H
Enter the current password.
75793CD26L
Enter the new password.
75793CD26N 75793CD26M
The new password is stored Enter the new password
in the MCU. again.
7-36
② Maintenance
75793CD27
75793CD27A 75793CD27B
75793CD27D 75793CD27C
· Alarm ( ) : Warning
Replacement : The elapsed time will be reset to zero.
Change cycle : The change or replace cycle can be changed in the unit of 50 hours.
· To change cycle, press or .
· Change or replace interval
No Item Interval
1 Engine oil 500
★1
2000
2 Hydraulic oil ★2
5000
3 Pilot line filter element 250
4 Hydraulic oil return filter 250
5 Engine oil filter 500
6 Fuel filter element 500
7 Fuel pre-filter 500
8 Hydraulic tank air breather 250
9 Radiator coolant 2000
10 Transmission oil and filter 1000
11 Axle oil (front and rear) 1500
★1
: Conventional hydraulic oil
★2
: Hyundai genuine long life hydraulic oil
7-37
③ Machine information
75793CD28
75793CD28A 7579S3CD28B
75793CD28C 75793CD28D
· Version
- Software versions of MCU, cluster and monitor can be
checked.
· Status info
- The machine status can be checked.
75793CD28E
④ Service contact
75793CD29
75793CD29A 75793CD29B
· The phone number of the service man can be checked and changed.
⑤ Service menu
75793CD30
75793CD30A 75793CD30B
7-38
(5) DISPLAY SET UP
① Clock
75793CD32
75793CD32A
② Display
· Brightness setting
75793CD33
75793CD33A
75793CD33B 75793CD33C
Manual (1st~8th step)
75793CD33D 75793CD33E
7-39
· Display type
75793CD33I
B type
③ Unit
75793CD34
75793CD34A 75793CD34B
· Temperature : ˚C ↔ ˚F
· Distance : km ↔ mile
· Pressure : bar ↔ Mpa ↔ kgf/m2 ↔ psi
7-40
④ Rear camera
75793CD35
75793CD35A 75793CD35B
75793CD35C 75793CD35D
75793CD35E 75793CD35F
· Reverse mode
- If transmission engages the reverse gear (R1~R3), the camera mode is displayed
automatically in main display.
· Active camera
- Three cameras can be installed on the machine.
- The display order can be set by this menu.
· If the camera was not equipped, this menu is not useful.
· In main display, if the button is pushed, the first ordered display camera will be viewed.
⑤ Language
75793CD36
75793CD36A 75793CD36B
· User can select preferable language and all display are changed the selected language.
7-41
3. SWITCHES
M
Rear wiper/washer switch
Beacon switch(option) M
P
Horn button
Starting switch
7709S3CD29
1) STARTING SWITCH
(1) There are three positions, OFF, ON and START.
· (OFF) : None of electrical circuits activate.
· (ON) : All the systems of machine operate.
· (START) : Use when starting the engine.
Release key immediately after starting.
※ If you turn ON the starting switch in cold weather, the fuel warm-
77073CD41
er is automatically operated to heat the fuel by sensing the cool-
ant temperature. Start the engine in 1~2 minutes after turning
ON the starting switch. More time may take according to ambi-
ent temperature.
※ Key must be in the ON position with engine running maintain
electrical and hydraulic function and prevent serious machine
damage.
7-42
2) HAZARD SWITCH
(1) Use for parking, or loading the machine.
ON
OFF (2) Both turn signal lights will flash simultaneously.
※ If the switch is left ON for a long time, the battery may be dis-
charged.
75793CD42
75793CD46
7-43
7) FAN CONTROL SWITCH
(1) This switch use to control the cooling fan.
OFF
AUTO (2) This switch has three positions.
MANUAL ·AUTO
UTO : The fan automatically work in reverse according to set
up interval and time.
※ Refer to page 7-31.
·OFF
OFF : Only forward rotation is possible.
75793CD49
·MANUAL
MANUAL : The fan rotates reverse only while pressing this position.
If release the switch, return to the OFF position.
(3) On pressing the switch, the indicator lamp is turned ON.
75793CD50
7-44
11) EMERGENCY TEST SWITCH (option)
(1) The emergency steering system can be manually tested. Push the
switch in order to determine if the emergency steering and the
emergency steering lamp are functional.
M
(2) When the switch is pressed, the emergency steering pump motor
will run. The emergency steering lamp will light. If the emergency
75793CD52
steering lamp does not light, do not operate the machine.
7-45
15) HORN BUTTON
Horn button (1) If you press the button on the top of the multifunction switch, the
horn will sound.
7609S3CD16
HB1003CD63
7-46
19) MULTI FUNCTION SWITCH
O J ⅠⅡ (1) Front wiper and washer switch
① When the switch is in J position, the wiper moves intermittently.
② When placed in Ⅰ or Ⅱ position, the wiper moves continuously.
③ If you push the grip of the lever, washer liquid will be sprayed and
the wiper will be activated 2-3 times.
73033CD29
※ 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.
7-47
GROUP 4 ELECTRICAL COMPONENT SPECIFICATION
Gravity
12V × 160Ah 1.280 over : over charged
Battery
(2EA) 1.280 ~ 1.250 : normal
1.250 below : discharged
CR-1
H BR ACC ST C
23 56
H 0 I II 4
Resistance between each pin
B-BR : 24V 1A
Key off : ∞Ω(for each pin)
Start key 0, I 1
B-ACC : 24V 10A
B Key on : 0Ω(for pin 1-2 & 1-3)
B-ST : 20V 40A
1 2 3 4 5 6 Start : 0Ω(for pin 1-5)
CS-2
A
- S +
Pa
B
Voltage
Pressure sensor C - Pin A, B : 24V
Pin B, C : 1~5V
CD-3 CD-26
CD-39 CD-40
CD-48
7-48
Part name Symbol Specifications Check item
1
Parking brake Resistance
2 24V 1A
solenoid normal : 15~25Ω
CN-71
1 2 1
Resistance at normal position
Relay 2
3 24V 20A about 200Ωbetween pin 1-3
(4pin)
4 4 3 ∞Ω between pin 2-4
AC RY(H1)
CR-2 CR-26 AC RY1
CR-5 CR-30 AC RY2
30
87a 87 85
86 Resistance
87
normal : about 160Ω
Relay 85
87a 30 86 24V 20A (for pin 85~86)
(5pin)
0Ω(for pin 30~87)
CR-5 CR-25 CR-35 CR-37
CR-40 CR-41 CR-46 CR-59 ∞Ω(for pin 30~87)
CR-60 CR-79
7-49
Part name Symbol Specifications Check item
2 3 4
1 Resistance
5
2
normal : about 160Ω
Relay 1 5 4
3 24V 20A (for pin 1~2)
(5 pin)
CR-2 CR-3 CR-4 CR-7 0Ω(for pin 3~4)
CR-26 CR-36 CR-38 CR-55 ∞Ω(for pin 3~5)
CR-58 CR-63
2 Resistance
Hydraulic C
- normal : ∞Ω
temperature 1
105。C over : 0Ω
CD-1
1 Resistance
Speaker 4Ω 20W
2 normal : 4Ω
CN-23(LH)
CN-24(RH)
7
3
1
10
4
12
9
11
Switch
∞Ωbetween pin 1-5 and 2-6
(Non-locking 24V 8A
1
11
9
7
type)
9
4
6
1
3
CS-21 CS-36
Work lamp
1
Work lamp, 24V 65W
2
Room lamp, Number plate lamp Resistance
Numbaer plate CL-1CL-21
CL-1 CL-6
CL-32CL-22 24V 10W normal : 1.2Ω
lamp CL-5 CL-22 CL-33CL-23
CL-5 CL-21
Room lamp
CL-6 CL-23 CL-36
24V 10W
7-50
Part name Symbol Specifications Check item
2 24V
24V Resistance
DC/DC 1 GND 12V 3A 8.8Ω(for pin A-B)
Converter 3 12V
12V
7.7Ω(for pin B-C)
CN-138
2 Resistance
PA
Receiver dryer 24V 2.5A 0Ω: 2.1±0.3~27±2kgf/cm²
1
∞Ω: ~2.1±0.3, 27±2~kgf/cm²
CN-29
REMOCON GND
SPK FRT RH+
REMOCON+
Resistance
BACK UP+
TEL MUTE
ANT 12V
GND
ACC
ILL+
ILL-
NC
NC
player
(for pin 1-6, 4-8)
10
11
12
13
14
15
16
8
1
2
3
4
5
6
7
CN-27
7-51
Part name Symbol Specifications Check item
M 1 Resistance
Washer pump 2 24V 2.5A normal : 26.4 Ω
(for pin1-2)
CN-103
CN-22 (FR)CN-22
CN-103 (RR)
E 3 1
Pf 2 2
B 1 3
4 24V 1.5A
Hi 4 5
Wiper motor Lo 5 6
2-speed -
M
Auto parking
CN-21 (FR) CN-102 (RR)
B
A Coil resistance
Cigar lighter 24V 5A 1.4W
1 normal : about 1MΩ
CL-2
B+
G
1 P
3~
2 L
U
Voltage
Alternator 3 FI 24V 70A
4 NC normal : 24~28V
CN-74
M
Nippondenso
Starter Operating or not
24V-3.7kW
B+ M
CN-45
1 Resistance
Aircon
24V 79W
compressor normal : 13.4Ω
CN-28
7-52
Part name Symbol Specifications Check item
Coil resistance
normal : 1-2Ω
Start relay 24V 300A Switch connection
∞Ωat normal open position
CR-23 0Ωwhen engaged
Resistance
Door switch 24V 2W
normal : about 5MΩ
CS-1 CS-55
3 E
G 24V
2 B
Flasher unit 1 L
85 ~ 190 C/M -
50dB
CR-11
6 Lo
4 Hi 24V 75W/70W
5 (H4 TYPE) Resistance
Head lamp 3 C
E
24V 4W normal : a fewΩ
2
ABL
1 T (T4W)
CL-3 CL-4
4 C
24V 5W
3 T
Combi lamp (R5W)
2 E -
(rear) 2×24V 21W
1 S
(P21W)
CL-15 CL-16
7-53
Part name Symbol Specifications Check item
Continuous capaci-
ty :
Master switch 180Amp -
Push in capacity :
1000Amp
CS-74
2
24V 200mA
Warning buzzer 1 -
90±5dB (ℓm)
CN-26
Resistance
Preheater 24V 200A
0.25~0.12Ω
CN-80
A A
B Resistance
Resistor 4W
C B A - B : 120Ω
CN-99
7-54
GROUP 5 CONNECTORS
1. CONNECTOR DESTINATION
Connector No. of Connector part No.
Type Destination
number pin Female Male
CN-5 DEUTSCH 48 I/conn (Frame harness-Main harness) DRB16-48SAE-L018 DRB12-48PAE-L018
CN-6 DEUTSCH 60 I/conn (Frame harness-Main harness) DRB16-60SBE-L018 DRB12-60PBE-L018
CN-7 AMP 15 I/conn (Main harness-Cab harness) 2-85262-1 368301-1
CN-9 AMP 12 I/conn (Cab harness-Main harness) 2-85262-1 368301-1
CN-10 DEUTSCH 23 I/conn (Frame harness-Front harness) HD34-24-23PE HD36-24-23SE
CN-11 DEUTSCH 8 I/conn (Main harness-Aircon harness) DT06-8S DT04-8P
CN-12 AMP 15 I/conn (Frame harness-Bottom harness) 2-85262-1 368301-1
CN-13 DEUTSCH 12 I/conn (Frame harness-Engine harness) DT06-12S DT04-12P
CN-14 DEUTSCH 12 I/conn (Frame harness-Grill harness) DT06-12S DT04-12P
CN-19 Econoseal J 6 I/conn (Emer steer harness-Front harness) S816-006002 S816-106602
CN-20 DEUTSCH 2 Horn DT06-2S -
CN-21 AMP 6 Front wiper motor 936257-1 -
CN-22 KET 2 Front washer tank MG640605 -
CN-23 KET 2 Speaker (LH) 7123-1520 -
CN-24 KET 2 Speaker (RH) 7123-1520 -
CN-25 DEUTSCH 2 Horn DT06-2S -
CN-26 250 2 Warning buzzer S810-002202 -
CN-27 MK II 16 Radio and USB player PK145-16017 -
CN-27A MK II 8 USB connector 174984-2 -
CN-28 NMWP 1 Aircon compressor PB625-01027 -
CN-29 KET 2 Receiver drier MG640795 -
CN-36 - - Fuse box 21Q7-10910 -
CN-45 Ring term - Starter R14-12 ST 710246-2
CN-56 AMP 20 Cluster 174047-2 -
CN-57 AMP 20 Monitor 174047-2 -
CN-58A DEUTSCH 40 MCU DRC26-40-SA -
CN-58B DEUTSCH 40 MCU DRC26-40-SB -
CN-60 MTA 2 Fusible link (40A) 07.00910 03.21000
CN-65 DEUTSCH 2 Back up buzzer DT06-2S -
CN-71 DEUTSCH 2 Parking solenoid DT06-2S-EP06 -
CN-74 PACKARD 4 Alternator 1218-6568 -
CN-83 NMWP 2 Aircon fan PB625-02027 -
CN-93 DEUTSCH 50 ECM DRC26-50S-04 -
7-55
Connector No. of Connector part No.
Type Destination
number pin Female Male
CN-94 DEUTSCH 4 ECM power DTP06-4S-EP06 -
CN-95 MTA 2 Fusible link (80A) 07.00960 03.21000
CN-96 - 2 Fuel heater 1530-0027 -
CN-99 DEUTSCH 2 Resister DT04-3P-EP10 -
CN-100 Econoseal J 3 Boom kick out S816-003002 S816-103002
CN-101A Econoseal J 3 Bucket leveler - S816-103002
CN-102 AMP 6 Rear wiper motor 936257-1 -
CN-103 KET 2 Rear washer tank MG640605 -
CN-112 - 16 Gear box 21L7-60290 -
CN-114 - 6 Joy stick 1-480704-0 -
CN-126 DEUTSCH 9 Data link HD10-9-96P -
CN-136 AMP 2 Ride control solenoid 85202-1 -
CN-138 250 3 DC/DC Converter S810-003202 -
CN-139 250 2 12V socket S810-002202 -
CN-141 Econoseal J 6 I/conn (Ride control harness-Front harness) S816-006002 S816-106002
CN-149 DEUTSCH 2 Mirror heat (LH) DT04-2S-EP06 DT04-2P-E005
CN-150 DEUTSCH 2 Mirror heat (RH) DT04-2S-EP06 DT04-2P-E005
CN-154 AMP 2 Fan speed solenoid 85202-5 -
CN-155 AMP 2 Fan reverse solenoid 85202-1 -
CN-157 AMP 60 T/M control unit 962175 -
CN-158 PACKARD 4 Gear shift lever - 1201-0974
CN-159 PACKARD 4 Gear shift lever 1201-5797 -
CN-162 Econoseal J 6 Pedal S816-006602 -
CN-249 DEUTSCH 4 Camera DT06-4S DT06-4P
CN-250 Econoseal J 4 Rear view camera S816-004002 S816-104002
Relay
CR-1 Ring term - Battery relay S820-104002 -
CR-2 AMP 5 Horn relay VCFM-1002 -
CR-3 AMP 5 Front work lamp relay VCFM-1002 -
CR-4 AMP 5 Wiper relay (Hi) VCFM-1002 -
CR-5 HELLA 5 Safety relay 8JA003526-001 -
CR-7 AMP 5 Aircon relay VCFM-1002 -
CR-11 HELLA 5 Flasher unit 8JA003526-001 -
CR-23 Ring term - Start relay ST 710289-2 ST 710384-2
CR-24 Shur 1 Preheater relay S822-014000 -
CR-25 HELLA 5 ECM power relay 8JA003526-001 -
7-56
Connector No. of Connector part No.
Type Destination
number pin Female Male
CR-26 AMP 5 Wiper relay (low) VCFM-1002 -
CR-36 AMP 5 Preheater relay VCFM-1002 -
CR-39 Ring term - Emergency steering pump relay S820-104000 -
CR-46 HELLA 5 Fuel warmer relay 8JA003526-001 -
CR-55 AMP 5 Rear work lamp relay VCFM-1002 -
CR-56 KET 4 Mirror heat relay MG610047-1 -
CR-58 AMP 5 Back up relay VCFM-1002 -
CR-63 AMP 5 Stop lamp relay VCFM-1002 -
Switch
CS-1 Shur 1 Door switch S822-014004 -
CS-2 SWP 6 Start key switch S814-006000 -
CS-5 Shur 1 Horn switch S822-014000 -
CS-11 SWP 8 Multi function switch S814-008000 -
CS-12 SWP 6 Multi function switch S814-006000 -
CS-17 SWF 12 Parking switch 589790 -
CS-21 SWF 12 Main light switch 589790 -
CS-23 SWF 12 Beacon switch 589790 -
CS-35 SWF 12 Rear wiper 589790 -
CS-36 SWF 12 Work lamp switch 589790 -
CS-41 SWF 12 Hazard switch 589790 -
CS-42 DEUTSCH 3 Clutch cut off dial switch - DT06-3S-E008
CS-55 SWF 12 Ride control switch 589790 -
CS-59 DEUTSCH 3 Transmission shift dial switch - DT06-3S-E008
CS-73 SWF 12 Fan reverse switch 589790 -
CS-74 RING TERM 4 Master switch ST710287-2 S820-205000
CS-75 SWF 12 Emergency steering test switch 589790 -
CS-76 SWF 12 Mirror heater switch 589790 -
CS-80 DEUTSCH 3 Econo mode dial switch DT06-3S-E008 -
7-57
Connector No. of Connector part No.
Type Destination
number pin Female Male
Light
CL-1 KET 3 Room lamp MG651032 -
CL-2 250 3 Cigar lighter S810-003202 -
CL-3 DEUTSCH 6 Head light (LH) DT06-6S -
CL-4 DEUTSCH 6 Head light (RH) DT06-6S -
CL-5 DEUTSCH 2 Work light (LH) DT06-2S-EP06 -
CL-6 DEUTSCH 2 Work light (RH) DT06-2S-EP06 -
CL-7 250 2 Beacon lamp S810-002202 -
CL-15 SWP 4 Combi lamp (RR, LH) S814-004000 -
CL-16 SWP 4 Combi lamp (RR, RH) S814-004000 -
CL-21 SWP 2 Numberplate lamp S814-002000 -
CL-22 DEUTSCH 2 Work light (LH) DT06-2S -
CL-23 DEUTSCH 2 Work light (RH) DT06-2S -
CL-24 SWP 2 Turn lamp (LH) S814-002000 -
CL-25 SWP 2 Turn lamp (RH) S814-002000 -
CL-30 KET 2 Room lamp MG610392 -
CL-32 DEUTSCH 2 Rear work light (RH) DT06-2S-EP06 DT04-2P-E005
CL-33 DEUTSCH 2 Rear work light (LH) DT06-2S-EP06 DT04-2P-E005
Sensor, sender
CD-1 AMP 2 Hyduaulic oil temp sendor 85202-1 -
CD-2 SWP 2 Fuel sendor S814-002000 -
CD-3 DEUTSCH 3 Brake fail pressure switch DT06-3S -
CD-4 DEUTSCH 4 Stop lamp/Clutch cut off pressure switch DT06-4S-EP06 -
CD-5 PACKARD 3 Clutch cut off pressure switch - 12015793
CD-10 Ring term 2 Air cleaner switch GP890469 -
CD-17 AMP 2 Engine pick-up sensor 85202-1 -
CD-26 DEUTSCH 3 Parking pressure switch DT06-3S -
CD-27 AMP 2 Turbin pick up sensor 85202-1 -
CD-39 DEUTSCH 3 Main pump pressure switch DT06-3S -
CD-40 DEUTSCH 3 Steering pump pressure switch DT06-3S -
CD-41 DEUTSCH 4 Boom down pressure switch DT06-4S -
CD-45 DEUTSCH 2 WIF sensor DT06-2S-EP06 -
CD-46 AMP 3 Output speed sensor 282087 -
CD-47 AMP 2 Gear chain senser 85202-5 -
CD-48 AMP 2 Oil filter 282080 -
CD-49 AMP 2 Converter sensor 85202-1 -
CD-73 AMP 2 Speed sendsor 174352-2 -
7-58
2. CONNECTION TABLE FOR CONNECTORS
1) 58-L TYPE CONNECTOR
No. of
Receptacle connector (female) Plug connector (male)
pin
1 1
S813-030100 S813-130100
1 2 1 2
S813-030200 S813-130200
7-59
2) PA TYPE CONNECTOR
No. of
Receptacle connector (female) Plug connector (male)
pin
2 5 1 3
1 3 2 5
S811-005002 S811-105002
3 7 1 4
1 4 3 7
S811-007002 S811-107002
4 9
1 5
1 5
4 9
S811-009002 S811-109002
5 11 1 6
11
1 6 5 11
S811-011002 S811-111002
7-60
No. of
Receptacle connector (female) Plug connector (male)
pin
6 13 1 7
13
1 7 6 13
S811-013002 S811-113002
1 9
8 17
17
1 9 8 17
S811-017002 S811-117002
110 21 1 11
21
1 11 1
10 21
S811-021002 S811-121002
7-61
3) J TYPE CONNECTOR
No. of
pin Receptacle connector (female) Plug connector (male)
1 2
1
2 12
S816-002001 S816-102001
2 3 1
3 1 2
S816-003001 S816-103001
3 1 4 2
4 2 3 1
S816-004001 S816-104001
8 5 2
6 3 1
8 5 2 6 3 1
S816-008001 S816-108001
7-62
4) SWP TYPE CONNECTOR
No. of
pin Receptacle connector (Female) Plug connector (male)
1 1
S814-001000 S814-101000
2 1
1 2
S814-002000 S814-102000
3 1
2 1 23
S814-003000 S814-103000
2 4 1 3
1 3 2 4
S814-004000 S814-104000
7-63
No. of
pin Receptacle connector (female) Plug connector (male)
3 6 1 4
3 6
1 4
S814-006000 S814-106000
4 8 1 5
4 8
1 5
S814-008000 S814-108000
4 12 1 9
12
4 12
1 9
S814-012000 S814-112000
3 14 11
1
14
1 11 3 14
S814-014000 S814-114000
7-64
5) CN TYPE CONNECTOR
No. of
pin Receptacle connector (female) Plug connector (male)
1 1
S810-001202 S810-101202
2 2
1 1
S810-002202 S810-102202
3 2
1 2 1 3
S810-003202 S810-103202
2 4 1 3
1 3 2 4
S810-004202 S810-104202
7-65
No. of
pin Receptacle connector (female) Plug connector (male)
3 6 1 4
1 4 3 6
S810-006202 S810-106202
4 8 1 5
1 5 4 8
S810-008202 S810-108202
7-66
6) ITT SWF CONNECTOR
No. of
pin Receptacle connector (female) Plug connector (male)
10
1 12
11
SWF589790
6 3
4
6
6189-0133
8) MWP02F-B CONNECTOR
No. of
pin Receptacle connector (female) Plug connector (male)
2 1
2
PH805-02028
7-67
9) AMP ECONOSEAL CONNECTOR
No. of
pin Receptacle connector (female) Plug connector (male)
12
1
12
13 24
36
25
24 36 1
13
36
25
344111-1
344111-1 344108-1
344108-1
85202-1
12 1 6
7 12
174045-2
7-68
12) KET 090 WP CONNECTORS
No. of
pin Receptacle connector (female) Plug connector (male)
2 1
MG640795
2
10
1 10
SWF593757
1
1
NMWP01F-B
7-69
15) DEUTSCH DT CONNECTORS
DT 06 - 3S - ★★★★
No. of
pin Receptacle connector (female) Plug connector (male)
1 2 2 1
2
DT06-2S DT04-2P
2 1 1 2
3 3
DT06-3S DT04-3P
4 1 1 4
3 2 2 3
DT06-4S DT04-4P
7-70
No. of
pin Receptacle connector (female) Plug connector (male)
6 1 1 6
4 3 3 4
DT06-6S DT04-6P
4 5 5 4
1 8
8 1
DT06-8S DT04-8P
7 6
6 7
12
1 12 12 1
DT06-12S DT04-12P
7-71
16) ECONOSEAL J TYPE CONNECTORS
No. of
pin Receptacle connector (female) Plug connector (male)
S816-001002 S816-101002
1 2 1
2
S816-002002 S816-102002
S816-003002 S816-103002
S816-004002 S816-104002
7-72
No. of
pin Receptacle connector (female) Plug connector (male)
S816-006002 S816-106002
S816-008002 S816-108002
10
S816-010002 S816-110002
12
S816-012002 S816-112002
7-73
No. of
pin Receptacle connector (female) Plug connector (male)
15
368301-1 2-85262-1
12040753
5
1 6
11 1
10
2
3
11 4
5
21
6
40 21 31
32
7
8
9
33 10
34
35
31 36
37
20
30
20
38
39
35 40
36
30
40
DRC26-40SA/B/C
7-74
GROUP 6 TROUBLESHOOTING
1. WHEN STARTING SWITCH IS TURNED ON, CLUSTER AND MONITOR LAMP DOES NOT
LIGHT UP
·Before carrying out below procedure, check all the related connectors are properly inserted and the
fuse [CN-36] No.12 is not blown out and ON/OFF of bulb.
·After checking, connect the disconnected connectors again immediately unless otherwise
specified.
Cause Remedy
YES
Defective cluster Replace
Check voltage Defective monitor Replace
between CN-56
(1), CN-57(1) and
chassis
Disconnection in Repair or
NO
wiring harness or replace
poor contact (after clean)
between CN-56
(1), CN-57 (1)
and fuse No. 12
MONITOR
CN-57
CLUSTER
FUSE[CN-36]
1
No.12
CN-56
Check voltage
YES 20 ~ 30 V
NO 0V
7609A7EL24
7-75
2. 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 Remedy
YES
Check voltage Defective Replace
YES controller
between CN-58A
(B36) and chassis
NO Disconnection in Repair or replace
Voltage : 27.5~30V wiring harness or (after clean)
poor contact
Check voltage between CN-58A
YES between CN-6
(B36) and CN-6 (49)
(49) and chassis
YES
Voltage : 26~30V Disconnection in Repair or replace
wiring harness or (after clean)
Check voltage poor contact
Check voltage between CN-13 between CN-13
NO
between (8) and chassis (8) and CN-6 (49)
alternator
terminal "2" and Disconnection in Repair or replace
chassis NO
wiring harness or (after clean)
Voltage : 26~30V poor contact
Starting switch : ON
between CN-13
(8) and alternator
terminal " 2 "
CONTROLLER(MCU)
49
ALTERNATOR
B36 8 " 2 " TERMINAL
CN-6 CN-13
CN-58A
Check valtage
YES 20 ~ 30 V
NO 0V 75797EL30
7-76
3. WHEN PARKING SOLENOID DOES NOT WORK
·Before carrying out below procedure, check all the related connectors are properly inserted and the
fuse [CN-36] No.29 is not blown out.
·After checking, connect the disconnected connectors again immediately unless otherwise specified.
Cause Remedy
YES
Defective parking Replace
Check voltage brake solenoid
YES between CS-17
Check voltage (4) and chassis
YES Disconnection in Repair or replace
between CN-5
Voltage : 20~30V NO wiring harness or (after clean)
(30) and chassis
Check voltage
poor contact
between CN-71 Voltage : 20~30V
between CS-17
(2) and chassis
(4) and CN-5 (30)
Starting switch : ON
Parking switch : ON-OFF YES
Voltage : 20~30V Disconnection in Repair or replace
wiring harness or (after clean)
poor contact
Check voltage between CN-12
between CN-12 (13) and CN-5
NO
(13) and chassis
(30)
Voltage : 20~30V
Disconnection in Repair or replace
NO
wiring harness or (after clean)
poor contact
between CN-12
(13) and CN-71
(2)
YES
Difective parking Replace
Check voltage
switch
between CS-17
NO
(7) and chassis
Disconnection in Repair or replace
Voltage : 20~30V NO
wiring harness or (after clean)
poor contact
between CS-17
(7) and Fuse
No.29
PARKING SWITCH
8 FUSE [CN-36]
7
4 No.29
CN-5 CN-12
CS-17
30 13 2
1
CN-71
7609A7EL31
7-77
4. 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 [CN-36] No.29 is not blown out.
·After checking, connect the disconnected connectors again immediately unless otherwise
specified.
Cause Remedy
YES
Defective T/M Replace
control unit
YES
Voltage : 20~30V Defective switch Replace
Parking switch : ON Check voltage
between CS-17
NO
(7) and chassis
Disconnection in Repair or replace
NO
Voltage : 20~30V wiring harness or (after clean)
poor contact
between CS-17 (7)
and fuse No.29
PARKING SWITCH
8 FUSE[CN-36]
7
3 No.29
T/M CONTROL UNIT
CS-17
21
CN-157
Check resistance
YES MAX 1Ω
7609A7EL32
NO MIN 1MΩ
7-78
5. MACHINE DOES NOT TRAVEL
·Before carrying out below procedure, check all the related connectors are properly inserted and the
fuse [CN-36] No.11 (transmission controller) is not blown out.
·After checking, connect the disconnected connectors again immediately unless otherwise
specified.
·Wiring diagram : See page 7-17.
Cause Remedy
YES
Defective clutch Replace
cut-off mode
Check resistance
YES switch
between CD-4
and chassis
Is there continuity
NO
between CN-157
(38) and chassis? Defective T/M Replace
NO
control unit
Is voltage between
Defective T/M Replace
CN-157(21) and NO
chassis 20-28V? control unit
Check resistance
YES MAX 1Ω
NO MIN 1MΩ
7-79
6. 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.28 is not blown out.
·After checking, connect the disconnected connectors again immediately unless otherwise
specified. FUSE BOX
SERVICE SOCKET 1 20A
25
SEAT HEAT/AIR-RIDE 20A
26
WORK LAMP_REAR 20A
27
Cause Remedy Br WIPER 20A
28
PARK, PILOT CUT
YES 20A
29
Check voltage Defective front Replace JOYSTICK-DETENT 10A
30
30A
YES between front wiper motor PRE-HEAT, FUEL WARMER
31
FAN REVERSE, ATT. 20A
wiper motor and RIDE CONTROL 10A
32
YES chassis
between CN-21(5) Starting switch : ON CN-36
Wiper switch : 1st
and chassis
Voltage : 20~30V
WIPER RY HI
Starting switch : ON Disconnection in Repair or replace Y
4
Wiper switch : 1st NO 3 2
YES Check voltage
B
1
wiring harness or (after clean) R
between CS-12 Br
5
(4) and chassis poor contact Br
2
3 4 5 1
between CN-21(5) CR-4
Voltage : 20~30V and CR-26(3)
Starting switch : ON WIPER RY LO
Wiper switch : OFF G
4 3 2
W
1
Y
FRONT WIPER 5
Y Y Y
3E 1 2
G LW W
Defective wiper Repair or replace 2Pf
B
2
B 3 4 5 1
NO 1B
L
3
R CR-26
Check voltage switch or (after clean) R
4
W
4 Hi 5
CS-12 (6) disconnection in M
5 Lo 6
CN-21
wiring harness or CN-102
Voltage : 20~30V poor contact
Starting switch : ON
Wiper switch : 1st
between CS-12(4)
and CR-26(4)
LOr
LW
Gr
Br
Br
G
poor contact
between CS-12(6)
and fuse [CN-36]
CS-11
CS-12
CS-5
CN-58A
WIPER INT SIG A23
A31
B02
1
2
3
4
5
6
8
7
6
5
4
3
2
1
No.28
HO
RW
BVi
BY
4BWG
Gr
W
G
L
WIPER RLY
Y
6
2
6
1
3
5
WASH SIG
C
Hi
J
C
W
II
II
J
Hi Lo
I
O
B+
C
MCU
F
L
R
O
L
R
Y 7 Lo
B 5
WB 8
BG 3
BW 2
MULTI FUNCTION SWITCH
7609A7EL33
7-80
7. WHEN STARTING SWITCH "ON" DOES NOT OPERATE
·Before carrying out below procedure, check all the related connectors are properly inserted and
and the fuse No.3 is not blown out.
·After checking, connect the disconnected connectors again immediately unless otherwise MASTER SW CN-60
3R 105
specified. 3R 106
RW
R
CS-2
2
6
5
4
1
B
0, I
1
H 0 I II
4
6
5
3
2
H
C ST ACC BR
START SWITCH
7579S7EL34
7-81
FUSE BOX
1
8. WHEN STARTING SWITCH IS TURNED ON, WORK LAMP DOES NOT LIGHTS UP 2
BEACON 10A
15
GW WORK LAMP_FRONT 20A
16
·Before carrying out below procedure, check all the related connectors are properly inserted, and 3 MIRROR,SER.SOCKET2 20A
17
4 ILL.LAMP 20A
the fuse [CN-36] No. 16, 27 is not blown out. HEAD LAMP 20A
18
5 19
·After checking, connect the disconnected connectors again immediately unless otherwise 6 BACK.STOP LAMP 10A
20
HORN/CONVERTER 20A
specified. 7
AIR-CON/HEATER 1 30A
21
8 22
FUEL WARMER 20A
23
9 CIGARLIGHTER 30A
24
10
Cause Remedy 11
YES 12 SERVICE SOCKET 1 20A
between LAMP,RH 2 31
YES CL-6 FAN REVERSE, ATT. 20A
1 34
chassis (2), CL-23 (2) and CL-35
W
LOr
1 2
Check voltage Voltage : 20~30V CN-7 (14), CN-6 2
B ILLUMINATION 1 5A
35
3
between Starting switch : ON (33). FR WORK LAMP
4 ILLUMINATION 2 5A
36
W
YES CR-3(5), 1
B 5
CR-55(5) and Disconnection in Repair or replace 2 CN-36
NO CL-36 6
chassis wiring harness or (after clean)
7
poor contact CL-32
RW
Voltage : 20~30V 1 8
Starting switch : ON between CN-7 2
B
Check voltage (14) -CR-3 (5) and
9
RR WORK LAMP
between CN-6 (33) - CR-55 RW
10
1
CR-3(3), (5) 2
B 11 FR WORK LAMP RY
CR-55(3) and CL-33 12
B
4 3 2
1
chassis Defective work Replace relay
13 W
5
Y
Voltage : 20~30V NO 14 2
lamp relay GW
3 4 5 1
Starting switch : ON 15
RR WORK 8 CR-3
YES LAMP,LH CN-9
Disconnection in Repair or replace 1
RW 9
B RR WORK LAMP RY
wiring harness or (after clean) 2 10 31
RR WORK CL-22 4 3 2
Check voltage poor contact 11 32 B
LAMP,RH 1
RW RW
between CR-3 (3), 12 33
between fuse 1
B VW
5
2 2
NO [CN-36] No. 16, CR-55 (3) and fuse CN-14 34 Y
CL-23 3 4 5 1
[CN-36] No. 16, 27 35 CR-55
27 and chassis
59
Voltage : 20~30V
Starting switch : ON Short circuit of Replace WORK LAMP SW
60
NO CN-6
fuse 12 11
1
3
Y
4
VW
6
LOr
6 7
LOr
4
9 9
3
7
R
11
12 1
12
B
CS-36
12 11
1
3
4 CLUSTER
R 17 ILLUMINATION
6
6 LOr CN-56
7
4
MONITOR
R R
9 9 18 ILLUMINATION
3
7 CN-57
R
11
12 1
12
B
7579S7EL35
CS-21
7-82