Hyundai HL955 Manual

Table of Contents

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Group 1 Safety Hints -------------------------------------------------------------------------------------------------------- 1-1

Group 2 Specifications ----------------------------------------------------------------------------------------------------- 1-10

Group 3 Operational Checkout Record Sheet --------------------------------------------------------------- 1-23

SECTION 2 ENGINE

Group 1 Structure and Function -------------------------------------------------------------------------------------- 2-1

Group 2 Engine speed and Stall rpm ----------------------------------------------------------------------------- 2-12

Group 3 Fuel Warmer System ---------------------------------------------------------------------------------------- 2-13

SECTION 3 POWER TRAIN SYSTEM

Group 1 Structure and Function (fault code) ----------------------------------------------------------------- 3-1

Group 2 Operational Checks and Troubleshooting ------------------------------------------------------- 3-78

Group 3 Test and Adjustments ---------------------------------------------------------------------------------------- 3-90

Group 4 Disassembly and Assembly ----------------------------------------------------------------------------- 3-92

SECTION 4 BRAKE SYSTEM

Group 1 Structure and Function -------------------------------------------------------------------------------------- 4-1

Group 2 Operational Checks and Troubleshooting ------------------------------------------------------- 4-32

Group 3 Tests and Adjustments -------------------------------------------------------------------------------------- 4-39

Group 4 Disassembly and assembly ------------------------------------------------------------------------------ 4-41

SECTION 5 STEERING SYSTEM

Group 1 Structure and Function -------------------------------------------------------------------------------------- 5-1

Group 2 Operational Checks and Troubleshooting ------------------------------------------------------- 5-13

Group 3 Tests and Adjustments -------------------------------------------------------------------------------------- 5-21

Group 4 Disassembly and Assembly ----------------------------------------------------------------------------- 5-28

SECTION 6 WORK EQUIPMENT

Group 1 Structure and Function -------------------------------------------------------------------------------------- 6-1

Group 2 Operational Checks and Troubleshooting ------------------------------------------------------- 6-40

Group 3 Tests and Adjustments -------------------------------------------------------------------------------------- 6-51

Group 4 Disassembly and Assembly ----------------------------------------------------------------------------- 6-63

CONTENTS

Chapters

Table of Contents

Troubleshooting

Summary of Contents for Hyundai HL955

Page 1: Table Of Contents
CONTENTS CONTENTS SECTION 1 GENERAL SECTION 1 GENERAL Group 1 Safety Hints -------------------------------------------------------------------------------------------------------- 1-1 Group 2 Specifications ----------------------------------------------------------------------------------------------------- 1-10 Group 3 Operational Checkout Record Sheet --------------------------------------------------------------- 1-23 SECTION 2 ENGINE SECTION 2 ENGINE Group 1 Structure and Function -------------------------------------------------------------------------------------- 2-1 Group 2 Engine speed and Stall rpm ----------------------------------------------------------------------------- 2-12 Group 3 Fuel Warmer System ---------------------------------------------------------------------------------------- 2-13 SECTION 3 POWER TRAIN SYSTEM...
Page 2 SECTION 7 ELECTRICAL SYSTEM SECTION 7 ELECTRICAL SYSTEM Group 1 Component Location --------------------------------------------------------------------------------------- 7-1 Group 2 Electrical Circuit ----------------------------------------------------------------------------------------------- 7-3 Group 3 Monitoring System ------------------------------------------------------------------------------------------ 7-22 Group 4 Electrical Component Specification --------------------------------------------------------------- 7-69 Group 5 Connectors ------------------------------------------------------------------------------------------------------- 7-76 Group 6 Troubleshooting ------------------------------------------------------------------------------------------------ 7-97...
Page 3 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.
Page 4 Revised edition mark (①②③…) Any additions, amendments or other changes When a manual is revised, an edition mark is will be sent to HYUNDAI distributors. recorded on the bottom outside corner of the Get the most up-to-date information before you pages.
Page 5 3. CONVERSION TABLE 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 Example Method of using the Conversion Table to convert from millimeters to inches...
Page 6 Millimeters to inches Millimeters to inches 1mm = 0.03937in 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142 1.181 1.220 1.260 1.299 1.339...
Page 7 Liter to U.S. Gallon Liter to U.S. Gallon 1ℓ = 0.2642 U.S.Gal 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019 5.283 5.548 5.812 6.6076 6.340 6.604 6.869 7.133 7.397 7.661 7.925 8.189...
Page 8 kgf·m to to lbf lbf·ft ft 1kgf·m = 7.233lbf·ft 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8 217.0 224.2 231.5 238.7 245.9 253.2...
Page 9 kgf/cm kgf/cm to to lbf/in lbf/in 1kgf / cm = 14.2233lbf / in 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5 426.7...
Page 10 TEMPERATURE 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.
Page 11: Section 1 General
SECTION 1 GENERAL SECTION 1 GENERAL Group 1 Safety Hints --------------------------------------------------------------------------------------------------------1-1 Group 2 Specifications -----------------------------------------------------------------------------------------------------1-10 Group 3 Operational Checkout Record Sheet ---------------------------------------------------------------1-23...
Page 12: Group 1 Safety Hints
SECTION 1 GENERAL SECTION 1 GENERAL GROUP 1 SAFETY HINTS GROUP 1 SAFETY HINTS FOLLOW SAFE PROCEDURE FOLLOW SAFE PROCEDURE Unsafe wor k practices are dangerous. Understand service procedure before doing work; Do not attempt shortcuts. WEAR PROTECTIVE CLOTHING WEAR PROTECTIVE CLOTHING Wear close fitting clothing and safety equipment appropriate to the job.
Page 13 PREPARE FOR EMERGENCIES PREPARE FOR EMERGENCIES Be prepared if a fire starts. Keep a first aid kit and fire extinguisher handy. Keep emergency numbers for doctors, ambulance ser vice, hospital, and fire department near your telephone. 73031GE03 WORK IN CLEAN AREA WORK IN CLEAN AREA Before starting a job : ·...
Page 14 PARK MACHINE SAFELY PARK MACHINE SAFELY Before working on the machine: · Park machine on a level surface. · Lower bucket to the ground. · Turn key switch to OFF to stop engine. Remove key from switch. · Move pilot control shutoff lever to locked position.
Page 15 Store flammable fluids away from fire hazards. Do not incinerate or puncture pressurized containers. Make sure machine is clean of trash, grease, and debris. Do not store oily rags ; They can ignite and burn spontaneously. 73031GE09 BEWARE OF EXHAUST FUMES BEWARE OF EXHAUST FUMES Prevent asphyxiation.
Page 16 ILLUMINATE WORK AREA SAFELY ILLUMINATE WORK AREA SAFELY Illuminate your work area adequately but safely. Use a portable safety light for working inside or under the machine. Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled fuel or oil.
Page 17 AVOID HIGH PRESSURE FLUIDS AVOID HIGH PRESSURE FLUIDS Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure 73031GE14 fluids.
Page 18 PREVENT ACID BURNS PREVENT ACID BURNS Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes. Avoid the hazard by: Filling batteries in a well-ventilated area. Wearing eye protection and rubber gloves.
Page 19 SERVICE TIRES SAFELY SERVICE TIRES SAFELY Explosive separation of a tire and rim parts can cause serious injury or death. Do not attempt to mount a tire unless you have the proper equipment and experience to perform the job. Always maintain the correct tire pressure. Do not inflate the tires above the recommended pressure.
Page 20 REPLACE SAFETY SIGNS REPLACE SAFETY SIGNS Replace missing or damaged safety signs. See the machine operator's manual for correct safety sign placement. 73031GE21 LIVE WITH SAFETY LIVE WITH SAFETY Before returning machine to customer, make sure machine is functioning properly, especially the safety systems.
Page 21: Group 2 Specifications
GROUP 2 SPECIFICATIONS GROUP 2 SPECIFICATIONS 1. MAJOR COMPONENT 1. MAJOR COMPONENT Hydraulic tank Radiator Bucket Tire Head light Main control valve Battery Boom Boom cylinder Counterweight Engine Main pump Air cleaner Bell crank Bucket cylinder Bucket link Front axle Steering cylinder Transmission Rear axle...
Page 22 2. SPECIFICATIONS WITH BOLT-ON CUTTING EDGE TYPE BUCKET (HL955) 757F2SE03 Description Unit Specification Operating weight kg (lb) 15100 (33290) Struck 2.4 (3.1) Bucket capacity Heaped 2.8 (3.7) Overall length 7630 (25' 0") Overall width 2740 ( 9' 0") Overall height 3390 (10' 10")
Page 23 WITH BOLT-ON CUTTING EDGE TYPE BUCKET (HL955 XT) 757F2SE03-1 Description Unit Specification Operating weight kg (lb) 15600 (34390) Struck 2.4 (3.1) Bucket capacity Heaped 2.8 (3.7) Overall length 8040 (26' 5") Overall width 2740 ( 9' 0") Overall height 3390 (11' 1") Ground clearance 410 ( 1' 4")
Page 24 WITH TOOTH TYPE BUCKET (HL955) 757F2SE02 Description Unit Specification Operating weight kg (lb) 15000 (33070) Struck 2.2 (2.9) Bucket capacity Heaped 2.6 (3.4) Overall length 7750 (25' 5") Overall width 2790 ( 9' 2") Overall height 3390 (11' 1") Ground clearance 410 ( 1' 4")
Page 25 WITH TOOTH TYPE BUCKET (HL955 XT) 757F2SE02-1 Description Unit Specification Operating weight kg (lb) 15500 (34170) Struck 2.2 (2.9) Bucket capacity Heaped 2.6 (3.4) Overall length 8250 (27' 2") Overall width 2790 ( 9' 2") Overall height 3390 (11' 1") Ground clearance 410 ( 1' 4")
Page 26 Item Front frame assembly 1160 2560 Rear frame assembly 1655 3650 Front fender (LH & RH) HL955 1100 Counterweight HL955 XT 1760 Cab assembly 1070 2360 Engine assembly 1150 Transmission assembly (4-speed/5-speed) 518/560 1140/1230 Drive shaft (front) Drive shaft (center)
Page 27 4. SPECIFICATION FOR MAJOR COMPONENTS 4. SPECIFICATION FOR MAJOR COMPONENTS 1) 1) ENGINE ENGINE Item Specification Model Cummins QSB6.7 Type 4-cycle turbocharged and charge air-cooled diesel engine Control type Electronic control Cooling method Water cooling Number of cylinders and arrangement 6 cylinders, in-line Firing order 1-5-3-6-2-4...
Page 28 2) 2) MAIN PUMP MAIN PUMP Item Specification Type Variable piston pump Capacity 54+38 cc/rev Maximum operating pressure 280 kgf/cm (3980 psi) Rated oil quantity 185ℓ/min (48.8 U.S.gpm / 40.6 U.K.gpm) Maximum speed 2230 rpm 3) 3) FAN AND BRAKE PUMP FAN AND BRAKE PUMP Item Specification...
Page 29 7) 7) CYLINDER CYLINDER Item Specification Bore dia×Rod dia×Stroke Ø125×Ø70×745 mm Boom cylinder Bore dia×Rod dia×Stroke Ø140×Ø75×485 mm Bucket cylinder Bore dia×Rod dia×Stroke Ø 65×Ø45×436 mm Steering cylinder 8) 8) DYNAMIC POWER TRANSMISSION DEVICES DYNAMIC POWER TRANSMISSION DEVICES Item Specification Model ZF 4WG 190 Converter...
Page 30 5. TIGHTENING TORQUE 5. TIGHTENING TORQUE Use following table for unspecified torque. 1) 1) BOLT AND NUT BOLT AND NUT (1) (1) Coarse thread Coarse thread 8.8T 10.9T 12.9T Bolt size kgf·m lbf·ft kgf·m lbf·ft kgf·m lbf·ft M 6 × 1.0 0.8 ~ 1.2 5.8 ~ 8.6 1.2 ~ 1.8...
Page 31 2) 2) PIPE AND HOSE PIPE AND HOSE (FLARE type) Thread size Width across flat (mm) kgf·m lbf·ft 1/4" 28.9 3/8" 36.2 1/2" 68.7 3/4" 1" 1-1/4" 3) 3) PIPE AND HOSE PIPE AND HOSE (ORFS type) Thread size Width across flat (mm) kgf·m lbf·ft 9/16-18...
Page 32 TIGHTENING TORQUE OF MAJOR COMPONENT TIGHTENING TORQUE OF MAJOR COMPONENT Torque Descriptions Bolt size kgf·m lbf·ft 57.9 ± 8.7 419 ± 63 Engine mounting bolt, nut (rubber, 2EA) M20×2.5 10.7 ± 1.6 77.4 ± 11.6 Engine mounting bolt (bracket, 8EA) M12×1.75 4.6 ±...
Page 33 Russia, CIS, Mongolia DEF compatible with AdBlue® ★3 : Soft water ★1 Ultra low sulfur diesel - sulfur content  15 ppm City water or distilled water ★4 : Hyundai Bio Hydraulic Oil - For more information, contact HYUNDAI dealers. 1-22...
Page 34: Group 3 Operational Checkout Record Sheet
GROUP 3 OPERATIONAL CHECKOUT RECORD SHEET GROUP 3 OPERATIONAL CHECKOUT RECORD SHEET ·Owner ·Date ·Hours ·Serial No. ·Technician ※ Use this sheet to record operational Use this sheet to record operational checkout results. checkout results. Perform the operational check before Perform the operational check before installing any test equipment.
Page 35 4. Brake system and clutch cut off checks 4. Brake system and clutch cut off checks □ □ · Park brake capacity check □ □ · Park brake transmission lockout check □ □ · Service brake pump flow check □ □...
Page 36 7. Steering system checks 7. Steering system checks □ □ ·Steering unit check □ □ ·Steering system leakage check ·Steering valve (EHPS) □ □ Low check pressure □ □ High check pressure 8. Accessory checks 8. Accessory checks □ □ ·Operating lights check □...
Page 37: Section 2 Engine
SECTION 2 ENGINE SECTION 2 ENGINE Group 1 Structure and Function -------------------------------------------------------------------------------------- 2-1 Group 2 Engine speed and Stall rpm ----------------------------------------------------------------------------- 2-12 Group 3 Fuel warmer system ------------------------------------------------------------------------------------------ 2-13...
Page 38: Group 1 Structure And Function (Fault Code)
SECTION 2 ENGINE SECTION 2 ENGINE GROUP 1 STRUCTURE AND FUNCTION GROUP 1 STRUCTURE AND FUNCTION 1. STRUCTURE 1. STRUCTURE Exhaust outlet connection Crankcase breather Lifting bracket Flywheel housing Lubricating oil filter cooler Lubricating oil filter Starting motor Water inlet connection Vibration damper Oil pan Air intake connection...
Page 39 2. SYSTEM DIAGRAMS 2. SYSTEM DIAGRAMS The following drawings show the flow through the engine systems. 1) 1) FUEL SYSTEM FUEL SYSTEM 760F2EG10 Fuel from supply tank 11 Fuel rail Water/fuel separator filter 12 Fuel rail pressure relief valve Priming pump 13 Common rail fuel return Fuel supply to fuel gear pump 14 High-pressure fuel line to injector...
Page 40 2) 2) LUBRICATING OIL SYSTEM LUBRICATING OIL SYSTEM 7609A2EG11 Lubricating oil pump Filter bypass valve Pressure regulating valve closed Filter bypass valve closed Pressure regulating valve open 10 Filter bypass valve open From lubricating oil pump 11 To lubricating oil filter To lubricating oil cooler 12 Full-flow lubricating oil filter To lubricating oil pan...
Page 41 (2) (2) Lubrication for the power components Lubrication for the power components 7609A2EG13 From lubricating oil cooler Oil supply to rod bearings Main lubricating oil rifle Crankshaft cross drilling from the main To overhead components bearing journal To upper main bearing J-jet piston-cooling nozzle To camshaft journal To accessory drive oil feed...
Page 42 (4) (4) Lubrication for the accessory drive Lubrication for the accessory drive 7609A2EG15 Oil supply to accessory drive Oil feed from block ※ Oil returns to pan through the gear housing.
Page 43 3) 3) COOLING SYSTEM COOLING SYSTEM 7609A2EG16 Coolant inlet from radiator and aftertreatment diesel Coolant flow to thermostat housing exhaust fluid (DEF) dosing valve and DEF tank Thermostat open - bypass passage closed Water pump lmpeller Coolant flow back to radiator Coolant flow past lubricating oil cooler 10 Thermostat closed - bypass passage open Coolant flow past cylinders...
Page 44 COOLING SYSTEM COOLING SYSTEM 760F2EG18 Coolant supply to variable geometry turbocharger from the cylinder block Variable geometry turbocharger coolant return to the EGR cooler outlet tube Coolant supply to the EGR cooler from the rear of the cylinder block EGR cooler coolant return to the coolant inlet connection De-aeration port (to coolant top tank) 760F2EG19 Coolant supply to aftertreatment DEF dosing valve and DEF tank...
Page 45 4) 4) AIR INTAKE SYSTEM AIR INTAKE SYSTEM 7609A2EG20 Air cleaner Intake port Turbocharger compressor inlet 10 Intake valves Turbocharger compressor outlet 11 EGR connection tube Charge air cooler inlet 12 EGR cooled exhaust gases Charge air cooler outlet 13 Charge air cooled intake air Air intake connection adapter 14 EGR valve Air intake connection...
Page 46 5) 5) EXHAUST SYSTEM EXHAUST SYSTEM 7609A2EG21 Exhaust valves Exhaust inlet to EGR cooler Exhaust port EGR cooler Exhaust manifold Cooled exhaust outlet to EGR valve Turbocharger EGR valve Turbocharger exhaust outlet 10 EGR valve differential pressure sensor...
Page 47 EXHAUST SYSTEM EXHAUST SYSTEM 760F2EG30 Exhaust from turbocharger Aftertreatment diesel oxidation catalyst (DOC) intake temperature sensor probe Aftertreatment DOC Aftertreatment DOC outlet temperature sensor probe Diesel exhaust fluid (DEF) supply to aftertreatment DEF dosing valve Aftertreatment DEF dosing valve Decomposion reactor Exhaust DEF mixture Aftertreatment selective catalyst reduction (SCR) intake temperature sensor probe 10 Aftertreatment SCR catalyst...
Page 48 EXHAUST SYSTEM EXHAUST SYSTEM 760F2EG31 Coolant flow from engine to aftertreatment DEF Aftertreatment DEF tank coolant valve Coolant flow to aftertreatment DEF tank (only when aftertreatment DEF tank coolant valve is open) Aftertreatment DEF tank Coolant return to engine Aftertreatment DEF supply from aftertreatment DEF tank Aftertreatment DEF flow to aftertreatment DEF dosing unit Aftertreatment DEF dosing unit Aftertreatment DEF return to aftertreatment DEF tank...
Page 49 GROUP 2 GROUP 2 ENGINE SPEED & STALL RPM ENGINE SPEED & STALL RPM 1. T 1. TEST CONDITION EST CONDITION Normal temperature of the whole system Coolant : Approx 80˚C (176˚F) : 45 ± 5˚C (113 ± 10˚F) Hydraulic oil Transmission oil : 75 ±...
Page 50 GROUP 3 F GROUP 3 FUEL WARMER SYSTEM UEL WARMER SYSTEM 1. S 1. SPECIFICATION PECIFICATION Operating voltage : 24±4V Power : 350±50W Current : 15A Fuel warmer 2. O 2. OPERATION PERATION T h e c u r r e n t o f f u e l w a r m e r s y s t e m i s automatically controlled without thermostat according to fuel temperature.
Page 51 SECTION 3 POWER TRAIN SYSTEM SECTION 3 POWER TRAIN SYSTEM Group 1 Structure and Function (fault code) ------------------------------------------------------------------ 3-1 Group 2 Operational Checks and Troubleshooting ------------------------------------------------------- 3-78 Group 3 Test and Adjustments ---------------------------------------------------------------------------------------- 3-90 Group 4 Disassembly and Assembly ------------------------------------------------------------------------------ 3-92...
Page 52: Group 1 Structure And Function (Fault Code)
SECTION 3 POWER TRAIN SYSTEM SECTION 3 POWER TRAIN SYSTEM GROUP 1 STRUCTURE AND FUNCTION GROUP 1 STRUCTURE AND FUNCTION 1. POWER TRAIN COMPONENT OVERVIEW 1. POWER TRAIN COMPONENT OVERVIEW Engine Transmission Front axle Center drive shaft Rear drive shaft Rear axle Front drive shaft 760F3PT01...
Page 53 HYDRAULIC CIRCUIT HYDRAULIC CIRCUIT (4-speed transmission) Pressure Temp reducing sensor valve 9+0.5 bar System pressure valve Valve block control circuit 16+2 bar Filter pressure differential valve Converter Filter Relief valve 11+2 bar Oil cooler Back pressure valve Pump 4.3+3 bar 16+2 bar Oil sump Lubrication...
Page 54 HYDRAULIC CIRCUIT HYDRAULIC CIRCUIT (5-speed transmission) Pressure Temp reducing sensor valve 9+0.5 bar Converter lock-up System clutch valve pressure valve Valve block control circuit 16+2 bar Converter lock-up clutch Filter pressure differential valve Filter Converter Relief valve 11+2 bar Oil cooler Back pressure valve...
Page 55 2. TORQUE CONVERTER 2. TORQUE CONVERTER FUNCTION FUNCTION 73033TM00 Turbine Pump Input flange Stator Transmission pump The converter is working according to the Trilok-system, i.e. it assumes at high turbine speed the characteristics, and with it the favorable efficiency of a fluid clutch. The converter is designed according to the engine power so that the most favorable operating conditions are obtained for each installation case.
Page 56 When the turbine speed is reaching about 80% of the pump speed, the torque multiplication becomes 1.0 i.e. the turbine torque becomes equal to that of the pump torque. From this point on, the converter is working similar to a fluid clutch. A stator freewheel serves to improve the efficiency in the upper driving range, in the torque multiplication range it is backing-up the torque upon the housing, and is released in the clutch range.
Page 57 CONVERTER LOCK-UP CLUTCH CONVERTER LOCK-UP CLUTCH (5-speed transmission) 2 3 4 2 3 4 Engine speed Input speed (turbine speed) Stator Figure A 7609A3PT22 Converter lock-up clutch Turbine wheel Stator Circuit cover/pump wheel Proportional valve Measuring point "Lock-up clutch" Cover System pressure to lock-up clutch valve System pressure from lock-up clutch valve to lock-up clutch...
Page 58 3. TRANSMISSION 3. TRANSMISSION LAYOUT LAYOUT 7577APT03 Reverse clutch (KR) Converter side output 12 Inductive transmitter Engine-dependent flange for engine speed power take-off Output shaft 13 4th clutch (K4) Forward clutch (KV) Transmission pump 14 Converter relief valve 2nd clutch (K2) 10 Connection to engine 15 1st clutch (K1) 3rd clutch (K3)
Page 59 INSTALLATION VIEW INSTALLATION VIEW 7609A3PT02 Converter Parking brake Full flow filter 10 Oil drain plug Transportation eye 11 Connection to engine Gearbox mounting pads 12 Output flange-Converter side Mounting possibility emergency steering 13 Output flange-Rear side pump 14 Temperature switch for oil temperature Breather behind converter Electrical hydraulic transmission control...
Page 60 3) 3) OPERATION OF TRANSMISSION OPERATION OF TRANSMISSION (4 speed transmission) (1) (1) Forward Forward ① Forward 1st Forward 1st In 1st forward, forward clutch (KV) and 1st clutch (K1) are engaged. Forward clutch and 1st clutch are actuated by the hydraulic pressure applied to the clutch piston. INPUT GEAR PATTERN OUTPUT...
Page 61 ② Forward 2nd Forward 2nd In 2nd forward, forward clutch (KV) and 2nd clutch (K2) are engaged. Forward clutch and 2nd clutch are actuated by the hydraulic pressure applied to the clutch piston. INPUT GEAR PATTERN OUTPUT OUTPUT 7577APT05 F2 3-10...
Page 62 ③ Forward 3rd Forward 3rd In 3rd forward, forward clutch (KV) and 3rd clutch (K3) are engaged. Forward clutch and 3rd clutch are actuated by the hydraulic pressure applied to the clutch piston. INPUT GEAR PATTERN OUTPUT OUTPUT 7577APT06 F3 3-11...
Page 63 ④ Forward 4th Forward 4th In 4th forward, 4th clutch (K4) and 3rd clutch (K3) are engaged. 4th clutch and 3rd clutch are actuated by the hydraulic pressure applied to the clutch piston. INPUT GEAR PATTERN OUTPUT OUTPUT 7577APT07 F4 3-12...
Page 64 (2) (2) Reverse Reverse ① Reverse 1st Reverse 1st In 1st reverse, reverse clutch (KR) and 1st clutch (K1) are engaged. Reverse clutch and 1st clutch are actuated by the hydraulic pressure applied to the clutch piston. INPUT GEAR PATTERN OUTPUT OUTPUT 7577APT08 R1...
Page 65 ② Reverse 2nd Reverse 2nd In 2nd reverse, reverse clutch (KR) and 2nd clutch (K2) are engaged. Reverse clutch and 2nd clutch are actuated by the hydraulic pressure applied to the clutch piston. INPUT GEAR PATTERN OUTPUT OUTPUT 7577APT09 R2 3-14...
Page 66 ③ Reverse 3rd Reverse 3rd In 3rd reverse, reverse clutch (KR) and 3rd clutch (K3) are engaged. Reverse clutch and 3rd clutch are actuated by the hydraulic pressure applied to the clutch piston. INPUT GEAR PATTERN OUTPUT OUTPUT 7577APT10 R3 3-15...
Page 67 4) 4) ELECTRO-HYDRAULIC SHIFT CONTROL WITH PROPORTIONAL VALVE ELECTRO-HYDRAULIC SHIFT CONTROL WITH PROPORTIONAL VALVE (1) (1) 4-speed transmission 4-speed transmission SECTION A-A SECTION B-B 73033CV01 Pressure reducing valve (9+0.5 bar) Intermediate sheet System pressure valve (16+2 bar) Duct plate Housing Oscillation damper Cable harness 10 Follow-on slide...
Page 68 (2) (2) 5-speed transmission 5-speed transmission SECTION A - A SECTION B - B 7609AW3PT30 Cable harness Pressure reducing valve (9+0.5 bar) Proportional valve Vibration damper Intermediate plate/duct plate Follow-on slide System pressure valve (16+2 bar) Y1~Y6 Proportional valve Transmission control, see schedule of hydraulic circuit, electro-hydraulic control unit and measuring points at page 3-2, 3-16, 3-17 and 3-90.
Page 69 Due to the direct proportional selection with separated pressure modulation for each clutch, the pressures to the clutches, which are engaged in the gear change, will be controlled. In this way, a hydraulic intersection of the clutches to be engaged and disengaged becomes possible. This is creating spontaneous shiftings without traction force interruption.
Page 70 6) 6) ELECTRIC CONTROL UNIT ELECTRIC CONTROL UNIT (1) (1) Complete system Complete system 760F3PT37 Transmission control unit (EST-37A) Kickdown switch Clutch cut off mode Transmission shift mode Monitor Gear selector (DW-3) with integrated kickdown switch Power supply connection Transmission Cable to inductive transmitter - speed central gear train 10 Cable to inductive transmitter - speed turbine 11 Cable to inductive transmitter - speed engine...
Page 71 ·Protection from operating errors as far as necessary, is possible via electronic protection (programming). ·Protection from over-speeds (On the basis of engine and turbine speed). ·Automatic reversing (Driving speed-dependent). ·Pressure cut-off possible (disconnecting of the drive train for maximum power on the power take-off).
Page 72 Temperature increases in the converter oil as well as overheated brakes will be the consequences to be find out later. Neutral position of the selector switch at higher machine speeds (above stepping speed) is not admissible. Either a suitable gear is to be shifted immediately, or the machine must be stopped at once. (4) (4) Independent calibration of the shifting elements Independent calibration of the shifting elements (AEB)
Page 73 4. FAULT CODE 1-1) MACHINE FAULT CODE Application Diagnostic Criteria HCESPN FMI 10 seconds continuous, Hydraulic Oil Temp. Measurement Voltage > 3.95 V 10 seconds continuous, Hydraulic Oil Temp. Measurement Voltage < 0.3 V (Results / Symptoms) 1. Monitor – Hydraulic Oil temperature display failure 2.
Page 74 Application Diagnostic Criteria HCESPN FMI 10 seconds continuous, Boom cylinder ‘rod’ pressure Measurement Voltage > 5.3V 10 seconds continuous, Boom cylinder ‘rod’ pressure Measurement Voltage < 0.3V (Results / Symptoms) 1. Monitor – Boom cylinder ‘rod’ press. display failure 2. Control Function – No Boom pressure calibration function operation, workload measurement sys. operation failure (Checking list) 1.
Page 75 Application Diagnostic Criteria HCESPN FMI 10 seconds continuous, Accel pedal position 2 voltage Measurement Voltage > 5.0 V 10 seconds continuous, Accel pedal position 2 voltage Measurement Voltage < 0.2 V (Results / Symptoms) 1. Monitor – Accel pedal position 2 voltage display failure 2.
Page 76 Application Diagnostic Criteria HCESPN FMI 10 seconds continuous, Battery input Voltage > 35V 10 seconds continuous, Battery input Voltage < 18V (Results / Symptoms) 1. Control Function – Disabled startup (Checking list) 1. Checking battery voltage 2. CN-58A (#1) – CN-36 (07 fuse) Checking Open/Short 3.
Page 77 Application Diagnostic Criteria HCESPN FMI (When mounting the A/C Controller) 10 seconds continuous, A/C controller Communication Data Error (Results / Symptoms) 1. Control Function – A/C Controller malfunction 10 seconds continuous, ECM Communication Data Error (Results /Symptoms) 1. Control Function – ECM operation failure 10 seconds continuous, TCU Communication Data Error (Results / Symptoms) 1.
Page 78 1-2) EHCU FAULT CODE HCESPN Description 2333 Communication timeout between EHCU and TCU 2331 Communication timeout between EHCU and MCU 2332 Communication timeout between EHCU and working joystick 2317 Communication timeout between EHCU and steering joystick 2319 Steering joystick position signal error 2320 Steering joystick - FNR enable switch error 2321...
Page 79 HCESPN Description 2315 Aux joystick position input voltage above normal or shorted to high source 2315 Aux joystick position input voltage below normal or shorted to low source 2315 Aux joystick position control block out of calibration 2315 Aux joystick position control block parameter invalid 2315 Aux joysitck position signal redundancy lost 2304...
Page 80 HCESPN Description 2328 EHCU sensor power voltage below normal or shorted to low source 2329 EHCU power voltage high 2329 EHCU power voltage low 2329 EHCU safety cpu error Armrest switch signal error 2334 Steering pilot pressure sensor data above normal range 2334 Steering pilot pressure sensor data below normal range 2335...
Page 81 2) ENGINE FAULT CODE 2) ENGINE FAULT CODE Fault code J1939 SPN Reason Effect (only when fault code is active) J1939 FMI Engine control module critical internal failure - Possible no noticeable performance effects, Bad intelligent device or component. Error engine dying, or hard starting.
Page 82 Fault code J1939 SPN Reason Effect (only when fault code is active) J1939 FMI Engine coolant temperature 1 sensor circuit - Fan will stay ON if controlled by ECM. Voltage above normal, or shorted to high source. High signal voltage or open circuit detected at engine coolant temperature circuit.
Page 83 Fault code J1939 SPN Reason Effect (only when fault code is active) J1939 FMI Coolant level sensor 1 circuit - Voltage below None on performance. normal, or shorted to low source. Low signal voltage detected at engine coolant level circuit. Coolant level - Data valid but below normal Engine power derate.
Page 84 Fault code J1939 SPN Reason Effect (only when fault code is active) J1939 FMI Fuel pump pressurizing assembly 1 circuit - Engine may run rough, may stop running, may Voltage above normal, or shorted to high not start, or may be difficult to start. 1347 source.
Page 85 Fault code J1939 SPN Reason Effect (only when fault code is active) J1939 FMI Idle shutdown vehicle accessories relay driver Vehicle accessories or ignition bus loads circuit - Voltage above normal, or shorted to controlled by the idle shutdown relay will not 1267 high source.
Page 86 Fault code J1939 SPN Reason Effect (only when fault code is active) J1939 FMI Intake manifold 1 temperature - Data erratic, Possible reduced engine performance. intermittent, or incorrect. The intake manifold temperature sensor is reading an erratic value at initial key on or while the engine is running. Battery 1 voltage - Data valid but below normal Engine may run rough, may stop running, may operational range - Moderately severe level.
Page 87 Fault code J1939 SPN Reason Effect (only when fault code is active) J1939 FMI Injector metering rail 1 pressure - Data valid but Possibly hard to start or low power. Engine below normal operational range - Moderately could possibly not not start.
Page 88 Fault code J1939 SPN Reason Effect (only when fault code is active) J1939 FMI Engine speed / position camshaft and Engine power derate. crankshaft misalignment - Mechanical system not responding properly or out of adjustment. Engine position signal from the crankshaft position sensor and camshaft position sensor do not match.
Page 89 Fault code J1939 SPN Reason Effect (only when fault code is active) J1939 FMI Accelerator pedal or lever position sensor 2 The engine will operate in limp home mode. 1239 circuit - Voltage above normal or shorted to high 2623 source.
Page 90 Fault code J1939 SPN Reason Effect (only when fault code is active) J1939 FMI Aftertreatment diesel exhaust fluid tank Possible reduced engine performance. 1677 temperature sensor - Voltage below normal or 3031 shorted to low source. Low signal voltage detected at the diesel exhaust fluid tank temperature sensor circuit.
Page 91 Fault code J1939 SPN Reason Effect (only when fault code is active) J1939 FMI Aftertreatment diesel exhaust fluid tank heater - None on performance. 1713 Data valid but above normal operating range - 3363 Moderately severe level. The diesel exhaust fluid tank heater is continuously in the on position.
Page 92 Fault code J1939 SPN Reason Effect (only when fault code is active) J1939 FMI Aftertreatment intake NOx sensor circuit - Possible reduced engine performance. 1885 Voltage below normal or shorted to low source. 3216 An internal circuit error has been detected by the aftertreatment intake NOx sensor.
Page 93 Fault code J1939 SPN Reason Effect (only when fault code is active) J1939 FMI Aftertreatment diesel particulate filter missing - Active aftertreatment diesel particulate filter 1993 Condition exists. The aftertreatment diesel regeneration will be disabled. 4795 particulate filter in the exhaust system is not present.
Page 94 Fault code J1939 SPN Reason Effect (only when fault code is active) J1939 FMI EGR Valve control circuit - Current above Possible reduced engine performance. 2353 normal or grounded circuit. A short circuit to 2791 ground has been detected in the EGR valve motor circuit.
Page 95 Fault code J1939 SPN Reason Effect (only when fault code is active) J1939 FMI 2555 Intake air heater 1 circuit - Voltage above The intake air heaters may be ON or OFF all normal, or shorted to high source. High voltage the time.
Page 96 Fault code J1939 SPN Reason Effect (only when fault code is active) J1939 FMI Engine coolant temperature - Data valid but Progressive power and/or speed derate 2963 above normal operational range - Least severe increasing in severity from time of alert. If the level.
Page 97 Fault code J1939 SPN Reason Effect (only when fault code is active) J1939 FMI Aftertreatment SCR outlet temperature - Data Possible reduced engine performance. 3165 valid but above normal operational range - Most 4363 severe level. The SCR outlet temperature sensor reading has exceeded the maximum engine protection temperature limit.
Page 98 Fault code J1939 SPN Reason Effect (only when fault code is active) J1939 FMI Aftertreatment diesel exhaust fluid tank heater - Possible reduced engine performance. Mechanical system not responding or out of 3242 adjustment. The aftertreatment diesel exhaust 3363 fluid temperature did not increase when the aftertreatment diesel exhaust fluid tank heater was commanded ON.
Page 99 Fault code J1939 SPN Reason Effect (only when fault code is active) J1939 FMI Aftertreatment diesel particulate filter intake Progressive power and/or speed derate temperature - Data valid but above normal increasing in severity from time of alert. If the 3311 operating range - Most severe level.
Page 100 Fault code J1939 SPN Reason Effect (only when fault code is active) J1939 FMI Aftertreatment diesel particulate filter outlet Possible reduced engine performance. temperature sensor circuit - Voltage below 3321 normal or shorted to low source. Low signal 3246 voltage detected at the aftertreatment diesel particulate filter outlet temperature sensor circuit.
Page 101 Fault code J1939 SPN Reason Effect (only when fault code is active) J1939 FMI Engine exhaust gas recirculation (EGR) system Possible reduced engine performance. 3382 - Data valid but below normal operating range - 3058 Moderately severe level. Measured egr flow is lower than commanded.
Page 102 Fault code J1939 SPN Reason Effect (only when fault code is active) J1939 FMI Aftertreatment diesel exhaust fluid tank level - None on performance. 3498 Data valid but below normal operating range - 1761 Moderately severe level. The aftertreatment diesel exhaust fluid tank level is very low.
Page 103 Fault code J1939 SPN Reason Effect (only when fault code is active) J1939 FMI 3547 Aftertreatment diesel exhaust fluid tank empty - Possible reduced engine performance. 4096 Condition exists. The diesel exhaust fluid tank is empty. 3555 Engine wait to start lamp - Abnormal update None on performance.
Page 104 Fault code J1939 SPN Reason Effect (only when fault code is active) J1939 FMI Aftertreatment diesel exhaust fluid pressure Possible reduced engine performance. 3575 sensor - Data valid but above normal operating 4334 range - Moderately severe level. The diesel exhaust fluid dosing unit has detected a blockage in the diesel exhaust fluid return flow.
Page 105 Fault code J1939 SPN Reason Effect (only when fault code is active) J1939 FMI 3714 Engine protection torque derate - Condition Possible reduced engine performance. 1569 exists. Critical fault codes related to engine operation are active. Engine speed at idle - Data valid but below Possible reduced engine performance.
Page 106 Fault code J1939 SPN Reason Effect (only when fault code is active) J1939 FMI 3844 Cruise control pause command - Condition Cruise control could possibly not operate. 5605 exists. The adaptive cruise control has dropped out and must be manually engaged. 3845 Cruise control disable command - Condition Cruise control could possibly not operate.
Page 107 Fault code J1939 SPN Reason Effect (only when fault code is active) J1939 FMI Accelerator pedal or lever position sensor 2 The engine will operate in Limp Home mode. 4149 circuit frequency - Abnormal frequency or pulse 2623 width or period. The accelerator pedal position sensor reading is out of range.
Page 108 Fault code J1939 SPN Reason Effect (only when fault code is active) J1939 FMI After treatment diesel par ticulate filter Possible reduced engine performance. temperature sensor module- Data valid but 4163 above normal operating range - Moderately 5742 severe level. High internal temperature detected in the aftertreatment diesel particulate filter temperature sensor module.
Page 109 Fault code J1939 SPN Reason Effect (only when fault code is active) J1939 FMI Aftertreatment diesel exhaust fluid dosing unit None on performance. 4245 heater temperature - Data erratic, intermittent or 5798 incorrect. The aftertreatment diesel exhaust fluid dosing unit heater temperature is irrational. Aftertreatment diesel exhaust fluid dosing None on performance.
Page 110 Fault code J1939 SPN Reason Effect (only when fault code is active) J1939 FMI After treatment SCR Inter mediate gas Possible reduced engine performance. 4518 temperature sensor circuit - Voltage above 5862 normal, or shorted to high source. High signal voltage detected at the aftreatment SCR intermediate temperature sensor circuit.
Page 111 Fault code J1939 SPN Reason Effect (only when fault code is active) J1939 FMI Engine injector metering rail 1 cranking Engine may not start or may be difficult to start. 4691 pressure - Data valid but below normal 5585 operating range - Moderately severe level. The fuel rail pressure during cranking is too low for the engine to start.
Page 112 3) 3) DEFINITION OF OPERATING MODES DEFINITION OF OPERATING MODES (1) (1) Normal Normal There's no failure detected in the transmission system or the failure has no or slight effects on transmission control. TCU will work without or in special cases with little limitations. (See following table) (2) (2) Substitute clutch control...
Page 113 4) 4) TRANSMISSION FAULT CODES TRANSMISSION FAULT CODES Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection · Logical error at direction select signal TCU shifts transmission to Check the cables from TCU to shift 3rd shift lever neutral if selector active...
Page 114 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection · S.C. to battery voltage at customer specific Customer specific Check the cable from TCU to function No. 1 (ride control) customer specific function No.
Page 115 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection · S.C. to batter y voltage or O.C. at No reaction, TCU uses Check the cable from TCU to the transmission sump temperature sensor default temperature sensor...
Page 116 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection · S.C. to battery voltage or O.C. at turbine OP mode : Substitute clutch Check the cable from TCU to the speed input control sensor...
Page 117 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection · S.C. to ground at output speed input Special mode for gear Check the cable from TCU to the TCU measures a voltage less than 1.00V selection sensor...
Page 118 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection · EEC1 timeout OP mode : Substitute Check EEC controller · Timeout of CAN-message EEC1 from clutch control Check wire of CAN-Bus ·...
Page 119 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection · EEC2 timeout No reaction, TCU uses Check EEC controller · Timeout of CAN-message EEC2 from default signal accelerator Check wire of CAN-Bus ·...
Page 120 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection O.C. at clutch K2 TCU shifts to neutral Check the cable from TCU to the The measured resistance value of the OP mode : Limp home gearbox valve is out of limit...
Page 121 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection O.C. at engine derating device No reaction Check the cable from TCU to the TCU detected a wrong voltage at the OP mode : Normal engine derating device output pin, that looks like a O.C.
Page 122 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection · O.C. at clutch KV TCU shifts to neutral Check the cable from TCU to the The measured resistance value of the OP mode : Limp home gearbox ·...
Page 123 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection · O.C. at relay reverse warning alarm No reaction Check the cable from TCU to the TCU detected a wrong voltage at the OP mode : Normal backup alarm device ·...
Page 124 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection · O.C. at converter lock up clutch solenoid Converter clutch always Check the cable from TCU to the TCU detected a wrong voltage at the o p e n , r e t a r d e r n o t converter clutch solenoid ·...
Page 125 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection · S.C. to ground at warning signal output No reaction Check the cable from TCU to the TCU detected a wrong voltage at the OP mode : Normal warning device ·...
Page 126 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection · Slippage at clutch K3 TCU shifts to neutral Check pressure at clutch K3 · TCU calculates a differential speed at OP mode : Limp home Check main pressure in the system ·...
Page 127 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection · Slippage at converter lockup clutch No reaction Check pressure at converter lockup TCU calculates a differential speed at OP mode : Normal clutch ·...
Page 128 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection · O.C. at joystick status indicator No reaction Check the cable from TCU to TCU detected a wrong voltage at the OP mode : Normal joystick status indicator ·...
Page 129 Fault code Meaning of the fault code Reaction of the TCU Possible steps to repair (Hex) possible reason for fault detection · S.C. to battery voltage at display output No reaction Check the cable from TCU to the TCU sends data to the display and OP mode : Normal display ·...
Page 130 5) 5) MEASURING OF RESISTANCE AT ACTUATOR/SENSOR AND CABLE MEASURING OF RESISTANCE AT ACTUATOR/SENSOR AND CABLE (1) (1) Actuator Actuator 76043PT19 = ∞ Open circuit Short cut to ground = R; R = 0, R = R or R = R, R (For S.C.
Page 131 5. AXLE 5. AXLE OPERATION OPERATION 1) 1) · The power from the engine passes through torque converter, transmission and drive shafts, and is then sent to the front and rear axles. · Inside the axles, the power passes from the bevel pinion to the bevel gear and is sent at right angles.
Page 132 2) 2) DIFFERENTIAL DIFFERENTIAL (1) (1) Description Description When the machine makes a turn, the outside wheel must rotate faster than the inside wheel. A differential is a device which continuously transmits power to the right and left wheels while allowing them to turn a different speeds, during a turn.
Page 133 6. TIRE AND WHEEL 6. TIRE AND WHEEL 7407APT10 Wheel rim O-ring Side ring Tire Lock ring Valve assembly 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. Various types of tires are available to suit the purpose.
Page 134: Group 2 Operational Checks And Troubleshooting
GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING 1. POWER TRAIN OPERATIONAL CHECKS 1. POWER TRAIN OPERATIONAL CHECKS This procedure is designed so that the mechanic can make a quick check of the system using a minimum amount of diagnostic equipment.
Page 135 ※ ※ Transmission oil must be at operating temperature for these checks. Transmission oil must be at operating temperature for these checks. Item Description Service action Transmission oil warm-up Transmission oil warm-up Start engine. Apply service brakes procedure procedure and release parking brake. Check completed.
Page 136 Item Description Service action Transmission noise Transmission noise Run engine at approximately 1600 check check rpm. Check completed. Engine running. Drive unit with transmission in each NOT OK NOT OK forward and reverse speed. Go to transmission makes excessive noise, chapter 2 LISTEN : Transmission must not in this group.
Page 137 Item Description Service action Forward, reverse and 4th Forward, reverse and 4th Park unit on level surface. speed clutch pack drag speed clutch pack drag Check completed. Apply service brakes. check check NOT OK NOT OK ※ Transmission must Transmission must Move gear selector lever to neutral.
Page 138 2. TROUBLESHOOTING 2. TROUBLESHOOTING 1) 1) TRANSMISSION TRANSMISSION ※ Diagnose malfunction charts are arranged from most probable and simplest to verify, to least likely, 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 : more difficult to verify.
Page 139 Problem Cause Remedy Machine will not move Low oil level. Add oil. Applied park brake. Check parking brake fuse. Check continuity to parking brake switch. No power to transmission contro- Check transmission controller fuse. ller. Malfunctioning parking brake Remove and inspect parking brake solenoid solenoid valve.
Page 140 Problem Cause Remedy Transmission pressure is Low oil level. Check transmission oil level and refill if low (all gears) necessary. Failed transmission pressure Verify transmission system pressure. Do switch. transmission system pressure test. Plugged suction strainer. Transmission pump may be noisy if transmission suction screen is clogged.
Page 141 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.
Page 142 Problem Cause Remedy Excessive transmission Too low engine low idle. Check engine low idle speed. noise (Under load or no Wo r n p a r t s o r d a m a g e d i n Remove transmission suction screen. Inspect load) transmission.
Page 143 Problem Cause Remedy Torque conver ter stall Low engine power. Do engine power test. RPM too low Mechanical malfunction. Remove and inspect torque converter. Transmission pressure Low oil level. Add oil. light comes ON when Cold oil. Warm oil to specification. shifting from forward to reverse (all other gears Leak in reverse pack.
Page 144 2) 2) DIFFERENTIAL / AXLE DIFFERENTIAL / AXLE Problem Cause Remedy Differential low on oil External leakage. Inspect axle and differential for leaks. Excessive differential Low oil level in differential. Check oil. Remove drain plug and inspect for and/or axle noise metal particles in differential case.
Page 145 3) 3) DRIVE LINE DRIVE LINE Problem Cause Remedy E x c e s s i v e d r i v e l i n e Yokes not in line on drive shafts. Inspect. Align drive shaft yokes. vibration or noise Worn front drive line support Inspect, repair.
Page 146 GROUP 3 TESTS AND ADJUSTMENTS GROUP 3 TESTS AND ADJUSTMENTS 1. TRANSMISSION MEASURING POINTS AND CONNECTIONS 1. TRANSMISSION MEASURING POINTS AND CONNECTIONS The measurements have to be carried out at hot transmission (about 80~95˚C). 52,63 67 65 51 57 53 58 56 60 55 5-SPEED T/M VIEW X 7609A3PT14...
Page 147 2) 2) DELIVERY RATES DELIVERY RATES Port Description Size Connection to the oil cooler 1 5/6″-12UNF-2B Connection from the oil cooler 1 5/6″-12UNF-2B 3) 3) INDUCTIVE TRANSMITTER AND SPEED SENSOR INDUCTIVE TRANSMITTER AND SPEED SENSOR Port Description Size Inductive transmitter n turbine M18×1.5 Speed sensor...
Page 148: Group 4 Disassembly And Assembly
GROUP 4 DISASSEMBLY AND ASSEMBLY GROUP 4 DISASSEMBLY AND ASSEMBLY 1. TRANSMISSION 1. TRANSMISSION 1) 1) DISASSEMBLY DISASSEMBLY Electro-hydraulic control and fine filter Electro-hydraulic control and fine filter ※ Attach transmission to assembly truck. Assembly truck 5870 350 000 Holding fixtures 5870 350 063 Clamping angles 5870 350 090...
Page 149 (2) (2) Removal of electric gear-shift control Removal of electric gear-shift control ① Remove gear-shift control (1). Loosen Torx screws (2) and separate g e a r - s h i f t c o n t r o l h o u s i n g f r o m intermediate plate.
Page 150 ⑤ Pull converter safety valve (1) out of housing hole. 7609ATM008 ⑥ Mark installation position of wiring harness (1) towards valve block (2). 7609ATM009 ⑦ Loosen Torx screws (1). Socket wrench TX-27 5873 042 002 7609ATM010 ⑧ Separate duct plate (1) and sealing plate (2) from valve block (3).
Page 151 ⑨ Remove retaining clamp (1). 7609ATM012 ⑩ Loosen Torx screws (1) and remove cover (2). Remove opposite cover (3) in the same way. Socket wrenchTX-27 5873 042 002 7609ATM013 ⑪ Remove wiring harness (1). Loosen cylindrical screws (3), remove fixing plates and remove pressure controllers (2).
Page 152 ⑬ Loosen two Torx screws (1) and preliminarily fix housing by means adjusting screws. (Housing is spring- loaded) Then loosen remaining Torx screws. Adjusting screws (s) 5870 204 036 7609ATM016 ⑭ Separate housing from valve housing by loosening the adjusting screws equally. Adjusting screws 5870 204 036 7609ATM017...
Page 153 (3) (3) Lock-up clutch solenoid valve Lock-up clutch solenoid valve (5-speed transmission) Mark installation position of connecting housing (4) towards valve block (5). Loosen cylindrical screws (1) and remove lock-up clutch valve. Loosen screw neck (2) and remove O-rings. 7609ATM020 Loosen torx screws (3) and remove connecting housing.
Page 154 2) 2) DISASSEMBLY DISASSEMBLY Inductive sensor, hall sensor, breather, oil Inductive sensor, hall sensor, breather, oil filler and oil drain plug. filler and oil drain plug. Attach transmission to assembly truck. Assembly truck 5870 350 000 Holding fixtures 5870 350 063 Clamping angles 5870 350 090 Remove positioned parts.
Page 155 3) 3) DISASSEMBLY DISASSEMBLY Engine connection, oil pressure pump, Engine connection, oil pressure pump, conver ter back-pressure valve and conver ter back-pressure valve and temperature sensor (measuring point temperature sensor (measuring point "63" after the converter). "63" after the converter). (1) (1) Engine connection Engine connection...
Page 156 ② Loosen bolted connection (1) oil feed housing/transmission housing front part with torx screws and bolted connection (2) oil pressure pump/transmission housing front part with cylindrical screws. ※ Separate oil feed housing together with oil pressure pump from transmission housing front part. 7609ATM026 ③...
Page 157 ⑤ Remove shaft seal (1) from the pump housing (2). 7609ATM030 (3) (3) Converter back-pressure valve Converter back-pressure valve ① Preload converter safety valve (1) by means of screw driver or assembly aid and remove locking plate (2). Assembly aid 5870 345 107 7609ATM031 ②...
Page 158 ④ Remove stator shaft (1). Pull pressure relief valve (2) out of the housing hole. 7609ATM034 4) 4) DISASSEMBLY DISASSEMBLY Without emergency steering pump Without emergency steering pump Loosen bolted connection cover (1) and cover front part (2) and remove cover (3 and 4) and seal.
Page 159 5) 5) DISASSEMBLY DISASSEMBLY Outputs flange Outputs flange (1) (1) Output flange on converter side Output flange on converter side ① Loosen hexagon screws (1), remove washer and O-ring. 7609ATM036 ② Pull off output flange (1) and remove shaft seal (2). 7609ATM037 (2) (2) Output flange on output side...
Page 160 (3) (3) Output flange on output side with Output flange on output side with parking brake parking brake ① Connect HP pump at port (see arrow) and apply approx. 80 bar pressure to the hydraulically actuated parking brake (1) until the brake disc (2) can be rotated by hand.
Page 161 ⑤ Loosen hexagon screws (1), remove washer and O-ring. Pull-off output flange (2) and remove shaft seal. Remove cylindrical screw with washer (3). 7609ATM044 3-105...
Page 162 6) 6) REMOVAL OF INPUT SHAFT, OUTPUT REMOVAL OF INPUT SHAFT, OUTPUT SHAFT, PUMP SHAFT (PTO-SHAFT) SHAFT, PUMP SHAFT (PTO-SHAFT) AND CLUTCHES AND CLUTCHES Force out both cylindrical pins (1). Loosen bolted connection (2) between housing front and rear part and separate housing rear part by means of lifting device.
Page 163 Use lifting device to bring housing rear part (1) into contact position with housing front part (2) again. 7609ATM049 ※ Due to the installation conditions, the removal of single clutches without using the special tool is not possible. Fix all clutches K1, K2, K3 and K4 by means of handle (1).
Page 164 ※ The suction tube (1) and the lubrication lines (2) are rolled in and are highly difficult to remove. In case of damage, use of the appropriate special tool is imperative for fitting or replacing these components. Rolling tool 5870 600 003 7609ATM053 Remove bearing outer rings (arrows) from the housing front part.
Page 165 (12) Lift the clutches out of the housing in numerical order as described in the legend. K1 clutch K2 clutch K3 clutch K4 clutch KR clutch KV clutch input shaft 7609ATM057 (13) Remove bearing outer rings (arrows) from the housing rear part. ※...
Page 166 7) 7) DISASSEMBLY DISASSEMBLY Clutches KV / KR / K1 / K2 /K3 / K4 input Clutches KV / KR / K1 / K2 /K3 / K4 input and output shaft and output shaft See opposite picture. clutch clutch clutch clutch clutch clutch...
Page 167 ④ Pull clutch (1) off the shaft. ※ Disassembly clutch (1) see figure TM070~TM075. 7609ATM064 ⑤ Fix idler gear (1) by means of cut-off device and pull it off the clutch shaft. Cut-off device 5870 300 024 Puller 5870 300 033 7609ATM065 ⑥...
Page 168 ⑧ Turn shaft (2) by 180˚ and snap out piston ring (1). 7609ATM068 ⑨ Pull tapered roller bearing (inner ring) off the shaft. Forcing device 5870 026 100 Grab sleeve 5873 001 057 Rapid grip 5873 011 011 7609ATM069 ⑩ Unsnap snap ring (1).
Page 169 ⑫ Preload compression spring (1) unsnap L-ring. Assembly aid 5870 345 088 7609ATM072 ⑬ Remove support shim (1), compression spring (2) and washer (3). 7609ATM073 ⑭ Lift piston (1) by means of compressed air out of the cylinder bore and remove it. 7609ATM074 ⑮...
Page 170 (2) (2) KR clutch KR clutch ① Remove stud bolt (1) and snap out piston ring (2). 7609ATM076 ② Pull tapered roller bearing (inner ring) off the shaft. Forcing device 5870 026 100 Grab sleeve 5873 001 059 7609ATM077 ③ Snap out retaining ring (1).
Page 171 ⑤ Fix idler gear (1) by means of cut-off device and pull it off the clutch shaft. Cut-off device 5870 300 024 Puller 5870 300 033 7609ATM080 ⑥ Snap retaining ring (2) out of the idler gear (1) and remove ball bearing (3). 7609ATM081 ⑦...
Page 172 ⑨ Pull tapered roller bearing (inner ring) off the shaft. Forcing device 5870 026 100 Grab sleeve 5873 001 057 Rapid grip 5873 011 011 7609ATM084 ⑩ Unsnap snap ring (1). 7609ATM085 ⑪ Remove end shim (1) and disc set (2) out the disc carrier (3).
Page 173 ⑬ Remove support shim (1), compression spring (2) and washer (3). 7609ATM088 ⑭ Lift piston (1) by means of compressed air out of the cylinder bore and remove it. 7609ATM089 ⑮ Remove both O-rings (1 and 2). 7609ATM090 (3) (3) K1 clutch K1 clutch ①...
Page 174 ② Pull tapered roller bearing (inner ring) off the shaft. Forcing device 5870 026 100 Grab sleeve 5873 001 059 7609ATM092 ③ Snap out retaining ring (1). 7609ATM093 ④ Remove axial bearing assy (1). 7609ATM094 ⑤ Take off idler gear (1), remove needle cage (2) and axial bearing assy (3).
Page 175 ⑥ Pull clutch (1) off the shaft. ※ Disassembly clutch (1) see figure TM099~TM104. 7609ATM096 ⑦ Turn shaft (2) by 180˚ and snap out piston ring (1). 7609ATM097 ⑧ Pull tapered roller bearing (inner ring) off the shaft. Basic tool 5873 002 001 Grab sleeve 5873 002 038...
Page 176 ⑩ Remove end shim (1) and disc set (2) out the disc carrier (3). 7609ATM100 ⑪ Preload cup springs unsnap L-ring (1). Assembly aid 5870 345 088 7609ATM101 ⑫ Remove cup spring package (1). 7609ATM102 ⑬ Lift piston (1) by means of compressed air out of the cylinder bore and remove it.
Page 177 ⑭ Remove both O-rings (1 and 2). 7609ATM104 (4) (4) K2 clutch K2 clutch ① Remove stud bolt (1) and snap out piston ring (2). 7609ATM105 ② Pull tapered roller bearing (inner ring) off the shaft. Forcing device 5870 026 100 Grab sleeve 5873 001 059 7609ATM106...
Page 178 ④ Remove axial bearing assy (1). 7609ATM108 ⑤ Take off idler gear (1), remove needle cage (2) and axial bearing assy (3). 7609ATM109 ⑥ Pull clutch (1) off the shaft. ※ Disassembly clutch (1) see figure TM113~TM118. 7609ATM110 ⑦ Turn shaft (2) by 180˚ and snap out piston ring (1).
Page 179 ⑧ Pull tapered roller bearing (inner ring) off the shaft. Forcing device 5870 026 100 Grab sleeve 5873 001 059 7609ATM112 ⑨ Unsnap snap ring (1). 7609ATM113 ⑩ Remove end shim (1) and disc set (2) out the disc carrier (3). 7609ATM114 ⑪...
Page 180 ⑫ Remove cup spring package (1). 7609ATM116 ⑬ Lift piston (1) by means of compressed air out of the cylinder bore and remove it. 7609ATM117 ⑭ Remove both O-rings (1 and 2). 7609ATM118 (5) (5) K3 clutch K3 clutch ① Snap out piston ring (1).
Page 181 ② Pull tapered roller bearing (inner ring) off the shaft. Forcing device 5870 026 100 Grab sleeve 5873 001 059 7609ATM120 ③ Remove axial bearing assy (1). 7609ATM121 ④ Take off idler gear (1), remove needle cage (2) and axial bearing assy (3). 7609ATM122 ⑤...
Page 182 ⑥ Remove stud bolt (1) and snap out piston ring (2). 7609ATM124 ⑦ Pull tapered roller bearing (inner ring) off the shaft. Basic tool 5873 002 001 Grab sleeve 5873 002 038 7609ATM125 ⑧ Unsnap snap ring (1). 7609ATM126 ⑨ Remove end shim (1) and disc set (2) out the disc carrier (3).
Page 183 ⑩ Preload cup springs unsnap L-ring (1). Assembly aid 5870 345 088 7609ATM128 ⑪ Remove cup spring package (1). 7609ATM129 ⑫ Lift piston (1) by means of compressed air out of the cylinder bore and remove it. 7609ATM130 ⑬ Remove both O-rings (1 and 2). 7609ATM131 3-127...
Page 184 (6) (6) K4 clutch K4 clutch ① Remove stud bolt (1) and snap out piston ring (2). 7609ATM132 ② Pull tapered roller bearing (inner ring) off the shaft. Forcing device 5870 026 100 Grab sleeve 5873 001 057 Rapid grip 5873 011 011 7609ATM133 ③...
Page 185 ⑤ Remove axial bearing assy (1) and idler gear (2). 7609ATM136 ⑥ Remove needle cage (1) and axial bearing assy (2). ※ The gear (3) cannot be removed (shrink fit). 7609ATM137 ⑦ Turn shaft (2) by 180˚ and snap out piston ring (1).
Page 186 ⑨ Unsnap snap ring (1). 7609ATM140 ⑩ Remove end shim (1) and disc set (2) out the disc carrier (3). 7609ATM141 ⑪ Preload cup springs unsnap L-ring (1). Assembly aid 5870 345 088 7609ATM142 ⑫ Remove cup spring package (1). 7609ATM143 3-130...
Page 187 ⑬ Lift piston (1) by means of compressed air out of the cylinder bore and remove it. 7609ATM144 ⑭ Remove both O-rings (1 and 2). 7609ATM145 (7) (7) Input shaft Input shaft ① Snap out piston ring (1). Turbine wheel shaft and drive gear (2) are fixed by a snap ring.
Page 188 ③ Pull tapered roller bearing (inner ring) off the drive gear. Grab sleeve 5873 001 058 Forcing device 5870 026 100 Rapid grip 5873 011 014 It is not possible to separate input shaft and gear (1) -shrink fit-. 7609ATM148 (8) (8) Output shaft Output shaft...
Page 189 8) 8) REASSEMBLY REASSEMBLY Clutches KV / KR / K1 / K2 / K3 / K4 Clutches KV / KR / K1 / K2 / K3 / K4 input and output shaft input and output shaft (1) (1) KV Clutch KV Clutch ①...
Page 190 ⑤ Press in preassembled idler gear (1) onto the shaft until contact is obtained. 7609ATM155 ⑥ Place both O-rings (1 and 2) into the piston grooves and oil them. 75 × 3 142 × 3 ※ Check function of the drain valve (see arrow) - There must be no jamming of the ball.
Page 191 ⑨ Mount inner installer (S) onto the disk carrier. Install disk (1), compression spring (2), support shim (3) and L-ring (4). ※ Installation position support shim and L-ring see TM161. Inner installer : see figure TM160 7609ATM159 ⑩ Preload compression spring by means of assembly aid (S1) and pressure piece (S2), until L-ring has engaged into the annular groove.
Page 192 ⑪ Install outer and inner disks alternately into the disk carrier (4) as personated in figure TM162. Friction disk-coated on one side (1 pcs) Outer disks (10 pcs) Inner disks (10 pcs) ※ Take care that the uncoated (blank) side of the friction disk (1) is showing towards the piston.
Page 193 ⑮ Then press end plate against the snap ring (upwards) and read disk clearance. ※ Disk clearance : 2.65~2.95 mm ※ In case of deviations, the disk clearance must be corrected with an appropriate snap ring (optional thicknesses = 2.1~4.2 mm). 7609ATM166 Heat up clutch inner diameter (approx.
Page 194 Heat up bearing inner ring (approx. 120˚C). 7609ATM170 Mount bearing inner ring (1) until contact is obtained. ※ Wear protective gloves. ※ Adjust bearing inner ring after cooling- down. 7609ATM171 Mount stud bolt (1). ·Tightening torque (M10/8.8×16) : 1.73 kgf·m (12.5 lbf·ft) Fit rectangular ring 40×2.5 (2).
Page 195 Install sealing cap orifice (1). ※ Wet contact surface with loctite (Type No. 262). 7609ATM174 (2) (2) KR Clutch KR Clutch ① Heat up bearing inner ring (approx. 120˚C) 7609ATM175 ② Mount bearing inner ring (1) until contact is obtained. Fit rectangular ring 40×2.5 (2).
Page 196 ④ Install ball bearing 50×90×18 (2) into the idler gear (1) until contact is obtained and fix it by means of retaining ring 90×3 (3). 7609ATM178 ⑤ Press in preassembled idler gear (1) onto the shaft until contact is obtained. 7609ATM179 ⑥...
Page 197 ⑧ Use a hand-operated press to place piston into the disk carrier by means of the assembly aid. Assembly aid 5870 345 088 7609ATM182 ⑨ Mount inner installer (S) onto the disk carrier. Install disk (1), compression spring (2), support shim (3) and L-ring (4). ※...
Page 198 ※ Different clutches (disc arrangements with relevant disc clearance) can be installed, depending on the par ts manual. ※ The actually installed clutch and disc arrangement must be taken from the corresponding parts manual. ※ Figure no. : TM186 and TM187 illustrates the different disc arrangements.
Page 199 ⑬ Mount end plate (1) and fix disk package by means of snap ring (2) (e.g. thickness = 2.65 mm / recommended value). 7609ATM188 ⑭ Press on end plate with F (approx. 100 N = 10 kg) and set dial indicator to "zero". 7609ATM189 ⑮...
Page 200 Install clutch until contact is obtained. Mount inner disks onto the inner disk carrier by means of short left/right rotations. ※ Wear protective gloves. 7609ATM192 Fix clutch (1) by means of retaining ring 55×2 (2). 7609ATM193 Heat up bearing inner ring (approx. 120˚C).
Page 201 Mount stud bolt (1). ·Tightening torque (M10/8.8×16) : 1.73 kgf·m (12.5 lbf·ft) Fit rectangular ring 40×2.5 (2). 7609ATM196 ※ Check closing and opening of the clutch by means of compressed air at the hole (see arrow). Closing and opening of the clutch must be clearly audible.
Page 202 ② Mount bearing inner ring (1) until contact is obtained. Fit rectangular ring 40×2.5 (2). ※ Wear protective gloves. ※ Adjust bearing inner ring after cooling- down. 7609ATM200 ③ Place both O-rings (1 and 2) into the piston grooves and oil them. 75×3 158×3 ※...
Page 203 ⑥ Mount inner installer (S) onto the disk carrier. Install cup spring package (1) and L-ring (2). ※ Installation position cup spring package and L-ring see figure TM206. Inner installer see figure TM205 7609ATM204 ⑦ Preload cup spring package by means of assembly aid (S1) and pressure piece (S2), until L-ring has engaged into the annular groove.
Page 204 ⑨ Mount end plate (1) and fix disk package by means of snap ring (2) (e.g. thickness = 2.65 mm / recommended value). 7609ATM208 ⑩ Press on end plate with F (approx. 100 N = 10 kg) and set dial indicator to "zero". 7609ATM209 ⑪...
Page 205 ⑬ Mount clutch (1) until contact is obtained. ※ Wear protective gloves. 7609ATM212 ⑭ Mount running disk 55×78×5 (1), axial cage 55×78×3 (2) and axial washer 55 ×78×1 (3) and oil it. ※ Install chamfer (see arrow) of running disk (1) showing towards the axial cage. 7609ATM213 ⑮...
Page 206 Mount axial washer 55×78×1 (1), axial cage 55×78×3 (2) and running disk 55 ×78×5 (3) and oil it. ※ Install chamfer (see arrow) of running disk (3) showing towards the axial cage. 7609ATM216 Fix idler gear (1) and single parts by means of retaining ring (2).
Page 207 Mount stud bolt (1). ·Tightening torque (M10/8.8×16) : 1.73 kgf·m (12.5 lbf·ft) Fit rectangular ring 40×2.5 (2). 7609ATM220 ※ Check closing and opening of the clutch by means of compressed air at the hole (see arrow). Closing and opening of the clutch must be clearly audible.
Page 208 ③ Place both O-rings (1 and 2) into the piston grooves and oil them. 75×3 142×3 ※ Check function of the drain valve (see arrow) - There must be no jamming of the ball. 7609ATM224 ④ Place piston (1) into the disk carrier. ※...
Page 209 ⑦ Preload cup spring package by means of assembly aid (S1) and pressure piece (S2), until L-ring has engaged into the annular groove. Assembly aid (S1) 5870 345 088 Assembly fixture (S＋S2) 5870 345 124 (Inner installer and pressure piece) ※...
Page 210 ⑩ Press on end plate with F (approx. 100 N = 10 kg) and set dial indicator to "zero". 7609ATM232 ⑪ Then press end plate against the snap ring (upwards) and read disk clearance. ※ Disk clearance : 1.75~2.05 mm (see figure TM230) ※...
Page 211 ⑭ Mount running disk 55×78×5 (1), axial cage 55×78×3 (2) and axial washer 55 ×78×1 (3) and oil it. ※ Install chamfer (see arrow) of running disk (1) showing towards the axial cage. 7609ATM236 ⑮ Mount needle cage 55×63×50 (1) and oil it.
Page 212 Fix idler gear (1) and single parts by means of retaining ring (2). 7609ATM240 Heat up bearing inner ring (approx. 120˚C). 7609ATM241 Mount bearing inner ring (1) until contact is obtained. ※ Wear protective gloves. ※ Adjust bearing inner ring after cooling- down.
Page 213 ※ Check closing and opening of the clutch by means of compressed air at the hole (see arrow). Closing and opening of the clutch must be clearly audible. 7609ATM244 (5) (5) Clutch K3 Clutch K3 ① Heat up bearing inner ring (approx. 120˚C) 7609ATM245 ②...
Page 214 ④ Place piston (1) into the disk carrier. ※ Observe installation position, see figure. 7609ATM248 ⑤ Use a hand-operated press to place piston into the disk carrier by means of the assembly aid. Assembly aid 5870 345 088 7609ATM249 ⑥ Mount inner installer (S) onto the disk carrier.
Page 215 Disk carrier with piston retraction : Cup spring package L-ring Disk carrier Piston with O-rings 7609ATM252 ※ Different clutches (disc arrangements with relevant disc clearance) can be installed, depending on the par ts manual. ※ The actually installed clutch and disc arrangement must be taken from the corresponding parts manual.
Page 216 ⑩ Mount end plate (1) and fix disk package by means of snap ring (2) (e.g. thickness = 2.65 mm / recommended value). 7609ATM255 ⑪ Press on end plate with F (approx. 100 N = 10 kg) and set dial indicator to "zero". 7609ATM256 ⑫...
Page 217 ⑭ Mount clutch (1) until contact is obtained. ※ Wear protective gloves. 7609ATM259 ⑮ Mount running disk 55×78×5 (1), axial cage 55×78×3 (2) and axial washer 55 ×78×1 (3) and oil it. ※ Install chamfer (see arrow) of running disk (1) showing towards the axial cage. 7609ATM260 Mount needle cage 55×63×50 (1) and oil it.
Page 218 Mount axial washer 55×78×1 (1), axial cage 55×78×3 (2) and running disk 55 ×78×5 (3) and oil it. ※ Install chamfer (see arrow) of running disk (3) showing towards the axial cage. 7609ATM263 ※ Pay attention that the running disk is flush with the shaft (see arrow) collar to ensure that all inner disks are mounted on the idler gear teeth.
Page 219 ※ Check closing and opening of the clutch by means of compressed air at the hole (see arrow). Closing and opening of the clutch must be clearly audible. 7609ATM267 (6) (6) K4 Clutch K4 Clutch ① Heat up bearing inner ring (approx. 120˚C) 7609ATM268 ②...
Page 220 ④ Secure gear by means of retaining ring 80×2.5 (1). 7609ATM271 ⑤ Mount lower axial washer 55×78×1 (1), axial needle cage 55×78×3 (2) and upper axial washer 55×78×1 (1) and oil it. ※ Upper and lower axial washer are identical. 7609ATM272 ⑥...
Page 221 ⑧ Mount axial washer 55×78×1 (1), axial needle 55×78×3 cage (2) and running disk 55×78×5 (3) and oil it. ※ Mount running disk (3) with the chamfer (see arrow) showing to the needle cage. 7609ATM275 ⑨ Place both O-rings (1 and 2) into the piston grooves and oil them.
Page 222 ⑫ Mount inner installer (S) onto the disk carrier. Install cup spring package (1) and L-ring (2). ※ Installation position cup spring package and L-ring see figure TM281. Inner installer see figure TM280 7609ATM279 ⑬ Preload cup spring package by means of assembly aid (S1) and pressure piece (S2), until L-ring has engaged into the annular groove.
Page 223 ⑮ Mount end plate (1) and fix disk package by means of snap ring (2) (e.g. thickness = 2.65 mm / recommended value). 7609ATM283 Press on end plate with F (approx. 100 N = 10 kg) and set dial indicator to "zero". Magnetic stand 5870 200 055 Dial indicator...
Page 224 Mount clutch (1) until contact is obtained. Mount inner disks onto the inner disk carrier by means of short left/right rotations. ※ Wear protective gloves. 7609ATM287 Secure clutch by means of retaining ring 55×2 (1). 7609ATM288 Heat up bearing inner ring (approx. 120˚C) 7609ATM289 Mount bearing inner ring (1) until contact...
Page 225 ※ Check closing and opening of the clutch by means of compressed air at the hole (see arrow). Closing and opening of the clutch must be clearly audible. 7609ATM291 (7) (7) Input shaft Input shaft ① Undercool input shaft (1) (approx. -80˚C), heat up drive gear (2) (approx.
Page 226 ④ Mount bearing inner ring (1) until contact is obtained. ※ Wear protective gloves. ※ Adjust bearing inner ring after cooling- down. 7609ATM295 ⑤ Heat up bearing inner ring (approx. 120˚ C) 7609ATM296 ⑥ Mount bearing inner ring (1) until contact is obtained.
Page 227 ⑧ Mount turbine shaft (1) until the snap ring engages into the input shaft groove. ※ Turbine shaft is axially fixed. Snap in and interlock rectangular ring 60 ×3 (2). 7609ATM299 With lock-up clutch (5-speed T/M) With lock-up clutch (5-speed T/M) ⑨...
Page 228 ③ Mount screen sheet (1). 7609ATM303 ④ Heat up bearing inner ring (approx. 120˚C) 7609ATM304 ⑤ Mount bearing inner ring (1) until contact is obtained. ※ Wear protective gloves. ※ Adjust bearing inner ring after cooling- down. 7609ATM305 3-172...
Page 229 9) 9) INSTALLATION OF INPUT SHAFT, OUT- INSTALLATION OF INPUT SHAFT, OUT- PUT SHAFT, PUMP SHAFT (POWER- PUT SHAFT, PUMP SHAFT (POWER- TAKE OFF SHAFT) AND CLUTCHES TAKE OFF SHAFT) AND CLUTCHES If the suction tube (1) in the housing front part is to be replaced, it is imperative to use the special tool (rolling tool) for a s s e m bl y.
Page 230 Mount O-rings 22×3 into the annular groove of the oil tubes (1 and 2) and oil them. Then insert tubes into the housing front part. 7609ATM309 ※ The spare parts service supplies the lubri- cating oil tubes (1 and 2) only as a com- plete package with the housing rear part.
Page 231 Housing rear part : Housing rear part : Legend see figure TM311. ※ Place bearing outer rings into the bearing holes using assembly grease. ※ If, contrary to the recommendation, the tapered roller bearings of clutches, input and output are not replaced, it is impera- tive to ensure the previous pairing (bear- ing inner ring/bearing outer ring).
Page 232 Position K2 clutch. 7609ATM316 (10) Slightly lift K4 clutch and position K1 clutch. 7609ATM317 (11) Press ball bearing 45×85×19 (1) onto the pump shaft (2) until contact is obtained. Mount rectangular ring 60×3 (3). Grease and centrically align rectangular ring. 7609ATM318 (12) Mount pump shaft (1) until contact is...
Page 233 ※ The figure left shows the installation position of the individual clutches in the housing rear part one more time. (13) Fix clutches K1, K2, K3 and K4 by using a handle. Handle 5870 260 010 ※ Clutches KV, KR and input shaft (2) are only fixed by the gear chain.
Page 234 (17) Put on screen sheet (1). Install preassembled output shaft (2). 7609ATM324 (18) Oil cylindrical screws (1) and use them to fix screen sheet . Tightening torque (M8/8.8×12) : 2.35 kgf·m (17.0 lbf·ft) ※ It is always necessar y to use new cylindrical screws.
Page 235 (20) Fit both cylindrical pins 10×24 (1) centrically to the mounting face. 7609ATM327 Checking of clearance of the gear drive Checking of clearance of the gear drive train train (21) Position driving element and rotate KV clutch shaft. ※ If you notice an interference of the movable parts (e.g.
Page 236 ASSEMBLY ASSEMBLY Outputs flange Outputs flange (1) (1) Output flange on output side Output flange on output side ① Use driver (S) to mount shaft seal 90×120×13, with the sealing lip showing to the oil sump. Driver 5870 048 237 ※...
Page 237 ③ Mount output flange (1) until contact is obtained. 7609ATM334 ④ Insert O-ring 48×4 into the space between output flange and shaft. Fix output flange (1) by means of washer (2) and hexagon screws (3). Oil hexagon screws before the assembly. ·Tightening torque (M10/8.×30) : 4.69 kgf·m (33.9 lbf·ft) ※...
Page 238 ② Press screen sheet (1) onto the input flange (2). Mount output flange (2) until contact is obtained. 7609ATM337 ③ Insert O-ring 48×4 into the space between output flange and shaft. ※ Fix output flange (1) by means of washer (2) and hexagon screws.
Page 239: Section 4 Brake System
⑤ Fix parking brake (1) on transmission housing using the hexagon screw - guide pin (2). ·Tightening torque (M20×1.5) : 4.69 kgf·m (33.9 lbf·ft) 7609ATM340 ⑥ Fix hexagon nut on brake caliper using the open end wrench insert. ·Tightening torque (M20×1.5) : 23.5 kgf·m (170 lbf·ft) 7609ATM341 ⑦...
Page 240 Shaft seal 90×120×13 Gearbox housing - rear section Roller bearing Output shaft Screen sheet 7609ATM344 ② Press screen sheet (1) onto the input flange (2). Mount output flange (2) until contact is obtained. 7609ATM345 ③ Insert O-ring 48×4 into the space between output flange and shaft.
Page 241 REASSEMBLY REASSEMBLY Engine connection, oil pressure pump, Engine connection, oil pressure pump, conver ter back-pressure valve and conver ter back-pressure valve and temperature sensor (measuring point temperature sensor (measuring point "63" after the converter). "63" after the converter). (1) (1) Converter back-pressure valve Converter back-pressure valve ①...
Page 242 (2) (2) Oil pressure pump Oil pressure pump ① Insert pressure relief valve (1) into the housing hole until contact is obtained. Mount two adjusting screws (S) and place gasket (2) and oil feed housing (3). ※ Use assembly grease. Adjusting screws (M8) 5870 204 011 7609ATM350...
Page 243 ⑤ Place control disk and fix it radially by means of two cylindrical screws M6×12 (1). ※ Do not tighten the cylindrical screws - just turn them in until contact is obtained and then turn them back by approx. 1/2 rotation.
Page 244 ⑨ Fit O-rings 9.5×1.6 to the cylindrical screws 10×75. ※ Grease O-rings. Fix transmission pump (2) by means of cylindrical screws (1). ·Tightening torque (10/8.8×75) : 4.69 kgf·m (33.9 lbf·ft) 7609ATM358 ⑩ Fix oil feed housing (1) equally by means of Torx screws (2).
Page 245 (3) (3) Engine connection (direct mount) Engine connection (direct mount) ① Position converter (1) by means of lifting device until contact is obtained. 7609ATM361 ② Position 1 washer/each / thickness = 1.0 mm (4 EA ) (1) onto the flex plate mounting webs (4 EA ).
Page 246 REASSEMBLY - without emergency REASSEMBLY - without emergency steering steering Fit adjusting screws (S) and assemble seal (1) and cover (2). 7609ATM364 Fix cover by means of hexagon screws (1). ·Tightening torque (M8/8.8×18) : 2.35 kgf·m (17.0 lbf·ft) 7609ATM365 3-190...
Page 247 REASSEMBLY REASSEMBLY Inductive sensor, Hall sensor, breather, Inductive sensor, Hall sensor, breather, oil filler and oil drain plug oil filler and oil drain plug Mount inductive sensors (1, 2 and 3) with O-rings 15×2. Inductive sensor - turbine speed Inductive sensor - speed/central gear chain Inductive sensor - engine speed ·Tightening torque :...
Page 248 REASSEMBLY REASSEMBLY Electro-hydraulic control with proportional valves : Electro-hydraulic control with proportional valves : ※ The following sketches show the sectional views of the electro-hydraulic control. Main pressure valve16+2 bar Pressure reducing valve 9 bar Wiring harness Cover Cover Housing Valve block Housing 7609ATM368...
Page 249 (1) (1) Fitting of electric control Fitting of electric control ※ All single parts are to be checked for damage and replaced, if required. Ensure free travel of the moving parts in the valve block prior to installation. Pistons can be exchanged individually. Prior to the installation, oil single parts.
Page 250 ⑤ Bring housing (1) into contact position by means of the Torx screws. This will preload the pistons, and you can remove the cylindrical pins (assembly aid). 7609ATM375 ⑥ Fix housing by means of Torx screws (1). ·Tightening torque (M5/10.9×30) : 0.56 kgf·m (4.06 lbf·ft) Reducing adapter 5870 656 056...
Page 251 ⑨ Install the single parts according to figure TM378. ※ Preload the compression springs of the follow-on slides and fasten the pistons preliminarily by means of cylindrical pins Ø 5.0 mm (assembly aid), see arrows (S). Install two adjusting screws. Adjusting screws M5 5870 204 036 7609ATM379...
Page 252 ⑬ Put on the flat gasket (1). Assemble the plug socket with the slot showing to the lug of the cover until contact. Fasten the cover by means of cap screws. ·Tightening torque (M5/10.9×30) : 0.56 kgf·m (4.06 lbf·ft) 7609ATM383 Reducer 5870 656 056 Socket spanner TX-27...
Page 253 Put on sealing plate (1) and duct plate (2). ※ Screens (3) to show upwards. ※ It is not permitted to reassemble the seal plate after opening the threaded joint shift unit/duct plate. In case of repair it is always necessary to mount a new seal plate.
Page 254 Mount stud bolts (1). ※ Wet screw-in thread with loctite (type No. 243). ·Tightening torque (M8/10.9×25) : 1.53 kgf·m (11.1 lbf·ft) Place seal (2) and duct plate (3) at the housing rear par t until contact is obtained. ※ 7609ATM391 Use assembly grease.
Page 255 Fix electro-hydraulic control unit (1) equally by means of Torx screws (2). ·Tightening torque (M6/10.9×76) : 3.06 kgf·m (22.1 lbf·ft) Socket wrench TX-27 5873 042 002 Reducing adapter 5870 656 056 7609ATM395 (2) (2) Lock-up clutch solenoid valve (5-speed Lock-up clutch solenoid valve (5-speed T/M) T/M) ①...
Page 256 Pipe - System pressure to lock-up Pipe - System pressure to lock-up clutch valve clutch valve ③ Fix pipes (1) with hollow screws (3) and O-rings and screw nut (2). Fit O-ring 13×2 on hollow screw (3), insert into eye of pipes, mount O-ring 18 ×2.5.
Page 257 ※ The opposite figure shows the following single parts : - Slightly oil the seal - Turn in the filter until contact with the sealing surface is obtained, and then tighten it by hand with approx. 1/3 to 1/2 rotation. ※...
Page 258 2. FRONT AXLE 2. FRONT AXLE 1) 1) DISASSEMBLY DISASSEMBLY (1) (1) Disassembly output and brake Disassembly output and brake ① Fix axle to assembly truck. Assembly truck 5870 350 000 Fixtures 5870 350 077 Clamping brackets 5870 350 075 Support 5870 350 125 ※...
Page 259 ③ Remove the breather valve (see arrow). ※ To avoid any damage, the breather valve must be removed when separating the output. 7609AAX004 ④ Secure the output with the lifting device and loosen hexagon screws. Then separate the output assy from the axle housing.
Page 260 ⑦ Use a lever to remove the cover from the output shaft. 7609AAX008 ⑧ Loosen locking screws and remove the releasing cover. 7609AAX009 ⑨ Press planetary carrier with a two-armed puller out of the profile of the output shaft. 7609AAX010 ⑩...
Page 261 ⑪ Pull the tapered roller bearing from the planetary carrier. Rapid grip 5873 014 016 Basic tool 5873 004 001 7609AAX012 ⑫ Disengage retaining ring. 7609AAX013 ⑬ Pull off planetary gear. 7609AAX014 ⑭ Lift the end plate out of the brake housing.
Page 262 ⑮ Lift the disk package out of the brake housing. 7609AAX016 Loosen hexagon screws, remove releasing cover and cup spring. 7609AAX017 Mount breather valve and press piston out of the brake housing by means of compressed air. 7609AAX018 If necessary, remove guide ring, back-up rings and grooved rings out of the annular grooves of the brake housing (see arrows).
Page 263 1 Brake housing 2 Guide ring 3 Back-up ring 4 Grooved ring 5 Grooved ring 6 Back-up ring 7 Slide ring seal 8 Output shaft 7609AAX020 Lift the brake housing from the output shaft by means of the lifting device. 7609AAX021 Use a lever to remove the slide ring seal from the brake housing.
Page 264 Use a lever to remove the slide ring seal from the output shaft. Resetting device 5870 400 001 7609AAX023 Pull the tapered roller bearing from the output shaft. Rapid grip 5873 014 013 Basic tool 5873 004 001 7609AAX024 3-208...
Page 265 (2) (2) Disassembly axle housing Disassembly axle housing ① Secure axle housing with the lifting device and loosen the hexagon screws. Then separate the axle housing from the axle drive housing. ※ Pay attention to releasing differential. 7609AAX025 ② Loosen the threaded connections and remove the releasing brake tube.
Page 266 (3) (3) Disassembly input Disassembly input ① Use the lifting device to lift the differential out of the axle drive housing. Load carrying fixture 5870 281 083 ※ Disassembly of the differential is described as of page 3-213. 7609AAX029 ② Pull the bearing outer ring (see arrow) out of the housing hole and remove the shim behind.
Page 267 ④ Heat slotted nut by means of hot air blower. ※ Slotted nut is secured with loctite (type No. : 262). 7609AAX033 ⑤ Loosen slotted nut and remove the shim behind. Slotted nut wrench 5870 401 139 Clamping device 5870 240 002 7609AAX034 ⑥...
Page 268 ⑧ Remove spacer ring and pull the tapered roller bearing from the input pinion. Gripping device AA00 684 425 Basic tool 5873 002 000 7609AAX037 ⑨ If necessary, force both bearing outer rings out of the axle drive housing. 7609AAX038 3-212...
Page 269 (4) (4) Disassembly differentials Disassembly differentials Disassembly hydraulic lock differential Disassembly hydraulic lock differential (option) (option) ① Remove axial roller cage (arrow). 7609AAX039 ② Pull both tapered roller bearings from the differential. Crown wheel side Crown wheel side Grab sleeve 5873 012 016 Basic tool 5873 002 001...
Page 270 ⑤ Remove single parts. 1 Pressure piece 2 Cage 3 Lever (12EA) 4 Disk carrier 5 Disk package 7609AAX043 ⑥ Preload differential by means of the press, loosen locking screws and housing cover. 7609AAX044 ⑦ Remove axle bevel gear with thrust washers from the differential housing.
Page 271 ⑨ Force out both differential axles (short) and remove the releasing spider gears with thrust washers from the differential housing. 7609AAX047 ⑩ Pull the differential axle (long) and remove the releasing spider gears with thrust washers from the differential housing. 7609AAX048 ⑪...
Page 272 Disassembly conventional differential Disassembly conventional differential (standard) (standard) ① Pull both tapered roller bearings from the differential. Grab sleeve 5873 012 016 Basic tool 5873 002 001 7609AAX051 ② Preload the differential by means of the press, loosen the hexagon screws and remove the releasing housing cover.
Page 273 ⑤ Force out both slotted pins. 7609AAX055 ⑥ Force out both differential axles (short) and remove the releasing spider gears with thrust washers from the differential housing. 7609AAX056 ⑦ Pull the differential axle (long) and remove the releasing spider gears with thrust washers from the differential housing.
Page 274 ⑨ Press crown wheel from the differential carrier. 7609AAX059 Disassembly limited slip differential Disassembly limited slip differential (option) (option) ① Pull both tapered roller bearings from the differential. Grab sleeve 5873 012 016 Basic tool 5873 002 001 7609AAX060 ② Preload the differential by means of the press, loosen locking screws and housing cover.
Page 275 ④ Remove spider shafts and axle bevel gears (see figure) out of the differential housing. 7609AAX063 ⑤ Remove the second axle bevel gear. 7609AAX064 ⑥ Lift the pressure ring out of the differential housing and remove the disk package and thrust washers behind. 7609AAX065 ⑦...
Page 276 (5) (5) Reassembly differentials Reassembly differentials Reassembly hydraulic lock differential Reassembly hydraulic lock differential (option) ① Mount two locating pins and press the heated crown wheel onto the differential housing until contact is obtained. Locating pins 5870 204 040 7609AAX067 ②...
Page 277 ⑤ Insert spider gears with thrust washers into the differential housing and fix them with the two spider shafts (short). ※ Thrust washers must be positioned with the tabs (see arrow 1) being located in the recesses of the differential housing. ※...
Page 278 ⑨ Mount two adjusting screws and insert the housing cover until contact with the differential housing is obtained. Locating pins 5870 204 040 Preload the differential by means of the press and bolt with new locking screws. ·Tightening torque (M16/12.9) : 40.8 kgf·m (295 lbf·ft) 7609AAX075 ⑩...
Page 279 ⑬ Preload disk package with an axial force of F = 50 Then check the setting dimension "A" = 1.05 ± 0.1 mm from the collar of the differential cover to the plane face of the outer disk (see also below sketch). Pressure piece 5870 100 069 Load cell...
Page 280 Preload the differential by means of the press and the pressure piece. Then finally tighten the housing cover with hexagon screws. ·Tightening torque (M14/10.9) : 18.9 kgf·m (136 lbf·ft) Pressure piece 5870 100 075 7609AAX083 Heat both tapered roller bearings and insert until contact is obtained.
Page 281 Reassembly conventional differential Reassembly conventional differential (standard) ① Mount two locating pins and press the heated crown wheel onto the differential housing until contact is obtained. Locating pins 5870 204 040 7609AAX086 ② Insert thrust washer into the differential housing. 7609AAX087 ③...
Page 282 ⑤ Insert spider gears with thrust washers into the differential housing and fix them with the two spider shafts (short). ※ Thrust washers must be positioned with the tabs (see arrow 1) being located in the recesses of the differential housing. ※...
Page 283 ⑨ Mount two adjusting screws and insert the housing cover until contact with the differential housing is obtained. Locating pins 5870 204 040 Preload the differential by means of the press and bolt with new locking screws. ·Tightening torque (M16/12.9) : 40.8 kgf·m (295 lbf·ft) 7609AAX094 ⑩...
Page 284 Reassembly limited slip differential Reassembly limited slip differential (option) ① Mount two locating pins and press the heated crown wheel onto the differential housing until contact is obtained. Locating pins 5870 204 040 7609AAX097 ② Insert thrust washer into the differential housing.
Page 285 ⑤ Insert the axle bevel gear until contact is obtained and install the inner disks with the teeth. 7609AAX101 ⑥ Preassemble the differential spider and insert it into the differential housing/into the pressure ring. 7609AAX102 ⑦ Mount second axle bevel gear. 7609AAX103 ⑧...
Page 286 ⑨ M o u n t o u t e r a n d i n n e r d i s k s i n alternating order, starting with an inner disk. The installation clearance of the internal parts is corrected by mounting outer disks with different thicknesses.
Page 287 ⑫ Fix the thrust washers into the housing cover by means of grease. 7609AAX108 ⑬ Mount two adjusting screws and insert the housing cover until contact with the differential housing is obtained. Locating pins 5870 204 040 Preload the differential by means of the press and bolt with new locking screws.
Page 288 (6) (6) Reassembly input Reassembly input ※ If crown wheel or input pinion are damaged, both parts must be jointly replaced. In case of a new installation of a complete bevel gear set pay attention to an identical mating number of input pinion and crown wheel.
Page 289 ③ Determine dimension III (bearing width). Dimension III e.g... . . 39.10 mm CALCULATION EXAMPLE “A„ : Dimension I ....221.10 mm Dimension II .
Page 290 ⑦ Heat the tapered roller bearing and insert it into the input pinion until contact is obtained. 7609AAX117 Setting of rolling torque of input pinion Setting of rolling torque of input pinion bearing bearing 0.15~0.41 0.15~0.41 kgf kgf·m m (1.11~2.95 (1.11~2.95 lbf lbf·ft ft) (without shaft seal) (without shaft seal)
Page 291 ⑪ Insert input flange and fix it by means of disk and slotted nut. ·Tightening torque : 122 kgf·m (885 lbf·ft) Slotted nut wrench 5870 401 139 Clamping device 5870 240 002 ※ Preliminarily mount slotted nut without loctite. 7609AAX121 While tightening rotate the input pinion While tightening rotate the input pinion several times in both directions.
Page 292 Determination of shims for setting of Determination of shims for setting of b e a r i n g r o l l i n g t o r q u e ( d i f fe r e n t i a l b e a r i n g r o l l i n g t o r q u e ( d i f fe r e n t i a l housing) and backlash (bevel gear set) housing) and backlash (bevel gear set)
Page 293 Insert the determined shim (e.g. s = 0.9 mm) into the hole of the axle housing and adjust the bearing outer ring (see arrow) until contact is obtained. 7609AAX127 Cover some drive and coast flanks of the crown wheel with marking ink. Then insert the premounted differential into the axle drive housing.
Page 294 Leakage test of lock Leakage test of lock Pressurize the lock (p = 1 bar), close shut-off valve and remove air line. No noticeable pressure loss is allowed No noticeable pressure loss is allowed to occur within 10 sec. to occur within 10 sec. ※...
Page 295 Reassembly of shaft seal (figure Reassembly of shaft seal (figure AX134~136) AX134~136) Loosen the slotted nut and pull the input flange from the input pinion. Slotted nut wrench 5870 401 139 Clamping device 5870 240 002 7609AAX134 Mount the shaft seal with the seal lip showing to the oil chamber.
Page 296 (7) (7) Reassembly axle housing Reassembly axle housing ① Grease O-ring (see arrow) and insert it into the axle housing. 7609AAX137 ② Mount two locating pins and bring the axle housing into contact position with the axle drive housing by using the lifting device.
Page 297 ⑤ M o u n t b ra ke t u b e w i t h t h r e a d e d connection and hexagon nut (see arrow). ·Tightening torque : 10.2 kgf·m (73.8 lbf·ft) 7609AAX141 ⑥ Provide screw plug with a new O-ring and fit it.
Page 298 (8) (8) Reassembly output and brake Reassembly output and brake ① Pull in wheel stud into the output shaft until contact is obtained. Wheel stud puller-basic tool 5870 610 001 Insert (M22 × 1.5) 5870 610 002 Special tool may only be used for repair solution when exchanging individual 7609AAX143 wheel studs with mounted output shaft.
Page 299 ④ Insert both bearing outer rings (see arrows) into the brake housing until contact is obtained. 7609AAX147 ⑤ Insert the premounted brake housing by means of the lifting device over the output shaft until contact is obtained. ※ Before clamping the seal rings (slide ring seal) to installation dimension, clean the sliding surfaces and apply an oil film.
Page 300 1 Brake housing 2 Guide ring 3 Back-up ring 4 Grooved ring 5 Grooved ring 6 Back-up ring 7 Slide ring seal 8 Output shaft 7609AAX151 ⑧ Flush-mount the slotted pins (6EA) into the holes of the piston. 7609AAX152 ⑨ Insert the piston into the brake housing and carefully install with the fixing device until contact is obtained.
Page 301 ⑩ Insert disk and cup spring with the convex side showing upwards into the piston. 7609AAX154 ⑪ Insert cover and fix it by means of hexagon screws. ·Tightening torque (M8/10.9) : 3.47 kgf·m (25.1 lbf·ft) 7609AAX155 ⑫ Mount outer and inner disks. ※...
Page 302 ⑭ Press stop bolt into the planetary carrier until contact is obtained. Stop bolt Planetary carrier 7609AAX158 ⑮ Insert the cylindrical roller bearing into the planetary gear – for this purpose press the cylindrical roller bearing through the packaging sleeve until the snap ring engages into the annular groove of the planetary gear.
Page 303 Wet front face (contact face bearing inner ring, arrow 1) and profile (teeth, arrow 2) in the output shaft with anti- corrosive agent. 7609AAX162 Align disk package centrally and radially. Then insert the planetary carrier by means of the lifting device into the teeth of the output shaft.
Page 304 1 Planetary carrier 2 Output shaft X Gap width 7609AAX166 Select the cover (optional) on the basis of the following table. Determined gap Offset to be used P/No. width (Delta) on the cover 0.13 ± 0.01 mm ZGAQ-04137 0.30~0.24 mm 0.239~0.18 mm 0.07 ±...
Page 305 Insert the cover into the output shaft until contact is obtained. 7609AAX170 Set the axial play of the sun gear shaft Set the axial play of the sun gear shaft 0.5~2.0 0.5~2.0 mm Deter mine dimension I, from the mounting face of the brake housing to the front face of the stop bolt.
Page 306 Measure dimension II, from the front face of the sun gear shaft to the mounting surface of the axle housing. Dimension II e.g... . . 17.15 mm Straightedge 5870 200 022 7609AAX174 CALCULATION EXAMPLE : Dimension I .
Page 307 Fix O-ring (see arrow) with grease into the countersink of the brake housing. 7609AAX177 Grease O-ring (see arrow) and install it to the axle housing. 7609AAX178 Mount two adjusting screws and use the lifting device to bring the output into contact position with the axle housing.
Page 308 Check brake hydraulics for leakages Check brake hydraulics for leakages ※ Before starting the test, completely breathe the brake hydraulics. Then pressurize the brake temporarily (5EA) with p = 100 bar max. High-pressure test : High-pressure test : Build up test pressure p = 100 bar max and close connection to HP pump via shut- 7609AAX181...
Page 309 4. REAR AXLE 4. REAR AXLE 1) 1) DISASSEMBLY - OUTPUT/BRAKE DISASSEMBLY - OUTPUT/BRAKE 1 Input 2 Output 3 Brake 4 Axle housing 5 Axle drive housing 7577AAXR001 ① Mount axle on assembly truck. ※ Special tool Assembly truck 5870 350 000 Supporting bracket (2EA) 5870 350 106 7577AAXR002 ②...
Page 310 Disassembly output assy/brake : For any replacement of components you can remove the output assy (with brake) as one unit. - In this context refer to work steps on page 3-255~264. - F i g u r e 7 5 7 7 A A X R 0 0 7 ~ 0 0 9 a n d assembly steps on page 3-268~272.
Page 311 ③ Remove stub shaft and sun gear shaft. ※ Pay attention to shim (placed in sun gear shaft) and mark allocation of shim to sun gear shaft and output side-assembly aid. ※ In certain cases the stub shaft/sun gear shaft could get stuck in the axle housing (gearing of axle bevel gear/differential).
Page 312 ⑦ Lift compl. planetary carrier out of brake housing. ※ Special tool Inner extractor 5870 300 019 Eye nut 5870 204 073 7577AAXR013 ⑧ Snap out retaining ring. ※ Special tool Set of external pliers 5870 900 015 7577AAXR014 ⑨ Pull off planetary gear.
Page 313 ⑩ Pull bearing inner ring off the planetary carrier. ※ Special tool Grab sleeve 5870 003 033 Basic tool 5870 003 001 7577AAXR016 ⑪ Take disc package out of brake housing. 7577AAXR017 ⑫ Loosen threaded joint. 7577AAXR018 ⑬ Remove lid, cup spring and disk. 7577AAXR019 3-257...
Page 314 ⑭ Lift piston off with lever. ※ Special tool Adjusting device 5 8 7 0 4 0 0 7577AAXR020 ⑮ Remove sealing elements (arrows - also refer to below sketch) from annular grooves of brake housing. 7577AAXR021 To the sketch : 1 Brake housing 2 Guide ring 3 Support ring...
Page 315 Lift brake housing off the output shaft by means of lifting device. ※ Special tool Lifting chain 5870 281 047 Eyebolts 5870 204 071 7577AAXR023 Remove screw neck (1) and breather valve (2). 7577AAXR024 Lift off shaft seal by lever and remove both bearing outer rings from brake housing - if required.
Page 316 Pull bearing inner ring from output shaft. ※ Special tool Rapid grip 5873 014 016 Basic tool 5873 004 001 7577AAXR026 If required - disassemble wear sleeve (arrow) of combi seal ring. 7577AAXR027 3-260...
Page 317 2) 2) REASSEMBLY - OUTPUT/BRAKE REASSEMBLY - OUTPUT/BRAKE 1 Planetary carrier 2 Brake housing 3 Disc package 4 Piston 5 Combi seal ring 6 Output shaft ※ Special tool Assembly truck 5870 350 000 7577AAXR028 Fixture 5870 350 112 Close apertures of oil supply holes with plugs.
Page 318 ② Apply sealing agent (Loctite no. 574) on contact faces of wear sleeve/output shaft and mount wear sleeve (part I/combi seal ring) considering installation dimension Y - see detailed sketch figure 7577AAXR031. ※ Special tool Pressing device 5870 506 172 7577AAXR032 (2) (2) Output shaft/brake housing...
Page 319 ④ Position preassembled brake housing on the output shaft. ※ Special tool Lifting chain 5870 281 047 Eyebolts 5870 204 071 7577AAXR036 ⑤ Insert sealing elements (arrows) into annular grooves of brake housing paying attention to installation position and arrangement - in this context refer to figure 7577AAXR028.
Page 320 ⑥ Flush - mount slotted pins (for installation position refer to arrow) into the piston if not disassembled, adjust adequately (flush-fitting). 7577AAXR039 ⑦ Oil sealing/sliding surface of piston and sealing elements (W - 10 oil). Carefully bring piston in contact position. 7577AAXR040 ⑧...
Page 321 ⑩ Mount heated bearing inner ring until contact. ※ Adjust bearing inner ring after cooling down. 7577AAXR043 ⑪ Apply anti-corrosive agent on spline (arrow-1). Only for assembly of a new planetary carrier or if disassembled : Insert shim (arrow-2) into planetary carrier until contact.
Page 322 ⑭ Evenly tighten locking screws crosswise - while rotating the brake housing in both directions several times (roller setting). ·Tightening torque (M18/12.9) : 51 kgf·m (369 lbf·ft) 7577AAXR047 ⑮ Apply a screw safety marking paint on correctly installed locking screws. 7577AAXR048 Mount O-ring (arrow) on lid.
Page 323 (3) (3) Brake Brake 1 Outer disc s = 2.0 mm 2 Outer disc s = 4.0 mm 3 Inner disc (lined disc) 4 End plate ※ Possible other versions could have a deviating equipment (number and arrangement of single discs), the illustration in the relating spare parts list fo r m s t h e b a s i s fo r t h e r e q u i r e d equipment.
Page 324 Only for assembly of new parts : Only for assembly of new parts : Install cylindrical roller bearing into planetary gear by pressing roller bearing into planetar y gear by means of assembly sleeve (arrow) until snap ring engages into annular groove of planetary gear.
Page 325 ① Determine dimension I from mounting face (brake housing/axle housing) to stop pin. Dimension I e. g ... 21.25 mm ※ Special tool Digital-depth gauge 5870 200 072 Gauge blocks 5870 200 066 Straightedge 5870 200 022...
Page 326 (5) (5) Reassemble output assy Reassemble output assy ① Fix disc package by means of locating screw - assembly aid. ※ Special tool Locating screw 5870 204 078 7577AAXR063 ② Oil O-ring and mount on collar of axle housing. 7577AAXR064 ③...
Page 327 ⑤ Connect output with axle housing evenly by means of hex screws. ·Tightening torque (M18x1.5/10.9) : 39.8 kgf·m (288 lbf·ft) 7577AAXR067 ⑥ Install screw plug (1) with new O-ring. ·Tightening torque (M24×1.5) : 5.1 kgf·m (36.9 lbf·ft) Mount breather valve (2). ·Tightening torque : 0.61 kgf·m (4.4 lbf·ft) Install screw neck (3) with new O-ring.
Page 328 (6) (6) Make leakage test on brake hydraulics Make leakage test on brake hydraulics Prior to starting the test, completely breathe brake hydraulics. High-pressure test : High-pressure test : Build up testing pressure p = 100 max and close connection to HP pump by means of a shutoff valve.
Page 329 3) 3) DISASSEMBLY - DIFFERENTIAL/INPUT DISASSEMBLY - DIFFERENTIAL/INPUT (1) (1) Differential Differential ① Mount axle on assembly truck. ※ Special tool Assembly truck 5870 350 000 Supporting bracket (2EA) 5870 350 106 7577AAXR002 ※ The following illustration shows the removal of the differential in the course of a complete disassembly of the axle.
Page 330 (2) (2) Input : Input : For axle version with pivot bearing only (figure 7577AAXR073) : ① Loosen bolted connection and pull off bearing flange. 7577AAXR073 ② Heat up hex nut (Loctite locking compound) by means of hot air blower. disassembly aid.
Page 331 ⑤ Lift shaft seal off. ※ Special tool Pry bar 5870 345 071 7577AAXR077 ⑥ Press input pinion out by means of press- off tool and remove releasing bearing inner ring. Special tool ※ Press-off tool 5870 280 044 7577AAXR078 ⑦...
Page 332 ⑨ Pull-off outside bearing outer ring. ※ Special tool Internal extractor 5870 300 019 Counter support 5870 300 020 7577AAXR081 ⑩ Force bearing outer ring out of inner bearing hole - pay attention to shim behind (contact pattern/bevel gear set). ※...
Page 333 4) 4) REASSEMBLY - INPUT / DIFFERENTIAL EASSEMBLY - INPUT / DIFFERENTIAL (1) (1) Input Input 1 Axle drive housing 2 Input pinion 3 Tapered roller bearing 4 Shim for contact pattern (bevel gear set) 5 Spacer ring (bearing roll.torque/pinion bearing) 6 Tapered roller bearing 7 Shaft seal...
Page 334 Determine shim for pinion position Determine shim for pinion position required to obtain an optimum contact required to obtain an optimum contact pattern on the bevel gear set (crown pattern on the bevel gear set (crown wheel/pinion) : wheel/pinion) : ②...
Page 335 ⑤ Determine dimension III bearing width, ensure here that the rollers are located without any play (rotate bearing inner ring in both directions several times - roller setting). Since the installed roller bearing is subject to a pre-load in installation position, deduct an experience value of -0.05 mm.
Page 336 ⑨ Mount heated bearing inner ring until contact position and adjust after cooling- down. 7577AAXR091 Set rolling torque of input pinion Set rolling torque of input pinion bearing 0.11~0.23 kgf bearing 0.11~0.23 kgf·m (without shaft m (without shaft seal) : seal) : ⑩...
Page 337 ⑫ Mount flange, fix with disc and hex nut. ※ While tightening - rotate pinion in both directions several times (roller setting). ·Tightening torque (M36×1.5) : 71.4 kgf·m (516 lbf·ft) ※ Special tool Clamping fork 5870 240 025 7577AAXR093 Check rolling torque of the pinion Check rolling torque of the pinion bearing.
Page 338 Contact pattern check of bevel gear Contact pattern check of bevel gear ⑭ Cover some tooth flanks of crown wheel with marking ink (contact pattern check). 7577AAXR095 ⑮ Insert pre-assembled differential. ※ Special tool Lifting bracket 5870 281 033 7577AAXR096 Position axle housing/crown wheel side (without O-ring) on axle drive housing.
Page 339 Roll input pinion over crown wheel in both directions (coast - drive flank meshing - contact pattern). ※ Special tool Clamping fork 5870 240 025 7577AAXR099 Disassemble differential. Compare contact pattern to examples – page 3-285. ※ If contact pattern differs considerably, use a suitable shim for correction (see figure 7577AAXR085, page 3-278).
Page 340 Remount differential - by mounting stub shaft into gearing of axle bevel gear (differential). ※ Special tool Lifting bracket 5870 281 033 7577AAXR103 Position axial roller ring on differential and fix by means of grease (assembly aid). 7577AAXR104 Oil O-ring (arrow) and mount it. Position complete axle half on the axle drive housing-by mounting the stub shaft into the gearing of the axle bevel gear...
Page 341 ※ BACKLASH CHECK ACKLASH CHECK Applied the paint (or red lead) on the surface of several bevel gear teeth. Turn the pinioin gear and check the contact pattern. Correct pattern Correct pattern WTHAX16 WTHAX17 Concave side Convex side ※ ADJUSTMENT DJUSTMENT Incorrect pattern : high contact Incorrect pattern : high contact...
Page 342 Incorrect pattern, low contact Incorrect pattern, low contact WTHAX21 WTHAX22 Concave side Convex side - Add the distance (+) ( ) + WTHAX23 3-286...
Page 343 SECTION 4 BRAKE AND FAN SYSTEM SECTION 4 BRAKE AND FAN SYSTEM Group 1 Structure and Function -------------------------------------------------------------------------------------- 4-1 Group 2 Operational Checks and Troubleshooting -------------------------------------------------------- 4-32 Group 3 Tests and Adjustments -------------------------------------------------------------------------------------- 4-39 Group 4 Disassembly and Assembly ------------------------------------------------------------------------------ 4-41...
Page 344: Group 1 Structure And Function
SECTION 4 BRAKE AND FAN SYSTEM SECTION 4 BRAKE AND FAN SYSTEM GROUP 1 STRUCTURE AND FUNCTION GROUP 1 STRUCTURE AND FUNCTION 1. OUTLINE 1. OUTLINE The variable displacement piston pump supplies the hydraulic oil that is required in order to operate the brake and the hydraulic fan system.
Page 345 FULL POWER HYDRAULIC BRAKE FULL POWER HYDRAULIC BRAKE SYSTEM SYSTEM ADVANTAGES ADVANTAGES - The full power hydraulic Response time Response time Full power brake actuation VS Full power brake actuation VS brake system has several advantages over Air/Hydraulic brake actuation Air/Hydraulic brake actuation traditional brake actuation systems.
Page 346 2. HYDRAULIC CIRCUIT 2. HYDRAULIC CIRCUIT Front Rear Parking Return line Return line Main pump 7609A4BS01 Fan & brake pump 20 Pressure switch 26 Oil cooler 15 Cut-off valve 21 Hydraulic tank 29 Fan motor 16 Accumulator 22 Air breather 30 Directional valve 17 Accumulator 23 Return filter...
Page 347 SERVICE BRAKE RELEASED SERVICE BRAKE RELEASED Front Rear Parking Return line Return line Main pump 7609A4BS02 When the pedal of brake valve (19) is released, the operating force is eliminated by the force of the spring, and the spool is returned. When the spool removes up, the drain port is opened and the hydraulic oil in the piston of axles return to the tank (21).
Page 348 SERVICE BRAKE OPERATED SERVICE BRAKE OPERATED Front Rear Parking Return line Return line Main pump 7609A4BS03 When the pedal of brake valve (19) is depressed, the operating force overcomes the force of the spring, and is transmitted to the spool. When the spool moves down, the inlet port is opened, and at the same time the hydraulic oil controlled the pressure level by the cut-off valve (15) enters the piston in the front and rear axles.
Page 349 PARKING BRAKE RELEASED PARKING BRAKE RELEASED Front Rear Parking brake switch Parking Return line Parking brake solenoid Return line Main pump 760F4BS04 When the parking brake switch is pressed A position, the solenoid valve is energized and the hydraulic oil controlled the pressure level by the cut-off valve enters the parking brake. It overcomes the force of the spring and pushes the piston rod.
Page 350 PARKING BRAKE OPERATED PARKING BRAKE OPERATED Front Rear Parking brake switch Parking Return line Parking brake solenoid Return line Main pump 760F4BS05 When the parking brake switch is pressed B position, the solenoid valve is deenergized and the valve open the drain port. At the same time, the hydraulic oil in the parking brake return to the tank through the solenoid valve.
Page 351 FAN MOTOR OPERATED FAN MOTOR OPERATED Front Rear Priority valve Parking Return line Return line Main pump 7609A4BS06 When the brake accumulators are fully charged, the priority valve switches position and the oil is directed to hydraulic fan motor through directional valve (30). The flow of the oil causes fan motor (29) to rotate the fan blade.
Page 352 DIRECTIONAL VALVE OPERATED DIRECTIONAL VALVE OPERATED Front Rear Priority valve Parking Return line Return line Main pump 760F4BS07 When the cooling fan reverse mode is selected manual or automatic mode, the solenoid valve in the directional valve (30) is energized and the flow of the oil is changed. The rotation of the fan is reversed to clear the radiators.
Page 353 3. FAN AND BRAKE PUMP 3. FAN AND BRAKE PUMP 1) 1) STRUCTURE STRUCTURE Hydraulic circuit VIEW A Port Port name Port size Delivery port SAE 3/4" Suction port SAE 1 1/4" L, L1, L2 Drain port 3/4-16UNF-2B 7609A4BS30 4-10...
Page 354 2) 2) OPERATION OPERATION 7609A4BS31 The pump is a variable displacement piston pump. This pump has a maximum delivery pressure of 250 kgf/cm . The axial piston type pump is used to supply oil flow to the cut off valve. The oil is pressurized by the movement of rotary group in the pump.
Page 355 4. BRAKE VALVE 4. BRAKE VALVE 1) 1) STRUCTURE STRUCTURE 75794BS07 Plug 15 Spacer 27 Boot Retainer 16 Retaining ring 28 Left pedal and base assy O-ring 17 Retainer 29 Sensor Spring 18 Shim 30 Washer Cap screw 19 Spring 31 Cap screw Washer 20 Spring...
Page 356 2) 2) OPERATION OPERATION Right pedal and base assy(opt) Left pedal and base assy Test connection Pressure switch Hydraulic circuit VIEW A - A Port Port name Port size P1, P2 Pressure port 3/4-16UNF T1, T2 Return port 3/4-16UNF A1, A2 Brake cylinder port 3/4-16UNF 75794BS08...
Page 357 (1) (1) Purpose Purpose The purpose of the brake valve is to sensitively increase and decrease the braking pressure when the brake pedal is actuated. (2) 2) Ready position Ready position When the braking system is ready for operation, its accumulator pressure acts directly on ports (P1, P2) of the brake valve.
Page 358 (7) (7) Maintenance of the brake valve Maintenance of the brake valve No special maintenance beyond the legal requirements is necessary. When using high-pressure cleaners on the machine, please make sure that the water jet is not aimed directly at the brake valve (to prevent damaging the bellows). For safety reasons the whole of the brake valve must be replaced if parts other than those For safety reasons the whole of the brake valve must be replaced if parts other than those listed above are damaged.
Page 359 5. CUT-OFF VALVE 5. CUT-OFF VALVE STRUCTURE STRUCTURE 1) 1) 7609A4BS32 Part name Port size P, PP SAE 3/4" PF 1/2 T1, S1, S2, S3, B1, B2, B3, G1 PF 3/8 PS, G2 PF 1/4 Hydraulic circuit Block Unload valve Fixed orifice with compensated Check valve 5-1 Solenoid valve...
Page 360 2) 2) OPERATION OPERATION The unloading valve (4) controls the minimum and maximum pressure of the braking system. When the service brake pressure is below the maximum pressure (125±5 bar), the unloading valve (4) is blocked and PS pilot pressure (brake priority pressure) increases. As soon as PS pilot pressure raises up above 15 bar, pump controller current is reduced by MCU (pressure sensor detects brake priority pressure, and pump supply flow and pressure in order to meet the brake system).
Page 361 6. BRAKE ACCUMULATOR 6. BRAKE ACCUMULATOR 1) 1) STRUCTURE STRUCTURE 31LL-40020 81L1-0003 Item (item17) (item16) Diameter 167 mm 138 mm Mounting height 219 mm 187 mm ℓ ℓ Norminal volume Priming pressure 50 kgf/cm 50 kgf/cm Operating medium Oil Operating pressure Max 210 kgf/cm Max 200 kgf/cm Thread M22×1.5...
Page 362 (4) (4) Maintenance of the accumulator 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) (5) Disposal of the accumulator Disposal of the accumulator...
Page 363 7. PRESSURE SENSOR AND SWITCH 7. PRESSURE SENSOR AND SWITCH STRUCTURE STRUCTURE 1) 1) - Normally closed Connector - Normally open Hex 22 10.8x2.4 7609A4BS12 2) 2) TECHNICAL DATA TECHNICAL DATA Adjusting range Actuating pressure Voltage Item Type Medium kgf/cm kgf/cm Parking 100 ±...
Page 364 2) 2) OPERATION OPERATION (1) (1) Purpose Purpose The pressure switches are used to visually or audibly warn the driver of the pressure within the system. Make contact / circuit closer Make contact / circuit closer (2) (2) 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.
Page 365 8. PARKING BRAKE SYSTEM 8. PARKING BRAKE SYSTEM 1) 1) STRUCTURE STRUCTURE 7609A4BS21 Housing Piston 11 Adjusting screw Pressure ring Lining pad 12 Lining spring Pressure bolt Lining pad 13 Counter nut Setting screw Guiding pin Plate spring pack 10 Rubber buffer 4-22...
Page 366 2) 2) OPERATION OPERATION The two identical lining pads (7, 8) slide on the guide surfaces on the top of the housing and are held in position by a lining spring (12). The brake itself is directly fixed on the gearbox with the two guide pins (9).
Page 367 3) 3) FITTING AND SETTING INSTRUCTIONS FITTING AND SETTING INSTRUCTIONS 7609A4BS22 Lock nut Screw cap Piston Setting screw Pressure bolt 10 Spring pack Adjusting screw Guiding bolt Counter nut Bleeding screw ※ The fitting or adjusting must always be carried out when the brake is cold. The fitting or adjusting must always be carried out when the brake is cold.
Page 368 (2) (2) Clearance adjusting Clearance adjusting ① Insert a setting gauge on both sides between the brake lining carrier and brake disc and hold them in position. ※ The thickness of the setting gauge must be adjusted to the desired air gap. The thickness of the setting gauge must be adjusted to the desired air gap.
Page 369 (3) (3) Adjusting instructions Adjusting instructions ① Place the machine on flat ground and secure against rolling away. ② Release the parking brake by application of the required release pressure (min. 130 bar). ③ Rotate the screw cap (5) in a counter-clockwise direction and unscrew it. ④...
Page 370 4) 4) EMERGENCY RELEASE OF THE PARKING BRAKE EMERGENCY RELEASE OF THE PARKING BRAKE In the event of a failure in pressure supply the parking brake can be released mechanically in the following way : 7609A4BS23 Lock nut Peg spanner Setting screw Ring spanner Screw cap...
Page 371 5) 5) MAINTENANCE AND REPAIR WORK MAINTENANCE AND REPAIR WORK Maintenance and replacement of the lining pads Maintenance and replacement of the lining pads (1) (1) The brake, particularly the brake lining carriers, must be visually inspected at regular intervals. If the remaining lining thickness is too thin, these intervals must be reduced accordingly to prevent extensive damage to the brake or the brake disc.
Page 372 7609A4BS25 Counter nut Lining pad Adjusting screw Lining spring Lining pad ⑦ Release the counter nut (1) and unscrew the adjusting screw (2) from the brake housing. ※ The lining spring (5) is pre-tensioned. The lining spring (5) must be held in position with a The lining spring (5) is pre-tensioned.
Page 373 (2) (2) Replacing the seals Replacing the seals 7609A4BS26 Piston Circlip Plate spring pack Setting screw Sealring 10 Dust protection cap Lock nut Pressure ring Detail sealring Housing Pressure bolt Detail sealring Leaking seals must be replaced in accordance with the following instructions : ①...
Page 374 ※ Observe the fitting direction of the grooved rings and use a suitable fitting needle with Observe the fitting direction of the grooved rings and use a suitable fitting needle with rounded edges to fit the new grooved rings. Take care - there is a danger of injury. rounded edges to fit the new grooved rings.
Page 375: Group 2 Operational Checks And Troubleshooting
GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING 1. OPERATIONAL CHECKS 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 structure and function, Group 1.
Page 376 ※Hydraulic oil must be at operating temperature for these checks (refer to page 6-55). Item Description Service action Parking brake capacity Parking brake capacity Start engine. check check Check completed. Fasten seat belt. Seat belt must be worn NOT OK NOT OK while doing this check to Release parking brake and put...
Page 377 Item Description Service action Service brake pump flow Service brake pump flow Stop engine. check check Check completed. Operate brake pedal approximately ※ Hydraulic oil must be at 20 times. NOT OK NOT OK operating temperature Start engine and run at low idle. Check for brake circuit for the check.
Page 378 Item Description Service action Brake accumulator Brake accumulator S t a r t a n d r u n e n g i n e fo r 3 0 precharge check precharge check seconds. Check completed. ※The axles and hydraulic Stop engine and turn start switch to NOT OK NOT OK...
Page 379 Item Description Service action S e r v i c e b ra ke p e d a l S e r v i c e b ra ke p e d a l Slowly depress brake pedal. check check Check completed.
Page 380 2. TROUBLESHOOTING 2. TROUBLESHOOTING 1) 1) SERVICE BRAKE 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.
Page 381 Problem Cause Remedy Brakes chatter Brakes chatter Air in brake system. Do brake bleed procedure. Worn brake surface material. Inspect brake surface material. Wrong oil in differential. Drain.Refill. H i s s i n g n o i s e w h e n H i s s i n g n o i s e w h e n Leakage in brake valve, or brake Do brake system leakage test.
Page 382: Group 3 Tests And Adjustments
GROUP 3 TESTS AND ADJUSTMENTS GROUP 3 TESTS AND ADJUSTMENTS 1. PARKING BRAKE PERFORMANCE 1. PARKING BRAKE PERFORMANCE 1) 1) MEASUREMENT CONDITION EASUREMENT CONDITION Tire inflation pressure : Specified pressure Road surface : Flat, dry, paved surface with 1/5 (11˚ ) gradient.
Page 383 3. HYDRAULIC BRAKE BLEEDING PROCEDURE 3. HYDRAULIC BRAKE BLEEDING PROCEDURE E s c a p i n g f l u i d u n d e r p r e s s u r e c a n E s c a p i n g f l u i d u n d e r p r e s s u r e c a n penetrate the skin causing serious injury.
Page 384: Group 4 Disassembly And Assembly
GROUP 4 DISASSEMBLY AND ASSEMBLY GROUP 4 DISASSEMBLY AND ASSEMBLY 1. FAN AND BRAKE PUMP 1. FAN AND BRAKE PUMP STRUCTURE STRUCTURE 1) 1) 1-110 1-102 1-106 1-101 1-109 1-104 1-107 1-111 7609A4BS11 1-1 Rotary group Pump housing 20 Shaft seal ring 1-101 Piston Port plate 21 O-ring...
Page 385 2) 2) GENERAL REPAIR GUIDELINES GENERAL REPAIR GUIDELINES ※ Observe the following guidelines when carrying out repairs on hydraulic pumps. Close off all openings of the hydraulic unit. Replace all of the seals. Use only original spare parts. Check all sealing and sliding surfaces for wear.
Page 386 ※ Change the shaft seal and check its sliding surface (drive shaft) and housing, grease the sealing ring. Visual check shaft seal and housing. 73096WE62 Assembling of the sealing ring carefully Ø25 m down to the stop ring. Ø34 mm 7609A4BS28 Assemble the retaining ring (circlip).
Page 387 Measure dimension A and note down. Check sealing surface (1). Replace gasket (2). 7609A6WE100 Assemble control valve. Tighten the bolts. ·Tightening torque : 1.58 kgf·m (11.4 lbf·ft) 73096WE66 Check dimension A. 7609A6WE101 5) 5) INSPECT HINTS INSPECT HINTS Renew all bearings. 75796WE79 4-44...
Page 388 Check : Wear on splines, rust Drive shaft seal wear grooves Bearing seat Splines for cylinder drive Bearing seat 75796WE80 Check : Sliding surface free of grooves. 75796WE81 Check : Bearing surfaces. 75796WE82 Check : That the retaining plate is free of grooves and that there is no wear in the slipper pad area.
Page 389 Check : Check to see that there are no scratches or metal deposits on the sliding surface (1) and that there is no axial play (2) (Pistons must only be replaced as a set). 75796WE84 Check : Cylinder bores Splines 75796WE85 Free of grooves, no signs of wear.
Page 390 2. FAN MOTOR 2. FAN MOTOR 1) 1) STRUCTURE STRUCTURE 1-104 1-107 1-111 1-110 1-102 1-106 1-101 1-109 7609A4BS20 1-1 Rotary group 1-2 Control plate 18 Bearing bushing 1-101 Piston Motor housing 20 Shaft seal 1-102 Cylinder Port plate 22 O-ring 1-104 Retaining plate Cam plate (swash plate) 25 Retaining ring (circlip)
Page 391 2) 2) SEALING THE DRIVE SHAFT SEALING THE DRIVE SHAFT Circlip Shaft seal 7609A4BS31 Remove key. Protect the drive shaft. Remove the circlip. 7609A4BS32 Change the shaft seal and check its sliding surface (drive shaft) and housing, grease the sealing ring. 7609A4BS33 Use installation tool or plastic strip for assembling seal.
Page 392 Use a suitable pipe to mount the shaft seal, but don't push it too deep. If the shaft ring touches the bearing ring you will damage the seal ring. 7609A4BS35 Assemble the circlip. 7609A4BS36 Assemble the circlip in the correct position.
Page 393 3) 3) DISASSEMBLE THE MOTOR DISASSEMBLE THE MOTOR Disassembly position. Mark the location of the port plate on the housing. 7609A4BS38 Remove the por t plate fixing bolts crosswise. 7609A4BS39 Remove the port plate. ※ Control plate can drop down-hold tight. 7609A4BS40 4-50...
Page 394 Remove control plate. 7609A4BS41 R e m o ve b e a r i n g o u t e r r i n g w i t h withdrawal tool. Do not damage the sealing surface. 7609A4BS42 Disassemble the taper roller bearing (near by port plate).
Page 395 Remove the rotary group in a horizontal position. 7609A4BS44 Remove the drive shaft to rear side. 7609A4BS45 Remove swash plate with special tool (see the next figure). 7609A4BS46 (10) Loosen the swash plate with a slide hammer (a small hook - diameter 6 mm - catches the end of the swash plate at the bottom).
Page 396 (11) Press down bearing. 7609A4BS48 (12) The external front bearing ring is pulled out of the pump housing. 7609A4BS49 (13) Disassemble circlip and shaft seal. 7609A4BS50 4-53...
Page 397 (14) Remove shaft seal and shim. 7609A4BS51 (15) Pre-tension the spring using a suitable device. 7609A4BS52 (16) Remove circlip. Remove spring and pressure pins. 7609A4BS53 4-54...
Page 398 4) 4) INSPECTION HINTS INSPECTION HINTS Check to see that there are no scratches or metal deposits on the sliding surface (1), and that there is no axial play (2), (pistons must only be replaced as a set). 7609A4BS54 Check cylinder bores (1) and splines (2). 7609A4BS55 Free of grooves, no signs of wear.
Page 399 M o u n t i n g s u r fa c e - c o n t r o l p l a t e undamaged. 7609A4BS58 5) 5) MOTOR ASSEMBLY MOTOR ASSEMBLY Fit the circlip into the housing. 7609A4BS59 Assemble shaft seal and shim against circlip.
Page 400 Press outer bearing ring into housing. Shaft seal with pre-assembled bearing into housing. ※ Protect splines of the shaft with plastic strip against damage of the seal lip. 7609A4BS62 Assemble swash plate. 7609A4BS63 Fit pressure pins using an assembly aid. 7609A4BS64 4-57...
Page 401 Pre-tension the spring using a suitable device. 7609A4BS65 7609A4BS66 Assemble piston with retaining plate. ※ Oil piston and slipper pad. 7609A4BS67 4-58...
Page 402 Fit rotary group. ※ Assembly aid : Hold the pistons by using an O-ring. 7609A4BS68 (10) Fit bearing (1) in port plate. Fit cyilindrical pin (2). Fit O-ring (3). Fit control plate (4). ※ Assembly : Hold the components in place with grease.
Page 403 (11) Fit control plate. Assembly aid : Grease 7609A4BS70 (12) Fit the port plate and fix it with the bolts crosswise. 7609A4BS71 4-60...
Page 404: Section 5 Steering System
SECTION 5 STEERING SYSTEM SECTION 5 STEERING SYSTEM Group 1 Structure and Function ---------------------------------------------------------------------------------- 5-1 Group 2 Operational Checks and Troubleshooting ---------------------------------------------------- 5-13 Group 3 Tests and Adjustments ----------------------------------------------------------------------------------- 5-21 Group 4 Disassembly and Assembly -------------------------------------------------------------------------- 5-28...
Page 405: Group 1 Structure And Function
SECTION 5 STEERING SYSTEM SECTION 5 STEERING SYSTEM GROUP 1 STRUCTURE AND FUNCTION GROUP 1 STRUCTURE AND FUNCTION 1. OUTLINE 1. OUTLINE The steering system of this machine consists of a variable displacement piston pump supplying a load sensing steering system and an closed center loader system. The components of the steering system are : ·Steering pump ·Steering valve (EHPS)
Page 406 2. HYDRAULIC CIRCUIT 2. HYDRAULIC CIRCUIT ELECTRONICS Return line Fan & brake pump 760F5SE01 Main pump (steering) 14 Steering cylinder 28 Pressure sensor Steering unit 21 Hydraulic tank 31 Motor pump (option) Accumulator 22 Air breather 32 Check block (option) Steering valve (EHPS) 23 Return filter 33 Pressure sensor (option)
Page 407 NEUTRAL NEUTRAL ELECTRONICS Return line Fan & brake pump 760F5SE02 The steering wheel is not being operated so control spool (G) does not move. · The oil from the steering pump enters port P of the priority valve in steering valve (EHPS) and the ·...
Page 408 LEFT TURN LEFT TURN ELECTRONICS Priority valve Return line Fan & brake pump 760F5SE03 · When the steering wheel is turned to the left, the pressure oil from the steering unit fill on the left side chamber of main steering spool (M), and main steering spool moves to the right in the direction. ·...
Page 409 RIGHT TURN RIGHT TURN ELECTRONICS Priority valve Return line Fan & brake pump 760F5SE04 · When the steering wheel is turned to the right, the pressure oil from the steering unit fill on the right side chamber of main steering spool (M), and main steering spool moves to the left in the direction. ·...
Page 410 3. STEERING VALVE 3. STEERING VALVE (EHPS ; Electro Hydraulic Power Steering) STRUCTURE STRUCTURE The main spool in the steering valve (EHPS) can either be activated by the pilot unit or by the joy- stick selected through the shuttle valves on each end of the main spool. Joystick steering(opt) Joystick Joystick steering(opt)
Page 411 2) 2) OPERATION OPERATION Neutral Neutral Shock valves Suction valves Pressure reducing valve 7607SE12 · In neutral position, the oil will pass from the pump across the integrated priority valve (18) in the steering valve for discharge through the EF port. When the steering unit is in neutral, flow through it is blocked and all flow through the priority valve (18) in steering valve is directed out the EF port and passed to the main control valve.
Page 412 (2) (2) Turning left Turning left Shock valves Suction valves Pressure reducing valve 7607SE13 · When the steering wheel is turned to the left, the pressure oil from the steering unit fill on the left side chamber of main steering spool (15), and main steering spool (15) moves to the right in the direction.
Page 413 (3) (3) Turning right Turning right Shock valves Suction valves Pressure reducing valve 7607SE14 · When the steering wheel is turned to the right, the pressure oil from the steering unit fill on the right side chamber of main steering spool (15), and main steering spool (15) moves to the left in the direction.
Page 414 (4) (4) Pressure reducing valves Pressure reducing valves 7607SE15 · Pressure reducing valve is a valve, which is supplying pilot oil to steering unit. That is one of advantage of steering system adopting steering valve. · Pressure reducing valves are pressure-limiting devices that limit pressure in one portion of a circuit while leaving system pressure unaffected.
Page 415 4. STEERING UNIT 4. STEERING UNIT STRUCTURE STRUCTURE 1) 1) SECTION A - A 7607SE17 Bearing Gear wheel Spool Neutral position spring Gear rim 10 Check valve Cross pin Sleeve 11 Distributor plate Housing Cardan shaft 12 End cover 2) 2) OPERATION OPERATION The steering unit consists of a rotary valve and a rotary meter.
Page 416 6. STEERING CYLINDER 6. STEERING CYLINDER 1) 1) STRUCTURE STRUCTURE 757F5SE05 Tube assembly 10 O-ring 19 Spherical bearing Rod assembly 11 Back up ring 20 Retaining ring Gland 12 O-ring 21 O-ring Dust wiper 13 Piston 22 Hexagon socket plug Retaining ring 14 Piston seal 23 Check valve...
Page 417: Group 2 Operational Checks And Troubleshooting
GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING 1. OPERATIONAL CHECKS 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.
Page 418 ※ Hydraulic oil must be at operating temperature for these checks (refer to page 6-55). Item Description Service action Steering unit check Steering unit check Run engine at low idle. Check completed. Turn steering wheel until frames are at maximum right (A) and then left NOT OK NOT OK (B) positions.
Page 419 2. TROUBLESHOOTING 2. TROUBLESHOOTING ※ Diagnose malfunction charts are arranged from most probable and simplest to verify, to least likely, more difficult to verify. Remember the following steps when troubleshooting a problem : Step 1. Operational check out procedure (see group 3 in section 1) Step 2.
Page 420 Problem Cause Remedy Slow or hard steering Slow or hard steering Too much friction in the mechanical Lubricate bearings and joints of steering parts of the machine. column or repair if necessary. Check steering column installation. Cold oil. Warm the hydraulic oil. Low priority valve pressure setting.
Page 421 Problem Cause Remedy Erratic steering Erratic steering Air in oil. Check for foamy oil. Low oil level. Add recommended oil. Sticking priority valve spool. Remove and inspect spool. Loose cylinder piston. Remove rod to inspect piston. Damaged steering unit. Remove and inspect. Spongy or soft steering Spongy or soft steering Air in oil.
Page 422 Problem Cause Remedy "Motoring" effect. "Motoring" effect. Leaf springs are stuck or broken and Replace leaf springs. The steering wheel can The steering wheel can have therefore reduced spring force. turn on its own. turn on its own. Inner and outer spools pinch, possibly Clean steering unit or contact the due to dirt.
Page 423 Problem Cause Remedy Backlash Backlash Cardan shaft fork worn or broken. Replace cardan shaft. Leaf springs without spring force or broken. Replace leaf springs. Worn splines on the steering column. Replace steering column. "Shimmy" effect. The "Shimmy" effect. The Air in the steering cylinder. Bleed cylinder.
Page 424 Problem Cause Remedy H e a v y k i c k - b a c k i n H e a v y k i c k - b a c k i n Wrong setting of cardan shaft and gear- Correct setting as shown in this manual.
Page 425: Group 3 Tests And Adjustments
GROUP 3 TESTS AND ADJUSTMENTS GROUP 3 TESTS AND ADJUSTMENTS 1. HYDRAULIC OIL CLEAN UP PROCEDURE USING PORTABLE FILTER CADDY 1. HYDRAULIC OIL CLEAN UP PROCEDURE USING PORTABLE FILTER CADDY ※ Service equipment and tool. ·Portable filter caddy ·Two 3658 mm (12 ft) × 1" I.D. 100R1 hoses with 3/4 M NPT ends ·Quick disconnect fittings ·Discharge wand...
Page 426 Start the filter caddy. Check to be sure oil is flowing through the filters. Operate filter caddy approximately 10 min- utes so oil in hydraulic oil tank is circulated through filter a minimum of four times. ※ Hydraulic oil tank capacity 110ℓ(29.1 U.S.
Page 427 2. TEST TOOLS 2. TEST TOOLS 1) 1) CLAMP-ON ELECTRONIC TACHOMET- CLAMP-ON ELECTRONIC TACHOMET- ER INSTALLATION ER INSTALLATION · Service equipment and tools Tachometer A : Clamp on tachometer. Remove paint using emery cloth and connect to a straight section of injec- tion line within 100 mm (4in) of pump.
Page 428 3. STEERING SYSTEM RESTRICTION TEST 3. STEERING SYSTEM RESTRICTION TEST · SPECIFICATION SPECIFICATION Oil temperature 45±5˚C (113±9˚F) Engine speed High idle Maximum pressure 4.5MPa (45 bar, 640psi) at steering valve (EHPS) · GAUGE AND TOOL GAUGE AND TOOL Gauge 0~7 MPa (0~70 bar, 0~1000 psi) 2EA ·...
Page 429 4. STEERING UNIT LEAKAGE TEST 4. STEERING UNIT LEAKAGE TEST · SPECIFICATION SPECIFICATION 45 ± 5˚C (113 ± 9˚F) Oil temperature Engine speed High idle Cap fitting Maximum leakage 7.5ℓ/min (2 gpm) · GAUGE AND TOOL GAUGE AND TOOL Temperature reader Measuring container (approx.
Page 430 5. 5. STEERING VALVE STEERING VALVE (EHPS) PRESSURE TEST PRESSURE TEST · SPECIFICATION SPECIFICATION 45 ± 5˚C (113 ± 9˚F) Oil temperature Engine speed High idle 24.5 ± 0.05 MPa Oil pressure (250 ± 5 bar, 3560 ± 71 psi) ·...
Page 431 6. STEERING VALVE 6. STEERING VALVE (EHPS) RELIEF RELIEF CARTRIDGE LEAKAGE TEST CARTRIDGE LEAKAGE TEST · SPECIFICATION SPECIFICATION 45 ± 5˚C (113 ± 9˚F) Oil temperature Relief valve Engine speed High idle Maximum leakage 1mℓ/min (16 drops per min) · GAUGE AND TOOL GAUGE AND TOOL Temperature reader...
Page 432: Group 4 Disassembly And Assembly
GROUP 4 DISASSEMBLY AND ASSEMBLY GROUP 4 DISASSEMBLY AND ASSEMBLY 1. STEERING UNIT 1. STEERING UNIT 1) 1) STRUCTURE STRUCTURE 7607SE10 Dust seal Ring 15 Gearwheel set Housing, spool, sleeve Cross pin 17 End cover Ball 11 Cardan shaft 18 Washer Thread bushing 12 Set of springs 20 Screw with pin...
Page 433 TOOLS TOOLS Holding tool + Guide ring 7607SE08 Assembly tool for O-ring and kin-ring. 7607SE09 Assembly tool for lip seal. (780-3A) 5-69(3) Assembly tool for cardan shaft. (780-3A) 5-69(4) 5-29...
Page 434 Assembly tool for dust seal. (780-3A) 5-70(1) Torque wrench 0~7.1 kgf·m (0~54.4 lbf·ft) 13 mm socket spanner 6, 8 mm and 12 mm hexagon sockets 12 mm screwdriver 2 mm screwdriver 13 mm ring spanner 6, 8 and 12 mm hexagon socket spanners Plastic hammer (780-3A) 5-70(2) Tweezers...
Page 435 3) 3) TIGHTENING TORQUE AND HYDRAULIC CONNECTIONS TIGHTENING TORQUE AND HYDRAULIC CONNECTIONS Hydraulic connections Hydraulic connections (1) (1) L : Left port R : Right port T : Tank T L P R P : Pump (780-3A) 5-71 (2) (2) Tightening torque Tightening torque Max.
Page 436 4) 4) DISASSEMBLY DISASSEMBLY Disassemble steering column from steering unit and place the steering unit in the holding tool. Screw out the screws in the end cover (6- off plus one special screw). (780-3A) 5-72(1) Remove the end cover, sideways. (780-3A) 5-72(2) Lift the gearwheel set (with spacer if fitted) off the unit.
Page 437 Remove distributor plate. (780-3A) 5-73(1) Screw out the threaded bush over the check valve. (780-3A) 5-73(2) Remove O-ring. (780-3A) 5-73(3) Take care to keep the cross pin in the sleeve and spool horizontal. The pin can be seen through the open end of the spool.
Page 438 Take ring, bearing races and needle bearing from sleeve and spool. The outer (thin) bearing race can sometimes "stick" in the housing, therefore check that it has come out. (780-3A) 5-74(1) (10) Press out the cross pin. Use the special screw from the end cover.
Page 439 (12) Press the neutral position springs out of their slots in the spool. (780-3A) 5-75(1) (13) Remove dust seal and O-ring. (780-3A) 5-75(2) (14) The steering unit is now completely disassembled. (780-3A) 5-75(3) ※ Cleaning Clean all parts carefully in Shellsol K or the like.
Page 440 Place the two flat neutral position springs in the slot. Place the curved springs between the flat ones and press them into place. 7607SE06 Line up the spring set. (780-3A) 5-76(4) Assemble the spool/sleeve and make sure the marks on spool and sleeve are opposite each other (see drawing page 5-36).
Page 441 Line up the springs and center them. (780-3A) 5-77(3) Guide the ring down over the sleeve. ※ The ring should be able to move-free of the springs. (780-3A) 5-77(4) Fit the cross pin into the spool / sleeve. (780-3A) 5-78(1) Fit bearing races and needle bearing.
Page 442 ※ Assembly pattern for standard bearings Outer bearing race Needle bearing Inner bearing race Spool Sleeve The inside chamfer on the inner bearing race must face the inner spool. 7607SE07 Installation instruction for O-ring Turn the steering unit until the bore is horizontal.
Page 443 (11) Hold the outer part of the assembly tool in the bottom of the steering unit housing and guide the inner part of the tool right to the bottom. (780-3A) 5-79(3) (12) Press and turn the O-ring into position in the housing.
Page 444 (780-3A) 5-80(3) (15) Guide the assembly tool right to the bottom. (780-3A) 5-80(4) (16) Press and turn the lip seal into place in the housing. (780-3A) 5-81(1) (17) With a light turning movement, guide the spool and sleeve into the bore. ※...
Page 445 (18) The spool set will push out the assembly tool guide. The O-ring are now in position. (780-3A) 5-81(3) (19) Turn the steering unit until the bore is vertical again. Put the check valve ball into the hole indicated by the arrow. (780-3A) 5-81(4) (20) Screw the threaded bush lightly into the...
Page 446 (22) Place the distributor plate so that the channel holes match the holes in the housing. (780-3A) 5-82(3) (23) Guide the cardan shaft down into the bore so that the slot is parallel with the connection flange. (780-3A) 5-82(4) (24) Place the cardan shaft as shown - so that it is held in position by the mounting fork.
Page 447 (26) (26) Important Important Fit the gearwheel (rotor) and cardan shaft so that a tooth base in the rotor is positioned in relation to the shaft slot as shown. Turn the gear rim so that the seven through holes match the holes in the housing.
Page 448 (30) Fit the six screws with washers and insert them. Cross-tighten all the screws and the rolled pin. ·Tightening torque : 3.1±0.6 kgf·m (22.4±4.3 lbf·ft) (780-3A) 5-84(3) (31) Place the dust seal ring in the housing. (780-3A) 5-84(4) (32) Fit the dust seal ring in the housing using special tool and a plastic hammer.
Page 449 2. STEERING CYLINDER 2. STEERING CYLINDER 1) 1) STRUCTURE STRUCTURE Tube assembly 10 O-ring 19 Spherical bearing Rod assembly 11 Back up ring 20 Retaining ring Gland 12 O-ring 21 O-ring Dust wiper 13 Piston 22 Hexagon socket plug Retaining ring 14 Piston seal 23 Check valve Rod seal...
Page 450 2) 2) TOOLS AND TIGHTENING TORQUE TOOLS AND TIGHTENING TORQUE (1) (1) Tools Tools Tool name Remark Wrench For gland (-) Driver Small and large sizes Torque wrench Capable of tightening with the specified torques (2) (2) Tightening torque Tightening torque Torque Part name Item...
Page 451 3) 3) DISASSEMBLY DISASSEMBLY (1) (1) Remove cylinder head and piston rod Remove cylinder head and piston rod ① Hold the clevis section of the tube in a vise. ※ Use mouth pieces so as not to damage the machined surface of the cylinder tube.
Page 452 ※ 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. ⑤ Place the removed piston rod assembly on a wooden V-block that is set level.
Page 453 (3) (3) Disassemble the piston assembly Disassemble the piston assembly ① Remove wear ring (15) and piston seal (14). Remove O-ring (16). ※ Exercise care in this operation not to damage the grooves. 76095SE23 (4) (4) Disassemble gland assembly Disassemble gland assembly ①...
Page 454 4) 4) ASSEMBLY ASSEMBLY Assemble gland assembly Assemble gland assembly ※ Check for scratches or rough surfaces if found smooth with an oil stone. ① Coat the inner face of gland (3) with hydraulic oil. 7577ASE34 ② Coat dust wiper (4) with grease and fit Press here(Straight down) dust wiper (4) to the bottom of the hole of Metal...
Page 455 ⑤ Fit back up ring (11) to gland (3). ※ Put the back up ring in the warm water of 11,10 30~50˚C. ⑥ Fit O-ring (10, 12) to gland (3). ⑦ Fit bushing (9) to gland (3). 76095SE25 Assemble piston assembly Assemble piston assembly ※...
Page 456 (3) (3) Install piston and gland assembly Install piston and gland assembly ① Fix the piston rod assembly to the work Grand assembly Piston rod bench. ② Apply hydraulic oil to the outer surface of piston rod (2), the inner surface of piston and gland (3).
Page 457 3. CENTER PIVOT PIN 3. CENTER PIVOT PIN 1) 1) CONSTRUCTION CONSTRUCTION Figure shows the construction of the center pivot pin assembly. This assembly serves to connect the front frame with the rear frame; two sets of assemblies are provided, one each for the upper and lower parts.
Page 458 2) 2) DISASSEMBLY DISASSEMBLY After supporting the front frame and the rear frame as horizontally as possible using wood blocks and jacks, disassemble as fo l l o w s : I n o r d e r t o fa c i l i t a t e t h e disassembly/assembly of the center pivot pins, remove the drive shaft, hydraulic line and steering cylinder first.
Page 459 Remove bolt (19), washer (20) and then UPPER take out cover (2) and shims (4, 5). 19,20 Take out dust seal (13) from the cover (2). (10) Remove the bearing (1), and dust seal (13). 75795SE16 (11) Remove bolt (19), washer (20) and then LOWER take out cover (17, 18) and shims (4, 5).
Page 460 4) 4) ASSEMBLY ASSEMBLY 19,20 19,20 Clearance A 14,15,27 Clearance B 23,24 UPPER UPPER LOWER 75795SE31 Assemble the center pivot group by reversing the order of disassembly while paying close attention to the following. Put the dust seal (12,13) into cover (2, 3, 17, 18). ※...
Page 461 Apply grease to lower collar (8) and insert it to the lower of roller bearing. After setting the bearing so that its upper surface is horizontal, tighten the all the bolt (19). After tightening, confirm that tapered roller bearing moves lightly ; if does not move smoothly, add shims (4, 5).
Page 462: Section 6 Work Equipment
SECTION 6 WORK EQUIPMENT Group 1 Structure and Function ----------------------------------------------------------------------------------- 6-1 Group 2 Operational Checks and Troubleshooting ----------------------------------------------------- 6-41 Group 3 Tests and Adjustments ----------------------------------------------------------------------------------- 6-52 Group 4 Disassembly and Assembly --------------------------------------------------------------------------- 6-64...
Page 463: Group 1 Structure And Function
SECTION 6 WORK EQUIPMENT GROUP 1 STRUCTURE AND FUNCTION 1. HYDRAULIC SYSTEM OUTLINE The loader hydraulic system is a pilot operated, closed center system which is supplied with flow from the variable displacement piston main hydraulic pump. The loader system components are : ·Main pump ·Main control valve ·Bucket cylinder...
Page 464 2. HYDRAULIC CIRCUIT (HL955, HL955XTD) 2. HYDRAULIC CIRCUIT (HL955, HL955XTD) A3 B3 B.D/F DUMP BUCKET BOOM AUX2 Joystick Control unit Control unit ELECTRONICS (Electro-Hydraulic & Joysick steering) EH18 EH20 EH19 EH22 EH21 EH17 B/Down B/up Aux down Aux up To MCV...
Page 465 HYDRAULIC CIRCUIT (HL955, HL955XTD, DIRECT STEERING, OPT) HYDRAULIC CIRCUIT (HL955, HL955XTD, DIRECT STEERING, OPT) BUCKET AUX1 BOOM 2/3spool Control Unit / Electro Hydraulic EH18 EH17 EH20 EH19 EH22 EH21 3spool 2spool Boom Bucket Bucket Bucket Boom Boom Down Dump Down 22 22 B.D/F...
Page 466 HYDRAULIC CIRCUIT (HL955TM) HYDRAULIC CIRCUIT (HL955TM) A3 B3 B.D/F DUMP BUCKET BOOM Joystick AUX2 Control unit Control unit ELECTRONICS (Electro-Hydraulic & Joysick steering) EH18 EH20 EH19 EH22 EH21 EH17 B/Down B/up Aux down Aux up To MCV B/in Dump 6 (4) 3 (2) 5 (3) 2 (1)
Page 467 HYDRAULIC CIRCUIT (HL955TM, DIRECT STEERING, OPT) HYDRAULIC CIRCUIT (HL955TM, DIRECT STEERING, OPT) BUCKET AUX1 BOOM Control Unit / Electro Hydraulic EH18 EH17 EH20 EH19 EH22 EH21 Boom Bucket Bucket Bucket Boom Boom Down Dump Down 22 22 B.D/F B.U CRAWD DUMP FRONT AXLE...
Page 468 3. WORK EQUIPMENT HYDRAULIC CIRCUIT Bucket Boom Boom Bucket Joystick Control unit (Electro-Hydraulic & Joysick steering) EH20 EH19 EH22 EH18 EH17 EH21 6(4) 3(2) 5(3) 2(1) ( ) : 2 Spool To MCV a3 b3 a1 b1 a2 b2 Steering valve (EHPS) EF port Steering valve (EHPS) LS port...
Page 469 WHEN THE RCV LEVER IS IN THE RAISE POSITION Bucket Boom Boom Bucket Joystick Control unit (Electro-Hydraulic & Joysick steering) EH18 EH17 EH20 EH19 EH22 EH21 6(4) 3(2) 5(3) 2(1) ( ) : 2 Spool To MCV a3 b3 a1 b1 a2 Steering valve (EHPS) EF port Steering valve...
Page 470 WHEN THE RCV LEVER IS IN THE LOWER POSITION Bucket Boom Boom Bucket Joystick Control unit (Electro-Hydraulic & Joysick steering) EH18 EH20 EH19 EH22 EH21 EH17 6(4) 3(2) 5(3) 2(1) ( ) : 2 Spool Regeneration check valve To MCV a3 b3 a1 b1 Steering valve (EHPS) EF port...
Page 471 WHEN THE RCV LEVER IS IN THE FLOAT POSITION Bucket Boom Boom Bucket Joystick Control unit EHCU (Electro-Hydraulic & Joysick steering) EH20 EH19 EH22 EH18 EH17 EH21 6(4) 3(2) 5(3) 2(1) ( ) : 2 Spool To MCV a3 b3 a1 b1 Steering valve (EHPS) EF port Steering valve...
Page 472 WHEN THE RCV LEVER IS IN THE DUMP POSITION Bucket Boom Boom Bucket Joystick Control unit (Electro-Hydraulic & Joysick steering) EH18 EH20 EH19 EH22 EH21 EH17 6(4) 3(2) 5(3) 2(1) ( ) : 2 Spool Regeneration check valve To MCV a3 b3 b1 a2 b2 Steering valve...
Page 473 WHEN THE RCV LEVER IS IN THE ROLL BACK (retract) POSITION Bucket Boom Boom Bucket Joystick Control unit (Electro-Hydraulic & Joysick steering) EH20 EH19 EH22 EH18 EH17 EH21 6(4) 3(2) 5(3) 2(1) ( ) : 2 Spool To MCV a3 b3 a1 a2 b2 Steering valve (EHPS) EF port...
Page 474 4. MAIN PUMP STRUCTURE (1/2) This variable displacement piston pump consists of steering pump and loader pump. Hydraulic circuit 75796WE88 Port Port name Port size Pressure port SAE 1" Pressure port SAE 1" Suction port SAE 2" Suction port SAE 1 1/2" M22 ×...
Page 475 · STEERING PUMP 75796WE11 1-1 High speed rotary 15 Taper roller bearing 28 Locking screw 1-2 Control plate 16 Taper roller bearing 30 Locking screw Adjusting piece 17 Bearing liner 33 Cylinder pin Pump housing 20 Shaft seal ring 36 O-ring Port plate 22 O-ring 51 Control valve...
Page 476 · LOADER PUMP 55-2 55-1 75796WE12 55-1 High speed rotary 62 Shim 71 Locking screw 55-2 Control plate 63 Taper roller bearing 72 Locking screw 56 Adjusting piece 64 Taper roller bearing 73 Cylinder pin 57 Pump housing 65 Bearing liner 89 Control valve 58 Port plate 66 Shaft seal ring...
Page 477 FUNCTION LS pressure 75796WE33 Drive shaft Counter spring 11 Control plate Swash plate Pressure & flow compensator valve 12 Pressure compensator spool Shoe plate Piston shoe 13 Flow compensator spool Counter piston Cylinder Piston 10 Control piston The steering pump and loader pump are variable displacement piston pump. The steering pump and loader pump are flow controlled by LS signal.
Page 478 Control piston (10) diameter is larger than counter piston (4) diameter, the oil pressure that is acting against control piston (10) overcomes the force of counter spring (6). The oil pressure than causes the pump to destoke. Pressure and flow compensator valve (7) also controls the maximum output of pump pressure. When steering and loader pressure rises above pressure compensator setting, pressure compensator spool (12) overrides flow compensator spool (13).
Page 479 Upstroking LS pressure LS pressure oil System pressure oil Return oil 75796WE35 Drive shaft 13 Flow compensator spool 19 LS line from the metering pump Swash plate 14 Case drain 20 Cavity Counter piston 15 Passage 21 Passage Counter spring 16 Passage 22 Passage 10 Control piston...
Page 480 Destroking LS pressure LS pressure oil System pressure oil Return oil 75796WE34 Drive shaft 13 Flow compensator spool 19 LS line from the metering pump Swash plate 14 Case drain 20 Cavity Counter piston 15 Passage 21 Passage Counter spring 16 Passage 22 Passage 10 Control piston...
Page 481 Low pressure standby LS pressure LS pressure oil System pressure oil Return oil 23 13 75796WE36 Drive shaft 13 Flow compensator spool 19 LS line from the metering pump Swash plate 14 Case drain 20 Cavity Counter piston 15 Passage 21 Passage Counter spring 16 Passage...
Page 482 Cross-drilled hole (24) limits the maximum travel of control piston (10) to the left. The pump supplies a sufficient amount of flow that compensates for system leakage. The pump also supplies a sufficient of flow that compensates for leakage to the pump case. The leakage to the pump case is a result of the cross-drilled hole.
Page 483 High pressure stall LS pressure LS pressure oil System pressure oil Return oil 23 13 75796WE36 Drive shaft 13 Flow compensator spool 19 LS line from the metering pump Swash plate 14 Case drain 20 Cavity Counter piston 15 Passage 21 Passage Counter spring 16 Passage...
Page 484 Adjustment of flow control Flow compensator setting must be carried out following procedures and conditions. ① Conditions Engine is running (at high or low idle). RCV is operated slowly (example : Boom up). Pressure gauges are installed. ※ Discharge pump flow should be less than max pump flow. ②...
Page 485 5. EH (electro hydraulic) CONTROL BLOCK STRUCTURE 10-4 10-5 10-6 Proportional pressure reducing valve 10-1 10-2 10-3 Filter screen EH18 EH17 EH20 EH19 EH22 EH21 Port Size 9/16-18UNF 1 ~ 6 9/16-18UNF 3/4-16UNF 10-4 10-1 10-6(4) 10-3(2) 10-5(3) 10-2(1) ( ) : 2-spool 6 (4) 3 (2) 5 (3)
Page 486 6. MAIN CONTROL VALVE STRUCTURE (1/3) ·Type : Closed center, Load pressure - Independent - Flow - Distribution A3 B3 VIEW A VIEW B Boom Bucket Hydraulic circuit 75796WE10 Port Port name Port size From main pump 1 5/16-12UN To hydraulic tank 1 5/16-12UN A1, B1 To bucket cylinder port...
Page 487 STRUCTURE (2/3) 75796WE13 11 Housing 70 Check valve 86 Counter balance valve 30 O-ring 72 Spool 87 Pressure reducing valve 31 O-ring 74 Locking screw 133 Valve seat 50 Housing 80 Pressure relief valve 134 Throttle bolt 60 Plate 83 Pressure relief valve 135 Valve seat 61 Cylinder screw 84 Flow control valve...
Page 488 STRUCTURE (3/3) 75796WE14 11 Housing 21 Throttle check valve 50 Housing 12 Cover 22 Throttle check valve 90 Spring retainer 13 Cover 23 Threaded steel pipe fitting 91 Compression spring 14 Cover 30 O-ring 93 Spring retainer 18 Cylinder screw 40 Spool 94 Spring 19 Cylinder screw...
Page 489 FUNCTION Boom Bucket Hydraulic circuit 75796WE15 Housing Loader holding valve Port relief valve Spool Counter balance valve Spring chamber Pressure compensator Regeneration check valve 6-25...
Page 490 Control block Proportional direction valve to the LUDV principle (Load pressure - Independent - Flow - Distribution) Actuator control At the spool (2) the direction and volume of flow is determined that flows to the actuator connections (A or B). The spring chambers (8) are supplied with pilot pressure either via the pilot connections a and b hydraulic control.
Page 491 BOOM SECTION OPERATION Spool in neutral Boom Bucket Hydraulic circuit 75796WE51 When the boom spool is in neutral position, oil from the pump will be blocked. Then, the pumps are at low pressure stand by. 6-27...
Page 492 Boom raise position Boom Bucket Load holding valve Hydraulic circuit 75796WE52 When the pilot pressure is led to the port b2, the boom spool moved to raise position. Oil from the pump flows to the cylinder port B2 through the load holding valve and oil from the cylinder flows into the tank passage through the cylinder port A2.
Page 493 Boom lower position Boom Bucket Hydraulic circuit 75796WE53 When the pilot pressure is led to the port a2, the boom spool moved to lower position. Oil from the pump flows to the cylinder port A2, through the load holding valve and oil from the cylinder flows into the tank passage through the cylinder port B2.
Page 494 Boom float position Boom Bucket Hydraulic circuit 75796WE54 When the boom spool is located in float position, the oil from the pump will be blocked. The cylinder ports (A2, B2) are connected to the tank passage, so the boom will be lowered due to it's own weight.
Page 495 BUCKET SECTION OPERATION Spool in neutral Boom Bucket Hydraulic circuit 75796WE55 When the bucket spool is in neutral position, oil from the pump will be blocked. Then, the pumps are at low pressure standby. 6-31...
Page 496 Bucket rollback position Boom Bucket Load holding valve Hydraulic circuit 75796WE56 When the pilot pressure is led to the port b1, the bucket spool moved to rollback position. Oil from the pump flows to the cylinder port B1 through the load holding valve and oil from the cylinder flows into the tank passage through the cylinder port A1.
Page 497 Bucket dump Boom Bucket Hydraulic circuit 75796WE57 When the pilot pressure is led to the port a1, the bucket spool moved to dump position. Oil from the pump flows to the cylinder port A1, through the load holding valve and oil from the cylinder flows into the tank passage through the cylinder port B1.
Page 498 7. SAFETY VALVE STRUCTURE Hydraulic circuit Port Port name Port size From MCU PF 3/8" Supply to RCV lever PF 1/4" To hydraulic tank PF 1/4" 75796WE16 Bowl and element assy Solenoid valve Check valve Accumulator Cartridge OPERATION This valve is used to cut off the pilot circuit. When the pilot cut off switch in the cab is pressed to ON position, the solenoid valve is activated and then the pilot oil flow into the pilot circuit.
Page 499 8. BOOM AND BUCKET CYLINDER The boom cylinders are two unit and the bucket cylinder is one unit. They use a bolt on rod guide. The piston (14) threads on to the rod (2) and is retained by a nut (20) and set screw (21). The piston seals against the tube (1) with piston seal (15).
Page 500 BUCKET CYLINDER 757F6WE18 Tube assembly 12 O-ring 23 Bushing Rod assembly 13 Back up ring 24 Bushing Gland 14 Piston 25 Dust seal Bushing 15 Piston seal 26 Dust seal Snap ring 16 Wear ring 27 Band assembly Rod seal 17 Dust ring 28 Pipe assembly Back up ring...
Page 501 9. HYDRAULIC OIL TANK STRUCTURE · The oil from the hydraulic tank is sent from the pump through main control valve to the cylinders. In the return circuit, the oil from various parts merges. · A part of oil is cooled in the oil cooler, passes through the hydraulic filter and returns to the hydraulic tank (1).
Page 502 RETURN OIL FILTER BYPASS VALVE When the filter is clogged Bypass valve (1) is opened and the oil returns directly to the tank without passing through the filter. ·Bypass valve set pressure : 1.36 kg/cm (19.3 psi) From MCV 770-3ATM (6-33) AIR BREATHER The air breather is equipped with the capacity to perform three functions...
Page 503 10. ACCUMULATOR The accumulator is installed at the safety valve. When the boom is left the raised position, and the control levers are operated with the engine stopped the pressure of the compressed nitrogen gas inside the accumulator sends pilot pressure to the control valve to actuate it and allow the boom and bucket to come down under their own weight.
Page 504 11. RIDE CONTROL SYSTEM (option) 1) ACCUMULATORS Pre-charging Use an inert gas such as nitrogen for pre-charging accumulator. ※ Do not use oxygen or shop air. ※ Nitrogen source and all components must be rated for a pressure at least as high as the nitrogen source.
Page 505 Structure WLACC03 Body 5A V-O-ring back-up washers 8A Gas valve O-ring Hydraulic cap Piston ring (piston) Gas valve guard Gas cap O-ring 9A Screw Piston 7A O-ring back-up washer V-O-ring Gas valve 2) REMOVE FROM HYDRAULIC SYSTEM Attention Before carrying out any maintenance work the accumulators must be unloaded (zero pressure).
Page 506: Group 2 Operational Checks And Troubleshooting
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.
Page 507 ※ Hydraulic oil must be at operating temperature for these checks (refer to page 6-55). Item Description Service action Hydraulic system warm-up Hold a hydraulic function over relief procedure to heat oil. (don't keep relief Check completed. condition over 5 seconds at a time) Run engine at high idle.
Page 508 Item Description Service action Bucket rollback circuit relief Position bucket at a 45˚ angle valve check against an immovable object. Check complete. Engage transmission in 3rd speed NOT OK forward. Replace boom lower check valve. LOOK : Bucket angle must not change.
Page 509 Item Description Service action Boom cylinder leakage Dump bucket until teeth or cutting check edge is perpendicular to the Drift is approximately the ground. same between first and H e a t hy d r a u l i c o i l t o second measurement.
Page 510 Item Description Service action Bucket leveler Position bucket fully dumped just (positioner) check above ground level. Check complete. Run engine at low idle. Move control lever to bucket NOT OK leveler detent position and Do bucket leveler checks. release. LOOK : Bucket must rollback to the level position and control lever must return to neutral.
Page 511 ※ MEASURING BOOM AND BUCKET CYCLE TIME 1) MEASUREMENT CONDITION ·Coolant temperature : Inside operating range ·Steering position : Neutral ·Hydraulic temperature : 40~50˚C ·Bucket : Unloaded ·Engine speed : High idling 2) MEASURING TOOL · Stop watch (1EA) 3) MEASURING PROCEDURE Lifting time of boom LIFTING TIME OF BOOM Set the bucket near the maximum tilt back...
Page 512 2. TROUBLESHOOTING ※ Diagnose malfunction charts are arranged from most probable and simplest to verify, to least likely, more difficult to verify. Remember the following steps when troubleshooting a problem : Step 1. Operational check out procedure (see section 1) Step 2.
Page 513 Problem Cause Remedy No steering or hydraulic Low oil level. Add recommended oil. function Failed hydraulic pump. Remove and inspect return filter for metal pump particles. No hydraulic functions Failed hydraulic pump. Remove and inspect return filter for steering normal metal pump particles, or replace the pump.
Page 514 Problem Cause Remedy Function drifts down Leaking cylinders. Do cylinder leakage checks in group 3. Leaking seals in circuit relief valve (port Inspect seals. Replace relief valve. relief valve) or valve stuck open. Leaking loader control valve (MCV). Repair or replace valve section. Boom drifts up Leakage in boom down spool.
Page 515 Problem Cause Remedy Hydraulic oil foams Low oil level. Add recommended oil. Wrong oil. Change to recommended oil. Water in oil. Change oil. Loose or faulty suction lines (air leak in Tighten or install new lines. system). Remote control valve Leaking plunger seals.
Page 516 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.
Page 517: Group 3 Tests And Adjustments
GROUP 3 TESTS AND ADJUSTMENTS 1. HYDRAULIC OIL CLEAN UP PROCEDURE USING PORTABLE FILTER CADDY ※ Service equipment and tool ·Portable filter caddy ·Two 4000 mm × 1in 100R1 Hoses ·Quick disconnect fittings. ·Discharge wand ·Various size fittings. ※ Brake system uses oil from hydraulic oil tank.
Page 518 Start the filter caddy. Check to be sure oil is flowing through the filters. Operate filter caddy approximately 10 minutes so oil in hydraulic oil tank is circulated through filter a minimum of four times. ※ Hydraulic oil tank capacity : 108ℓ(28.5 U.S.
Page 519 2. BOOM HEIGHT KICKOUT ADJUSTMENT The bucket can be adjusted to a height desired by using the boom kick-out device. Park the machine on level ground and bl o ck t h e t i r e s t o p r eve n t s u d d e n movement of the machine.
Page 520 3. TEST TOOLS CLAMP-ON ELECTRONIC TACHOMETER INSTALLATION ·Service equipment and tools Tachometer A : Clamp on tachometer. Remove paint using emery cloth and connect to a straight section of injection line within 100 mm (4 in) of pump. Finger Tighten only-do not over tighten. B : Black clip ( - ).
Page 521 4. HYDRAULIC OIL WARM UP PROCEDURE Install temperature reader (see temperature reader installation procedure in this group). Run engine at high idle. Hold a hydraulic function over relief to heat the oil. Periodically cycle all hydraulic functions to distribute warm oil. Heat oil to test specification (approx.
Page 522 5. MAIN HYDRAULIC PUMP FLOW TEST · SPECIFICATION Oil temperature 45±5˚C (113±9˚F) Engine speed 2230±25 rpm Test pressure 200±5 bar (2900 psi) Maximum pump flow 185ℓ/min (48.9 gpm) · FLOW METER GAUGE AND TOOL Flow meter Gauge 0~35 MPa (0~350 bar, 0~5000 psi) Temperature reader Make test connections.
Page 523 LS relief valve (3980±70 psi) Boom 340±10 kg/cm raise (U) (4840±140 psi) Bucket 340±10 kg/cm rollback (R) (4840±140 psi) HL955/XTD: 300±10 kg/cm (4270±140 psi) Bucket dump (D) HL955TM: 150±10 kg/cm (2130±140 psi) · Gauge and tool Gauge 0~35 MPa (0~350 bar, 0~5000 psi)
Page 524 7. LOADER CYLINDER DRIFT TEST · SPECIFICATION Oil temperature 45±5˚C (113±9˚F) Boom horizontal Bucket horizontal Bucket unloaded Item Standard value Retraction of boom 7 mm cylinder rod Retraction of bucket ★ 10 mm, 12 mm cylinder rod ★ : HL955TM ·...
Page 525 8. BOOM AND BUCKET CYLINDER LEAKAGE TEST · SPECIFICATION Oil temperature 45±5˚C (113±9˚ F) Engine speed Low idle Maximum leakage 15 mℓ/min (1/2 oz/min) · GAUGE AND TOOL Temperature reader Stop watch Measuring container Fasten temperature sensor to head end port of cylinder to be tested.
Page 526 9. PILOT CONTROL VALVE (EH CONTROL BLOCK) PRESSURE TEST · SPECIFICATION Oil temperature 45±5˚C (113±9˚F) Engine speed High idle EH control block Minimum pressuer 30 bar Pressure range 35 ~ 50 bar · GAUGE AND TOOL Gauge 0~7 MPa (0~70 bar, 0~1000 psi) Lower boom to ground.
Page 527 Oil temperature 45±5˚C (113±9˚F) Engine speed High idle Maximum cycle time (seconds) Function Operating conditions HL955 / XTD HL955TM Boom raise Bucket flat on ground to full height Boom lower (float) Full height to ground level Bucket dump Boom at full height...
Page 528 11. HYDRAULIC OIL FILTER INSPECTION PROCEDURE Lower the bucket to the ground, stop the engine, move the control lever back and forth several times, and clean all over the upper surface of the hydraulic oil tank. Remove the bolts and take out the filter case cover and O-ring.
Page 529: Group 4 Disassembly And Assembly
GROUP 4 DISASSEMBLY AND ASSEMBLY 1. MAIN PUMP STRUCTURE (1/2) 75796WE11 1-1 High speed rotary 15 Taper roller bearing 28 Locking screw 1-2 Control plate 16 Taper roller bearing 30 Locking screw Adjusting piece 17 Bearing liner 33 Cylinder pin Pump housing 20 Shaft seal ring 36 O-ring...
Page 530 STRUCTURE (2/2) 55-2 55-1 75796WE12 55-1 High speed rotary 62 Shim 71 Locking screw 55-2 Control plate 63 Taper roller bearing 72 Locking screw 56 Adjusting piece 64 Taper roller bearing 73 Cylinder pin 57 Pump housing 65 Bearing liner 89 Control valve 58 Port plate 66 Shaft seal ring...
Page 531 GENERAL REPAIR GUIDELINES ※ Observe the following guidelines when carrying out repairs on hydraulic pumps. Close off all openings of the hydraulic unit. Replace all of the seals. Use only original spare parts. Check all sealing and sliding surfaces for wear.
Page 532 SEALING / CLEANING THE CONTROL vALvE Disassemble the control valve. ※ Measure dimension A and note down. Check sealing surface (1). 75796WE62 DISASSEMBLE THE PUMP Remove the control valve. 75796WE63 Mark the location of the connection plate on the housing. 75796WE64 6-67...
Page 533 Remove the connection plate fixing bolts and the connection plate. ※ Distributor plate and adjustment piston can drop down. 75796WE65 Remove distributor plate. Take note of the orientation. ※ Remove bearing with withdrawal tool. Do not damage the sealing surface. 75796WE66 Remove the rotary group in a horizontal position.
Page 534 Remove swash plate and bearing shells. 75796WE68 Remove the circlip and the shaft seal. 75796WE69 Remove the drive shaft through rear side. 75796WE70 Pre-tension the spring (1) using a suitable device. Remove circlip (2). Remove spring (1) and pressure pins (3). 75796WE72 6-69...
Page 535 (10) Use bearing puller to remove outer bearing race of front bearing out of housing press seat. 75796WE74 (11) Remove the control plate. 75796WE75 (12) Use bearing puller to remove outer bearing race of rear bearing - press seat. 75796WE76 (13) Disassemble the guide of control piston (Mounting position: pilot valve side).
Page 536 (14) Disassemble the guide of the opposite piston. 75796WE78 INSPECT HINTS Renew all bearings. 75796WE79 Check : Wear on splines, rust Drive shaft seal wear grooves Bearing seat Splines for cylinder drive Bearing seat 75796WE80 Check : Sliding surface free of grooves. 75796WE81 6-71...
Page 537 Check : Bearing surfaces. 75796WE82 Check : That the retaining plate is free of grooves and that there is no wear in the slipper pad area. 75796WE83 Check : Check to see that there are no scratches or metal deposits on the sliding surface (1) and that there is no axial play (2) (Pistons must only be replaced as a set).
Page 538 Free of grooves, no signs of wear. 75796WE86 Check : Cylinder sliding surface free of grooves, no wear, no embedded foreign particles. That there are no scratches on the control plate. (Only replace them as a set). 75796WE87 Check : (10) M o u n t i n g s u r fa c e - c o n t r o l p l a t e undamaged.
Page 539 (12) Check : Check running conditions of the opposite piston. 75796WE90 0~0.05mm ADjUSTMENT OF TAPER ROLLER BEARING SET Cast iron housing must have initial tension of the bearings: 0~0,05 mm, grind position A if necessary. Position A 75796WE91 PUMP ASSEMBLY Fit the seal into the housing.
Page 540 Fit pressure pins using an assembly aid. 75796WE94 Pre-tension the spring using a suitable device. 75796WE95 Assemble piston with retaining plate. ※ Oil piston and slipper pad. 75796WE97 6-75...
Page 541 Fit rotary group. ※ Hold the piston by using an O-ring. Fit O-ring (1). 75796WE98 Fit bearing (1) in connection plate. Fit cyilindrical pin (2). Fit O-rings (3) 4 pieces. Fit adjustment spool (4) and guide piston (4a). Fit distributor plate (5) (direction of rotation dependent) ※...
Page 542 Fit distributor plate. ※ Assembly aid : Grease 75796WE100 For clockwise rotation pumps the distributor plate is off-set by 4˚ to the right from the centre position. (Clockwise and anti-clockwise rotation distributor plates are not identical). 75796WE101 (10) Fit connection plate and control valve. 75796WE63 6-77...
Page 543 2. MAIN CONTROL vALvE STRUCTURE (1/2) 75796WE13 11 Housing 70 Check valve 86 Counter balance valve 30 O-ring 72 Spool 87 Pressure reducing valve 31 O-ring 74 Locking screw 133 valve seat 50 Housing 80 Pressure relief valve 134 Throttle bolt 60 Plate 83 Pressure relief valve 135 valve seat...
Page 544 STRUCTURE (2/2) 75796WE14 11 Housing 21 Throttle check valve 50 Housing 12 Cover 22 Throttle check valve 90 Spring retainer 13 Cover 23 Threaded steel pipe fitting 91 Compression spring 14 Cover 30 O-ring 93 Spring retainer 18 Cylinder screw 40 Spool 94 Spring 19 Cylinder screw...
Page 545 GENERAL PRECAUTIONS Clean room with no dust is recommended for maintenance. Because hydraulic components are precision, and have minute clearance. Tool and wash-oil must be clean, too. Handle them carefully. At removing control valve from the machine, wash around the piping port, and neither dust nor water should go into inside with plugging.
Page 546 DISASSEMBLY AND ASSEMBLY Spool ① Loosen the bolt (2EA). ·Tool : Wrench 4 mm ·Tightening torque : 0.85 kgf·m (6.1 lbf·ft) 75796WE41 ② Remove the cover, spring retainer, spring and spool. 75796WE42 Spool Spring Spring ratainer Bolt Cover 75796WE43 Port relief valve ·Tool : Spanner 24 mm 75796WE44 6-81...
Page 547 ·Tightening torque : 10.2 kgf·m (73.8 lbf·ft) 75796WE45 Precharge valve ·Tool : Spanner 24 mm 75796WE46 ·Tightening torque : 6.1 kgf·m (44.3 lbf·ft) 75796WE47 6-82...
Page 548 SECTION 7 ELECTRICAL SYSTEM SECTION 7 ELECTRICAL SYSTEM Group 1 Component Location ----------------------------------------------------------------------------------------- 7-1 Group 2 Electrical Circuit -------------------------------------------------------------------------------------------------- 7-3 Group 3 Monitoring System --------------------------------------------------------------------------------------------- 7-22 Group 4 Electrical Component Specification ------------------------------------------------------------------ 7-69 Group 5 Connectors --------------------------------------------------------------------------------------------------------- 7-76 Group 6 Troubleshooting -------------------------------------------------------------------------------------------------- 7-97...
Page 549: Group 1 Component Location
SECTION 7 ELECTRICAL SYSTEM SECTION 7 ELECTRICAL SYSTEM GROUP 1 COMPONENT LOCATION GROUP 1 COMPONENT LOCATION 1. LOCATION 1 1. LOCATION 1 760F7EL20 Kick down button Gear select lever 14 Pilot cut off switch Horn button Radio & USB player 15 Parking brake switch FNR switch 10 Aircon &...
Page 550 2. LOCATION 2 2. LOCATION 2 G IN IN E IS SI 760F7EL21 Head lamp Master switch 15 Camera (opt) Horn Start relay 16 Work lamp Angle sensor 10 Fuel sender 17 Control unit (electro Work lamp 11 Battery relay hydraulic &...
Page 551: Group 2 Electrical Circuit
GROUP 2 ELECTRICAL CIRCUIT GROUP 2 ELECTRICAL CIRCUIT · · ELECTRICAL CIRCUIT (1/3, machine serial number : ~#0376) ELECTRICAL CIRCUIT (1/3, machine serial number : ~#0376) ----- MCU ----- MULTI FUNCTION SWITCH MONITOR CLUSTER FRONT WIPER SPARE SPARE HAZARD SW HOUR METER 12345 RESISTOR...
Page 552 GROUP 2 ELECTRICAL CIRCUIT GROUP 2 ELECTRICAL CIRCUIT · · ELECTRICAL CIRCUIT (1/3, machine serial number : #0377~) ELECTRICAL CIRCUIT (1/3, machine serial number : #0377~) ----- MCU ----- MULTI FUNCTION SWITCH MONITOR CLUSTER FRONT WIPER HAZARD SW SPARE SPARE HOUR METER 12345 RESISTOR...
Page 553 · · ELECTRICAL CIRCUIT (2/3, ELECTRICAL CIRCUIT (2/3, machine serial number : ~#0376) machine serial number : ~#0376) ----- EH CONTROLLER ----- SHIFT LEVER ----- TCU ----- CN-43 JOYSTIC STTERING CD-46 LOCK-UP PROPORTIONAL V/V CN-04 SPEED SENSOR OUTPUT TCU_VPS2(53) CD-17 FUEL HEATER TCU_AIP7(50) CN-196...
Page 554 · · ELECTRICAL CIRCUIT (2/3, ELECTRICAL CIRCUIT (2/3, machine serial number : #0377~) machine serial number : #0377~) ----- EH CONTROLLER ----- OSPE steering Sol & PVES coil SHIFT LEVER ----- TCU ----- CN-43 JOYSTIC STTERING CD-46 LOCK-UP PROPORTIONAL V/V CN-04 SPEED SENSOR OUTPUT 4 3 2 1 4 3 2 1 4 3 2 1...
Page 555 · · ELECTRICAL CIRCUIT (3/3, ELECTRICAL CIRCUIT (3/3, machine serial number : ~#0376) machine serial number : ~#0376) CN-05 CN-19 AIR CONDITIONER CONTROL SWITCH ASSY SEERING PUMP RELAY SEERING PUMP RELAY AC-01 AC-02 STEERING PUMP PS MCU_24V MP3 PLAYER POWER CONNECT SUB CONNECTOR GROUND_MCU ANTENA...
Page 556 CN-373 0.85BrW CN-86L LVDS NEG HL970 447 #8 => #9 0.85R POWER 24V HL980 CS-85 0.85Gr ADJUST SIGNAL STORE CN-26A HL955 CN-26A Operator CN-152 BUTTON RIGHT VIEW CAMERA CS-85L HL960 Presence CN-404 SIGNAL TO MAIN HARNESS 0.85Y HORN LVDS POS ERROR 0.85B...
Page 557 MEMORANDUM MEMORANDUM...
Page 558 1. ILLUMINATION CIRCUIT 1. ILLUMINATION CIRCUIT 1) 1) OPERATING FLOW OPERATING FLOW Main light switch on monitor Switch ON, Select position lamp MCU [CN-58A (A13)] Illumination relay [CR-210 (87)] Fuse box [CN-37 (23)] Switch and button indicator lamp Cigar lighter lamp [CL-02] I/conn [CN-01 (37)] I/conn [CN-24 (10)] Number plate lamp [CL-21 (2)]...
Page 559 ILLUMINATION CIRCUIT ILLUMINATION CIRCUIT CR-210 DPF CONTROL SW RELAY CN-58A ILLUMINATION LIGHT RELAY CN-11 AC HARNESS ILLUMINATION CL-02 CIGAR CS-105 PARKING SW HAZARD SW CS-17 NUMBER CS-41 PILOT CUT OFF SW PLATE CN-01 CN-24 LAMP CL-21 CN-07 REAR COMBI CS-04 CL-16 ILL- REAR...
Page 560 2. HEAD LIGHT CIRCUIT 2. HEAD LIGHT CIRCUIT OPERATING FLOW OPERATING FLOW Main light switch on monitor Switch ON, Select head lamp MCU [CN-58A (A14)] Driving relay [CR-211 (87)] Multi function switch [CS-11(8)] Multi function switch MIDDLE [CS-11(7)] I/conn [CN-05 (32)] LH Head light low beam ON [CL-03 (6)] RH Head light low beam ON [CL-04 (6)] Multi function switch DOWN [CS-11(6)]...
Page 561 HEAD LIGHT CIRCUIT HEAD LIGHT CIRCUIT DRIVING RELAY CR-211 DRIVING LIGHT RELAY CN-58A HEAD LIGHT LH CLUSTER CN-05 CL-03 RS232 RX RS232 TX PROGRAM DUMP HEAD LIGHT RH RS232 PC SHILD HIGH BEAM RH TURN LH TURN BATT. 24V IG 24V CL-04 CAN2 LOW CAN2 HI...
Page 562 3. WORK LIGHT SWITCH 3. WORK LIGHT SWITCH OPERATING FLOW OPERATING FLOW ※ Main light switch on monitor : Select position lamp. Work lamp switch Work lamp switch (select Front) MCU [CN-58B (B09)] Front work lamp relay [CR-03 (87)] I/conn [CN-07 (06)] LH Front work lamp ON [CL-32 (1)] RH Front work lamp ON [CL-33 (1)] Work lamp switch...
Page 563 WORK LIGHT SWITCH WORK LIGHT SWITCH WORK LAMP FRONT RY CR-03 WORK LAMP REAR RY CR-55 ECO FEELING SIGNAL ILLUMINATION LIGHT RELAY DRIVING LIGHT RELAY WORK LAMP FRONT WORK LAMP REAR FUEL WARMER AIRCON RUN SIGNAL CN-58B CN-07 WORK CL-32 LAMP FRONT CN-24...
Page 564 4. STARTING CIRCUIT 4. STARTING CIRCUIT 1) 1) OPERATING FLOW OPERATING FLOW Master switch [CS-74 (1) → (2)] Battery(+) terminal Fusible link [CN-351 (40A)] I/conn [CN-01 (16, 17)] Fuse box [CN-36] Start switch [CS-02 (1)] ECM power relay [CR-30 (30)] Power relay [CR-35 (30)] ※...
Page 565 STARTING CIRCUIT STARTING CIRCUIT JOYSTIC STEERING MONITOR CLUSTER USB PLAYER POWER CONNECT FUSE BOX TURN LAMP START KEY SW RADIO B+ TCU 24V B+ AC/HEATER B+ CLUSTER 24V B+ SPEED SENSOR MCU B+ OUTPUT CN-04 RMCU B+ ECM POWER ROOM LP SPARE 02 CD-46 CN-13...
Page 566 5. CHARGING CIRCUIT 5. CHARGING CIRCUIT When the starter is activated and the engine is started, the operator releases the key switch to the ON position. Charging current generated by operating alternator flows into the battery through the battery relay (CR-01).
Page 567 CHARGING CIRCUIT CHARGING CIRCUIT FUSE BOX TURN LAMP START KEY SW RADIO B+ TCU 24V B+ AC/HEATER B+ CLUSTER 24V B+ CN-04 MCU B+ RMCU B+ ECM POWER ROOM LP CN-13 SPARE 02 SPARE 03 CN-36 RESISTOR 3W/300 RS-01 ALTERNATOR CN-01 STARTER CR-23...
Page 568 6. ELECTRIC 6. ELECTRIC PARKING, PILOT CUT OFF CIR PARKING, PILOT CUT OFF CIRCUIT CUIT 1) 1) OPERATING FLOW OPERATING FLOW (1) (1) Parking OFF Parking OFF Fuse box [CN-39 (41)] Parking switch OFF [CS-17 (5)→(4)] I/conn [CN-05 (14)] I/conn [CN-12 (13)] Parking solenoid ON (activated) Parking brake released (by hydraulic pressure) [CS-17 (2)→(1)]...
Page 569 ELECTRIC PARKING ELECTRIC PARKING, PILOT CUT OFF CIRCU , PILOT CUT OFF CIRCUIT IT PARKING SW CS-17 PILOT CUT OFF SW SDDK-DIAGNOSTIC EUPR-DIAGNOSTIC ED11 ED10-PARKING BRAKE SW(+) VMGA1-GROUND_BRAKE PEDAL AU1-+5V SUPPLY_BRAKE PEDAL EU1-SIGNAL SENSOR_BRAKE PEDAL CN-157 CS-04 EH CONTROLLER DIN _SAFETY SWITCH SIGNAL SENSOR POWER GROUND - 5V DC SENSOR POWER + RCV SELECT, 5V=JOYSTICK...
Page 570 7. WIPER AND WASHER CIRCUIT 7. WIPER AND WASHER CIRCUIT 1) 1) OPERATING FLOW OPERATING FLOW Fuse box [CN-39 (40)] Wiper relay Hi [CR-4 (3)→(4)] Front wiper motor [CN-21 (1)] Wiper relay Lo [CR-26 (5), (2)] Multi function switch [CS-12 (6)] Rear washer relay [CR-203 (2, 3)] Rear wiper relay [CS-25 (2, 5)] I/conn [CN-07 (5)]...
Page 571 WIPER AND WASHER CIRCUIT WIPER AND WASHER CIRCUIT MULTI FUNCTION SWITCH FRONT WIPER WASHER PUMP FRONT CN-102 WASHER PUMP REAR CN-103 WIPER FRONT LOW RY CR-26 FUSE BOX 12V CONVERTOR WIPER FRONT SEAT HEAT/AIR-RIDE HIGH RY WORK LAMP_FRONT WIPER PARK, PILOT CUT CR-04 AUTO GREASE AIR PRE-HEAT...
Page 572 HAZARD, TURN AND ROTARY CIRCUIT HAZARD, TURN AND ROTARY CIRCUIT BEACON RELAY CR-117 BEACON RELAY CN-58B CN-01 CN-07 REAR COMBI CL-16 BEACON LAMP REAR COMBI CL-117 CL-15 FLASHER UNIT MAIN LIGHT SW : ON(1st step) CR-11 CLUSTER HIGH BEAM RH TURN LH TURN BATT.
Page 573: Group 3 Monitoring System
GROUP 3 MONITORING SYSTEM GROUP 3 MONITORING SYSTEM 1. CLUSTER 1. CLUSTER 1) 1) STRUCTURE STRUCTURE The cluster consists of gauges, lamps and LCD as shown below, to warn the operator in case of abnormal machine operation or conditions for the appropriate operation and inspection. ·...
Page 574 (2) (2) Fuel gauge Fuel gauge ① This gauge indicates the amount of fuel in the fuel tank. ② Fill the fuel when the indicator moves red range or lamp blinks in red, refuel as soon as possible to avoid running out of fuel. ※...
Page 575 3) 3) WARNING LAMPS WARNING LAMPS SCR system cleaning warning lamp SCR system cleaning inhibit warning lamp HEST warning lamp Emergency warning lamp T/M oil temp warning lamp Stop engine warning lamp Check engine warning lamp Engine overheat warning lamp Fuel level warning lamp Battery charging warning lamp Brake fail warning lamp...
Page 576 ② Immediately pull the machine to a convenient stop. Stop the engine. Investigate the cause. ※ Consult a HYUNDAI dealer to investigate the cause. Consult a HYUNDAI dealer to investigate the cause. 77073CD19 ※ Do not operate until the cause has been corrected.
Page 577 (8) (8) Engine oil pressure warning lamp Engine oil pressure warning lamp ① This lamp is comes ON and the buzzer sounds after starting the engine because of the low engine oil pressure. ② If the lamp comes ON and the buzzer sounds during engine operation, shut OFF engine immediately.
Page 578 ※ Refer to page 7-28. Refer to page 7-28. ※ Please contact your Hyundai service center or local dealer. Please contact your Hyundai service center or local dealer. (14) (14) Engine coolant low level warning lamp Engine coolant low level warning lamp ①...
Page 579 These lamps will be ON when a stationary (manual) SCR sys- tem cleaning is not performed. · Stop the engine immediatary. · Please contact your Hyundai service center or local dealer. (17) (17) SCR system cleaning SCR system cleaning inhibit warning lamp inhibit warning lamp ①...
Page 580 ※ Manual SCR system cleaning Manual SCR system cleaning ※ Manual SCR system cleaning applies if the machine is in a Manual SCR system cleaning applies if the machine is in a Safety button fireproof area. fireproof area. ※ To stop a manual SCR system cleaning before it has com- To stop a manual SCR system cleaning before it has com- pleted, set to the SCR system cleaning switch to the inhibit pleted, set to the SCR system cleaning switch to the inhibit...
Page 581 (19) (19) DEF/AdBlue® level warning lamp DEF/AdBlue® level warning lamp ① This warning lamp indicates when ON or blinking, that the DEF/AdBlue® level is low as table below. ※ It is recommended that the DEF/AdBlue® tank be filled It is recommended that the DEF/AdBlue® tank be filled completely full of the DEF/AdBlue®...
Page 582 4) 4) PILOT LAMPS PILOT LAMPS Joystick steering pilot lamp Parking brake pilot lamp FNR select pilot lamp Pilot cut off pilot lamp Differential lock pilot lamp High beam pilot lamp 760F3CD10 (1) (1) High beam pilot lamp High beam pilot lamp ①...
Page 583 (5) (5) Differential lock pilot lamp Differential lock pilot lamp (option) ① This lamp lights ON when the differential lock function is operating. ※ Refer to page 7-65. Refer to page 7-65. 78093CD33 (6) (6) Pilot cut off pilot lamp Pilot cut off pilot lamp ①...
Page 584 2. MONITOR 2. MONITOR (7 inch touch screen) ·The monitor is adjustable. - Vertical : 30˚ - Horizontal : 15˚ Menu bar (touch screen) Lamps Lamps (see page 7-56) (see page 3-36) Switch(see page 7-59) Switchs (see page 3-39) 760F3CD20-1 1) 1) MAIN DISPLAY MAIN DISPLAY...
Page 585 (1) (1) Menu bar Menu bar ① Clock setting 760F3CD07A-1 760F3CD07-1 ② Wiper speed ※ In main display, you can move to right side menu by touching each icon. ① Clock setting Clock setting Set the time (hour, minute and AM or PM) ②...
Page 586 ② ② Fuel rate Fuel rate Fuel rate ·Set average fuel rate or a days fuel used on main display screen. ·Refer to page 7-49. 760F3CD08B-1 ③ ③ Engine mode Engine mode and operation history Engine mode and operation history ·Set the engine mode (A).
Page 587 ⑤ Quick menu ⓐ User switching 760F3CD08H-1 760F3CD08F-1 ⓑ Active fault ※ Move the quick menu screen by touching ⓐ User switching User switching · When multiple users share a machine, it allows users to switch user settings of machine. ·...
Page 588 (3) (3) Fault and maintenance warning Fault and maintenance warning 760F3CD16-1 760F3CD14-1 760F3CD15-1 ① If you touch the warning sign (red icon), move to the quick menu. ② You can check the fault message and move the mainte- nance screen by touching relevant area. 760F3CD17-1 (4) (4) Machine monitoring warning...
Page 589 2) 2) MAIN MAIN AND AND SUB MENU SUB MENU (1) (1) Structure Structure Main menu Sub menu Description Engine setting Engine mode, Engine speed Kick down Mode 1 (down/up), Mode 2 (down only) C.C.O mode Clutch cut off mode (Off, L, M, H) Shift mode Transmission shift mode (manual, AL, AN, AH) T.C.
Page 590 (2) (2) Mode Mode ① Engine setting mode Engine setting mode 760F3CD24A 760F3CD24B-1 760F3CD24C 760F3CD24F-1 760F3CD24G · Engine mode Engine mode The operator can adjust the machine's performance. - Econo : Maximum fuel efficiency for general loading. - Standard : General digging and loading operation. - Power : Maximum power output for hard digging operation or hill climb.
Page 591 ② Kick down mode 760F3CD29A 760F3CD29B · Manual mode (shift mode : manual) Kick down switch It is effective 2nd speed to 1st speed only and recover to 2nd speed quickly when push the switch one more time. · Automatic mode (shift mode : AL, AN, AH) Joystick steering Mode 1 (down/up) It shifts down quickly from current gear to one step lower speed by...
Page 592 ④ Shift mode Shift mode 760F3CD28A 760F3CD28B · Four modes are available for operator's preference and job condition. - Manual : Machine is operated by selected gear on lever. - AL (Auto Light) : Automatic shifting point is fast for long-distance transportation and fuel efficiency.
Page 593 ⑥ Work load mode Work load mode 760F3CD33A 760F3CD33B-1 · Weighing system : Set the workload measurements. · Weighing display : Set the display on main display screen. · Initialization : Workload initialization. · Error detection : Set error detection ON/OFF. - OFF : Errors are not displayed.
Page 594 ⑦ Boom/bucket detent mode Boom/bucket detent mode 760F3CD35A 760F3CD35B OFF : Detent functions are not operated. · ON : Boom or bucket detent functions are operated. · Save position : Refer to page 4-22 in operator's manual. · ⑧ Bucket priority mode (option) Bucket priority mode (option) 760F3CD34A 760F3CD34B...
Page 595 ⑪ Speedometer frequency setting Speedometer frequency setting mode mode 760F3CD73A-1 760F3CD73B · Press speedometer setting bar (or ) for 3 seconds. ※ Only for the service person. Do not adjust arbitrary. Only for the service person. Do not adjust arbitrary. ※...
Page 596 ⑭ Calibration Calibration 760F3CD49A-1 760F3CD49B 760F3CD49C-1 · Press NEXT button after following the instruction at each step. · If correction is right, NEXT button will be activated, then go to next stage. · After following each step correctly, the message "Calibration is done" will be shown. Press complete button, then process be ended.
Page 597 · Boom pressure calibration Boom pressure calibration 760F3CD70A 760F3CD70B-1 Display A Press START button after following the instruction. After a few minutes, "Calibration fail" or "Calibration success" message will be shown. Press complete button then process be ended. ※ Using button Using button - Using instead of NEXT, complete button.
Page 598 · 760F3CD72A 760F3CD72B-1 AEB mode controls the disk clearance of the transmission, automatically. To start AEB setting, press AEB bar (or ) for 3 seconds. To cancel AEB setting, press If "OK" in actual gear window, press to complete AEB setting. Display during AEB mode Display during AEB mode Symbol...
Page 599 (3) (3) Monitoring Monitoring ① Machine monitoring Machine monitoring 760F3CD41A-1 760F3CD41B-1 · Monitor the status of the machine. ② Operation history Operation history 760F3CD42A-1 760F3CD42B-1 · Hour meter / ODO meter Hour meter / ODO meter · Total Total - Total distance (this item cannot be initialized). - Total working hour can check on service meter.
Page 600 ④ Fuel consumption history Fuel consumption history 760F3CD141 760F3CD141A 760F3CD141C 760F3CD141E 760F3CD141G · Dispaly the fuel consumption history. - General record (average fuel rate and a days fuel used) - Hourly record - Daily record - Mode record ⑤ Machine information Machine information 760F3CD46A-1 760F3CD46B...
Page 601 (4) (4) Management Management ① Machine security Machine security 760F3CD47A-1 760F3CD47B 760F3CD47C · ESL system setting ESL system setting ESL : Engine Starting Limit ESL mode is designed to be a theft deterrent or will pre- vent the unauthorized operation of the machine. If the ESL mode was selected ON, the password will be required when the start switch is turned ON.
Page 602 Axle oil (front and rear) 1500 Aircon & heater outer ﬁ lter 1000 Crankcase Breather Filter 2000 DEF/AdBlue® supply module ﬁ lter 4500 DEF/AdBlue® tank ﬁ lter 4000 : Conventional hydraulic oil : Hyundai genuine long life hydraulic oil 7-51...
Page 603 ③ Service menu Service menu 760F3CD75A-1 760F3CD75B-1 760F3CD75C-1 760F3CD75D-1 760F3CD75E 760F3CD75F-1 760F3CD75G-1 760F3CD45A-1 760F3CD45B-1 · Sensor monitoring Sensor monitoring : Display information of each sensors. · Speed limit setting Speed limit setting : 20~40 km/h (5 km/h intervals) · Weighing system compensation Weighing system compensation - Calibration workload depending on work tool.
Page 604 (5) (5) Preference Preference ① Brightness setting Brightness setting 760F3CD76A-1 760F3CD76B-1 760F3CD76C-1 · Manual nual - Manual setting for LCD brightness. · Automatic Automatic - Automatic control of LCD brightness as set level of day/night. · Setting day time Setting day time - Set the time for daylight.
Page 605 ④ Display style/ Display style/ Language Language 760F3CD81A-1 760F3CD81B 760F3CD81C-1 760F3CD81D 760F3CD81E-1 · Set the display type A or B. · User can select preferable language and all display are changed the selected language. · 13 multiple language available. ⑤ Sound output setting Sound output setting 760F3CD79A-1...
Page 606 ⑥ Camera setting Camera setting 760F3CD39A-1 760F3CD39B-1 · Active camera Active camera - Four cameras can be installed on the machine. · Display order Display order - Set the channel sequence of each camera. · Active when the reverse gear is selected Active when the reverse gear is selected - If transmission engages the reverse gear (R1~R3), the camera mode is displayed automatically in main display.
Page 607 3) 3) PILOT LAMPS PILOT LAMPS Preheat pilot lamp Fuel warmer pilot lamp Warming up pilot lamp Ride control pilot lamp Float mode pilot lamp Engine auto shutdown pilot lamp Fan reverse pilot lamp Seat belt pilot lamp Clutch cut off pilot lamp T/C lock up pilot lamp 760F3CD90-1 (1) (1)
Page 608 (4) (4) Engine auto shutdown pilot lamp Engine auto shutdown pilot lamp ① This lamp lights ON when the engine auto shutdown function is activated. ※ Refer Refer to page 7-47. to page 7-47. STOP AUTO 760F3CD92 (5) (5) Clutch cut off pilot lamp Clutch cut off pilot lamp ①...
Page 609 (8) (8) Fan reverse pilot lamp Fan reverse pilot lamp ① This lamp lights ON when the cooling fan reverse mode is acti- vated ※ Refer to page 7-44. Refer to page 7-44. 7707A3CD40 (9) (9) Torque converter lock up pilot lamp Torque converter lock up pilot lamp (option) ①...
Page 610 3) 3) SWITCHES SWITCHES Left/Right switch Enter switch ESC switch Menu/Home switch Camera switch Main light switch Work mode switch Beacon lamp switch Work light switch Ride control switch Rear wiper and washer switch Fine modulation switch Central grease lubrication switch Quick coupler switch Detent setting switch Mirror defrost switch...
Page 611 Left / Right move switch Left / Right move switch (3) (3) ① Move in menu (left, up / right, down). ② Decrease / Increase input value. ③ Stop buzzer sound. 760F3CD22 (4) (4) Enter switch Enter switch ① Select menu (enter). 75793CD94 (5) (5) Camera switch...
Page 612 (9) (9) Quick coupler switch Quick coupler switch (option) ① Locking attachment Locking attachment The quick coupler pins move in the engaged position and buzzer sounds. The green pilot lamp is turned ON. ※ Check for engagement as followings. Check for engagement as followings. 760F3CD86A-1 Put down pressure on the attachment.
Page 613 (11) (11) Work mode switch Work mode switch ① Weighing system Weighing system Manual Manual Accumulate the weight in memory A, B, C manually. The green pilot lamp is turned ON. ※ Refer to the page 7-68 for workload button. Refer to the page 7-68 for workload button.
Page 614 (13) (13) Beacon lamp switch Beacon lamp switch (option) ① This switch turns ON the rotary light on the cab. ② The green pilot lamp is turned ON. 760F3CD88 (14) (14) Mirror defrost switch Mirror defrost switch (option) ① In condition of ON, it operates for 15 minutes. After 15 minutes, the defrost function stops automatically.
Page 615 3. SWITCHES 3. SWITCHES Workload button Starting switch Kick down button Starting button(opt) FNR switch Pilot cut off switch Horn button Parking brake switch FNR select button SCR system cleaning switch Horn button Diffetential lock switch Multi function switch Emergency test switch Workload button Hazard switch Kick down switch...
Page 616 PILOT CUT OFF SWITCH When the switch is pressed to OFF position, the hydraulic pilot line Safety button will be cut off, so the work equipment will not operate. Press the ON position in order to unlock the hydraulic pilot line. Lock This switch can be set to ON or OFF position only when the safety button is pulled to the unlock position.
Page 617 6) 6) SCR (selective catalytic reduction) SYSTEM CLEANING SYSTEM CLEANING SWITCH SWITCH This switch is used to select the SCR system cleaning. Safety button (2) (2) Inhibit position Inhibit position (①) ① The inhibit position disallows any automatic or manual SCR system cleaning.
Page 618 9) 9) KICK DOWN SWITCH KICK DOWN SWITCH (1) (1) Manual mode Manual mode Kick down switch It is effective 2nd speed to 1st speed only and recover to 2nd speed quickly when push the switch one more time. Gear (2) (2) Automatic mode Automatic mode...
Page 619 WORKLOAD BUTTON WORKLOAD BUTTON This button is used to calculate the weight manually. Workload button If the button is not pushed, the weight of the weighing system is not calculated. This button is pushed for one second more, calculated weight will be accumulated.
Page 620: Group 4 Electrical Component Specification
GROUP 4 ELECTRICAL COMPONENT SPECIFICATION GROUP 4 ELECTRICAL COMPONENT SPECIFICATION Part name Symbol Specifications Check item Gravity 12V × 160Ah 1.280 over : over charged Battery (2EA) 1.280 ~ 1.250 : normal 1.250 below : discharged Rated load : 24V Coil resistance Battery relay 100A (continuity)
Page 621 Part name Symbol Specifications Check item Pilot cut off, parking brake, Resistance diff lock, 24V 1A normal : 15~25Ω CN-68 CN-177 attach lock, CN-71 CN-178 unlock solenoid CN-79 Max load : 6W Resistance Air cleaner pressure switch ∞Ω: normal (open) N.O Type CD-10 Lock-up,...
Page 622 Part name Symbol Specifications Check item Resistance normal : about 160Ω Relay 24V 20A (for pin 1~2) (5 pin) CR-2 CR-4 CR-25 CR-26 0Ω(for pin 3~4) CR-37 CR-58 CR-79 CR-115 ∞Ω(for pin 3~5) CR-117 CR-136 CR-302 CR-303 Resistance Hydraulic, normal : ∞Ω transmission temperature 105。C over : 0Ω...
Page 623 Part name Symbol Specifications Check item Resistance DC/DC 12V 3A 8.8Ω(for pin A-B) Converter 7.7Ω(for pin B-C) 20A/13mA CN-138 Operation by external power source Horn 24V 2A - conncet 24V power to (+) terminal CN-120 CN-121 - ground the (-) terminal Resistance Receiver dryer 24V 2.5A...
Page 624 Part name Symbol Specifications Check item 24V 1.5A Wiper motor 2-speed Auto parking CN-21 (FR) CN-102 (RR) Coil resistance Cigar lighter 24V 5A 1.4W normal : about 1MΩ CL-2 Denso Voltage Alternator 3 FI 24V 95A normal : 24~28V 4 NC CN-74 Denso PA90L Starter...
Page 625 Part name Symbol Specifications Check item Resistance at each switch posi- Blower 24V 9.5A tion motor normal : 0.5-2Ω Resistance Door switch 24V 2W normal : about 5MΩ CS-1 CS-55 Flasher unit 85 ~ 190 C/M 50dB CR-11 24V 75W/70W (H4 TYPE) Resistance Head lamp...
Page 626 Part name Symbol Specifications Check item 24V 200mA Warning buzzer 90±5dB (ℓm) CN-26 Resistance Preheater 24V 200A 0.25~0.12Ω CN-80 Resistance Resistor A - B : 120Ω CN-99 7-75...
Page 627: Group 5 Connectors
GROUP 5 CONNECTORS GROUP 5 CONNECTORS 1. CONNECTOR DESTINATION 1. CONNECTOR DESTINATION Connector part No. Connector No. of Type Destination number Female Male CN-1 DEUTSCH I/conn (Frame harness-Main harness) DRB16-48SAE-L018 DRB12-48PAE-L018 CN-2 DEUTSCH I/conn (Front harness-Main harness) DRB12-60SBE-L018 DRB12-60PBE-L018 CN-4 DEUTSCH I/conn (Engine harness-Main harness) DRB16-60SAE-L018 DRB12-60PAE-L018...
Page 628 Connector part No. Connector No. of Type Destination number Female Male CN-74 PACKARD Alternator 1218-6568 CN-79 DEUTSCH Differential lock solenoid DT06-2S-EP06 CN-79A Differential lock solenoid S816-106002 CN-83 NMWP Aircon fan PB625-02027 CN-100 DEUTSCH Boom kick out DT06-3S-EP06 CN-101 DEUTSCH Bucket leveler DT06-3S-EP06 CN-102 Front washer tank...
Page 629 Connector part No. Connector No. of Type Destination number Female Male CN-177 DEUTSCH Quick coupler unlock solenoid DT06-2S-EP04 CN-177A Econoseal J I/conn (Front harness-Quick coupler harness) S816-003002 S816-103002 CN-178 DEUTSCH Quick coupler lock solenoid DT06-2S-EP04 CN-196 PACKARD Fuel heater 2-967325-3 CN-203 Rear wiper motor 936257-1...
Page 630 Connector part No. Connector No. of Type Destination number Female Male CR-46 HELLA Fuel warmer relay 8JA003526-001 CR-55 Rear work lamp relay VCFM-1002 CR-56 Mirror heat relay MG610047-1 CR-58 Back up relay VCFM-1002 CR-63 Stop lamp relay VCFM-1002 Switch CS-1 Shur Door switch S822-014004...
Page 631 Connector part No. Connector No. of Type Destination number Female Male Sensor, sender CD-1 Hyduaulic oil temp sendor 85202-1 CD-2 YAZAKI Fuel sendor 7123-7424 CD-3 DEUTSCH Brake fail pressure switch DT06-3S CD-4 DEUTSCH Stop lamp pressure switch DT06-3S CD-5 PACKARD Clutch cut off pressure switch 1215793 CD-10...
Page 632 2. CONNECTION TABLE FOR CONNECTORS 2. CONNECTION TABLE FOR CONNECTORS 58-L TYPE CONNECTOR 58-L TYPE CONNECTOR 1) 1) No. of Receptacle connector (female) Plug connector (male) S813-030100 S813-130100 S813-030200 S813-130200 7-81...
Page 633 2) 2) PA TYPE CONNECTOR PA TYPE CONNECTOR No. of Receptacle connector (female) Plug connector (male) S811-005002 S811-105002 S811-007002 S811-107002 S811-009002 S811-109002 S811-011002 S811-111002 7-82...
Page 634 No. of Receptacle connector (female) Plug connector (male) S811-013002 S811-113002 S811-017002 S811-117002 S811-021002 S811-121002 7-83...
Page 635 J TYPE CONNECTOR J TYPE CONNECTOR No. of Receptacle connector (female) Plug connector (male) S816-002001 S816-102001 S816-003001 S816-103001 S816-004001 S816-104001 S816-008001 S816-108001 7-84...
Page 636 SWP TYPE CONNECTOR SWP TYPE CONNECTOR No. of Plug connector (male) Receptacle connector (Female) S814-001000 S814-101000 S814-002000 S814-102000 S814-003000 S814-103000 S814-004000 S814-104000 7-85...
Page 637 No. of Receptacle connector (female) Plug connector (male) S814-006000 S814-106000 S814-008000 S814-108000 S814-012000 S814-112000 S814-014000 S814-114000 7-86...
Page 638 5) 5) CN TYPE CONNECTOR CN TYPE CONNECTOR No. of Receptacle connector (female) Plug connector (male) S810-001202 S810-101202 S810-002202 S810-102202 S810-003202 S810-103202 S810-004202 S810-104202 7-87...
Page 639 No. of Receptacle connector (female) Plug connector (male) S810-006202 S810-106202 S810-008202 S810-108202 7-88...
Page 640 6) 6) ITT SWF CONNECTOR ITT SWF CONNECTOR No. of Receptacle connector (female) Plug connector (male) SWF589790 7) 7) HW090 SEALED CONNECTOR HW090 SEALED CONNECTOR No. of Receptacle connector (female) Plug connector (male) 6189-0133 8) 8) MWP02F-B CONNECTOR MWP02F-B CONNECTOR No.
Page 641 9) 9) AMP ECONOSEAL CONNECTOR AMP ECONOSEAL CONNECTOR No. of Receptacle connector (female) Plug connector (male) 344111-1 344108-1 344108-1 344111-1 AMP TIMER CONNECTOR AMP TIMER CONNECTOR No. of Receptacle connector (female) Plug connector (male) 85202-1 AMP 040 MULTILOCK CONNECTOR AMP 040 MULTILOCK CONNECTOR No.
Page 642 KET 090 WP CONNECTORS KET 090 WP CONNECTORS No. of Receptacle connector (female) Plug connector (male) MG640795 ITT SWF CONNECTOR ITT SWF CONNECTOR No. of Receptacle connector (female) Plug connector (male) SWF593757 MWP NMWP CONNECTOR MWP NMWP CONNECTOR No. of Receptacle connector (female) Plug connector (male) NMWP01F-B...
Page 643 DEUTSCH DT CONNECTORS DEUTSCH DT CONNECTORS DT 06 - 3S - ★★★★ Modifications (see below) Number of contacts (P : Pin, S : Socket) 04 : Receptacle, 06 : Plug Deutsch connetors ※ Modification E003 : Standard end cap - gray E004 : Color of connector to be black E005 : Combination - E004 &...
Page 644 No. of Receptacle connector (female) Plug connector (male) DT06-6S DT04-6P DT06-8S DT04-8P DT06-12S DT04-12P 7-93...
Page 645 ECONOSEAL J TYPE CONNECTORS ECONOSEAL J TYPE CONNECTORS No. of Receptacle connector (female) Plug connector (male) S816-001002 S816-101002 S816-002002 S816-102002 S816-003002 S816-103002 S816-004002 S816-104002 7-94...
Page 646 No. of Receptacle connector (female) Plug connector (male) S816-006002 S816-106002 S816-008002 S816-108002 S816-010002 S816-110002 S816-012002 S816-112002 7-95...
Page 647 No. of Receptacle connector (female) Plug connector (male) 368301-1 2-85262-1 METRI-PACK TYPE CONNECTOR METRI-PACK TYPE CONNECTOR No. of Receptacle connector (female) Plug connector (male) 12040753 DEUTSCH MCU CONNECTOR DEUTSCH MCU CONNECTOR No. of Receptacle connector (Female) Plug connector (Male) DRC26-40SA/B/C 7-96...
Page 648: Group 6 Troubleshooting
GROUP 6 TROUBLESHOOTING GROUP 6 TROUBLESHOOTING 1. 1. WHEN STARTING SWITCH IS TURNED ON, CLUSTER WHEN STARTING SWITCH IS TURNED ON, CLUSTER AND MONITOR AND MONITOR LAMP DOES NOT LAMP DOES NOT LIGHT UP LIGHT UP ·Before carrying out below procedure, check all the related connectors are properly inserted and the fuse No.17 is not blown out and ON/OFF of bulb.
Page 649 WHEN BATTERY LAMP LIGHTS UP WHEN BATTERY LAMP LIGHTS UP (engine is started) ·Before carrying out below procedure, check all the related connectors are properly inserted. ·After checking, connect the disconnected connectors again immediately unless otherwise specified. Cause Remedy Defective Replace Check voltage controller...
Page 650 3. WHEN PARKING SOLENOID DOES NOT WORK 3. WHEN PARKING SOLENOID DOES NOT WORK ·Before carrying out below procedure, check all the related connectors are properly inserted and the fuse No.41 is not blown out. ·After checking, connect the disconnected connectors again immediately unless otherwise specified. Cause Remedy Defective parking...
Page 651 4. TRANSMISSION IS NOT RETURNED TO NEUTRAL WHEN PARKING BRAKE IS APPLIED 4. TRANSMISSION IS NOT RETURNED TO NEUTRAL WHEN PARKING BRAKE IS APPLIED ·Before carrying out below procedure, check all the related connectors are properly inserted and the fuse No.15 (transmission control unit) and No.41 are not blown out. ·After checking, connect the disconnected connectors again immediately unless otherwise specified.
Page 652 5. MACHINE DOES NOT TRAVEL 5. MACHINE DOES NOT TRAVEL ·Before carrying out below procedure, check all the related connectors are properly inserted and the fuse No.15 (transmission control unit) is not blown out. ·After checking, connect the disconnected connectors again immediately unless otherwise specified.
Page 653 6. WHEN STARTING SWITCH IS TURNED ON, WIPER MOTOR DOES NOT OPERATE 6. WHEN STARTING SWITCH IS TURNED ON, WIPER MOTOR DOES NOT OPERATE ·Before carrying out below procedure, check all the related connectors are properly inserted and the fuse No.40 is not blown out. ·After checking, connect the disconnected connectors again immediately unless otherwise specified.
Page 654 7. WHEN STARTING SWITCH "ON" DOES NOT OPERATE 7. WHEN STARTING SWITCH "ON" DOES NOT OPERATE FUSE BOX ·Before carrying out below procedure, check all the related connectors are properly inserted the TURN LAMP fuse No.2 is not blown out. START KEY SW RADIO B+ ·After checking, connect the disconnected connectors again immediately unless otherwise...
Page 655 8. WHEN STARTING SWITCH IS TURNED ON, WORK LAMP DOES NOT LIGHTS UP 8. WHEN STARTING SWITCH IS TURNED ON, WORK LAMP DOES NOT LIGHTS UP ·Before carrying out below procedure, check all the related connectors are properly inserted, and the fuse No.26, 39 is not blown out.

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Hyundai HL955 Manual

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Section 3 Power Train Systemsection 3 Power Train System

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