Hyundai HL780-3

WHEEL LOADER HYUNDAI HL780-3
HL780-3 Service Manual Open index screen
CONTENTS
Foreword
SECTION 1 GENERAL
Group 1 Safety Hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Group 2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Group 3 Operational checkout record sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
SECTION 2 ENGINE
Group 1 Structure and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
SECTION 3 POWER TRAIN SYSTEM

Group 1 Structure and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Group 2 Operational checks and troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Group 3 Tests and adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
Group 4 Disassembly and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52
SECTION 4 BRAKE SYSTEM

SECTION 5 STEERING SYSTEM

SECTION 6 WORK EQUIPMENT

SECTION 7 ELECTRICAL SYSTEM

Group 1 Component location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Group 2 Electrical circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Group 3 Monitoring system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
Group 4 Electrical component specification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33
Group 5 Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-42
Group 6 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-58
FOREWORD
1. STRUCTURE
This service manual has been prepared as an aid to improve the quality of repairs by giving the
serviceman an accurate understanding of the product and by showing him the correct way to perform
repairs and make judgements. Make sure you understand the contents of this manual and use it to
full effect at every opportunity.
This service manual mainly contains the necessary technical information for operations performed in
a service workshop.
For ease of understanding, the manual is divided into the following sections.
Structure and function

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Before starting a job :
şClean work area and machine.
şMake sure you have all necessary tools to do
your job.
şHave the right parts on hand.
şRead all instructions thoroughly; do not attempt
shortcuts.
PROTECT AGAINST FLYING DEBRIS

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Make certain all parts are reinstalled correctly if the
roll-over protective structure (ROPS) is loosened or
removed for any reason. Tighten mounting bolts
to proper torque.
The protection offered by ROPS will be impaired if
ROPS is subjected to structural damage, is
involved in an overturn incident, or is in any way
altered by welding, bending, drilling, or cutting. A
damaged ROPS should be replaced, not reused.
1-9
GROUP 2 SPECIFICATION
1. MAJOR COMPONENTS
Tooth Bucket Boom Tire Head light Hydraulic tank Air cleaner Radiator
Main control valve Step Main pump Battery Counterweight
Bucket link Bell crank Bucket cylinder Cab Precleaner Muffler Engine
Boom Front axle Boom cylinder Transmission Rear axle Fuel tank
Steering cylinder Torque converter
1-10
2. SPECIFICATIONS
1) WITHOUT TOOTH AND CUTTING EDGE TYPE BUCKET

B
F
I
J
6200
4540
H
3621
K
C
G
40
760 6430
D
0
E 2472
A
Description Unit Specification

Operating weight kg(lb) 28715(63306)
Struck 4.0(5.2)
Bucket capacity m3(yd3)
Heaped 4.7(6.2)
Overall length A 9195(30' 2")
Overall width B 3450(11' 4")
Overall height C 3670(12' 0")
Ground clearance D 475( 1' 7")
Wheelbase E mm(ft-in) 3700(12' 2")
Tread F 2440( 8' 0")
Dump clearance at 45Ş G 3480(11' 5")
Dump reach H 1435( 4' 8")
Width over tires I 3220(10' 7")
Dump angle J 45
Degree (Ş)
Roll back angle(Carry position) K 48
Lift(With load) 6.4
Cycle time Dump(With load) sec 1.6
Lower(Empty) 3.6
Maximum travel speed km/hr(mph) 37.4(23.3)
Braking distance 12(39' 4")
m(ft-in)
Minimum turning radius(Center of outside tire) 6.43(21' 1")
Gradability Degree (Ş) 30
First gear 7.6(4.7)
Second gear 13.3(8.3)
Forward
Third gear 22.3(13.9)
Fourth gear 37.4(23.3)
Travel speed km/hr(mph)
First gear 7.6(4.7)
Reverse
1-11
2) BOLT-ON CUTTING EDGE TYPE BUCKET
B
F
I
J
6200
4540
H
3621
K
C
G
40
763 6430
D
5
E 2472
A

Struck 4.2(5.5)
Heaped 5.0(6.5)
Tread F 2440( 8' 0")
Dump reach H 1470( 4' 10")
Dump angle J 45
Degree (Ş)
Lift(With load) 6.4
Lower(Empty) 3.6
m(ft-in)
First gear 7.6(4.7)
Forward
First gear 7.6(4.7)
Reverse
1-12
3) WITH TOOTH TYPE BUCKET
B
F
I
J
6200
4540
H
3621
K
C
G
40
772 6430
D
5
E 2472
A

Struck 4.0(5.2)
Heaped 4.7(6.2)
Tread F 2440( 8' 0")
Dump reach H 1590( 5' 3")
Dump angle J 45
Degree (Ş)
Lift(With load) 6.4
Lower(Empty) 3.6
m(ft-in)
First gear 7.6(4.7)
Forward
First gear 7.6(4.7)
Reverse
1-13
3. WEIGHT
Item kg lb
Front frame assembly 2825 6228

Rear frame assembly 3174 6997
Front fender(LH & RH) 42 93
Counterweight 1200 2646
Cab assembly 1000 2205
Engine assembly 1348 2972
Transmission assembly 796 1755
Torque converter assembly 293 646
Drive shaft(Torque converter to transmission) 14 31
Drive shaft(Front) 30 66
Drive shaft(Center) 50 110
Drive shaft(Rear) 23 51
Front axle(Include differential) 1600 3527
Rear axle(Include differential) 1550 3417
Tire(4EA) 430 948
Hydraulic tank assembly 231 509
Fuel tank assembly 412 908
Main pump assembly 40 88
Main control valve 94 207
Flow amplifier 29 64
Boom 2070 4564
Bell crank 258 569
Bucket link 55 121
5.0m3 bucket, with bolt on cutting edge 2540 5600
4.7m3 bucket, with tooth 2310 5093
4.7m bucket, without tooth and cutting edge
3
2120 4673
Boom cylinder assembly(2EA) 290 639
Bucket cylinder assembly(2EA) 150 331
Steering cylinder assembly(2EA) 65 143
Seat 40 88
Battery 55 121
1-14
4. SPECIFICATION FOR MAJOR COMPONENTS
1) ENGINE
Item Specification
Model Cummins NTA 855-C )Cummins N14-C

Type 4-cycle turbocharged, after cooled diesel engine
Cooling method Water cooling
Number of cylinders and arrangement 6 cylinders, in-line
Firing order 1-5-3-6-2-4
Combustion chamber type Direct injection type
Cylinder bore ź stroke 140ź152mm(5.51"ź5.98")
Piston displacement 14010cc(854.9cu in)
Compression ratio 14.5 : 1
Rated gross horse power 340ps at 2100rpm
Maximum gross torque at 1400rpm 149kgfşm(1078lbfşft) )156kgfşm
Engine oil quantity 40ֻ (10.6 U.S. gal)
Dry weight 1303kg(2872.6lb) )1322kg
High idling speed 2260 Ź 50rpm
Low idling speed 800 Ź 50rpm
Rated fuel consumption 158.8g/psşhr )160.3g/psşhr
Starting motor Delco Remy 42MT(24V)
Alternator DAC HC60(24V-60AMP)
Battery 2ź12Vź200Ah
): Low emission engine
2) MAIN PUMP
Item Specification
Type Fixed displacement tandem gear pump

Capacity 100cc/rev
Maximum operating pressure 210kgf/cm2(2987psi)
Rated oil quantity 200ֻ.min(53U.S.gpm)
Rated speed 2100rpm
1-15
3) BRAKE PUMP
Item Specification
Type Fixed displacement tandem gear pump

Capacity 16cc/rev
Maximum operating pressure 150kgf/cm2(2130psi)
Rated oil quantity 31.9ֻ/ min(8.4U.S.gpm)
4) MAIN CONTROL VALVE
Item Specification
Type 2 spool
Operating method Hydraulic pilot assist
Main relief valve pressure 210kgf/cm2(2987psi)
Overload relief valve pressure(Boom) 250kgf/cm2(3556psi)
Overload relief valve pressure(Bucket) 230kgf/cm2(3271psi)
5) REMOTE CONTROL VALVE
Item Specification
Type Pressure reducing type

Minimum 5.8kgf/cm2(82.5psi)
Operating
Maximum 19kgf/cm2(270psi)
Single operation stroke Lever 70mm(2.8in)
6) CYLINDER
Item Specification
Boom cylinder Bore diaźRod diaźStroke ‫ٻ‬200ź‫ٻ‬110ź863mm

Bucket cylinder Bore diaźRod diaźStroke ‫ٻ‬160ź‫ٻ‬80ź580mm
Steering cylinder Bore diaźRod diaźStroke ‫ٻ‬110ź‫ٻ‬55ź480mm
1-16
7) DYNAMIC POWER TRANSMISSION DEVICES
Item Specification
Model Clark 8602

Torque converter
Type Single-stage, single-phase
Model Clark 6421
Type Semi-automatic power shift
Transmission
Gear shift Forward fourth gear, reverse fourth gear
Adjustment Electrical single lever type, kick-down system
Drive devices 4-wheel drive
Axle Front Front fixed location
Rear Oscillation 13Şof center pin-loaded
Wheels Tires 29.5-25, 22PR(L3)
Travel Four-wheel, wet-disc type, full hydraulic
Brakes Spring applied, hydraulic released brake on front
Parking
axle
Type Full hydraulic, articulated
Steering
Steering angle 40Şto both right and left angle, respectively
1-17
5. TIGHTENING TORQUE
The torques given are standard figures. Any figures specifically described in this manual has priority.
1) BOLT AND NUT
(1) Coarse thread
8T 10T
Bolt size
kgfşm lbfşft kgfşm lbfşft
M 6 ź 1.0 0.85 ~ 1.25 6.15 ~ 9.04 1.14 ~ 1.74 8.2 ~ 12.6
M 8 ź 1.25 2.0 ~ 3.0 14.5 ~ 21.7 2.73 ~ 4.12 19.7 ~ 29.8
M10 ź 1.5 4.0 ~ 6.0 28.9 ~ 43.4 5.5 ~ 8.3 39.8 ~ 60
M12 ź 1.75 7.4 ~ 11.2 53.5 ~ 79.5 9.8 ~ 15.8 71 ~ 114
M14 ź 2.0 12.2 ~ 16.6 88.2 ~ 120 16.7 ~ 22.5 121 ~ 167
M16 ź 2.0 18.6 ~ 25.2 135 ~ 182 25.2 ~ 34.2 182 ~ 247
M18 ź 2.5 25.8 ~ 35.0 187 ~ 253 35.1 ~ 47.5 254 ~ 343
M20 ź 2.5 36.2 ~ 49.0 262 ~ 354 49.2 ~ 66.6 356 ~ 482
M22 ź 2.5 48.3 ~ 63.3 350 ~ 457 65.8 ~ 98.0 476 ~ 709
M24 ź 3.0 62.5 ~ 84.5 452 ~ 611 85.0 ~ 115 615 ~ 832
M30 ź 3.5 124 ~ 168 898 ~ 1214 169 ~ 229 1223 ~ 1655
M36 ź 4.0 174 ~ 236 1261 ~ 1703 250 ~ 310 1808 ~ 2242
(2) Fine thread

8T 10T
Bolt size
kgfşm lbfşft kgfşm lbfşft
M 8 ź 1.0 2.17 ~ 3.37 15.7 ~ 24.3 3.04 ~ 4.44 22.0 ~ 32.0
M10 ź 1.25 4.46 ~ 6.66 32.3 ~ 48.2 5.93 ~ 8.93 42.9 ~ 64.6
M12 ź 1.25 7.78 ~ 11.58 76.3 ~ 83.7 10.6 ~ 16.0 76.6 ~ 115
M14 ź 1.5 13.3 ~ 18.1 96.2 ~ 130 17.9 ~ 24.1 130 ~ 174
M16 ź 1.5 19.9 ~ 26.9 144 ~ 194 26.6 ~ 36.0 193 ~ 260
M18 ź 1.5 28.6 ~ 43.6 207 ~ 315 38.4 ~ 52.0 278 ~ 376
M20 ź 1.5 40.0 ~ 54.0 289 ~ 390 53.4 ~ 72.2 386 ~ 522
M22 ź 1.5 52.7 ~ 71.3 381 ~ 515 70.7 ~ 95.7 512 ~ 692
M24 ź 2.0 67.9 ~ 91.9 491 ~ 664 90.9 ~ 123 658 ~ 890
M30 ź 2.0 137 ~ 185 990 ~ 1338 182 ~ 248 1314 ~ 1795
M36 ź 3.0 192 ~ 260 1389 ~ 1879 262 ~ 354 1893 ~ 2561
1-18
2) PIPE AND HOSE
Thread size Width across flat'mm( kgfşm lbfşft

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

1/4" 19 4 28.9
3/8" 22 5 36.2
1/2" 27 6 43.4
3/4" 36 13 94.0
1" 41 15 109
1-19
4) TIGHTENING TORQUE OF MAJOR COMPONENT
No. Items Size kgfşm lbfşft
1 Engine mounting bolt, nut M20ź2.5 57.9 Ź 8.7 419Ź 63

2 Engine Radiator mounting bolt, nut M12ź1.75 12.3 Ź 2.5 89.0Ź 18
3 Fuel tank mounting bolt M20ź2.5 57.9 Ź 8.7 419Ź 63
4 Main pump housing mounting bolt 1/2-13UNC 12.8Ź 3 92.6Ź 22
5 Steering pump housing mounting bolt 1/2-13UNC 12.8Ź 3 92.6Ź 22
6 Main control valve mounting bolt M12ź1.75 12.8Ź 3 92.6Ź 22
7 Steering unit mounting bolt M10ź1.5 6.9 Ź 1.4 49.9Ź 10
8 Flow amplifier mounting bolt M10ź1.5 6.9 Ź 1.4 49.9Ź 10
Hydraulic
9 system Brake valve mounting bolt M 8ź1.25 2.5 Ź 0.5 18.1Ź 3.6
10 Cut-off valve mounting bolt M 8ź1.25 2.5 Ź 0.5 18.1Ź 3.6
11 Remote control lever mounting bolt M 6ź1.0 1.1 Ź 0.2 8.0Ź 1.4
12 Pilot supply unit mounting bolt M 8ź1.25 2.5 Ź 0.5 18.1Ź 3.6
13 Safety valve M 8ź1.25 2.5 Ź 0.5 18.1Ź 3.6
14 Hydraulic oil tank mounting bolt M20ź2.5 57.9 Ź 8.7 419 Ź 63
15 Transmission mounting bolt M22ź2.5 48.0Ź 2 347 Ź 14
16 Front axle mounting bolt M33ź2.0 225Ź 25 1627Ź181
Power train
17 Rear axle support mounting bolt, nut M33ź2.0 225Ź 25 1627Ź181
system
18 Tire mounting nut M22ź1.5 48.5Ź 2.5 351Ź 18
19 Drive shaft joint mounting bolt, nut 1/2-13UNC 12.3Ź 2 89.0Ź 14
20 Counterweight mounting bolt M30ź3.5 199 Ź 29.9 1439Ź216
21 Others Operator's seat mounting bolt M 8ź1.25 3.4 Ź 0.8 24.6Ź 5
22 ROPS Cab mounting bolt(4EA) 1.25-12UNF 126 910
1-20
6. RECOMMENDED LUBRICANTS
Use only oils listed below or equivalent.
Do not mix different brand oil.
Ambient temperature Ş
C( Ş
F)
Capacity
Service point Kind of fluid
ֻ(U.S. gal) -20 -10 0 10 20 30 40
(-4) (14) (32) (50) (68) (86) (104)
SAE 30
SAE 10W
Engine oil pan Engine oil 40(10.6)
SAE 10W-30
SAE 15W-40
Transmission Oil 60(15.9) DEXRONє
Front : 50(13.2)
Axle Gear oil SAE 80W-90LSD/API GL-5
Rear : 50(13.2)
Tank: ISO VG 32
210(55.5)
Hydraulic tank Hydraulic oil ISO VG 46
System:
260(68.7) ISO VG 68
ASTM D975 NO.1

Fuel tank Diesel fuel 470(124)
ASTM D975 NO.2
NLGI NO.1
Fitting
Grease As required
(Grease nipple)
NLGI NO.2
Mixture of
antifreeze
Radiator 73(19.3) Ethylene glycol base permanent type
and water
50 : 50
1-21
GROUP 3 OPERATIONAL CHECKOUT RECORD SHEET
şOwner 9
şDate 9
şHours 9
şSerial No. 9
şTechnician 9
Ɠ Use this sheet to record operational

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

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

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

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

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

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

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

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

şSteering system leakage check Ә Ә
şFlow amplifier
Low check pressure Ә Ә
High check pressure Ә Ә
8. Accessory checks
şOperating lights check Ә Ә

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

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

şTransmission
şTorque converter
şFront, center, rear and upper drive shafts
şFront and rear axles
Engine power is transmitted to the transmission through the torque converter.
The transmission is a hydraulically engaged four speed forward, four speed reverse countershaft type
power shift transmission. A calliper-disc type parking brake is located on the front axle.
The transmission outputs through universal joints to three drive shaft assemblies. The front drive shaft
is a telescoping shaft which drives the front axle. The front axle is mounted directly to the loader frame.
The front axle is equipped with limited slip differential.
The rear axle is mounted on an oscillating pivot. The rear axle is equipped with limited slip differential.
The power transmitted to front axle and rear axle is reduced by the pinion gear and ring gear of
differential. It then passes from the differential to the sun gear shaft(Axle shaft) of final drive.
The power of the sun gear is reduced by a planetary mechanism and is transmitted through the
planetary hub to the wheel.
3-1
1) HYDRAULIC SCHEMATIC
1-2-3
To transmission
lube
Oil cooler
F-R
Charging
Filter pump
assembly
Vent
Converter Clutch
safety valve regulator
Torque
converter Removable
screen
Oil sump
3-2
2) HYDRAULIC CIRCUIT
Torque
converter Clutch
regulator valve
REV
R FWD
Converter
Filter safety 4
valve F
Cooler
Pump
3
3
Lubrication
Filter
Air 2
2
breather
Oil sump
1
1
Forward Reverse Neutral

Speed
1 2 3 4 1 2 3 4 1 2 3 4
R X X X X
F X X X X
3 X X X X X X X X X
2 X X X X X X
1 X X X
X : Solenoid activated
3-3
2. TORQUE CONVERTER
1) STRUCTURE
7 8 9 6 11
Converter pressure
Lube & drain
Oil to cooler
10
2 1 5
1 Impeller 5 Output shaft 9 Regulating valve
2 Turbine 6 Housing cover 10 Front bearing
3 Stator 7 Impeller cover 11 Turbine shaft
4 Drive plate 8 Converter housing
The torque converter assembly is composed of : Torque converter, output shaft for driving the
transmission, coupling and flange to mount the converter charging pump to supply oil under pressure to
operate transmission clutches and for converter cooling.
The torque converter is composed of four members : The impeller(1) which is the driving member, the
turbine(2) which is the driven member, the reaction member(3) which is splined on a fixed support, and
the drive plate(4) which couples the converter to the engine. The impeller and drive plate members
form the outer shell. The turbine runs within the outer shell and is connected to the output shaft(5). The
oil is the only connection between the turbine and impeller members. The reaction member is splined to
the converter support which is fixed and does not rotate in either direction. A gear is splined to the
impeller hub and drives through gears rotating the charging pump mounted on the converter housing
cover(6).
3-4
2) OPERATION
With the engine running, the converter charging pump draws oil from the transmission sump and
directs it through oil filters to the modulation valve located on top of the transmission. From the
modulation valve it is then directed through the control cover on the transmission to the converter
and to the transmission clutches.
The pressure modulation valve mounted on the top of the transmission remains closed until
required pressure is delivered to the transmission for actuating the direction and speed clutches.
This modulation valve consists of a hardened valve spool operating in a closely fitted bore. The
valve spool is backed up by a spring to hold the valve spool against its seat until the oil pressure
builds up to the specified pressure. The valve spool then moves towards the spring until a port is
exposed along the side of the bore. The oil can then flow through this port into a distributor which
directs the oil into the converter inlet port.
After entering the converter, the oil is directed through the stator support to the converter cavity and
exits between the turbine shaft and converter support. The oil then passes through an oil distributor
which directs the oil out of the converter by way of a down stream regulating valve and then to the
oil cooler. After leaving the cooler the oil is directed through a hose to the lubricating oil inlet on the
transmission, then through a series of tubes to the transmission, bearings, and clutches. The oil
then returns to the transmission sump.
A safety valve is built in the transmission control cover and will open to bypass oil only if an
excessive pressure is built up due to a blocked passage.
The rear compartment of the converter unit also houses the converter output shaft. A flexible hose
provides an overflow to the transmission sump.
The three members of the torque converter are composed of a series of blades. The blades are
curved in such a manner as to force the oil to circulate from the impeller to the turbine, through the
reaction member again into the impeller. This circulation causes the turbine to turn in the same
direction as the impeller. Oil enters the inner side of the impeller and exits from the outer side into
the outer side of the turbine. If then exits from the inner side of the turbine and after passing
through the reaction member, again enters the inner side of the impeller.
The down stream regulating valve(9) on the converter consists of a valve body and regulator spool.
The spool is backed up by a spring to hold the valve until converter oil pressure builds up to
specified pressure. The valve is used to maintain a given converter pressure to insure proper
performance under all conditions.
Ɠ Converter "stall" is achieved whenever the turbine and turbine shaft are stationary and the
engine is operating at full power or wide open throttle.
Ɠ Do not maintain "stall" for more than 30 seconds at a time. Excessive heat will be
generated and may cause converter or transmission seal damage.
3-5
3. TRANSMISSION
1) STRUCTURE
Control valve assembly
REVERSE
INPUT
P
FORWARD
IDLER
P
3rd
1st
OUTPUT
4th
2nd
P : Pinned bearing
The control valve assembly on the transmission consists of a valve body with selector valve spools
connected to the steering column by exterior linkage. A detent ball and spring in the selector spool
provides four positions, one position for each speed range. A detent ball and spring in the direction
spool provides three positions, one each for forward, neutral, and reverse.
3-6
The control valve also contains a shut-off valve spool operated by an hydraulic cylinder located on the
control cover. This valve is connected to the brake system by a hose line. When the wheel brakes are
applied, hydraulic fluid enters the valve and overcomes a spring force. This forces the spool to shift over
and block pressure from entering the directional clutches. In this manner a neutral is established
without moving the control levers.
With the engine running and the directional control lever in neutral position, oil pressure is blocked at the
control valve, and the transmission is in neutral. Movement of the forward and reverse spool will direct
oil, under pressure, to either the forward or reverse direction clutch as desired, and the opposite one is
open to relieve pressure.
The direction or speed clutch assembly consists of a drum with internal gear teeth and a bore to receive
a hydraulically actuated piston. A piston is inserted into the bore of the drum. The piston is oil tight by
the use of sealing rings. A friction disc with internal teeth is inserted into the drum and rests against the
piston. Next, a disc with splines at the outer diameter is inserted. Discs are alternated until the required
total is achieved. After inserting the last disc, a series of springs and pins are assembled in such a
manner that these springs rest on teeth of the piston. A heavy back-up plate is then inserted and
secured by a snap ring. A hub with I.D. and O.D. splines is inserted into the splines of discs with teeth
on the inner diameter and a splined shaft extending through the clutch support. This hub is retained by
a snap ring. The discs and inner shaft are free to increase in speed or rotated in the opposite direction
as long as no pressure is present in the direction or speed clutch.
To engage the clutch, as previously stated, the control valve is placed in the desired position. This
allows oil under pressure to flow from the control cover valve, through a tube in the transmission case,
to a chosen clutch. Once into the drum, oil is directed through a drilled hole into the rear side of the
piston bore. Pressure of the oil forces the piston and discs over against the heavy back-up plate. The
discs, with teeth on the outer diameter, clamping against discs, with teeth on inner diameter, enables the
clutch drum and drive shaft to be locked together and allows them to turn as a unit.
There are bleed balls in the clutch drums which allow quick escape for oil when the pressure to the
piston is released.
The transmission gear train consists of six shafts : Input shaft, reverse shaft, idler shaft, first and third
shaft, second and fourth shaft, output shaft.
A screen mounted in a frame is positioned on the bottom of the transmission case, to screen out any
foreign material. This screen is covered by the sump pan. This pan is provided with magnets to catch
any metallic particles.
3-7
2) OPERATION OF TRANSMISSION
(1) Forward
‫ ڸ‬Forward 1st
In 1st forward, forward clutch and 1st clutch are engaged.
Forward clutch and 1st clutch are actuated by the hydraulic pressure applied to the clutch piston.
REVERSE
INPUT
FORWARD
IDLER
3rd
1st
OUTPUT OUTPUT
4th
2nd
3-8
‫ ڹ‬Forward 2nd
In 2nd forward, forward clutch and 2nd clutch are engaged.
Forward clutch and 2nd clutch are actuated by the hydraulic pressure applied to the clutch piston.
REVERSE
INPUT
FORWARD
IDLER
3rd
1st
OUTPUT OUTPUT
4th
2nd
3-9
‫ ں‬Forward 3rd
In 3rd forward, forward clutch and 3rd clutch are engaged.
Forward clutch and 3rd clutch are actuated by the hydraulic pressure applied to the clutch piston.
REVERSE
INPUT
FORWARD
IDLER
3rd
1st
OUTPUT OUTPUT
4th
2nd
3-10
‫ ڻ‬Forward 4th
In 4th forward, forward clutch and 4th clutch are engaged.
Forward clutch and 4th clutch are actuated by the hydraulic pressure applied to the clutch piston.
REVERSE
INPUT
FORWARD
IDLER
3rd
1st
OUTPUT OUTPUT
4th
2nd
3-11
(2) Reverse
‫ ڸ‬Reverse 1st
In 1st reverse, reverse clutch and 1st clutch are engaged.
Reverse clutch and 1st clutch are actuated by the hydraulic pressure applied to the clutch piston.
REVERSE
INPUT
FORWARD
IDLER
3rd
1st
OUTPUT OUTPUT
4th
2nd
3-12
‫ ڹ‬Reverse 2nd
In 2nd reverse, reverse clutch and 2nd clutch are engaged.
Reverse clutch and 2nd clutch are actuated by the hydraulic pressure applied to the clutch piston.
REVERSE
INPUT
FORWARD
IDLER
3rd
1st
OUTPUT OUTPUT
4th
2nd
3-13
‫ ں‬Reverse 3rd
In 3rd reverse, reverse clutch and 3rd clutch are engaged.
Reverse clutch and 3rd clutch are actuated by the hydraulic pressure applied to the clutch piston.
REVERSE
INPUT
FORWARD
IDLER
3rd
1st
OUTPUT OUTPUT
4th
2nd
3-14
‫ ڻ‬Reverse 4th
In 4th reverse, reverse clutch and 4th clutch are engaged.
Reverse clutch and 4th clutch are actuated by the hydraulic pressure applied to the clutch piston.
REVERSE
INPUT
FORWARD
IDLER
3rd
1st
OUTPUT OUTPUT
4th
2nd
3-15
3) ELECTRIC SOLENOID CONTROL VALVE
Direction & Solenoids Clutches
speed energized pressurized X
Z Y
Forward 1st UXYZ Forward & 1st 3rd 2nd 1st
Forward 2nd UYZ Forward & 2nd
Forward 3rd UZ Forward & 3rd
U
Forward 4th U Forward & 4th FWD
Neutral 1st XYZ 1st
Neutral 2nd YZ 2nd
Neutral 3rd Z 3rd
Neutral 4th - 4th
Reverse 1st VXYZ Reverse & 1st
REV
Reverse 2nd VYZ Reverse & 2nd V
Reverse 3rd VZ Reverse & 3rd
Reverse 4th V Reverse & 4th
Energized
Inlet
Pilot pressure
Vent
De-energized
Vent
3-16
4. EGS LEVER
1) SHIFT LEVER OPERATION
EGS lever applications share the principle of selecting direction and gear positions.
Direction is selected by placing the lever in one of three detented positions(Neutral, Forward or
Reverse).
Gear shifts are made by bringing the lever either in the upshift position or in the downshift
position. These positions are spring returned.
With the EGS, shifts are made relative to the previous position : The EGS remembers the selected
gear position and shifts either to a higher gear or to a lower gear.
The EGS display always shows the selected shift lever position, the selected direction, the gear
position and the gear direction.
This operating principle accounts for the flexibility of the EGS system : It makes possible to control
any(Electric) powershift transmission with the same shift lever, provided the correct software(A
program for the EGS computer) is installed.
It also facilitates features such as kickdown, automatic powerup in neutral, preset gear selection
after a direction change, etc..
Forward
LOCK
Heatsink
Upshift
SPRING RETURN
Neutral
Downshift
SPRING RETURN
Reverse Display - LEDS

LOCK
The forward driving direction is selected by pushing the lever away from the driver(This usually
corresponds with pushing it to the normal driving direction).
The reverse driving direction is selected by pulling the lever towards the driver.
The neutral can be selected by placing the lever into its central detented position.
An upshift is requested by rotating the shift lever counter clockwise.
A downshift is requested by rotating the shift lever clockwise.
3-17
2) FUNCTIONAL DESCRIPTION
(1) Automatic powerup in neutral
When power is first applied to the EGS, neutral is always selected.
This is regardless of the position of the shift lever(It can be in either forward, neutral or reverse
position).
In order to start driving, the driver first has to place the shift lever into the neutral(Central detented)
position before a specific direction can be selected.
(2) Neutral start protection
Each EGS can have an output signal, which is deactivated whenever the shift lever is in the
neutral position.
This signal can be used to control a normal closed relay preventing engine start up whenever the
shift lever is not in the neutral detented position.
If during powerup the shiftlever is in forward or in reverse, the neutral start protection will not be
activated(Due to the function automatic powerup in neutral). Only after leaving this function
automatic powerup in neutral the neutral start protection will be activated.
(3) Kickdown
This EGS lever is also available with a shift lever integrated push button, which is used for the
kickdown function.
Usually it's used for requesting a downshift from 2nd to 1st gear, which is dropped after a direction
change : F2ơKickdownơF1ơR2
This is called kickdown.
If however the speed is too high, the kickdown request is stored for a certain time. If during this
time the speed has not slowed down sufficiently, the request is dropped.
3-18
3) DISPLAY FUNCTION
The EGS has an internal bicolor LED display for displaying the selected shiftlever position, the
selected shiftlever direction, the transmission position and the transmission direction.
Application specific details are described in a separate document : EGS functional description.
This EGS functional description can be requested for each EGS unit. This description overrules
the below description wherever applicable.
(1) Displayed information
Typically four types of information about the EGS and the transmission can be of interest to the
driver :
Selected shiftlever position and transmission position
Selected shiftlever direction and transmission direction
Application specific information
Diagnostic information
‫ ڸ‬Selected position and direction
The difference between shift lever position and transmission position might not be immediately
clear, but when one remembers that the EGS can protect the transmission(Example : By not
allowing a downshift), it becomes clear that the requested position(The shift lever position) can
be different from the actual engaged position(The position of the transmission).
Both shift lever position and transmission position can be divided in two subcategories:
Gear position (1st, 2nd, 3rd, 4th)
Driving direction (Forward, neutral, reverse)
Application specific information
This can be anything(Whatever the customer wants to see).
As an example : On an EGS automatically controlling the lockup clutch, it's interesting to see
whether or not the converter is in lockup. This can be indicated on the EGS
display by using the LED 7-yellow.
‫ ڹ‬Diagnostic information
Two types of diagnostic information are considered :
ON LINE diagnostics
This information is given during normal driving when something special happens.
In most applications, the LED 8 is used to indicate standstill. This helps to spot problems with
the speed sensor in an early stage before the lack of protection resulting from the failure can
produce damaged to the drivetrain.
Which on line diagnostic functions are provided is detailed in the application specific EGS
Functional description.
OFF LINE diagnostics
There are three selftest modes built into the EGS. Details about their function and usage are
described in clause 5), Selftest functions.
3-19
(2) Display layout
The EGS uses LED's(Light Emitting Diodes) to give information to the driver.
It consists of eight multicolor LED's :
Labeled 1 to 8 and can light up in red, green and yellow.
1 2 3 4 5 6 7 8
N T F N R
These numbered LED's are used for displaying both the shift lever selection and the transmission
engagement.
They also used to indicate diagnostic information in the different test modes.
The red LED is labeled N and when this lights up it indicates that the transmission is placed in
neutral(This is possible even while the shift lever is not in neutral).
The yellow LED is labeled T which stands for troubleshooting. This LED is ON while working in
one of the three selftest modes described in clause 5), Selftest function.
(3) Display method
Basically the gear position is shown by turning ON the LED that corresponds with the selected
position. In 1st gear, LED 1 is ON, in 2nd gear, LED 2 is ON etc..
The selected direction is shown with the color of the LED :
Red Indicates Neutral
Green Indicates Forward
Yellow Indicates Reverse
Additionally LED N(Red) is ON while the transmission is in neutral.
The position shown is always the selected shiftlever position. Most of the time, the actual
transmission position will be the same as the shown one, and in that case that's all there is.
However if, because of an active protection or because of some internally generated delay, there
is a discrepancy between transmission position and shift lever position, a 2nd LED will indicate the
transmission position(Color indicates direction).
To let the driver know the difference between both indications, the transmission LED blinks while
the shift lever LED stays ON all the time.
While this may seem a bit confusing at first, it's very easy to understand the shown information in
reality.
Example : Driving in 4th gear forward at high speed. ơ LED 4 - Green
When the driver is making a downshift, but due to a
too high speed the EGS will protect the transmission
and will not allow the requested downshift. Thus the
transmission will stay in 4th gear forward, while the
shiftlever is in 3rd gear forward. ơ LED 3 - Green &
LED 4 - Blinking green
3-20
4) CONNECTOR PIN DESIGNATIONS
Below table lists the function of each EGS connector pin for the transmission :
Pin Comment
1 Battery plus
2 Battery ground
3 Neutral start signal
4 CV Solenoid 1
5 CV Solenoid 2
6 CV Forward solenoid
7 CV Reverse solenoid
8 Null
9 CV High / Low solenoid
10 Speed sensor input HOT
11 Speed sensor input GND
12 Travel speed signal
13 Speed output
14 Declutch
15 Extension kick down
16 Shield ground(Internally connected to wire 2)
CV stands for control valve.
3-21
5) SELFTEST FUNCTIONS
The EGS has special circuitry to help verifying its operation.
Three selftest modes are built into the EGS control programs :
Input test
Speed sensor test + Lamptest
Output test
The EGS furthermore has the ability to check for possible problems while driving(On line
diagnostics).
As described in clause(2), Display layout at page 3-20, the T LED is used for identifying different
troubleshooting modes. This is done in combination with the status of the N LED.
(1) Operation of the N and T LED's
‫ ڸ‬Overview
Situation LED
In normal situations(Driving, no problems) T LED is always OFF

When error is detected T LED is ON or BLINKING
In selftest mode T LED is always ON
‫ ڹ‬Detailed operation
Situation N LED T LED
Normal operation On when transmission neutral OFF

Internal fault ON Blinking SLOWLY
Input test Blinking SLOWLY ON
Output test Blinking FAST ON
Speed sensor test OFF ON
(2) Selftest operation

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

Speed sensor test REV & UP
Output test FWD & DOWN
3-22
‫ ڹ‬Input test
When EGS shiftlever is held in the forward up position while power is applied, input test mode
is activated.
In this mode, driving is not possible, since all EGS outputs remain OFF until the testmode is left.
This test is used to verify operation of the shiftlever and its inputs.
The LED's(Gear position indicators) on the EGS top cover are used to display test information :
Shift lever position LED Color LED Number

Neutral RED 4
UP RED 5
DOWN RED 3
FWD GREEN 4
FWD & UP GREEN 5
FWD & DOWN GREEN 3
REV YELLOW 4
REV & UP YELLOW 5
REV & DOWN YELLOW 3
Wire 14 = GROUND RED 1 (Together with above LED)
Wire 15 = GROUND GREEN 1 (Together with above LED)
ƓIf wire 14 and wire 15 are grounded simultaneously LED 1 lights up yellow.
‫ ں‬Speed sensor test

When EGS is held in the reverse up position while power is applied, speed sensor test mode is
activated.
In this mode, driving is possible.
The test begins with a lamp test and then displays the speed sensor information.
‫ ڻ‬Speed display
The LED corresponding with below table burns to indicate converter turbine speed :
Turbine rpm LED Number(Green)
0 1 BLINKS
0 - 249 1 ON
250 - 499 2 ON
500 - 749 3 ON
750 - 999 4 ON
1000 -1249 5 ON
1250 - 1499 6 ON
1500 - 1749 7 ON
1750 -1999 8 ON
Above 2000 8 BLINKS
3-23
‫ ڹ‬Output test
When EGS is held in the forward down position while power is applied, output test mode is
activated.
In this mode, driving is not possible, since all EGS outputs remain OFF until the testmode is left.
LED's 1 - 8 light up sequentially during output test :
First LED 1 is switched on shortly, then LED 2 etc..
When LED 8 is switched off, LED 1 is again switched on and so on.
The color of the LED indicates its status :
Color Status
GREEN Output OK
YELLOW Output NOT connected or shorted to battery plus
RED Output shorted to ground(or to another output)
The LED numbers correspond to output wires as follows :
LED Number Output wire
1 6
2 7
3 4
4 5
5 13
6 9
7 8
8 3
ƓTo find the function of the corresponding output wires - See EGS functional description
3-24
6) REPLACING OF EP-ROM
35
25
33
26
27 31
34
38
D 40
39
42
43
(1) Remove screw(33).

(5) Remove plate(26) and seal(27).
(6) Slide the PCB's(42, 43) out of the housing, with rear cover connected(31, 35).
(7) Remove plastic cover(40).
(8) Replace EP-ROM(39).
Ɠ Notice the correct position of the mark on the EP-ROM (See D).
(9) Reassemble the EGS.
Ɠ Notice the correct slots for the different ports.
A
See on the right figure.
A : Slots for cover(40) B
B : Slots for PCB(42) C
C : Slots for PCB(43)
3-25
5. AXLE
1) OPERATION
ş The power from the engine passes through torque converter, transmission and drive shafts, and is
then sent to the front and rear axles.
ş Inside the axles, the power passes from the bevel pinion to the bevel gear and is sent at right
angles. At the same time, the speed is reduced and passes through the both differentials to the
axle shafts. The power of the axle shafts is further reduced by planetary-gear-type final drives and
is sent to the wheels.
(1) Front axle
Parking brake assy
1 Final drive 2 Differential 3 Axle
(2) Rear axle
1 Final drive 2 Differential 3 Axle
3-26
2) SECTION OF FRONT AXLE DIFFERENTIAL
A A
1
5
1 Bevel pinion 3 Sun gears 5 Side gear(Differential)

2 Bevel gear 4 Shaft
3-27
3) SECTION OF REAR AXLE DIFFERENTIAL
A A
1
5
1 Bevel pinion 3 Sun gear 5 Side gear(Differential)

2 Bevel gear 4 Shaft
3-28
4) DIFFERENTIAL
(1) Description 3
When the machine makes a turn, the 2 4
outside wheel must rotate faster than the
inside wheel. A differential is a device
which continuously transmits power to the
right and left wheels while allowing them
to turn a different speeds, during a turn.
The power from the drive shaft passes
through bevel pinion(1) and is transmitted
to the bevel gear(2). The bevel gear
changes the direction of the motive force
by 90Ş , and at the same time reduces the
1
speed.
It then transmits the motive force through
the differential(3) to the axle gear shaft(4).
(2) When driving straight forward

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

When turning, the rotating speed of the Pinion gear
left and right wheels is different, so the Side gear Side gear
pinion gear and side gear inside the
differential assembly rotate in accordance
with the difference between the rotating
speed of the left and right wheels.
The power of the carrier is then
transmitted to the axle gear shafts. Carrier
Pinion gear Ring gear
3-29
5) TORQUE PROPORTIONING DIFFERENTIAL
(1) Function
‫ ڸ‬Because of the nature of their work, 4-
wheel-drive loaders have to work in
places where the road surface is bad.
In such places, if the tires slip, the ability
to work as a loader is reduced, and also
the life of the tire is reduced.
The torque proportioning differential is
installed to overcome this problem.
In structure it resembles the differential of
an automobile, but the differential pinion
gear has an odd number of teeth.
Because of the difference in the
resistance from the road surface, the
position of meshing of the pinion gear
and side gear changes, and this changes
the traction of the left and right tires.
(2) Operation
‫ ڸ‬When travelling straight(Equal Spider rotating
direction
resistance from road surface to left and
right tires)
Under this condition, the distances
involving the engaging points between
right and left side gears and pinion-a and FL FR
a b
b-are equal and the pinion is balanced as Engaging Engaging
point point
FLźa=FRźb. Thus, FL=FR, and the
right and left side gears are driven with
the same force. Left side gear Pinion Right side gear
3-30
‫ ڹ‬When travelling on soft ground
(Resistance from road surface to left and
right tires is different)
If the road resistance to the left wheel is
Spider rotating
smaller, the left side gear tends to rotate direction
forward, and this rotation changes the
engaging points between the side gears
and pinion. As a result, the distances
involving the engaging points becomes FL
Small road FR Large road
a>b. The pinion now is balanced as FL resistance a b resistance
źa=FRźb, where FL>FR. The right Engaging Engaging
side gear is driven with a greater force point point
than the left side gear. The torque can
Left side gear Right side gear
be increased by up to about 30% for Pinion
either side gear.
The pinion therefore does not run idle
and driving power is transmitted to both
side gears until the difference between
road resistance to the right and left
wheels reaches about 30%.
3-31
6) FINAL DRIVE(Front & rear)
1 Axle shaft 3 Ring gear 4 Sun gear

2 Planetary gear
(1) To gain a large drive force, the final drive uses a planetary gear system to reduce the speed and
send drive force to the tires.
(2) The power transmitted from the differential through axle shaft(1) to sun gear(4) is transmitted to
planetary gear(2). The planetary gear rotates around the inside of a fixed ring gear(3) and in this
way transmits rotation at a reduced speed to the planetary carrier.
This power is then sent to the wheels which are installed to the planetary carriers.
3-32
6. TIRE AND WHEEL
4
6
1 Wheel rim 3 O-ring 5 Side ring

2 Tire 4 Lock ring 6 Valve assembly
1) The tire acts to absorb the shock from the ground surface to the machine, and at the same time
they must rotate in contact with the ground to gain the power which drives the machine.
2) Various types of tires are available to suit the purpose. Therefore it is very important to select the
correct tires for the type of work and bucket capacity.
3-33
GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING
1. POWER TRAIN OPERATIONAL CHECKS

This procedure is designed so that the mechanic can make a quick check of the system using a
minimum amount of diagnostic equipment. If you need additional information, read structure and
function, Group 1.
A location will be required which is level and has adequate space to complete the checks.
The engine and all other major components must be at operating temperature for some checks.
Locate system check in the left column and read completely, following the sequence from left to right.
Read each check completely before performing.
At the end of each check, if no problem is found(OK), that check is complete or an additional check is
needed. If problem is indicated(NOT OK), you will be given repair required and group location.
If verification is needed, you will be given next best source of information:
Chapter 2. Troubleshooting
Group 3. Tests and adjustments
3-34
Ɠ Transmission oil must be at operating temperature for these checks.
Item Description Service action
Transmission oil warm- Start engine. Apply service OK

up procedure brakes and release parking brake. Check completed.
TRANS Move gear selector lever to
forward "F" position.(Gear selector
lever 2nd speed) is selected.
Increase engine speed to high idle
for 30 seconds.
Move gear selector lever to
neutral "N" position and run for 15
seconds.
Repeat procedure until
transmission temperature gauge
arrow points to bar above dial.
Transmission noise Run engine at approximately OK

check 1300rpm. Check completed.
Engine running
Drive unit with transmission in NOT OK
each forward and reverse speed. Go to transmission makes
excessive noise group 3.
LISTEN : Transmission must not
make excessive noise in any
range.
Engine rpm must not "lug down"
as unit is shifted between gears.
3-35
Transmission "quick Release parking brake and shift to OK

shift" check 2nd forward. Check completed.
Engine running P Drive machine at approximately NOT OK
5km/h and press gear selector Check connector at base
lever switch once. of control valve.
LOOK/FEEL : Transmission must IF OK
shift to and remain in 1st gear. Go to transmission
controller circuit in group
Operate acceleration pedal until
1.
high idle.
LOOK/FEEL : Transmission must
shift back to 2nd gear.
Shift to (3rd or 4th) gear and press
gear selector lever switch once.
LOOK/FEEL : Transmission must
not shift down.
Forward and reverse Park unit on level surface. OK

clutch pack drag check Check completed.
Apply service brakes.
Ɠ Transmission must
NOT OK
be warmed up for Move gear selector lever to
If unit moves, repair
this check neutral.
transmission.
Engine running
Move gear selector lever to 1st.
P Release parking brake and
service brakes.
Run engine at low idle.
LOOK : Unit must not move in
either direction.
NOTE : If unit moves forward, the
forward pack is dragging.
3-36
Transmission pressure, Run engine at low idle. OK

pump flow, and leakage Check completed.
Release parking brake.
check
NOT OK
Engine running Shift transmission to reverse, then
Do transmission leakage
forward, and then to 1st, 2nd, 3rd
test, system pressure test,
and 4th speeds.
or pump flow test in group
Wait 5 seconds after each shift 3.
and observe transmission
pressure indicator light.
LOOK : Indicator light must not
come on.
NOTE : If light comes on in one
gear only, leakage is indicated on
that gear.
If light comes on in all gears, low
pump flow or pressure is
indicated.
Transmission shift Run engine at approximately OK

modulation check 1300rpm. Check completed.
Engine running
Put transmission in 1st forward, NOT OK
shift several times from forward to Go to unit shifts too fast,
reverse and reverse to forward. chapter 2 in this group.
Repeat check in 2nd gear.
LOOK : Unit must slow down and
change direction smoothly.
Torque converter check Start engine. Apply service OK

brakes and release parking brake. Check completed.
Move gear selector lever to 2nd NOT OK
speed. If stall rpm are too low or
too high, problem may be
Move gear selector control lever
engine power or torque
to forward "F" position.
converter.
Increase engine speed to high
IF OK
idle.
Replace transmission
LOOK : Torque converter stall torque converter.
rpm must be within the following
range.
Stall rpm : 2070 ~ 2210rpm
Move gear selector control lever
to neutral "N" position and run for
15 seconds.
3-37
2. TROUBLESHOOTING
1) TRANSMISSION
Ɠ Diagnose malfunction charts are arranged from most probable and simplest to verify, to least
likely, more difficult to verify. Remember the following steps when troubleshooting a problem :
Step 1. Operational check out procedure (See group 3 in section 1.)
Step 2. Operational checks (In this group.)
Step 3. Troubleshooting
Step 4. Tests and / or adjustments (See group 3.)
Problem Cause Remedy
Transmission slippage Low oil level. Add oil.

Wrong oil grade. Change oil.
Restricted transmission pump Remove and clean screen.
suction screen or transmission Change filters.
filters.
Leak in transmission control Remove valve and inspect gaskets.
valve or gasket.
Low transmission pump flow Do transmission pump flow test.
due to worn pump.
Weak or broken pressure Do transmission system pressure test.
regulating valve spring.
Malfunctioning pressure Remove and inspect pressure regulating valve.
regulating valve.
3-38
Machine will not move Low oil level. Add oil

Applied park brake. Check parking brake fuse.
Check continuity to parking brake switch.
No power to transmission Check transmission controller fuse.
controller.
Malfunctioning parking brake Remove and inspect parking brake solenoid
solenoid valve. valve.
Check for power to solenoid valve.
Restricted modulation orifice. 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 modulation valve. Remove end cover to inspect modulation spool.
Replace if necessary.
Malfunctioning transmission Check speed sensor.
speed sensor.
3-39
Transmission pressure Low oil level. Check transmission oil level and refill if
is low(All gears) necessary.
Failed transmission pressure Verify transmission system pressure. Do
switch. transmission system pressure test.
Plugged suction strainer. Transmission pump may be noisy if transmission
suction screen is clogged. Drain oil.
Remove and clean suction screen.
Also, check condition of transmission filter.
Stuck transmission pressure Remove transmission pressure regulating valve.
regulating valve or broken Inspect for damage(See transmission control
spring. valve).
Failed control valve gasket. Inspect transmission control valve for external
leakage. Remove control valve.
Inspect or replace gasket.
Stuck modulation valve. Remove end cover to inspect modulation spool
and check torque on cap screws retaining control
valve to transmission.
Transmission system Failed transmission pump. Do pump flow test.

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

shifts too low
Low transmission pressure. Do transmission system pressure test.
Restricted transmission pump Remove and clean screen.
suction screen.
Low transmission pump flow. Do transmission pump flow test.
Excessive transmission Do transmission element leakage test using
element leakage. system pressure.
Stuck modulation valve. Remove end cover to inspect modulation spool.
Restricted modulation orifice. Remove orifice and inspect for contamination and
/or plugging.
Restricted oil passages Remove control valve and inspect oil passage.
between control valve and
transmission elements.
3-40
Transmission direction Wrong transmission controller. Check if transmission controller has been
shifts too fast changed.
System pressure too high. Do transmission system pressure test.
Stuck modulation valve. Remove and inspect modulation valve.
Replace if necessary. Also remove end cover to
inspect modulation spool and control valve
housing.
Stuck or missing check valves. Inspect transmission control valve.
Missing O-ring from end of Remove orifice and inspect port for O-ring.
modulation orifice.
Broken piston return spring. Disassemble and inspect clutch.
Machine "creeps" Warped disks and plates in Check transmission.

in neutral transmission.
Transmission hydraulic High oil level. Transmission overfilled or hydraulic pump seal
system overheats leaking.
Low oil level. Add oil.
Wrong oil grade. Change oil.
Park brake dragging. Check for heat in park brake area.
Pinched, restricted or leaking Check cooler lines.
lube lines.
Machine operated in too high Operate machine in correct gear range.
gear range.
Malfunction in temperature Install temperature sensor the verify temperature.
gauge or sender. Do tachometer/temperature reader installation
procedure.
Restricted air flow through oil Do radiator air flow test.
cooler or radiator.
Failed oil cooler bypass Disassemble and inspect.
valve(In thermal bypass valve).
Failed thermal bypass valve. Remove thermal bypass valve and check to see if
machine still overheats. Do transmission oil
cooler thermal bypass valve test.
Internally restricted oil cooler. Do oil cooler restriction test.
Leakage in transmission Do transmission system pressure, element
hydraulic system. leakage, and shift modulation test.
Malfunction in converter relief Do converter out pressure test.
valve.
Low transmission pump output. Do transmission pump flow test.
3-41
Excessive transmission Too low engine low idle. Check engine low idle speed.
noise(under load or no
Worn parts or damaged in Remove transmission suction screen. Inspect
load)
transmission. for metal particles.
Repair as necessary.
Warped drive line between Inspect drive line.
engine and torque converter.
Low or no lube. Do converter-out and lube pressure test. Do
transmission pump flow test.
Foaming oil Incorrect type of oil. Change oil.

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

Low engine speed. Check engine speed.
Failed universal joints on Check universal joints.
transmission drive shaft or
differential drive shafts.
Machine lacks power Engine high idle speed set too Check high idle adjustment.
and acceleration low.
Incorrect transmission oil. Change oil.
Aerated oil. Add oil.
Low transmission pressure. Do transmission system pressure test.
Warped transmission clutch. Do transmission clutch drag checks.
Torn transmission control valve Inspect gasket.
gasket.
Brake drag. Do brake drag check.
Failed torque converter. Do torque converter stall speed test.
Low engine power. Do engine power test.
Torque converter stall Aerated oil. Put clear hose on thermal bypass outlet port.
RPM too high Run machine to check for bubbles in oil.
Stuck open converter relief Do converter-out pressure test.
valve.
Leakage in torque converter Do converter-out pressure test.
seal.
Torque converter not Replace torque converter.
transferring power(Bent fins,
broken starter).
3-42
Torque converter stall Low engine power. Do engine power test.

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

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

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

Low transmission pressure Do transmission system pressure test.
circuit.
Leak in transmission pressure Do converter out pressure test.
circuit.
Failed transmission pump. Do transmission pump flow test.
Clogged filter. Inspect filter. Replace.
Low converter charging Low oil level. Fill to proper level.

pump output
Sump screen plugged. Clean screen and sump.
Air leaks at pump intake hose Tighten all connections or replace hose if
and connections or collapsed necessary.
hose.
Defective oil pump. Replace pump.
Low flow through cooler Defective safety by-pass valve Replace spring.
with low converter in spring.
pressure
Converter by-pass valve Check for worn by-pass ball seat.
partially open.
Excessive converter internal Remove, disassemble, and rebuild converter
leakage, check converter lube assembly, replacing all worn or damaged parts.
flow.
Broken or worn sealing rings in See Group 3.
transmission clutches.
3-43
Low flow through cooler Plugged oil cooler. Indicated if Back flush and clean oil cooler.
with high converter out transmission lube pressure is
pressure low.
Restricted cooler return line. Clean out lines.
Lube oil ports in transmission Check lube lines for restrictions.
plugged. Indicated if
transmission lube pressure is
high.
Noisy converter Worn coupling gears. Replace.

Worn oil pump. Replace.
Worn or damaged bearings. A complete disassembly will be necessary to
determine what bearing is faulty.
3-44
2) DIFFERENTIAL / AXLE
Differential low on oil External leakage. Inspect axle and differential for leaks.
Excessive differential Low oil level in differential. Check oil. Remove drain plug and inspect for
and/or axle noise metal particles in differential case.
Disassemble and determine cause.
Incorrect type of oil. Change oil
Dragging brakes. Do brake check.
Failed pinion bearing. Remove and inspect pinion.
Check to ensure pinion housing was indexed.
Incorrect gear mesh pattern Remove pinion gear housing and inspect ring and
between ring and pinion gear. pinion gear.
Failed differential pinion gears Remove differential housing drain plug and
and / or cross shafts. inspect for metal particles. Disassemble and
inspect.
Failed axle bearing. Do axle bearing adjustment check.
Mechanical failure in axle Remove differential. Inspect, repair.
planetary.
Oil seeping from outer Excessive end play in axle. Do axle bearing adjustment check.
axle seal
Worn outer bearing and/or cup. Disassemble and inspect outer axle bearing, cup,
spacer, and seal. Replace, if necessary.
Overfilled differential. Check differential oil return system for excessive
internal restriction.
Axle overheats Low differential oil. Add oil.

Overfilled differential. See differential overfills with oil in this group.
Brake drag. See brakes drag in this group.
3) DRIVE LINE
Excessive drive line Yokes not in line on drive Inspect. Align drive shaft yokes.
vibration or noise shafts.
Worn front drive line support Inspect, repair.
bearing.
Bent drive shaft. Inspect all drive shafts. Replace.
Loose yoke retaining Inspect. Replace.
nuts(Drive shafts wobble at
high speed).
Rear axle oscillating support. Inspect, repair.
Lack of lubrication. Lubricate with proper grade of grease.
3-45
GROUP 3 TESTS AND ADJUSTMENTS
1. CLUTCH CUT OFF PRESSURE SWITCH TEST

The setting pressure of the clutch cut off
Brake valve
pressure switch should be suited with the
specification. The rated pressure is 25kgf/cm2.
For the detailed method for pressure
adjusting, refer to page 4-25.
Clutch cut off

pressure switch
3-46
2. PRESSURE AND OIL FLOW CHECKS
1) TRANSMISSION CLUTCH PRESSURE CHECK AND CONNECTION PORTS
B
J F
L A
VIEW Z
D
E
C
M K
E(H)
Z G I
O P
Port Description Port Description
A Forward clutch port 1/8 NPTF I 3rd clutch pressure check point on
B Reverse clutch port 1/8 NPTF modulator valve
C Lubr oil pressure check port 1/4 NPTF J 4th clutch pressure check point on
modulator valve
D Clutch pressure check port 1/4 NPTF
K Lube oil port from cooler
E Forward clutch pressure check point on
modulator valve L Port for outlet to converter
F Reverse clutch pressure check point on M Port for oil supply from filter
modulator valve O Port for charging pump suction line
G 1st clutch pressure check point on P Port for drain connection from converter
modulator valve
H 2nd clutch pressure check point on
modulator valve
3-47
2) TESTING
Before testing is carried out, ensure that the oil is at the correct level and at normal operating
temperature 82.2~93.3Ş C(180~200Ş F).
3) TORQUE CONVERTER STALL TEST
Mark the engine crankshaft pulley with chalk or reflective tape and check the maximum no-load
speed of the engine using a stroboscopic tachometer.
Raise the loader arms and set the machine against fixed obstruction. Apply firmly the footbrake.
Select forward 3th and, with the throttle fully open, check engine speed which should be as shown
in technical data. Torque converter stall speed is 2140Ź70rpm.
Ɠ Do not apply the clutch cut off switch during this test as the clutch disconnect will be
activated and a false reading will result.
Repeat the above test whilst simultaneously operating the loader arm raise service to blow off the
main relief valve.
Engine speed should be as shown in technical data.
If engine speeds are appreciably below the stated figures, the engine is losing power and should be
serviced or overhauled. Where the engine speed does not change significantly from the governed
speed, check the transmission for clutch slippage or internal leakage. Above phenomenon is also
indicated an incorrect torque converter.
4) CLUTCH PRESSURE TEST
Connect a pressure gauge to the clutch pressure points. Run the engine at idling speed, engage
clutches in sequence(As in previous test) and note the gauge readings which should be as shown
in technical data. Clutch pressure should be in 12.7~15.4kgf/cm2(180~220psi).
Clutch pressure should not vary by more than 0.34bar(5psi) from one another. Any clutch showing a
greater variation should be disassembled for servicing.
Ɠ Never use service brake while making clutch pressure checks.
Units having brake actuated declutching in forward and/or reverse will not give a true
reading.
Always use parking brake when making clutch pressure checks.
5) CONVERTER LUBE FLOW TEST
Disconnect converter drain back line at transmission with engine running at 2000rpm and measure
oil into a gallon container. Measure oil leakage for 15 seconds and multiply the volume of oil by four
to get gallons per minute(GPM) leakage.
Ɠ Leakage not to exceed 5 gallon(18.9liter) max.
3-48
6) OIL PRESSURE TEST AT CONVERTER REGULATING VALVE PORT
Install hydraulic pressure gauge at pressure connection on converter regulating valve. Check and
record oil pressure at 2000rpm and at maximum speed(Engine at full throttle).
şConverter out pressure : 3.9~4.9kgf/cm2(55~70psi)
If a flow meter is available, install in line between converter charging pump and oil filters. Flow
meter must be able to withstand 21.0kgf/cm2(300psi).
Disconnect hose between pump and filter at filter end and using suitable fittings connect to
pressure port of tester. Install hose between filter and tester, connecting same to reservoir port of
tester.
Do not use tester load valve at any time during test. When taking flow reading, all readings should
be taken on the first(Left) half of flow gauge. Whenever the needle shows on the right half of
gauge, correct by switching to higher scale.
If a flow meter is not available for checking converter pump output, proceed with manual
transmission and converter checks. If the converter shows leakage within specifications and clutch
pressures 12.7~15.4kgf/cm2(180~220psi) are all equal within 0.4kgf/cm2(5psi) refer to Group 2 on low
converter charging pump output.
şCharging pump rating : 40GPM(Pumps are rated at 2000rpm)
Pump output listed applies to a new pump in each case. A 20˔ tolerance below this figure is
permissible ; However, if pump output is more than 20˔ below specification the pump must be
replaced and not rebuilt.
7) CLUTCH LEAKAGE TEST
Check clutch pressures at low engine idle with oil at operating temperatures 82~93Ş C(180~200Ş F).
Engine speed must remain constant during entire leakage check. Shift lever into forward 4 speeds.
Record pressures. Shift lever in reverse and 1st. Record pressure. All pressure must be equal
within 0.4kgf/cm2(5psi). If clutch pressure varies in any one clutch more than 0.4kgf/cm2(5psi), repair
clutch.
If a flow meter is available install in line coming out of converter pump. See flow diagram for
location of pressure on flow checks. Check pump volume at 2000rpm and at low engine idle.
Record readings. See pump volume specifications at 2000rpm.
Install flow meter in the line coming from transmission to converter. Check oil volume at 2000rpm
and at low idle in the following speed selections. Record readings.
şForward - Low speed through high
şReverse - Low speed
Subtract readings in each speed from pump volume reading to get transmission clutch leakage.
şExample : Pump volume at idle 8gallon Pump volume 8gal
Forward-Low speed through high 6gallon Forward-Low speed 6gal
Reverse-Low speed 6gallon Clutch leakage 2gal
If clutch leakage varies more than 1gallon from one clutch to another, repair clutch.
Ɠ Leakage must not exceed max 4 gallon(15.1liter).
3-49
3. CONVERTER CHARGE PUMP REPLACEMENT AND PRIMING PROCEDURE
1) The cause for pump failure must be found and corrected before a replacement pump is installed.
Check all of the hoses, tubes, O-rings, adaptors and split flanges.
2) Replace any collapsed or damaged hoses, damaged split flange O-rings, tube O-rings and
adaptors.
3) After all checks have been made and corrections completed install the pump.
4) See below filling instruction.
5) Start the engine. Run the engine at low idle for two minutes, watch the clutch pressure gage and
listen for cavitation of the pump.
6) If the pressure does not come up, check the oil level and bleed off air from system as follows.
7) To bleed off the air from the system, loosen the pressure gage line at the pressure regulating valve
or loosen the pressure hose at the oil filter or pressure regulating valve. Crank the engine over until
the air is displaced with oil. Do not start the engine.
8) If bleeding the lines does not correct the problem it may become necessary to prime the pump.
Disconnect the suction hose or pressure hose, whichever is higher, and fill the port with
transmission oil, reconnect the hose and tighten.
9) Start the engine and check pressure.
10) Recheck oil level with hot oil 82~93Ş C(180~200Ş F) with engine at idle. Add oil as necessary to
bring oil level to full mark.
Ɠ Filling instruction
Use only type oil recommended. Fill transmission through filler opening until fluid comes up to low
mark on transmission dipstick.
If the dipstick is not accessible oil level check plugs are provided.
Remove lower check plug, fill until oil runs from lower oil hole. Replace filler and level plug.
Run engine two minutes at 500~600rpm to prime torque converter and hydraulic lines. Recheck
level of fluid in transmission with engine running at idle(500~600rpm).
Add quantity necessary to bring fluid level to low mark on dipstick or runs freely from lower oil level
check plug hole. Install oil level plug or dipstick. Recheck with hot oil 82~93Ş C(180~200Ş F).
Bring oil level to high mark on dipstick or runs freely from upper oil level plug.
3-50
4. TORQUE CONVERTER TO ENGINE INSTALLATION PROCEDURE
1) Remove all burrs from flywheel mounting
face and nose pilot bore. Clean drive plate
surface with solvent.
Mount dial
2) Check engine flywheel and housing for indicator here
conformance to standard SAE#3-SAE J-

Flywheel
927 tolerance specifications for pilot bore housing
size, pilot bore runout and mounting face
Engine
flatness. Measure and record engine
crankshaft end play. Flywheel
pilot bore
3) Install two 63.50mm(2.50") long
transmission to flywheel housing guide
Flywheel
studs in the engine flywheel housing as
shown. Rotate the engine flywheel to align
a drive plate mounting screw hole with the
Converter
flywheel housing access hole. Flywheel housing
4) Install a 101.60mm(4.00") long drive plate 4" Stud
locating stud .3750-24 fine thread in a drive

plate nut. Align the locating stud in the
2.5"
drive plate with the flywheel drive plate Aligning
stud
mounting screw hole positioned in step
No.3.
Drive
5) Locate torque converter on flywheel plate
housing aligning drive plate to flywheel and
torque converter to flywheel housing.
Ɠ Install torque converter to flywheel Flywheel
housing
housing screws. Tighten screws to Bolt
specified torque. Remove torque

converter to engine guide studs. Install
remaining screws and tighten to
specified torque.
6) Remove drive plate locating stud.
7) Install drive plate attaching screw and
washer. Snug screw but do not tighten.
8) Measure engine crankshaft end play after
transmission has been completely installed Flywheel
on engine flywheel. This value must be
within 0.025mm of the end play recorded in
step No.2.
3-51
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 four accumulator. The accumulator has a gas precharge and an
inlet check valve to maintain a pressurized volume of oil for reserve brake applications.
Oil through the accumulator flows to the brake valves. The brake valve is a closed center design,
dual circuit operated by a pedal.
The front and rear brakes will operate simultaneously with only one brake pedal depressed.
The differential contains annular brake piston and double sided disk.
Brake pump flow also goes to the parking brake solenoid valve.
The brake system contains the following components:
Brake pump
Parking brake solenoid valve
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 Brake pressure
700 (Full power)
Brake torque(lb in)

air/hydraulic and full power hydraulic brake
actuation system. 600
Brake pressure
Full power systems can supply significantly 500 (Air/hydraulic)
higher brake pressures with relatively low Brake torque
400
reactive pedal forces. The reactive pedal (Air/hydraulic)
force felt by the operator will be proportional 300
Brake torque
to the brake line pressure being generated. 200 (Full power)
This is referred to as brake pressure
modulation. 100
Another key design feature of full power
0 1 2 3 4
systems is the ability to control maximum
brake line pressure. In addition, because Time(Seconds)
these systems operate with hydraulic oil,
filtration can be utilized to provide long
component life and low maintenance
operation.
Because these systems are closed center,
by using a properly sized accumulator,
emergency power-off braking that is
identical to power-on braking can be
achieved. These systems can be either
dedicated, where the brake system pump
supplies only the demands of the brake
system or non-dedicated, where the pump
supplies the demands of the brake system
as well as some secondary down stream
hydraulic devise.
Another important note is that all seals
within these system must be compatible
with the fluid medium being used.
4-2
2. HYDRAULIC CIRCUIT
FRONT 28 REAR 29
17 19
20
8 2.4 2.1 2.5 2.2
5.1 1.1 5.2 1.2
A B
16
15 15 P T
15
21 22 23
7
15
27
28
Steering system
18
1
MCV RCV Lever

Return line
5
21
2 1
Return line
23
24
25
26 27 22
1 Steering pump 18 Pressure switch 25 Hydraulic oil tank

2 Main pump 19 Pressure switch 26 Return filter
7 Cut off valve 20 Pressure switch 27 Bypass valve
8 Brake valve 21 Line filter 28 Axle
15 Accumulator 22 Oil cooler 29 Parking brake
16 Parking brake solenoid valve 23 Check valve
17 Pressure switch 24 Air breather
4-3
1) SERVICE BRAKE RELEASED
FRONT 28 REAR 29
17 19
20
8 2.4 2.1 2.5 2.2
5.1 1.1 5.2 1.2
A B
16
15 15 P T
15
21 22 23
7
15
27
28
Steering system
18
1
MCV RCV Lever
Return line
5
21
2 1
Return line
23
24
25
26 27 22
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 exhaust port is opened and the hydraulic oil in the piston of axles
return to the tank(25).
Therefore, the service brake is kept released.
4-4
2) SERVICE BRAKE OPERATED
FRONT 28 REAR 29
17 19
20
2.4 2.1 2.5 2.2
8
1.1 5.1 1.2 5.2
A B
16
15 15 P T
15
21 22 23
7
15
27
28
Steering system
18
1
MCV RCV Lever
Return line
5
21
2 1
Return line
23
24
25
26 27 22
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 28 REAR 29
17 19
20
8 2.4 2.1 2.5 2.2
5.1 1.1 5.2 1.2
A B
16
P T
15 15
15
21 22 23
7
15
27
28
Steering system
18
1
MCV RCV Lever
Return line
5
21
2 1
Return line
23
24
25
26 27 22
When the parking brake switch is pushed, the solenoid valve(16) is energized and the hydraulic oil
controlled the pressure level by the cut off valve(7) enters the parking brake(29). It overcomes the
force of the spring and pushes the piston. This releases the brake.
Therefore, the hydraulic oil pressure is applied to the parking brake piston through the solenoid
valve(16) and the parking brake(29) is kept released.
4-6
4) PARKING BRAKE OPERATED
FRONT 28 REAR 29
17 19
20
8 2.4 2.1 2.5 2.2
5.1 1.1 5.2 1.2
A B
16
15 15 P T
15
21 22 23
7
15
27
28
Steering system
18
1
MCV RCV Lever
Return line
5
21
2 1
Return line
23
24
25
26 27 22
When the parking brake switch is pushed once more, the solenoid valve(16) is deenergized and the
valve open the exhaust port.
At the same time, the hydraulic oil in the parking brake(29) return to the tank through the solenoid
valve(16). When the piston is returned by the force of the spring, the parking brake is applied.
4-7
3. BRAKE PUMP
1) STRUCTURE
100 85 62 90 30,31,32 10 24 35,36,37 90
70 80 90 7 60 20 90
7 Cover 32 Wear plate back up seal 70 Cap screw

10 Housing 35 Wear plate 80 Cap screw
20 Driven gear 36 Wear plate seal 85 Location ring
24 Drive gear 37 Wear plate back up seal 90 Plain bearing
30 Wear plate 60 O-ring 100 Coupling
31 Wear plate seal 62 O-ring
Hydraulic brake pump used for the brake system on construction machinery are pressure loaded type
gear pumps. This gear pump have a maximum delivery pressure of 150kg/cm2(2130psi).
The pressure loaded type gear pump is designed so that the clearance between the gear and the side
wear plate can be automatically adjusted according to the delivery pressure. Therefore, the oil leakage
from the side wear plate is less than that in the case of the fixed side plate type under a high discharge
pressure.
Consequently, no significant reduction of the pump delivery occurs, even when the pump is operated
under pressure.
4-8
2) PRINCIPLE OF OPERATION
(1) Mechanism for delivering oil

The drawing at right shows the
operational principle of an external gear
pump in which two gears are rotating in
mesh.
The oil entering through the suction port is
trapped in the space between two gear Suction Discharge
teeth, and is delivered to the discharge
port as the gear rotates.
Except for the oil at the bottom of the gear
teeth, the oil trapped between the gear
teeth, is prevented from returning to the
suction side with the gears in mesh.
Since the gears are constantly delivering
oil, the oil delivered to the discharge port
is forced out of the port.
The amount of discharge increases with
the speed of rotation of the gear.
If there is no resistance in the oil passage
into which the discharged oil flows, the oil
merely flows through the passage,
producing no increase in pressure.
If however, the oil passage is blocked with
something like a hydraulic cylinder, there
will be no other place for the oil to flow, so
the oil pressure will rise. But the pressure
which rises in this way will never go
higher, once the hydraulic cylinder piston
starts moving because of the oil pressure.
As described earlier, the pump produces
the oil flow, but not the oil pressure. We
can therefore conclude that pressure is a
consequence of load.
In other words, the pressure depends on
a counterpart.
4-9
(2) Internal oil leakage
Oil leaks from a place under higher
pressure to a place under lower pressure,
provided that a gap or a clearance exists
in between.
In the gear pump, small clearances are
provided between the gear and the case
and between the gear and the side plate
to allow the oil to leak out and to serve as
a lubricant so that the pump will be
rge
protected from seizure and binding.
scha
Di
The drawing at right shows how the
leaked oil flows in the pump. As such,
there is always oil leakage in the pump
from the discharge side(Under higher
pressure) to the suction side. The
n
delivery of the pump is reduced by an ctio
Su
amount equal to the pump discharge.
In addition, the delivery of the pump will
also decrease as the amount of oil
leakage increases because of expanded
radial clearance resulting from the wear of
pump parts, the lower oil viscosity
resulting from increases in the oil
temperature, and the initial use of low
viscosity oil.
4-10
(3) Forces acting on the gear
The gear, whose outer surface is
subjected to oil pressure, receives forces
jointing towards its center.
Due to the action of the delivery pressure,
the oil pressure in higher on the delivery
side of the pump, and due to suction
pressure, is lower on the suction side. In
the intermediate section, the pressure will
gradually lower as the position moves
from the delivery side to the suction side. Drive gear
This phenomenon is shown in the
drawing at right.
In addition, the gears in mesh will receive
Suction Discharge
interacting forces. side side
These forces pushing the gears toward
the suction side are received by the
bearings. Since the gears are pressed
Driven gear
toward the suction side by these forces,
the radial clearance becomes smaller on
the suction side in the case. In some
pumps, the clearance may become zero,
thus allowing the gear teeth and the case Pressure distribution
to come into light contact.
For this reason, an excessive increase in
the delivery pressure must be avoided,
since it will produce a large force which
will act on the gears, placing an overload
on the bearings, and resulting in a
shortened service life of the bearing or
interference of the gear with the case.
4-11
(4) "Trapping" phenomenon of the oil
When a gear pump is rotating with the
gears in mesh as shown in the drawing at
right, in some instances two sets of gear
Delivery Suction side
teeth are in mesh while in other instances side
only one set of the gear teeth is in mesh.
When two sets of the teeth are in mesh
simultaneously, the oil in the space Trapping starts
between the meshed gear teeth will be
trapped inside-the front and rear exits will The space
reaches the
be completely shut. minimum
This is called the "trapping" phenomenon
of oil.
The space in which the oil is trapped Trapping ends
moves from the suction side to the
delivery side as the gears rotate. The
volume of the space gradually decreases
from the start of trapping until the space
reaches the center section, and then
gradually increases after leaving the
center section until the end of trapping. Fixed side plate type
Since the oil itself is non-shrinkable, a
reduction of the volume of space will
greatly increase the oil pressure, unless
Side plate
some plosion in made to relieve oil
pressure. The high pressure oil will
cause the pump to make noise and
vibrate.
To prevent this, relief notches are Relief notch
provided on the side plates to release the
oil to the delivery side.
As shown in the drawing at right, the relief
notches are provided in such a way that Pressure loaded type Bushing
the oil can be relieved from the tapping
space to the delivery side when the
volume of the space is reduced.
Relief notches are also provided on the
suction side to prevent the formation of a
vacuum in the space by allowing the oil to
enter the space from the suction side
when the space is reduced.
4-12
4. BRAKE VALVE
1) STRUCTURE
13,15
11
12
7
8,9
10,14
37
6
5
3 2
1
4 17
19 36
20 18
24
21
23
25
27 28
26 30
29
31
32
33
34
35
1 Base plate 13 Rivet 27 Ring

2 Bushing 14 Pin 28 Spool
3 Nut 15 Pedal cover 29 Retainer
4 Screw 17 Guide pin 30 Spring
5 Piston 18 Spring 31 Spool
6 Bellows 19 Washer 32 Spring
7 Pin 20 Cap 33 Snap ring
8 Bracket 21 Spring 34 Washer
9 Bracket 23 Cap 35 Plug
10 Retaining ring 24 Ball 36 Bolt
11 Plate 25 Spring 37 Bolt
12 Pedal 26 Housing
4-13
2) OPERATION
Set of springs
Upper spool
5.1
2.4 2.1
1.1
Lower spool
5.2
2.5 2.2
1.2
Leading edges
2.4
5.1
1.1 2.1
2.5
5.2
1.2 2.2
4-14
(1) Purpose
The purpose of the brake valve is to sensitively increase and decrease the braking pressure when
the brake pedal is actuated.
(2) Ready position
When the braking system is ready for operation, its accumulator pressure acts directly on ports
(1.1, 1.2) of the brake valve. A connection is established between ports(2.1, 2.2) and ports(5.1,
5.2) so that the wheel brakes ports(2.1, 2.2) are pressureless via the returns ports(5.1, 5.2).
(3) Partial braking
When the brake valve is actuated, an amount of hydraulic pressure is output as a ratio of the foot
force applied.
The spring assembly(21) beneath base plate(1) 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(28) is mechanically actuated via
spring assembly(21), and the lower spool(31) is actuated hydraulically by spool(28). As spools
(28 and 31) move downward, they will first close returns(5.1, 5.2) via the control edges, thus
establishing a connection between accumulator ports(1.1, 1.2) and ports(2.1, 2.2) for the wheel
brake cylinders. The foot force applied now determines the output braking pressure. The
control spools(28 and 31) 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(28 and 31) are in a partial braking position, causing
ports(1.1, 1.2) and(5.1, 5.2) to close and holding the pressure in ports(2.1, 2.2).
(4) Full braking position
When pedal(12) is fully actuated, end end position of the brakes is reached and a connection
established between accumulator ports(1.1, 1.2) and brake cylinder ports(2.1, 2.2). Returns
(5.1, 5.2) are closed at this point.
When the braking process is ended, a connection is once again established between brake
cylinder ports(2.1, 2.2) and return ports(5.1, 5.2), closing accumulator ports(1.1, 1.2).
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(37) on base plate(1) below pedal(12) 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
(21) will mechanically actuate spool(28). In the event of the upper circuit failing, the lower circuit
will remain operational since the lower spool(31) is mechanically actuated by spring assembly(21)
and spool(28).
(7) Installation requirements
Return lines(5.1, 5.2) must be connected directly to the tank.
The connecting lines must be installed is such a way as to permit proper bleeding.
4-15
(8) Maintenance of the brake valve
No special maintenance beyond the legal requirements is necessary.
When using high-pressure cleaners on the machine, please make sure that the water jet is not
aimed directly at the brake valve(To prevent damaging the bellows).
For safety reasons the whole of the brake valve must be replaced if parts other than those
listed above are damaged.
(9) Repair work
When working on the braking system, always make sure that there is absolutely no
pressure in the system. Even when the engine is switched off there will be some residual
pressure in the system.
When doing repair work, make sure your environment is very clean.
Immediately close all open ports on the components and on pipes using plugs.
(10) Replacing the pedal cover
Pedal cover(15) is simply pulled of by hand. The new pedal cover is pushed over pedal(12) and
tightened manually. Fasten the bellows with the strap retainers.
(11) Replacing the complete actuating mechanism
Carefully clamp the unit vertically in a fixture. The actuating mechanism can be removed by
taking out the four bolts(36) below base plate(1). Make sure that spring assembly (21) does not
fall out. When installing the new actuating mechanism, make sure that spring assembly (21) is
fitted in the right order. Tighten the four bolts(36).
(12) Replacing the bellows
To change bellows(6) it is advisable to remove pedal(12). For this purpose, loosen retaining ring
(10) and knock out pin(14) 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(12) and bellows(6).
Now fit the new bellows(6) and proceed in reverse order as described above. The upper portion
of bellows(6) is fastened to piston(5), its lower portion to base plate(1) secure the bellows using
clamps.
(13) Replacing the grooved ring
Carefully clamp the unit vertically in a fixture. Unscrew plug(35) and pull spool(28 and 31) out
downwards. Check the spools for damage. If they are found to be damaged, the whole brake
valve needs to be replaced(Pairs of spools and housings are matched in manufacturing).
If the spools are not damaged in any way, remove the whole actuating mechanism as described
above. Remove spring assembly(21) and grooved ring(27) and put in a new greased grooved
ring with its lips pointing downwards. Install both the spring assembly as shown in the drawing,
and the pedal. Put in spring(30), followed by spool(31), using a slight turning motion if possible.
Insert spring(32) and close the unit with screw plug(35).
Check return ports(5.1, 5.2) to see if there is a gap of approx. 2mm between the lower edged of
the hole and the control edge of spool(28). If this is not the case, take out screw plug(35) once
more and change the setting by removing or adding distance washers(19) in the upper spring
plate. Replace the screw plug and once again check the distance between the lower edge of the
hole at ports(5.1, 5.2) and the control edge of spool(28).
4-16
5. CUT OFF VALVE
1) STRUCTURE
1 35 37 36 38 30 3 2 5 6 4 34 7
31
32
23
33
21
16 15 14 20 21
VIEW A
1 Housing 15 Washer 33 Spool

2 Spool 16 Screw plug 34 Nut
3 O-ring 20 Shuttle valve 35 Ball
4 Back up ring 21 Retaining ring 36 Spring
5 Cap 23 Spring 37 Washer
6 Spring 30 Screw 38 Plug
7 Pipe 31 Ball
14 Return valve 32 Plug
4-17
2) OPERATION
E1 E2
27
G
F 21 22 23
5
28
27
28
1
1
5
21
Item Spec
22
Cut-in pressure 120+10kgf/cm2
cut off pressure 150-10kgf/cm2
Flow rate 45 /min
23 Flow rate to the brake circuits 3+1 /min
Max pressure at port 5 Max 200kgf/cm2
Temperature of medium -30 ~ +80 C
VIEW A Ambient temperature -30 ~ +80 C
Medium Mineral oil
Torque M12 1.5 2.9 0.31kg m
M16 1.5 4.1 0.51kg m
M18 1.5 5.1 0.51kg m
4-18
(1) Purpose
The purpose of the cut off valve is to control the pressure level in the accumulators.
The cut off valve must keep the pressure level of the brake accumulators between 120 kgf/cm2 and
150kgf/cm2. This is obtained by a switching mechanism which pressurizes the braking system
again to approx. 150kgf/cm2, only if the pressure has dropped to less than 120kgf/cm2.
(2) Ready position
When the braking system is ready for operation(i.e. the accumulators are charged) the pump
stream is present at port 1 of the cut off valve. A connection is established between ports 1 and 5
so that the pump stream is, with a small difference in pressures, returned directly to the reservoir.
The rear of main spool(33) is pressureless. The pressure within the braking system will hold
control spool(2) in its locked position(E1) in which the rear of main spool(33) is directly connected
to return 5 via hole(G). Check valve(14) in the hole to port 27 secures the accumulator pressure
of the operating accumulator. This is available as an additional braking volume for the braking
system, preventing excessively frequent actuation of the cut off valve in the event of a leakage.
Shuttle valves(20) additionally secure each braking circuit against pressure looses in the event of
a broken pipe.
(3) Charging process
As the accumulator pressure falls to the preset value, control spool(2) will, through the force of
spring assembly(6), overcome its locked position(E1) and move to another locked position(E2).
Via orifice(F) and oil stream flows to the rear of main spool(33). The pressure building up at the
rear of main spool(33) and the pressure present below main spool(33) put main spool(33) in a
floating position, permitting a partial stream to continue to reach port 5 and the remaining stream
to flow to ports(21, 22, 23) via check valve(14) until the pressure within the braking system is
approx. 150kgf/cm2. Control spool(2) will then once again move to locked position(E1) in which a
connection is established between ports 1 and 5. The whole of the pump stream once again
flows to the reservoir via port 5. Check valve(14) again secures the accumulator pressures.
The connecting line must be installed in such a way as to permit proper bleeding. The double
check valve can be mounted in any position.
(5) Maintenance of the cut off valve
(6) Repair work
When doing repair wok, make sure your environment is very clean.
For safety reasons the whole of the cut off valve must be replaced if damaged.
4-19
6. BRAKE ACCUMULATOR
1) STRUCTURE
81L1-0004
Item
(Item15)
Diameter 136mm
Mounting height 160mm
Norminal volume 1.0m3
Priming pressure 50kgf/cm2
Operating medium Oil
B
Operating pressure Max 200kgf/cm2
Thread M18 1.5
A
Operating
C -30 ~ 80 C
temperature range
Priming gas Nitrogen
D
A Fluid portion C Diaphragm
B Gas portion D Valve disk
2) OPERATION
(1) Purpose
Fluids are practically incompressible and are thus incapable of accumulating pressure energy. In
hydropneumatic accumulators, the compressibility of a gas is utilized to accumulate fluid. The
compressible medium used in the accumulators is nitrogen.
In braking systems, the purpose of the accumulators is to store the energy supplied by the
hydraulic pump. They are also used as an energy reserve when the pump is not working, as a
compensator for any losses through leakage, and as oscillation dampers.
(2) Operation
The accumulator consists of a fluid portion(A) and a gas portion(B) with a diaphragm(C) as a gas-
tight dividing element. The fluid portion(A) is connected to the hydraulic circuit, causing the
diaphragm accumulator to be filled and the gas volume to be compressed as the pressure rises.
When the pressure falls, the compressed gas volume will expand, thus displacing the
accumulated pressure fluid into the circuit.
The diaphragm bottom contains a valve disk(D) which, if the diaphragm accumulator is
completely empty, closes the hydraulic outlet, thus preventing damage to the diaphragm.
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.
4-20
(4) Maintenance of the accumulator
The accumulator should be checked annually. It should be replaced if the initial gas
pressure has fallen by more than 30%(Please refer to Performance testing and
checking of the accumulator).
(5) Disposal of the accumulator
Before the accumulator is scrapped, its gas filling pressure must be reduced. For this
purpose, drill a hole through gas chamber(B) using a drill approx. 3mm in diameter. The
gas chamber is located on the side opposite the threaded port above the welding seam
around the center of the accumulator.
Wear safety goggles when doing this job.
(6) Performance testing and checking of the accumulator
The accumulator is gradually pressurized via the test pump; until the initial gas pressure is
reached, the hydraulic pressure in the accumulator will rise abruptly. This is apparent
from gauge M. If the initial gas pressure is more than 30% below the prescribed value,
the accumulator needs to be replaced. If the measuring process needs to be repeated,
wait for intervals of 3 minutes between the individual tests. Any accumulator whose initial
gas pressure is insufficient must be scrapped following the instructions under Disposal of
the accumulator.
The amount of initial gas pressure can also be checked from the vehicle. Start the
vehicle's engine. The pump will now supply oil to the accumulators. Until the initial gas
pressure is reached, the hydraulic pressure in the accumulator will rise abruptly. This is
apparent from the gauge in the cab. If the initial gas pressure is more than 30% below the
prescribed value, that initial pressure lies outside the permissible range for at least one of
the accumulators fitted in the vehicle. This accumulator can be traced only by using the
method described above, i.e. all accumulators have to be individually tested. The
accumulator whose initial gas pressure is insufficient must be replaced and scrapped
following the instruction under Disposal of the accumulator.
Accumulator M
A Safety valve
4-21
(7) Repair work
pressure in the system. Even when the engine in switched off there will be some residual
For safety reasons the accumulators need to be replaced as a whole if damaged.
4-22
7. PRESSURE SWITCHES
1) STRUCTURE
Normally closed
H1
Normally open
H2
H1 H2 Adjusting range Adjusting pressure Voltage

Item Type Medium G mm mm kg/cm2 kg/cm2 V
Parking NC Oil M12 1.5 55 9 20 ~ 50 21 2 Max 42

Charging NC Oil M12 1.5 55 9 50 ~ 150 100 10 Max 42
Brake stop NO Oil M12 1 43 9 3~6 3~6 Max 42
Clutch cut off NO Oil PF 1/4" 55 9 20 ~ 50 24 2 Max 42
NC : Normally closed NO : Normally open
4-23
2) OPERATION
(1) Purpose
The pressure switches are used to visually or audibly warn the driver of the pressure within the
system.
(2) Make contact / circuit closer
The pressure switch can be fitted in the braking system or directly on one of its components.
The system pressure acts on an absorption area within the switch, making an electrical contact as
the pressure on that area is increased. The resulting current is used to activate a warning facility,
for instance.
(3) Break contact / circuit breaker
The pressure switch can be fitted in the braking system or directly on one of its components.
The system pressure acts on a absorption area within the switch, breaking an electrical contact
as the pressure on that area is increased. The current is now broken, e.g. to deactivate a
warning facility.
No special measures need to be taken.
(5) Maintenance of the pressure switch
When using high-pressure cleaners on the vehicle, please make sure that the water jet is not
directed at the pressure switch(Corrosion of contacts).
(6) Repair work
For safety reasons the pressure switch needs to be replaced as a whole if damaged.
4-24
(7) Adjusting and testing pressure switch
The adjusting screw located between the two contact plugs can be set to the desired value within
a certain range. For adjusting range, please refer to the table Technical data on the previous
page.
After making the adjustment, the adjusting screw should be secured using wax or a similar
material.
( )
Screw
(+)
4-25
8. PARKING BRAKE
2 5 7
11
1 4 3 8 10 6 9
1 Brake settle 5 Spring pack 9 Ring

2 Vent valve 6 Piston 10 Chamber
3 Brake lining carrier 7 Set screw 11 Counter nut
4 Brake lining carrier 8 Pressure piece
4-26
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.
Chapter 2 : Troubleshooting
Group 3 : Tests and adjustments
4-27
ƓHydraulic oil must be at operating temperature for these checks(Refer to page 6-52).
Parking brake capacity Start engine. OK

check 20 30 Check completed.
20 Fasten seat belt.
Seat belt must be worn 10
10
40
NOT OK
while doing this check to 5 0 mph
30
Release parking brake and put
0
km/h 50
Inspect parking brake. Go
prevent possible injury transmission in 2nd gear forward.
to group 3.
when machine stops
Drive machine at 8 km/hr and
suddenly.
switch parking brake ON.
LOOK/FEEL : Machine must
come to a stop within 2 meters(6
feet) when parking brake is
engaged at 8 km/hr.
Transmission must shift to neutral.
Parking brake Turn parking brake to ON. OK

transmission lockout Check completed.
Place transmission in 2nd forward.
check
NOT OK
Engine running. Slowly increase engine speed to
Go to transmission control
high idle.
circuit in section 3.
LOOK : Machine must not move.
4-28
Service brake pump Stop engine. OK

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

check Check completed.
Apply service brakes, release park
Engine running.
brake and put transmission in 2nd NOT OK
forward. Check brake pressure in
group 3.
Increase engine speed to high
idle. IF OK
Inspect brake disk, see
LOOK : Machine may not move
group 3.
or move at a very slow speed.
Repeat check three times to
ensure accurate results.
4-29
Brake accumulator Start and run engine for 30 OK

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

ON STAR
T
Stop engine.
F
OF
NOT OK
Wait 2 minutes.
If brake leakage is
Turn key switch to ON and wait 5 indicated with brakes
seconds. released, check leakage
at accumulator inlet check
LOOK : Brake oil pressure
valve and brake valve. If
warning lamp must not come on
brake leakage is indicated
within 2 minutes after stopping
with brakes applied, check
engine.
for leakage at brake valve
and brake pistons.
Check individual
component leakage.
4-30
Service brake pedal Slowly depress brake pedal. OK

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

brake system drag slope. Check completed.
checks
Lower bucket approximately
Engine running NOT OK
50mm(2 in) from ground.
Adjust park brake, go to
Release parking and service group 3.
brakes.
NOT OK
LOOK : Machine must move or
Check floor mat
coast.
interference to pedal or
NOTE : If machine does not debris build-up.
move, check brake pedals to be
sure they fully release when feet IF OK
are removed from pedals. Check for brake pressure
when brake is released.
Drive machine at high speed for
about 5 minutes.
Go to brake pressure test
Brake drag is indicated if brake on group 3.
areas in differential case are hot.
NOTE : Observe parking brake.
If disk is hot, parking brake drag is
indicated.
Clutch cut off check Place clutch cut off switch in ON OK

position. Check completed.
Release parking brake. NOT OK
Adjust clutch cut off
Run engine at half speed in 1st
switch, see group 3.
forward.
Firmly depress brake pedal.
FEEL : Transmission must
disengage when brake pedal is
depressed at 30% of pedal stroke.
NOTE : Clutch cut off pressure
switch can be adjusted to operator
preference to match your loading
needs.
4-31
2. TROUBLESHOOTING
1) SERVICE BRAKE
Diagnose malfunction charts are arranged from most probable and simplest to verify, to least likely,
more difficult to verify. Remember the following steps when troubleshooting a problem :
Step 1. Operational check out procedure(See section 1)
Step 2. Operational checks(In this group)
Step 4. Tests and adjustments(See group 3)
Poor or no brakes Brake accumulator charge low. Do brake accumulator check.

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

Clutch cut off switch out of Adjust switch.
adjustment.
Brake valve malfunction. Disassemble and inspect.
Low oil level. Check oil level.
Brakes drag Brake pedal not returning Inspect floor mat and pedal.
properly.
Debris holding valve partially Do brake valve pressure test.
open in brake valve.
Stuck brake piston. Repair.
Wrong oil in hub. Drain and refill.
Brakes lock up Brake valve malfunction. Clean or replace brake valve.
4-32
Brakes chatter Air in brake system. Do brake bleed procedure.

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

light will not go out or pressure warning switch.
stays on excessively
Brake accumulator pressure Recharge accumulator.
long after start-up
too low.
Low brake pump standby Do brake pump standby pressure test.
pressure setting.
Leakage in pressure reducing Do pressure reducing valve manifold leakage
manifold block. test.
Leakage in brake system. Do brake system components leakage tests.
Worn brake pump. Do brake pump flow test.
4-33
2) PARKING BRAKE MALFUNCTIONS
Brake will not hold Pads not adjusted correctly. Adjust parking brake.
Malfunctioning parking brake Inspect and replace.
solenoid.
Worn brake pads. Disassemble, inspect, repair.
Brake piston hangs up in bore. Remove and inspect. Repair.
Brake disk overheats Pads out of adjustment. Adjust parking brake.

Brake not released. Release parking brake.
Disassemble, inspect brake.
Repair if necessary.
Inspect for loosen or broken lines between brake
pressure switch and indicator on dash.
Parking brake indicator Faulty wiring or switch. Inspect for loose or broken lines between brake
in monitor does not pressure switch and indicator on dash.
come on when brake Inspect for a faulty indicator on dash. Replace if
applied necessary.
Brake will not apply Pads out of adjustment. Adjust parking brake.
Malfunctioning wiring, switch, Check electric circuit.
or solenoid.
Restriction between brake Remove hose and inspect. Replace.
valve and brake.
Brake will not release Brake pressure too low. Adjust brake pressure.
Malfunctioning parking brake Inspect and replace.
solenoid.
Pads out of adjustment. Adjust parking brake.
4-34
1. PARKING BRAKE PERFORMANCE

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

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

Inspect for wear of brake lining carrier.
Adjust the gap(A) 2mm by adjust screw.
Brake disc
Screw
4-35
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. B
Search for leaks with a piece of
cardboard. Protect hands and body from
high pressure fluids.
Ɠ If an accident occurs, see a doctor
immediately. Any fluid injected into the
skin must be surgically removed within a
few hours or gangrene may result.
Doctors unfamiliar with this type of injury
should reference a knowledgeable
medical source.
A
Two people are required to bleed brake
system oil, one to operate brake valve and
other to open and close bleed screws.
1) Install frame locking bar. Engage parking
brake.
2) Put a clear plastic tube on bleed screw(B)
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.
Ɠ If bubbles continue for more than 2
minutes, stop bleeding procedure.
Check for and correct problem, then
continue.
5) Open on bleed screw on differential and
axle assembly until hydraulic oil starts to
flow. Close bleed screw when oil is free of
Frame locking bar
air. Release brake pedal.
6) Repeat steps 1)~5) for each bleed screw.
7) Push either brake pedal and hold down.
8) Check hydraulic oil level.
4-36
GROUP 4 DISASSEMBLY AND ASSEMBLY
1. BRAKE PUMP
1) STRUCTURE
60
37
35
20
10
31
90
90
36
24
80
30
32
90
70
7
62
85
100
7 Cover 32 Wear plate back up seal 70 Cap screw

10 Housing 35 Wear plate 80 Cap screw
20 Driven gear 36 Wear plate seal 85 Location ring
24 Drive gear 37 Wear plate back up seal 90 Plain bearing
30 Wear plate 60 O-ring 100 Coupling
31 Wear plate seal 62 O-ring
4-37
2) GENERAL INSTRUCTION
(1) Cleanliness
‫ ڸ‬Cleanliness is the primary means of assuring satisfactory hydraulic pump life. Components
such as flanges and covers are best cleaned in soap and hot water, then air dried. Gears
should be washed in solvent, air dried, and oiled immediately.
Certain cleaning solvents are flammable. Do not allow sources of ignition in the area
when using cleaning solvents.
‫ ڹ‬Protect all exposed surfaces and open cavities from damage and foreign material.
Ɠ Gear journals and gear faces are super finished. Take care not to touch these surfaces
after oil and solvent have been removed.
(2) Lubrication of moving parts
During assembly, all running surfaces(Bearing and wear plate) must be lightly lubricated with a
clean oil or aerosol lubricant.
(3) Tools required for assembly
‫ ڸ‬Torque wrench (0~50kgfşm, 0~360lbfşft)
‫ ڹ‬Open end wrenches
‫ ں‬Seal installation tools (Inner and outer)
‫ ڻ‬Shaft bullet (Seal protector)
‫ ڼ‬Installation plate
(4) Tightening torque
Torque
Item
kgfşm lbfşft
Screw(70) 4.7 34
Screw(80) 16.5 119
4-38
3) DISASSEMBLY
Ɠ Plug all ports prior to cleaning and
disassembling pump to prevent ingress of
debris or contamination.
Clean the pump throughtly with a solvent,
ensuring no loose debris or contamination
remains on the unit.
Dry pump using compressed air or clean
lint-free cloths.
Ɠ Ensure that interface location ring(85) and
splined coupling(100) are retained for
reassembly.
(1) Remove the cap screw(70, 80) securing
the cover(7) to housing(10).
(2) Remove the cover(7) from the

housing(10).
Ɠ Under NO circumstances attempt to prise
or chisel cover from housing as such
action could damage the machined
sealing faces.
(3) Before removing wear plate(30) from the

housing(10) mark it using a soft pencil or
a felt-tip pen to ensure correct
reassembly.
Remove wear plate(30) complete with
wear plate seal(31) and back up seal(32).
4-39
Ɠ Mark the gears using a soft pencil or felt-
tip pen to ensure reassembly in the same
relative position, then withdraw the drive
shaft/gear and driven gear separately to
prevent jamming.
Again, to ensure correct reassembly, mark
remaining wear plate(35) using a soft
pencil a felt-tip pen. Remove wear
plate(35) from housing(10) complete with
wear plate seal(36) and back up seal(37).
4-40
4) MANDATORY REPLACEMENT PARTS
Discard all seals including interface seals, shaft seals, wear plate seals and back up seals. Fit new
seals on reassembly.
5) 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
cardboard boxes.
6) INSPECTION OF PARTS
Wash all parts in a solvent and dry using compressed air or clean, lint-free cloths.
(1) Mounting flange, housing and cover
The pump must be replaced if the damage listed is present.
Feature Damage
Corrosion, nicks or burrs(Slight burrs can be removed
Surfaces
using and india stone)
Machined sealing lnterfaces Scores or cracks
Bearing bores Incorrect diameter, grooves or distorted
Bearing Loose
(2) Gears
Feature Damage
Surfaces using an lndia stone).
Wear due to seal(s)
Journals Pitting, wear, sufficient wear to change outside diameter
Gears Cracks or heavy scoring or chipped
Splines/keyways Distortion of wear
4-41
(3) Floating wear plates
Feature Damage
Corrosion, nicks or burrs, amounts of scoring,erosion
Surfaces
or any cracks, discoloration caused by overheating
Removing burrs or minor scoring from Scoring of wear plate.

end faces and teeth of the gears.
(4) Bolts / Studs

These must be replaced if the damage listed is present.
Feature Damage

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

Feature Damage
Surfaces Cracks or socring

PTEF Coating Worn
Bearing Loosen in mating component
(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
4-42
7) WEAR PLATES, SEALS AND BACK UP SEAL, SUB-ASSEMBLY
Refer to illustration on assembly drawing for the correct fitment of the wear plate seal and back up
seal in the groove of the wear plates(30, 35).
It is critical that the wear plates are assembled into the pump with regard to the following :
(1) The seal side of the wear plate must be adjacent to the cover(7) or housing(10).
(2) The high pressure side of the wear plate must be adjacent to the outlet port. Refer to assembly
drawing.
4-43
8) ASSEMBLY
(1) Lightly oil surfaces with clean hydraulic oil.
(2) Place housing(10) vertically with front

section gear pockets upper most.
Side wear plate(35) complete with seal

(36) and back up seal(37) down through
the housing(10) to the bottom of the gear
pockets.
Ɠ Be sure to refit the wear plate you have
marked from this position.
Fit the gears within the housing taking
care to replace as marked, with the teeth
reassembled to their original related
position.
Fit the wear plate(30) complete with
seal(31) and back up seal(32).
(3) Fit new O-ring(60) into groove in

housing(10). Fit cover(7).
Tighten cap screws(70, 80) to half torque
and then full torque in diagonal sequence
to figure as per assembly drawing.
4-44
1. OUTLINE
1 Steering pump
2 Flow amplifier
3 Steering unit
4 Steering cylinder 1
5 Hydraulic tank
6
6 Main pump
The steering system of this machine is a dynamic load sensing steering system.
This system offers faster response from the priority valve of flow amplifier(2) and the pump. Also if
offers advantages in connection with cold start up and improvements in system stability.
The components of the steering system are :
şSteering pump(1)
şFlow amplifier(2)
şSteering unit(3)
şSteering cylinders(4)
The flow amplifier(2) contain a directional valve, an amplification stage, a priority valve, a pilot
pressure relief valve and shock and suction valve.
The steering pump(1), draws hydraulic oil from the hydraulic oil tank(5).
Outlet flow from the steering pump(1) flows to the priority valve of flow amplifier(2). The priority valve
of flow amplifier preferentially supplies flow, on demand, to the steering unit(3). When the machine
is steered, the steering unit routes flow to the steering cylinders(4) 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 pump(6) for the operation of the
attachment.
5-1
LH RH
6 CL CR
L R
J
P
EF
T
PP
D K 21Mpa
HP LS HT
L R
G MCV
5
RCV lever
Return line
P T LS
Brake system
2 1
Return line
24
23
25
26 27 22
Emergency steering system
1 Steering pump 9 Steering cylinder 25 Hydraulic tank

2 Main pump 22 Oil cooler 26 Return filter
5 Steering unit 23 Check valve 27 Check valve
6 Flow amplifier 24 Air breather
5-2
1) NEUTRAL
LH RH
6 CL CR
L R
J
P
EF
T
PP
D K 21Mpa
HP LS HT
L R
G MCV
5
RCV lever
Return line
P T LS
Brake system
2 1
Return line
24
23
25
26 27 22
ş The steering wheel is not being operated so control spool(G) does not move.
ş The oil from the steering pump(A) enters port HP of the priority valve of flow amplifier and the inlet
pressure oil moves the spool(D) to the right.
ş Almost all of pump flow goes to the loader system(main control valve) through the EF port and
partly flows into the hydraulic tank(27) through the control spool(D).
ş This small flow is useful to prevent the thermal shock problem of the steering unit(5).
5-3
2) LEFT TURN
LH RH
6 CL CR
L R
EF
T
PP
D K 21Mpa
HP LS HT
L R
MCV
G
RCV lever
5
Return line
P T LS
Brake system
2 1
Return line
24
23
25
26 27 22
ş When the steering wheel is turned to the left, the spool(G) within steering unit(5) connected with
steering column shaft is pushed to the right direction.
ş The oil discharged from the steering pump(1) flows into HP port of flow amplifier(6).
ş The delivered oil passes through the priority valve spool (D) of flow amplifier(6), through the main
orifice of steering unit(5). The position of priority spool(D) is determined when the pressure
difference between front and rear of main orifice is balanced with control spring(K) force.
ş The oil supplied through the directional spool(J) from the steering unit(5) is combined with the direct
oil from the priority valve spool(D) in the amplifier spool(M). The amplified oil flows into the small
chamber of the left steering cylinder and large chamber of the right steering cylinder respectively.
ş Oil returned from left and right cylinder returns to hydraulic tank through directional spool(J) of flow
amplifier(6).
ş When the above operation is completed, the machine turns to the left.
5-4
3) RIGHT TURN
LH RH
6 CL CR
L R
EF
T
PP
D K 21Mpa
HP LS HT
L R
MCV
G
RCV lever
5
Return line
P T LS
Brake system
2 1
Return line
24
23
25
26 27 22
ş When the steering wheel is turned to the right, the spool(G) within steering unit(5) connected with
steering column shaft is pushed to the left direction.
ş The oil discharged from the steering pump(1) flows into HP port of flow amplifier(6).
ş The delivered oil passes through the priority valve spool (D) of flow amplifier(6), through the main
orifice of steering unit(5). The position of priority spool(D) is determined when the pressure
difference between front and rear of main orifice is balanced with control spring(K) force.
ş The oil supplied through the directional spool(J) from the steering unit(5) is combined with the direct
oil from the priority valve spool(D) in the amplifier spool(M). The amplified oil flows into the small
chamber of the right steering cylinder and large chamber of the left steering cylinder respectively.
ş Oil returned from left and right cylinder returns to hydraulic tank through directional spool(J) of flow
amplifier(6).
ş When the above operation is completed, the machine turns to the right.
5-5
3. STEERING PUMP
1) STRUCTURE
70
56
57
85 80
55
2
95
90
32
31 30
21
20
35
36
37 90
60
1 Mounting flange 32 Back up seal 60 O-ring

2 Front cover 35 Wear plate 70 Cap screw
3 Body 36 Moulded seal 80 Cap screw
20 Drive gear 37 Back up seal 85 Location sleeve
21 Drive gear 55 Shaft seal 90 Bearing
30 Wear plate 56 Shaft seal 95 Seal
31 Moulded seal 57 Multistep push clip
5-6
2) OPERATION
21 56 57 85 55 90 30,31,32 35,36,37 90
37 36
Z
SECTION Z-Z
A
Z
DETAIL A
1 70 2 90 60 20 90 3
The steering pump is a fixed displacement gear type pump. The pump is drive at engine speed by
the torque converter. The pump shafts are supported by bearings(90) in the body(3) and front
cover(2). The wear plates(30, 35) are located between the gear surface and cover(2) and body(3).
As the drive gear(21) turns driven gear(20), the gear teeth come out of mesh.
Oil flows from the hydraulic tank through the inlet the cavity between the gear teeth. As the gears
continue to rotate, the oil becomes trapped between the gear teeth and the body(3).
The trapped oil is then carried to the pump outlet. Oil is forced out the outlet to supply the hydraulic
functions. 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 wear plates(30, 35) against the gear faces. This
controls internal leakage to maintain pump displacement.
Outlet pressure fills the area bounded by the pressure balance moulded seals(31, 36) to force the
wear plate against the high pressure area or the gear faces. Pump shaft lubrication is achieved by
routing outlet pressure oil into the area between the gear shafts and the bearings. The oil is
collected at the end of the shafts in the hollow areas in the body and cover and routed back to
return.
5-7
4. FLOW AMPLIFIER
1) STRUCTURE
21 7 38 4 9C 21
16
T
HT
2 2
24
28
CR CL
34 34
23
L HP R
1 P 29
9A 1
27 13,14
1 1
8 41
40 35
10
11,12
37
22
P
9B HP EF 30
LS
15 PP 16
2
2
31
42 6 19 20 5 36
1 O-ring 12 Spring washer 28 Spring

2 O-ring 13 Screw 29 Spring
5 Washer 15 End cover 31 Throttle check valve
6 Washer 16 End cover 34 Orifice
7 O-ring 19 Relief valve 35 Orifice
8 O-ring 20 Plug 36 Orifice
9A Amplifier valve 21 Shock, suction valve 37 Plug
9B Priority valve 22 Spring seat 38 Plug
9C Directional valve 23 Spring seat 40 Spring
10 Check valve 24 Spring guide 41 Spring
11 Screw 27 Orifice 42 Orifice
5-8
2) OPERATION
(1) Introduction
The flow amplifier contain a directional valve, an amplification stage, a priority valve, a pilot
pressure relief valve and shock and suction valves.
The flow amplifier amplifies the oil flow from the steering unit cylinder ports L or R by an
amplification factor of 8. The amplified oil flow is directed from the flow amplifier ports CL or CR
to the steering cylinder. The amplified flow is proportional to the rate of the steering wheel
rotation. If the oil flow from the pump fails, the flow amplifier cuts off the amplification.
(2) Priority valve
The priority valve is used in load sensing systems where the same pump supplies oil to both
steering system and working hydraulics.
The steering system always has first priority.
The pressure on the LS connection is almost zero during measuring(Steering unit in neutral
position).
(3) Shock valves
The shock valves protect the flow amplifier against shock from external forces on the steering
cylinders. The shock valves in flow amplifier limit the maximum pressure drop from CL to HT and
from CR to HT.
(4) Suction valves
The suction valves ensure oil suction on the side of the steering cylinder pistons where in
unfavorable conditions cavitation might occur.
(5) HP-HT ports characteristic
The pilot pressure relief valve protects the steering unit against excess pressure. The pilot
pressure relief valve together with the priority valve limit the maximum steering pressure HP-HT.
5-9
(6) Neutral 9C
T
HT
CR CL
L HP R
P
HP EF LS
PP
42 9B 30
CL CR
L R
L R 9C
Steering unit
P
LS
9A
EF
TO MCV
42 T
P T PP
9B 30
HP LS HT
5-10
In neutral position, the oil passes from the pump across the integrated priority valve(9B) in the flow
amplifier for discharge through the EF port. With the steering unit in neutral, flow through it is blocked
and all flow through the priority valve(9B) in flow amplifier is directed out the EF port to the main control
valve.
With the engine off, the priority valve spool(9B) is pushed to the left by the spring(30). The passage to
the EF port is blocked while the passage to the P port is open.
When the machine is first started, all pump flow is routed to the steering unit which blocks the flow.
With the flow blocked, the pressure increases.
Steering inlet pressure is supplied through the dynamic orifice(42) in the spool. This causes the priority
valve spool(9B) to shift to the right against the spring(30) and open the EF port.
As long as the steering unit is in neutral, just enough pressure is maintained at the steering unit to keep
the priority valve spool(9B) shifted to the right.
The operating pressure in the loader system has no effect on the operation of the priority valve(9B) of
flow amplifier. With the loader actuated in relief, the priority valve(9B) will not shift until the machine is
steered.
Flow through the priority valve spool(9B) passes from the P port through the orifice(42) and into the LS
port. It flows through the steering unit LS passage which is routed to return when the steering unit is in
neutral. This provides a warm-up circuit for the steering unit to prevent binding of the steering unit due
to oil temperature extremes.
In neutral position, also the directional valve(9C) is in its center position.
This means that knock and impacts from the cylinder are not transmitted to the steering unit. The flow
amplifier is thus of the non-reaction type.
5-11
(7) Mid-turn
9C
T
HT
CR CL
L HP R
P
S
C
N
A
M
HP EF LS
PP
9B 9A
CL CR
L R
L R 9C
Steering unit
P
LS
9A
EF
T
P T PP
9B
HP LS HT
5-12
If the steering wheel is turned to the left, a LS signal is passed to the priority valve(9B). The priority
valve(9B) is reversed so that more oil is passed across the P port to the steering unit for discharge
through the L port of the flow amplifier.
The directional valve(9C) is reversed through the pressure being transmitted across the boring in the
spool whereby the spool is moved the right.
The opening shall allow connection between the pilot flow and the pressure control/amplifier valve(9A).
The pilot pressure from the orifice in chamber C moves the valve to the left and passage for the pilot
flow therefore is possible out of hole F.
The main flow passes from the priority valve(9B) to the circular channel M. As the amplifier spool is
moved to the left, the passage will now be open across the holes N to the chamber S.
The spool goes to a position so that the pressure in chamber S equals the pressure in chamber C.
The passage is now open for the main flow through the priority valve(9B) across the holes A.
The main flow and pilot flow merge and is passed across the directional valve(9C) to the steering
cylinder through CL port.
The return oil passes across the directional valve(9C) to the hydraulic tank.
5-13
(8) Full turn
T
HT
CR CL
L HP R
P
HP EF LS
PP
9B T 30
CL CR
L R
L R 9C
Steering unit
P
LS
EF
TO MCV
T
P T PP
D
HP LS HT
5-14
When the machine is steered to a full turn, the frames bottom against the steering stops. To limit
steering system pressure, a relief system is built into the priority valve assembly(9B).
When the frames bottom is stopped, the pressure in the steering cylinders increases. This pressure is
sensed at the LS port. When the pressure in the LS port increases enough to push priority valve
spool(9B) off its seat, oil in the load sensing circuit flows to return through the T port. Load sensing
pressure is limited to the pressure setting of the relief valve.
Pressure to the steering unit(Pilot pressure), which is sensed at the left end of the priority valve
spool(9B) in flow amplifier, continues to increase until it can move the spool to the right against the load
sensing pressure plus spring(30) force. At this time, all oil flows out of the EF port to the loader control
valve.
If the loader attachment is being operated while steering, the loader function will slow until the machine
reaches the steering stops. At that time, the loader cycle speed will increase until the machine is
steered again.
5-15
5. STEERING UNIT
1) STRUCTURE
12 3 32
4 15 5 18,20
22,23
1 5 7 8 9 2 11 13 14 16 17 18,21
1 Dust seal ring 9 Cross pin 17 End cover

2 Housing, spool, sleeve 11 Shaft 18 Washer
3 Ball 12 Spring set 20 Pin screw
4 Bushing 13 O-ring 21 Screw
5 O-ring/Roto Glyd ring 14 Distributor plate 22 Name plate
7 Bearing assy 15 Gearwheel set 23 Drive screw
8 Ring 16 O-ring 32 Check valve
5-16
2) OPERATION
A Neutral
B Steering
cylinder
C Anti-cavitation valves
D Load sense port to priority valve
E Gerotor
K System pressure oil

Spool I G Return
L Work pressure oil
J H
G M Trapped oil
Steering shaft Sleeve F
Return N Return pressure oil
From priority valve
The steering unit consists of a spool(I) inside a sleeve(H) within a housing. When steering wheel is not
moving, the steering unit is in the neutral(A) position. In neutral, the spool and sleeve are aligned so
that oil flow through the steering unit is blocked. The steering cylinder(B) are held stationary by trapped
oil in the left and right workports.
When the steering unit is turned to the right, the spool rotates relative to the sleeve, and opens
passages which allow pump flow through the spool and sleeve assembly. Oil flows to the gerotor(E)
causing the gerotor gear to rotate. Oil flow from the gerotor flows back into the steering unit where it is
directed out the right workport to the respective ends of the steering cylinders.
A bypass orifice is machined into the spool and sleeve assembly. It is a variable orifice that introduces
a small leak into the pressure side of the steering unit. Its purpose is to dampen the initial pressure
surge when the steering wheel is partially turned. When the steering wheel is fully turned, the leak is
closed off.
Return oil flows back in through the left workport through the spool and sleeve assembly to return. The
load sensing orifice is located between the sleeve and the gerotor. This orifice feeds the load sensing
circuit between the steering unit and the priority valve of flow amplifier through the LS port.
When the rotation of the steering wheel stops, the gerotor gear continues to move, turning the sleeve,
until the sleeve stops the flow to the gerotor. At this point, the steering unit is back in the neutral
position and will remain there until the steering wheel is moved again.
The steering unit has a variable steering which is proportional to the speed the steering wheel is rotated.
A variable orifice bypasses oil around the gerotor. Turning the steering wheel slowly takes
approximately seven turn(Variable orifice small) lock to lock versus four turns(variable orifice large)
when turning the steering wheel quickly.
5-17
6. STEERING CYLINDER
1) STRUCTURE
8,9 3 10 5,6 7 11,12 4 24,25,26 2 14,15 16 17 13 19 18
1 23 20 21 22 27,28
1 Tube assy 11 O-ring 21 Pipe assy

2 Rod assy 12 Back up ring 22 O-ring
3 Gland 13 Piston 23 Bolt
4 Bushing 14 O-ring 24 U-bolt
5 Rod seal 15 Back up ring 25 Nut
6 Back up ring 16 Piston seal 26 Spring washer
7 Buffer ring 17 Wear ring 27 Spherical bearing
8 Dust wiper 18 Piston nut 28 Retaining ring
9 Snap ring 19 Screw
10 O-ring 20 Pipe assy
2) OPERATION
This machine use to cross connected cylinder for steering operation.
The steering cylinder use a gland(3) to remove piston and sealed seals. Dust wiper(8) located on
the in side of the gland protects cylinder inner parts from dust. The piston(13) is fastened to the
rod(2) by a piston nut(18).
The piston uses a single wear ring(17) with a piston seal(16) to seal between the piston(13) and
tube(1). The gland seals against the tube with two O-rings(10, 11). The rod(2) is sealed against
the gland(3) with a rod seal(5).
5-18
This procedure is designed so the service man can make a quick check of the steering system using
a minimum amount of diagnostic equipment. If you need additional information, prefer to structure
and function in group 1.
Locate system check in the left column and read completely, following this sequence from left to right.
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 :
şChapter 2 : Troubleshooting
şGroup 3 : Tests and adjustments
5-19
ƓHydraulic oil must be at operating temperature for these checks(Refer to page 6-52).
Steering unit check Run engine at low idle. OK

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

check frames are against stop. Check completed.
Heat hydraulic oil to Left Right
Hold approximately 2kg on steering NOT OK
operating temperature.
wheel. Do steering system leakage
Run engine at high idle.
test in group 3 to isolate
Count steering wheel revolutions for
the leakage.
1 minute.
Repeat test in opposite direction.
LOOK : Steering wheel should
rotate less than 7rpm.
NOTE : Use good judgment;
Excessive steering wheel rpm does
not mean steering will be affected.
5-20
Priority valve(In flow Park machine on a hard surface. OK

amplifier) low pressure Check completed.
Hold brake pedal down.
check NOT OK
Do priority valve pressure
Steer machine to the right and left test in group 3.
as far as possible.
LOOK : Machine must turn at least
half way to the right and left stops.
Priority valve(In flow Steer to steering stop and release OK

amplifier) 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 priority valve
Turn steering wheel to steering stop
pressure test in group 3.
and hold, observe engine rpm.
LOOK : Steering stall engine rpm
must be higher than hydraulic stall
rpm
5-21
2. TROUBLESHOOTING
Ɠ Diagnose malfunction charts are arranged from most probable and simplest to verify, to least likely,
more difficult to verify. Remember the following steps when troubleshooting a problem :
Step 1. Operational check out procedure (See group 3 in section 1.)
Step 2. Operational checks (In this group.)
Step 4. Tests and adjustments (See group 3.)
No steering Low oil level. Add recommended oil.

Failed steering pump. Remove and inspect return filter for metal
pump particles.
Stuck priority valve spool. Remove and inspect priority valve spool.
Broken priority valve spring. Remove and inspect spring.
Relief valve in flow amplifier stuck open. Do relief cartridge leakage test in group 3.
Failed hydraulic lines. Check.
Slow or hard steering Too much friction in the mechanical parts Lubricate bearings and joints of steering
of the machine. column or repair if necessary.
Check steering column installation.
Cold oil. Warm the hydraulic oil.
Worn hydraulic pump. Do hydraulic pump performance check .
Sticking priority valve spool. Remove and inspect.
Broken priority valve spring. Remove and inspect.
Pinched or restricted LS line. Inspect line. Do flow amplifier LS port
flow test in group 3.
Constant steering to Air in system. Check for foamy oil.

maintain straight travel
Leakage in steering system. Do steering system leakage check.
Worn steering unit. Do steering unit neutral leakage test in
group 3.
Leaf spring without spring force or 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.
Slow steering wheel Leakage in steering unit gerotor. Do steering system leakage check.
movement will not cause
any frame movement Worn steering unit gerotor. Do steering leakage check.
5-22
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 splines on Remove and inspect.
no resistance and causes steering unit.
no frame movement
Lack of oil in steering unit. Start engine and check steering operation.
Leakage in steering system. Do steering system leakage test in group
3.
Erratic steering Air in oil. Check for foamy oil.

Low oil level. Add recommended oil.
Sticking priority valve spool. Remove and inspect spool.
Loose cylinder piston. Remove rod to inspect piston.
Damaged steering unit. Remove and inspect.
Spongy or soft steering Air in oil. Check for foamy oil.

Low oil level. Add recommended oil.
Free play at steering Loose steering wheel nut. Tighten.

wheel
Worn or damaged splines on steering Inspect.
column or unit.
Steering unit binding or Binding in steering column or misalignment Inspect.

steering wheel does not of column.
immediately return to
High return pressure. Check for a pinched or damaged return
neutral when released
line.
Contamination in steering unit. Inspect hydraulic filter for contamination.
Repair cause of contamination. Flush
hydraulic system.
Steering unit locks up Large particles of contamination in steering Inspect hydraulic filter for contamination.
unit. Repair cause of contamination. Flush
hydraulic system.
ƕ Thermal shock Do flow amplifier LS port flow test in group
3. This oil flow provides a warm-up flow
to steering unit when not using the
steering.
Worn or damaged steering unit. Repair or replace steering unit.
ƕ Thermal stock is caused by a large temperature differential(Approx. 30Ş C, 50Ş

F) between the steering unit
and hydraulic oil. If the steering is not operated for a long period of time and the orifice in the bottom of
the priority valve spool is plugged, the steering unit may bind up when the steering is operated if the
hydraulic oil is hot enough.
5-23
Abrupt steering wheel Improperly timed gerotor gear in steering Time gerotor gear.
oscillation unit.
Steering wheel turns by Lines connected to wrong port. Reconnect lines.

itself
Worn or damaged steering unit. Repair or replace steering unit.
Vibration in steering High flow amplifier setting. Do flow amplifier pressure test in group 3.
system or hoses jump
Neutral position of Steering column and steering unit out of Align the steering column with steering
steering wheel cannot be line. unit.
obtained, i.e. there is a
Too little or no play between steering Adjust the play and, if necessary, shorten
tendency towards
column and steering unit input shaft. the splines journal.
"motoring"
Pinching between inner and outer spools. Contact the nearest service shop.
"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.
Steering wheel can be Oil is needed in the tank. Fill with clean oil and bleed the system.
turned the whole time
Steering cylinder worn. Replace or repair cylinder.
without the steered
wheels moving Gear wheel set worn. Replace gear wheel set.
Spacer across cardan shaft forgotten. Install spacer.
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.
Jerky steering LS port orifice missing. Inspect orifice.

Orifice in top end of priority valve spool Disassemble and inspect.
missing.
5-24
"Shimmy" effect Air in the steering cylinder. Bleed cylinder.

The steered wheels Find and remove the reason for air
vibrate collection.
(Rough tread on tires gives
Mechanical connections or wheel bearings Replace worn parts.
vibrations)
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 flow amplifier. valves.
both directions without
the steered wheels
turning
Steering is too slow and Insufficient oil supply to steering unit, pump Replace pump or increase number of
heavy when trying to turn defective or number of revolutions too low. revolutions.
quickly
Relief valve setting too low. Adjust valve to correct setting.
Relief valve sticking owing to dirt. Clean the valve.
Spool in flow amplifier sticking owing to Clean the valve, check that spool moves
dirt. easily without spring.
Too weak spring in priority valve. Replace spring by a stronger.
"Kick back" in steering Fault in the system. Contact authorized man or shop.
wheel from system
Kicks from wheels
Heavy kick-back in Wrong setting of cardan shaft and gear- Correct setting as shown in Group 4.
steering wheel in both wheel set.
directions
Turning the steering Hydraulic hoses for the steering cylinders Connect lines to correct ports.
wheel activates the have been switched around.
steered wheels opposite
Hard point when starting Spring force in flow amplifier too weak. Replace spring by a stronger.
to turn the steering wheel
Air in LS and / or PP pipes. Bleed LS and PP pipes.
Clogged orifices in LS or PP side in flow Clean orifices in spool and in connecting
amplifier. plugs for LS and PP.
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 only)
Leakage at either input Shaft defective. Replace shaft seal.

shaft, end cover, gear-
Screws loose. Tighten screws as shown in Group 4.
wheel set, housing or top
part Washers or O-rings defective. Replace washer or O-rings.
5-25
Amplification too large Dirty, leaky or missing check valve(10). Clean or replace check valve.
Clean and check that the piston moves
Piston(9A) sticks in the open position.
easily.
Amplification too small Piston(9A) sticks in the closed position. Clean and check that the piston moves
easily.
Piston(9A) incorrectly installed. Rotate the piston 180Ɓon its axis.
Heavy turning of steering Dirty orifices(34) in directional valve. Clean or replace orifice.
wheel and slow increase
Dirty orifices(35) in amplifier valve. Clean or replace orifice.
of amplification
Dirty orifice(27) in housing. Clean or replace orifice.
Dirty orifice(36) in LS port. Clean or replace orifice.
Dirty orifice in throttle check valve(31) in Clean or replace throttle check valve.
PP port.
Dirty orifice(42) in priority valve. Clean or replace orifice.
No end stop in one or One or both shock valves(21) set too low. Setting takes a long time without special
both directions equipment. Contact the nearest service
shop.
Missing spring seat(23) for directional Fit end stop plates.
valve.
"Hard" point when Air in LS and/or PP pipes. Bleed pipes.

starting to turn the
Spring(30) force in the built in priority valve Check or replace of necessary.
steering wheel
too weak.
Orifices in respectively LS or PP ports Take out and clean orifices.
blocked.
No pressure build-up LS pressure relief valve(19) adjusted too Remove plug(20) and set to specified
low. pressure.
Spool and sleeve in steering unit put Take out spool set and turn the inner spool
together incorrectly. 180Ɓin the outer sleeve.(See Group 4)
Emergency control ball in steering unit Install new ball.
missing.
Pump does not run or is defective. Repair or replace pump.
5-26
1. HYDRAULIC OIL CLEAN UP PROCEDURE USING PORTABLE FILTER CADDY

Ɠ SERVICE EQUIPMENT AND TOOL
şPortable filter caddy
şTwo 3658mm(12ft) ź 1" I.D. 100R1
hoses with 3/4 M NPT ends
şQuick disconnect fittings
şDischarge wand
şVarious size fittings and hoses
Ɠ Brake system uses oil from hydraulic oil
tank. Flush all lines in the brake and
pilot system.
Disassemble and clean major
components for brake and steering
system.
Brake and steering components may fail
if brake, steering system is not cleaned
after hydraulic oil tank contamination.
1) If hydraulic system is contaminated due to a
major component failure, remove and
disassemble steering cylinders to clean
debris from cylinders.
2) Install a new return filter element. Clean
filter housing before installing new element.
Ɠ For a failure that creates a lot of debris,
remove access cover from hydraulic
tank. Drain and clean hydraulic tank of
fill the specified oil to hydraulic tank
through upper cover.
3) To minimize oil loss, pull a vacuum in
hydraulic tank using a vacuum pump.
Connect filter caddy suction line to drain
port at bottom of hydraulic oil tank using
connector. Check to be sure debris has not
closed drain port.
4) Put filter caddy discharge line into hydraulic
oil tank filter hole so end is as far away from
drain port as possible to obtain a through
cleaning of oil.
5-27
5) Start the filter caddy. Check to be sure oil
is flowing through the filters.
Operate filter caddy approximately 10
minutes so oil in hydraulic tank is circulated
through filter a minimum of four times.
Ɠ Hydraulic tank capacity 210ֻ(55.5U.S.
gal).
Leave filter caddy operating for the next
steps.
6) Start the engine and run it at high idle.
Ɠ For the most effective results, cleaning
procedure must start with the smallest
capacity circuit then proceed to the next
largest capacity circuit.
7) Operate all functions, one at a time, through
a complete cycle in the following order:
clam, steering, bucket, and boom. Also
include all auxiliary hydraulic functions.
Repeat procedure until the total system
capacity has circulated through filter caddy
seven times, approximately 30 minutes.
Each function must go through a minimum
of three complete cycles for a through
cleaning for oil.
Ɠ Filtering time for machines with auxiliary
hydraulic functions must be increased
because system capacity is larger.
8) Stop the engine. Remove the filter caddy.
9) Install a new return filter element.
10) Check oil level in hydraulic tank ; Add oil if
necessary.
5-28
2. TEST TOOLS
1) CLAMP-ON ELECTRONIC TACHOMETER
INSTALLATION
ş Service equipment and tools
Tachometer
A : Clamp on tachometer.
Remove paint using emery cloth and B
connect to a straight section of D
injection line within 100mm(4in) of C
pump. Finger tighten only-do not over
tighten.
B : Black clip(-). Connect to main frame. A
C : Red clip(+). Connect to transducer.
D : Tachometer readout. Install cable.
2) DIGITAL THERMOMETER INSTALLATION

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

The display monitor tachometer is accurate
enough for test work.
20 30
10 20
40
10
5 30
0 mph
0 50
km/h
5-29
3. STEERING SYSTEM RESTRICTION TEST
ş SPECIFICATION
Oil temperature 65Ź6Ş C(150Ź10Ş F)
Engine speed High idle
Maximum pressure 2.1MPa(21bar, 300psi)
at flow amplifier
Loader control valve 2.0MPa(20bar, 285psi)
ş GAUGE AND TOOL
Gauge 0~7MPa(0~70bar, 0~1000psi) 2EA
ş This test will check for restrictions in the
steering system which can cause
overheating of hydraulic oil.
1) Install temperature reader.
(See temperature reader installation
procedure in this group) EF
HP
2) Heat hydraulic oil to specifications.(See
hydraulic oil warm up procedure at page 6-
52)
3) Connect fitting.
Do not operate steering or loader
Main pump
functions or test gauge may be
damaged.
4) Run engine at specification and read
pressure gauges.
If pressure is more than specification at the
flow amplifier, inspect flow amplifier for a
priority valve spool. Make sure orifice
plugs are installed in ends of priority valve
spool.
Check for plugged orifice in flow amplifier
LS port.
5-30
4. STEERING UNIT LEAKAGE TEST
SPECIFICATION
Oil temperature 40Ź6Ş C(100Ź10Ş
F)
Maximum leakage 7.5ֻ/min(2gpm)
GAUGE AND TOOL
Temperature reader
Measuring container(Approx. 20ֻ)
Stop watch
1) Install frame locking bar to prevent machine
from turning.
procedure in this group)
hydraulic oil warm up procedure at page
6-52)
4) Disconnect return hose from fitting.
Install cap fitting.
5) Run engine at specifications. Rotate
steering wheel against locking bar using
approximately 1.2kgşm of force.
Measure oil flow from return hose for 1
minute.
Frame locking bar
6) Leakage is greater than specifications,
repair or replace steering unit.
5-31
5. FLOW AMPLIFIER PRESSURE TEST
ş SPECIFICATION
Oil temperature 65Ź6Ş C(150Ź10ŞF)
Oil pressure 20.1~21.1MPa
(205~215bar, 2900~3100psi)
ş GAUGE AND TOOL
Gauge 0~35MPa(0~350bar, 0~5000psi)
Relief valve
Temperature reader
1) Connect gauge to test port.
2) Install temperature reader.(See installation
3) Install frame locking bar.
6-52)
5) Run engine at specifications and turn
steering wheel rapidly hold approximately
22N(5lb force) pressure on wheel with
frames locked.
Ɠ If steering wheel is turned slowly, it will
continue to with the frames locked.
This will give an incorrect pressure
reading.
If steering wheel continues to turn
rapidly with the frames locked, steering
system leakage is indicated.
6) Read pressure gauge. This is the flow
amplifier relief pressure.
7) If pressure in not to specification, remove
plug and turn adjusting screw in relief valve
using a hex head wrench to adjust
pressure. Frame locking bar
If pressure cannot be adjusted to
specification, disassemble and inspect flow
amplifier.
5-32
6. FLOW AMPLIFIER LS PORT FLOW TEST
ş SPECIFICATION
Engine speed Low idle
LS port flow(Approx.) 1ֻ/min(0.3 gpm) EF
LS
B
HP
ş GAUGE AND TOOL
Temperature reader
Measuring container PP
Stop watch A
Flow amplifier LS port flow test will check for

a plugged or missing orifice in the bottom of
the priority valve spool. A plugged orifice
will block warm up flow to the steering unit
which can cause thermal shock.(See for an
explanation of thermal shock)
A missing orifice can cause the pump to be
loaded to high pressure at all times causing
overheating.
6-52)
3) Disconnect line from LS port and install
plug(A).
4) Connect line(B) to flow amplifier.
5) Start engine and run at specification.
6) Measure flow from LS port for 1 minute.
If flow is low, low steering system neutral
pressure or a plugged orifice in bottom
priority valve spool is indicated.
If flow is high, remove priority valve spool
and inspect for a missing orifice.
Do hydraulic system restriction test in this
group.
5-33
7. FLOW AMPLIFIER RELIEF CARTRIDGE
LEAKAGE TEST
ş SPECIFICATION
Engine speed High idle A
Maximum leakage 1ֹ/min(16 drops per min)
ş GAUGE AND TOOL
Temperature reader
T
Measuring container
Stop watch B

6-52)
C
3) Install plug(A) in HT port.
4) Disconnect line from T port on flow
amplifier. Install plug(B) in line.
5) Connect line(C) to flow amplifier.
6) Start engine and run at specification.
7) Measure oil leakage from T port.
8) If leakage is more than specification,
disassemble and inspect cartridge for
damage or debris.
5-34
1. STEERING PUMP
1) STRUCTURE
70
56
57
85 80
55
2
95
90
32
31 30
21
20
35
36
37 90
60

20 Drive gear 37 Back up seal 85 Location sleeve
21 Drive gear 55 Shaft seal 90 Bearing
30 Wear plate 56 Shaft seal 95 Seal
5-35
(1) Cleanliness
such as flanges and covers are best cleaned in soap and hot water, then air dried. Gears should
be washed in solvent, air dried, and oiled immediately.
Torque
Item
kgfşm lbfşft
Screw(70) 16.5 119
Screw(80) 78.2 569
5-36
3) DISASSEMBLY
Clean the pump thoroughly with a solvent,
lint-free cloths.
(1) Remove the cap screw(70).
Remove the mounting flange(1). Under
no circumstances attempt to prise
mounting flange from cover as such
action could damage the machine
interface. If necessary use of a soft faced
mallet to remove mounting flange is
recommended.
(2) Remove the cap screws(80) securing the

cover(2) to body(3).
(3) Refit the mounting flange(1) to cover(2)

with two cap screws(70) and detach the
cover(2) complete with the mounting
flange from the body(3) using a pulling
tool centered on the drive shaft.
or chisel cover from body as such action
could damage the machined sealing
faces.
5-37
Remove the shaft seal(55) from cover(2)
making sure that no damage is sustained
to the surface of the seal bore in the cover.

body(3) mark it using a soft pencil or a felt-
tip pen to ensure correct reassembly.
wear plate seal and back up seal.

prevent jamming.
plate(35) from body(3) complete with wear
plate seal and back up seal.
5-38
cardboard boxes.
Feature Damage
Surfaces
Bearing Loose
(2) Gears
Feature Damage
Wear due to seal(s)
5-39
Feature Damage
Surfaces

(4) Bolts/Studs
Feature Damage

(5) Plain bearings

Feature Damage

PTEF Coating Worn
(6) Coupling
Feature Damage

5-40
(1) The seal side of the wear plate must be adjacent to the cover(2) or body(3).
drawing.
5-41
8) ASSEMBLY
(2) Place body(3) vertically with front section

gear pockets upper most.

and back up seal down through the
housing to the bottom of the gear pockets.
position.
Fit the wear plate(30) complete with seal
and back up seal.
(3) Fit new O-ring(60) into groove in body(3).

Fit front cover(2) over the drive gear and
secure with cap screws(70).
Tighten cap screws(80) to half torque and
then full torque in diagonal sequence to
figure as per assembly drawing.
5-42
(4) Fit shaft seal(55) using appropriate tooling
as per assembly drawing, in correct
position and direction.
Ɠ Molybdenum disulphide grease should be
sparingly applied to the lip of the shaft
seal.
(5) Apply a small ring of loctite low strength

gasket eliminator to the interface of
mounting flange(1) and fit to front
cover(2), ensure that location sleeve(85) is
in place and correctly positioned.
(6) Secure mounting flange(1) with cap

screws(70) and tighten to half torque and
then full torque in a diagonal sequence to
5-43
2. FLOW AMPLIFIER
1) STRUCTURE
20
5
19
38
4
6
9
A
36
21
7 26
2
25 21
16
14 7 23
13 3 29
27 31 28
24
34
1 41 15
9C 11
35 2 12
12 9A
11 24
28
9A 29
34 22
8 23
13
14
30
10 1
40 9B
42
A 37

2 O-ring 13 Screw 29 Spring
4 O-ring 15 End cover 31 Throttle check valve
5 Washer 16 End cover 34 Orifice
6 Washer 19 Relief valve 35 Orifice
7 O-ring 20 Plug 36 Orifice
8 O-ring 21 Shock, suction valve 37 Plug
9 Housing 22 Spring seat 38 Plug
9A Amplifier valve 23 Spring seat 40 Spring
9B Priority valve 24 Spring seat 41 Spring
9C Directional valve 25 Drive screw 42 Orifice
10 Check valve 26 Name plate
11 Screw 27 Orifice
5-44
2) TOOLS
ş Guide screws : M8ź1.0
ş Hook : Wire
ş Hexagon keys : 4, 5, 6, 8 and 10mm

ş Ratchet for socket spanners
ş Hex socket for external : 13, 17 & 19mm
ş Hex socket for internal : 8 % 10mm
ş Multigrip pliers
ş Ring spanner : 13mm
ş Screwdrivers : 3 and 10mm
ş Steel Mandrels : 3, 5 and 8mm
ş Torque wrench : 12.2kgfşm(88lbfşft)
ş Magnetic rod
5-45
3) DISASSEMBLY
(1) Removing pressure relief valve
‫ ڸ‬Unscrew plug with washer (Hexagon
socket for 8mm internal hexagon).
‫ ڹ‬Screw pressure relief valve out(10mm

hexagon key).
‫ ں‬Take out washer(Magnetic rod).
(2) Disassembly pressure relief valve

‫ ڸ‬Hold cartridge(Multigrip pliers) and screw
the adjustment screw out(5mm hexagon
key).
5-46
‫ ڹ‬Pressure relief valve shown disassembled.
(3) Removing end cover at PP-connection

‫ ڸ‬Unscrew screws with spring washer
using hexagon socket for 13mm external
hexagon and 10mm internal hexagon.
‫ ڹ‬Remove end cover.
‫ ں‬Remove stop and 2 springs.
5-47
‫ ڻ‬Remove spring.
‫ ڼ‬Remove plate and 6 O-rings.
‫ ڽ‬Remove spring guide.
(4) Removing end cover at LS-connection

‫ ڸ‬Unscrew screws with spring washer
using hexagon socket for 13mm external
hexagon and 10mm internal hexagon.
5-48
‫ ڹ‬Remove end cover.
‫ ں‬Remove stop and 2 springs.
‫ ڻ‬Remove stop and spring.
‫ ڼ‬Remove plate and 4 O-rings.
5-49
‫ ڽ‬Remove spring guide.
(5) Removing spools

‫ ڸ‬Remove directional spool.
‫ ڹ‬Remove amplifier spool.
‫ ں‬Remove priority valve spool.
5-50
(6) Removing orifices and throttle check
valve
‫ ڸ‬Unscrew orifice in LS-connection with
6mm hexagon key.
‫ ڹ‬Unscrew throttle check valve in PP-

connection with 6mm hexagon key.
‫ ں‬Unscrew orifice in housing with 4 mm

hexagon key.
(7) Removing shock valves

‫ ڸ‬Remove shock valve with screwdriver
and hexagon key.
5-51
(8) Overview of disassembled parts
‫ ڸ‬Housing and end cover with accessories.
‫ ڹ‬Spool with accessories.
(9) Disassembly of directional spool

‫ ڸ‬Unscrew orifice with 4mm hexagon key.
Use a mandrel.
‫ ڹ‬Directional spool shown disassembled.
5-52
(10) Disassembly of priority valve spool
‫ ڸ‬Unscrew plug or throttle check valve with
8mm hexagon key.
‫ ڹ‬Priority valve spool with plug for external

PP shown disassembled.
‫ ں‬Priority valve spool with throttle check

valve for internal PP shown disassembled.
(11) Disassembly of amplifier spool

‫ ڸ‬Carefully remove the spring ring from the
recess with 3mm screwdriver.
Ɠ Avoid damage to the spring ring.
5-53
‫ ڹ‬Carefully guide the spring ring back.
‫ ں‬Carefully take the spring ring from the

recess and guide it back with 3mm
screwdriver.
Ɠ Avoid damage to the spring ring.
‫ ڻ‬Press pin out gently with finger.
‫ ڼ‬Take out plug.
5-54
‫ ڽ‬Take out spring.
‫ ھ‬Take out pin 3mm screwdriver.
‫ ڿ‬Take out inner spool.
‫ ۀ‬Unscrew check valve with hexagon

socket for 17mm external hexagon and
mandrel in the pin hole.
Ɠ Avoid damaging the spool surface.
5-55
‫ ہ‬Unscrew orifice out of plug with 4mm
hexagon key. Use a mandrel.
‫ ۂ‬Amplifier spool shown disassembled.
(12) Disassembly of check valve

‫ ڸ‬Unscrew plug with 4mm hexagon key and
hexagon socket for 17mm external
hexagon.
‫ ڹ‬Check valve shown disassembled.
5-56
(13) Disassembly of shock valve / suction
valve
‫ ڸ‬Unscrew locknut with hexagon socket for
13mm external hexagon. Use a mandrel.
Ɠ When readjusting shock valve hold
locknut with 13mm ring spanner.
‫ ڹ‬Take out disc and spring.
‫ ں‬Take off housing.
‫ ڻ‬Unscrew pilot valve with hexagon socket

for 19mm external hexagon. Use a
mandrel.
5-57
‫ ڼ‬Take out pilot valve and spring.
‫ ڽ‬Take out spool.
‫ ھ‬Unscrew adjustment screw and take out

spring and ball.
‫ ڿ‬Shock valve/suction valve shown

disassembled.
5-58
Ɠ Cleaning
Clean all parts carefully with low aromatic
kerosene.
Ɠ Inspection and replacement
Replace all gaskets and sealing washers.
Check all other parts carefully and
replace if necessary.
Ɠ Lubrication
Before assembly, lubricate all parts with
hydraulic oil.
5-59
4) ASSEMBLY
(1) Assembly of shock valve / suction
valve
‫ ڸ‬Guide spring with cone into housing.
‫ ڹ‬Fit adjustment screw.
‫ ں‬Fit spool.
‫ ڻ‬Fit spring.
5-60
‫ ڼ‬Fit pilot valve.
Remember O-ring.
‫ ڽ‬Tighten with torque wrench for 19mm

external hexagon. Use a mandrel.
şTightening torque : 2 Ź 0.5kgfşm
(14.5 Ź 3.6lbfşft)
‫ ھ‬Fit housing.
‫ ڿ‬Fit spring.
5-61
‫ ۀ‬Fit disc.
‫ ہ‬Fit locknut.
şTightening torque : 1.5 Ź 0.2kgfşm
(10.8 Ź 1.4lbfşft)
(2) Assembly of check valve

‫ ڸ‬Fit ball, spring and plug.
(3.6 Ź 0.7lbfşft)
(3) Assembly of amplifier spool

‫ ڸ‬Fit orifice in plug.
(3.6 Ź 0.7lbfşft)
5-62
‫ ڹ‬Fit check valve.
(14.5 Ź 2.2lbfşft)
Ɠ Avoid damaging spool surface.
Remember O-ring.
‫ ں‬Place inner spool in the correct position.
‫ ڻ‬Guide inner spool in.
‫ ڼ‬Fit pin.
5-63
‫ ڽ‬Push spring ring into position. Place
spring ring into the recess with ends
facing away from pin holes.
‫ ھ‬Fit spring.
‫ ڿ‬Fit plug.
‫ ۀ‬Fit pin.
5-64
‫ ہ‬Push spring ring into position. Place
spring ring into the recess with ends
facing away from pin holes.
(4) Assembly of priority valve spool

‫ ڸ‬Fit plug or throttle check valve.
External PP : Plug.
Internal PP : Throttle check valve.
(7.2 Ź 2.2lbfşft)
(5) Assembly of directional spool

‫ ڸ‬Screw in orifice.
(3.6 Ź 0.7lbfşft)
(6) Installation of orifice and throttle check

valve
‫ ڸ‬Fit orifice in housing.
(3.6 Ź 0.7lbfşft)
5-65
‫ ڹ‬Fit orifice in LS - connection.
(7.2 Ź 2.2lbfşft)
‫ ں‬Fit throttle check valve in PP -

connection.
(7.2 Ź 2.2lbfşft)
Ɠ Comments on flow amplifiers with internal PP :

1. 1/4 BSP. F in PP - connection.
Fit washer and plug.
(29.7 Ź 2.2lbfşft)
2. 7/16 - 20 UNF in PP - connection.
Fit O-ring and plug.
(10.8 Ź 3.6lbfşft)
(7) Installation of shock valves

‫ ڸ‬Guide shock valve in and secure it by
hand.
Remember O-ring.
5-66
(8) Assembly of pressure relief valve
‫ ڸ‬Guide adjustment screw, spring and cone
up into the cartridge.
‫ ڹ‬Screw the adjustment screw so far in that

the 10mm hexagon key fully engages.
(9) Installation of pressure relief valve

‫ ڸ‬Let the washer drop into the hole.
‫ ڹ‬Fit pressure relief valve.

(22.4 Ź 2.2lbfşft)
5-67
‫ ں‬Fit plug with washer.
(44.1 Ź 3.6lbfşft)
(10)Installation of spools
‫ ڸ‬Fit directional spool.
Fit priority valve spool.
Ɠ Spring control must be placed in correct
position against LS - connection.
‫ ڹ‬Fit spring.
Ɠ Spring must be by the LS - connection.
‫ ں‬Fit amplifier spool.

Ɠ The orifice must be placed in correct
position against LS - connection.
5-68
(11) Installation of end cover at PP -
connection
‫ ڸ‬Fit spring with vaseline on amplifier spool.
Ɠ The spring must be fitted at the PP -
connection.
‫ ڹ‬Fit spring guide with vaseline.
‫ ں‬Fit large and small springs with vaseline.
‫ ڻ‬Fit guide screws.
5-69
‫ ڼ‬Fit 4 large and 2 small O-rings.
‫ ڽ‬Guide plate in.
‫ ھ‬Fit stop(Thickness : 5mm) in end cover

with vaseline.
‫ ڿ‬Guide end cover in.
5-70
‫ ۀ‬Fit screw with spring washer.
‫ ہ‬Fit screws with spring washer.

(18.8 Ź 3.6lbfşft)
şTightening torque : 8.2 Ź 1kgfşm
for large screw (59.3 Ź 7.2lbfşft)
(12) Installation of end cover at LS -

connection
‫ ڸ‬Fit guide screws.
Fit remote control with vaseline.
‫ ڹ‬Fit large and small springs with vaseline.
5-71
‫ ں‬Guide in plate with 4 O-rings.
‫ ڻ‬Fit stop for priority valve spool (Thickness

: 8mm) with vaseline.
‫ ڼ‬Fit stop for directional spool (Thickness :

5mm) with vaseline.
‫ ڽ‬Guide in end cover.
5-72
‫ ھ‬Fit large screw with spring washer.
‫ ڿ‬Fit screws with spring washers.

(18.8 Ź 3.6lbfşft)
şTightening torque : 8.2 Ź 1kgfşm
for large screw (59.3 Ź 7.2lbfşft)
‫ ۀ‬Fit plastic plugs.
This completes assembly.
5-73
3. STEERING UNIT
1) STRUCTURE
1
2
5
7
32
3
4 8
2
11 12
13
14
15
16
18
15 21
16
17
18
20
1 Dust seal ring 9 Cross pin 17 End cover

2 Housing, Spool, sleeve 11 Shaft 18 Washer
3 Ball 12 Spring set 20 Pin screw
4 Bushing 13 O-ring 21 Screw
5 O-ring/Roto glyd ring 14 Distributor plate 32 Check valve
7 Bearing assy 15 Gearwheel set
8 Ring 16 O-ring
5 - 74
2) TOOLS
(1) Holding tool.
(2) Assembly tool for O-ring and kin-ring.
(3) Assembly tool for lip seal.
(4) Assembly tool for cardan shaft.
5 - 75
(5) Assembly tool for dust seal.
(6) Torque wrench 0~7.1kgfşm

(0~54.4lbfşft)
13mm socket spanner
6, 8mm and 12mm hexagon sockets
12mm screwdriver
2mm screwdriver
13mm ring spanner
6, 8 and 12mm hexagon socket spanners
Plastic hammer
Tweezers
5 - 76
3) TIGHTENING TORQUE AND HYDRAULIC CONNECTIONS
(1) Hydraulic connections
L: Left port
R: Right port
T: Tank
TLPR P: Pump

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

3/8 BSP.F 6.1(44.1) 2.0(14.5) 5.1(36.9) -
1/2 BSP.F 10.2(73.8) 3.1(22.4) 8.2(59.3) -
7/16-20 UNF - - - 2.0(14.5)
3/4-16 UNF - - - 6.1(44.1)
M 12ź1.5 4.1(29.7) 2.0(14.5) 3.1(22.4) 2.0(14.5)
M 18ź1.5 7.1(51.4) 2.0(14.5) 5.1(36.9) 5.1(36.9)
M 22ź1.5 10.2(73.8) 3.1(22.4) 8.2(59.3) 7.1(51.4)
5 - 77
4) DISASSEMBLY
(1) Disassemble steering column from
steering unit and place the steering unit in
the holding tool.
Screw out the screws in the end cover(6-
off plus one special screw).
(2) Remove the end cover, sideways.
(3) Lift the gearwheel set (With spacer if

fitted) off the unit.
Take out the two O-rings.
(4) Remove cardan shaft.
5 - 78
(5) Remove distributor plate.
(6) Screw out the threaded bush over the

check valve.
(7) Remove O-ring.
(8) Take care to keep the cross pin in the

sleeve and spool horizontal. The pin can
be seen through the open end of the
spool. Press the spool inwards and the
sleeve, ring, bearing races and needle
bearing will be pushed out of the housing
together.
5 - 79
(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.
(10) Press out the cross pin. Use the special

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

pumice stone on both spool and sleeve
close to one of the slots for the neutral
position springs (See drawing).
If the mark is not visible, remember to
leave a mark of your own on sleeve and
spool before the neutral position springs
are disassembled.
(11) Carefully press the spool out of the sleeve.
5 - 80
(12) Press the neutral position springs out of
their slots in the spool.
(13) Remove dust seal and O-ring.
(14) The steering unit is now completely

disassembled.
Ɠ Cleaning
Clean all parts carefully in Shellsol K or
the like.
Ɠ Inspection and replacement
Replace all seals and washers. Check all
parts carefully and make any
replacements necessary.
Ɠ Lubrication
Before assembly, lubricate all parts with
hydraulic oil.
5 - 81
5) ASSEMBLY
(1) Assemble spool and sleeve.
Ɠ When assembling spool and sleeve only
one of two possible ways of positioning
the spring slots is correct. There are
three slots in the spool and three holes in
the sleeve in the end of the spool / sleeve
opposite to the end with spring slots.
Place the slots and holes opposite each
other so that parts of the holes in the
sleeve are visible through the slots in the
spool.
(2) Place the two flat neutral position springs

in the slot.
Place the curved springs between the flat
ones and press them into place (See
assembly pattern).
Ɠ Assembly pattern
ş Weak springs (Blue)
2 - off flat, blue : Part no. 150-0748
2 - off curved, blue : Part no. 150-0749
ş Blue set
Spare set : Part no. 150-4265
(3) Line up the spring set.
5 - 82
(4) Guide the spool into the sleeve. Make
sure that spool and sleeve are placed
correctly in relation to each other (See
page 3-76, No.(1)).
(5) Press the springs together and push the

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

Ɠ The ring should be able to rotate free of
the springs.
5 - 83
(8) Fit the cross pin into the spool / sleeve.
(9) Fit bearing races and needle bearing as

shown on below drawing.
Ɠ Assembly pattern for standard bearings

1
1 Outer bearing race 2
2 Needle bearing 3
3 Inner bearing race
4 Spool
5 Sleeve 4
Installation instruction for O-ring

(10) Turn the steering unit until the bore is
horizontal. Guide the outer part of the
assembly tool into the bore for the spool /
sleeve.
5 - 84
(11) Grease O-ring with hydraulic oil and place
them on the tool.
(12) Hold the outer part of the assembly tool in

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

the housing.
5 - 85
(14) Draw the inner and outer parts of the
assembly tool out of the steering unit bore,
leaving the guide from the inner part in the
bore.
Installation instructions for lip seal

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

bottom.
5 - 86
(17) Press and turn the lip seal into place in the
housing.
(18) With a light turning movement, guide the

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

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

vertical again. Put the check valve ball
into the hole indicated by the arrow.
5 - 87
(21) Screw the threaded bush lightly into the
check valve bore. The top of the bush
must lie just below the surface of the
housing.
(22) Grease the O-ring with mineral oil approx.

viscosity 500 cSt at 20Ɓ
C.
(23) Place the distributor plate so that the

channel holes match the holes in the
housing.
(24) Guide the cardan shaft down into the bore

so that the slot is parallel with the
connection flange.
5 - 88
(25) Place the cardan shaft as shown - so that
it is held in position by the mounting fork.
(26) Grease the two O-rings with mineral oil

approx. viscosity 500 cSt at 20Ɓ C and
place them in the two grooves in the gear
rim. Fit the gearwheel and rim on the
cardan shaft.
(27) 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.
(28) Fit the spacer, if any.
5 - 89
(29) Place the end cover in position.
(30) Fit the special screw with washer and

place it in the hole shown.
(31) Fit the six screws with washers and insert

them. Cross-tighten all the screws and
the rolled pin.
(22.4 Ź 4.3lbfşft)
(32) Place the dust seal ring in the housing.
5 - 90
(33) Fit the dust seal ring in the housing.
(34) Press the plastic plugs into the connection

ports.
Ɠ Do not use a hammer!
5 - 91
5. STEERING CYLINDER
1) STRUCTURE
8,9 3 10 5,6 7 11,12 4 24,25,26 2 14,15 16 17 13 19 18
1 23 20 21 22 27,28
1 Tube assy 11 O-ring 21 Pipe assy

2 Rod assy 12 Back up ring 22 O-ring
3 Gland 13 Piston 23 Bolt
4 Bushing 14 O-ring 24 U-bolt
5 Rod seal 15 Back up ring 25 Nut
6 Back up ring 16 Piston seal 26 Spring washer
7 Buffer ring 17 Wear ring 27 Spherical bearing
8 Dust wiper 18 Piston nut 28 Retaining ring
9 Snap ring 19 Screw
10 O-ring 20 Pipe assy
5-92
2) TOOLS AND TIGHTENING TORQUE
(1) Tools
Tool name B Remark
L-wrench 5 B
17
Spanner
70
Wrench For gland

(-) Driver Small and large sizes
Torque wrench Capable of tightening with the specified torques

Torque
Part name Item Size
kgfşm lbfşft
Gland 3 M115ź3 60Ź10 434Ź72
Piston 13 M 45ź2 75Ź8 542Ź58
Piston nut 18 M 45ź2 100Ź10 723Ź72
Set screw 19 M 10ź1.5 5.4Ź0.5 39Ź3.6
Bolt 23 M 10ź1.5 5.4Ź0.5 39Ź3.6
Nut 25 M 10ź1.5 3.2ź0.3 23Ź2.2
5-93
3) DISASSEMBLY
(1) Remove cylinder head and piston rod
‫ ڸ‬Hold the clevis section of the tube in a
vise.
Ɠ Use mouth pieces so as not to damage
the machined surface of the cylinder
tube. Do not make use of the outside
piping as a locking means.
‫ ڹ‬Pull out piston rod(2) about 200mm

(7.8in). Because the piston rod is rather
heavy, finish extending it with air m
0m
20
pressure after the oil draining operation.
‫ ں‬Loosen and remove the gland(3).

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

assembly together from cylinder tube(1).
Ɠ Since the piston rod assembly is heavy Lift
in this case, lift the tip of the piston rod(2)
with a crane or some means and draw it
out. However, when piston rod(2) has
been drawn out to approximately two
thirds of its length, lift it in its center to Pull straight Oil pan
draw it completely. sideways
5-94
Note that the plated surface of piston
rod(2) is to be lifted. For this reason, do
not use a wire sling and others that may
damage it, but use a strong cloth belt or
a rope.
‫ ڼ‬Place the removed piston rod assembly

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

‫ ڸ‬Remove the set screw(19). 15 14 16 17 13 19 18
‫ ڹ‬Remove the piston nut(18).
‫ ں‬Remove piston assembly(13), back up
ring(15) and O-ring(14).
‫ ں‬Remove the gland(3) assembly from Lift with a crane

piston rod(2).
Ɠ If it is too heavy to move, move it by Plastic
hammer 8,9 5,6 7 4
striking the flanged part of gland(3) with
a plastic hammer. Pull straight
Ɠ Pull it straight with gland assembly lifted
with a crane.
Exercise care so as not to damage the lip
of rod bushing(4) and packing(5,6,7,8,9)
3 2
by the threads of piston rod(2).
5-95
(3) Disassemble the piston assembly
‫ ڸ‬Remove wear ring(17). 16 17
Remove and piston seal(16).

Ɠ Exercise care in this operation not to
damage the grooves.
(4) Disassemble gland assembly

9,8 10 7 12,11 4
‫ ڸ‬Remove back up ring(12), and O-ring
(11).
‫ ڹ‬Remove O-ring (10).
‫ ں‬Remove snap ring(9) and dust wiper(8).
‫ ڻ‬Remove back up ring(6), rod seal(5) and
buffer ring(7).
damage the grooves.
Ɠ Do not remove seal and ring, if does not
damaged.
5-96
4) ASSEMBLY
(1) Assemble gland assembly
Ɠ Check for scratches or rough surfaces if
found smooth with an oil stone.
‫ ڸ‬Coat the inner face of gland(3) with
hydraulic oil.
3
‫ ڹ‬Coat dust wiper(8) with grease and fit Press here

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

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

Therefore, confirm it before fitting them. Push bar
Ɠ Fitting rod seal(5) up side down may
damage its lip. Therefore check the
correct direction that is shown in fig.
6
5-97
‫ ڼ‬Fit back up ring(12) to gland (3).
Ɠ Put the backup ring in the warm water of
4
30~50Ɓ C.
11
‫ ڽ‬Fit O-ring(11) to gland(3).
12
3
10
(2) Assemble piston assembly

Ɠ Check for scratches or rough surfaces.
‫ ڸ‬If found smooth with an oil stone. 13
Coat the outer face of piston(13) with
hydraulic oil.
‫ ڹ‬Fit piston seal(16) to piston

Ɠ Put the piston seal in the warm water of
16
60~100Ɓ C for more than 5 minutes.
Ɠ After assembling the piston seal, press
its outer diameter to fit in.
‫ ں‬Fit wear ring(17) to piston(13).

‫ ڻ‬Fit back up ring(15) and O-ring(14) to 15 14 17 13
piston(13).
5-98
(3) Install piston and gland assembly
‫ ڸ‬Fix the piston rod assembly to the work Gland assembly
bench. Piston rod
‫ ڹ‬Apply hydraulic oil to the outer surface of
piston rod(2), the inner surface of piston
and gland.
‫ ں‬Insert gland assembly to piston rod(2).
‫ ڻ‬Fit piston assembly to piston rod.

Piston assembly
Piston rod
‫ ڼ‬Tighten piston nut(18) to piston rod(2).

şTightening torque : 100Ź10kgfşm 2 19 18
(723Ź72lbfşft)
Tighten set screw(19) to piston nut(18).
şTightening torque : 5.4Ź0.5kgfşm
(39Ź3.6lbfşft)
5-99
(4) Overall assemble
‫ ڸ‬Place a V-block on a rigid work bench. Fix with bar
Mount the cylinder tube assembly on it Lift
and fix the assembly by passing a bar
through the clevis pin hole to lock the
assembly.
‫ ڹ‬Insert the piston rod assembly in to the Straight
cylinder tube assembly, while lifting and
moving the piston rod assembly with a Apply liquid packing
crane.
Ɠ Be careful not to damage piston seal by
thread of cylinder tube.
‫ ں‬Match the bolts holes in the cylinder
head flange to the tapped holes in the Tube
cylinder tube assembly and tighten
socket bolts to a specified torque. Piston rod
Ɠ Refer to the table of tightening torque.
Wrench
Gland
5-100
SECTION 6 WORK EQUIPMENT
1. HYDRAULIC SYSTEM OUTLINE

The loader hydraulic system is a pilot operated, open center system which is supplied with flow from
the fixed displacement main hydraulic pump.
The pilot control system is a low pressure, closed center hydraulic system which is supplied with flow
from main pump.
The loader system components are :
şMain pump
şMain control valve
şBucket cylinder
şBoom cylinders
şPilot supply unit
şRemote control valve(Pilot control valve)
şSafety valve
The pilot supply unit consists of the pressure reducing valve, relief valve and accumulator.
Flow from the steering pump not used by the steering system leaves the flow amplifier EF port.
It flows to the inlet port plate of a mono block type main control valve.
The main control valve is a tandem version spool type, open center valve which routes flow to the
boom, bucket or auxiliary cylinders(Not shown) when the respective spools are shifted.
Flow from the steering pump is routed to the pilot supply unit where the steering pump outlet pressure
is reduced to pilot circuit pressure. The pilot supply unit flow to the remote control valve.
The remote control valve routed flow to either end of each spool valve section in the main control
valve to control spool stroke.
A accumulator mounted on pilot supply unit supplies a secondary pressure source to operated
remote control valve so the boom can be lowered if the engine is off.
The return circuit for the main hydraulic system have return filter inside the hydraulic tank. The return
filter uses a filter element and a bypass valve. The bypass valve is located in the upside of filter.
6-1
FRONT REAR 9 10 11
LH RH LH RH
19
20 17
6 CL CR 4
8 2.4 2.1 2.5 2.2 T P
B.D/F B.U IN OUT
5.1 1.1 5.2 1.2

L R
A B
5 1 3 4 2
16 P
3 T
15 15 P T
a3
B3
15 EF T
A3 Floating Ride
14
T b3
PP P
21 22 23 21MPa
7 HP LS HT
B2
25MPa
15 A2 F2
L R
Boom down Boom up
b2 13
27 a2
28
B1
23MPa
23MPa
12 P1
F1
18 A1 Dump Roll back
1 a1 b1
3MPa
U
P 21Mpa
5
5 P2 T
P T LS
21
2 1
23
24
25
26 27 22
1 Steering pump 10 Bucket cylinder 19 Pressure switch

2 Main pump 11 Boom cylinder 20 Pressure switch
3 Main control valve 12 Pilot supply unit 21 Line filter
4 Remote control valve 13 Line filter 22 Oil cooler
5 Steering unit 14 Safety valve 23 Check valve
6 Flow amplifier 15 Accumulator 24 Air breather
7 Cut off valve 16 Solenoid valve 25 Hydraulic tank
8 Brake valve 17 Pressure switch 26 Return filter
9 Steering cylinder 18 Pressure switch 27 Bypass valve
6-2
3. WORK EQUIPMENT HYDRAULIC CIRCUIT
10 11
4 T P
LH RH
B.D/F B.U IN OUT
5 1 3 4 2
3 T
a3
B3
T
A3 14
Floating Ride
b3
P
B2
25MPa
A2
Boom down Boom up
a2 b2 F2
13
B1
23MPa
23MPa
A1 F1
Dump Roll back
a1 b1
P1 12
3MPa
P 21MPa
Flow amplifier EF port U
P2 T
Steering system
Brake system
2 1
Return line
24
23
25
26 27 22
1 Steering pump 11 Boom cylinder 23 Check valve

2 Main pump 12 Pilot supply unit 24 Air breather
3 Main control valve 13 Line filter 25 Hydraulic tank
4 Remote control valve 14 Safety valve 26 Return filter
10 Bucket cylinder 22 Oil cooler 27 Check valve
6-3
1) WHEN THE RCV LEVER IS IN THE RAISE POSITION
10 11
4 T P
LH RH
B.D/F B.U IN OUT
5 1 3 4 2
3 T
a3
B3
T
A3 14
Floating Ride
b3
P
B2
25MPa
A2
Boom down Boom up
a2 b2 F2
13
B1
23MPa
23MPa
A1 F1
Dump Roll back
a1 b1
P1 12
3MPa
P 21MPa
P2 T
Steering system
Brake system
2 1
Return line
24
23
25
26 27 22
ş When the RCV lever(4) is pulled back, the boom spool on the second block is moved to raise
position by pilot oil pressure from port 3 of RCV.
ş The oil from main pump(2) flows into main control valve(3) and then goes to the large chamber of
boom cylinder (11) by pushing the load check valve of the boom spool through center bypass circuit
of the bucket spool.
ş The oil from the small chamber of boom cylinder(11) returns to hydraulic oil tank(25) through the
boom spool at the same time.
ş When this happens, the boom goes up.
6-4
2) WHEN THE RCV LEVER IS IN THE LOWER POSITION
10 11
4 T P
LH RH
B.D/F B.U IN OUT
5 1 3 4 2
3 T
a3
B3
T
A3 14
Floating Ride
b3
P
B2
25MPa
A2
Boom down Boom up
a2 b2 F2
13
B1
23MPa
23MPa
A1 F1
Dump Roll back
a1 b1
P1 12
3MPa
P 21MPa
P2 T
Steering system
Brake system
2 1
Return line
24
23
25
26 27 22
ş When the RCV lever(4) is pushed forward, the boom spool on the second block is moved to lower
position by pilot pressure from port 5 of RCV.
ş The oil from main pump(2) flows into main control valve and then goes to small chamber of boom
cylinder(11) by pushing the load check valve of the boom spool through center bypass circuit of the
bucket spool.
ş The oil returned from large chamber of boom cylinder(11) returns to hydraulic tank(25) through the
boom spool at the same time.
ş 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 boom float spool on the third block, 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
10 11
5th control valve

4 T P
LH RH
B.D/F B.U IN OUT
5 1 3 4 2
3 T
a3
B3
T
A3 14
Floating Ride
b3
P
B2
25MPa
A2
a2 Boom down Boom up
b2 F2
13
B1
23MPa
23MPa
A1 F1
Dump Roll back
a1 b1
P1 12
3MPa
P 21MPa
P2 T
Steering system
Brake system
2 1
Return line
24
23
25
26 27 22
ş When the RCV lever(4) is pushed further forward from the lower position, the boom down pilot
port(5) is connected with tank port(T) by shift of 5th control valve. Thus, the boom spool is return
to neutral position and the boom float spool is moved to float position by pilot oil pressure from port
1 of RCV.
ş The work ports(A3), (B3), (A2), (B2) 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.
ş 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
10 11
4 T P
LH RH
B.D/F B.U IN OUT
5 1 3 4 2
3 T
a3
B3
T
A3 14
Floating Ride
b3
P
B2
25MPa
A2
Boom down Boom up
a2 b2 F2
13
B1
23MPa
23MPa
A1 F1
Dump Roll back
a1 b1
P1 12
3MPa
P 21MPa
P2 T
Steering system
Brake system
2 1
Return line
24
23
25
26 27 22
ş If the RCV lever(4) is pushed right, the bucket spool on the first block is moved to dump position by
pilot oil pressure from port 2 of RCV.
ş The oil from main pump(2) flows into main control valve(3) and then goes to the small chamber of
bucket cylinder(10) by pushing the load check valve of the bucket spool.
ş The oil at the large chamber of bucket cylinder(10) returns to hydraulic tank(25) through the bucket
spool.
ş When this happens, the bucket is dumped.
ş When the dumping speed of bucket is faster, the oil returned from the large chamber of bucket
cylinder combines with the oil from the pump, and flows into the small chamber of the cylinder.
bucket dump speed.
6-7
5) WHEN THE RCV LEVER IS IN THE ROLL BACK(Retract) POSITION
10 11
4 T P
LH RH
B.D/F B.U IN OUT
5 1 3 4 2
3 T
a3
B3
T
A3 14
Floating Ride
b3
P
B2
25MPa
A2
Boom down Boom up
a2 b2 F2
13
B1
23MPa
23MPa
A1 F1
Dump Roll back
a1 b1
P1 12
3MPa
P 21MPa
P2 T
Steering system
Brake system
2 1
Return line
24
23
25
26 27 22
ş If the RCV lever(4) is pulled left, the bucket spool on the first block is moved to roll back position by
pilot oil pressure from port 4 of RCV.
ş The oil from main pump(2) 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.
ş The oil at the chamber of bucket cylinder(10) returns to hydraulic tank(25) through the bucket spool.
ş When this happens, the bucket roll back.
ş When the rolling speed of bucket is faster, the return oil from the small chamber of bucket cylinder
combines with the oil from the pump, and flows into the large chamber of the cylinder.
bucket rolling speed.
6-8
6) WHEN THE RCV LEVER IS IN THE HOLD POSITION
10 11
4 T P
LH RH
B.D/F B.U IN OUT
5 1 3 4 2
3 T
a3
B3
T
A3 14
Floating Ride
b3
P
B2
25MPa
A2
Boom down Boom up
a2 b2 F2
13
B1
23MPa
23MPa
A1 F1
Dump Roll back
a1 b1
P1 12
3MPa
P 21MPa
P2 T
Steering system
Brake system
2 1
Return line
24
23
25
26 27 22
ş The oil from main pump(2) flows into main control valve(3).
ş 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(25) through center bypass circuit
of each spool.
ş In this condition, each cylinder keeps the neutral position, so the boom and the bucket is holded.
6-9
4. MAIN PUMP OPERATION
1) STRUCTURE
70
56
57
1
85
80
55
2
95
90
32
31 30
22
20
35
36 37
90
60
1 Flange 32 Back up seal 60 O-ring

2 Cover 35 Wear plate 70 Cap screw
20 Driven gear 37 Back up seal 85 Location ring
22 Drive gear 55 Shaft seal 90 Plain bearing
30 Wear plate 56 Oil seal 95 Seal
6-10
2) OPERATION
22 56 57 85 55 90 30,31,32 35,36,37 90
37 36
Z
SECTION Z-Z
A
Z
DETAIL A
1 70 2 90 60 20 90 9
The main hydraulic pump is a fixed displacement gear type pump. The pump is drive at engine
speed by the torque converter. The pump shafts are supported by bearings(90) in the body(9) and
cover(2). The wear plates(30, 35) are located between the gear surface and cover(2) and body(9).
As the drive gear(22) turns the driven gear(20), the gear teeth come out of mesh.
Oil flows from the hydraulic tank through the inlet the cavity between the gear teeth. As the gears
continue to rotate, the oil becomes trapped between the gear teeth and the body(9).
The trapped oil is then carried to the pump outlet. Oil is forced out the outlet to supply the hydraulic
functions. 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 wear plates(30, 35) against the gear faces. This
controls internal leakage to maintain pump displacement.
Outlet pressure fills the area bounded by the pressure balance moulded seals(31, 36) to force the
wear plate against the high pressure area or the gear faces. Pump shaft lubrication is achieved by
routing outlet pressure oil into the area between the gear shafts and the bearings. The oil is
collected at the end of the shafts in the hollow areas in the body and cover and routed back to
return.
6-11
5. REMOTE CONTROL VALVE
1) STRUCTURE (1/3)
1.10
1.8
1.2A
1.17 1.3A
1.18
1.19
1.10
1.12 1.4
1.1 1.6 1.1
1.9
1.5
1.7
1.21 1.24
1.19
1.18
1.17
1.13
1.12
1.11
1.14
1.20
1.16
1.23
1.15
1.1 Half handle 1.9 Screw 1.17 Screw

1.2A Insulation cap 1.10 Self locking nut 1.18 Lock washer
1.3A Pusher 1.11 Screw 1.19 Belleville washer
1.4 Rocker arm 1.12 Washer 1.20 Fitting clamp
1.5 Spacer 1.13 Hollow lever 1.21 Thimble
1.6 Spacer 1.14 Nut 1.23 Complete handle
1.7 Contact switch 1.15 Nut 1.24 Cable
1.8 Spacer 1.16 Bellows
6-12
STRUCTURE (2/3)
2.25
2.24
2.7
C C
A C 2.1
2.8
2.2A 2.23
2.9 B
C
2.10 2.22
2.3
2.11
2.21
2.12 2.20
2.13
C C
A C 2.4
A C 2.5
2.14 2.19
2.15 2.15
2.16 2.16
2.15
2.6
2.17
2.18
2.1 Bracket 2.8 Counter nut 2.17 Connector blade

2.2A Shim 2.9 Nut 2.18 Junction box
2.2B Shim 2.10 Press screw 2.19 Complete solenoid
2.2C Shim 2.11 Plunger 2.20 Spring ring
2.3 Joint 2.12 Circlip 2.21 Armature
2.4 Flange 2.13 Shim 2.22 Joint
2.5 Plug 2.14 Plunger guide 2.23 Friction washer
2.6 Electric bracket 2.15 O-ring 2.24 Friction washer
6-13
STRUCTURE (3/3)
C C
A C
2.37 2.37
2.38
2.38 2.38 2.38
2.39 2.39
2.40 2.40
2.41 2.41
2.4A 2.4A
2.4B 2.4B
2.4C 2.4C
2.43 2.43
3.8
3.7 2.44
3.9 3.6
2.45
3.12
3.10 3.13
3.11
3.2
3.14
3.15 3.3
3.16
3.5,3.17 3.4
4.1A
4.1B 3.1
2.37 Complete plunger 2.45 Spring 3.10 Nut

2.38 1/2 washer 3.1 Plug 3.11 Screw
2.39 Spring retainer 3.2 O-ring 3.12 Plate
2.40 Spring 3.3 Intermediate plate 3.13 O-ring
2.41 Spring 3.4 Screw 3.14 Piston
2.4A Shim 3.5 Housing 3.15 Spring
2.4B Shim 3.6 Plug 3.16 Washer
2.4C Shim 3.7 Identification plate 3.17 Housing
2.43 Spool 3.8 Pin 4.1A Spool
2.44 Socket 3.9 Screw 4.2A Spool
6-14
2) OPERATION
5 1
5 T 1
3
4 P
14 5 2
15
T 1
5
SECTION X-X
Electromagnetic lock
T P 9
10
22bar
11
5
5 1 34 2 4
3
7
(1) Hydraulic functional principle 2
Pilot devices with end position locks operate as
direct operated pressure reducing valves.
T 8
x P x
They basically comprise control lever(1), four
pressure reducing valves, housing(6) and locks. 6
Each pressure reducing valve comprises control
spool(2), control spring(3), return spring(4) and
push rod(5). Port 4 Port 2
At rest control lever(1) is held in its neutral position
by return springs(4). Ports(1, 2, 3, 4) are
connected to tank port T via bore(8).
When control lever(1) is deflected push rod(5) is pressed against return spring(4) and control
spring(3).
Control spring(3) initially moves control spool(2) downwards and closes the connection between
the relevant port and tank port T. At the same time the relevant port is connected to port P via
bore(8). The closed loop control phase starts, as soon as control spool(2) finds its balance
between the force from control spring(3) and the force, which results from the hydraulic pressure
in the relevant port(Port 1, 2, 3 or 4).
Due to the interaction between control spool(2) and control spring(3) the pressure in the relevant
port is proportional to the stroke of push rod(5) and hence to the position of control lever(1).
This closed loop pressure control dependent on the position of the control lever and the
characteristics of the control spring permits the proportional hydraulic control of the main
directional valve.
Rubber sleeve(9) protects the mechanical components in the housing from contamination.
6-15
(2) End position lock
Only those control ports, for which it is necessary to hold the control lever in a deflected position
are equipped with end position locks.
Electromagnetic lock
An additional spring(7) under push rod(5) warns, due to the increase in force which is required to
keep this spring compressed, that the stroke of push rod(5) and control lever(1) is nearly at its
end.
Once this point has been exceeded ring(10) is placed in contact with solenoid armature(11).
If the solenoid is energized, control lever(1) is held in its end position by means of the
electromagnetic force.
The lock is released automatically when the solenoid is deenergized.
(3) Fifth control port
This remote control valve is equipped with a fifth control port, which is used to control the boom
floating function. This function may be operated by moving spool(14) against spring(15) under
the influence of the pressure acting in port 1.
As soon as this pressure reaches 22bar, control port 5 is connected with T.
6-16
6. MAIN CONTROL VALVE
1) STRUCTURE
300.12 300.11
300.10
54
86 300.13
14
99
85
3
is
ax
70
2
is
ax
1
is
ax
35,36
43
74,76
72,75
70.15
70.11 70 40
70.13 99
68.23
68.27 43 19
68 70.14
70.12 53
68.24
70.9
68.22 86
54
85
11 Housing 68.23 O-ring 74 Spring(Axis 1,2)

14 Short cover 68.24 Thrust ring 75 Spring(Axis 3)
19 Long cover 68.27 O-ring 76 Spring(Axis 3)
35 Spool(Axis 1,2) 70 Overload relief valve 85 Screw
36 Spool(Axis 3) 70.9 Seal 86 Seal ring
40 Ring 70.11 O-ring 99 O-ring
43 Spring retainer 70.12 Piston seal 300 Plate
53 Snap ring 70.13 O-ring 300.10 Plate
54 Bleed screw 70.14 O-ring 300.11 Locking screw
68 Main relief valve 70.15 Thrust ring 300.12 Bolt
68.22 O-ring 72 Spring(Axis 1,2) 300.13 O-ring
6-17
STRUCTURE
A3 B3
a3 b3
A2 B2
a2 b2
A1 B1
a1 b1
a3
B3
A3
Floating Ride
b3
B2
A2 25MPa
Boom down Boom up
a2 b2
B1 23MPa
A1 23MPa
Dump Roll back
a1 b1
P 21MPa
Port Port name Port size
P From main pump SAE 6000psi 1 1/2"

T To hydraulic tank SAE 6000psi 1 1/2"
A1, B1 To bucket cylinder port SAE 6000psi 1 1/4"
A3, B3, A2, B2 To boom cylinder port SAE 6000psi 1 1/4"
a1, b1 Bucket pilot port PF 1/4
a2, a3, b2, b3 Boom pilot port PF 1/4
6-18
2) BOOM SECTION OPERATION
(1) Spool in neutral
a3
LH RH B3
A3
Floating Ride
b3
B2
25MPa
A2
Boom down Boom up
a2 b2
A2 B2
a2 b2
Overload relief valve

Low pressure passage
If the remote control valve is not operated, the oil supplied from the pump port passes through the
neutral passage to the low pressure passage at the outlet section, and then returns to the tank port.
6-19
(2) Boom raise position
a3
LH RH B3
A3
Floating Ride
b3
B2
25MPa
A2
Boom up
a2 b2
A2 B2
a2 b2
When the pilot pressure from remote control valve is supplied to the pilot port(b2), the spool moves to
the left and the neutral passage is closed.
The oil supplied from the pump pushes up the load check valve(1) and flow into boom cylinder port(B2,
B3).
The pump pressure reaches proportionally the load of cylinder and fine control finished by shut off of the
neutral passage.
The return oil from cylinder port(A2, A3) flows into the tank via the low pressure passage.
6-20
(3) Boom lower position
a3
LH RH B3
A3
Floating Ride
b3
B2
25MPa
A2
Boom down
a2 b2
A2 B2
a2 b2
When the pilot pressure from remote control valve is supplied to the pilot port(a2), the spool moves to
the right and the neutral passage is closed.
The oil supplied from the pump pushes up the load check valve(2) and flow into boom cylinder port(A2,
A3).
neutral passage.
The return oil from cylinder port(B2, B3) flows into the tank via the low pressure passage.
6-21
(4) Boom float position
a3
LH RH B3
A3
Floating
b3
B2
25MPa
A2
Boom down Boom up
a2 b2
A3 B3
a3 b3
If the operator overrides the additional spring(7) in the RCV lower position, the pilot pressure from
remote control valve rises further and then the boom float spool is pushed to the end position, opening
up the neutral passage to tank and simultaneously(A2, A3), (B2, B3) ‫ آ‬T.
Parallel the boom down spool will be released to neutral, became of moving spool in the remote control
valve at 22bar(Refer to page 6-15).
In float position the boom drops quickly due to its own weight.
When the bucket touches the ground and the wheeled loader is moving, the bucket raised or lowered
following the unevenness of the ground due to the (A2, A3), (B2, B3) ‫ آ‬T connecting.
6-22
3) BUCKET SECTION OPERATION
(1) Spool in neutral
B1
23MPa
23MPa
A1
Dump Roll back
a1 b1
21MPa
A1 B1
a1 b1

Low pressure passage
If the remote control valve is not operated, the oil supplied from the pump port passage through the
neutral passage to the low pressure passage at the outlet section, and then return to the tank port.
6-23
(2) Retract (Roll back) position
B1
23MPa
23MPa
A1
Roll back
a1 b1
21MPa
A1 B1
a1 b1
When the pilot pressure from remote control valve is supplied to the pilot port(b1), the spool moves to
the left and the neutral passage is closed.
The oil supplied from the pump pushes up the load check valve(1) and flow into boom cylinder port(B1).
neutral passage.
The return oil from cylinder port(A1) flows into the tank via the low pressure passage.
6-24
(3) Dump position
B1
23MPa
23MPa
A1
Dump
a1 b1
21MPa
A1 B1
a1 b1
When the pilot pressure from remote control valve is supplied to the pilot port(a1), the spool moves to
the right and the neutral passage is closed.
The oil supplied from the pump pushes up the load check valve(1) and flow into boom cylinder port(A1).
neutral passage.
The return oil from cylinder port(B1) flows into the tank via the low pressure passage.
6-25
3) MAIN RELIEF VALVE
ş The main relief valve is installed at the inlet of Main poppet(A) Valve seat
Pilot poppet(C)
the main control valve. When the oil goes
Z
above the set pressure, the relief valve
drains the oil to the tank.
In this way, it sets the maximum pressure in
the hydraulic circuit and protects the circuit. P
T Y
ş The valve poppet(C) is connected via the
D1
throttle drillings(D1) and (D2) with the P port. D2 Pressure spring(F) Adjustment
If static pressure increases above the set screw(E)
pressure value, the valve poppet(C) opens
and allows oil to flow freely to tank(Y). This P
oil generates a pressure drop in the spring
chamber of the main poppet, the closing
force of the spring(Z) is cancelled, and the T
main poppet(A) opens to allow the pump
flow to flow to tank(T).
Damped opening and closing is obtained by
the throttled volumetric change. P
ş The set pressure can be varied by changing T Y
the tension of pressure spring(F). To
change the set pressure, remove cap nut,
loosen lock nut and turn adjustments
screw(E) and follows.
P
T Y
6-26
4) OVERLOAD RELIEF VALVE
ş The overload relief valve(Combined relief/ Annular passage
anticavition valve) is in the boom cylinder and
Valve body(1)
bucket cylinder circuit in the main control Main poppet(2)
Pilot poppet(3)
valve.
If shock causes any abnormally high
pressure in the cylinder when the main AB
valves is at neutral, the overload relief valve
releases the abnormal pressure and protects
the cylinder from damage.
T
ş During normal operation, the poppet(2) is Pressure spring(4)
positioned against the body(1) to seal the A1 A3 A2 Main poppet spring
workport(A) oil from the return(T) passage.
ş As the circuit pressure approach the relief A,B
pressure setting, the pressure forces the pilot
poppet(3) off its seat and allows oil to flow
freely via the annular passage to tank.
This oil generates a pressure drop in the
T
spring chamber of the main poppet(2), the
closing force of the spring(4) is cancelled.
The main poppet(2) opens to allow flow from
P to T.
ş If cavitation in the workport occurs, the oil
pressure in the workport drop below return
pressure. AB
Tank line return pressure oil works against
the shoulder(A3) of the poppet to force it
open against the spring and the workport
T
pressure at (A2)-(A1).
A,B
6-27
7. PILOT OIL SUPPLY UNIT
1) STRUCTURE
19 20 21 34 17 15 14 13 9 8 12 10 11 2 3 4 16
P1
18 22 23 24 25 26 27 28 29 30 32 33 31
P2
Port Port name Port size
3Mpa
U P1 From main pump 3/4 UNF
P2 Plugging 3/4 UNF
4.5Mpa U Supply to RCV lever 9/16 UND
T To hydraulic tank 9/16 UND
P1 T
HYDRAULIC CIRCUIT
1 Plug 14 Plug 24 Valve seat

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

2 Retainer 7 Spring ring 12 Knob
3 Adjust stem 8 O-ring 13 Socket set screw
4 Housing 9 O-ring 14 Spring pin
5 Clutch ring 10 Back up ring
6-30
9. BOOM AND BUCKET CYLINDER
The boom cylinders and the bucket cylinders are two 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
9,8 6,5 3 7 24 23 11,10 4 2 25,26,27 14,13 17 15 16 22 19 18 24 23
20 1 21 12 28,29
1 Tube assy 11 Back up ring 21 Pipe assy

2 Rod assy 12 Piston 22 Pipe assy
3 Gland 13 O-ring 23 O-ring
4 Bushing 14 Back up ring 24 Bolt
5 Rod seal 15 Piston seal 25 Clamp
6 Back up ring 16 Wear ring 26 Bolt
7 Buffer ring 17 Dust ring 27 Spring washer
8 Dust wiper 18 Lock nut 28 Bushing
9 Snap ring 19 Set screw 29 Dust seal
10 O-ring 20 Bolt
6-31
2) BUCKET CYLINDER
9,8 6,5 7 3 4 11,10 2 25 1 14,13 12 17 15 16 19 18 28,29
26,27 20 24 23 21 22

5 Rod seal 15 Piston seal 25 Band assy
6 Back up ring 16 Wear ring 26 Bushing
7 Buffer ring 17 Dust ring 27 Dust seal
10 O-ring 20 Bolt
6-32
10. HYDRAULIC OIL TANK
1) STRUCTURE
ş The oil from the hydraulic tank is sent from the pump through control valve to the cylinders.
In the return circuit, the oil from various parts merges.
ş A part of oil is cooled in the oil cooler, passes through the hydraulic filter and returns to the
hydraulic tank(1).
ş If the hydraulic return oil filter becomes clogged, return filter bypass valve(5) acts to allow the oil to
return directly to the hydraulic tank(1). This prevents damage to the hydraulic filter(4). The
bypass valve(5) is also actuated when negative pressure is generated in the circuit.
7
3
9
4
1
2 5
12,13
8 7
9 10,11
1 Hydraulic tank wa 6 Spring 11 Spring washer

2 Level gauge 7 Cover 12 Overheat switch
3 Air breather 8 Cover wa 13 O-ring
4 Element 9 O-ring
5 Bypass valve 10 Bolt
6-33
2) RETURN OIL FILTER BYPASS VALVE
(1) When the filter is clogged
Bypass valve(1) is opened and the oil
returns directly to the tank without passing 1
through the filter.
Bypass valve set pressure : 1.36kg/cm2
(19.3psi)
From MCV
6-34
3) AIR BREATHER
The air breather is equipped with the
capacity to perform three functions
simultaneously-as an air filter, breathing
valve, and as a lubrication opening.
(1) Preventing negative pressure inside
the tank
The tank is a pressurized sealed type, so
negative pressure is formed inside the
hydraulic tank when the oil level drops
during operations. When this happens, 4
the difference in pressure between the
tank and the outside atmospheric 1
pressure opens the poppet in the
breather, and air from the outside is let 2
into the tank or prevent negative pressure.
3
(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. 1 Body 3 Strainer
2 Element 4 Cap
6-35
11. ACCUMULATOR
The accumulator is installed at the pilot oil 1
supply unit. When the boom is left the 2
raised position, and the control levers are
operated with the engine stopped the
pressure of the compressed nitrogen gas
inside the accumulator sends pilot pressure 3
to the control valve to actuate it and allow 4
the boom and bucket to come down under 5
their own weight.
Type of gas Nitrogen gas(N2)
Volume of gas 0.75ֻ(0.2 U.S.gal)
Charging pressure of gas 16kg/cm2(228psi)
1 Screw plug
Max actuating pressure 30kg/cm2(427psi)
2 Sealing ring
3 Diaphragm
4 Closure button
5 Steel pressure vessel
6-36
This procedure is designed so the mechanic can make a quick check of the system using a minimum
amount of diagnostic equipment. If you need additional information, read structure and function,
Group 1.
şChapter 2 : Troubleshooting
şGroup 3 : Tests and adjustments
6-37
Ɠ Hydraulic oil must be at operating temperature for these checks(Refer to page 6-52).
Hydraulic system warm- Hold a hydraulic function over OK

up procedure relief to heat oil.(Don't keep relief Check completed.
Run engine at high idle. condition over 5 seconds at a
Refer to page 6-51. time)
Periodically cycle all hydraulic
functions to distribute warm oil.
Repeat procedure until oil is at
FEEL : Hydraulic tank must be
uncomfortable to hold your hand
against.
(Approximately 45~55ŞC)
Hydraulic pump With bucket flat on ground, OK
performance check actuate boom raise. Time how Check completed.
Heat hydraulic oil to long it takes to raise boom to full
NOT OK
operating temperature. height.
Go to priority valve(In flow
LOOK : Boom must raise to full amplifier) high pressure
height in less than 7 seconds. check at page 5-32.
IF OK
Do steering system
leakage check at page 5-
31.
IF OK
Do main hydraulic pump
flow test at page 6-53.
Control valve lift check With bucket partially dumped, OK
Run machine at low idle. lower boom to raise front of Check complete.
machine.
NOT OK
Slowly move boom control Repair lift checks in
lever(RCV lever) to boom lower loader control valve.
position.
Slowly move bucket control lever
to bucket dump position.
LOOK : Boom must not raise
before moving down.
Bucket must not rollback before
dumping.
6-38
Bucket rollback circuit Position bucket at a 45Şangle OK

relief valve check against an immovable object. Check complete.
Engage transmission in 3rd speed NOT OK
forward. Do loader system and
circuit relief valve test at
LOOK : Bucket angle must not
page 6-54.
change.
Bucket dump circuit Raise front of machine which OK
relief valve low pressure bucket at 45Şangle. Go to next check.
check
Backdrag with bucket while NOT OK
observing bucket angle. Do loader system and
circuit relief valve test at
LOOK : Bucket must not rollback.
page 6-54.
Pilot control valve float With the bucket partially dumped, OK
check lower boom to raise front of Check complete.
Run engine at low idle. machine.
NOT OK
Push control lever to the float
Do pilot control valve
detent position and release lever.
LOOK : Front of machine lower to
the ground and valve must remain
in float position when lever is
released.
Boom cylinder and Set the boom and bucket OK
bucket cylinder drift horizontal, then stop the engine. Check complete.
check
Stop the engine, wait for 5 NOT OK
Heat hydraulic oil to
minutes, then start measuring. Go to next check.
B
Measure the amount the lift and
dump cylinder rods retract during
15 minutes.(Unloaded bucket)
A A : Retraction of boom cylinder
rod
B : Retraction of bucket cylinder
rod
Boom cylinder must drift less than
40mm.
Bucket cylinder must drift less
than 40mm.
6-39
Boom cylinder leakage Dump bucket until teeth or cutting OK

check edge is perpendicular to the Drift is approximately the
Heat hydraulic oil to ground. same between first and
operating temperature. Raise boom until cutting edge is second measurement.
about 1m(3ft) above ground. Repair loader control
Stop engine. Measure drift from valve or circuit relief valve.
tooth or cutting edge to ground for
NOT OK
1 minute.
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 1m(3ft) off OK
check ground with bucket level. Drift is approximately the
Heat hydraulic oil to Stop engine. Place a support same between first and
operating temperature. under boom. second measurement.
Measure drift from tooth or cutting Repair loader control
edge to ground for 1 minute. valve or circuit relief valve
Wait 10 minutes. at page 6-54.
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.
Pilot control valve Stop engine. Turn key switch to OK
(RCV lever) check OFF position. Check completed.
Move control lever to all positions
and then release. NOT OK
Repair pilot control valve.
LOOK : Lever must return to
neutral when released from all
positions.
6-40
Bucket leveler Position bucket fully dumped just OK

(Positioner) check above ground level. Check complete.
Move control lever to bucket NOT OK
leveler detent position and Do bucket leveler checks
release. in group 3.
LOOK : Bucket must rollback to
the level position and control lever
must return to neutral.
If bucket is in a rolled back
position when key is turned ON,
control lever must be returned to
neutral manually if placed in the
bucket leveler detent position.
After bucket is dumped once,
bucket leveler will work normally.
Boom height kickout Position bucket flat on ground. OK
check Check complete.
Move control lever to boom raise
detent position and release. NOT OK
Do boom height kickout
LOOK : Boom must raise to the
check in group 3.
set height and stop.
Control lever must return to
neutral.
Cycle time check Function Operating condition. Maximum cycle time
Heat hydraulic oil to
Boom raise Bucket flat on ground to full height. 6.3sec
Run engine at high idle. Boom lower(Float) Full height to level ground. 3.6sec
Bucket dump Boom at full height. 1.3sec
Bucket rollback Boom at full height. 1.7sec
Steering(No. of Frame stop to frame stop. 1.6sec (3.9 turns)
turns)
OK
Check complete.
NOT OK
Go to slow hydraulic
functions in group 3.
6-41
Ɠ MEASURING BOOM AND BUCKET CYCLE TIME
1. MEASUREMENT CONDITION
şCoolant temperature : Inside operating range
şSteering position : Neutral
şHydraulic temperature : 45~55Ş C
şBucket : Unloaded
şEngine speed : High idling
2. MEASURING TOOL
şStop watch(1 EA)
3. MEASURING PROCEDURE
Lifting
Liftingtime
time of
of boom
boom
1) LIFTING TIME OF BOOM
Set the bucket near the maximum tilt back
position and at the lowest position on the
ground. Raise the bucket and measure
the time taken for bucket to reach the
maximum height of the boom.
2) LOWERING TIME OF BOOM

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

Raise the boom to the maximum height and Dumping time of
Dumping time ofbucket
bucket
measure the time taken for the bucket to Rollback time of
Rollback time of bucket
bucket
move from the maximum tilt back position
to the maximum dump position
4) ROLL BACK TIME OF BUCKET
Raise the boom to the maximum height and
measure the time taken for the bucket to
reach the maximum tilt back position.
6-42
2. TROUBLESHOOTING
Ɠ Diagnose malfunction charts are arranged from most probable and simplest to verify, to
least likely, more difficult to verify. Remember the following steps when troubleshooting a
problem :
Step 1. Operational check out procedure (See section 1)

Step 2. Operational checks (See group 2)
Step 4. Tests and adjustments (See group 3)
Noisy hydraulic pump Low oil supply or wrong viscosity. Fill hydraulic tank with recommended
oil.
Plugged or pinched suction line. Clean or replace line.
Air in oil. Check for foamy oil. Tighten
connections.
Replace O-rings and or lines.
Loose or missing hydraulic line clamps. Tighten or replace clamps.
Hydraulic lines in contract with frame. Inspect and repair.
Worn or damaged pump. Do hydraulic pump performance check
in group 2. Do hydraulic pump flow
test in group 3.
No or Slow hydraulic Failed or worn hydraulic pump. Do performance check.

functions
Cold oil. Warm oil up.
Slow engine speed. Adjust engine speed control linkage.
Check high idle speed.
Suction line air leak. Check for foamy oil.
Low oil supply. Add recommended oil.
Wrong oil viscosity. Use recommended oil.
Oil leaking past cylinders or control Check cylinder drift in group 2.
valve.
Blocked or damaged line. Inspect lines.
Faulty or misadjusted pilot oil supply Do pilot oil supply unit pressure test in
unit. group 3.
Faulty pilot control valve(RCV). Do pilot control valve(RCV) pressure
test in group 3.
Binding loader control valve(MCV) Inspect valve.
spool.
Faulty flow amplifier. Check priority valve, orifice of flow
amplifier specification.
6-43
No steering or hydraulic Low oil level. Add recommended oil.
function
Failed hydraulic pump. Remove and inspect return filter for
metal pump particles.
Failed main hydraulic pump drive. Remove main hydraulic pump and
inspect drive gear.
No hydraulic functions Failed hydraulic pump. Remove and inspect return filter for
steering normal metal pump particles, or replace the
pump.
Failed pilot line filter. Remove and inspect line filter for RCV.
Faulty safety valve. Safety valve leakage test or ON, OFF
function test.
Stuck open system and port relief Replace relief valve.
valve.
Faulty or misadjusted pilot supply unit. Do pilot supply unit pressure test in
group 3.
Boom float function Low pilot control pressure. Do pilot supply unit pressure test in
does not work group 3.
Faulty pilot control valve(RCV). Do pilot control valve pressure test.
Main control valve spool binding in Inspect and repair valve.
bore.
One hydraulic function Faulty pilot control valve(RCV). Do pilot control valve pressure test.
does not work.
Stuck open port relief valve. Replace relief valve.
Oil leaking past cylinder packings. Do boom and bucket cylinder leakage
test in group 3.
Blockage in oil lines or valve. Inspect lines for damage.
Disconnect and inspect lines for internal
blockage.
Main control valve spool stuck in bore. Inspect and repair valve.
Low hydraulic power Leakage within work circuit. Do cylinder drift check in group 2.
Low system relief valve(Main relief Do loader system and port relief valve
valve) setting. pressure test in group 3.
Low port relief valve setting. Do loader system and port relief valve
Faulty or misadjusted pilot oil supply Do pilot supply unit pressure test in
unit. group 3.
Leaking system relief valve. Remove and inspect valve.
Worn hydraulic pump. Do hydraulic pump performance check
in group 2.
Faulty pilot control valve(RCV). Do pilot control valve pressure test in
group 3.
6-44
Function drifts down Leaking cylinders. Do cylinder leakage checks in group 2.

Leaking seals in circuit relief valve(Port Inspect seals. Replace relief valve.
relief valve) or valve stuck open.
Leaking loader control valve. Repair or replace valve section.
Boom drifts up Leakage in boom down spool. Remove and inspect boom down spool.
Boom down does not Safety valve not operated. Operate valve.
work(Engine off)
Stuck pilot control valve. Inspect.
Faulty line filter. Remove and inspect filter.
Accumulator 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 Inspect for dented or kinked lines.
valve(MCV). Do hydraulic system restriction test in
group 3.
Pinched or restricted priority valve of Run engine at low idle. Steer machine
flow amplifier "LS" line. back and forth. If engine load
decreases while steering, a restricted
"LS" line or priority valve of flow
amplifier malfunction is indicated.
Do priority valve of flow amplifier "LS"
port flow test in group 3.
Malfunctioning flow amplifier. Do hydraulic system restriction test in
group 3.
Leaking system main relief valve. Remove and inspect valve and seals.
Worn hydraulic pump(Internal leakage). Do hydraulic pump performance check
in group 2.
Function drops before Stuck open lift check valve. Do control valve lift check in group 2.
raising when valve is
activated
6-45
Hydraulic oil foams Low oil level. Add recommended oil.

Wrong oil. Change to recommended oil.
Water in oil. Change oil.
Loose or faulty suction lines (Air leak in Tighten or install new lines.
system).
Remote control valve Leaking plunger seals. Remove, inspect and replace plunger
(RCV) leaking seals.
Ɠ Followings are general precautions for the hydraulic system and equipment.
1) Every structure has its limit of strength and durability. The relief valve is installed to limit the
pressure on the hydraulic equipment and protect various parts of the wheel loader from possible
damage. Therefore, never change the preset pressure of the relief valve unless absolutely
necessary.
2) Since the hydraulic equipment is built with precision, the presence of only the slightest amount of
dust and/or other particles in the hydraulic circuit might cause wear and/or damage, resulting in
unstable functions and/or damage, resulting in unstable functions and/or unexpected accidents.
Therefore, always keep hydraulic oil clean. Periodically, check the filter in the return circuit and
replace the element as necessary.
3) Extract about 200cc of hydraulic oil from the tank as a sample every 6 months. If possible, have it
analyzed by a specialist to confirm that the oil can still be used. Never extract the oil for sampling
until the oil temperature has become the normal operating temperature. Since the replacement
period varies depending on operating conditions, refer to Operator's Manual and change oil.
4) Should the equipment get damaged due to the presence of metal particles and/or foreign matter in
the circuit drain out the hydraulic oil and carry out flushing. Also, replace the filter element and
clean the hydraulic tank. Change the hydraulic oil entirely.
5) When checking the filter, if found metal particles in the element, drain out the hydraulic oil entirely,
flush the whole circuit, and then fill with new oil. The presence of metal particles may indicate
internal damage to the equipment. In such a case, check carefully before flushing, and repair or
replace as required.
6) To add and/or change the hydraulic oil, always use recommended oil.(Refer to the list of
recommended oils and lubricants at page 1-21, Recommended lubricants.) Never mix oil of
different makes of kinds.
7) To change the hydraulic oil, use a clean vessel and funnel for pouring it into the tank. Never use
cloth because it might cause the presence of lint in the circuit.
8) When removing the hydraulic equipment, be sure to put plugs or caps on hoses, tube lines and
ports. Also, enter mating marks for later identification.
6-46
9) Disassemble and/or assemble the hydraulic equipment only in a clean place free of dust. When
disassembling, be careful about the interchangeability of parts, and clean the disassembled parts
with pure and clean mineral cleansing oil. Clean the internal passages as well. After the parts
have dried, wipe them off with a clean lint-free cloth.
10) When overhauling the hydraulic equipment replace all O-rings, backup rings, etc. with new ones.
Assemble O-rings with grease or vaseline applied.
11) After installing the equipment, add more hydraulic oil to make up for that lost during disassembly.
12) Tighten joints correctly. Loose joints will cause the hydraulic oil to leak. If the oil leaks, the tank oil
level drops and air gets sucked in, so the pump will break down. Also loose joints in suction lines
will take air in and might cause abnormal noise, malfunction or damage to pumps.
6-47
1. HYDRAULIC OIL CLEAN UP PROCEDURE USING PORTABLE FILTER CADDY

Ɠ SERVICE EQUIPMENT AND TOOL
şPortable filter caddy
şTwo 3658(12ft) ź 1in I.D. 100R1
hoses with 1in NPT Ends
şQuick disconnect fittings.
şDischarge wand
şVarious size fittings.
Ɠ Brake system uses oil from hydraulic oil
tank. Flush all lines in the brake and
pilot system. Disassemble and clean
major component for hydraulic system.
Brake and steering components may fail
if brake, steering system is not cleaned
after hydraulic oil tank hydraulic oil tank
contamination.
1) If hydraulic system is contaminated due to a
major component failure, remove and
disassemble steering cylinders to clean
debris from cylinders.
2) Install a new return filter element. Clean
filter housing before installing new element.
Ɠ For a failure that creates a lot of debris,
remove access cover from hydraulic oil
tank. Drain and clean hydraulic oil tank
of fill the specified oil to hydraulic oil
tank through upper cover.
3) To minimize oil loss, pull a vacuum in
hydraulic oil tank using a vacuum pump.
Connect filter caddy suction line to drain
port at bottom of hydraulic oil tank using
connector. Check to be sure debris has not
closed drain port.
4) Put filter caddy discharge line into hydraulic
oil tank filler hole so end is as far away from
drain port as possible to obtain a thorough
cleaning of oil.
6 -48
5) Start the filter caddy. Check to be sure oil is
flowing through the filters.
Operate filter caddy approximately 10
minutes so oil in hydraulic oil tank is
circulated through filter a minimum of four
times.
Ɠ Hydraulic oil tank capacity 210ֻ(55.5 U.
S. gal)
Leave filter caddy operation for the next
steps.
6) Start the engine and run it at high idle.
Ɠ For the most effective results, cleaning
procedure must start with the smallest
capacity circuit then proceed to the next
largest capacity circuit.
7) Operate all functions, one at a time, through
a complete cycle in the following order:
Clam, steering, bucket, and boom. Also
include all auxiliary hydraulic functions.
Repeat procedure until the total system
capacity has circulated through filter caddy
seven times, approximately 30 minutes.
Each function must go through a minimum
of three complete cycles for a through
cleaning for oil.
Ɠ Filtering time for machines with auxiliary
hydraulic functions must be increased
because system capacity is larger.
8) Stop the engine. Remove the filter caddy.
9) Install a new return filter element.
10) Check oil level in hydraulic oil tank ; Add oil
if necessary.
6 -49
2. BOOM HEIGHT KICKOUT ADJUSTMENT
1) Lift the boom up to a desired height, set the
Proximity switch
boom control lever at hold, then stop the
Boom
engine. Front frame
Be careful lest work equipment fall
down.
Put the hydraulic safety lock lever in the
LOCK position.
2) Loosen the nuts. Move the proximity

switch so that the boom is in line with the Front frame Nut
center of the sensing surface of proximity Proximity switch
Boom
switch.
Then tighten the nuts.
3) Loosen the nuts so that a clearance Boom Nut

between the boom and the probe of the Front frame
Proximity switch
proximity switch are 3Ź1mm.
3Ź1mm
4) Start the engine. Position the bucket on

Detent position
the ground. Then lift the bucket to a
desired height by using the control lever
and release the hand.
Confirm the lever automatically returns to
the neutral position and the boom(The
bucket) stop at the adjusted position.
6 -50
3. TEST TOOLS
1) CLAMP-ON ELECTRONIC TACHOMETER
INSTALLATION
şService equipment and tools
Tachometer
A : Clamp on tachometer.
Remove paint using emery cloth and B
connect to a straight section of injection D
line within 100mm(4in) of pump. Finger C
Tighten only-do not over tighten.
B : Black clip(-). Connect to main frame.
C : Red clip(+). Connect to transducer. A
D : Tachometer readout. Install cable.
2) DIGITAL THERMOMETER INSTALLATION

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

The display monitor tachometer is accurate
enough for test work.
20 30
10 20
40
10
5 30
0 mph
0 50
km/h
6 -51
4. HYDRAULIC OIL WARM UP PROCEDURE
1) Install temperature reader(See temperature
reader installation procedure in this group).
2) Run engine at high idle.
3) Hold a hydraulic function over relief to heat
the oil.
4) Periodically cycle all hydraulic functions to
distribute warm oil.
5) Heat oil to test specification(Approximately
50Ɓ
C).
6 -52
5. MAIN HYDRAULIC PUMP FLOW TEST
ş SPECIFICATION
Oil temperature 65Ź6ƁC(150Ź10Ɓ F)
Engine speed 2100Ź25rpm
Test pressure 210Ź5bar(2987psi)
Maximum pump flow 213ֻ/min(56.3gpm)
ş FLOW METER GAUGE AND TOOL
Temperature reader
1) Make test connections.
2) Install temperature reader. TO MCV
(See temperature reader installation procedure
Flow meter
in this group.)
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.
6 -53
6. LOADER SYSTEM AND PORT RELIEF
VALVE PRESSURE TEST
ş SPECIFICATION
Oil temperature (45~55Ɓ
C) D
Relief valve Engine speed Relief pressure
210Ź5kg/cm2
System(M) High
(2987Ź70psi)
Boom 250Ź5kg/cm2
Low
raise(U) (3556Ź70psi)
Bucket 230Ź5kg/cm2 U
Low
rollback(R) (3270Ź70psi) R
M
Bucket 230Ź5kg/cm2
Low
dump(D) (3270Ź70psi)
ş GAUGE AND TOOL A

A : Test port
M : System(Main) relief valve
R : Bucket rollback relief
D : Bucket dump relief
U : Boom raise relief
1) Install pressure gauge to test port(A). TO MCV
(See temperature reader installation procedure
in this group.)
3) Heat hydraulic oil to specifications. (See
group.)
4) To check the system relief(M), run engine at
high idle. Lower boom to bottomed
position.
Slowly activate boom down function while
watching pressure gauge. If pressure is not
to specification, loosen lock nut on system
relief valve(M) and adjust to specification.
6 -54
Ɠ Do not adjust the system relief valve
above 260kg/cm2 (3700psi). Damage to
the pump will result from excessive
pressure settings.
5) To check the bucket dump, bucket rollback,
and boom raise, adjust the system relief
valve to 260kg/cm2 (3700psi).
Run engine to maintain 800~850rpm when
hydraulic function is activated over relief.
Activate the function to be checked with the
cylinder bottomed. Read the pressure
gauge.
If pressure is not to specification cycle relief
valve over relief 10 times to flush.
Read pressure gauge again. Turn screw
to adjust valve to specification.
Ɠ Do not work machine with system relief
adjusted above specification or
structural damage may occur.
6) Adjust system relief valve to specification.
6 -55
7. HYDRAULIC SYSTEM RESTRICTION TEST
ş SPECIFICATION
Oil temperature 65Ź6Ɓ C(150Ź10Ɓ F)
Maximum pressure 2MPa(20bar, 285psi) at
flow amplifier
Maximum pressure at main control valve
1MPa(10bar, 145psi)
ş GAUGE AND TOOL
Gauge 0~7MPa(0~70bar, 0~1000psi) 2EA
This test will check for restrictions in the
hydraulic system which can cause EF
overheating of hydraulic oil. HP

procedure in this group.)
2) Heat hydraulic oil to specifications. (See Main pump
group.)
3) Connect fitting and gauge to flow amplifier.
4) Connect fitting and gauge to main control
valve.
Do not operate steering or loader
functions or test gauge may be
damaged.
5) Run engine at specification and read
pressure gauges.
loader control valve, check for a kinked,
dented or obstructed hydraulic line. Check
loader control valve for a binding spool.
steering unit, inspect neutral condition of Hyd tank
the steering unit and flow amplifier for a
stuck spool. Make sure orifice plugs are
installed in ends of priority valve spool.
Check for plugged orifice in priority valve
"LS" port and dynamic signal orifice on flow
amplifier body.
6 -56
8. LOADER CYLINDER DRIFT TEST
ş SPECIFICATION A
Oil temperature 40Ź6Ɓ
C(100Ź10Ɓ
F)
Boom horizontal
Bucket horizontal
Bucket unloaded
B
Item Standard value
Retraction of boom
40mm A : Retraction of bucket cylinder rod
cylinder rod
B : Retraction of boom cylinder rod
Retraction of bucket
40mm
cylinder rod
ş GAUGE AND TOOL

Stop watch
Temperature reader
Put the safety lock lever in the lock
position.
Do not go under the work equipment.
1) Set the boom and bucket horizontal, then
stop the engine.
2) Stop the engine, wait for 5 minutes, then
start measuring.
3) Measure the amount the boom and bucket
cylinder rods retract during 15 minutes.
6 -57
9. BOOM AND BUCKET CYLINDER LEAKAGE
TEST
ş SPECIFICATION
Maximum leakage 15 ֹ/min(1/2 oz/min)
ş GAUGE AND TOOL
Temperature reader
Stop watch
Measuring container
1) Fasten temperature sensor to head end
port of cylinder to be tested. Cover sensor
with a shop towel.
group.)
Never work under raised equipment
unless it is supported with a hoist or
support stands.
3) Full extend the cylinder to be tested. If
testing the boom cylinders, restrain boom in
the fully raised position using a hoist or a
stand.
Ɠ Check cylinders for leakage in the fully
extended position only. In the retracted
position contacts the end of the cylinder
and seals off piston seal leakage.
4) Remove and plug cylinder rod end hose or
line.
5) Run engine at 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
loader control valve or circuit relief valve.
6 -58
10. PILOT CONTROL VALVE PRESSURE TEST
ş SPECIFICATION
Oil temperature 40Ź6Ɓ C(100Ź10ƁF)
Begine metering 1/4" of lever travel
Pressure in detent :
Boom float detent 2.2MPa(22bar)
Pressure at feel position :
Boom power down 19~22bar
Boom raise 19~22bar
Bucket rollback 19~22bar
Bucket dump 19~22bar
ş GAUGE AND TOOL
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.
Ɠ 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 test fittings and gauge to the pilot
pressure port of function to be checked.
4) Heat hydraulic oil to specification.(See
group.)
6 -59
5) Run engine at specification. Activate
function to be checked and record pressure
reading.
Ɠ If boom raise or bucket rollback FEEL
positions are not operation due to boom
or bucket position, plug boom float
detent wires into bucket leveler solenoid
or boom height kickout solenoid. This
will provide a feel position on the
control lever.
6 -60
11. PILOT OIL SUPPLY UNIT PRESSURE TEST
ş SPECIFICATION
Engine speed Low idle and stop
Pilot pressure setting 30~35bar(430~500psi)
Relief valve setting pressure 45bar
Accumulator precharging pressure 16bar
U
ş GAUGE AND TOOL
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(A).
A
3) Heat hydraulic oil to specification.(See
group.)
4) Run engine at low idle for 1 minute and
stop engine, wait for 5 minutes. Then start
measuring.
5) If pressure in not within specifications,
replace valve. The valve is staked and
should not be adjusted.
6 -61
12. CYCLE TIME TEST
ş SPECIFICATION
Oil temperature 65Ź6Ɓ C(150Ź10Ɓ
F)
Function Operating conditions Maximum cycle time(Seconds)
Boom raise Bucket flat on ground to full height 6.3

Boom lower(Float) Full height to ground level 3.6
Bucket dump Boom at full height 1.3
Bucket rollback Boom at full height 1.7
Steering(Number of turns) Frame stop to stop 1.6(3.9 turns)
Hydraulic pump performance cycle time.
Function Operating conditions Maximum cycle time(Seconds)

Bucket flat on ground to full height
Boom raise 8.0
while holding steering over relief
6 -62
13. HYDRAULIC OIL FILTER INSPECTION
PROCEDURE
1) Lower the bucket to the ground, stop the
engine, move the control lever back and
forth several times, and clean all over the
upper surface of the hydraulic oil tank.
2) Remove the bolts(1) and take out the filter 1
case cover(3) and O-ring(4). 2
3) Remove the spring(5) and bypass valve(6). 3

4
4) Remove the filter element(7) from the tank.
5
5) Check the element and the filter case
bottom for debris. Excessive amounts of 6
brass and steel particles can indicate a
7
failed hydraulic pump or a pump failure in
process. A rubber type of material can
indicated cylinder packing or other packing
failure.
Ɠ The hydraulic oil filter in the filter case of
the hydraulic oil tank should be
replaced every 250 operating hours(For
the first replacement, at 50 hours) or
more often. When the filter element is
replaced, please keep as follows.
(1) Clean the inside of the filter case.
(2) Place new element in the proper positions
inside the filter case.
(3) Install the bypass valve and spring.
Make sure the element stand upright, and
check for complete contact of the element
bottom with the filter case bottom.
(4) Install the O-ring and filter case covers.
Tighten them with bolt. Replace the O-
ring with new one if damaged.
6 -63
1. MAIN PUMP
1) STRUCTURE
70
56
57
1
85
80
55
2
95
90
32
31
30
22
20
35
36 37
90
60

20 Driven gear 37 Back up seal 85 Location ring
22 Drive gear 55 Shaft seal 90 Plain bearing
30 Wear plate 56 Oil seal 95 Seal
6 -64
(1) Cleanliness
such as flanges and covers are best cleaned in soap and hot water, then air dried. Gears
should be washed in solvent, air dried, and oiled immediately.
Torque
Item
kgfşm lbfşft
Screw(70) 9 65
Screw(80) 40.5 293
6 -65
3) DISASSEMBLY
Clean the pump throughtly with a solvent,
lint-free cloths.
(1) Remove the cap screw(70).
Remove the mounting flange(1). Under
no circumstances attempt to prise
mounting flange from cover as such
action could damage the machine
interface. If necessary use of a soft faced
mallet to remove mounting flange is
recommended.
(2) Remove the cap screws(80) securing the

cover(2) to body(9).
(3) Refit the mounting flange(1) to cover(2)

with two cap screws(70) and detach the
cover(2) complete with the mounting
flange from the body(9) using a pulling
tool centred on the drive shaft.
or chisel cover from body as such action
could damage the machined sealing
faces.
6 -66
Remove the shaft seal(55) from cover(2)
making sure that no damage is sustained
to the surface of the seal bore in the
cover.

body(9) mark it using a soft pencil or a
felt-tip pen to ensure correct reassembly.

prevent jamming.
plate(35) from body(9) complete with
6 -67
cardboard boxes.
Feature Damage
Surfaces
Bearing Loose
(2) Gears
Feature Damage
Wear due to seal(s)
6 -68
Feature Damage
Surfaces

(4) Bolts/Studs
Feature Damage

(5) Plain bearings

Feature Damage

PTEF Coating Worn
(6) Coupling
Feature Damage

6 -69
(1) The seal side of the wear plate must be adjacent to the cover(2) or body(9).
drawing.
6 -70
8) ASSEMBLY
(2) Place body(9) vertically with front section

gear pockets upper most.

and back up seal down through the
housing to the bottom of the gear pockets.
position.
Fit the wear plate(30) complete with seal
and back up seal.
(3) Fit new O-ring(60) into groove in body(9).

Fit front cover(2) over the drive gear and
secure with cap screws(70).
Tighten cap screws(80) to half torque and
then full torque in diagonal sequence to
6 -71
(4) Fit shaft seal(55) using appropriate tooling
as per assembly drawing, in correct
position and direction.
Ɠ Molybdenum disulphide grease should be
sparingly applied to the lip of the shaft
seal.
(5) Apply a small ring of loctite low strength

gasket eliminator to the interface of
mounting flange(1) and fit to front
cover(2), ensure that location sleeve(85)
is in place and correctly positioned.
(6) Secure mounting flange(1) with cap

screws(70) and tighten to half torque and
then full torque in a diagonal sequence to
6 -72
2. BOOM AND BUCKET CYLINDER
1) BOOM CYLINDER
9,8 6,5 3 7 24 23 11,10 4 2 25,26,27 14,13 17 15 16 22 19 18 24 23
20 1 21 12 28,29

5 Rod seal 15 Piston seal 25 Clamp
6 Back up ring 16 Wear ring 26 Bolt
7 Buffer ring 17 Dust ring 27 Spring washer
10 O-ring 20 Bolt
6 -73
2) BUCKET CYLINDER
9,8 6,5 7 3 4 11,10 2 25, 25-1 1 14,13 12 17 15 16 19 18 28,29
26,27 20 24 23 21 22

5 Rod seal 15 Piston seal 25 Band assy
6 Back up ring 16 Wear ring 25-1 Bolt
7 Buffer ring 17 Dust ring 26 Bushing
8 Dust wiper 18 Lock nut 27 Dust seal
9 Snap ring 19 Set screw 28 Bushing
10 O-ring 20 Bolt 29 Dust seal
6 -74
2) TOOLS AND TIGHTENING TORQUE
(1) Tools
Tool name Remark
8
10
Allen wrench B
14
17
17
Spanner
19
(-) Driver Small and large sizes
Tourque wrench Capable of tightening with the specified torques

Size
Part name Item Size
kgfşm lbfşft
Bucket cylinder 20 M16ź2.0ź65 23Ź2 166Ź14
Socket head bolt
Boom cylinder 20 M20ź2.5ź70 46Ź5 333Ź36
Bucket cylinder 19 M10ź1.5ź12 5.4Ź0.5 39Ź3.6
Set screw
Boom cylinder 19 M10ź1.5ź12 5.4Ź0.5 39Ź3.6
Bucket cylinder 18 M64ź3.0ź38 150Ź15 1085Ź108
Piston nut
Boom cylinder 18 M90ź3.0ź45 150Ź15 1085Ź108
Bucket cylinder 12 D160ź63 100Ź10 723Ź72
Piston
Boom cylinder 12 D200ź77 100Ź10 723Ź72
Bucket cylinder 24 M10ź1.5ź55 5.4Ź0.5 39Ź3.6
Socket head bolt
Boom cylinder 24 M12ź1.75ź60 9.4Ź1 68Ź7.2
Bucket cylinder 25-1 M12ź1.75ź45 5.5Ź0.6 40Ź4.3
Hex head bolt
Boom cylinder 26 M10ź1.5ź15 3.2Ź0.5 23Ź3.6
6 -75
3) DISASSEMBLY
(1) Remove gland and piston rod
‫ ڸ‬Hold the clevis section of the tube in a
vise. Use mouth pieces so as not to
damage the machined surface of the
cylinder tube. Do not make use of the
outside piping as a locking means.
‫ ڹ‬Pull out piston rod(2) about 200mm

(7.8 in). Because the piston rod is rather
heavy, finish extending it with air
m
0m
20
pressure after the oil draining operation.
‫ ں‬Loosen and remove socket blots(20) of

the gland(3) in sequence. 20
Ɠ Cover the extracted piston rod(2) with
rag to prevent it from being accidentally
damaged during operation. 3
2
Cover hear
with rag Hexagon
socket wrench
‫ ڻ‬Draw out gland(3) and piston rod (2)

assembly together from cylinder tube(1).
1
Ɠ Since the piston rod assembly is heavy Lift
in this case, lift the tip of the piston rod(2) 2
with a crane or some means and draw it
3
out. However, when piston rod(2) has
been drawn out to approximately two
thirds of its length, lift it in its center to Oil pan
Pull straight
draw it completely. sideways
6 -76
Note that the plated surface of piston
rod(2) is to be lifted. For this reason, do
not use a wire sling and others that may
damage it, but use a strong cloth belt or a
rope.
‫ ڼ‬Place the removed piston rod assembly

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

‫ ڸ‬Loosen the screw(19) and remove the 13,14 17 15 12 16 19
piston nut(18).
‫ ڹ‬Remove piston assembly(12), back up
ring(14), O-ring(13).
‫ ں‬Remove the gland assembly from piston

Lift with a crane
rod(2).
Ɠ If is too heavy to move, move it by Plastic 3 4 2
Hammer
striking the flanged part of gland(3) with a
plastic hammer. Pull straight
Ɠ Pull it straight with gland assembly lifted
with a crane.
Exercise care so as not to damage the lip
of rod bushing(4) and packing(5, 6, 7, 8,
9) by the threads of piston rod(2).
6 -77
(3) Disassemble the piston assembly
‫ ڸ‬Remove wear ring(16). 16 15 16
Remove and piston seal(15).
Exercise care in this operation not to
damage the grooves.
(4) Disassemble gland assembly

‫ ڸ‬Remove back up ring(11), and O-ring 9,8 6,5 7 11 10 4
(10).
‫ ڹ‬Remove snap ring(9) and dust wiper(8).
‫ ں‬Remove back up ring(6), rod seal(5) and
buffer ring(7).
damage the grooves.
Ɠ Do not remove seal and ring, if does not
damaged.
6 -78
4) ASSEMBLY
(1) Assemble gland assembly
‫ ڸ‬Coat the inner face of gland(3) with
hydraulic oil.
3
‫ ڹ‬Coat dust wiper(8) with grease and fit

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

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

Therefore, confirm it before fitting them.
Push bar
Ɠ Fitting rod seal(5) up side down may
damage its lip. Therefore check the
correct direction that is shown in fig.
5
6 -79
‫ ڼ‬Fit back up ring(11) to gland(3).
Ɠ Put the backup ring in the warm water of
30~50Ş C.
10
‫ ڽ‬Fit O-ring(9) to gland(3).
11
(2) Assemble piston assembly

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

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

piston(12). 14,13 17 15 16 12
‫ ڻ‬Fit back up ring(14) and O-ring(13) to
piston(12).
6 -80
(3) Install piston and gland assembly
‫ ڸ‬Fix the piston rod assembly to the work Gland assembly
bench.
Piston rod
‫ ڹ‬Apply hydraulic oil to the outer surface of
piston rod(2), the inner surface of piston
and gland.
‫ ں‬Insert gland assembly to piston rod(2).
‫ ڻ‬Fit piston assembly to piston rod.

şTightening torque : 100Ź10kgfşm Piston assembly
(723Ź72lbfşft)
Piston rod
‫ ڼ‬Tighten piston nut(18) and screw(19) to

piston rod(2). 2 19 18
şTightening torque
Item kgfşm lbfşft
18 150 Ź 15 1085 Ź 108

19 5.4 Ź 0.5 39 Ź 3.6
6 -81
(4) Overall assemble
Fix with bar
‫ ڸ‬Place a V-block on a rigid work bench.
Mount the cylinder tube assembly(1) on it Lift 1
and fix the assembly by passing a bar
through the clevis hole to lock the
assembly. Straight
‫ ڹ‬Insert the piston rod assembly in to the
cylinder tube assembly, while lifting and
moving the piston rod assembly with a Apply liquid packing
crane.
Ɠ Be careful not to damage piston seal by
thread of cylinder tube.
‫ ں‬Match the bolts holes in the cylinder
head flange to the tapped holes in the
cylinder tube assembly and tighten
socket bolts to a specified torque.
Ɠ Refer to the table of tightening torque.
Hexagon
socket wrench
6 -82
SECTION 7 ELECTRICAL SYSTEM
GROUP 1 COMPONENT LOCATION
1. LOCATION 1
8 14
1 9 15
2 10 16
3 11
12
4
13
5
6
17
18
19
20
7 21
22
23
1 Multi function switch 9 Beacon switch(Opt) 17 Rear wiper/washer switch

2 Starting switch 10 Work lamp switch 18 Air conditioner switch
3 Horn button 11 Main light switch 19 Hazard switch
4 Cluster 12 Clutch cut off switch 20 Aircon & heater switch
5 EGS lever 13 Parking brake switch 21 Check unit
6 Kick down switch 14 Ride control switch(Opt) 22 Relay board
7 Service meter 15 Cold start switch(Opt) 23 Fuse box
8 Emergency steering pilot lamp(Opt) 16 Buzzer stop switch
7-1
2. LOCATION 2
12
16
9 8
15
10
5
14
2
6
1
13
11
1 Alternator 7 Oil temp sender 13 Battery

2 Start relay 8 Tail stop flasher lamp 14 Speed meter sender
3 Clutch oil press switch 9 Work lamp 15 Front turn lamp
4 Back up buzzer 10 Head lamp 16 Air cleaner switch
5 Horn 11 Number plate lamp
6 Coolant temp sender 12 Proximate switch
7-2
GROUP 2 ELECTRICAL CIRCUIT
7-3
CAB SIDE T/M HARNESS
FRONT SIDE
FRAME SIDE
GAUGE SIDE
7-4
1. ILLUMINATION CIRCUIT
1) OPERATING FLOW
Fuse box (No.20) Illumination switch [CS-39(1)] Switch ON, 1st step
[CS-39(7)] Hazard and illumination switch indicator lamp ON
[CS-39(5)] Fuse box(11) I/conn [CN-3(6)] RH Combi clearance lamp ON [CL-16(4)]
I/conn [CN-10(1)] LH Head clearance lamp ON [CL-3(4)]
I/conn [CN-7(14)] All cluster guage lamp ON
Fuse box(12) I/conn [CN-3(8)] No. plate lamp ON [CL-21(2)]
LH Combi clearance lamp ON [CL-15(4)]
I/conn [CN-10(2)] RH Head clearance lamp ON [CL-4(4)]
2) CHECK POINT
Engine Key switch Check point Voltage
‫ ڸ‬- GND (Switch input)

‫ ڹ‬- GND (Switch output)
OFF ON 20~25V
‫ ں‬- GND (To light)
‫ ڻ‬- GND (To gauge lamp)
Ɠ GND : Ground
7-5
ILLUMINATION CIRCUIT
FUSE BOX
CN-36
CN-8 LH HEAD LIGHT
2
CL-3
ILL & HEAD LAMP SW 3 RH HEAD LIGHT
CL-4
CN-10 3
NUMBERPLATE LAMP
CS-39
CL-21
1
RH COMBI
CN-3
3 CL-16
LH COMBI
CL-15
SPEED METER
CN-127
T/M TEMP
CS-41
CN-7
JT-29
CN-119
WATER TEMP
HAZARD SW
CN-117
VOLT METER
CN-104
FUEL METER
4
CN-107
7-6
2. HEAD LIGHT CIRCUIT
1) OPERATING FLOW
Fuse box(No.19) Head light switch [CS-39(4)] Light switch ON, 2nd step [CS-39(2)]
Multi function switch [CS-11(8)]
Multi function switch DOWN [CS-11(7)] I/conn [CN-10(4)] LH Head light low beam
[CL-3(1)]
RH Head light low beam
[CL-4(1)]
Multi function switch UP [CS-11(6)] I/conn [CN-10(3)] LH Head light high beam
[CL-3(2)]
RH Head light high beam
[CL-4(2)]
I/conn [CN-7(3)] Cluster high beam pilot lamp
ON [CL-41(2)]
2) CHECK POINT

‫ ں‬- GND (Multi function input)
‫ ڻ‬- GND (Multi function output)
OFF ON 20~25V
‫ ڼ‬- GND (Multi function output)
‫ ڽ‬- GND (Low beam)
‫ ھ‬- GND (High beam)
‫ ڿ‬- GND (Passing B+)
Ɠ GND : Ground
7-7
HEAD LIGHT CIRCUIT
FUSE BOX
CN-36
LH HEAD LIGHT
ILL & HEAD LAMP SW
1
CL-3
RH HEAD LIGHT
CS-39 CL-4
CN-8
HI BEAM PILOT LAMP
7
CN-10
CL-41
4
EARTH
3
5 6
CS-11
MULTI FUNCTION SW CN-7 JT-28
7-8
3. WORK LIGHT CIRCUIT
1) OPERATING FLOW
Fuse box(No.17) Work light switch [CS-21(5)] Work light switch ON [CS-21(1)]
I/conn [CN-5(4)] Front work lamp(LH) ON [CL-6(2)]
Front work lamp(RH) ON [CL-5(2)]
Work light switch [CS-21(6)] Work light switch ON [CS-21(2)]
I/conn [CN-3(4)] Rear work lamp(LH) ON [CL-22(2)]
Rear work lamp(RH) ON [CL-23(2)]
Work lamp switch indicator lamp ON
2) CHECK POINT

OFF ON 20~25V
‫ ں‬- GND (Front work light)
‫ ڻ‬- GND (Rear work light)
Ɠ GND : Ground
7-9
WORK LIGHT SWITCH
FUSE BOX
CN-36
3
1 1 FRONT WORK
WORK LAMP SW LIGHT,LH
CN-5
CL-6
FRONT WORK
LIGHT,RH
CL-5
CS-21
2 3
2
4
REAR WORK
CN-3 LIGHT,LH
CL-22
REAR WORK
LIGHT,RH
CL-23
7-10
4. STARTING CIRCUIT
1) OPERATING FLOW
Battery(+) terminal Battery relay(M8, B+ terminal) Fusible link [CN-60(1)]
I/conn [CN-1(1)] Fuse box (No.13) Start switch [CS-2(1)]
Ɠ 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-2(1)] Battery relay [CR-1]
Battery relay operating(All power is supplied with the electric component)
Start switch [CS-2(3)] Fuse box [No.4] I/conn [CN-2(8)]
I/conn [CN-4(9)] Engine stop solenoid [CN-79]
(2) When start key switch is in START position
Start switch START [CS-2(5)] Start safety relay [CR-5(2)] Start safety relay [CR-5(4)]
I/conn [CN-3(3)] I/conn [CN-4(7)] Start relay [CR-23(2)]
Starter(Terminal B and M connector of start motor)
+
2) CHECK POINT
‫ ڸ‬- GND (Battery B+)

‫ ڹ‬- GND (Fusible link)
‫ ں‬- GND (Start key B+)
‫ ڻ‬- GND (Start key BR terminal)
‫ ڼ‬- GND (I/conn CN-2(1))
Running ON 20~25V
‫ ڽ‬- GND (Start key R2 terminal)
‫ ھ‬- GND (Start safety relay output)
‫ ڿ‬- GND (Check unit)
‫ ۀ‬- GND (Start key IG terminal)
‫ ہ‬- GND (Engine stop solenoid)
Ɠ GND : Ground
7-11
STARTING CIRCUIT
CN-36
ELECTRIC GEAR SELECTOR PROLIX SW CHECK UNIT
CS-7
FUSE BOX
CN-58
SAFETY RY 8
CN-111
CR-5
BATT RY
60R 60R 60B 60B
TO STARTER
CN-15
CR-1 MASTER SW
1
CN-60 STARTER
TO BATT
2
DO-4
CN-45
9 4 CN-1
DO-3
START RY
6
3 CR-23
ENGINE STOP SOL
CS-2
5
CN-79
10
START SWITCH
CN-4
CN-2
CN-3
7-12
5. ENGINE STOP CIRCUIT
1) OPERATING FLOW
Start key OFF [CS-2(3)] Fuse box (No.4) I/conn [CN-2(8)] I/conn [CN-4(9)]
Engine stop solenoid OFF [CN-79]
2) CHECK POINT
‫ ۀ‬- GND (Start key IG terminal)

OFF OFF 0V
‫ ہ‬- GND (Engine stop solenoid)
Ɠ GND : Ground
3) WIRING DIAGRAM - See page 7-12.
7-13
6. CHARGING CIRCUIT
When the starter is activated and the engine is started, the operator releases the key switch to the
ON position.
Charging current generated by operating alternator flows into the battery through the battery
relay(CR-1).
The current also flows from alternator to each electrical component and controller through the fuse
box.
1) OPERATING FLOW
(1) Warning flow
Altermator [CN-74(I)] I/conn [CN-4(6)] I/conn [CN-2(2)] Check unit [CN-58(2)ơ(18)]
I/conn [CN-6(1)] Cluster charge warning lamp ON [CL-46(1), Below 24V]
JT-27(4)ơ(10) Volt meter [CN-104(B)]
(2) Charging flow
Alternator Starter [CN-45(B+)] Battery relay [CR-1]
Battery(+) terminal Charging
I/conn [CN-60(1),(2)] I/conn [CN-1(1),(2)] Fuse box
2) CHECK POINT
‫ ڸ‬- GND (Battery)

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

Ɠ GND : Ground
7-14
CHARGING CIRCUIT
FUSE BOX
6
CHECK UNIT
CN-1 CN-60
CN-58
JT-27
CN-36
5
24V
CHARGE WARNING LAMP
CL-46
2
7 1
MASTER SW
DO-5
BATT RY 60R
60R 60B 60B
TO STARTER
CR-1
VOLT METER
STARTER
TO BATT
CN-104
CN-6
CN-45
3
ALTERNATOR
CN-74
4
CN-2 CN-4
7-15
7. ELECTRIC PARKING, DECLUTCH CIRCUIT
1) OPERATING FLOW
(1) Parking OFF
Fuse box (No.6) Parking switch OFF [CS-17(6)‫(آ‬8)] I/conn [CN-8(3)]
Parking solenoid ON (Activated) Parking brake released (By hydraulic pressure)
(2) Parking ON
Fuse box (No.6) Parking switch ON Parking solenoid [CN-71] OFF
Parking brake applied [By spring force]
[CS-17(6)‫(آ‬2)] Parking switch indicator lamp ON
[CS-17(5)‫(آ‬1)] I/conn [CN-15(4)]
EGS [CN-111(14)] T/M declutch
(3) Declutch ON
Fuse box (No.6) Clutch cut-off switch ON Clutch cut-off switch [CS-42(6)‫(آ‬2)]
Clutch cut-off switch indicator lamp ON
Clutch cut-off switch [CS-42(5) ‫(آ‬1)]
Service brake applied
Service brake pressure switch ON [CD-5]
I/conn [CN-15(4)] Declutch
Clutch oil pressure switch
2) CHECK POINT
‫ ڸ‬- GND (Parking switch input)

‫ ڹ‬- GND (Parking switch output)
‫ ں‬- GND (Parking switch input)
Running ON ‫ ڻ‬- GND (Parking switch output) 20~25V
‫ ڼ‬- GND (Parking solenoid)
‫ ڽ‬- GND (Press switch clutch cut-off)
‫ ھ‬- GND (Decutch input signal)
Ɠ GND : Ground
7-16
ELECTRIC PARKING, DECLUTCH CIRCUIT
FUSE BOX
ELECTRIC GEAR SELECTOR CHECK UNIT
CN-58
PROLIX SW
CN-111
CS-7
CN-36
CN-15
7 NEUTRAL RY
CR-38
2 1 3
PARKING SW
CN-8
CS-17
4
CLUTCH CUT-OFF SW
6
5
CD-5
CN-71
CS-43
CS-42
DO-9
PARKING CLUTCH EMERGENCY
SOLENOID CUT-OFF TRAVEL SW
7-17
8. WIPER AND WASHER CIRCUIT
1) OPERATING FLOW
Fuse box (No.7) Wiper relay [CR-4(1)‫(آ‬3)] Front wiper motor [CN-21(6)]
Front relay 2 [CR-26(2), (3)]
Multi function switch [CS-12(6)]
Rear wiper & washer switch [CS-3(1)]
Rear wiper motor [CN-102(6)]
(1) Front washer switch ON
‫ ڸ‬Washer switch ON [CS-12(6)‫(آ‬2)] Washer tank [CN-22(2)] Washer operating
Check unit [CN-58(21)‫(آ‬15)] Wiper relay 2
[CR-26(2)‫(آ‬4)] Wiper motor [CN-21(2)]
Wiper motor operating(Low)
(2) Front wiper switch ON
‫ ڸ‬INT position
Wiper switch ON [CS-12(1)] Check unit [CN-58(10)‫(آ‬15)] Wiper relay[CR-26(2)‫(آ‬4)]
Wiper motor [CN-21(2)] Wiper motor intermittently operating
‫ ڹ‬Lo position
Wiper switch ON [CS-12(6)‫(آ‬4)] Wiper motor [CN-21(2)] Wiper motor operating (Low)
‫ ں‬Hi position
Wiper switch ON [CS-12(6)‫(آ‬3)] Wiper relay [CR-4(1)‫(آ‬4)] Wiper motor [CN-21(3)]
Wiper motor operating(High)
(3) Auto-parking(When switch OFF)
Wiper motor [CN-21(2)] OFF Fuse box (No.7) Wiper relay [CR-4(4)‫(آ‬3)]
Wiper relay 2 [CR-26(3)] Wiper motor [CN-21(5)‫(آ‬4)] Wiper motor stop
(4) Rear wiper and washer switch
‫ ڸ‬Wiper switch ON(1st step)
Wiper switch ON [CS-3(1)‫(آ‬6)] Wiper motor [CN-102(5)] Wiper motor operating
Rear wiper and washer switch indicator lamp ON
‫ ڹ‬Washer switch ON(2nd step)
Washer switch ON [CS-3(1)‫(آ‬3)] Rear washer tank [CN-103(2)] Washer operating
2) CHECK POINT

‫ ڸ‬- GND (Front wiper switch power input)
‫ ڹ‬- GND (Rear wiper switch power input)
‫ ں‬- GND (Wiper relay power input)
‫ ڻ‬- GND (Front wiper motor Lo power input)
‫ ڼ‬- GND (Front wiper motor High power input)
Stop ON 20~25V
‫ ڽ‬- GND (Wiper relay power input)
‫ ھ‬- GND (Front washer power output)
‫ ڿ‬- GND (Rear washer power output)
‫ ۀ‬- GND (Front wiper motor power output)
‫ ہ‬- GND (Rear wiper motor power output)
Ɠ GND : Ground
7-18
WIPER AND WASHER CIRCUIT
REAR WIPER CHECK UNIT FUSE BOX
CN-102
CN-58
CN-36 6
WIPER RELAY 2
CR-26
2 3
WIPER RELAY
CR-4
5
7
1 7 5
4
CS-11
CS-12
CS-5
CN-21
8
10
2
CS-3
FRONT WIPER
CN-22
CN-103
REAR WIPER & WASHER SW FRONT WASHER REAR WASHER MULTI FUNCTION SWITCH
7-19
MONITORING CIRCUIT
CHECK UNIT T/M TEMP

BRAKE OIL
CL-45
A/CLEANER FILTER
CN-119
WATER TEMP
CL-50
CN-58
ENGINE OIL
CL-49
CN-117
OVER HEAT
FUEL METER
HYD TEMP
CL-48
PARKING CL-47
CN-6
CN-107
CL-44
FUEL SENDER
24V
CD-2 BRAKE OIL PS
CN-7
CD-3
T/M OIL TEMP
JT-27
CD-29
CN-9
CN-8 CN-11
PARKING PS
CD-26 CN-2
ENG OIL PRESS
CD-18
OVER HEAT SW
CD-10
CD-1
CD-9
CN-3 CN-4 AIR FILTER
WATER TEMP
HYD TEMP CD-8
7-20
HAZARD, TURN AND ROTARY CIRCUIT
FUES BOX
COMBI LAMP RH
CL-16
ROTARY LAMP
COMBI LAMP LH
CN-5 CL-7
CN-2
CL-15
FLASHER UNIT CN-36
CR-11
RH TURN LAMP,RR
CL-43
LH TURN LAMP,RR
CL-42
CN-7 EARTH
LH COMBI LAMP,FR
CS-11
CS-12
CS-5
CL-24
RH COMBI LAMP,FR
CN-8
CL-25
JT-28
CS-41
CS-23
HAZARD SW BEACON LAMP SW MULTI FUNCTION SWITCH CN-10
7-21
3. MONITORING SYSTEM
1. CLUSTER
The gauges panel consists of gauges and monitors as shown below, to warn the operator in case of
abnormal machine operation or conditions for the appropriate operation and inspection.
ş Gauges : Indicate operating status of the machine.
ş Warning lamp : Indicate abnormality of the machine.
ş Pilot lamp : Indicate operating status of the machine.
Ɠ The monitor installed on this machine does not entirely guarantee the condition of the
machine.
Daily inspection should be performed according to chapter 6, MAINTENANCE.
Engine oil pressure warning lamp T/M oil pressure warning lamp
Overheat warning lamp Hyd oil temp warning lamp
Battery charging warning lamp Brake fail warning lamp
Left turning pilot lamp Right turning pilot lamp
High beam pilot lamp Parking brake pilot lamp
20 30
20 P
10
40
10
5 30
0 mph
0 50
km/h
E F
WATER FUEL
TRANS BATT
T/M oil temperature gauge Battery volt meter

Engine coolant temperature gauge Speedometer
Air cleaner warning lamp Fuel gauge
1) SPEEDOMETER
(1) Specification
30
20 Input Hz Input pulse
10 20
40
10
5 0 mph
30 Vpp = 20V MIN
0
km/h 50 1km = 26.2Hz
GND 1.8V MAX
(2) Indicated standard
Standard(km/h) 0 20 40
+4.8 +4.8
Allowable(km/h) 0
0 0
7-22
2) FUEL GAUGE
(1) This gauge indicates the amount of fuel in the fuel tank.
Red
Red White
White
(2) Fill the fuel when the red range illuminates.
E F
(3) The gauge indicates continuously the current fuel amount
FUEL
even after turn OFF the starting switch. This does not mean
that the gauge is out of order.
Ɠ If the gauge illuminates the red range even though the
machine is on the normal condition, check the electric
device as that can be caused by the poor connection of
electricity or sensor.
Fuel quantity Tolerance Resistance(‫)װ‬ Zone
E +0.7, -0.7 240 Red

F +2.0, -2.0 33.5 White
3) ENGINE COOLANT TEMPERATURE GAUGE

(1) This indicates the temperature of coolant.
Green
Green Red
Red şGreen range : 37-105Ş C(99-221Ş F)
şRed range : 105Ş C(221ŞF) Above
(2) The green range illuminates when operating.
WATER
(3) Keep idling engine at low speed until the green range
illuminates, before operation of machine.
(4) When the red range illuminates, turn OFF the engine, check
the radiator and engine.
Temperature
(Ş
C) Tolerance Resistance(‫)װ‬ Zone
37 +11.7, -13.9 533.2 Green

105 +1.7, -1.8 73.3 Red
7-23
4) TRANSMISSION OIL TEMPERATURE GAUGE
(1) This range indicates the temperature of transmission oil.
Green
Green Red
Red şGreen range : 37-120Ş C(99-248ŞF)
şRed range : 120Ş C(248ŞF) Above
(2) The green range indicates when operating.
TRANS
(3) Keep idling engine at low speed until the green range
indicates, before operation of machine.
(4) If the indicator is in the red range, it means the transmission is
overheated. Be careful that the indicator does not move into
the red range.
Temperature
(Ş
C) Tolerance Resistance(‫)װ‬ Zone
37 +13.9, -16.7 767.7 Green

120 +2.8, -2.8 65.4 Red
5) BATTERY VOLT METER

(1) This gauge indicates the voltage in the charging system when
the engine is running.
White
White Green
Green Red
Red (2) If the indicator is below 24V(White range), it means that the
electricity is being discharged. If the indicator is above
30V(Red range), an unusually high voltage may damage the
BATT
alternator. Check the charging system in both cases.
Temperature Input voltage
(Ş
C) Tolerance (V) Zone
24 +0.50, -0.50 24 Green

30 +0.25, -0.25 30 Red
6) DIRECTION PILOT LAMP

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

(1) This lamp works when the illuminating direction is upward.
(2) This lamp comes ON when the dimmer switch is operated,
e.g., when passing another vehicle.
7-24
8) PARKING BRAKE PILOT LAMP
(1) When the parking brake is actuated, the lamp lights ON.
Ɠ Check the lamp is OFF before driving.
P
9) BRAKE FAIL WARNING LAMP
(1) The lamp lights ON when the oil pressure of service brake
drops below the normal range.
(2) When the lamp is ON, stop the engine and check for its
cause.
Ɠ Do not operate until any problems are corrected.
10) TRANSMISSION OIL PRESSURE WARNING LAMP

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

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

(1) This lamp is ON when key ON, it is turned OFF after starting
the engine.
(2) Check the battery charging circuit when this lamp comes ON,
during engine operation.
7-25
13) ENGINE OIL PRESSURE WARNING LAMP
(1) If lamp comes ON during engine operation, shut OFF
engine immediately. Check oil level.
14) OVERHEAT WARNING LAMP

(1) This lamp is turned ON when the temperature of cooling water
is over the normal temperature (110Ş
C, 230Ş
F).
(2) Check the cooling system when the lamp is ON.
15) HYDRAULIC OIL TEMP WARNING LAMP

(1) This warning lamp operates and the buzzer sounds when the
temperature of hydraulic oil is over 105Ş
C(221Ş
F).
(2) Check the hydraulic oil level when the lamp is turned ON.
(3) Check for debris between oil cooler and radiator.
7-26
2. SWITCHES
Emergency steering pilot lamp(Option) Ride control switch(Option)

Beacon switch(Option) Cold start switch(Option)
Work lamp switch Prolix switch
Main light switch Buzzer stop switch
Clutch cut off switch
Parking brake switch
2
2
R
Switch panel
Rear wiper/washer switch
Multi function switch Air conditioner switch
Starting switch Hazard switch
Horn button Kick down switch
Kick down switch
Override switch
1) STARTING SWITCH
(1) There are three positions, OFF, ON and START.
F
ON STAR
T
(2) OFF : None of electrical circuits activate.
OF
(3) ON : All the systems of machine operate.

(4) START : Use when operating the engine.
Release key immediately after starting.
7-27
2) OVERRIDE SWITCH
(1) This switch is for an emergency in case the EGS(Electronic Gear
Selection) is inoperative.
Forward
(2) The machine can travel with forward 2th or backward 2th at EGS
prolix switch ON.
N
Backward
3) HAZARD SWITCH
(1) Use for parking, or roading machine.
Ɠ If the switch is left ON for a long time, the battery may be
discharged.
(2) The below indicator lamp is turned ON when operating this switch.
4) CLUTCH CUT OFF SWITCH

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

(1) This switch is pressed, the parking brake will start to operate and the
gauge panel warning lamp will comes ON.
Ɠ When operating the gear selector lever, be sure to release the
P
parking brake. If the machine is operated with the parking
brake engaged, the brake will overheat and may cause the
brake system to go out of order.
7-28
6) MAIN LIGHT SWITCH
(1) This switch use to operates the clearance lamp and head light by two step.
ϦFirst step : Clearance lamp and cluster illumination lamp comes
ON. Also, the below indicator lamp comes ON.
ϦSecond step : Head light comes ON.
7) WORK LAMP SWITCH

(1) This switch turns ON the working lamps located on the cab and
radiator door.
8) AIR CONDITIONER SWITCH

(1) This switch use to operates the air conditioner.
(2) Refer to the air conditioner and heater for detail operation.
9) REAR WIPER AND WASHER SWITCH

(1) The switch use to operates the rear wiper and washer by two step.
şFirst step : The rear wiper operates.
şSecond step : The washer liquid is sprayed and the rear wiper is
operated only while pressing. If release the switch,
return to the first step position.
7-29
10) BUZZER STOP SWITCH
(1) The red lamp on the cluster lights ON and the buzzer sounds when
the machine has a problem.
In this case, if the switch is pressed, the buzzer will be stopped. Be
sure to check machine for problems.
(2) Wait until the lamp is turned OFF, if the red lamp lights ON after the
buzzer stopped.
If not, stop engine and check the system which the lamp is ON.
11) COLD START SWITCH(Option)

(1) This switch is used for starting the engine in cold weather.
If pressed, starting aid fluid is injected for easier engine starting.
Ɠ Never hold the push button switch in for more than 5 seconds,
as this can damage the electric valve solenoid.
12) CAB LAMP SWITCH

(1) This switch turns ON the cab room lamp.
13) KICK DOWN SWITCH
Kick down switch (1) The kick-down button is pushed, gear selection will instantly changes
from F2(R2) to F1(R1).
(2) If the button is pushed or machine speed reaches up to 6km/hr,
the gear selection will automatically change to F2(R2).
7-30
14) EMERGENCY STEERING PILOT LAMP(Option)
Primary
Primary
(1) Primary
Emergency
Emergency If the oil pressure in the steering pump drops, the lamp will light up. If
this lamp flashes during operation, the action alarm should sound.
Ɠ If the lamp lights up, immediately pull the machine to a safe
place and stop the machine.
(2) Emergency
This lamp will flash if the oil pressure in the emergency steering
pump drops. The lamp notifies the operator that if the steering
system also failed at this time, there is no emergency steering
system for backup.
Ɠ Immediately pull the machine to a convenient stop and stop the
engine.
Ɠ This machine is equipped with ground driven emergency
steering pump. It is normal for the lamp to flash after 5
seconds when the machine is stopped.
15) MULTI FUNCTION SWITCH

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

‫ ڸ‬This switch is used to turn the head lights direction.
Up ‫ ڹ‬Switch positions
şUp : To flash for passing
M
şMiddle : Head lights low beam ON
Down şDown : Head lights high beam ON
‫ ں‬If you release the switch when it's in up position, the switch will return
to middle.
(3) Turning switch
Left turning ‫ ڸ‬This switch is used to warn or signal the turning direction of the
machine to other vehicles or equipment.
‫ ڹ‬Push the lever up for turning left, pull the lever down for turning right.
Right turning
7-31
16) HORN BUTTON
(1) If you press the middle of the steering wheel, the horn will sound.
Horn button
17) BEACON SWITCH(Option)

(1) This switch turns ON the rotary light on the cab.
18) EGS PROLIX SWITCH

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

(1) This switch is pressed, the ride control system will start to operate.
The ride control system significantly reduces pitching and loping
without slowing down the travel speed.
7-32
GROUP 4 ELECTRICAL COMPONENT SPECIFICATION
Part name Symbol Specifications Check
Check specific gravity

12V 200Ah 1.280 over : Over charged
Battery
(2EA) 1.280 ~ 1.250 : Normal
1.250 below : Recharging
Rated load : Check coil resistance

24V Normal : About 50
Battery relay
100A(Continuity) Check contact
1000A(30seconds) Normal :
Check disconnection
Normal : 0
Fusible link 24V 60A (Connect ring terminal and
check resistance between
terminal 1 and 2)
Check contact
OFF : (For each
terminal)
Start key -
ON : 0 (For terminal 1-3)
(For terminal 1-5)
START : 0 (For terminal 1-3
Pa
Check contact
Pressure switch N.C TYPE
CD-3 CD-26 Normal : 0 (CLOSE)
CD-25 CD-39 CD-41
Check contact
Pressure switch N.O TYPE
Normal : (OPEN)
CD-4 CD-40
CD-5 CD-11
7-33
Pressure switch 0.5kg/cm2 Check contact

(For engine oil) (N.C TYPE) Normal : 0 (CLOSE)
T Check resistance
Coolant temp - Normal :
sensor
CD-9 225 F Over : 0
C
Coolant Check resistance
-
temp sensor 192 13.5 at 73.9 C
Pressure :
Air cleaner Check contact
635mmH2O
pressure switch Normal :
(N.O TYPE)
2 Check LED lamp

Parking
1 24V 1.2A Check Resistance
solenoid
About 24
CN-71
Check resistance
Reed switch :
Fuel sender Full : About 30
Magnetic type
Low level : About 300
7-34
T/M oil C Check resistance

temperature 1/2 P.T.F 137.2 14.5
sender at 87.8 C
1 2 1
Check resistance
2
Normal : About 200
Relay 3
24V 20A (For terminal 1-3)
(4pin) 4 4 3
:
CR-2 CR-26 AC RY1
CR-5 AC RY2 AC RY2
CR-30 (For terminal 2-4)
Check resistance
Normal : About 160
(For terminal 2-6)
Relay
24V 20A :0
(5pin)
(For terminal 1-3)
:
(For terminal 1-3)
Proximate
switch 24V 400mA -
CN-101
Check resistance
Hydraulic
- Normal :
temperature
105 C over : 0
CD-1
Check contact
Normal : 1.12
(For terminal 2-4)
Aircon resistor - : 2.07
(For terminal 3-4)
: 3.17
(For terminal 4-1)
7-35
Check resistance
Speaker 4 20W
Normal : 50
CN-23(LH)
CN-24(RH)
Check contact
OFF :
Switch 24V 8A (For terminal 1-5, 2-6)
(Locking type)
:0
CS-17 CS-23 CS-42 CS-50 (For terminal 5-7, 6-8)
CS-21 CS-41 CS-54
Switch Check contact

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

Beacon lamp
(H1 TYPE) Normal : A few
CL-7
Check operation
- Supply power(24V) to
Hour meter
terminal No.2 and contact
terminal No.1 and ground
7-36
Check operation
22-28V 2A
Horn Supply power(24V) to each
110dB
CN-20 CN-25 terminal and connect ground
Check contact
Receiver dryer 24V 2.5A
Normal :
Check resistance
Cassette radio 24V 20W+20W Power ON : 4 +4
(For terminal 1-6, 4-8)
24V 0.5A
Back up buzzer -
110dB
Check contact
Washer pump 24V 2.5A Normal : 26.4
(For terminal 1-2)
CN-103 CN-22
6
5
4
3
24V 1.5A
Hi
Wiper motor 2 2-speed -
E M Lo 1
Auto parking
CN-102 CN-21
7-37
Cigar lighter 24V 5A -
Check contact
Ether 24V 15A
Normal : 1.1
Engine stop Check resistance

24V
solenoid Normal : 15-25
Check voltage
Alternator 20V 60A
Normal : 24-28V
Delco Remy
Starter Operating or not
28MT 24V
1
Aircon Check contact
2 24V 79W
compressor Normal : 13.4
CN-28
7-38
2 Check contact
Start relay 1 24V 200A
Normal : 11.3
CR-23
24V 9A
Blower -
2900 150rpm
Check resistance
Blower switch - Normal : 0 (For terminal 1-2,
3, 4, 5, 6)
Mode actuator
DC Servo motor
and -
temp actuator 9-16V 300mA Max
R 2 Check resistance
Intake actuator M 12V
F 1 Normal : 2.0
Working
temperature of
Thermostat contact point -
A/C ON : 4.5 C
A/C OFF : 1.5 C
7-39
3 E
G 24V
2 B
Flasher unit 85 ~ 190 C/M -
1 L
50dB
CR-11
24V 75W/70W
(H4 TYPE) Check disconnection
Head lamp
24V 4W Normal : A few
(T4W)
4 C
24V 5W
3 T
(R5W)
Combi lamp 2 E -
1 S 2 24V 21W
(P21W)
CL-15 CL-16
24V 21W
Turn lamp -
(P21W)
T/M speed Internal resistance

-
sensor 1480 7.5%
Continuous
capacity :
Master switch 180Amp -
Push in capacity :
1000Amp
7-40
2
24V 200mA
Warning buzzer 1 -
90 5dB( m)
CN-26
Air conditioner
24V -
fan
CN-83
Ether switch
and buzzer Check contact
stop switch 24V 8A OFF :
(Rocker switch (For terminal 1-5, 2-6)
push button)
Check contact
OFF :
Prolix switch
24V 8A (For terminal 1-5, 2-6)
(Locking type)
:0
(For terminal 5-7, 6-8)
Check contact
Emergency Change over OFF :
travel switch switch (For terminal 5-4, 5-6
1-2, 2-3)
Check contact
Normal : 80~90
(For terminal 1-5, 2-6
Joy stick lever -
3-7, )
:
(For terminal 4-8)
7-41
GROUP 5 CONNECTORS
1. CONNECTOR DESTINATION
Connector No. of Connector part No.
Type Destination
number pin Female Male
CN-1 58 2 I/conn(Frame harness-Main harness) S813-030200 S813-130200
CN-2 SWP 12 I/conn(Frame harness-Main harness) S814-012000 S814-112000
CN-5 SWP 8 I/conn(Cab harness-Main harness) S814-008000 S814-108000
CN-6 SWP 12 I/conn(Gauge harness-Main harness) S814-012000 S814-112000
CN-7 SWP 14 I/conn(Gauge harness-Main harness) S814-014000 S814-114000
CN-8 SWP 12 I/conn(Front harness-Main harness) S814-012000 S814-112000
CN-9 SWP 8 I/conn(T/M check harness-Main harness) S814-008000 S814-108000
CN-10 SWP 8 I/conn(Front harness-Main harness) S814-008000 S814-108000
CN-11 SWP 6 I/conn(Front harness-Front cowl harness) S814-006000 S814-106000
CN-12 SWP 12 I/conn(Main harness-AC AVA Assy) S814-012000
CN-13 Fasten 8 I/conn(Main harness-AC AVA Assy) S810-008202
CN-15 - 12 I/conn(Main harness-T/M harness) S814-012000 S814-112000
CN-20 - 1 Horn S819-010122
CN-21 - 6 Front wiper motor 6189-0133
CN-22 - 2 Front washer tank S814-002000
CN-23 Shur 1 Speaker(LH) S822-014000 S822-114004
CN-24 Shur 1 Speaker(RH) S822-014000 S822-114004
CN-25 - 1 Horn S819-010122
CN-26 Fasten 2 Warning buzzer S810-002202
CN-27 PA 9 Cassette and radio S811-009003
CN-28 - 2 Compressor(Air conditioner) 0297-3407
CN-29 - 2 Receiver drier 21L7-12000
CN-30 PA 13 Air conditioner controller S811-013002
CN-36 - 20 Fuse box 21L7-00230
CN-45 Ring term - Starter S820-414000
CN-48 - 1 Hour meter S819-010112
CN-58 - 36 Check unit 344111-1
CN-60 58 2 Fusible link S813-130200
CN-65 Shur 1 Back up buzzer S822-014000
CN-71 J 2 Parking solenoid S816-002001
CN-74 Ring term - Alternator S820-406000 S814-101000
CN-78 Shur 2 Ether S822-014000
CN-79 Ring term - Fuel cut off solenoid S820-106000
CN-83 - 2 Air conditioner fan PH805-02028
CN-100 J 3 Boom kick out S816-003001
CN-101 J 3 Bucket leveler S816-003001
7-42
Connector No. of Connector part No.
Type Destination
number pin Female Male
Light
CL-1 - 2 Room lamp MG610392
CL-2 Fasten 3 Cigar lighter S810-003202
CL-3 SWP 4 Head light(LH) S814-004000
CL-4 SWP 4 Head light(RH) S814-004000
CL-5 SWP 2 Work light(LH) S814-002000
CL-6 SWP 2 Work light(RH) S814-002000
CL-7 Fasten 1 Beacon lamp S810-001202
CL-15 SWP 4 Combi lamp(RR, LH) S814-004000
CL-16 SWP 4 Combi lamp(RR, RH) S814-004000
CL-21 SWP 2 Numberplate lamp S814-002000
CL-22 SWP 2 Work light(LH) S814-002000
CL-23 SWP 2 Work light(RH) S814-002000
CL-24 SWP 2 Turn lamp(LH) S814-002000
CL-25 SWP 2 Turn lamp(RH) S814-002000
CL-41 SWF 2 Hi beam lamp(Dash board) 913328
CL-42 SWF 2 Turn lamp(LH, Dash board) 913328
CL-43 SWF 2 Turn lamp(RH, Dash board) 913328
CL-44 SWF 2 Parking lamp(Dash board) 913328
CL-45 SWF 2 Brake fail lamp(Dash board) 913328
CL-46 SWF 2 Charge lamp(Dash board) 913328
CL-47 SWF 2 Hydraulic oil lamp(Dash board) 913328
CL-48 SWF 2 Over heat lamp(Dash board) 913328
CL-49 SWF 2 Engine oil lamp(Dash board) 913328
CL-50 SWF 2 Air cleaner lamp(Dash board) 913328
CL-51 SWF 2 Transmission oil lamp(Dash board) 913328
CL-52 SWF 2 Glow lamp(Dash board) 913328
CL-53 SWF 2 Steering pressure lamp 913328
CL-54 SWF 2 Steering pump pressure lamp 913328
Sensor, sender
CD-1 - 1 Hyduaulic oil temp sendor 1-150656
CD-2 SWP 2 Fuel sendor S814-002000
CD-4 - 1 Stop lamp pressure switch S819-010112
CD-5 - 1 Clutch cut off pressure switch S819-010112
CD-8 Ring term - Water temp sendor S820-106000
CD-9 - 1 Over heat switch S819-010122
CD-10 Ring term 2 Air cleaner switch S822-014000
CD-18 Ring term - Engine oil pressure switch S820-106000
CD-26 - 1 Parking press S819-010122
7-44
2. CONNECTION TABLE FOR CONNECTORS
1) 58-L TYPE CONNECTOR
No. of
pin Receptacle connector(Female) Plug connector(Male)
1 1
S813-030100 S813-130100
1 2 1 2
S813-030200 S813-130200
7-45
2) PA TYPE CONNECTOR
No. of
11 33
22 55
1 3 22 55
S811-005002 S811-105002
33 77 1 44
11 4
4 3 77
S811-007002 S811-107002
44 99 1
1 55
11 5
44 9
S811-009002 S811-109002
55 11
11 1
1 66
11
1
1 66 5 11
11
S811-011002 S811-111002
7-46
No. of
6 13
13 1 77
13
1
1 77 66 13
S811-013002 S811-113002
8
8 17 11 99
17
17
11 99 8 17
17
S811-017002 S811-117002
10
10 21
21 11 11
11
21
1 11
11 10
10 21
21
S811-021002 S811-121002
7-47
3) 58-X TYPE CONNECTOR
No. of
1 1
S813-060100 S813-160100
22 1
11 22
S813-060200 S813-160200
7-48
4) J TYPE CONNECTOR
No. of
Receptacle connector(Female) Plug connector(Male)
pin
1 1
2 2
S816-002001 S816-102001
22 3 1
3 1 2
S816-003001 S816-103001
7-49
5) SWP TYPE CONNECTOR
No. of
1
1 1
S814-001000 S814-101000
22 1
2
11
S814-002000 S814-102000
3 1
2 1 2 33
S814-003000 S814-103000
22 4
1 33
1 33 2 4
4
S814-004000 S814-104000
7-50
No. of
3 6 11 44
33 66
11 44
S814-006000 S814-106000
44 88
1 5
11 5 4 88
S814-008000 S814-108000
44 1212 11 99
12
11 9 9 44 12
12
S814-012000 S814-112000
3 14
14 11 11
14
11 11 33 14
11
S814-014000 S814-114000
7-51
6) CN TYPE CONNECTOR
No. of
1 1
S810-001202 S810-101202
2
2 2
11 1
1
S810-002202 S810-102202
3 22
11 22 1 33
S810-003202 S810-103202
2 44 1 44
11 33 22 33
S810-004202 S810-104202
7-52
No. of
33 66 11 44
11 4 3
3 66
S810-006202 S810-106202
4 8 11 55
4 8
11 55 4
4 88
S810-008202 S810-108202
7-53
7) BS TYPE CONNECTOR
No. of
2 1
1
2
S812-002001 S812-102001
1 1 2
33
2 3
S812-003001 S812-103001
22 11 3
3
44
1 33 22 44
S812-004001 S812-104001
33 11 4
66
1 4 33 6
6
S812-006001 S812-106001
7-54
8) LC TYPE CONNECTOR
No. of
55 10
10
10
11 6
S815-010000
66 12
12
12
11 77
S815-012000
8 16
16
1 9
S815-016000
99 18
18
18
1 10
10
S815-018000
7-55
No. of
12
12 24
24
24
11 13
S815-024000
7-56
9) 375 FASTEN TYPE CONNECTOR
No. of
Receptacle connector(Female) Plug connector(Male)
pin
1 22 11 2
S810-002402 S810-102402
7-57
GROUP 6 TROUBLESHOOTING
1. WHEN STARTING SWITCH IS TURNED ON, CLUSTER LAMP DOES NOT LIGHT UP
şBefore carrying out below procedure, check all the related connectors are properly inserted and the
fuse No.2 is not blown out and ON/OFF of bulb.
şAfter checking, connect the disconnected connectors again immediately unless otherwise specified.
Cause Remedy
YES
Defective cluster Replace
YES Check voltage
between CN-58
(1) and chassis
Disconnection in Repair or replace
NO
wiring harness or (After clean)
Check voltage poor contact
between CN-7(4) between
and chassis
CN-58(1) and
fuse No.2

NO
poor contact
between CN-7(4)
and fuse No.2
CLUSTER
FUSE
4
No.2
CN-7
CN-58
Check voltage
YES 20 ~ 30V
NO 0V
7-58
2. WHEN COOLANT OVERHEAT LAMP LIGHTS UP(Engine is started)
şBefore carrying out below procedure, check all the related connectors are properly inserted.
Cause Remedy
YES
Coolant overheat Check engine
(105Ş
CŹ2Ş C) system
YES
Defective Replace
Check resistance
YES overheat switch
between CN-4
Does display go (11) and chassis
off when Disconnection in Repair or replace
Starting switch : OFF NO
disconnect CD-9 wiring harness or (After clean)
Check resistance
and connector? YES poor contact
between CN-2(4)
Starting switch : ON between CD-9
Engine : start
and chassis
and CN-2(4)
Starting switch : OFF
Check resistance Disconnection in Repair or replace

NO
between CN-6(4) wiring harness or (After clean)
NO
and chassis poor contact
between CN-6(4)
Before checking, and CN-2(4)
disconnect CD-9

NO
CLUSTER OVERHEAT SWITCH

T
4 4 11
CN-6 CN-2 CN-4 CD-9
CHECK UNIT
24
CN-58
Check resistance
YES MAX 1‫װ‬
NO MIN 1M‫װ‬
7-59
3. WHEN AIR CLEANER LAMP LIGHTS UP(Engine is started)
Cause Remedy
YES
Defective air Repair air cleaner
cleaner or air or replace air
cleaner switch cleaner switch
Does display go YES
off when Disconnection in Repair or replace
disconnect CD-10 wiring harness or (After clean)
and connector? poor contact
Starting switch : ON between CN-11
Engine : start
Check resistance (4) and CD-10
between CN-11
NO YES
(4) and chassis Disconnection in Repair or replace
Before checking, poor contact
disconnect CD-10
between CN-11
Check resistance
between CN-3(5) (4) and CN-3(5)
NO
and chassis YES
Check resistance poor contact CN-3
between CN-6(6)
NO (5) and CN-6(6)
and chassis
NO
CLUSTER
AIR CLEANER SWITCH
6 5 4 Pa
CN-6 CN-3 CN-11 CD-10
CHECK UNIT
36
CN-58
Check resistance
YES MAX 1‫װ‬
NO MIN 1M‫װ‬
7-60
4. WHEN ENGINE OIL PRESSURE LAMP LIGHTS UP(Engine is started)
Cause Remedy
YES
Engine oil leakage, Check engine oil
or defective switch level or replace
switch
YES
Does display go
off when wiring harness or (After clean)
disconnect CD-18 Check resistance poor contact
YES
and connector? between CN-4 between CN-4(10)
Starting switch : ON (10) and chassis -CD-18
Engine : start
Disconnection in Replace
Check resistance NO
wiring harness or
between CN-6(5)
NO
and chassis poor contact
between CN-6(5) -
Starting switch : OFF CN-2(5)- CN-4(10)
Before checking,
disconnect CD-18
NO
ENGINE OIL PRESSURE SWITCH

CLUSTER
5 5 10 Pa
CN-6 CN-2 CN-4 CD-18
CHECK UNIT
23
CN-58
Check resistance
YES MAX 1‫װ‬
NO MIN 1M‫װ‬
7-61
5. WHEN HYDRAULIC OIL TEMPERATURE LAMP LIGHTS UP(Engine is started)
Cause Remedy
YES
High temperature Check hydraulic
of hydraulic oil or oil temperature
defective switch (105Ş CŹ2Ş C),
Does display go hydraulic cooling
off when or replace switch
disconnect CD-1
and connector? YES
Starting switch : ON
Engine : start
Check resistance poor contact
between CN-6(8) between CN-6(8)
NO
and chassis and CD-1
Before checking, Defective cluster Replace
disconnect CD-1 NO
HYDRAULIC OIL
CLUSTER TEMPERATURE SWITCH
T
8
CN-6 CD-1
CHECK UNIT
12
CN-58
Check resistance
YES MAX 1‫װ‬
NO MIN 1M‫װ‬
7-62
6. WHEN TORQUE CONVERTER OIL TEMPERATURE GAUGE DOES NOT OPERATE
(Check torque converter oil temperature lamp ON/OFF)
Cause Remedy
YES
YES
between CN-7 wiring harness or (After clean)
(10) and chassis poor contact
between CN-
Starting switch : ON Check resistance
7(10) and CN-9(6)
Engine : start between CN-9(6)
See : TABLE NO
and chassis YES
Starting switch : OFF wiring harness or (After clean)
See : TABLE
between CD-29 between CN-9(6)
NO
and chassis and CD-29
See : TABLE Defective sender Replace
NO
TRANS
TRANSMISSION OIL
CLUSTER TEMPERATURE SENDER
10 6
CN-7 CN-9 CD-29
Check resistance
YES MAX 1‫װ‬
NO MIN 1M‫װ‬
Check table
Temperature
50Ş
C 92Ş
C 120Ş
C 130Ş
C
Item
Unit resistance(‫)װ‬ 168.7 (34) 19.5 12.4
Tolerance 0Ş~ -10Ş (-) Ź3Ş +10Ş~ 0Ş
Angle -30Ş -8Ş +27Ş +30Ş
7-63
7. WHEN COOLANT TEMPERATURE GAUGE DOES NOT OPERATE
(Check coolant temperature lamp ON/OFF)
Cause Remedy
YES
YES
Check resistance wiring harness or (After clean)
between CN-7 poor contact
(11) and chassis
between CN-7
Starting switch : ON (11) and CN-2(3)
Engine : start Check resistance
See : TABLE between CN-2(3) YES
NO Disconnection in Repair or replace
and chassis
Before checking, poor contact
disconnect connector between CN-2(3)
See : TABLE
Check resistance and CN-4(12)
between CN-4
NO
(12) and chassis YES
Starting switch : OFF wiring harness or (After clean)
See : TABLE
between CD-8 between CN-4
NO
and chassis (12) and CD-8
See : TABLE Coolant overheat Check coolant
NO
TRANS
or defective temperature or
sender replace
CLUSTER WATER TEMPERATURE SENDER
11 3 12
CN-7 CN-2 CN-4 CD-8
Check resistance
YES MAX 1‫װ‬
NO MIN 1M‫װ‬
Check table
Temperature
(40Ş
C) 91Ş
C 105Ş
C 120Ş
C
Item
Unit resistance(‫)װ‬ 222 (41.3) 28 19.2
Tolerance Ź5Ş (-) Ź4.5 (-)
Angle -30Ş 0Ş +13Ş +30Ş
7-64
8. WHEN FUEL GAUGE DOES NOT OPERATE(Check warning lamp ON/OFF)
Cause Remedy
YES
YES
between CN-7 wiring harness or (After clean)
(12) and chassis poor contact
Starting switch : OFF between CN-7
See : TABLE (12) and CN-2(7)
Check resistance
between CN-2(7)
NO YES
and chassis Disconnection in Repair or replace
See : TABLE wiring harness or (After clean)
poor contact
Check resistance between CD-2(1)
between CD-2(2) and CN-2(7)
NO
and chassis
YES
See : TABLE Check circuit Repair or replace
Check resistance
between CD-2(2) (After clean)
between CD-2(2)
and chassis
NO and CD-2(1) with
chassis
See : TABLE Defective sensor Replace
NO
E F
FUEL
FUEL SENDER
CLUSTER
1
12 7 2
CD-2
CN-7 CN-2
Check resistance
YES MAX 1‫װ‬
NO MIN 1M‫װ‬
Check table
Temperature
Empty (1/2) Full
Item
Unit resistance(‫)װ‬ 95 (32.5) 7
Tolerance Ź2.5Ş Ź5Ş Ź2.5Ş
Angle -30Ş 0Ş +30Ş
7-65
9. WHEN GAUGES OF FUEL, HYDRAULIC OIL AND COOLANT INDICATE HIGH OR FULL
Cause Remedy
YES Defective cluster Replace
Check resistance
between CN-7
(13) and chassis
Starting switch : ON NO
Voltage : 20~30v
poor contact
between CN-7
(13) and chassis
CLUSTER
13
CN-7
Check resistance
YES MAX 1‫װ‬
NO MIN 1M‫װ‬
7-66
10. WHEN BATTERY LAMP LIGHTS UP(Engine is started)
Cause Remedy
YES
Check voltage Defective cluster Replace
YES
between CN-6(1)
and chassis Disconnection in Repair or replace
NO
poor contact
between CN-6(1)
and CN-58(18)
YES
Defective check Replace
Check voltage
YES unit
between CN-58
(2) and chassis
Voltage : 27.5~30V
NO
poor contact
Check voltage Check voltage between CN-58(2)
YES
between between CN-2(2) and CN-2(2)
alternator terminal and chassis
YES
"I" and chassis Voltage : 26~30V Disconnection in Repair or replace
Voltage : 26~30V wiring harness or (After clean)
between CN-4(6) between CN-4(6)
NO
and chassis and CN-2(2)

NO
poor contact
between CN-4(6)
and alternator
terminal " I "
Defective alternator Replace

NO
CLUSTER CHECK UNIT
1 18
CN-6
2
CN-58
ALTERNATOR
2 6 "I" TERMINAL
Check valtage
CN-2 CN-4
YES 20 ~ 30V
NO 0V
7-67
11. WHEN PARKING SOLENOID DOES NOT WORK
fuse No.6 is not blown out.
Cause Remedy
YES
Defective parking Replace
brake solenoid
Check voltage YES Disconnection in

between CN-71
wiring harness or
(2) and chassis
poor contact
Starting switch : ON between CN-71(2)
Parking switch : ON-OFF
Check voltage
and CN -8(3)
Voltage : 20~30V between CN-8(3)
NO and chassis YES
Parking switch : OFF
Voltage : 20~30V Check voltage wiring harness or (After clean)
between CS-17 poor contact
(8) and chassis between CS-17(8)
NO Parking switch : OFF and CN-8(3)
Voltage : 20~30V
YES
Defective parking Replace
Check voltage
switch
between CS-17
NO
(6) and chassis
NO Disconnection in Repair or replace
Voltage : 20~30V
poor contact
between CS-17(6)
and CN-36(6)
PARKING SWITCH
CN-71
8 3 2
6 CN-8 1
CS-17 2
FUSE
1
No.6
PARKING SOLENOID
7-68
12. TRANSMISSION IS NOT RETURNED TO NEUTRAL WHEN PARKING BRAKE IS APPLIED
fuse No.1(T/M controller) and No.6 are not blown out.
Cause Remedy
YES
Defective T/M Replace
Check voltage
YES controller
between CN-111
(14) and chassis
Voltage : 20~30V NO
poor contact
Check voltage between CS-17(6)
between CN-15 and fuse No.6
(1) and chassis
YES
Starting switch : ON Disconnection in Repair or replace
Parking switch : ON wiring harness or (After clean)
Prolix switch : OFF
Voltage : 20~30V poor contact
Check voltage
between CN-15
between CS-17
NO (4) and CS-17(1)
(1) and chassis
Voltage : 20~30V YES
Parking switch : ON Check voltage Defective switch Replace
between CS-17
NO
(5) and chassis Disconnection in Repair or replace
NO
poor contact
between CS-17(5)
and fuse No.6
4
PROLIX SWITCH
FUSE
CN-15
5
No.1
6
8
CS-7
PARKING SWITCH
FUSE
6
No.6
5
1
CS-17
7-69
13. MACHINE DOES NOT TRAVEL
fuse No.1(Transmission controller) is not blown out.
şWiring diagram : See page 7-17.
Cause Remedy
YES
poor contact
Is there continuity
YES between CS-42(5)
between CN-15
(4) and chassis? - CS-42(1) -CD-5 -
CN-15(4)
Disconnect parking
switch connector
Clutch cut-off switch Defective parking Repair or replace
:OFF NO
Is voltage switch or (After clean)
YES between CN-15 disconnection
(4) and chassis
wiring harness or
20-30V?
poor contact
Parking switch : OFF between CN-15
Is there continuity (4) and CS-17(1)
YES
between CN-15 (2)
and chassis?
‫ڞ‬
NO
Is voltage between Disconnection in Repair or replace

NO
CN-15(1) and wiring harness or (After clean)
chassis 20-30V? poor contact
Starting switch : ON between CN-15
(2) and chassis

NO
poor contact
between CN-15
(1) and fuse No.1
YES
Defective T/M Replace
Is problem controller(EGS)
‫ڞ‬ removed when
EN-111 is YES
replaced? Is problem Defective T/M Replace
removed when harness
NO T/M harness is
replaced?
Check solenoid Repair or replace
NO
(After clean)
7-70
14. WHEN STARTING SWITCH IS TURNED ON, HEAD LAMP DOES NOT LIGHTS UP
fuse No.19 is not blown out and ON/OFF of bulb. FUSE BOX
Cause Remedy
YES
Defective bulb Replace
Check voltage
YES
between CL-3(1) -
(3) and CL-4(1) -(3)
Voltage : 20~30V Disconnection in Repair or replace
NO
Starting switch : ON wiring harness or (After clean)
Check voltage Head lamp switch : ON
YES between CN-8(3) poor contact
and (6) between CN-8(3)-
(6) and CL-4(1)-
Voltage : 20~30V
Starting switch : ON CL-3(1)
CN-36
Head lamp switch : ON
NO ILL & HEAD LAMP SW LH HEAD LIGHT
between CS-11 between CN-8(3) CL-3
(7) and chassis and CS-11(7) RH HEAD LIGHT
Head lamp switch : YES
ON-OFF Defective Replace
CS-39
multifunction switch CL-4
CN-8
Check voltage
YES
between CS-11 Disconnection in Repair or replace
NO
(8) and chassis wiring harness or (After clean)
HI BEAM PILOT LAMP
Voltage : 20~30V poor contact

Starting switch : ON Check voltage between CS-11(8) CL-41
between CS-39 and CS-39(2) CN-10
NO
(2) and chassis
YES
Defective head Replace switch
Check voltage lamp switch
between CS-39
NO EARTH
(4) and chassis
NO
CS-11
poor contact
between CS-39(4)
and fuse No.19
MULTIFUNCTION SW CN-7 JT-28
7-71
15. WHEN STARTING SWITCH IS TURNED ON, WIPER MOTOR DOES NOT OPERATE
şAfter checking, connect the disconnected connectors again immediately unless otherwise specified. FUSE BOX
CHECK UNIT
Cause Remedy
YES
Defective front Replace
CN-58
Check voltage
YES between front wiper motor
wiper motor and
chassis Poor connection of Replace
Check voltage Voltage : 20~30V
NO
YES chassis
between CN-21 Starting switch : ON
Wiper switch : 1st
(2) and chassis
Voltage : 20~30V
Starting switch : ON Disconnection in Repair or replace
Check voltage Wiper switch : 1st NO
YES wiring harness or (After clean)
between CS-12
(4) and chassis poor contact CN-36
between CS-12(4)
Voltage : 20~30V WIPER RELAY2
and CN-21(2)
Check voltage
Wiper switch : OFF
CS-12(6) Defective wiper Replace
NO
switch CR-26
Voltage : 20~30V
Wiper switch : 1st Disconnection in Repair or replace
NO WIPER RELAY
poor contact
between CS-12(6)
and fuse No.7
CR-4
CS-11
CN-21
CS-12
CS-5
FRONT WIPER
MULTI FUNCTION SWITCH
7-72
16. WHEN STARTING SWITCH "ON" DOES NOT OPERATE
şBefore carrying out below procedure, check all the related connectors are properly inserted and and FUSE BOX
the fuse No.15 is not blown out.
Cause Remedy
YES
Defective cable Repair or replace
Check voltage (After clean)
YES assembly
between CN-60(2)
and chassis
Short circuit or Replace
Voltage : 20~30V NO
Check voltage defect of fusible
YES
between CR-1 link or defective
(M4) and chassis
battery relay
Voltage : 20~30V
NO
Check voltage wiring harness or
YES between CS-2
(1)[and CS-2(2)] poor contact
CN-36
and chassis between CS-2(2) -
Voltage : 20~30V
CN-2(1)-CR-1
(M4)
Check voltage NO BATT RY
60R
wiring harness or 60R 60B 60B
and specific
gravity of battery poor contact
MASTER SW
between fuse No. CR-1
Specific gravity : MIN 1.28
Voltage : MIN 24V 13 and CS-2(1) or
defect of start TO STARTER
switch CN-1
CN-60
Battery capacity Repair or replace

NO DO-4
too low (After clean)
CN-2
CS-2
START SWITCH
7-73
17. WHEN STARTING SWITCH IS TURNED ON, WORK LAMP DOES NOT LIGHTS UP
şBefore carrying out below procedure, check all the related connectors are properly inserted, and the
FUSE BOX
Cause Remedy
YES
Check voltage Defective lamp Replace
YES between each
lamp(2) and
chassis Disconnection in Repair or replace
NO
Check voltage Voltage : 20~30V wiring harness or (After clean)
YES Starting switch : ON poor contact
between CS-21
(2) and chassis between CN-3(4)
and CS-21(2)
Voltage : 20~30V
Check voltage Defective work Replace switch
NO
between CS-21 lamp switch
(6) and chassis YES
Disconnection is Repair or replace CN-36
between CS--21(6)
between fuse No. FRONT WORK
NO and fuse No.16 LIGHT,LH
16 and chassis
WORK LAMP SW
CN-5 CL-6
Voltage : 20~30V
Starting switch : ON Short circuit of fuse Replace FRONT WORK
NO LIGHT,RH
CL-5
CS-21
REAR WORK
CN-3 LIGHT,LH
CL-22
REAR WORK
LIGHT,RH
CL-23
7-74
18. WHEN ENGINE DOES NOT START
şCheck supply of the power at engine stop solenoid while starting switch is ON. ELECTRIC GEAR SELECTOR
şBefore carrying out below procedure, check all the related connectors are properly inserted. FUSE BOX
şAfter checking, connect the disconnected connectors again immediately unless other wise specified.
şCheck forward reverse switch at neutral position.
CN-111
Cause Remedy
YES
Defective battery Check engine
system charge or
replace (After
checking specific
gravity of battery)
YES
Check voltage Defective magnet Replace
Check operation YES between starter of start motor
of start motor magnet coil and
SAFETY RY
chassis Defective start Replace
Starting switch : start NO
Starting switch : start relay
YES CR-5
‫ڞ‬
Check operation Check voltage
NO of starter relay YES
between CR-5(4)
and chassis CN-36
Starting switch : start
wiring harness or CN-15 STARTER
TO BATT
Check operation poor contact
of start safety between CN-3(3)
NO
relay and CR-5(4)
CN-45
Check switch : neutral YES
Defective relay Replace START RY
Check voltage
between CR-5(3)
NO CR-23
and chassis ENGINE STOP SOL

‫ڟ‬
CN-79
YES
Defective start Replace
Check voltage relay
‫ڞ‬ between CR-23
(2) and chassis
Voltage : 20~30V NO
Starting switch : ON wiring harness or
poor contact
between CN-3(3)-
CR-23(2) CN-2
YES
CS-2
CN-4
wiring harness or
‫ڟ‬ between CN-15 between CN-15(3)
(3) and chassis and CR-5(3)
START SWITCH CN-3
Defective EGS-2 Replace
NO
7-75

Hyundai HL780-3

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Hyundai HL780-3

Uploaded by

Copyright:

Available Formats

WHEEL LOADER HYUNDAI HL780-3

HL780-3 Service Manual Open index screen

SECTION 3 POWER TRAIN SYSTEM

SECTION 4 BRAKE SYSTEM

SECTION 5 STEERING SYSTEM

SECTION 6 WORK EQUIPMENT

SECTION 7 ELECTRICAL SYSTEM

Structure and function

2. Convert 550 mm into inches.

Millimeters to inches ‫ڟ‬

0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

Kilogram to Pound 1kg = 2.2046lb

0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84

0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378

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

0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980

7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1

14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0

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

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

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

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

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

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

FOLLOW SAFE PROCEDURE

WEAR PROTECTIVE CLOTHING

WARN OTHERS OF SERVICE WORK

USE HANDHOLDS AND STEPS

WORK IN CLEAN AREA

PROTECT AGAINST FLYING DEBRIS

PROTECT AGAINST NOISE

SUPPORT MACHINE PROPERLY

SERVICE COOLING SYSTEM SAFELY

HANDLE FLUIDS SAFELY-AVOID FIRES

BEWARE OF EXHAUST FUMES

REMOVE PAINT BEFORE WELDING OR

SERVICE MACHINE SAFELY

STAY CLEAR OF MOVING PARTS

AVOID HEATING NEAR PRESSURIZED FLUID

PREVENT BATTERY EXPLOSIONS

USE TOOLS PROPERLY

USE PROPER LIFTING EQUIPMENT

DISPOSE OF FLUIDS PROPERLY

LIVE WITH SAFETY

KEEP ROPS INSTALLED PROPERLY

Main control valve Step Main pump Battery Counterweight

Steering cylinder Torque converter

1) WITHOUT TOOTH AND CUTTING EDGE TYPE BUCKET

Description Unit Specification

Description Unit Specification

Description Unit Specification

Front frame assembly 2825 6228

Model Cummins NTA 855-C )Cummins N14-C

Type Fixed displacement tandem gear pump

Type Fixed displacement tandem gear pump

4) MAIN CONTROL VALVE

5) REMOTE CONTROL VALVE

Type Pressure reducing type

Boom cylinder Bore diaźRod diaźStroke ‫ٻ‬200ź‫ٻ‬110ź863mm

Model Clark 8602

1) BOLT AND NUT

(1) Coarse thread

(2) Fine thread