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
1. STRUCTURE
This service manual has been prepared as an aid to improve the quality of repairs by giving the
serviceman an accurate understanding of the product and by showing him the correct way to perform
repairs and make judgements. Make sure you understand the contents of this manual and use it to
full effect at every opportunity.
This service manual mainly contains the necessary technical information for operations performed in
a service workshop.
For ease of understanding, the manual is divided into the following sections.
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Contact your Hyundai distributor for the latest information.
0-1
2. HOW TO READ THE SERVICE MANUAL
Distribution and updating Revised edition mark(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) Symbol Item Remarks
Consecutive page number for
Special safety precautions are
each section necessary when performing the
3. Additional pages : Additional pages are work.
Safety
indicated by a hyphen(-) and number after the
Extra special safety precautions
page number. File as in the example. are necessary when performing
10 - 4 the work because it is under
internal pressure.
10 - 4 - 1
Added pages Special technical precautions or
10 - 4 - 2
10 - 5 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.
0 1 2 3 4 5 6 7 8 9
0-3
Millimeters to Inches 1mm = 0.03937in
0 1 2 3 4 5 6 7 8 9
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
0 1 2 3 4 5 6 7 8 9
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
0-4
Liter to U.S. Gallon 1ֻ = 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.631 25.625 25.889 26.153
0 1 2 3 4 5 6 7 8 9
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
0-5
kgşm to lbşft 1kgşm = 7.233lbşft
0 1 2 3 4 5 6 7 8 9
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 10005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
0-6
kg/cm2 to lb/in2 1kg/cm2 = 14.2233lb/in2
0 1 2 3 4 5 6 7 8 9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 2863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 5603 2617 2631 2646 2660 2674 2688
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
0-7
TEMPERATURE
Fahrenheit-Centigrade Conversion.
A simple way to convert a fahrenheit temperature reading into a centigrade temperature reading or vice verse
is to enter the accompanying table in the center or boldface column of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
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
0-8
REPLACE SAFETY SIGNS
Replace missing or damaged safety signs. See
the machine operator's manual for correct safety
sign placement.
1-9
GROUP 2 SPECIFICATION
1. MAJOR COMPONENT
Boom cylinder Main control valve Main pump Air cleaner Battery
Bucket link Bell crank Head light Cab Rain cap Muffler Counterweight
Boom Front axle Steering cylinder Step Transmission Rear axle Fuel tank
1-10
2. SPECIFICATIONS
1) WITHOUT TOOTH AND CUTTING EDGE TYPE BUCKET
F
J
B
I
4700
H
3580
K
3033
40Ş
C
G
46
5280 34
D
E 1636
A
1-11
2) BOLT-ON CUTTING EDGE TYPE BUCKET
B
F
I
4700
H
3580
K
3033
4 0Ş
C
G
46
3
5350 4
D
E 1636
A
1-12
3) WITH TOOTH TYPE BUCKET
B
4700
H
3580
K
3033
C
40Ş
G
46
3
5460 4
D
E 1636
A
1-13
3. WEIGHT
Item kg lb
1-14
4. SPECIFICATION FOR MAJOR COMPONENTS
1) ENGINE
Item Specification
2) MAIN PUMP
Item Specification
1-15
3) BRAKE PUMP
Item Specification
Item Specification
Type 2 spool
Operating method Hydraulic pilot assist
Main relief valve pressure 215kgf/cm2(3058psi)
Overload relief valve pressure 240kgf/cm2(3414psi)
Item Specification
6) CYLINDER
Item Specification
1-16
7) DYNAMIC POWER TRANSMISSION DEVICES
Item Specification
Model ZF 4WG130
Torque converter
Type Single-stage, single-phase
Type Full-automatic power shift
Transmission Gear shift Forward fourth gear, reverse third gear
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 17.5-25, 12PR(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 OF MAJOR COMPONENT
No. Items Size kgfşm lbfşft
1-18
6. TORQUE CHART
Use following table for unspecified torque.
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
1-19
2) PIPE AND HOSE
3) FITTING
1-20
7. 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 12.6(3.3)
SAE 10W-30
SAE 15W-40
Torque converter
Oil 20(5.3) DEXRONє
Transmission
Front :
18.4(4.9)
Axle Gear oil SAE 80W-90LSD/API GL-5
Rear :
18.4(4.9)
Tank: ISO VG 32
60(15.9)
Hydraulic tank Hydraulic oil ISO VG 46
System:
87(23) ISO VG 68
NLGI NO.1
Fitting
Grease As required
(Grease nipple)
NLGI NO.2
Mixture of
antifreeze
Radiator 30(7.9) 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
OK NOT
Item Comments
OK
1-22
4. Brake system and clutch cut off checks
5. Driving checks
1-23
7. Steering system checks
8. Accessory checks
1-24
SECTION 3 POWER TRAIN SYSTEM
GROUP 1 STRUCTURE AND FUNCTION
Front axle Front drive shaft Center drive shaft Rear drive shaft Rear axle
3-1
HYDRAULIC CIRCUIT
K4 KR K1 K3 KV K2
P1 P2 P3 P4 P5 P6
B D B D B D B D B D B D
Pressure
Temp reducing
sensor valve
System
pressure
Valve block control circuit valve
Converter
Relief Filter
valve
Oil sump
Lubrication
Main oil circuit
Forward Reverse
Speed Neutral
1 2 3 4 1 2 3
Y1 X
Y2 X X X
Y3 X X
Y4 X X X
Y5 X X X
Y6 X X
X : Pressure regulator under voltage
3-2
2. TORQUE CONVERTER
5 1 2 3 4
The converter is working according to the Trilok-system, i.e. it assumes at high turbine speed the
characteristics, and with it the favorable efficiency of a fluid clutch.
The converter will be defined according to the engine power so that the most favorable operating
conditions for each installation case are given.
The Torque converter is composed of 3 main components :
Pump wheel - turbine wheel - stator(Reaction member)
These 3 impeller wheels are arranged in such a ring-shape system that the fluid is streaming through
the circuit components in the indicated order.
Pressure oil is constantly streaming out of the transmission pump through the converter. In this way, the
converter can fulfill its task to multiply the torque of the engine, and at the same time, the heat created in
the converter is dissipated through the escaping oil.
The oil, escaping out of the pump wheel, enters the turbine wheel and is there inversed in the direction
of flow.
According to the rate of inversion, the turbine wheel and with it also the output shaft, receive a more or
less high reaction moment. The stator(Reaction member), following the turbine, has the task to inverse
again the oil which is escaping out of the turbine and to delivery it under the suitable discharge direction
to the pump wheel.
Due to the inversion, the stator receives a reaction moment.
The relation turbine moment/pump moment is called torque conversion. This is the higher the greater
the speed difference of pump wheel and turbine wheel will be.
Therefore, the maximum conversion is created at standing turbine wheel.
With increasing output speed, the torque conversion is decreasing. The adaption of the output speed to
a certain required output moment is infinitely variable and automatically achieved by the torque
converter.
3-3
If the turbine speed is reaching about 80% of the pump speed, the conversion becomes 1.0 i.e. the
turbine moment becomes equal to that of the pump moment.
From this point on, the converter is working similar to a fluid clutch.
A stator freewheel serves to improve the efficiency in the upper driving range, it is backing up in the
conversion range the moment upon the housing, and is released in the coupling range.
In this way, the stator can rotate freely.
Turbine wheel
From the engine
TT
TP
To the gearbox
Starting
condition 1 1.5 Reaction member 2.5
nT = 0
(Stator) Machine stopped
Intermediate
condition 1 <1.5 <2.5 nT < n engine
Condition shortly
before the converter 1 1 nT = 0.8n engine
clutch is closed. 0
3-4
3. TRANSMISSION
1) LAYOUT
12
1
11
10
3
9 4
5
15
14
13 6
3-5
2) INSTALLATION VIEW
1 2 9 10 11 12 14
15
20
3
19
8 16
3 13
18
4 17
7 6 5
3-6
3) 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.
KR KR
KV IN
K4
K2
INPUT
K3 K1
KV
OU
GEAR PATTERN
K2
K1 K3
K4
OUTPUT OUTPUT
3-7
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.
KR KR
KV IN
K4
K2
INPUT
K3 K1
KV
OU
GEAR PATTERN
K2
K1 K3
K4
OUTPUT OUTPUT
3-8
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.
KR KR
KV IN
K4
K2
INPUT
K3 K1
KV
OU
GEAR PATTERN
K2
K1 K3
K4
OUTPUT OUTPUT
3-9
ڻForward 4th
In 4th forward, 4th clutch and 3rd clutch are engaged.
4th clutch and 3rd clutch are actuated by the hydraulic pressure applied to the clutch piston.
KR KR
KV IN
K4
K2
INPUT
K3 K1
KV
OU
GEAR PATTERN
K2
K1 K3
K4
OUTPUT OUTPUT
3-10
(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.
KR KR
KV IN
K4
K2
INPUT
K3 K1
KV
OU
GEAR PATTERN
K2
K1 K3
K4
OUTPUT OUTPUT
3-11
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.
KR KR
KV IN
K4
K2
INPUT
K3 K1
KV
OU
GEAR PATTERN
K2
K1 K3
K4
OUTPUT OUTPUT
3-12
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.
KR KR
KV IN
K4
K2
INPUT
K3 K1
KV
OU
GEAR PATTERN
K2
K1 K3
K4
OUTPUT OUTPUT
3-13
4) ELECTRO-HYDRAULIC SHIFT CONTROL WITH PROPORTIONAL VALVE
2 1 3
A A
Y6 Y1
Y5 Y2
B
Y4 Y3
3 6
2 6 1 4 11 9 10
Y5
Transmission control see schedule of measuring points, hydraulic schematic and electro-hydraulic
control unit at page 3-2, 3-14 and 3-44.
The six clutches of the transmission are selected through the 6 proportional valves P1 to P6. The
proportional valve(Pressure regulator-unit) consists of pressure regulator(e.g. Y1), booster valve
oscillation damper.
The pilot pressure of 9 bar for the control of the follow-on slides is created by the reducing valve.
The pressure oil (16+2 bar) is directed through the follow-on slide to the corresponding clutch.
3 - 14
By the direct proportional selection with separate pressure modulation for each clutch, the
pressures to the clutches, taking part in the gear change, are controlled. In this way, a hydraulic
overlab of the clutches to be engaged and disengaged is achieved.
This is leading to fast shiftings without traction force interruption.
At the shifting, the following criteria are considered:
- Speed of engine, turbine, central gear train and output.
- Transmission temperature.
- Shifting mode(Up-, down-, reverse shifting and gear engaging from neutral).
- Load level(Full- and partial load, traction, coasting inclusive consideration of load cycles during the
shifting).
The system pressure valve is limiting the maximum control pressure to 16+2 bar and releases the
main stream to the converter and lubricating circuit.
A converter relief valve is installed in the converter inlet, which protects the converter against high
internal pressures(Opening pressure 9bar).
Within the converter, the oil transfers the power transmission according to the well-known
hydrodynamic principle(See torque converter, page 3-3).
In order to avoid cavitation, the converter must be always completely filled with oil.
This is achieved by a converter back pressure valve, following the converter, with an opening
pressure of about 3.5bar.
The oil, escaping from the converter, is directed to a oil cooler.
The oil is directed from the oil cooler to the transmission and from there to the lubricating-oil circuit
so that all lubricating points are supplied with cooled oil.
In the electro-hydraulic control unit there are 6 pressure regulators installed.
5) GEAR SELECTOR(DW-3)
3 - 15
6) DISPLAY
(1) Function
The display can be used with the gear selector(DW-3). It indicates speed and driving direction as
well as the activated kickdown.
When driving in the automatic mode, a bar indicator gives additionally also information about the
selected driving range; The automatic range is symbolized by arrows above and below the bar
indicator. In case of possible errors in the system, a wrench appears on the display, combined
with indication of the error number. Also sporadically occurring errors can be indicated.
d f e First position g
h S
T
O
P
b a c Second position
3 - 16
(2) Definition of the error codes
Introduction
The error codes consists of two hexadecimal numbers.
The first number shows the type of signal, the second number shows signal and the type of the
error.
Description of error codes
3 - 17
Number Meaning of error code
3A hex Short circuit to battery voltage at output speed input
3B hex Short circuit to ground or open circuit at output speed input
3C hex Logical error at output speed input
3 - 18
Number Meaning of error code
B1 hex Slippage at clutch K1
B2 hex Slippage at clutch K2
B3 hex Slippage at clutch K3
B4 hex Slippage at clutch K4
B5 hex Slippage at clutch KV
B6 hex Slippage at clutch KR
Summary
This is only a proposal for error codes. If necessary, we will change the error codes or we will add
new error codes.
3 - 19
7) ELECTRIC CONTROL UNIT
(1) Complete system
2
1
5
12
4 10
3 9
2
6 7 13
11 8
14
1 Control unit(EST-37)
2 Kickdown switch
3 Clutch cut off switch
4 Full automatic switch
5 Display
6 Gear selector(DW-3) with integrated kickdown switch
7 Supply-system connection
8 Transmission
9 Cable to inductive transmitter - speed central gear train
10 Cable to inductive transmitter - speed turbine
11 Cable to inductive transmitter - speed engine
12 Cable to speed sensor output and speedometer
13 Cable to plug connection on the electro - hydraulic control unit
14 Brake pressure sensor/load sensor
(2) Description of the basic functions
The powershift-reversing transmissions will be equipped with the electronic transmission control
unit(EST-37), developed for them.
The system is processing the wishes of the driver according to the following criteria.
şSpeed definition as a function of gear selector position, driving speed and load level.
3 - 20
şProtection against operating errors, as far as possible and practical.
şProtection against overspeeds(On the basis of engine and turbine speed).
şReversing-automatic system(Driving speed-dependent).
şPressure cut off(Disconnecting of the drive train for maximum power on the power take-off).
şSwitch for manual or automatic operation.
şReversing function button, respectively kickdown function.
(3) Gearshifts
The control unit(EST-37) is shifts the required speeds fully-automatically under consideration of
the following criteria.
şGear selector position
şDriving speed
şLoad level
At the same time, the following speeds are picked up by the control unit(EST-37).
şn Engine
şn Turbine
şn Central gear train
şn Output
- Neutral position
Neutral position is selected through the gear selector.
After the ignition is turned on, the electronics remains in the waiting state; By the position neutral
of the gear selector, respectively by pressing on the key neutral, the control unit(EST-37)
becomes ready for operation.
Now, a speed can be engaged.
- Speed engagement
In principle, the speed, adapted to the driving speed(At standing, or rolling machine), will be
engaged. The engagement is realized in dependence on load and rotational speed.
- Upshifting under load
Upshifting under load will be then realized if the machine can still accelerate by it.
- Downshifting under load
Downshifting under load will be realized if more traction force is needed.
- Upshifting in coasting condition
In the coasting condition, the upshifting will be suppressed if the speed of the machine on a slope
shall not be further increased.
- Downshifting in coasting condition
Downshiftings in the coasting condition will be realized if the machine shall be retarded.
- Reversing
At speeds below the reversing limit, direct reversing can be carried out at any time in the speeds
1Fء1R and 2Fء2R(As a rule, this is the maximum driving speed of the 2nd speed).
3 - 21
Reversings in the speeds 3 and 4 are realized dependent on the driving speed.
- Above the programmed reversing limit, the machine is braked down by downshifts of the
electronic control unit(EST-37) to the permitted driving speed, and only then, the reversing into
the correspondingly preselected speed will be carried out.
- Below the permitted driving speed, the reversing is carried out immediately.
(4) Specific kickdown function
By means of the kickdown-button, integrated in the gear selector, it is at any time possible to
select in the speeds 2F and 2R(i.e. position 2 of the gear selector, at automatic mode also in the
2nd speed of the automatic range) the 1st speed by a short touch. This kickdown state can be
cancelled by :
1. Pressing the kickdown-button again
2. Realization of a reversal operation
3. Change of the gear selector position by the following modification
Gear selector(DW-3) - (Rotation) of the driving position 1...4.
The kickdown function will be always terminated by shifting to neutral.
(5) Clutch cut off
Especially at wheel loaders, the clutch cut off can be activated through a switch signal. It is
interrupting the power flow in the transmission as long as this signal is active. Besides, this
function can be used for the transmission-neutral shifting at applied hand brake or as emergency-
stop(In this case, a restarting is only possible through the gear selector-neutral position).
3 - 22
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
3 - 23
2) SECTION OF FRONT AXLE DIFFERENTIAL
A A
1
5
SECTION A-A
3 - 24
3) SECTION OF REAR AXLE DIFFERENTIAL
A A
1
5
SECTION A-A
3 - 25
4) DIFFERENTIAL
(1) Description 3
When the machine makes a turn, the 2 4
outside wheel must rotate faster than the
inside wheel. A differential is a device
which continuously transmits power to the
right and left wheels while allowing them
to turn a different speeds, during a turn.
The power from the drive shaft passes
through bevel pinion(1) and is transmitted
to the bevel gear(2). The bevel gear
changes the direction of the motive force
by 90 degree, and at the same time
1
reduces the speed.
It then transmits the motive force through
the differential(3) to the axle gear shaft(4).
3 - 26
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 traveling 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 - 27
ڹWhen traveling on soft ground
(Resistance from road surface to left and
right tires is different)
If the road resistance to the left wheel is
Spider rotating
smaller, the left side gear tends to rotate direction
forward, and this rotation changes the
engaging points between the side gears
and pinion. As a result, the distances
involving the engaging points becomes FL
Small road FR Large road
a>b. The pinion now is balanced as FL resistance a b resistance
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 - 28
6) FINAL DRIVE(Front & rear)
(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 - 29
6. TIRE AND WHEEL
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 - 30
GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING
Chapter 2 : Troubleshooting
Group 3 : Tests and adjustments
3-31
Ɠ Transmission oil must be at operating temperature for these checks.
3-32
Item Description Service action
3-33
Item Description Service action
LOOK/FEEL : Transmission
must shift to former(2nd or 3rd or
4th) gear.
NOTE : If gear selector lever kick
down switch or RCV lever switch
is pressed twice, transmission
will shift down the immediately
back to former gear.
Forward, reverse and Park unit on level surface. OK
4th speed clutch pack Check completed.
Apply service brakes.
drag check
NOT OK
Ɠ Transmission must Move gear selector lever to
If unit moves, repair
be warmed up for neutral.
transmission.
this check.
Move gear selector lever to 1st.
Engine running.
Release parking brake and
service brakes.
Run engine at low idle.
LOOK : Unit must not move in
either direction.
NOTE : If unit moves forward,
either the forward pack or the 4th
speed pack is dragging.
3-34
Item Description Service action
3-35
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.)
3-36
Problem Cause Remedy
Broken ring or pinion gear. If drive shaft rotate with transmission in gear but
machine does not move, a differential failure is
indicated. Repair.
3-37
Problem Cause Remedy
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 transmission.
Remove and clean suction screen.
Also, check condition of transmission filter.
Stuck transmission pressure Remove transmission pressure regulating valve.
regulating valve or broken Inspect for damage(See transmission control
spring. valve).
Failed control valve gasket. Inspect transmission control valve for external
leakage. Remove control valve.
Inspect or replace gasket.
Stuck PPC valve. Remove end cover to inspect modulation spool
and check torque on cap screws retaining control
valve to transmission.
3-38
Problem Cause Remedy
Transmission shifts too Wrong transmission controller. Check if transmission controller has been
fast changed
System pressure too high. Do transmission system pressure test.
Stuck PPC valve. Remove and inspect PPC valve.
Replace if necessary. Also remove end cover to
inspect PPC valve and control valve housing.
Replace if necessary.
Stuck or missing check valves. Inspect transmission control valve.
Missing O-ring from end of Remove orifice and inspect port for O-ring.
modulation orifice.
Broken piston return spring. Disassemble and inspect clutch.
Incorrect transmission oil. Change oil(DEXRON є or DEXRON ѕ)
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 sensor. 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 test.
Malfunction in converter relief Do converter out pressure test.
valve.
Low transmission pump output. Do transmission pump flow test.
3-39
Problem Cause Remedy
Excessive transmission Too low engine low idle. Check engine low idle speed.
noise(Under load or no
Worn parts or damaged in Remove transmission suction screen. 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.
Oil ejected from dipstick Plugged breather. Inspect breather on top of transmission.
Replace.
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).
3-40
Problem Cause Remedy
3-41
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.
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 nuts(Drive Inspect. Replace.
shafts wobble at high speed).
Rear axle oscillating support. Inspect, repair.
Lack of lubrication. Lubricate with proper grade of grease.
3-42
GROUP 3 TESTS AND ADJUSTMENTS
Brake valve
3-43
2. TRANSMISSION MEASURING POINTS AND CONNECTIONS
The measurements have to be carried outat hot transmission(About 80~95Ş
C).
48 47 21
34
65 51 68
69 49
H J
K
G
57 60
A F
B E 16
53 55 15
C D
58 56 52,63
VIEW X VIEW Y
3 - 44
2) DELIVERY RATES
4) CONNECTIONS
3-45
SECTION 4 BRAKE SYSTEM
GROUP 1 STRUCTURE AND FUNCTION
1. OUTLINE
Ɠ The brakes are operated by a pressure compensated, closed center hydraulic system.
Flow is supplied by a fixed displacement, gear type brake pump.
BRAKE SYSTEM
The fixed displacement brake pump supplies flow to service brake circuit and park brake circuits. It
flows to four accumulator. The accumulator has a gas precharge and an inlet check valve to
maintain a pressurized volume of oil for reserve brake applications.
Oil through the accumulator flows to the brake valves. The brake valve is a closed center design,
dual circuit operated by a pedal.
The front and rear brakes will operate simultaneously with only one brake pedal depressed.
The differential contains annular brake piston and double sided disk.
Brake pump flow also goes to the parking brake solenoid valve.
The brake system contains the following components:
şBrake pump
şParking brake solenoid valve
şBrake valve
şAccumulators
şPressure 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(lbşin)
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 29 REAR
20
17 A B
P T
16
15
8
15 21 18
7 BR1 BR2 M2
DS1
A 1st pump
S1 B 2nd pump
DS2 S2 Return line C Brake pump
S3
19 T
N
Steering system MCV P1 RCV lever
12 3Mpa
U
22 P2 T
C B A 1
23 Return line
24 25 26
4-3
1) SERVICE BRAKE RELEASED
FRONT 29 REAR
20
17 A B
P T
16
15
8
15 21 18
7 BR1 BR2 M2
DS1
A 1st pump
S1
B 2nd pump
DS2 S2 Return line C Brake pump
S3
19 T
N
Steering system MCV P1 RCV lever
12 3Mpa
U
22 P2 T
C B A 1
23 Return line
24 25 26
When the pedal of brake valve(7) is released, the operating force is eliminated by the force of the
spring, and the spool is returned.
When the spool removes up, the exhaust port is opened and the hydraulic oil in the piston of axles
(29) return to the tank(24).
Therefore, the service brake is kept released.
4-4
2) SERVICE BRAKE OPERATED
FRONT 29 REAR
20
17 A B
P T
16
15
8
15 21 18
7 BR1 BR2 M2
DS1
A 1st pump
S1
B 2nd pump
DS2 S2 Return line C Brake pump
S3
19 T
N
Steering system MCV P1 RCV lever
12 3Mpa
U
22 P2 T
C B A 1
23 Return line
24 25 26
When the pedal of brake valve(7) is depressed, the operating force overcomes the force of the
spring, and is transmitted to the spool. When the spool moves down, the inlet port is opened, and
at the same time the hydraulic oil controlled the pressure level by the other spool in the brake valve
enters the piston in the front and rear axles. Therefore, the service brake is applied.
4-5
3) PARKING BRAKE RELEASED
FRONT 29 REAR
20
A B
17
P T
16 ڸ
15 ڹ
8 P
15 21 18
7 BR1 BR2 M2 Parking brake switch
DS1
A 1st pump
S1 B 2nd pump
DS2 S2 Return line
S3
C Brake pump
19 T
N
Steering system MCV P1 RCV lever
12 3Mpa
U
22 P2 T
C B A 1
23 Return line
24 25 26
When the parking brake switch is pushed()ڹ, the solenoid valve(17) is energized and the hydraulic
oil enters the front axle. It overcomes the force of the spring and pushes the piston. This releases
the brake.
Therefore, the hydraulic oil pressure is applied to the parking brake piston in front axle through the
solenoid valve(17) and the parking brake is kept released.
4-6
4) PARKING BRAKE OPERATED
FRONT 29 REAR
20
17 A B
P T
16
ڸ
15 ڹ
8
P
15 21 18
7 BR1 BR2 M2
Parking brake switch
DS1
A 1st pump
S1
DS2 S2 Return line B 2nd pump
S3 C Brake pump
19 T
N
Steering system MCV P1 RCV lever
12 3Mpa
U
22 P2 T
C B A 1
23 Return line
24 25 26
When the parking brake switch is pushed( )ڸonce more, the solenoid valve(17) is deenergized
and the valve open the exhaust port.
At the same time, the hydraulic oil return to the tank through the solenoid valve(17). When the
piston is returned by the force of the spring, the parking brake is applied.
4-7
3. BRAKE PUMP
1) STRUCTURE
22 23 26 28 27 31 32,33
24
21 27 29 30 26
25
Hydraulic pumps used for the work equipment hydraulic units on construction machinery are pressure
loaded type gear pumps. This gear pump have a maximum delivery pressure of 150kgf/cm2(2130psi).
The pressure loaded type gear pump is designed so that the clearance between the gear and the side
plate can be automatically adjusted according to the delivery pressure. Therefore, the oil leakage from
the side plate is less than that in the case of the fixed side plate type under a high discharge pressure.
Consequently, no significant reduction of the pump delivery occurs, even when the pump is operated
under pressure.
4-8
2) PRINCIPLE OF OPERATION
4-10
(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
e
protected from seizure and binding. charg
Dis
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.
4-11
(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
72
42 80
41
26
86
14
27 1.25
4
82
28
5 32
36
55 21
64 37
9 65 41
1
18
43
1.47
1.22
12
30
29
12 1.23
87 31
59
24
115
1 Housing 24 Reducer 43 Locking screw
1.22 Spool 26 Spring 55 O-ring
1.23 Spool 27 Spring 59 O-ring
1.25 Spool 28 Spring 64 Thrust ring
1.47 Spool 29 Spring 65 Shaft seal
4 Sleeve 30 Spring 72 Pedal unit
5 Sleeve 31 Spring 80 O-ring
9 Sleeve 32 Spring 82 Spring
12 Spring retainer 36 Circlip 86 Unit RV
14 Spring retainer 37 Circlip 87 Sleeve
18 Unit WVI 41 Locking screw 115 Locking screw
21 Spring retainer 42 Locking screw
4-13
2) OPERATION
A
M1
T S1
M2
BR1 BR2 M2
DS1
BR1
S1
DS2 S3
S2
DS2
S3
BR2 S2
T
N
VIEW A
4-14
(1) Accumulator charging valve
The accumulator loading valve or
pressure switch-off valve has the purpose
S2
to keep a pressure level within certain limit
values(Switch-off pressure, switch-on
pressure) in an accumulator circuit. The 1
switching pressure difference is approx S1
18% of the switch-off pressure. 3 T
Switching over of pump flow from accumulator load into neutral circulation
The pump delivers into the accumulator circuit via the check valve(3) during the loading
procedure. For this the pressure is passed to the load signal side of the pressure compensator(2)
via the control line and pilot control. This throttles the pump flow until the pressure, which builds
up in the accumulator circuit, overcomes the spring force of the pressure setting element(1).
The pilot control element switches the load signal line of the pressure compensator(2) from S1 to
T. The pressure compensator(2) then switches the pump flow from P to N and the check valve(3)
closes. The loading pressure is complete and the pump flow flows with low ՠp through the
loading valve.
Switching over of pump flow from neutral circulation into accumulator load
If the pressure in the accumulator circuit decreases to the lower switching point(Adding pressure)
P is connected to the load signal chamber of the pressure compensator(2) and the pump delivers
again into the accumulator circuit.
4-15
(2) 2 circuit brake valve
The 2-circuit remotely powered braking
valve is direct controlled pressure relief
valve in 3-way design with infinite
4 2 7 2 1
mechanical operation.
BR1 BR2 M2
It has a maximum pressure relief of
secondary circuits and infinite adjustability
DS1
of pressure in the secondary circuits
(Braking circuits) proportional to the
direction of the operating element(4).
With failure of one braking circuit the
SP1 T SP2
second braking circuit remains fully
functional because of the mechanical 3 5 2 1
contact of both spools(2).
The operating force at the pedal remains
unchanged.
The 2-circuit remotely powered brake valve consists mainly of housing(1) and control spool(2),
main compression spring(3), operating element(4) and the return springs(5) and (6).
The valve is operated via the operating element(4). It pushes the main control spring(3) against
both control spools(2). First the control edges close at channel T, afterwards the flow from SP and
BR is released in both braking circuits.
The pressure building up in the brake lines pushes simultaneously via the pilot oil drillings(7)
behind the control spool against the main compression spring(3) so that the braking
pressure(Secondary pressure) rises proportional to the operating element kept constant the
control spools(2) moves into control position and holds the controlled pressure in channels BR1
and BR2 constant. The operating force of the operating element is proportional to its deflection.
When the main compression spring(3) is unloaded the pressure springs and the control spools
move in such a way that they close SP towards BR and open BR towards T and thus close the
secondary circuits(Braking circuits).
4-16
5. BRAKE ACCUMULATOR
1) STRUCTURE
31EC-0219 81L1-0004
Item
(Item16) (Item15)
Diameter 121mm 121mm
Mounting height 145mm 151mm
Norminal volume 0.75m 3
0.75m3
Priming pressure 7kgf/cm2 50kgf/cm2
Operating medium Oil Oil
B
Operating pressure Max 56kgf/cm 2
Max 180kgf/cm2
Thread M18ź1.5 M18ź1.5
A
Operating
C -30 ~ 80Ş
C -30 ~ 80Ş
C
temperature range
Priming gas Nitrogen 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.
(3) Installation requirements
The accumulators can be fitted in the hydraulic circuit, directly on a component or in blocks on
suitable consoles.
They should be fitted in as cool a location as possible.
Installation can be in any position.
4-17
(4) Maintenance of the accumulator
No special maintenance beyond the legal requirements is necessary.
The accumulator should be checked annually. It should be replaced if the initial gas
pressure has fallen by more than 30%(Please refer to Performance testing and
checking of the accumulator).
(5) Disposal of the accumulator
Before the accumulator is scrapped, its gas filling pressure must be reduced. For this
purpose, drill a hole through gas chamber(B) using a drill approx. 3mm in diameter. The
gas chamber is located on the side opposite the threaded port above the welding seam
around the center of the accumulator.
Ɠ 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
4-18
(7) Repair work
When working on the braking system, always make sure that there is absolutely no
pressure in the system. Even when the engine in switched off there will be some residual
pressure in the system.
Ɠ When doing repair work, make sure your environment is very clean.
Immediately close all open ports on the components and on pipes using plugs.
For safety reasons the accumulators need to be replaced as a whole if damaged.
4-19
6. PRESSURE SWITCHES
1) STRUCTURE
şNormally closed
H1
şNormally open
H2
ş Technical data
H1 H2 Adjusting range Adjusting pressure Voltage
Item Type Medium G
mm mm kg/cm2 kg/cm2 V
4-20
2) OPERATION
(1) Purpose
The pressure switches are used to visually or audibly warn the driver of the pressure within the
system.
(2) Make contact / circuit closer
The pressure switch can be fitted in the braking system or directly on one of its components.
The system pressure acts on an absorption area within the switch, making an electrical contact as
the pressure on that area is increased. The resulting current is used to activate a warning facility,
for instance.
(3) Break contact / circuit breaker
The pressure switch can be fitted in the braking system or directly on one of its components.
The system pressure acts on a absorption area within the switch, breaking an electrical contact
as the pressure on that area is increased. The current is now broken, e.g. to deactivate a
warning facility.
(4) Installation requirements
No special measures need to be taken.
(5) Maintenance of the pressure switch
No special maintenance beyond the legal requirements is necessary.
When using high-pressure cleaners on the vehicle, please make sure that the water jet is not
directed at the pressure switch(Corrosion of contacts).
(6) Repair work
When working on the braking system, always make sure that there is absolutely no
pressure in the system. Even when the engine is switched off there will be some residual
pressure in the system.
Ɠ When doing repair work, make sure your environment is very clean.
Immediately close all open ports on the components and on pipes using plugs.
Ɠ For safety reasons the pressure switch needs to be replaced as a whole if damaged.
4-21
(7) Adjusting and testing pressure switch
The adjusting screw located between the two contact plugs can be set to the desired value within
a certain range. For adjusting range, please refer to the table Technical data on the previous
page.
After making the adjustment, the adjusting screw should be secured using wax or a similar
material.
(,)
Screw
(+)
4-22
GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING
1. OPERATIONAL CHECKS
This procedure is designed so the mechanic can make a quick check of the system using a minimum
amount of diagnostic equipment. If you need additional information, read structure and function,
Group 1.
A location will be required which is level and has adequate space to complete the checks.
The engine and all other major components must be at operating temperature for some checks.
Locate system check in the left column and read completely, following the sequence from left to right.
Read each check completely before performing.
At the end of each check, if no problem is found(OK), that check is complete or an additional check is
needed. If problem is indicated(NOT OK), you will be given repair required and group location.
If verification is needed, you will be given next best source of information:
Chapter 2 : Troubleshooting
Group 3 : Tests and adjustments
4-23
ƓHydraulic oil must be at operating temperature for these checks(Refer to page 6-54).
4-24
Item Description Service action
4-25
Item Description Service action
4-26
Item Description Service action
4-27
2. TROUBLESHOOTING
1) SERVICE BRAKE
Diagnose malfunction charts are arranged from most probable and simplest to verify, to least likely,
more difficult to verify. Remember the following steps when troubleshooting a problem :
Step 1. Operational check out procedure(See section 1)
Step 2. Operational checks(In this group)
Step 3. Troubleshooting
Step 4. Tests and adjustments(See group 3)
Brakes drag Brake pedal not returning Inspect floor mat and pedal.
properly.
Debris holding valve partially Do brake valve pressure test.
open in brake valve.
Warped brake disk. Inspect brake disk.
Stuck brake piston. Repair.
Incorrect oil. Change oil.
4-28
Problem Cause Remedy
Hissing noise when Leakage in brake valve, or Do brake system leakage test.
brake pedal is held with brake piston.
engine stopped
4-29
2) PARKING BRAKE MALFUNCTIONS
Brake will not hold Pads not adjusted correctly. Adjust parking brake.
Malfunctioning parking brake Inspect and replace.
solenoid.
Worn brake disk and/or brake Disassemble, inspect, repair.
pads.
Brake piston hangs up in bore. Remove and inspect. Repair.
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.
4-30
GROUP 3 TESTS AND ADJUSTMENTS
2) MEASURING PROCEDURE
(1) Start the engine and drive the machine
straight up a 1/5 gradient with the bucket
unloaded.
(2) Depress the service brake, place the gear
selector lever in neutral, then stop the
engine.
(3) Turn the parking brake switch ON, then
20%
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.
4-31
3. HYDRAULIC BRAKE BLEEDING PROCEDURE
Escaping fluid under pressure can
penetrate the skin causing serious injury.
Avoid the hazard by relieving pressure
before disconnecting hydraulic or other
lines. Tighten all connections before B
applying pressure.
Search for leaks with a piece of
cardboard. Protect hands and body from
high pressure fluids.
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.
Two people are required to bleed brake
system oil, one to operate brake valve and
other to open and close bleed screws. A
4-32
GROUP 4 DISASSEMBLY AND ASSEMBLY
1. BRAKE PUMP
1) STRUCTURE
33
32
31
23
24
25
27
30
26 28
26
25
24
23 22
29
27
12
21
17
4-33
2) GENERAL
(1) Introduction
Each unit comprises an end cover, body housing, the bush/gear assembly and a mounting flange
bolted together. The gear/bush assembly consists of a pair of meshing gears supported by plain
bearings in the bushes. The drive gear journal extends through the mounting flange to form the
drive shaft. A lip type shaft seal and O-rings provide external sealing whilst special lobe seals and
backing rings are used internally.
(2) Routine maintenance
No maintenance is necessary other than periodic checks for tightness of the mounting bolts and
visual examination for oil leakage. The unit should be kept externally clean, especially in the area
of the shaft seals as dirt can accelerate seal wear and cause leakage.
The unit must be operated only with clean oil and the system manufacturer's directions for
periodic renewal of system oil filter elements must be strictly observed.
(3) Field servicing
Seal kits and spare parts are available to enable units to be serviced.
4-34
3) DISASSEMBLY
33
32
31
23
24
25
27
30
26 28
26
25
24
23 22
29
27
12
21
17
Ɠ Before disassembling ensure that the unit itself, bench and tools are thoroughly clean.
(1) Lightly mark the end cover(31), body(30) and spacer plate(22) to ensure reassembly in the
correct position.
(2) Remove the bolts(33) and separate the brake pump unit from the main pump using a soft faced
hammer.
(3) Remove splined coupling(21) and O-rings(12, 17) sealing the internal passages between the
pump sections.
(4) Remove the spacer plate(22) from the body(30), free from spacer plate using a soft faced
hammer.
(5) Remove the backup seal(24), the seal element(25) and the body O-ring(23).
(6) Remove the end cover(31) from the body(30).
(7) Remove the backup seal(24), the seal element(25) and the body O-ring(23).
Ɠ Before removing the internal components each bushing(26, 27) must be marked to denote its
location within the body. On the plain area of the bush away from the seal location, lightly mark.
(8) With the unit laying on its side grasp hold of the drive shaft(29) and pull it squarely out of the body
(30) bringing the bushing(26, 27) with it.
(9) Remove the driven gear(28) and the two remaining bushing(26, 27).
4-35
4) INSPECTION AND REPAIR
(1) Assessment
Each components should be thoroughly cleaned, carefully examined and assessed for suitability
re-use. Below is a guide for inspecting the various components.
(2) Body
ڸInspect the body bore cut-in where both gears wipe into the body.
ڹThe body can only be re-used if the cut-in is bright and polished in appearance and the depth
does not exceed 0.15mm(0.006").
ںThe body should be replaced if the surface is scored, has a matt appearance or shows signs that
the tip of the gears have dug in and torn away the surface material.
ڻThe body should be inspected to ensure that there is no superficial damage which may
adversely effect performance or sealing. Pay particular attention to the port threads and body O-
ring seal recesses.
(3) Spacer plate and end cover
ڸThe inner surfaces should be inspected to ensure that there is no unusual wear or scoring in the
regions where the body O-rings and backing rings contact, which result in external leakage.
ڹCheck the shaft seal recess for scoring or damage that could result in oil leakage around the
outer diameter of the shaft seal. Replacement shaft seals can be refitted with Loctite hydraulic
sealant to overcome slight damage in this area.
(4) Bushing
ڸThe side faces which abut the gears should be perfectly flat showing no sign of scoring.
Characteristically there are bright polished areas on this surface caused by loading against the
gear side faces, which is often more pronounced on the low pressure side. The bush should be
replaced if there is any general scoring or fine scoring with a matt appearance or tearing of the
surface material. Often there is a witness where the tips of the opposing gears have wiped an
overlap reassembling a half moon shape. There must be no noticeable wear step as it is critical
that the bush side face is completely flat to the gear side face.
ڹThe bearing liners are acceptable providing that they are not scored or show other damage.
The general outside area of the bush should not show any prominent signs of wear.
(5) Gears
ڸThe gear side faces should be examined for bruising or scoring. Often operation on
contaminated fluid shows scoring between the root of the gear and the journal undercut, which
leaves a wear step. If a wear step can be felt, coincidental with the root diameter, by drawing a
sharp pointed tool across the surface from the undercut outwards towards the tip of the gear,
then the gear is unserviceable.
ڹThe gear teeth should then be carefully examined to ensure that there are no signs of bruising or
pitting.
ںThe journal bearing surfaces should be completely free from scoring or bruising. The surface
should appear highly polished and smooth to touch.
ڻExamine the area where the shaft seal lips run on the drive shaft, this shows up as a polished
ring or rings. If a noticeable groove can be felt or there is scoring the shaft should be replaced.
ڼProvided the drive shaft is not damaged from the drive-coupling and the gears have not been
harmed as described above, then the gears can be re-used. If, however, the gears are
damaged they must be replaced as a matched pair.
ڽAs a matter of good practice, when pumps have been disassembled, all the seals should be
replaced. It is most important that only the genuine seals are used.
4-36
5) ASSEMBLY
33
32
31
23
24
25
27
30
26 28
26
25
24
23 22
29
27
12
21
17
Ɠ Ensure that all parts are perfectly clean and lightly lubricate the bushes and gears with hydraulic
oil(Ensure body O-ring recess and end faces remain free from oil). This will assist with their
assembly when they are later fitted into the body.
(1) Refit the cover drive shaft bushing(26) and cover driven bushing(27) into the undowelled end of
the body(30) from where they were removed.
(2) Place the end cover(31) against the body(30) and then stand the assembly on the cover so that
the hollow dowels are uppermost, i.e. the bushing should be at the bottom with the bushings
against the cover.
(3) Fit the drive shaft(29) and driven gear(28) back into their original positions in the body(30).
(4) Refit the separate plate drive shaft bushing(27) and the separate plate driven bushing(26) into
their original bores.
(5) Fit the new body O-ring(23).
(6) Fit the new seal element(25) and backup seal(24) to the bushing.
(7) Carefully refit the spacer plate(22) to the body(30). If the spacer plate(22) is not fitted squarely
the backup seal(24) may become misplaced and trapped, resulting in internal damage if the unit
is run in this condition.
4-37
ASSEMBLY
33
32
31
23
24
25
27
30
26 28
26
25
24
23 22
29
27
12
21
17
4-38
6) RUNNING-IN
Pressure gauge
Flow
meter
Relief valve
Strainer
Tank
(1) A unit which has been re-assembled with either new gears, bushes or body, must be carefully
run-in before it is subjected to full working conditions.
(2) Ideally this should be done on a test rig(See figure) where pressure can be gradually applied and
any wipings from the body cut-in arrested by filters.
(3) It is recommended that the unit is run-in at 1500rpm, initially, at zero pressure for one minute then
in stages with the pressure increased by 500psi every minute, until maximum rated pressure has
been attained. Frequently check the system temperature, ensuring that it does not exceed the
maximum permissible figure of 80Ɓ C. If the temperature exceeds the system or unit specification
the test must be delayed and operated off-load until acceptable temperatures are obtained.
4-39
SECTION 5 STEERING SYSTEM
GROUP 1 STRUCTURE AND FUNCTION
1. OUTLINE
The steering system of this machine consists of a fixed-displacement pump supplying a load sensing
steering system and an open center loader system.
The components of the steering system are :
şSteering pump(1st pump)
şSteering unit
şOverload valve block
şPriority valve
şSteering cylinders
The steering pump, the first pump of main pump, draws hydraulic oil from the hydraulic tank.
Outlet flow from the pump flows to the priority valve. The priority valve preferentially supplies flow, on
demand, to the steering unit. When the machine is steered, the steering unit routes flow to the
steering cylinders to articulate the machine.
When the machine is not being steered, or if pump flow is greater than steering flow, the priority valve
supplies flow to the loader system.
That is, output flow from the steering pump enters into the first pump of main pump for the operation
of the attachment.
5-1
2. HYDRAULIC CIRCUIT
LH RH
6 5
L
T 21Mpa
MCV RCV lever
P
LS
4 CF EF
LS
P
23 Return line
24
25 26
5-2
1) NEUTRAL
LH RH
6 5
L G
T 21Mpa
MCV RCV lever
P
LS
4 CF EF
LS
P
Brake system
A 1st pump
B A 1 B 2nd pump
Return line
23 Return line
24
25 26
ş The steering wheel is not being operated so control spool(G) does not move.
ş The oil from the steering pump(B) enters port P of the priority valve and the inlet pressure oil moves
the spool(D) to the right.
ş Oil flow into LS port to the hydraulic tank(24) through orifice and return filter.
ş So, the pump flow is routed to the loader system(Main control valve) through the EF port.
5-3
2) LEFT TURN
LH RH
6 5
L G
E
R
T 21Mpa
MCV RCV lever
P
LS
4 CF EF
LS
P
23 Return line
24
25 26
ş When the steering wheel(E) is turned to the left, the spool(G) within the steering unit(5) connected
with steering column turns in left hand direction.
ş At this time, the oil discharged from the steering pump flows into the spool(G) of the steering unit(5)
through the spool(D) of priority valve and flows into the gerotor(H).
ş Oil flow from the gerotor flows back into the spool(G) where it is directed out the left work port(L) to
the respective chamber of the steering cylinders(9).
ş Oil returned from left and right cylinder returns to hydraulic tank through the spool of the steering unit.
ş When the above operation is completed, the machine turns to the left.
5-4
3) RIGHT TURN
LH RH
6 5
L G
E
R
H
T 21Mpa
MCV RCV lever
P
LS
4 CF EF
LS
P
Brake system
B A 1 A 1st pump
Return line B 2nd pump
23 Return line
24
25 26
ş When the steering wheel(E) is turned to the right, the spool(G) within the steering unit(5) connected
with steering column turns in right hand direction.
ş At this time, the oil discharged from the steering pump flows into the spool(G) of the steering unit(5)
through the spool(D) of priority valve and flows into the gerotor(H).
ş Oil flow from the gerotor flows back into the spool(G) where it is directed out the right workport to the
respective chamber of the steering cylinders(9).
ş Oil returned from left and right cylinder returns to hydraulic tank through the spool of the steering unit.
ş When the above operation is completed, the machine turns to the right.
5-5
3. PRIORITY VALVE
1) STRUCTURE
1 2 3 4 9 6 5
LS
EF CF
5-6
2) OPERATION
(1) Neutral
4 P A 5 A
CF EF
LS
LS
EF CF LOADER ACTUATED(D)
The priority valve is a pressure control valve that maintains priority pressure to the closed center
steering unit. With the steering unit in neutral, flow through is blocked and all flow through the priority
valve is directed out the EF port to the main control valve.
With the engine off, the spool(4) is pushed to the left(Viewed from sectional drawing at previous page)
by the spring(5). The passage to the EF port is blocked while the passage to the CF port is open.
When the machine is first started, all pump flow is routed to the steering unit which blocks the flow.
With the flow blocked, the pressure increases.
Steering inlet pressure is supplied through the pilot orifice to the left end of the spool. This causes the
priority valve spool(4) to shift to the right against the spring and open the EF port.
As long as the steering unit is in neutral, just enough pressure is maintained at the steering unit to keep
the priority valve spool shifted to the right.
The operating pressure in the loader system has no effect on the operation of the priority valve. With
the loader actuated in relief(D), the priority valve will not shift until the machine is steered.
Flow through the priority valve spool passes from the CF port through the orifice(A) and into the LS port.
It flows through the steering unit LS passage which is routed to return when the steering unit is in
neutral. This provides a warm-up circuit for the steering unit to prevent binding of the steering unit due
to oil temperature extremes.
5-7
(2) Midturn
4 P A 5 A
CF EF
LS
LS
When the machine is steered, load sensing pressure from the steering unit flows through the orifices LS
port in the priority valve. Load sensing pressure plus spring(5) force move the spool(4) to the against
the pilot pressure on the left end of the spool. This restricts flow to the loader through the EF port while
the CF port is opened to the steering unit.
The load sensing circuit is control circuit that routes steering workport pressure to the spring side of the
priority valve spool. It allows the priority valve spool to sense the pressure that is required to steer the
unit under varying conditions.
During normal steering conditions, oil is entered into the load sensing circuit through an orifice in the
steering unit. When steering at the full steer rate(D), the orifice opens to an unrestricted passage. At
low engine speed, the spool will shift to the full left position, directing all flow to the steering unit. At high
idle, the steering system can use about one-half of the pump flow. Therefore, the excess oil flows to
the main control valve.
The load-sensing circuit receives the majority of its flow from the load sensing orifice in the steering unit.
Some flow is also supplied from the CF port through orifice(A) in the priority valve spool.
5-8
(3) Full turn
4 P 5
CF EF
LS
LS
EF CF
When the machine is steered to a full turn, the frames bottom against the steering stops.
Pressure to the steering unit(Pilot pressure), which is sensed at the left end of the priority valve spool(4),
continues to increase until it can move the spool to the right against the load sensing pressure plus
spring force. At this time, all oil flows out of the EF port to the main control valve.
If the loader attachment is being operated while steering, the loader function will slow until the machine
reaches the steering stops. At that time, the loader cycle speed will increase until the machine is
steered again.
5-9
4. STEERING UNIT
1) STRUCTURE
1 2
24
2 5
6
7
3
4
2
A
2
8
14 9 10
13
14 A
14
15
14
17
16 18
21
18
20
5-10
2) OPERATION
A NEUTRAL
B
C Anti-cavitation valves
E Gerotor
The steering unit consists of a spool(I) inside a sleeve(H) within a housing. When steering wheel is not
moving, the valve is in the neutral(A) position. In neutral, the spool and sleeve are aligned so that oil
flow through the valve is blocked. The steering cylinder(B) are held stationary by trapped oil in the left
and right workports.
When the steering unit is turned to the right, the spool rotates relative to the sleeve, and opens
passages which allow pump flow through the spool and sleeve assembly. Oil flows to the gerotor(E)
causing the gerotor gear to rotate. Oil flow from the gerotor flows back into the valve where it is
directed out the right workport to the respective ends of the steering cylinders.
A bypass orifice is machined into the spool and sleeve assembly. It is a variable orifice that introduces
a small leak into the pressure side of the steering unit. Its purpose is to dampen the initial pressure
surge when the steering wheel is partially turned. When the steering wheel is fully turned, the leak is
closed off.
Return oil flows back in through the left workport through the spool and sleeve assembly to return. The
load sensing orifice is located between the sleeve and the gerotor. This orifice feeds the load sensing
circuit between the steering unit and the priority valve through the LS port.
When the rotation of the steering wheel stops, the gerotor gear continues to move, turning the sleeve,
until the sleeve stops the flow to the gerotor. At this point, the valve is back in the neutral position and
will remain there until the steering wheel is moved again.
The valve has a variable steering which is proportional to the speed the steering wheel is rotated. A
variable orifice bypasses oil around the gerotor. Turning the steering wheel slowly takes approximately
seven turn(Variable orifice small) lock to lock versus four turns(Variable orifice large) when turning the
steering wheel quickly.
5-11
5. OVERLOAD VALVE
2
9
3 8
7
6
9
P R 5
T L
5
6 4
7
8 4
R
P, T, L, R port 3/4-16 UNF
T
Shock valves 270-290 bar
P
Screw M10ź1ź46
HYDRAULIC CIRCUIT
5-12
6. STEERING CYLINDER
1) STRUCTURE
19,20,21 18
2) OPERATION
This machine use to cross connected cylinder for steering operation.
The steering cylinder use a gland(3) to remove piston and sealed seals. Dust wiper(8) located on
the in side of the gland protects cylinder inner parts from dust. The piston(13) is fastened to the
rod(2) by a nut(17).
The piston uses a single wear ring(16) with a piston seal(15) to seal between the piston and tube.
The gland seals against the tube with two O-rings. The rod is sealed against the gland with a rod
seal(5).
5-13
GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING
1. OPERATIONAL CHECKS
This procedure is designed so the service man can make a quick check of the steering system using
a minimum amount of diagnostic equipment. If you need additional information, prefer to structure
and function in group 1.
A location will be required which is level and has adequate space to complete the checks.
The engine and all other major components must be at operating temperature for some checks.
Locate system check in the left column and read completely, following this sequence from left to right.
Read each check completely before performing.
At the end of each check, if no problem is found(OK), that check is complete or an additional check is
needed. If problem is indicated(NOT OK), you will be given repair required and group location.
If verification is needed, you will be given next best source of information :
Chapter 2 : Troubleshooting
Group 3 : Tests and adjustments
5-14
ƓHydraulic oil must be at operating temperature for these checks(Refer to page 6-54).
Item Description Service action
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 Left Right frames are against stops. Check completed.
Heat hydraulic oil to
operating temperature. Hold approximately 2kg on NOT OK
Run engine at high idle. steering wheel. Do steering system
leakage test in group 3 to
Count steering wheel revolutions isolate the leakage.
for 1 minute.
Repeat test in opposite direction.
LOOK : Steering wheel should
rotate less than 5rpm.
NOTE : Use good judgment;
Excessive steering wheel rpm
does not mean steering will be
affected.
Priority valve low Park machine on a hard surface. OK
pressure check Check completed.
Hold brake pedal down.
NOT OK
Run engine at high idle. Do priority valve pressure
Steer machine to the right and left test in group 3.
as far as possible.
LOOK : Machine must turn at
least half way to the right and left
stops.
5-15
Item Description Service action
5-16
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 3. Troubleshooting
Step 4. Tests and adjustments(See group 3)
5-17
Problem Cause Remedy
5-18
Problem Cause Remedy
Steering unit locks up Large particles of contamination in Inspect hydraulic filter for contamination.
steering unit. Repair cause of contamination. Flush
hydraulic system.
5-19
Problem Cause Remedy
5-20
GROUP 3 TESTS AND ADJUSTMENTS
5-21
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 tank capacity : 60ֻ(15.9U.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.
5-22
2. TEST TOOLS
10 40
0 MPH 30
0 50
VDO
5-23
3. STEERING SYSTEM RESTRICTION TEST
ş SPECIFICATION
Oil temperature 65Ź6Ş C(150Ź10Ş F)
Engine speed High idle
Maximum pressure 2.0Mpa(20bar, 285psi)
at steering unit
ş GAUGE AND TOOL
Gauge 0~7.0Mpa(0~70bar, 0~1000psi) 1EA
5-24
4. STEERING UNIT LEAKAGE TEST
ş SPECIFICATION
Oil temperature 40Ź6Ş C(100Ź10Ş
F)
Engine speed High idle
Maximum leakage 5.7cc/ 10min
ş GAUGE AND TOOL
Temperature reader T
5-25
5. STEERING UNIT PRESSURE TEST
ş SPECIFICATION
Oil temperature 65Ź6Ş C(150Ź10Ş F)
Engine speed High idle
Relief pressure 20.5~21.5Mpa
(205~215bar, 3200~3300psi)
ş GAUGE AND TOOL
Gauge 0~35.0Mpa(0~350bar, 0~5000psi)
CF
Temperature reader
steering unit.
2) Install temperature reader.(See temperature
installation procedure in this group.)
3) Install frame locking bar.
4) Heat hydraulic oil to specifications.(See
hydraulic oil warm up procedure at page
6-54.)
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
Frame locking bar
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 Relief valve
system leakage is indicated.
6) Read pressure gauge. This is the steering
unit relief pressure. A
7) If pressure in not to specification, remove
the plug(A) from steering unit. Turn
adjusting screw in relief cartridge using a
hex head wrench to adjust pressure.
If pressure cannot be adjusted to
specification, disassemble and inspect
steering unit.
5-26
6. PRIORITY VALVE "LS" PORT FLOW TEST
ş SPECIFICATION
Oil temperature 40Ź6Ş C(100Ź10Ş F)
Engine speed Low idle
LS port flow(Approx) 0.5ֻ/min(0.13gpm)
ş GAUGE AND TOOL
Temperature reader
Measuring container LS
Stop watch
Priority valve LS port flow test will check for a
plugged or missing orifice in the priority valve
spool. A plugged orifice will block warm up
flow to the steering unit which can cause
thermal shock.(See for an explanation of A
thermal shock, page 5-19). B
5-27
GROUP 4 DISASSEMBLY AND ASSEMBLY
1. PRIORITY VALVE
1) STRUCTURE
1
2
3
7 6
5-28
2) TOOLS
şOpen-end spanner 22mm.
şNylon pin.
şHexagon socket spanner 8mm.
şTorque wrench.
şSocket spanner 22mm.
şHexagon socket spanner insert 8mm.
3) DISASSEMBLY
Ɠ Cleanliness is the primary means of
assuring satisfactory the priority valve life.
Select clean place.
Before removing the piping, clean the
surrounding area of valve ports.
PP
LS
5-29
(3) Pull out the plug with seal ring and spring.
LS
PP
LS
5-30
4) MODIFICATION
(1) The control spring pressure can be altered by replacing the spring(See table below). Replace
name plate so that code no. and control spring pressure match each other again.
Control spring
d(mm) Di(mm) L(mm)
pressure(bar)
4 1.8 6.9 54
7 Di
2.0 6.5 55
d
L
(2) Cleaning
Clean all parts carefully in low aromatic kerosene.
(3) Inspection and replacement
Check all parts carefully and make any replacements necessary. All seal rings must be replaced.
(4) Lubrication
Before assembly, lubricate all parts with hydraulic oil.
5) ASSEMBLY
(1) Guide the spool into the bore. Use the
nylon pin to center the spool in the bore.
PP
LS
PP
LS
5-31
(3) Guide the spring and LS plug into the
bore.
Remember seal ring.
LS
LS
PP
LS
5-32
6) TROUBLESHOOTING
Steering wheel 1. Relief valve of steering unit is clogged Disassembly, clean and reassembly.
is heavy with dirt.
2. Spool is stuck. Disassembly, clean and reassembly or
replace.
3. Orifice of plug and spool is clogged. Disassembly, clean and reassembly.
(Steering wheel a. Pump is faulty. Check pump.
is heavy at
engine low idle)
Abnormal noise 1. Relief valve of steering unit is clogged Disassembly, clean and reassembly.
with dirt.
2. Spool is stuck. Disassembly, clean and reassembly or
replace.
5-33
2. STEERING UNIT
1) STRUCTURE
1 2
24
2 5
6
7
3
4
2
A
2
8
14 9 10
13
14 A
14
15
14
17
16 18
21
18
20
5-34
2) TOOLS
(1) Holding tool.
5-35
3) DISASSEMBLY
(1) Disassemble steering column from
steering unit and place the steering unit in
the holding tool. Screw out the screws in
the end cover(7-off-one rolled pin).
5-36
(5) Remove cardan shaft.
5-37
(9) Remove O-ring.
5-38
(13) Pull sleeve and spool out of the housing.
5-39
(17) Remove dust seal and O-ring.
Cleaning
Clamp all parts carefully in Shellsol K or the
like.
Inspection an replacement
Replace all seals and washer. Check all
parts carefully and make any replacements
necessary.
Lubrication
Before assembly, lubricate all parts with
hydraulic oil.
5-40
4) ASSEMBLY
(1) Assemble spool and sleeve.
Ɠ The sleeve and spool are correctly B A
assembled when
ڸThe slots-in sleeve and spool-for the
neutral position springs are opposite
each other and
ڹOne of the 3 T-shaped grooves(A) in the
spool is opposite one of the sets(B) of
small holes in the sleeve.
5-41
(5) Guide the spool into the sleeve.
5-42
(9) Fit the cross pin into the spool/sleeve.
5-43
(12) Put the steering unit in the holding tool
keeping the bore vertical. Guide the outer
part of the assembly tool into the bore.
Guide the inner part of the tool right to the
bottom.
5-44
(15) The spool set will push out the assembly
tool guide. The O-ring is now in position.
5-45
(19) Grease the O-ring with mineral oil
approximate viscosity 500cSt at 20Ş
C and
place it in the groove.
5-46
(23) Guide the cardan shaft down into the bore
so that the slot is parallel with the
connection flange.
5-47
(27) Place the end cover in position.
5-48
(31) Fit the dust seal ring in the housing using
special tool and a plastic hammer.
5-49
3. OVERLOAD VALVE
1) STRUCTURE
2
9
3 8
7
6
9
P R 5
T L
5
6 4
7
8 4
5-50
2) TOOLS
(1) Hexagon socket spanner, 8mm.
5-51
3) DISASSEMBLY
(1) Remove the rolled pin.
8
7
1,2
5-52
(5) Remove the check valve(9).
9
5-53
4) ASSEMBLY
Cleaning
Clean all parts carefully in Shellsol K or the
like.
Inspection an replacement
Replace all seals and washers. Check all
parts carefully and make any replacements
necessary.
Lubrication
Before assembly, lubricate all parts with
hydraulic oil.
8
7
5-54
(4) Fit the rolled pin.
5-55
(8) Press the plastic plugs into the connection
ports. The overload valve is now
assembled.
5) TROUBLESHOOTING
Steering cylinder 1. Overload valve seat side is clogged Disassembly, clean, reassembly.
reaction is bad with dirt.
2. Anti cavitation check valve seat is Disassembly, clean, reassembly.
clogged with dirt.
3. Damage of O-ring for adjusting. Replace.
Abnormal noise 1. Overload valve seat side clogged Disassembly, clean, reassembly.
with dirt.
5-56
4. STEERING CYLINDER
1) STRUCTURE
19,20,21 18
5-57
2) TOOLS AND TIGHTENING TORQUE
(1) Tools
17 B
Spanner 32
36
Steel bar For gland
(-) Driver Small and large sizes
Torque wrench Capable of tightening with the specified torques
5-58
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.
m
0
m
after the oil draining operation. 20
3
2
5-59
Ɠ Note that the plated surface of piston
rod(2) is to be lifted. For this reason, do
not use a wire sling and others that may
damage it, but use a strong cloth belt or
a rope.
Wooden block
5-60
(3) Disassemble the piston assembly
ڸRemove wear ring(16) and piston seal 15 16
(15).
Ɠ Exercise care in this operation not to
damage the grooves.
5-61
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.
5-62
ڽFit back up ring(11) to gland (3).
Ɠ Put the backup ring in the warm water of
30~50Ş C- 4
ھFit O-ring(10) to gland(3). 10
ڿFit O-ring(12) to gland(3). 11
3
12
5-63
(3) Install piston and gland
ڸFix the piston rod assembly to the work
Gland assembly Piston rod
bench.
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).
5-64
(4) Overall assemble
Fix with a bar
ڸPlace a V-block on a rigid work bench.
Mount the cylinder tube assembly(1) on it Lift
and fix the assembly by passing a bar
through the clevis pin hole to lock the
assembly.
Straight
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
tube assembly and tighten socket bolts to
a specified torque. Piston rod
Ɠ Refer to the table of tightening torque.
Wrench
Gland
5-65
GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING
1. OPERATIONAL CHECKS
This procedure is designed so the mechanic can make a quick check of the system using a minimum
amount of diagnostic equipment. If you need additional information, read Structure and function,
Group 1.
A location will be required which is level and has adequate space to complete the checks.
The engine and all other major components must be at operating temperature for some checks.
Locate system check in the left column and read completely, following the sequence from left to right.
Read each check completely before performing.
At the end of each check, if no problem is found(OK), that check is complete or an additional check is
needed. If problem is indicated(NOT OK), you will be given repair required and group location.
If verification is needed, you will be given next best source of information:
Chapter 2 : Troubleshooting
Group 3 : Tests and adjustments
6-39
Ɠ Hydraulic oil must be at operating temperature for these checks(Refer to page 6-54).
6-40
Item Description Service action
6-41
Item Description Service action
6-42
Item Description Service action
6-43
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 time of boom
1) LIFTING TIME OF BOOM
Set the bucket near the maximum tilt back
position and at the lowest position on the
ground. Raise the bucket and measure
the time taken for bucket to reach the
maximum height of the boom.
6-44
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 :
Noisy hydraulic pump Low oil supply or wrong viscosity. Fill reservoir with recommended oil.
Plugged or pinched suction line. Clean or replace line.
Air in oil. Check for foamy oil. Tighten
connections.
Replace O-rings and or lines.
Loose or missing hydraulic line clamps. Tighten or replace clamps.
Hydraulic lines in contract with frame. Inspect and repair.
Worn or damaged pump. Do hydraulic pump performance check
in group 2. Do hydraulic pump flow
test in group 3.
6-45
Problem Cause Remedy
No steering or hydraulic Low oil level. Add recommended oil.
function
Failed hydraulic pump. Remove and inspect return filter for
metal pump particles.
Failed main hydraulic pump drive. Remove main hydraulic pump and
inspect drive gear.
No hydraulic functions Failed hydraulic pump. Remove and inspect return filter for
steering normal metal pump particles, or replace the
pump.
Failed pilot line filter. Remove and inspect line filter for RCV.
Faulty safety valve. Safety valve leakage test or ON, OFF
function test.
Stuck open system and port relief Replace relief valve.
valve.
Faulty or misadjusted pilot supply unit. Do pilot supply unit pressure test in
group 3.
Boom float function Low pilot control pressure. Do pilot supply unit pressure test in
does not work group 3.
Faulty pilot control valve(RCV). Do pilot control valve pressure test.
Main control valve spool binding in Do pressure reducing valve pressure
bore. test in group 3.
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
pressure test in group 3.
Faulty or misadjusted pilot oil supply Do pilot oil supply unit pressure test in
unit . group 3.
Leaking system relief valve. Remove and inspect valve.
Worn hydraulic pump. Do hydraulic pump performance check
in group 2.
Faulty pilot control valve(RCV). Do pilot control valve(RCV) pressure
test in group 3.
6-46
Problem Cause Remedy
Boom drifts up Leakage in boom down spool. Remove and inspect boom down spool.
Boom down does not Safety valve not operated. Operate valve.
work
Stuck pilot control valve. Inspect.
Engine off.
Faulty line filter. Remove and inspect filter.
Accumulation not operated. Inspect.
Main control valve spool stuck. Inspect and repair valve.
Oil overheats Low oil viscosity in hot weather. Use recommended oil.
Excessive load. Reduce load.
Holding hydraulic system over relief. Reduce load.
Leakage in work circuit. Do boom and bucket cylinder leakage
test in group 3.
Plugged fins in oil cooler. Inspect and clean oil cooler.
Internally plugged oil cooler. Do hydraulic oil cooler restriction test.
Incorrect system or circuit relief valve Do loader system and circuit relief valve
setting. pressure test in group 3.
Restriction in oil lines or main control Inspect for dented or kinked lines.
valve. Do hydraulic system restriction test in
group 3.
Pinched or restricted priority valve LS Run engine at low idle. Steer machine
line. back and forth. If engine load
decreases while steering, a restricted
LS line or priority valve malfunction is
indicated.
Do priority valve LS port flow test in
group 3.
Malfunctioning priority valve. Do hydraulic system restriction test in
group 3.
Leaking system main relief valve. Remove and inspect valve and seals.
Worn hydraulic pump(Internal leakage). Do hydraulic pump performance check
in group 2.
Function drops before Stuck open lift check valve. Do control valve lift check in group 2.
raising when valve is
activated
6-47
Problem Cause Remedy
Remote control valve Leaking plunger seals. Remove, inspect and replace plunger
(RCV) leaking seals.
6-48
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.
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.
6-49
GROUP 3 TESTS AND ADJUSTMENTS
6 -50
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 tank capacity : 60ֻ(15.9U.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 -51
2. BOOM HEIGHT KICKOUT ADJUSTMENT
1) Lift the boom up to a desired height, set the
boom control lever at hold, then stop the Proximity switch
Front frame
engine.
Plate
Be careful lest work equipment fall
down.
Put the hydraulic safety lock lever in the
LOCK position.
Boom
Boom
3Ź1mm
6 -52
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
C
line within 100mm(4in) of pump. Finger
tighten only-do not over tighten.
B : Black clip(-). Connect to main frame.
C : Red clip(+). Connect to transducer. A
D : Tachometer readout. Install cable.
10 40
0 MPH 30
0 50
VDO
6 -53
4. HYDRAULIC OIL WARM UP PROCEDURE
1) Install temperature reader(See temperature
reader installation procedure in this group).
2) Run engine at high idle.
3) Hold a hydraulic function over relief to heat
the oil.
4) Periodically cycle all hydraulic functions to
distribute warm oil.
5) Heat oil to test specification(Approx 50Ɓ
C).
6 -54
5. MAIN HYDRAULIC PUMP FLOW TEST
ş SPECIFICATION
Oil temperature 65Ź6ƁC(150Ź10Ɓ F)
Engine speed 2300Ź25rpm
Test pressure 220Ź10bar(3190psi)
Maximum pump flow 65ֻ/min(17.2gpm)
ş FLOW METER GAUGE AND TOOL
Gauge 0~35MPa(0~350bar, 0~5000psi)
Temperature reader
1) Make test connections.
2) Install temperature reader.
(See temperature reader installation
procedure in this group.)
3) Heat hydraulic oil to specifications.
(See hydraulic oil warm up procedure in this
group.)
4) Run engine at test specifications.
5) Close flow meter loading valve to increase
pressure to test specifications.
To MCV
6) Read flow meter.
7) If flow is below specifications, check suction
line and suction pressure for abnormality
before removing pump.
6 -55
6. LOADER SYSTEM AND PORT RELIEF
VALVE PRESSURE TEST
ş SPECIFICATION
Oil temperature(45~55Ɓ
C)
215*5kgf/cm2
System(M) High
(3130*70psi)
U
Boom 240Ź5kgf/cm2
Low
raise(U) (3410Ź70psi) D
Bucket 240Ź5kgf/cm 2
M
Low
rollback(R) (3410Ź70psi)
Bucket 240Ź5kgf/cm2
Low
dump(D) (3410Ź70psi)
R
6 -56
Ɠ Do not adjust the system relief valve
above 250kgf/cm2 (3560psi). Damage to
the pump will result from excessive
pressure settings.
5) To check the bucket dump, bucket rollback,
and boom raise, adjust the system relief
valve to 250kgf/cm2 (3560psi).
Run engine to maintain 800~850rpm when
hydraulic function is activated over relief.
Activate the function to be checked with the
cylinder bottomed. Read the pressure
gauge.
If pressure is not to specification cycle relief
valve over relief 10 times to flush.
Read pressure gauge again. Turn screw
to adjust valve to specification.
Ɠ Do not work machine with system relief
adjusted above specification or
structural damage may occur.
6) Adjust system relief valve to specification.
6 -57
7. HYDRAULIC SYSTEM RESTRICTION TEST
ş SPECIFICATION
Oil temperature 65Ź6Ɓ C(150Ź10Ɓ F)
Engine speed High idle
Maximum pressure at steering(Orbitrol)
valve 2MPa(20bar, 285psi)
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
overheating of hydraulic oil.
1) Install temperature reader.(See temperature T
6 -58
8. LOADER CYLINDER DRIFT TEST
A
ş SPECIFICATION
Oil temperature 40Ź6Ɓ
C(100Ź10Ɓ
F)
Boom horizontal
Bucket horizontal
Bucket unloaded
B
Item Standard value
Retraction of boom
20mm A : Retraction of bucket cylinder rod
cylinder rod
B : Retraction of boom cylinder rod
Retraction of bucket
30mm
cylinder rod
6 -59
9. BOOM AND BUCKET CYLINDER LEAKAGE
TEST
ş SPECIFICATION
Oil temperature 40Ź6Ɓ C(100Ź10Ɓ
F)
Engine speed Low idle
Maximum leakage 12cc/10min
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.
2) Heat hydraulic oil to specifications.(See
hydraulic oil warm up procedure in this
group.)
Never work under raised equipment
unless it is supported with a hoist or
support stands.
3) Full extend the cylinder to be tested. If
testing the boom cylinders, restrain boom in
the fully raised position using a hoist or a
stand.
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 low idle. Activate control
lever to extend cylinder for 1 minute over
relief while measuring leakage for open
port.
If leakage is within specification, excessive
cylinder drift is caused by leakage in the
main control valve or circuit relief valve.
6 -60
10. PILOT CONTROL VALVE PRESSURE TEST
ş SPECIFICATION
Oil temperature 40Ź6Ɓ C(100Ź10Ɓ F)
Engine speed Low idle
Begin metering 1/4" of lever travel
Pressure at feel positionƕ:
Boom power down 18.1~19.0bar
Boom raise 19.0~30.0bar
Bucket rollback 19.0~30.0bar
Bucket dump 19.0~30.0bar
ş GAUGE AND TOOL
Gauge 0~7MPa(0~70bar, 0~1000psi)
ƕ As the control lever is moved from neutral,
the pilot pressure will suddenly jump up to T
P
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
19.0bar 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.
A
1) Lower boom to ground.
Block(Rear frame mounting)
2) Connect gauge to the pilot pressure port(A)
of function to be checked.
3) Install temperature reader.
(See temperature reader installation
procedure in this group.)
4) Heat hydraulic oil to specification.(See
hydraulic oil warm up procedure in this
group.)
6 -61
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 -62
11. PILOT OIL SUPPLY UNIT PRESSURE TEST
ş SPECIFICATION
Oil temperature 40Ź6Ɓ C(100Ź10Ɓ F)
Engine speed Low idle and stop
Pilot pressure setting 30~35bar(430~500psi)
Relief valve setting pressure
45bar
Accumulator precharging pressure
16bar
ş GAUGE AND TOOL
Gauge 0~7MPa(0~70bar, 0~1000psi)
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) on the block.
2) Install temperature reader.
(See temperature reader installation
procedure in this group.)
A
3) Heat hydraulic oil to specification.(See
Block(Rear frame mounting)
hydraulic oil warm up procedure in this
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 -63
12. CYCLE TIME TEST
ş SPECIFICATION
Oil temperature 65Ź6Ɓ C(150Ź10Ɓ
F)
Engine speed High idle
6 -64
13. HYDRAULIC OIL FILTER INSPECTION
PROCEDURE
1) Lower the bucket to the ground, stop the
engine, move the control lever back and 1
forth several times, and clean all over the 2
upper surface of the hydraulic oil tank.
2) Remove the bolts(1) and take out the filter 3
case cover(3) and O-ring(4). 4
6 -65
GROUP 4 DISASSEMBLY AND ASSEMBLY
1. MAIN PUMP
1) STRUCTURE
10
5
6
7
7
6
5
16
9 4
3
19
20
4
5
6
7 1
14
2
7
18 6
5
15 13
12
11
6 -66
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(Bushing and spacer plate) must be lightly lubricated with a
clean oil or aerosol lubricant.
(3) Tools required for assembly
ڸTorque wrench(0~20kgfşm, 0~150lbfşft)
ڹOpen end wrenches
ںSeal installation tools(Inner and outer)
ڻShaft bullet(Seal protector)
ڼInstallation plate
6 -67
3) DISASSEMBLY
10
5
6
7
7
6
5
16
9 4
3
19
20
4
5
6
7 1
14
2
7
18 6
5
15 13
12
11
Ɠ Prior to starting work ensure that the pump and the working area are thoroughly clean and free
from sources of contamination.
(1) Mark end cover(16), center body(13), front body(10) and mounting flange(3) to ensure correct
assembly.
(2) Remove the 4 bolts(18), serrated washers(19), nut(20) clamping the units together, separate the
pumps by removing the rear unit from the location dowels in the center body - use a soft faced
hammer.
(3) Remove splined coupling(11) and discard O-ring(12) sealing the internal passages between the
pump sections.
(4) Disassemble rear pump by removing the end cover(16) from the body(13), free cover front
location spigot using a soft faced hammer.
(5) Remove drive shaft(15) from its bore by pushing it out from the connection hole in the rear face,
this will also remove balance plate(7).
Ɠ Note position of gear and balance plate for correct reassembly.
6 -68
DISASSEMBLY
10
5
6
7
7
6
5
16
9 4
3
19
20
4
5
6
7 1
14
2
7
18 6
5
15 13
12
11
6 -69
4) INSPECTION AND REPAIR
(1) Assessment
Each components should be thoroughly cleaned, carefully examined and assessed for suitability
re-use. Below is a guide for inspecting the various components.
(2) Body
ڸInspect the body bore cut-in where both gears wipe into the body.
ڹThe body can only be re-used if the cut-in is bright and polished in appearance and the depth
does not exceed 0.15mm(0.006").
ںThe body should be replaced if the surface is scored, has a matt appearance or shows signs that
the tip of the gears have dug in and torn away the surface material.
ڻThe body should be inspected to ensure that there is no superficial damage which may adversely
effect performance or sealing. Pay particular attention to the port threads and body O-ring seal
recesses.
(3) Mounting flange and end cover
ڸThe inner surfaces should be inspected to ensure that there is no unusual wear or scoring in the
regions where the body O-rings and backing rings contact, which result in external leakage.
ڹCheck the shaft seal recess for scoring or damage that could result in oil leakage around the
outer diameter of the shaft seal. Replacement shaft seals can be refitted with Loctite hydraulic
sealant to overcome slight damage in this area.
(4) Balance plate
ڸThe side faces which abut the gears should be perfectly flat showing no sign of scoring.
Characteristically there are bright polished areas on this surface caused by loading against the
gear side faces, which is often more pronounced on the low pressure side. The balance plate
should be replaced if there is any general scoring or fine scoring with a matt appearance or
tearing of the surface material. Often there is a witness where the tips of the opposing gears
have wiped an overlap reassembling a half moon shape. There must be no noticeable wear
step as it is critical that the balance plate side face is completely flat to the gear side face.
ڹThe bearing liners are acceptable providing that they are not scored or show other damage. The
general outside area of the balance plate should not show any prominent signs of wear.
(5) Gears
ڸThe gear side faces should be examined for bruising or scoring. Often operation on
contaminated fluid shows scoring between the root of the gear and the journal undercut, which
leaves a wear step. If a wear step can be felt, coincidental with the root diameter, by drawing a
sharp pointed tool across the surface from the undercut outwards towards the tip of the gear,
then the gear is unserviceable.
ڹThe gear teeth should then be carefully examined to ensure that there are no signs of bruising or pitting.
ںThe journal bearing surfaces should be completely free from scoring or bruising. The surface
should appear highly polished and smooth to touch.
ڻExamine the area where the shaft seal lips run on the drive shaft, this shows up as a polished
ring or rings. If a noticeable groove can be felt or there is scoring the shaft should be replaced.
ڼProvided the drive shaft is not damaged from the drive-coupling and the gears have not been
harmed as described above, then the gears can be re-used. If, however, the gears are
damaged they must be replaced as a matched pair.
ڽAs a matter of good practice, when pumps have been disassembled, all the seals should be
replaced. It is most important that only the genuine seals are used.
6 -70
5) ASSEMBLY
10
5
6
7
7
6
5
16
9 4
3
19
20
4
5
6
7 1
14
2
7
18 6
5
15 13
12
11
Ɠ Prior to assembly all parts must be perfectly clean and lubricated with clean hydraulic oil.
Ɠ Renew all seals using clean hydraulic oil as a lubricant.
(1) Front pump
ڸFit inner shaft seal(1) into the recess in the mounting flange, with the garter spring facing into the
pump, refit circlip(2) into its groove.
Fit outer shaft seal with garter spring facing uppermost. Coat lips of seals with a high melting
point grease.
Ɠ If the seal recess has been scored, then seal outside diameter can be coated with loctite
hydraulic sealant to prevent leakage.
ڹStand pump body on its rear face, fit seal element(5) and seal energizer(6) to the groove in the
balance plate. Carefully feed the balance plate into the body bores. Ensure that the seals
remain in position and that the two small holes through the balance plate are to the low pressure
side of the unit, i.e. side with large 4 bolt port pattern.
6 -71
ASSEMBLY
10
5
6
7
7
6
5
16
9 4
3
19
20
4
5
6
7 1
14
2
7
18 6
5
15 13
12
11
ںInsert drive shaft(9) and driven gear(8) into their original bores.
ڻReplace top balance plate with small holes to low pressure side of the unit, fit seal element(5)
and seal energizer(6) to grooves in balance plate.
ڼFit O-ring(4) to groove in mounting flange and apply a small amount of loctite sealant to the body
lower face, i.e. outboard of oval spigot. This sealant is to prevent moisture entering this area
preventing corrosion.
ڽCarefully feed mounting flange over the drive shaft, ensure flange is in its original position-4mm
hole in rear face of flange must be to the low pressure side of the unit. Tap flange on to its
location spigot with a soft faced hammer.
6 -72
10
5
6
7
7
6
5
16
9 4
3
19
20
4
5
6
7 1
14
2
7
18 6
5
15 13
12
11
ںFit seal element(5) and seal energizer(6) to grooves in balance plate(7) and carefully feed into
body bores. Ensure seals remain in position and that the two small holes through the balance
plate are to the low pressure side, i.e. the side without a port.
ڻFit drive gear(15) ensuring that it locates in the splined coupling(11), fit driven gear(14).
ڼReplace upper balance plate in its original position, i.e. with 2 small holes to low pressure side, fit
seal element(5) and seal energizer(6) to groove in plate.
ڽFit O-ring(4) to groove in end cover, apply a small amount of loctite sealant to lower face of body,
i.e. outboard of oval spigot.
ھStuds(18) to be screwed into cover(16). Prior to fitting flange(3) washers(19) and nuts(20).
şTightening torque : 9.5Ź0.7kgfşm(68.7Ź5.1lbfşft)
ڿPour a small amount of clean hydraulic oil into ports and check that the unit rotates without undue
force. If excessive force it required then seals in balance plates are possibly trapped and the unit
should be disassembled and reassembled correctly.
6 -73
6) RUNNING-IN
Pressure gauge
Flow
meter
Relief valve
Strainer
Tank
(1) A unit which has been reassembled with either new gears, balance plate or body, must be
carefully run-in before it is subjected to full working conditions.
(2) Ideally this should be done on a test rig(See figure) where pressure can be gradually applied and
any wipings from the body cut-in arrested by filters.
(3) It is recommended that the unit is run-in at 1500rpm, initially, at zero pressure for one minute then
in stages with the pressure increased by 500psi every minute, until maximum rated pressure has
been attained. Frequently check the system temperature, ensuring that it does not exceed the
maximum permissible figure of 80Ɓ C. If the temperature exceeds the system or unit specification
the test must be delayed and operated off-load until acceptable temperatures are obtained.
6 -74
2. RCV LEVER
1) STRUCTURE
B
17
12
4 1
29 24 2 13
3
28 5 6
23
26 4 7
21 2 2
1
3
27
15
16 A
10 9 4 1
8
3 2
18 14
25
15 19
11 30
22
20
A
B
6 -75
2) DISASSEMBLY AND ASSEMBLY
(1) Detach the rubber boot(21) from the
retainer collar and lift the boot clear from 21
the selector assembly.
The capscrew(19) can now be easily
accessed.
Selector assy
6 -76
(5) The spindle guides can now be replaced.
The O-rings on the spindle guide must be
replaced before the valve is reassembled. O-ring
6 -77
3. BOOM AND BUCKET CYLINDER
1) BOOM CYLINDER
3 1 20 24 25,26 21 27,28
8,9
INTERNAL DETAIL
6 -78
2) BUCKET CYLINDER
23-3,23-5,23-6
8,9
INTERNAL DETAIL
6 -79
3) TOOLS AND TIGHTENING TORQUE
(1) Tools
8 B
Allen wrench
12
17
Spanner
19
(-) Driver Small and large sizes
Torque wrench Capable of tightening with the specified torques
6 -80
4) 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.
3
19
2
Cover here
with rag
6 -81
Ɠ Note that the plated surface of piston
rod(2) is to be lifted. For this reason, do
not use a wire sling and others that may
damage it, but use a strong cloth belt or a
rope.
Wooden block
6 -82
(3) Disassemble the piston assembly
ڸRemove wear ring(16), dusting(17), and 17 15 16
piston seal (15).
Ɠ Exercise care in this operation not to
damage the grooves.
6 -83
5) 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
6 -84
ڼFit back up ring(11) to gland(3).
Ɠ Put the backup ring in the warm water of
30~50Ş C.
11
ڽFit O-ring(9) to gland(3).
10
6 -85
(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).
6 -86
(4) Overall assemble Fix with a bar
ڸPlace a V-block on a rigid work bench.
Mount the cylinder tube assembly(1) on it
Lift
and fix the assembly by passing a bar
through the clevis hole to lock the
assembly.
ڹInsert the piston rod assembly in to the Straight
Gland
6 -87
SECTION 7 ELECTRICAL SYSTEM
GROUP 1 COMPONENT LOCATION
1. LOCATION 1
9 15
10 16
11
12 17
1 13
2 14
3
4 18
5 Switch panel 19
20
6 21
7
22
8 23
24
7-1
2. LOCATION 2
8
7
6
1
5
14
16
10
11
12
4
13
15
3
2
7-2
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-2(6)] RH Combi clearance lamp ON [CL-16(4)]
I/conn [CN-4(1)] LH Head lamp ON [CL-3(4)]
Fuse box(12) I/conn [CN-2(5)] No. plate lamp ON [CL-21(2)]
LH Combi clearance lamp ON [CL-15(4)]
I/conn [CN-4(2)] RH Head lamp ON [CL-4(4)]
I/conn [CN-7(14)] All cluster guage lamp ON
2) CHECK POINT
7-5
ILLUMINATION CIRCUIT
CN-36
126 GL
046 RL
143 RG
FUSE BOX
CN-4 CL-3
2
LH HEAD LIGHT
CS-39
CL-4
3
CN-8
RH HEAD LIGHT
3
CL-21
CL-16
CN-2
3 RH COMBI
CL-15
LH COMBI
1.25R CN-127
3 E
B km/h
4
306 1.25R 8 S
G3
SPEED METER
CS-41
CN-7 CN-119
T/M TEMP
HAZARD SW
CN-117
WATER TEMP
JT-29
CN-104
VOLT METER
4
CN-107
FUEL METER
7-6
2. HEAD LIGHT CIRCUIT
1) OPERATING FLOW
Fuse box(No.19) Head light switch [CS-39(4)] Light switch ON, 2nd step [CS-39(2)]
Multi function switch [CS-11(8)]
Multi function switch MIDDLE [CS-11(7)] I/conn [CN-4(3)] LH Head light low beam
ON [CL-3(1)]
RH Head light low beam
ON [CL-4(1)]
Multi function switch DOWN [CS-11(6)] I/conn [CN-4(4)] LH Head light high beam
ON [CL-3(2)]
RH Head light high beam
ON [CL-4(2)]
I/conn [CN-7(3)] Cluster high beam pilot
lamp ON [CL-41(2)]
2) CHECK POINT
7-7
HEAD LIGHT CIRCUIT
CN-36
FUSE BOX
CL-3
CS-39
CN-8
1
LH HEAD LIGHT
CL-4
CL-41
7
HI BEAM PILOT LAMP
4
CN-7 JT-28
3
5 8
CS-11
7-8
3. WORK LIGHT SWITCH
1) OPERATING FLOW
Fuse box(No.17) Front work light switch [CS-21(6)] Work light switch ON [CS-21(2)]
I/conn [CN-5(4)] LH Front work lamp ON [CL-6(2)]
RH Front work lamp ON [CL-5(2)]
Front work lamp switch indicator lamp ON
Rear work light switch [CS-20(6)] Work light switch ON [CS-20(2)]
I/conn [CN-5(3)] LH Rear work lamp ON [CL-22(2)]
RH Rear work lamp ON [CL-23(2)]
Rear work lamp switch indicator lamp ON
2)
7-9
WORK LIGHT SWITCH
CN-36
FUSE BOX
CN-5
3
1
CL-6
CS-21
FRONT WORK
LIGHT,LH
CL-5
FRONT WORK
LIGHT,RH
1 3
FRONT WORK LAMP
2 4
CS-20
CL-22
REAR WORK
LIGHT,LH
CL-23
7-10
4. STARTING CIRCUIT
1) OPERATING FLOW
Battery(+) terminal Battery relay(M8, B+ terminal) Fusible link [CN-60(1)]
I/conn [CN-1(1)] Fuse box (No.13) Start switch [CS-2(1)]
※ The gear selector lever is neutral position. It is necessary condition before the starting.
The gear selector lever 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(2)] 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-3(3)]
I/conn [CN-13(5)] Fuel shut off 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(2)] I/conn [CN-13(4)] Start relay [CR-23(1)]
Starter(Terminal B+ and M connector of start motor)
2) CHECK POINT
7-11
5. FUEL SHUT OFF CIRCUIT
1) OPERATING FLOW
Start key OFF [CS-2(3)] Fuse box (No.4) I/conn [CN-2(3)] I/conn [CN-13(5)]
Fuel shut off solenoid [CN-79(1)]
2) CHECK POINT
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(D+)] I/conn [CN-13(3)] I/conn [CN-3(1)]
Check unit [CN-58(2)]
I/conn [CN-6(1)] Cluster charge warning lamp ON [CL-46(1), Below 24V]
JT-27(4)→(10) Volt meter [CN-104(B)]
(2) Charging flow
Alternator [CN-74(B+)] 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
① - GND (Battery)
② - GND (Battery relay)
③ - GND (ALT B+)
Running ON 20~28V
④ - GND (ALT D+)
⑤ - GND (Check unit)
⑥ - GND (Fuse box)
7-14
7. ELECTRIC PARKING, DECLUTCH CIRCUIT
1) OPERATING FLOW
(1) Parking OFF
Fuse box (No.6) Parking switch OFF [CS-17(6) (8)] I/conn [CN-8(10)]
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) (2)] Parking switch indicator lamp ON
[CS-17(5) (1)] I/conn [CN-15(F)]
Control unit [X1(21)] T/M declutch
(3) Declutch ON
Fuse box (No.20) Clutch cut-off switch ON Clutch cut-off switch [CS-42(6) (2)]
Clutch cut-off switch indicator lamp ON
Clutch cut-off switch [CS-42(5) (1)]
Service brake applied
Service brake pressure switch ON [CD-5]
I/conn [CN-15(E)] Control
unit [X1(66)] Declutch
Clutch oil pressure switch
2) CHECK POINT
7-16
8. WIPER AND WASHER CIRCUIT
1) OPERATING FLOW
Fuse box (No.7) Wiper relay Hi [CR-4(1) (3)] Front wiper motor [CN-21(1)]
Wiper relay Lo [CR-26(2), (4)]
Multi function switch [CS-12(6)]
Rear wiper & washer switch [CS-3(1)]
Rear wiper motor [CN-102(1)]
(1) Front washer switch ON
① Washer switch ON [CS-12(6) (2)] Washer tank [CN-22(2)] Washer operating
Check unit [CN-58(21) (15)] Wiper relay Lo
[CR-26(4) (1)] Wiper motor [CN-21(5)]
Wiper motor operating(Low)
(2) Front wiper switch ON
① INT position
Wiper switch ON [CS-12(6) (1)] Check unit [CN-58(10) (15)] intermittent signal Wiper
relay Lo [CR-26(4) (1)] Wiper motor [CN-21(5)] Wiper motor intermittently operating
② Lo position
Wiper switch ON [CS-12(6) (4)] Wiper relay Lo [CR-26(3) (1)] Wiper motor [CN-21(5)]
Wiper motor operating (Low)
③ Hi position
Wiper switch ON [CS-12(6) (3)] Wiper relay Hi [CR-4(1) (4)] Wiper motor [CN-21(4)]
Wiper motor operating(High)
(3) Auto-parking(When switch OFF)
Switch OFF Fuse box (No.7) Wiper relay Hi [CR-4(1) (3)] Wiper motor
[CN-21(1) (2)] Multi function switch [CS-12(5) (4)] Wiper relay Lo [CR-26(3) (1)]
Front wiper motor [CN-21(5)] Wiper motor stop
(4) Rear wiper and washer switch
① Wiper switch ON(1st step)
Wiper switch ON [CS-3(1) (6)] Wiper motor [CN-102(5)] Wiper motor operating
Rear wiper and washer switch indicator lamp ON
② Washer switch ON(2nd step)
Washer switch ON [CS-3(1) (3)] Rear washer tank [CN-103(2)] Washer operating
2) CHECK POINT
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.
20 30
10 km/h 20 P
10 40
0 MPH 30
0 50
VDO
E F
WATER FUEL
TRANS BATT
Speedometer
T/M oil temperature gauge Battery volt meter
Engine coolant temperature gauge Fuel gauge
Engine oil pressure warning lamp T/M oil pressure warning lamp
1) SPEEDOMETER
(1) The speedometer displays the speed of machine in mph and
20 30
km/h.
10 km/h 20
10 40
0 MPH 30
0 50
VDO
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.
(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.
(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.
7-23
5) BATTERY VOLT METER
(1) This gauge indicates the voltage in the charging system when
White
White Green
Green Red
Red the engine is running.
(2) If the indicator is below 24V(White range), it means that the
electricity is being discharged. If the indicator is above
BATT
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.
7-24
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.
7-25
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
3. SWITCHES
1) STARTING SWITCH
(1) There are three positions, OFF, ON and START.
ON STAR
T
(2) OFF : None of electrical circuits activate.
F
OF
7-27
2) FULL AUTOMATIC SWITCH
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.
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.
7-29
10) 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.
7-30
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.
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 button on the top of the multifunction switch, the horn
Horn button will sound.
7-32
GROUP 4 ELECTRICAL COMPONENT SPECIFICATION
CR-1
Ɠ Check disconnection
2 Normal : 0װ
Fusible link 24V 60A (Connect ring terminal and
1 check resistance between
CN-60 terminal 1 and 2)
105 BW
036 GY
001 LW
603 LR
Ɠ Check contact
OFF : ſ(װFor each terminal)
6 5 4 3 2 1
ON : 0(װFor terminal 1-3)
Start key -
ST
ſ(װFor terminal 1-5)
ACC START : 0(װFor terminal 1-3
OFF
HT and 1-5)
C R2 R1 IG BR B OFF CS-2
Pa Ɠ Check contact
Pressure switch N.C TYPE
Normal : 0(װClose)
CD-3 CD-26
CD-25 CD-39
Pa
Ɠ Check contact
Pressure switch N.O TYPE
Normal : ſ(װOpen)
CD-4 CD-5
CD-40
7-33
Part name Symbol Specifications Check
1 Pa
Pressure switch 0.5kg/cm2 Ɠ Check contact
(For engine oil) 2 (N.C TYPE) Normal : 0(װClose)
CD-18
T Ɠ Check resistance
Coolant temp
- Normal : ſװ
sensor
225Ş
F Over : 0װ
CD-9
Ş
Coolant - Ɠ Check resistance
temp sensor 192Ź13.5 װat 73.9Ş
C
CD-8
1 Ɠ Check resistance
Reed switch : Full : About 30װ
Fuel sender
2 Magnetic type Low level : About 300װ
CD-2
Transmission °C
1/2 P.T.F Ɠ Check resistance
oil temperatur
137.2Ź14.5 װat 87.8Ş
C
sender
CD-29
7-34
Part name Symbol Specifications Check
1 2 1
Ɠ Check resistance
2
Normal : About 200װ
Relay 3 24V 20A (For terminal 1-3)
(4pin) 4 4 3 : ſװ
CR-2 CR-7 AC RY1 (For terminal 2-4)
CR-5 CR-10 CR-30 AC RY2
Ɠ Check resistance
1
3 4 6 Normal : About 160װ
2
(For terminal 2-6)
4
Relay 24V 20A : 0װ
6
(5pin) (For terminal 1-3)
3 1 2
: ſװ
CR-4 CR-26 CR-35 (For terminal 1-3)
1 B
Proximate -
2 S 24V 400mA
switch
3 E
CN-100 CN-101
Ɠ Check resistance
Hydraulic - Normal : ſװ
temperature
105Ş
C Over : 0װ
CD-1
Ɠ Check contact
2 Lo 1 Normal : 1.12װ
4
(For terminal 2-4)
Hi 2
Air conditioner - : 2.07װ
3 ML 3
resistor (For terminal 3-4)
1 MH 4 : 3.17װ
(For terminal 4-1)
Ɠ Check resistance
Speaker 4 װ20W
Normal : 50װ
CN-23(LH)
CN-24(RH)
7-35
Part name Symbol Specifications Check
10 9 8 7 6 5 4 3 2 1
10 6 5
Ɠ Check contact
OFF : ſװ
Switch 24V 8A (For terminal 1-5, 2-6)
(Locking type) 9 8 2 7 1 : 0װ
CS-17 CS-21 CS-41 CS-50 (For terminal 5-7, 6-8)
CS-20 CS-23 CS-42 CS-54
10 9 8 7 6 5 4 3 2 1
CS-3 CS-39
Work lamp
Work lamp, 2 24V 70W
Room lamp, Number plate Ɠ Check disconnection
Number plate 1 lamp Normal : A fewװ
lamp Room lamp
CL-1 CL-6 CL-22
CL-5 CL-21 CL-23 24V 10W
CL-7
Ɠ Check operation
Supply power(24V) to
Hour meter
h -
terminal No.2 and contact
terminal No.1 and ground
CN-48
Ɠ Check operation
22-28V 2A Supply power(24V) to each
Horn
110dB terminal and connect ground
CN-20 CN-25
7-36
Part name Symbol Specifications Check
PA 1 Ɠ Check contact
Receiver dryer 24V 2.5A
2 Normal : ſװ
CN-29
1 SL+
2 ACC
3 NC
4 SR+ Ɠ Check resistance
Cassette radio 5 NC 24V 20W+20W Power ON : 4װ+4װ
6 SL-
7 B+
(For terminal 1-6, 4-8)
8 SR-
9 NC CN-27
CN-65
M 1 Ɠ Check contact
Washer pump 24V 2.5A Normal : 26.4 װ
2 (For terminal 1-2)
CN-103 CN-22
24V 1.5A
Wiper motor
Hi
2-speed -
E
Lo M
Auto parking
CN-103 CN-22
CL-2
7-37
Part name Symbol Specifications Check
B+
G
3~ Ɠ Check voltage
Alternator I 20V 60A
Normal : 24-28V
GND
CN-74
B+
M Delco Remy
Starter Ɠ Operating or not
28MT 24V
M
CN-45
1
Air conditioner Ɠ Check contact
24V 79W
compressor 2 Normal : 13.4װ
CN-28
1 Ɠ Check contact
Start relay 24V 200A
2 Normal : 11.3װ
CR-23
M 1
-
Blower 24V 9A
2 2900Ź150rpm
1 GND
2 COM 2 4 5 3 6
Ɠ Check resistance
3 MH
Blower switch 4
- Normal : 0(װFor terminal 1-2,
LOW
5 ML
3, 4, 5, 6)
1
6 HI CS-58
7-38
Part name Symbol Specifications Check
M+ 1
Mode actuator S+ 2
M DC Servo motor
3
and M-
-
4
9-16V 300mA
FS
temperature
5
Max
S-
actuator
NC 6
R 2
12V Ɠ Check resistance
Intake actuator M Normal : 2.0װ
F 1
Working
1 temperature of
Thermostat contact point -
2 A/C ON : 4.5Ş C
A/C OFF : 1.5ŞC
3 E
G 24V
Flasher unit 2 B 85 ~ 190 C/M -
1 L 50dB
CR-11
1 Lo
2 Hi 24V 75W/70W
Head lamp Ɠ Check disconnection
3 E (H4 TYPE) Normal : A fewװ
24V 4W(T4W)
4 C
CL-3 CL-4
4 C
3 T 24V 5W(R5W)
Combi lamp 2 E 2ź24V 21W -
1 S (P21W)
CL-15 CL-16
7-39
Part name Symbol Specifications Check
1
Turn lamp 24V 21W -
2 (P21W)
CL-24 CL-25
Continuous
Capacity :
Master switch 180Amp -
Push in capacity:
1000Amp
2
Warning buzzer 24V 200mA -
1 90Ź5dB(ֻm)
CN-26
M 1
Air conditioner 24V -
fan 2
CN-83
1
2
Buzzer stop 3
4 Ɠ Check contact
switch 5 5 1
6 24V 8A OFF : ſװ
(Rocker switch 7 6 2 (For terminal 1-5, 2-6)
push button) 8
9
10 10 9 CS-34
1 Ɠ Check contact
5 BL- BL+ 1
2
6 BK- BK+ 2 Normal : 80~90װ
3
7-40
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-3 SWP 12 I/conn(Frame harness-Main harness) S814-012000 S814-112000
CN-4 SWP 8 I/conn(Front harness-Main harness) S814-008000 S814-108000
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 6 I/conn(T/M check harness-Main harness) S814-006000 S814-106000
CN-12 SWP 12 I/conn(Gauge harness-Main harness) S814-012000 S814-112000
CN-13 SWP 12 I/conn(Frame-Engine harness) S814-012000 S814-112000
CN-15 - 10 I/conn(Main harness-T/M harness) 6029199086 6029199085
CN-16 - 10 I/conn(Main harness-T/M harness) 6029199086 6029199085
CN-20 - 2 Horn 35215-0200
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 - 2 Horn 35215-0200
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 Grommet - Receiver drier 21L7-12000
CN-30 PA 13 Air conditioner controller S811-013002
CN-36 - 20 Fuse box S812-002001
CN-45 Ring term - Starter S820-410000 S820-310000
CN-48 - 1 Hour meter S819-010112
CN-58 - 36 Check unit 344111-1
CN-60 58 2 Fusible link S813-130200
CN-62 - 5 Glow controller 963013-1
CN-65 Shur 1 Back up buzzer S822-014000
CN-71 J 2 Parking solenoid S816-002001
CN-74 Ring term - Alternator S820-408000 S820-104000
CN-79 - 2 Fuel cut off solenoid 827551-2
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
7-41
Connector No. of Connector part No.
Type Destination
number pin Female Male
CN-102 - 6 Rear wiper motor 6189-0133
CN-103 - 2 Rear washer tank S814-002000
CN-104 Ring term - Volt meter S821-105000
CN-107 Ring term - Fuel gauge S821-105000
CN-114 - 8 Joy stick S816-008002
CN-117 Ring term - Water temp S821-105000
CN-119 Ring term - Transmission temp S821-105000
CN-125 Ring term - Glow terminal S820-308000
CN-127 - 8 Speed meter 1630070
CN-130 - 3 Excess fuel solenoid APV-P3AC
Relay
CR-1 Ring term - Battery relay S820-104000
CR-2 Fasten 4 Horn relay S810-004202
CR-4 Fasten 6 Wiper relay Hi S810-006202
CR-5 Fasten 4 Safety relay S810-004202
CR-7 Fasten 4 Air-con relay S810-004202
CR-11 Fasten 3 Flasher unit S810-003702
CR-23 J 2 Start relay S816-002003
CR-26 Fasten 4 Wiper relay Lo S810-004202
CR-30 Fasten 4 Back up relay S810-004202
CR-35 Fasten 6 Ride control relay S810-006202
Switch
CS-2 SWP 6 Start key switch S814-006000
CS-3 SWF 10 Rear wiper switch 593757
CS-5 Shur 1 Horn switch S822-014000
CS-11 SWP 8 Multi function switch S814-008000
CS-12 SWP 6 Multi function switch S814-006000
CS-17 SWF 10 Parking switch 593757
CS-20 SWF 10 Rear work lamp switch 593757
CS-21 SWF 10 Front work lamp switch 593757
CS-23 SWF 10 Beacon switch 593757
CS-34 SWF 10 Buzzer stop switch 593757
CS-39 SWF 10 Illumination and head lamp switch 593757
CS-41 SWF 10 Hazard switch 593757
CS-42 SWF 10 Clutch cut off switch 593757
CS-50 SWF 10 Ride control 593757
CS-51 SWF 10 Full automatic switch 593757
CS-54 SWF 10 Air conditioner switch 593757
CS-58 Fasten 6 Blower switch S810-006202
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 Transmission error 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 switch S819-010122
CD-2 SWP 2 Fuel sendor S814-002000
CD-3 - 1 Brake fail pressure switch S819-010112
CD-4 - 1 Stop lamp pressure switch S819-010112 S820-105000
CD-5 - 1 Clutch cut off pressure switch S819-010112
CD-8 Ring term - Water temp sendor S820-105000
CD-9 - 1 Over heat switch 1-150656
CD-18 - 2 Engine oil pressure switch 827551-2
CD-25 - 1 Transmission oil pressure switch S819-010122
7-43
Connector No. of Connector part No.
Type Destination
number pin Female Male
CD-29 Ring term - Transmission temp sendor S820-105000
CD-39 - 2 Steering pressure switch S819-010122
CD-40 - 2 Steering pump pressure switch S819-010122
7-44
2. CONNECTION TABLE FOR CONNECTORS
1) 58-L TYPE CONNECTOR
No. of
Receptacle connector(Female) Plug connector(Male)
pin
1 1
S813-030100 S813-130100
1 2 1 2
S813-030200 S813-130200
7-45
2) PA TYPE CONNECTOR
No. of
Receptacle connector(Female) Plug connector(Male)
pin
2 5 1 3
1 3 2 5
S811-005002 S811-105002
3 7 1 4
1 4 3 7
S811-007002 S811-107002
4 9 1 5
1 5 4 9
S811-009002 S811-109002
5 11 1 6
11
1 6 5 11
S811-011002 S811-111002
7-46
No. of
Receptacle connector(Female) Plug connector(Male)
pin
6 13 1 7
13
1 7 6 13
S811-013002 S811-113002
8 17 1 9
17
1 9 8 17
S811-017002 S811-117002
10 21 1 11
21
1 11 10 21
S811-021002 S811-121002
7-47
3) 58-X TYPE CONNECTOR
No. of
Receptacle connector(Female) Plug connector(Male)
pin
1 1
S813-060100 S813-160100
2 1
1 2
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
2 3 1
3 1 2
S816-003001 S816-103001
7-49
5) SWP TYPE CONNECTOR
No. of
Receptacle connector(Female) Plug connector(Male)
pin
1 1
S814-001000 S814-101000
2 1
1 2
S814-002000 S814-102000
3 1
2 1 23
S814-003000 S814-103000
2 4 1 3
1 3 2 4
S814-004000 S814-104000
7-50
No. of
Receptacle connector(Female) Plug connector(Male)
pin
3 6
1 4
1 4 3 6
S814-006000 S814-106000
4 8
1 5
1 5 4 8
S814-008000 S814-108000
4 12 1 9
12
4 12
1 9
S814-012000 S814-112000
3 14 1 11
14
1 11 3 14
S814-014000 S814-114000
7-51
6) CN TYPE CONNECTOR
No. of
Receptacle connector(Female) Plug connector(Male)
pin
1 1
S810-001202 S810-101202
2 2
1 1
S810-002202 S810-102202
3 2
1 2 1 3
S810-003202 S810-103202
2 4 1 4
1 3 2 3
S810-004202 S810-104202
7-52
No. of
Receptacle connector(Female) Plug connector(Male)
pin
3 6 1 4
1 4 3 6
S810-006202 S810-106202
4 8 1 5
1 5 4 8
S810-008202 S810-108202
7-53
7) BS TYPE CONNECTOR
No. of
Receptacle connector(Female) Plug connector(Male)
pin
2 1
1 2
S812-002001 S812-102001
1 3 1 2
2 3
S812-003001 S812-103001
2 4 1 3
1 3 2 4
S812-004001 S812-104001
3 6 1 4
1 4 3 6
S812-006001 S812-106001
7-54
8) LC TYPE CONNECTOR
No. of
Receptacle connector(Female) Plug connector(Male)
pin
5 10
10
1 6
S815-010000
6 12
12
1 7
S815-012000
8 16
16
1 9
S815-016000
9 18
18
1 10
S815-018000
7-55
No. of
Receptacle connector(Female) Plug connector(Male)
pin
12 24
24
1 13
S815-024000
7-56
9) 375 FASTEN TYPE CONNECTOR
No. of
Receptacle connector(Female) Plug connector(Male)
pin
1 2 1 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
CLUSTER
FUSE
4
No.2
CN-7
CN-58
Check voltage
YES 20 ~ 28V
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.
şAfter checking, connect the disconnected connectors again immediately unless otherwise specified.
Cause Remedy
YES
Coolant overheat Check engine
(105Ş
CŹ2Ş C) system
YES
Defective Replace
Check resistance
YES overheat switch
between CN-13
Does display go (10) 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-3(9)
Starting switch : ON between CD-9
Engine : start
and chassis
and CN-3(9)
Starting switch : OFF
CHECK UNIT
24
CN-58
Check resistance
YES MAX 1װ
NO MIN 1Mװ
7-59
3. WHEN ENGINE OIL PRESSURE LAMP LIGHTS UP(Engine is started)
şBefore carrying out below procedure, check all the related connectors are properly inserted.
şAfter checking, connect the disconnected connectors again immediately unless otherwise specified.
Cause Remedy
YES
Engine oil leakage, Check engine oil
or defective switch level or replace
switch
YES
Disconnection in Repair or replace
Does display go
off when wiring harness or (After clean)
disconnect CD-18 Check resistance poor contact
YES
and connector? between CN-13 between CN-13(7)
Starting switch : ON (7) and chassis -CD-18
Engine : start
Starting switch : OFF
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-3(5)- CN-13(7)
Before checking,
disconnect CD-18
Defective cluster Replace
NO
23
CN-58
Check resistance
YES MAX 1װ
NO MIN 1Mװ
7-60
4. WHEN HYDRAULIC OIL TEMPERATURE LAMP LIGHTS UP(Engine is started)
şBefore carrying out below procedure, check all the related connectors are properly inserted.
şAfter checking, connect the disconnected connectors again immediately unless otherwise specified.
Cause Remedy
YES
High temperature Check hydraulic
of hydraulic oil or oil temperature
defective switch (105Ş CŹ2Ş C),
hydraulic cooling
or replace switch
HYDRAULIC OIL
CLUSTER TEMPERATURE SWITCH
T
8 10
CHECK UNIT
12
CN-58
Check resistance
YES MAX 1װ
NO MIN 1Mװ
7-61
5. WHEN TORQUE CONVERTER OIL TEMPERATURE GAUGE DOES NOT OPERATE
(Check torque converter oil temperature lamp ON/OFF)
şBefore carrying out below procedure, check all the related connectors are properly inserted.
şAfter checking, connect the disconnected connectors again immediately unless otherwise specified.
Cause Remedy
YES
Defective cluster Replace
YES
Check resistance Disconnection in Repair or replace
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(4)
Engine : start between CN-9(4)
See : TABLE NO
and chassis YES
Disconnection in Repair or replace
Starting switch : OFF wiring harness or (After clean)
See : TABLE
Check resistance poor contact
between CD-29 between CN-9(4)
NO
and chassis and CD-29
Starting switch : OFF
See : TABLE Defective sender Replace
NO
TRANS
TRANSMISSION OIL
CLUSTER TEMPERATURE SENDER
Ş
C
10 4
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
7-62
6. WHEN COOLANT TEMPERATURE GAUGE DOES NOT OPERATE
(Check coolant temperature lamp ON/OFF)
şBefore carrying out below procedure, check all the related connectors are properly inserted.
şAfter checking, connect the disconnected connectors again immediately unless otherwise specified.
Cause Remedy
YES
Defective cluster Replace
YES
Disconnection in Repair or replace
Check resistance wiring harness or (After clean)
between CN-7 poor contact
(11) and chassis
between CN-7
Starting switch : ON (11) and CN-3(7)
Engine : start Check resistance
See : TABLE between CN-3(7) YES
NO Disconnection in Repair or replace
and chassis
wiring harness or (After clean)
Starting switch : OFF
Before checking, poor contact
disconnect connector between CN-3(7)
See : TABLE
Check resistance and CN-13(8)
between CN-13
NO
(8) and chassis YES
Disconnection in Repair or replace
Starting switch : OFF wiring harness or (After clean)
See : TABLE
Check resistance poor contact
between CD-8 between CN-13
NO
and chassis (8) and CD-8
Starting switch : OFF
See : TABLE Coolant overheat Check coolant
NO
TRANS
or defective temperature or
sender replace
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
7-63
7. WHEN FUEL GAUGE DOES NOT OPERATE(Check warning lamp ON/OFF)
şBefore carrying out below procedure, check all the related connectors are properly inserted.
şAfter checking, connect the disconnected connectors again immediately unless otherwise specified.
Cause Remedy
YES
Defective cluster Replace
YES
Check resistance Disconnection in Repair or replace
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(11)
Check resistance
between CN-2(11)
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(11)
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 11 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
7-64
8. WHEN GAUGES OF FUEL, HYDRAULIC OIL AND COOLANT INDICATE HIGH OR FULL
şBefore carrying out below procedure, check all the related connectors are properly inserted.
şAfter checking, connect the disconnected connectors again immediately unless otherwise specified.
Cause Remedy
YES Defective cluster Replace
Check resistance
between CN-7
(13) and chassis
Disconnection in Repair or replace
Starting switch : ON NO
Voltage : 20~28V
wiring harness or (After clean)
poor contact
between CN-7
(13) and chassis
CLUSTER
13
CN-7
Check resistance
YES MAX 1װ
NO MIN 1Mװ
7-65
9. WHEN PARKING SOLENOID DOES NOT WORK
şBefore carrying out below procedure, check all the related connectors are properly inserted and the
fuse No.6 is not blown out.
şAfter checking, connect the disconnected connectors again immediately unless otherwise specified.
Cause Remedy
YES
Defective parking Replace
brake solenoid
PARKING SWITCH
8
FUSE
6
No.6
CS-17
CN-71
D-1
2
2
1
PARKING SOLENOID
7-66
10. TRANSMISSION IS NOT RETURNED TO NEUTRAL WHEN PARKING BRAKE IS APPLIED
şBefore carrying out below procedure, check all the related connectors are properly inserted and the
fuse No.14(Transmission controller) and No.6 are not blown out.
şAfter checking, connect the disconnected connectors again immediately unless otherwise specified.
Cause Remedy
YES Defective T/M Replace
controller
Check voltage
between CN-15 YES
Disconnection in Repair or replace
(F) and chassis
wiring harness or (After clean)
Starting switch : ON poor contact
Parking switch : ON Check voltage
Prolix switch : OFF between CN-15
between CS-17
Voltage : 20~28V NO (F) and CS-17(1)
(1) and chassis
Voltage : 20~28V YES
Parking switch : ON Check voltage Defective switch Replace
between CS-17
NO
(5) and chassis Disconnection in Repair or replace
NO
Voltage : 20~28V wiring harness or (After clean)
poor contact
between CS-17(5)
and fuse No.6
CN-15
PARKING SWITCH
FUSE
6
No.6
5
1
CS-17
7-67
11. MACHINE DOES NOT TRAVEL
şBefore carrying out below procedure, check all the related connectors are properly inserted and the
CONTROL UNIT
fuse No.1(Transmission controller) is not blown out.
şAfter checking, connect the disconnected connectors again immediately unless otherwise specified.
CANB-H
CANF-H
CANF-T
CANB-L
VMGA2
CANF-L
VMGA1
ADM8
ADM7
VPE2
VPE1
ED10
ED11
ED12
ED13
AIP7
AIP6
VGS
AIP3
ED5
ED2
ED9
ED6
ED3
ED7
SD3
SD4
AU1
EU1
ER1
ED4
ED8
ER2
EF1
EF6
EF2
EF3
VPI
63
64
65
66
67
68
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
816
820
X1
Cause Remedy
YES
Defective clutch Replace
cut-off switch
CN-15
YES Check resistance CN-36
between CD-5
044 BY
205 BY
and chassis
Is there continuity
NO between CN-
Defective T/M Replace
15(E) and NO
chassis? controller
poor contact
between CN-15(F)
and CS-17(1)
CD-5
D-1
CLUTCH CUT-OFF SW
7-68
12. WHEN STARTING SWITCH IS TURNED ON, HEAD LAMP DOES NOT LIGHTS UP
şBefore carrying out below procedure, check all the related connectors are properly inserted and the
fuse No.19 is not blown out and ON/OFF of bulb.
şAfter checking, connect the disconnected connectors again immediately unless otherwise specified. CN-36
Cause Remedy
YES
Defective bulb Replace
Check voltage
YES
between CL-3(1) -
(3) and CL-4(1) -(3)
Voltage : 20~28V Disconnection in Repair or replace
NO
Starting switch : ON wiring harness or (After clean)
Check voltage Head lamp switch : ON
poor contact
YES between CN-
10(4) and CN- between CN-10(4)-
8(11), (12) CL-3(1), 4(1) and
Voltage : 20~28V CL-3(3) - CN-8(11),
Starting switch : ON CL-4(3) - CN-8(12).
Head lamp switch : ON FUSE BOX
CL-3
Disconnection in Repair or replace
NO CS-39
wiring harness or (After clean) CN-8
Check voltage
poor contact
between CS-11 LH HEAD LIGHT
between CN-10(4)
(7) and chassis
and CS-11(7)
CL-4
Starting switch : ON
Head lamp switch :
YES
ON-OFF Defective Replace
ILL & HEAD LAMP SW
multifunction switch RH HEAD LIGHT
CS-11
poor contact
between CS-39(4)
and fuse No.19
7-69
13. WHEN STARTING SWITCH IS TURNED ON, WIPER MOTOR DOES NOT OPERATE
şBefore carrying out below procedure, check all the related connectors are properly inserted and the
fuse No.7 is not blown out. CHECK UNIT CN-36
şAfter checking, connect the disconnected connectors again immediately unless otherwise specified.
Cause Remedy
CN-58
YES
Check voltage Defective front Replace
YES between front wiper motor
wiper motor and
chassis Poor connection of Replace
Check voltage Voltage : 20~28V
NO
YES chassis
between CN-21(5) Starting switch : ON
Wiper switch : 1st
and chassis
Voltage : 20~28V
Starting switch : ON Disconnection in Repair or replace
Check voltage Wiper switch : 1st NO
YES wiring harness or (After clean) FUSE BOX
between CS-12
(4) and chassis poor contact
between CS-12(4)
Voltage : 20~28V
Check voltage Starting switch : ON
and CN-21(5)
Wiper switch : OFF CR-26
between CS-12
WIPER RY Lo
(6) and chassis Defective wiper Replace
NO
switch
Voltage : 20~28V
Starting switch : ON
Wiper switch : 1st Disconnection in Repair or replace
NO
wiring harness or (After clean)
poor contact
between CS-12(6)
CR-4
and fuse No.7
WIPER RY Hi
CS-11
CS-12
CS-5
CN-21
MULTIFUNCTION SWITCH FRONT WIPER
7-70
14. WHEN STARTING SWITCH ON DOES NOT OPERATE
şBefore carrying out below procedure, check all the related connectors are properly inserted and and
the fuse No.15 is not blown out. CN-36
şAfter checking, connect the disconnected connectors again immediately unless otherwise specified.
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 : 20~28V NO
Check voltage defect of fusible
YES
between CR-1 link or defective
(M4) and chassis
battery relay
Voltage : 20~28V
Disconnection in Replace
NO
Check voltage wiring harness or
YES between CS-2
(1)[and CS-2(2)] poor contact
FUSE BOX
and chassis between CS-2(2) -
Voltage : 20~28V
CN-2(1)-CR-1
CR-1
(M4) 60R 60R 60B 60B
CN-2
DO-1
CS-2
START SWITCH
7-71
15. 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 No.16 is not blown out.
şAfter checking, connect the disconnected connectors again immediately unless otherwise specified.
Cause Remedy
YES CN-36
Check voltage Defective lamp Replace
YES between each
lamp(2) and
chassis Disconnection in Repair or replace
NO
Voltage : 20~28V wiring harness or (After clean)
Starting switch : ON poor contact
Check voltage
YES between CN-5(3) -
between CN-5(4),
(3) and chassis CL-22(2), CL23(2)
and CN-5(4) - CL-
Voltage : 20~28V 5(2), CL-6(2)
Starting switch : ON
Check voltage Disconnection in Repair or replace
YES between CS-21 NO
wiring harness or (After clean)
(2), CS-20(2) and poor contact
chassis between CN-5(3) -
Voltage : 20~28V
Starting switch : ON
CS-20(2) and CN-
5(4) - CS-21(2)
FUSE BOX
Check voltage CN-5
between CS-21 Defective work Replace switch
(6), CS-20(6) and NO
lamp switch
chassis
Voltage : 20~28V YES CL-6
Disconnection in Repair or replace
Starting switch : ON
wiring harness or (After clean) CS-21
FRONT WORK
Check voltage poor contact LIGHT,LH
between CS-21(6),
between fuse No. CL-5
NO CS-20(6) and fuse
16 and chassis
No.16 FRONT WORK
LIGHT,RH
Voltage : 20~28V
Starting switch : ON Short circuit of fuse Replace WORK LAMP FRONT
NO
CS-20
CL-22
REAR WORK
LIGHT,LH
CL-23
7-72
16. WHEN ENGINE DOES NOT START
şCheck supply of the power at engine stop solenoid while starting switch is ON.
şBefore carrying out below procedure, check all the related connectors are properly inserted. CONTROL UNIT
CN-36
şAfter checking, connect the disconnected connectors again immediately unless other wise specified.
şCheck forward reverse switch at neutral position.
ADM1
ADM5
SDDL
VPS2
VPS1
VPE2
AIP7
AIP6
AIP8
AIP4
AIP1
ER2
SD2
EU2
ED1
ED5
ED2
ED9
ED6
EF4
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
Cause Remedy
450
YES
Defective battery Check engine
system charge or
replace (After
CN-15
checking specific
G
C
D
H
A
B
K
E
F
J
gravity of battery)
YES
820 LY
Check voltage Defective magnet Replace
Check operation YES between starter of start motor
of start motor magnet coil and
chassis Defective start Replace
Starting switch : Start NO
Starting switch : Start relay
YES CR-5
ڞ
Check operation Check voltage FUSE BOX
NO of starter relay YES
between CR-5(4)
and chassis SAFETY RY
Starting switch : Start
Disconnection in Replace CN-45
Starting switch : OFF NO TO BATT
wiring harness or
Check operation poor contact
of start safety between CN-3(2)
NO
relay and CR-5(4) STARTER
CR-23
Check switch : Neutral YES
Defective relay Replace
Check voltage
START RY
between CR-5(3)
NO
and chassis
Starting switch : OFF NO
ڟ
YES
Defective start Replace
Check voltage relay
ڞ between CR-23
CN-13
(1) and chassis
Disconnection in Repair or replace CN-3
Voltage : 20~28V NO
Starting switch : ON wiring harness or CN-79
poor contact
between CN-3(2)- FUEL SHUT OFF SOL
CR-23(1) CS-2
YES
Disconnection in Repair or replace
wiring harness or
Check voltage poor contact
ڟ between CN-15 between CN-15(B) START SWITCH
(B) and chassis and CR-5(3)
Starting switch : OFF
Defective DW-3 Replace
NO
7-73