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Hyundai HL940 T3 Manual

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SECTION 1 GENERAL

SECTION 1 GENERAL

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

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

Group 3 Operational Checkout Record Sheet -------------------------------------------------------------- 1-24

SECTION 2 ENGINE

SECTION 2 ENGINE

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

Group 2 Engine speed and Stall rpm ---------------------------------------------------------------------------- 2-6

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 ------------------------------------------------------- 3-71

Group 3 Test and Adjustments --------------------------------------------------------------------------------------- 3-83

Group 4 Disassembly and Assembly ----------------------------------------------------------------------------- 3-84

SECTION 4 BRAKE SYSTEM

SECTION 4 BRAKE SYSTEM

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

Group 2 Operational Checks and Troubleshooting ------------------------------------------------------- 4-31

Group 3 Tests and Adjustments -------------------------------------------------------------------------------------- 4-38

Group 4 Disassembly and assembly ----------------------------------------------------------------------------- 4-40

SECTION 5 STEERING SYSTEM

SECTION 5 STEERING SYSTEM

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

Group 2 Operational Checks and Troubleshooting ------------------------------------------------------- 5-8

Group 3 Tests and Adjustments ------------------------------------------------------------------------------------- 5-14

Group 4 Disassembly and Assembly ----------------------------------------------------------------------------- 5-19

SECTION 6 WORK EQUIPMENT

SECTION 6 WORK EQUIPMENT

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

Group 2 Operational Checks and Troubleshooting ------------------------------------------------------ 6-35

Group 3 Tests and Adjustments ------------------------------------------------------------------------------------- 6-45

Group 4 Disassembly and Assembly ----------------------------------------------------------------------------- 6-57

CONTENTS

CONTENTS

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Summary of Contents for Hyundai HL940 T3

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 -------------------------------------------------------------- 1-24 SECTION 2 ENGINE SECTION 2 ENGINE Group 1 Structure and Function ------------------------------------------------------------------------------------ 2-1 Group 2 Engine speed and Stall rpm ---------------------------------------------------------------------------- 2-6 SECTION 3 POWER TRAIN SYSTEM 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 Electrical Component Specification ---------------------------------------------------------------- 7-22 Group 4 Connectors -------------------------------------------------------------------------------------------------------- 7-29 Group 5 Troubleshooting ------------------------------------------------------------------------------------------------- 7-62...
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 ---------------------------------------------------------------1-24...
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 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: Support Machine Properly
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 cut off switch to locked position. ・...
Page 15: Remove Paint Before Welding Or Heating
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 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 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 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 SPECIFICATION GROUP 2 SPECIFICATION 1. MAJOR COMPONENT 1. MAJOR COMPONENT Hydraulic tank Radiator Bucket Tire Head light Boom Boom cylinder Main control valve Battery Counterweight Engine Main pump Bell crank Bucket cylinder Air cleaner Bucket link Front axle Steering cylinder Transmission Rear axle...
Page 22 2. SPECIFICATIONS 2. SPECIFICATIONS 1) 1) WITH BOLT-ON CUTTING EDGE TYPE BUCKET WITH BOLT-ON CUTTING EDGE TYPE BUCKET (HL940 T3) 940A2SE03 Description Unit Specification Operating weight kg (lb) 13200 (29105) Struck 2.0 (2.6) Bucket capacity Heaped 2.3 (3.0) Overall length 7600 (24' 11")
Page 23 WITH BOLT-ON CUTTING EDGE TYPE BUCKET WITH BOLT-ON CUTTING EDGE TYPE BUCKET (HL940XT T3) 940A2SE03-2 Description Unit Specification Operating weight kg (lb) 13645 (30085) Struck 2.0 (2.6) Bucket capacity Heaped 2.3 (3.0) Overall length 8190 (26' 10") Overall width 2600 (8' 6") Overall height 3300 (10' 10") Ground clearance...
Page 24 WITH BOLT-ON CUTTING EDGE TYPE NARROW BUCKET WITH BOLT-ON CUTTING EDGE TYPE NARROW BUCKET (HL940 T3) 940A2SE02 Description Unit Specification Operating weight kg (lb) 13160 (29015) Struck 1.8 (2.4) Bucket capacity Heaped 2.1 (2.7) Overall length 7560 (24' 10") Overall width 2550 (8' 4")
Page 25 WITH BOLT-ON CUTTING EDGE TYPE WITH BOLT-ON CUTTING EDGE TYPE NARROW NARROW BUCKET BUCKET (HL940XT T3) 940A2SE02-1 Description Unit Specification Operating weight kg (lb) 13605 (30000) Struck 1.8 (2.4) Bucket capacity Heaped 2.1 (2.7) Overall length 8150 (26' 9") Overall width 2550 (8' 4") Overall height 3300 (10' 10")
Page 26 1070 2360 Quick coupler 1040 2295 Boom cylinder assembly Bucket cylinder assembly (HL940 T3/HL940XT T3) 95/115 210/255 Steering cylinder assembly Seat (Including suspension and armrest) Under guard Kit Engine Hood assembly Mud guard assembly (LH / RH)
Page 27 4. SPECIFICATION FOR MAJOR COMPONENTS 4. SPECIFICATION FOR MAJOR COMPONENTS 1) 1) ENGINE ENGINE Item Specification Model HYUNDAI HE6.7 Type 4-cycle turbocharged, charge air cooled diesel engine Control type Electronic control Cooling method Water cooling Number of cylinders and arrangement...
Page 28: Main Control Valve
6) 6) CYLINDER CYLINDER Item Specification Boom cylinder Bore dia×Rod dia×Stroke Ø110×Ø65×738 mm Bucket cylinder (HL940 T3) Bore dia×Rod dia×Stroke Ø125×Ø70×560 mm Bore dia×Rod dia×Stroke Ø125×Ø75×580 mm Bucket cylinder (HL940XT T3) Steering cylinder Bore dia×Rod dia×Stroke Ø 65×Ø40×429 mm 1-17...
Page 29 7) 7) DYNAMIC POWER TRANSMISSION DEVICES DYNAMIC POWER TRANSMISSION DEVICES Item Specification Model ZF 4WG160 Torque converter Type Single-stage, single-phase Ratio 2.302 : 1 Type Full-automatic power shift Transmission Gear shift Forward fourth gear, reverse third gear Control Electrical single lever type, kick-down system Drive devices 4-wheel drive Axle...
Page 30 5. TIGHTENING TORQUE OF MAJOR COMPONENT 5. 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 Engine mounting bolt (bracket, 8EA) M12×1.75 11.7 ± 1.8 84.6 ±...
Page 31: Torque Chart
6. TORQUE CHART 6. TORQUE CHART 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 32 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 33: New Machine
※ Do not mix HYUNDAI genuine oil with any other lubricating oil as it may result in damage to the systems of Do not mix HYUNDAI genuine oil with any other lubricating oil as it may result in damage to the systems of major components.
Page 34 Ambient temperature ˚C (˚F) Capacity Service point Kind of fluid ℓ (U.S. gal) (-58) (-22) (-4) (14) (32) (50) (68) (86) (104) SAE 15W-40 Engine ★ Engine oil 18 (4.8) SAE 5W-40 oil pan SAE 0W-40 SAE 10W-30 Transmission Engine oil 35 (9.2) SAE 15W-40 FR : 23 (6.1)
Page 35: 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 36 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 37 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 38: Section 2 Engine
SECTION 2 ENGINE SECTION 2 ENGINE Group 1 Structure and Function -------------------------------------------------------------------------------------- 2-1 Group 2 Engine speed and Stall rpm ----------------------------------------------------------------------------- 2-6...
Page 39: Group 1 Structure And Function (Fault Code)
SECTION 2 ENGINE SECTION 2 ENGINE GROUP 1 STRUCTURE AND FUNCTION GROUP 1 STRUCTURE AND FUNCTION 1. SYSTEM DIAGRAMS 1. SYSTEM DIAGRAMS The following drawings show the flow through the engine systems. 1) 1) FUEL SYSTEM FUEL SYSTEM 7607AEG02 From fuel tank 11 Fuel rail Water/fuel separator (not mounted on engine) 12 To injectors...
Page 40: Lubricating Oil System
2) 2) LUBRICATING OIL SYSTEM LUBRICATING OIL SYSTEM 7607AEG03 Gerotor lubricating oil pump Filter bypass valve From lubricating oil pump Filter bypass valve closed Pressure regulating valve closed 10 Filter bypass valve open Pressure regulating valve open 11 To lubricating oil filter To lubricating oil cooler 12 Full-flow lubricating oil filter To lubricating oil pump supply...
Page 41 (2) (2) Lubrication for the power components Lubrication for the power components 7607AEG05 From lubricating oil cooler To camshaft Main lubricating oil rifle Crankshaft main journal To valve train Oil supply to rod bearings From main lubricating oil rifle Directed piston-cooling nozzle To piston-cooling nozzle 10 To internal lubrication of air compressor (3) (3)
Page 42: Cooling System
3) 3) COOLING SYSTEM COOLING SYSTEM 7607AEG07 Coolant inlet Coolant flow to thermostat housing Pump lmpeller Coolant bypass passage Coolant flow past lubricating oil cooler Coolant flow back to radiator Coolant flow past cylinders 10 Bypass closed Coolant flow from cylinder block to cylinder head 11 Coolant bypass in cylinder head Coolant flow between cylinders 12 Coolant flow to water pump inlet...
Page 43: Exhaust System
5) 5) EXHAUST SYSTEM EXHAUST SYSTEM 7607AEG09 Exhaust valve Turbocharger Exhaust manifold Turbocharger exhaust outlet...
Page 44 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 45 SECTION 3 POWER TRAIN SYSTEM SECTION 3 POWER TRAIN SYSTEM Group 1 Structure and Function -------------------------------------------------------------------------------------- 3-1 Group 2 Operational Checks and Troubleshooting ------------------------------------------------------- 3-71 Group 3 Test and Adjustments ---------------------------------------------------------------------------------------- 3-83 Group 4 Disassembly and Assembly ------------------------------------------------------------------------------ 3-84...
Page 46: Section 3 Power Train System
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 Front axle Transmission Front drive shaft Center drive shaft Rear drive shaft Rear axle 940F3PT01 The power train consists of the following components:...
Page 47: Hydraulic Circuit
HYDRAULIC CIRCUIT HYDRAULIC CIRCUIT 940T33PT18 1 Return flow to sump 2 Pilot pressure 3 Main pressure 4 Lubrication 5 Converter pressure...
Page 48 Positions 15, 16, 51, 52, 53, 55, 56, 57, 58, 60, 65, 66 correspond to the numbers on the installation drawing. 2 Clutch K3 1 Clutch K2 4 Clutch K1 3 Clutch KV (clutch forward) 5 Clutch KR (clutch reverse) 6 Clutch K4 8 Downstream valve 7 Pilot valve...
Page 49 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 50 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 51 3. TRANSMISSION 3. TRANSMISSION DIAGRAM DIAGRAM 940T33PT10 Clutch KV (clutch forward) Input Clutch KR (clutch reverse) Clutch K4 Clutch K2 Clutch K1 Clutch K3 Output Engine-dependent PTO 10 Inductive sensor for engine speed 11 Pump 12 Inductive sensor for speed of central gear 13 Inductive sensor for turbine speed chain 14 Emergency steering pump (optional)
Page 52: Installation View
INSTALLATION VIEW INSTALLATION VIEW 940T33PT11 Full flow filter 37 System pressure connection M16 x 1.511 Lifting eye 47 Speed sensor for speed/central gear hain Transmission suspension holes 48 Speed sensor for engine speed 11 Electrohydraulic transmission control unit 49 Plug connection for machine connector 12 PTO coaxial, engine-dependent 54 Differential pressure switch for pressure 21 Speed sensor for turbine speed...
Page 53 INSTALLATION VIEW INSTALLATION VIEW 940T33PT12 Converter 16 Connection from oil cooler Transmission suspension holes 20 Oil drain plug M38 x 1.5 Name plate (tightening torque : 80 Nm) Connection for oil level measurement 22 Input flange 10 Breather 25 Output flange 15 Connection to oil cooler 39 Connection of return flow to sump...
Page 54 3) 3) ELECTRONIC TRANSMISSION CONTROL UNIT ELECTRONIC TRANSMISSION CONTROL UNIT 960T33PT13 Transmission connector Machine connector The electronic transmission control unit controls the electro-hydraulic transmission control unit. The electronic control unit (EC4A) is designed as on-site electronics. An internal plug connection and awiring harness (plug-in connector 1) connect the electronic transmission control unit and the internal elements of the transmission.
Page 55 4. 4. FAULT CODE FAULT CODE 1-1) 1-1) MACHINE FAULT CODE 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.
Page 56 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.
Page 57 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 58 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 59 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 ●...
Page 60 1-2) 1-2) EHCU FAULT CODE 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...
Page 61 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 62 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 63 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 64 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 65 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 66 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 67 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 68 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 69 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 70 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 71 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 72 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 73 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 74 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 75 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 76 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 77 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 78 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 79 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 80 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 81 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 82 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 83 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 84 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 85 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 86 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 87 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 88 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 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. 4149 circuit frequency - Abnormal frequency or pulse 2623 width or period. The accelerator pedal position sensor reading is out of range.
Page 90 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 91 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 92 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 93 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 94 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 95 4 4 ) ) TRANS TRANSMISSION MISSION F F A A U U L L T CO T CODES FaultDescription OpMode Cause PossibleSteptoRepair The cause of the missing or insufficient voltage on terminal 30 must be located. 1. Check the fuse of the terminal 30 control units. 2.
Page 96 FaultDescription OpMode Cause PossibleSteptoRepair control unit, in particular with regard to defective plug connections such as corroded or damaged plug contacts. Pay special attention to the ground wiring. 5. Check the function of the alternator as well as the settings of the alternator control unit and replace both if necessary.
Page 97 FaultDescription OpMode Cause PossibleSteptoRepair sensors (AU3) 1. Wiring or plug connection is defective. 1. Check the wiring, in particular with regard to undervoltage 2. Sensor has an internal defect. defective plug connections such as corroded or 3. Control unit has an internal defect. damaged plug contacts.
Page 98 FaultDescription OpMode Cause PossibleSteptoRepair and oil filter restriction 2. Sensor has an internal defect. defective plug connections such as corroded or switch (AU2) 3. Control unit has an internal defect. damaged plug contacts. undervoltage 2. Check the correct wiring of the pins. EC4: Supply for speed 3.
Page 99 FaultDescription OpMode Cause PossibleSteptoRepair 3. Control unit has an internal defect. damaged plug contacts. 2. Check the correct wiring of the pins. 3. Check the function of the sensor or replace the sensor. 4. Replace the control unit if the error continues to occur.
Page 100 FaultDescription OpMode Cause PossibleSteptoRepair 3. Check the function of the connected component or replace the component. 4. Replace the control unit if the error continues to occur. The cause of the increased temperature input in the control unit must be located. The measured temperature on the control unit 1.
Page 101 FaultDescription OpMode Cause PossibleSteptoRepair controller hardware application. detected The cause of the incorrect voltage must be located. 1. Switch the ignition off, wait 10 seconds and switch the ignition back on. Check if the error is still active. 2. Check the wiring, in particular with regard to defective plug connections such as corroded or damaged plug contacts.
Page 102 FaultDescription OpMode Cause PossibleSteptoRepair The cause of the unknown speed must be located. The control unit does not recognize the speed at 1. Check the wiring from the speed sensor to the the input. control unit, in particular with regard to defective plug 1.
Page 103 FaultDescription OpMode Cause PossibleSteptoRepair rotation unknown: 1. Wiring or plug connection is defective. 1. Check the wiring from the sensor to the control unit, Internal speed 2. Wiring or plug connection has a poor contact. in particular with regard to defective plug connections 3.
Page 104 FaultDescription OpMode Cause PossibleSteptoRepair replace it if needed. 4. Replace the control unit if the error continues to occur. The cause of the unknown rotational direction must be The control unit does not recognize the located. rotational direction at the input. 1.
Page 105 FaultDescription OpMode Cause PossibleSteptoRepair 1. Wiring or plug connection is defective. 2. Check the wiring between the connected 2. Component has an internal defect. component and the control unit, in particular with 3. Control unit has an internal defect. regard to defective plug connections such as corroded or damaged plug contacts.
Page 106 FaultDescription OpMode Cause PossibleSteptoRepair 4. Replace the control unit if the error continues to occur. 1. Switch the ignition off, unplug the control unit and measure the resistance of the connected component using a terminal tester. The measured line resistance between the 2.
Page 107 FaultDescription OpMode Cause PossibleSteptoRepair 4. Replace the control unit if the error continues to occur. The measured voltage at the sensor input 3 is too high: cable is defective and is contacted to battery voltage clutch cut off / inch pedal sensor has an check the cable from TCU to the sensor Voltage sensor input 3 internal defect connector pin is contacted to...
Page 108 FaultDescription OpMode Cause PossibleSteptoRepair (EU4) defect allowed thresholds. connectors check the sensor 4 Change the sensor 1. Using the circuit diagram, check if a component is assigned to the output. 2. Check the wiring, in particular that it is wired correctly.
Page 109 FaultDescription OpMode Cause PossibleSteptoRepair or damaged plug contacts. 4. Check the function of the connected component and replace it if needed. 5. Replace the control unit if the error continues to occur. 1. Switch the ignition off, wait 10 seconds and switch the ignition back on.
Page 110 FaultDescription OpMode Cause PossibleSteptoRepair replace it if needed. 6. Replace the control unit if the error continues to occur. 1. Using the circuit diagram, check if a component is assigned to the output. 2. Check the wiring, in particular that it is wired correctly.
Page 111 FaultDescription OpMode Cause PossibleSteptoRepair component and the control unit, in particular with regard to defective plug connections such as corroded or damaged plug contacts. 4. Check the function of the connected component and replace it if needed. 5. Replace the control unit if the error continues to occur.
Page 112 FaultDescription OpMode Cause PossibleSteptoRepair a terminal tester. 5. Check the function of the proportional valve and replace it if needed. 6. Replace the control unit if the error continues to occur. 1. Using the circuit diagram, check if a component is assigned to the output.
Page 113 FaultDescription OpMode Cause PossibleSteptoRepair 2. Component has an internal defect. using a terminal tester. 3. Control unit has an internal defect. 3. Check the wiring between the connected component and the control unit, in particular with regard to defective plug connections such as corroded or damaged plug contacts.
Page 114 FaultDescription OpMode Cause PossibleSteptoRepair 4. Switch the ignition off, unplug the control unit, and measure the resistance of the proportional valve using a terminal tester. 5. Check the function of the proportional valve and replace it if needed. 6. Replace the control unit if the error continues to occur.
Page 115 FaultDescription OpMode Cause PossibleSteptoRepair high. 2. Switch the ignition off, unplug the control unit and 1. Wiring or plug connection is defective. measure the resistance of the connected component 2. Component has an internal defect. using a terminal tester. 3. Control unit has an internal defect. 3.
Page 116 FaultDescription OpMode Cause PossibleSteptoRepair 3. Control unit has an internal defect. defective plug connections such as corroded or damaged plug contacts. 4. Switch the ignition off, unplug the control unit, and measure the resistance of the proportional valve using a terminal tester. 5.
Page 117 FaultDescription OpMode Cause PossibleSteptoRepair 1. Switch the ignition off, wait 10 seconds and switch the ignition back on. Check if the error is still active. 2. Switch the ignition off, unplug the control unit and measure the resistance of the connected component using a terminal tester.
Page 118 FaultDescription OpMode Cause PossibleSteptoRepair proportional valve. 3. Check the wiring between the proportional valve 2. Proportional valve has an internal defect. and the control unit, in particular with regard to 3. Control unit has an internal defect. defective plug connections such as corroded or damaged plug contacts.
Page 119 FaultDescription OpMode Cause PossibleSteptoRepair 5. Replace the control unit if the error continues to occur. 1. Switch the ignition off, wait 10 seconds and switch the ignition back on. Check if the error is still active. 2. Switch the ignition off, unplug the control unit and measure the resistance of the connected component using a terminal tester.
Page 120 FaultDescription OpMode Cause PossibleSteptoRepair too low. proportional valve or with which valve the error is 1. Wiring or plug connection contacts another bypassed. proportional valve. 3. Check the wiring between the proportional valve 2. Proportional valve has an internal defect. and the control unit, in particular with regard to 3.
Page 121 FaultDescription OpMode Cause PossibleSteptoRepair 5. Replace the control unit if the error continues to occur. 1. Switch the ignition off, wait 10 seconds and switch the ignition back on. Check if the error is still active. 2. Switch the ignition off, unplug the control unit and measure the resistance of the connected component using a terminal tester.
Page 122 FaultDescription OpMode Cause PossibleSteptoRepair too low. proportional valve or with which valve the error is 1. Wiring or plug connection contacts another bypassed. proportional valve. 3. Check the wiring between the proportional valve 2. Proportional valve has an internal defect. and the control unit, in particular with regard to 3.
Page 123 FaultDescription OpMode Cause PossibleSteptoRepair driver 2 (ADM2) short that looks like a s.c. to battery voltage cable is the connectors check the resistance of the device at to battery defective and is contacted to battery voltage ADM2 device has an internal defect connector pin is contacted to battery voltage TCU detected a wrong voltage at the output pin, that looks like a o.c.
Page 124 FaultDescription OpMode Cause PossibleSteptoRepair 1. Wiring or plug connection contacts vehicle component and the control unit, in particular with ground. regard to defective plug connections such as corroded 2. Component has an internal defect or damaged plug contacts. 3. Control unit has an internal defect. 3.
Page 125 FaultDescription OpMode Cause PossibleSteptoRepair 3, Control unit has an internal defect. damaged plug contacts. 2. Check the correct wiring of the pins. 3. Check the function of the sensor or replace the sensor. 4. Replace the control unit if the error continues to occur.
Page 126 FaultDescription OpMode Cause PossibleSteptoRepair The measured voltage from sensor output signal 1 and output signal 2 don’t match or are out of range. 1. Check the cable from TCU to the sensor Voltage sensor input 2 1. Cable is defective 2.
Page 127 FaultDescription OpMode Cause PossibleSteptoRepair not drop when the vehicle is operated at idle even after a longer period of time, then the temperature sensor needs to be replaced. If this error occurs while driving, then remain at a standstill, switch the ignition off, then on again and wait another 40 seconds.
Page 128 FaultDescription OpMode Cause PossibleSteptoRepair If the control unit resets the error itself, then this is a matter of a sporadically occurring error. Check the following points only when the error is active. 1. Check the CAN connection for interruptions, in particular with regard to defective plug connections such as corroded or damaged plug contacts.
Page 129 FaultDescription OpMode Cause PossibleSteptoRepair 3. Sending control unit has an internal defect. first. 4. Receiving control unit has an internal defect. 2. If this error continues to be active, please contact your vehicle manufacturer. If the control unit resets the error itself, then this is a The control unit does not receive the CAN matter of a sporadically occurring error or an excessive message or the message contains faulty data.
Page 130 FaultDescription OpMode Cause PossibleSteptoRepair If the control unit resets the error itself, then this is a The control unit does not receive the CAN matter of a sporadically occurring error or an excessive message or the message contains faulty data. bus load.
Page 131 FaultDescription OpMode Cause PossibleSteptoRepair HCE. If the control unit resets the error itself, then this is a The control unit does not receive the CAN matter of a sporadically occurring error or an excessive message or the message contains faulty data. bus load.
Page 132 FaultDescription OpMode Cause PossibleSteptoRepair Engine speed control The transmission control unit requires a certain request does not take engine speed; the engine controller does not set If this error continues to be active, please contact HCE. 523502 effect Normal this speed; Engine torque limit The transmission control unit requires a limited request does not take...
Page 133 FaultDescription OpMode Cause PossibleSteptoRepair speed in Reverse Protection Function 7 (SF07) Unwanted Read out the operating data with Testman and send 523600 direction change Trm Shutdown Unwanted change of driving direction detected them to your ZF contact. Protection Function 8 Read out the operating data with Testman and send 523600 (SF08)
Page 134 FaultDescription OpMode Cause PossibleSteptoRepair 2. If this error continues to occur, please contact HCE. detected 1. CAN bus message is faulty. The control unit requires that the internal supply Protection error voltage is switched off but this does not happen. 523603 reaction failed TCU Shutdown...
Page 135 FaultDescription OpMode Cause PossibleSteptoRepair 2. Wiring or plug connection has a poor contact. connections such as corroded or damaged plug 3. Distance speed sensor – sensor ring too large. contacts. 4. Speed sensor has an internal defect. 2. Check the function of the sensor and, if necessary, replace it.
Page 136 FaultDescription OpMode Cause PossibleSteptoRepair replace it. The control unit recognizes a rotational direction The cause of the different rotational directions must be at the input, which does not agree with the located. other rotational directions. 1. Check the wiring from the sensor to the control unit, EF3 direction of 1.
Page 137 FaultDescription OpMode Cause PossibleSteptoRepair diagnosis unit. If the measured oil temperature does not drop when the vehicle is operated at idle even after a longer period of time, then the temperature sensor needs to be replaced. The cause of the increased temperature at the converter must be located.
Page 138 FaultDescription OpMode Cause PossibleSteptoRepair HCE. 2. Incorrect software on the engine controller. 1.Check the software version of the transmission Signal ‘Requested Launch Gear’ from vehicle controller contains faulty data. control unit and program the current software version 1 .Incorrect software on the transmission control if required.
Page 139 FaultDescription OpMode Cause PossibleSteptoRepair 4. Clutch faulty. 4. Check the function of the proportional valves and 5. Transmission input speed signal faulty. replace them if needed. 6. Transmission output speed signal faulty. 5. Check if all speeds are present and correct. 7.
Page 140 FaultDescription OpMode Cause PossibleSteptoRepair unintendedly the clutch is closed. If this value is too high, it is located. interpreted as slip on the clutch. 1. Check the existing system pressure. 1. Insufficient pressure on the clutch. 2. Check the filter and replace it if needed (compare 2.
Page 141 FaultDescription OpMode Cause PossibleSteptoRepair 6. Transmission output speed signal faulty. 5. Check if all speeds are present and correct. 7. Distance speed sensor – sensor ring too large. 6. Check the wiring, in particular with regard to 8. Significant oscillation of the engine speed. defective plug connections such as corroded or damaged plug contacts.
Page 142 FaultDescription OpMode Cause PossibleSteptoRepair 1. Check CAN bus 2. Check the software version of the transmission control unit and program the current software version if required. Message ZFTC2 invalid ZFTC2 message is missing or provides wrong 3. If this error continues to occurs, please contact your 523431 or timed out Trm Shutdown...
Page 143 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 144 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 145 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 146: Tire And Wheel
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 147: 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 148 ※ ※ 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 149 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 150 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 151: Troubleshooting
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 152 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 153 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. switch. Do transmission system pressure test. Plugged suction strainer. Transmission pump may be noisy if transmission suction screen is clogged.
Page 154 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 155 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 156 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 157 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 158 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 159: Group 3 Test And Adjustments
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). Measurement Measurement Measuring Measuring variable pressure/ variable pressure/ point point...
Page 160: Group 4 Disassembly And Assembly
GROUP 4 DISASSEMBLY AND ASSEMBLY GROUP 4 DISASSEMBLY AND ASSEMBLY 1. AXLE 1. AXLE 1) 1) DISASSEMBLY DISASSEMBLY (1) (1) Output and brake disassembly Output and brake disassembly 7409AAX001 Input Brake Axle drive housing Output Axle housing ① Mount axle on assembly truck. Assembly truck 5870 350 000 Supporting bracket (2EA) 5870 350 106...
Page 161 ③ Drain oil from both outputs. ※ Use suitable reservoir-environmental protection. 7409AAX004 Disassembly output assy /brake 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 figure AX007~AX009 and assembly steps page 3-128~130.
Page 162 ② Take up output by means of a lifting bracket. Loosen bolted connection (output /axle housing) and separate output from axle housing. Pay attention to releasing end plate and multi discs. Lifting bracket 5870 281 043 7409AAX008 ③ Remove stub shaft and sun gear shaft. ※...
Page 163 ⑥ Loosen locking screws and remove lid. Pay attention to releasing planetary ※ carrier, risk of accident. 7409AAX012 ⑦ Lift compl. planetary carrier out of brake housing. Inner extractor 5870 300 019 Eye nut 5870 204 073 7409AAX013 ⑧ Snap out retaining ring. Set of external pliers 5870 900 015 7409AAX014...
Page 164 ⑩ Pull bearing inner ring off the planetary carrier. Grab sleeve 5873 003 033 Basic tool 5873 003 001 7409AAX016 ⑪ Take disc package out of brake housing. 7409AAX017 ⑫ Loosen threaded joint. 7409AAX018 ⑬ Remove lid, cup spring and disk. 7409AAX019 3-88...
Page 165 ⑭ Lift piston off with lever. Adjusting device 5870 400 001 7409AAX020 ⑮ Remove sealing elements (arrows also refer to AX022) from annular grooves of brake housing. 7409AAX021 1 Brake housing 2 Guide ring 3 Support ring 4 Grooved ring 5 Grooved ring 6 Support ring 7409AAX022...
Page 166 Remove screw neck (1) and breather valve (2). 7409AAX024 Lift off shaft seal by lever and remove both bearing outer rings from brake housing, if required. Pry bar 5870 345 071 7409AAX025 Pull bearing inner ring from output shaft. Rapid grip 5873 014 016 Basic tool 5873 004 001...
Page 167 (2) (2) Differential and input disassembly Differential and input disassembly ■ Differential Differential ① Mount axle on assembly truck. Assembly truck 5870 350 000 Supporting bracket (2EA) 5870 350 106 7409AAX101 ※ The following illustration shows the removal of the differential in the course of a complete disassembly of the axle.
Page 168 Conventional differential (STD) Conventional differential (STD) ※ D e s c r i p t i o n o f d i s a s s e m bl y a n d reassembly of the limited slip differential from page 3-94. ①...
Page 169 ⑤ Remove axle bevel gear, thrust washer and constant spacer. Differential carrier Crown wheel Constant spacer Thrust washer Axle bevel gear 7409AAX108 ⑥ Force slotted pin (fixing) out of both spider shaft halves (split version), then remove both spider shaft halves in arrow direction and take components (see AX110) out of differential carrier.
Page 170 ⑧ Remove O-ring (arrow). Remove bearing outer ring and shim behind (rolling torque differential bearing) from axle housing. ※ Mark shim (position/bearing allocation), assembly aid. Striker 5870 650 004 7409AAX112 Limited slip differential (option) Limited slip differential (option) 1 Housing cover 2 Crown wheel 3 Spider shaft (split version) (2EA) 4 Double slotted pins...
Page 171 ② Pull the tapered roller bearing from the housing cover /differential carrier. Grab sleeve 5873 002 035 Basic tool 5873 002 001 Pressure piece 5873 100 047 7409AAX123 ③ Use the press to fix the differential ; loosen the locking screws and remove the cover.
Page 172 ■ Input Input For axle version with pivot bearing only (see AX128) ① Loosen bolted connection and pull off bearing flange. 7409AAX128 ② H e a t u p h ex nu t ( l o c t i t e l o ck i n g compound) by means of hot air blower disassembly aid.
Page 173 ⑤ Lift shaft seal off. Pry bar 5870 345 071 7409AAX132 ⑥ Press input pinion out by means of press off tool and remove releasing bearing inner ring. Press-off tool 5870 280 044 7409AAX133 ⑦ Remove spacer ring from pinion. 7409AAX134 ⑧...
Page 174 ⑨ Pull-off outside bearing outer ring. Internal extractor 5870 300 019 Counter support 5870 300 020 7409AAX136 ⑩ Force bearing outer ring out of inner bearing hole, pay attention to shim behind (contact pattern/bevel gear set). ※ Mark shim (thickness/position and bearing allocation), assembly aid.
Page 175 2) 2) ASSEMBLY ASSEMBLY (1) (1) Input assembly Input assembly 7409AA201 Axle drive housing Protection plate Input pinion Input flange Tapered roller bearing 10 Disc Shim for contact pattern (bevel gear set) 11 Hexagon nut Spacer ring 12 Bearing flange (bearing roller torque/ pinion bearing) (only for axle version with pivot bearing) Tapered roller bearing...
Page 176 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): ※...
Page 177: Calculation Example
② Read pinion dimension "X" (pinion basic dimension e.g. = 148) from pinion, or determine it in case of a + or - deviation + 0.1 from pinion dimension due to production (value concerned is marked by hand on the pinion, e.g.+ 0.1). Pinion dimension "X"...
Page 178 ④ Undercool bearing outer ring (see arrow) and bring it into contact position in the inner bearing hole /pinion bearing by means of the fixture. Assembly fixture 5870 345 049 7409AAX207 ⑤ Install outside bearing outer ring /pinion bearing. Assembly fixture 5870 345 049 7409AAX208 ⑥...
Page 179 Set rolling torque of input pinion Set rolling torque of input pinion bearing 0.11~0.23 bearing 0.11~0.23 kgf kgf·m (0.81~1.70 (0.81~1.70 lbf lbf·ft ft) (without shaft seal) : ) (without shaft seal) : ⑦ Mount spacer ring (s = optional). ※ We recommend to reinstall the spacer ring found during disassembly (e.g.
Page 180 ⑩ Check rolling torque of the pinion bearing. Bearing rolling torque (without shaft seal) : 0.11~0.23 kgf·m (0.81~1.70 lbf·ft). Try to achieve upper value. ※ In case of a deviation from the required r o l l i n g t o r q u e c o r r e c t i t w i t h a corresponding spacer ring (see AX210) 7409AAX213 Torque wrench...
Page 181 ③ Insert steel outer disc (2) and thrust washer (3) into the differential carrier (1) ※ Pay attention to installation position of outer disc and thrust washer see position/figure. 7409AAX216 ④ Insert axle bevel gear. 7409AAX217 ⑤ Differential spider single parts : Spider shaft (one part) Spider gear (4EA) Thrust washer (4EA)
Page 182 ⑦ Install split spider shaft (4) with spider gears (2) and thrust washers (3). ※ Insert thrust washers with tabs showing upwards (see arrow) and being located in recess. ※ Pay attention to installation position of spider shaft/ halves-slotted pin/location holes of spider shaft towards differential carrier.
Page 183 ⑪ Install two adjusting screws (M16) (see arrows) and press crown wheel to contact position. For input version with bevel gear set only, see specification in the corresponding spare parts list : If a bevel gear set is specified, the pairing number/crown wheel (e.g.
Page 184 Determine shims for bearing rolling Determine shims for bearing rolling t o r q u e / d i f fe r e n t i a l b e a r i n g a n d t o r q u e / d i f fe r e n t i a l b e a r i n g a n d backlash /bevel gear set backlash /bevel gear set ⑮...
Page 185 Insert determined shim (e.g. s = 1.00 mm) and bearing outer ring into hole of axle housing on crown wheel side. ※ Observe allocation of shim regarding installation position. Driver tool 5870 058 021 Handle 5870 260 002 7409AAX230 Insert determined shim (e.g. s = 1.00 mm) and bearing outer ring into hole of axle housing on differential carrier side.
Page 186 Position axle housing of crown wheel side (without O-ring) on axle drive h o u s i n g , p ay a t t e n t i o n t o ra d i a l installation position. Lifting chain 5870 281 047 Eyebolts...
Page 187 If disassembled : Insert shim(s) (2) into sun gear shaft (1) and mount stub shaft (3). ※ If position was not allocated, as specified in disassembly instructions on AX103, s u n g e a r s h a f t c l e a r a n c e ( s e e AX330~AX334) must be set on both output sides.
Page 188 Fix axle housing finally by means of hexagon screws. Rotate differential several times in both directions roller setting. ·Tightening torque (M18/10.9) : 39.8 kgf·m (288 lbf·ft) 7409AAX242 (3) (3) Limited slip differential (OPT) assembly Limited slip differential (OPT) assembly 1 Housing cover 2 Crown wheel 3 Spider shaft (split version) (2EA) 4 Double slotted pins...
Page 189 ② Mount the single parts, see AX249 and AX250. Single parts differential spider : 1 Spider shaft (one piece) 2 Spider gear (4EA) 3 Thrust washer (4EA) 4 Spider shaft (two pieces) 5 Slotted pins (2 pieces, 5×50 mm) 6 Slotted pins (2 pieces, 8×50 mm) 7409AAX249 ③...
Page 190 ⑤ Mount two adjusting screws and press the crown wheel until contact is obtained. 7409AAX252 ⑥ Mount the housing cover. 7409AAX253 ⑦ Bolt housing cover, crown wheel and differential housing. ·Tightening torque (M16×1.5/12.9) : 42.8 kgf·m (302 lbf·ft) ※ It is only permitted to use new locking screws.
Page 191 (4) (4) Shaft seal /input flange assembly Shaft seal /input flange assembly ① Remove flange. Clamping fork 5870 240 025 7409AAX289 ② For new parts assembly only : Mount protection plate on screen sheet on input flange and bring to contact position.
Page 192 Shaft seal Protection plate Input flange Tapered roller bearing Input pinion "Z" Axle drive housing X = Install. dimension 16.6 ± 0.2 mm Detailed sketch "Z" 7409AAX292 ④ Mount flange, fix with washer and hexagon nut. During tightening, rotate pinion several times in both directions (roller setting).
Page 193 (6) (6) Oil dipstick, drain plugs and breather valve assembly Oil dipstick, drain plugs and breather valve assembly 7409AAX295 Oil dipstick Drain plug /axle drive housing (Axle version with pivot bearing is fitted with another drain plug) Drain plug/output Depending on version Breather valve or screw plug Provide oil dipstick and drain plugs with new O-ring and install them.
Page 194 (7) (7) Output and brake assembly Output and brake assembly Planetary carrier Brake housing Disc package Piston Combi seal ring Output shaft Assembly truck 5870 350 000 Fixture 5870 350 112 7409AAX301 Close apertures of oil supply holes with plugs. Hand tool 5870 320 014 Ratchet wrench...
Page 195 1 Brake housing 2 Output shaft 3 Shaft seal (part I) combi seal ring 4 Wear sleeve (part II) "X" = installation dimension /shaft seal + 0.2 "Y" = installation dimension /wear sleeve Detail "Z" + 0.2 Detail "Z" 7409AAX304 ②...
Page 196 Output shaft /brake housing Output shaft /brake housing ① Mount heated bearing inner ring until contact. ※ Adjust bearing inner ring after cooling down. 7409AAX306 ② Press outside bearing outer ring into brake housing until contact. Driver tool 5870 050 010 7409AAX307 ③...
Page 197 ⑤ Insert sealing elements (arrows) into annular grooves of brake housing paying attention to installation position and arrangement, in this context refer to AX311. ※ Guide ring installation : Clean annular groove of brake housing with spirit. Then insert guide ring into annular groove - Ensure an exact contact p o s i t i o n o f t h e w h o l e g u i d e r i n g 7409AAX310...
Page 198 ⑥ Flush-mount slotted pins (for installation position refer to arrow) into the piston, if not disassembled, adjust adequately (flushfitting). 7409AAX312 ⑦ Oil sealing/sliding surface of piston and sealing elements. Carefully bring piston in contact position. 7409AAX313 ⑧ I n s e r t d i s c , c u p s p r i n g a n d l i d considering the installation position, see detail sketch.
Page 199 ⑩ Mount heated bearing inner ring until contact. ※ Adjust bearing inner ring after cooling down. 7409AAX316 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 200 ⑭ Evenly tighten locking screws crosswise while rotating the brake housing in both directions several times (roller setting). ·Tightening torque (M8/12.9) : 51.0 kgf·m (369 lbf·ft) 7409AAX320 ⑮ Apply a screw safety marking paint on correctly installed locking screws. 7409AAX321 Mount O-ring (arrow) on lid.
Page 201 Brake Brake ※ Possible other versions could have a deviating equipment (number and arrangement of single discs), the illustration in the relating spare parts list for ms the basis for the required equipment. Outer disc s = 2.0 mm Outer disc s = 4.0 mm Inner disc (lined disc) End plate 7409AAX324...
Page 202 ④ Heat up planetary gears and mount to the pin of the planetary carrier until contact is obtained, with the large radius /bearing inner ring showing downwards (arrow). ※ Adjust bearing after cooling down. 7409AAX328 ⑤ Fix planetary gears with retaining ring. ※...
Page 203 ② Mount stub shaft with fitted sun gear shaft (without shim) into differential /axle bevel gear until contact. 7409AAX332 ③ Determine dimension "II" from mounting face (brake housing /axle housing) to front face /sun gear shaft. Dimension II e. g... . 19.00 mm CALCULATION EXAMPLE: Dimension I .
Page 204 Assemble output assy Assemble output assy ① Fix disc package by means of locating screw, assembly aid. Locating screw 5870 204 078 7409AAX335 ② Oil O-ring and mount on collar of axle housing. 7409AAX336 ③ Take up output by means of lifting bracket.
Page 205 ⑤ Connect output with axle housing evenly by means of hex. screws. ·Tightening torque (M18×1.5/10.9) : 39.8 kgf·m (288 lbf·ft) 7409AAX339 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 : 0.6 kgf·m (4.4 lbf·ft) Install screw neck (3) with new O-ring.
Page 206 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 - 10 bar maximum and close connection to HP pump by means of a shutoff valve A pressure drop by maximum 3% (3 bar) is permissible during a 5 minute test...
Page 207 ※ 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 208 Incorrect pattern, low contact Incorrect pattern, low contact WTHAX21 WTHAX22 Concave side Convex side - Add the distance (+) ( ) + WTHAX23 3-132...
Page 209 2. TRANSMISSION TRANSMISSION Preparatory Activities Mounting transmission on assembly truck Special tools: • 5870.350.090 Connection plate • 5870.350.063 Clamping plate • 5870.350.000 Assembly truck Risk of injury due to uncontrolled motion of the load. Death or serious injury possible. ð Only use the suspension points intended for transportation purposes.
Page 210 Preparatory Activities Loosen screw plug (1) and drain oil from the transmission. Fig. 22 3-134...
Page 211 Dismantling Dismantling Removing the pressure filter Loosen the pressure filter (1). Fig. 23 Loosen internal hexalobular bolts and remove filter head (1). Fig. 24 3-135...
Page 212 Dismantling Removing cover plate (filler neck) Loosen hexagon screws and remove cover sheet (1) with seal. Fig. 25 Loosen hexagon screws and remove cover sheet (1) with seal. Fig. 26 3-136...
Page 213 Dismantling Removing pressure controller and speed sensors Remove the cable ties. Disconnect plug connections and remove cable (1). Fig. 27 Loosen cap screws. Pull the pressure controller (1) out of the housing hole. Fig. 28 Loosen cap screws. Pull the speed sensors (1) out of the housing holes.
Page 214 Dismantling Removing the temperature sensors and the breather Loosen the breather (1). Loosen the temperature sensors (2). Fig. 30 Removing output flanges Removing output flange on input side Loosen hexagon screws (1). Remove washer (2). Fig. 31 3-138...
Page 215 Dismantling Remove O‑ring (1). Fig. 32 Pull off output flange (1). Fig. 33 Remove shaft seal (1) from the housing hole. Fig. 34 3-139...
Page 216 Dismantling Removing output flange on gearshift side Loosen hexagon screws (1). Remove washer (2). Fig. 35 Remove O‑ring (1). Fig. 36 Pull off output flange (1). Fig. 37 3-140...
Page 217 Dismantling Remove shaft seal (1) from the housing hole. Fig. 38 Removing and dismantling shift system Removing filter bypass valve Loosen the tappet switch (1). Fig. 39 3-141...
Page 218 Dismantling Remove piston (3) from hole (1). Remove compression spring (2) from hole (1). Fig. 40 Removing control unit (ECA4) Loosen internal hexalobular bolts. Remove control unit (1). Fig. 41 3-142...
Page 219 Dismantling Removing the pressure controllers Separate plug connections (1) on the pressure controllers. Loosen internal hexalobular bolts and remove fixing plate (3). Remove cable (2). Fig. 42 Loosen internal hexalobular bolts and remove clamping plate (1). Pull out the pressure controllers (2). Fig.
Page 220 Dismantling Loosen internal hexalobular bolts. Remove valve block (1) and intermediate plate. Fig. 44 Press the piston inwards with AA02.414.200 [Driver tool] and remove the fixing plate. Fig. 45 Remove compression spring (2) and piston (1) from the hole. Fig. 46 3-144...
Page 221 Dismantling Loosen internal hexalobular bolts. Remove valve block (1) and intermediate plate. Fig. 47 Press the plug inwards with AA02.416.754 [Driver tool] and remove the spring clip (1). Fig. 48 Pull the plug (3) out of the hole. Remove control piston (2) and compression spring (1) from the hole.
Page 222 Dismantling Press the plug inwards using AA02.416.230 [Driver tool] and remove fixing plate (1). Fig. 50 Pull the plug (3) out of the hole. Remove compression spring (2) and control piston (1) from the hole. Fig. 51 Removing duct plate Remove piston (2) and compression spring (1) from holes (3).
Page 223 Dismantling Remove valves (1) from duct plate. Fig. 53 Loosen internal hexalobular bolts. Remove duct plate and seal. Fig. 54 Remove screw plugs from duct plate. Fig. 55 3-147...
Page 224 Dismantling Removing cover plate (PTO) Loosen hexagon screws and remove cover plate (1). Fig. 56 Remove O‑ring (1). Fig. 57 Removing and dismantling engine connection Removing the converter Special tools: • AA02.676.915 Load ring 3-148...
Page 225 Dismantling Mark installation position of the cover towards the torque converter bell housing. Loosen hexagon nuts (2). Remove cap screws (1). Fig. 58 Risk of crushing due to moving parts. Slight or moderate injury possible. ð Do not reach into danger area! Lift off the cover and the converter using two AA02.676.915 [Load ring] and the crane.
Page 226 Dismantling Risk of crushing due to hydraulic tool. Slight to moderate injury possible. ð Do not reach into danger area. Force input shaft and the converter out of the cover. Fig. 61 Remove V-ring (1). Pull the ball bearing (2) out of the cover. Fig.
Page 227 Dismantling Loosen hexagon screws. Remove flexplates (1). Fig. 64 Removing torque converter bell housing Special tools: • AA02.247.426 Eyebolt Loosen hexagon screws (1). Fig. 65 3-151...
Page 228 Dismantling Lift torque converter bell housing with two AA02.247.426 [Eyebolt] and a crane. Fig. 66 Removing the oil feed housing and pressure oil pump Special tools: • 5870.345.036 Pry bar • 5870.450.003 Magnetic holder Loosen internal hexalobular bolts. Loosen cap screws and remove fixing plate (1).
Page 229 Dismantling Pull off the oil feed housing and gear pump evenly with 5870.345.036 [Pry bar]. Fig. 68 Place the oil feed housing on 5870.450.003 [Magnetic holder]. Force out the gear pump. Fig. 69 Push pressure plate inwards with a mandrel and remove fixing plate (1).
Page 230 Dismantling Remove pressure plate (3). Remove compression spring (2) and piston (1) from housing hole. Fig. 71 Checking gear pump Remove shaft sealing ring (1). Remove O‑ring (2). Fig. 72 Check individual parts of the gear pump ※ for wear marks before assembling the transmission.
Page 231 Dismantling Lift off cover (1). Check the cover (1), outer rotor (2), inner rotor (3) and the housing (4) for wear marks. In case of any damage, install new gear pump. Insert the outer rotor (2) and inner rotor (3) with the chamfered tooth side facing the housing (4).
Page 232 Dismantling Pull pump shaft (1) out of the transmission. Fig. 77 Remove R‑ring (1) from radial groove of the pump shaft. Fig. 78 Remove securing ring (1). Press off the ball bearing (2). Fig. 79 3-156...
Page 233 Dismantling Removing the cover (emergency steering pump) Loosen hexagon screws. Remove cover (1). Remove seal. Fig. 80 Separating the housings Special tools: • AA02.691.822 Handle • 5870.204.083 Eyebolt • 5870.204.086 Eyebolt Risk of injury due to parts flying away. Slight or moderate injury possible. ð...
Page 234 Dismantling Loosen cap screws (1). Remove fixing plate (2). Fig. 82 Fasten clutches K1, K2, K3 and K4 in the housing rear section with AA02.691.822 [Handle]. Fig. 83 Screw two 5870.204.083 [Eyebolt] into the housing rear section. Screw in two 5870.204.086 [Eyebolt]. Fig.
Page 235 Dismantling Risk of injury due to uncontrolled motion of the load. Death or serious injury possible. ð Only use the suspension points intended for transportation purposes. ð Only use secure, permitted, and tested means of transport, chain hoist, and lifting equipment with sufficient load capacity and suitable lifting technology.
Page 236 Dismantling Loosen cap screws. Fig. 85 Remove output shaft from the front part of the housing using AA01.100.718 [Eyebolt] and crane. Fig. 86 Use 5873.001.058 [Gripping device] and 5873.001.001 [Basic tool] to pull off both bearing inner rings from the output shaft. Remove screen sheet (1).
Page 237 Dismantling Dismantling housing front part Remove screen sheet (1). Fig. 88 Loosen cap screws. Remove oil tubes (1). No further dismantling possible. ※ Fig. 89 Pull bearing outer rings out of housing holes. The Figure shows the positions of the bearing outer rings.
Page 238 Dismantling Removing and dismantling clutches and input shaft Removing clutches Special tools: • 5870.350.000 Assembly truck • AA02.415.533 Assembly fixture • AA02.691.822 Handle Risk of injury due to uncontrolled motion of the load. Death or serious injury possible. ð Only use the suspension points intended for transportation purposes.
Page 239 Dismantling Rotate the housing rear section 180. Remove four AA02.691.822 [Handle]. Remove clutches from the housing rear section in the sequence specified. • 1 = Clutch K1 • 2 = Clutch K2 • 3 = Clutch K3 • 4 = Clutch K4 •...
Page 240 Dismantling Pull off bearing inner ring with 5873.001.057 [Gripping device] and 5873.001.001 [Basic tool]. Fig. 94 Pull off clutch from shaft. Fig. 95 Remove snap ring (1). Remove end shim from the disk carrier. Remove disk pack. Fig. 96 3-164...
Page 241 Dismantling Preload compression spring with 5870.345.088 [Assembly fixture] and press. Remove L-ring (1). Fig. 97 Remove supporting ring, compression spring and shim. Fig. 98 Press the piston (1) out of the disk carrier using compressed air. Fig. 99 3-165...
Page 242 Dismantling Remove securing ring. Fig. 100 Pull off idler gear from shaft with 5870.300.024 [Disassembly device] and 5870.300.033 [Extractor]. Fig. 101 Remove securing ring. Pull out the ball bearing (1). Fig. 102 3-166...
Page 243 Dismantling Remove needle cage (1). Fig. 103 Remove piston ring (1). Fig. 104 Pull off bearing inner ring with 5873.001.057 [Gripping device] and 5873.001.001 [Basic tool]. Fig. 105 3-167...
Page 244 Dismantling Dismantling KR clutch Special tools: • 5873.001.057 Gripping device • 5873.001.001 Basic tool • 5870.345.088 Assembly fixture • 5870.300.024 Disassembly device • 5870.300.033 Extractor Remove stud bolt (1). Remove piston ring (2). Fig. 106 Pull off bearing inner ring with 5873.001.057 [Gripping device] and 5873.001.001 [Basic tool].
Page 245 Dismantling Pull off clutch from shaft. Fig. 108 Remove snap ring (1). Remove end shim from the disk carrier. Remove disk pack. Fig. 109 Preload compression spring with 5870.345.088 [Assembly fixture] and press. Remove L-ring (1). Fig. 110 3-169...
Page 246 Dismantling Remove supporting ring, compression spring and shim. Fig. 111 Press the piston (1) out of the disk carrier using compressed air. Fig. 112 Remove securing ring. Fig. 113 3-170...
Page 247 Dismantling Pull off idler gear from shaft with 5870.300.024 [Disassembly device] and 5870.300.033 [Extractor]. Fig. 114 Remove securing ring. Pull out the ball bearing (1). Fig. 115 Remove needle cage (1). Fig. 116 3-171...
Page 248 Dismantling Remove piston ring (1). Fig. 117 Pull off bearing inner ring with 5873.001.057 [Gripping device] and 5873.001.001 [Basic tool]. Fig. 118 9.15.4 Dismantling clutch K1 Special tools: • 5873.001.057 Gripping device • 5873.001.001 Basic tool • 5870.345.088 Assembly fixture 3-172...
Page 249 Dismantling Remove stud bolt (1). Remove piston ring (2). Fig. 119 Pull off bearing inner ring with 5873.001.057 [Gripping device] and 5873.001.001 [Basic tool]. Fig. 120 Remove securing ring. Fig. 121 3-173...
Page 250 Dismantling Remove thrust washer (1), axial needle cage (2) and axial washer (3). Fig. 122 Remove idler gear (1). Fig. 123 Remove needle cage (1). Fig. 124 3-174...
Page 251 Dismantling Remove axial washer (1), axle needle cage (2) and thrust washer (3). Fig. 125 Pull off clutch from shaft. Fig. 126 Remove snap ring (1). Remove end shim from the disk carrier. Remove disk pack. Fig. 127 3-175...
Page 252 Dismantling Preload compression spring with 5870.345.088 [Assembly fixture] and press. Remove securing ring (1). Fig. 128 Remove guide rings and compression spring. Fig. 129 Press the piston (1) out of the disk carrier using compressed air. Fig. 130 3-176...
Page 253 Dismantling Remove piston ring (1). Fig. 131 Pull off bearing inner ring with 5873.001.057 [Gripping device] and 5873.001.001 [Basic tool]. Fig. 132 Dismantling clutch K2 Special tools: • 5873.001.057 Gripping device • 5873.001.001 Basic tool • 5870.345.085 Assembly aid 3-177...
Page 254 Dismantling Remove stud bolt (1). Remove piston ring (2). Fig. 133 Pull off bearing inner ring with 5873.001.057 [Gripping device] and 5873.001.001 [Basic tool]. Fig. 134 Remove securing ring. Fig. 135 3-178...
Page 255 Dismantling Remove thrust washer (1), axial needle bearing (2) and axial washer (3). Fig. 136 Remove idler gear (1). Fig. 137 Remove needle cages (1). Fig. 138 3-179...
Page 256 Dismantling Remove axial washer (1), axial needle bearing (2) and thrust washer (3). Fig. 139 Pull off clutch from shaft. Fig. 140 Remove snap ring (1). Remove end shim from the disk carrier. Remove disk pack. Fig. 141 3-180...
Page 257 Dismantling Preload compression spring with 5870.345.085 [Assembly aid] and press. Remove securing ring (1). Fig. 142 Remove guide rings and compression spring. Fig. 143 Press the piston (1) out of the disk carrier using compressed air. Fig. 144 3-181...
Page 258 Dismantling Remove piston ring (1). Fig. 145 Pull off bearing inner ring with 5873.001.057 [Gripping device] and 5873.001.001 [Basic tool]. Fig. 146 Dismantling clutch K3 Special tools: • 5873.001.058 Gripping device • 5873.001.001 Basic tool • 5873.001.057 Gripping device • 5870.345.085 Assembly aid 3-182...
Page 259 Dismantling Remove stud bolt (1). Remove piston ring (2). Fig. 147 Pull off bearing inner ring with 5873.001.058 [Gripping device] and 5873.001.001 [Basic tool]. Fig. 148 Remove piston ring (1). Fig. 149 3-183...
Page 260 Dismantling Pull off bearing inner ring with 5873.001.057 [Gripping device] and 5873.001.001 [Basic tool]. Fig. 150 Remove thrust washer (1), axial needle bearing (2) and axial washer (3). Fig. 151 Remove idler gear (1). Fig. 152 3-184...
Page 261 Dismantling Remove needle cages (1). Fig. 153 Remove axial washer (1), axial needle bearing (2) and thrust washer (3). Fig. 154 Pull off clutch from shaft. Fig. 155 3-185...
Page 262 Dismantling Remove snap ring (1). Remove end shim from the disk carrier. Remove disk pack. Fig. 156 Preload compression spring with 5870.345.085 [Assembly aid] and press. Remove securing ring (1). Fig. 157 Remove guide rings and compression spring. Fig. 158 3-186...
Page 263 Dismantling Press the piston (1) out of the disk carrier using compressed air. Fig. 159 Dismantling clutch K4 Special tools: • 5873.001.057 Gripping device • 5873.001.001 Basic tool • 5870.345.085 Assembly aid Remove stud bolt (1). Remove piston ring (2). Fig.
Page 264 Dismantling Pull off bearing inner ring with 5873.001.057 [Gripping device] and 5873.001.001 [Basic tool]. Fig. 161 Remove securing ring. Fig. 162 Pull off clutch from shaft. Fig. 163 3-188...
Page 265 Dismantling Remove snap ring (1). Remove end shim from the disk carrier. Remove disk pack. Fig. 164 Preload compression spring with 5870.345.085 [Assembly aid] and press. Remove securing ring (1). Fig. 165 Remove guide rings and compression spring. Fig. 166 3-189...
Page 266 Dismantling Press the piston (1) out of the disk carrier using compressed air. Fig. 167 Remove thrust washer (1), axial needle bearing (2) and axial washer (3). Fig. 168 Remove idler gear (1). Fig. 169 3-190...
Page 267 Dismantling Remove needle cages (1). Fig. 170 Remove axial washers (1) and axial needle bearing (2). Fig. 171 Remove piston ring (1). Fig. 172 3-191...
Page 268 Dismantling Pull off bearing inner ring with 5873.001.057 [Gripping device] and 5873.001.001 [Basic tool]. No further dismantling possible. ※ Fig. 173 Dismantling input shaft Special tools: • 5873.001.058 Gripping device • 5873.001.001 Basic tool Remove R-rings (1). Pull off bearing inner rings (2) with 5873.001.058 [Gripping device] and 5873.001.001 [Basic tool].
Page 269 Dismantling 9.16 Dismantling housing rear section Force the converter safety valve out of the housing hole. Fig. 175 Pull bearing outer rings out of housing holes. The Figure shows the positions of the bearing outer rings. • 1 = Output shaft •...
Page 270 Assembly Assembly 10.1 Assembling housing rear section Grease O‑rings. Slide O-rings (1) onto the oil tube Fig. 178 Insert oil tube (1) in housing holes. Fix oil tube with cap screws. Tightening torque: 23 Nm Fig. 179 Insert bearing outer rings in housing holes until contact is obtained.
Page 271 Assembly Assembling and installing clutches and input shaft Assembling clutch KV Special tools: • 5870.345.124 Assembly fixture • 5870.345.088 Assembly fixture Carry out the following two work steps ※ immediately one after the other. Risk of burn injuries due to contact with hot surfaces.
Page 272 Assembly Slide on needle cage (1). Fig. 183 Insert ball bearing (1) into idler gear until contact is obtained. Insert securing ring. Fig. 184 Press idler gear onto the shaft until contact is obtained. Fig. 185 3-196...
Page 273 Assembly Insert securing ring in the shaft. Fig. 186 Check clearance of the ball in the drain valve (1). Oil O-rings (2) and insert them twist-free in the radial grooves. Fig. 187 Oil O-rings and piston bearing surfaces. Insert piston (1) into the disk carrier until contact is obtained.
Page 274 Assembly Insert shim (2) and compression spring (1). Fig. 189 Insert 5870.345.124 [Assembly fixture] (1) in the disk carrier. Slide on supporting ring (2). Slide on new L‑ring (3) with the offset front face facing downwards. Fig. 190 Push L‑ring downwards with 5870.345.124 [Assembly fixture] and 5870.345.088 [Assembly fixture] until it engages in the radial groove of the disk...
Page 275 Assembly Setting disk clearance Insert outer disk (1) with the uncoated side facing the piston. Fig. 192 Insert inner disks and outer disks. Insert last outer disk with the uncoated side facing the end shim. For the arrangement refer to the current ※...
Page 276 Assembly Position dial gauge on the end shim. Push end shim downwards with 100 N and set dial gauge to zero. Lift end shim on the snap ring until contact is obtained and check the necessary Disk clearance 2.45 mm until 2.75 mm. If the disk clearance is too small, install a thinner snap ring.
Page 277 Assembly Carry out the following two work steps ※ immediately one after the other. Risk of burn injuries due to contact with hot surfaces. Slight or moderate injury possible. ð Wear protective gloves. Heat the bearing inner ring. Slide on bearing inner ring (1) until contact is Fig.
Page 278 Assembly Check function of the clutch with compressed air. à Closing and opening of the clutch is clearly audible. If closing and opening is not audible, remove and check clutch. Fig. 200 Assembling clutch KR Special tools: • 5870.345.124 Assembly fixture •...
Page 279 Assembly Insert piston ring (1). Fig. 202 Slide on needle cage (1). Fig. 203 Insert ball bearing (1) into idler gear until contact is obtained. Insert securing ring. Fig. 204 3-203...
Page 280 Assembly Press idler gear onto the shaft until contact is obtained. Fig. 205 Insert securing ring in the shaft. Fig. 206 Check clearance of the ball in the drain valve (1). Oil O-rings (2) and insert them twist-free in the radial grooves. Fig.
Page 281 Assembly Oil O-rings and piston bearing surfaces. Insert piston (1) into the disk carrier until contact is obtained. Fig. 208 Insert shim (2) and compression spring (1). Fig. 209 Insert 5870.345.124 [Assembly fixture] (1) in the disk carrier. Slide on supporting ring (2). Slide on new L‑ring (3) with the offset front face facing downwards.
Page 282 Assembly Push L‑ring downwards with 5870.345.124 [Assembly fixture] and 5870.345.088 [Assembly fixture] until it engages in the radial groove of the disk carrier. Fig. 211 Setting disk clearance Insert outer disk (1) with the uncoated side facing the piston. Fig. 212 Insert inner disks and outer disks.
Page 283 Assembly Insert end shim (1). Insert snap ring e. g. 2.70 mm. Fig. 214 Position dial gauge on the end shim. Push end shim downwards with 100 N and set dial gauge to zero. Lift end shim on the snap ring until contact is obtained and check the necessary Disk clearance 2.45 mm until 2.75 mm.
Page 284 Assembly Slide clutch onto shaft until contact is obtained. Insert idler gear into the disk pack by short mutual rotary motions. Fig. 217 Carry out the following two work steps ※ immediately one after the other. Risk of burn injuries due to contact with hot surfaces.
Page 285 Assembly Screw in stud bolt (1) and tighten. Tightening torque: 17 Nm Insert piston ring (2). Fig. 219 Check function of the clutch with compressed air. à Closing and opening of the clutch is clearly audible. If closing and opening is not audible, remove and check clutch.
Page 286 Assembly Carry out the following two work steps ※ immediately one after the other. Risk of burn injuries due to contact with hot surfaces. Slight or moderate injury possible. ð Wear protective gloves. Heat the bearing inner ring. Slide bearing inner ring (1) onto shaft until Fig.
Page 287 Assembly Check clearance of the ball in the drain valve (1). Oil O-rings (2) and insert them twist-free in the radial grooves. Fig. 223 Oil O-rings and piston bearing surfaces. Insert piston (1) into the disk carrier until contact is obtained. Fig.
Page 288 Assembly Preload compression spring with 5870.345.088 [Assembly fixture] and press. Insert securing ring (1). Fig. 226 Setting disk clearance Insert outer disk (1) with the uncoated side facing the piston. Fig. 227 Insert inner disks and outer disks. Insert last outer disk with the uncoated side facing the end shim.
Page 289 Assembly Insert end shim (1). Insert snap ring e. g. 2.85 mm. Fig. 229 Position dial gauge on the end shim. Push end shim downwards with 100 N and set dial gauge to zero. Lift end shim on the snap ring until contact is obtained and check the necessary Disk clearance 2.05 mm until 2.35 mm.
Page 290 Assembly Slide clutch onto shaft until contact is obtained. Fig. 232 Slide on thrust washer (3) with the chamfer facing the axle needle cage. Slide on axial needle cage (2). Slide on the axial washer (1). Fig. 233 Slide on needle cage (1). Fig.
Page 291 Assembly Slide idler gear (1) onto shaft until contact is obtained. Insert idler gear into the disk pack by short mutual rotary motions. Fig. 235 Slide on the axial washer (3). Slide on axial needle cage (2). Slide on thrust washer (1) with the chamfer facing the axle needle cage.
Page 292 Assembly Carry out the following two work steps ※ immediately one after the other. Risk of burn injuries due to contact with hot surfaces. Slight or moderate injury possible. ð Wear protective gloves. Heat the bearing inner ring. Slide bearing inner ring (1) onto shaft until Fig.
Page 293 Assembly Check function of the clutch with compressed air. à Closing and opening of the clutch is clearly audible. If closing and opening is not audible, remove and check clutch. Fig. 240 Assembling clutch K2 Special tools: • 5870.345.085 Assembly aid Carry out the following two work steps ※...
Page 294 Assembly Insert piston ring (1). Fig. 242 Check clearance of the ball in the drain valve (1). Oil O-rings (2) and insert them twist-free in the radial grooves. Fig. 243 Oil O-rings and piston bearing surfaces. Insert piston (1) into the disk carrier until contact is obtained.
Page 295 Assembly Slide on guide ring (3) with the offset front face facing upwards. Slide on compression spring (2). Slide on guide ring (1) with the offset front face facing downwards. Fig. 245 Preload compression spring with 5870.345.085 [Assembly aid] and press. Insert securing ring (1).
Page 296 Assembly Insert inner disks and outer disks. For the arrangement refer to the current ※ spare parts list. Insert friction disk (1) with the uncoated side facing the end shim. Fig. 248 Insert end shim (1). Insert snap ring e. g. 3.15 mm. Fig.
Page 297 Assembly Carry out the following two work steps ※ immediately one after the other. Risk of burn injuries due to contact with hot surfaces. Slight or moderate injury possible. ð Wear protective gloves. Heat internal spline of the disk carrier. Fig.
Page 298 Assembly Slide on needle cages (1). Fig. 254 Slide idler gear (1) onto shaft until contact is obtained. Insert idler gear into the disk pack by short mutual rotary motions. Fig. 255 Slide on the axial washer (3). Slide on the axial needle bearing (2). Slide on thrust washer (1) with the chamfer facing the axial needle bearing.
Page 299 Assembly Insert securing ring in the shaft. Fig. 257 Carry out the following two work steps ※ immediately one after the other. Risk of burn injuries due to contact with hot surfaces. Slight or moderate injury possible. ð Wear protective gloves. Heat the bearing inner ring.
Page 300 Assembly Screw in stud bolt (1) and tighten. Tightening torque: 17 Nm Insert piston ring (2). Fig. 259 Check function of the clutch with compressed air. à Closing and opening of the clutch is clearly audible. If closing and opening is not audible, remove and check clutch.
Page 301 Assembly Check clearance of the ball in the drain valve (1). Oil O-rings (2) and insert them twist-free in the radial grooves. Fig. 261 Oil O-rings and piston bearing surfaces. Insert piston (1) into the disk carrier until contact is obtained. Fig.
Page 302 Assembly Preload compression spring with 5870.345.085 [Assembly aid] and press. Insert securing ring (1). Fig. 264 Setting disk clearance Insert friction disk (1) with the uncoated side facing the piston. Fig. 265 Insert inner disks and outer disks. For the arrangement refer to the current ※...
Page 303 Assembly Insert end shim (1). Insert snap ring e. g. 3.15 mm. Fig. 267 Position dial gauge on the end shim. Push end shim downwards with 100 N and set dial gauge to zero. Lift end shim on the snap ring until contact is obtained and check the necessary Disk clearance 2.00 mm until 2.30 mm.
Page 304 Assembly Slide clutch onto shaft until contact is obtained. Fig. 270 Slide on thrust washer (3) with the chamfer facing the axial needle bearing. Slide on the axial needle bearing (2). Slide on the axial washer (1). Fig. 271 Slide on needle cages (1). Fig.
Page 305 Assembly Slide idler gear (1) onto shaft until contact is obtained. Insert idler gear into the disk pack by short mutual rotary motions. Fig. 273 Slide on the axial washer (3). Slide on the axial needle bearing (2). Slide on thrust washer (1) with the chamfer facing the axial needle bearing.
Page 306 Assembly Adjust bearing inner ring. Insert piston ring (1). Fig. 276 Carry out the following two work steps ※ immediately one after the other. Risk of burn injuries due to contact with hot surfaces. Slight or moderate injury possible. ð Wear protective gloves. Heat the bearing inner ring.
Page 307 Assembly Screw in stud bolt (1) and tighten. Tightening torque: 17 Nm Insert piston ring (2). Fig. 278 Check function of the clutch with compressed air. à Closing and opening of the clutch is clearly audible. If closing and opening is not audible, remove and check clutch.
Page 308 Assembly Carry out the following three work steps ※ immediately one after the other. Risk of burn injuries due to contact with cold surface. Slight to moderate injury possible. ð Wear protective gloves. Cool down shaft. Fig. 280 Risk of burn injuries due to contact with hot surfaces.
Page 309 Assembly Carry out the following two work steps ※ immediately one after the other. Risk of burn injuries due to contact with hot surfaces. Slight or moderate injury possible. ð Wear protective gloves. Heat the bearing inner ring. Slide bearing inner ring (1) onto shaft until Fig.
Page 310 Assembly Slide on the axial washer (1). Slide on the axial needle bearing (2). Slide on the axial washer (1). Fig. 284 Slide on needle cages (1). Fig. 285 Slide on idler gear (1). Fig. 286 3-234...
Page 311 Assembly Slide on the axial washer (3). Slide on the axial needle bearing (2). Slide on thrust washer (1) with the chamfer facing the axial needle bearing. Fig. 287 Check clearance of the ball in the drain valve (1). Oil O-rings (2) and insert them twist-free in the radial grooves.
Page 312 Assembly Slide on guide ring (3) with the offset front face facing upwards. Slide on compression spring (2). Slide on guide ring (1) with the offset front face facing downwards. Fig. 290 Preload compression spring with 5870.345.085 [Assembly aid] and press. Insert securing ring (1).
Page 313 Assembly Insert inner disks and outer disks. For the arrangement refer to the current ※ spare parts list. Insert friction disk (1) with the uncoated side facing the end shim. Fig. 293 Insert end shim (1). Insert snap ring e. g. 3.15 mm. Fig.
Page 314 Assembly Carry out the following two work steps ※ immediately one after the other. Risk of burn injuries due to contact with hot surfaces. Slight or moderate injury possible. ð Wear protective gloves. Heat internal spline of the disk carrier. Fig.
Page 315 Assembly Carry out the following two work steps ※ immediately one after the other. Risk of burn injuries due to contact with hot surfaces. Slight or moderate injury possible. ð Wear protective gloves. Heat the bearing inner ring. Slide bearing inner ring (1) onto shaft until Fig.
Page 316 Assembly Check function of the clutch with compressed air. à Closing and opening of the clutch is clearly audible. If closing and opening is not audible, remove and check clutch. Fig. 301 Assembling input shaft Carry out the following three work steps ※...
Page 317 Assembly Insert securing ring (1) in the input shaft. Fig. 303 Grease O‑ring. Insert O‑ring (1) in the radial groove of the input shaft. Fig. 304 Insert snap ring in the radial groove on the turbine shaft. Fig. 305 3-241...
Page 318 Assembly Insert turbine shaft in the input shaft until the snap ring audibly engages. Fig. 306 Risk of burn injuries due to contact with hot surfaces. Slight or moderate injury possible. ð Wear protective gloves. Slide the heated bearing inner rings (2) on until contact is obtained.
Page 319 Assembly Insert clutch KV (1), input shaft (2) and clutch KR (3) together in the housing rear section. Fig. 308 Insert clutch K4 (1). Fig. 309 Insert clutch K3 (1). Fig. 310 3-243...
Page 320 Assembly Insert clutch K2 (1). Fig. 311 Lift up clutch K4 (2) slightly and insert clutch K1 (1). Fig. 312 Fasten clutches K1, K2, K3 and K4 in the housing rear section with AA02.691.822 [Handle]. Fig. 313 3-244...
Page 321 Assembly Assembling housing front part Special tools: • AA02.068.532 Pipe roller Insert suction tube (1) in housing front part. Fasten suction tube with cap screw. Tightening torque: 23 Nm Fig. 314 Apply oil to inner diameter of the suction tube and to rollers of AA02.068.532 [Pipe roller].
Page 322 Assembly Grease O-rings. Insert O-rings (1) in radial grooves of the oil tube. Fig. 316 Grease O-rings. Insert O-rings (1) in radial grooves of the oil tube. Fig. 317 Insert oil tubes (1). Fix oil tubes with cap screws. Tightening torque: 23 Nm Fig.
Page 323 Assembly Insert bearing outer rings in housing holes until contact is obtained. The Figure shows the positions of the bearing outer rings. • 1 = Output shaft • 2 = Clutch K3 • 3 = Clutch K2 • 4 = Clutch KV •...
Page 324 Assembly Slide on screen sheet (1). Fig. 321 Carry out the following two work steps ※ immediately one after the other. Risk of burn injuries due to contact with hot surfaces. Slight or moderate injury possible. ð Wear protective gloves. Heat the bearing inner ring.
Page 325 Assembly Place on screen sheet (1). Fig. 323 Insert output shaft with AA01.100.718 [Eyebolt] and crane. Fig. 324 Fasten screen sheets with cap screws (1). Tightening torque: 23 Nm Fig. 325 3-249...
Page 326 Assembly Assembling the housings Special tools: • 5870.204.083 Eyebolt • 5870.204.086 Eyebolt • AA02.691.822 Handle Operating supplies and auxiliary materials: • 0666.790.033 LOCTITE 574 Apply 0666.790.033 [LOCTITE 574] onto the mounting face (1). Fig. 326 Screw two 5870.204.083 [Eyebolt] into the housing rear section.
Page 327 Assembly Risk of injury due to uncontrolled motion of the load. Death or serious injury possible. ð Only use the suspension points intended for transportation purposes. ð Only use secure, permitted, and tested means of transport, chain hoist, and lifting equipment with sufficient load capacity and suitable lifting technology.
Page 328 Assembly Bolt in and tighten cap screws (1). Tightening torque: 46 Nm Fasten fixing plate (2) with cap screws. Tightening torque: 46 Nm Fig. 329 Mounting cover (emergency steering pump) Special tools: • 5870.204.011 Fixing pin Screw two 5870.204.011 [Fixing pin] into the housing.
Page 329 Assembly Place the cover (1). Fasten cover with hexagon screws. Tightening torque: 23 Nm Fig. 331 Mounting the oil feed housing and oil pressure pump Special tools: • 5870.204.007 Locating pin • 5870.204.011 Locating pin • 5870.055.070 Driver tool • 5870.260.002 Handle •...
Page 330 Assembly Bolt in four 5870.204.011 [Locating pin]. Put on seal (1). Fig. 333 Insert the piston (1) in the oil feed housing. Insert compression spring (2). Insert pressure plate (3). Fig. 334 Push pressure plate inwards with a mandrel and insert fixing plate (1). Fig.
Page 331 Assembly Slide on the oil feed housing (1). Fig. 336 Checking gear pump Remove shaft sealing ring (1). Remove O‑ring (2). Fig. 337 Check individual parts of the gear pump ※ for wear marks before assembling the transmission. The gear pump is only available as a complete unit.
Page 332 Assembly Lift off cover (1). Check the cover (1), outer rotor (2), inner rotor (3) and the housing (4) for wear marks. In case of any damage, install new gear pump. Insert the outer rotor (2) and inner rotor (3) with the chamfered tooth side facing the housing (4).
Page 333 Assembly Slide O-rings onto cap screws. Fasten gear pump (1) with cap screws. Tightening torque: 46 Nm Fig. 342 Fasten the oil feed housing (1) with internal hexalobular bolts. Tightening torque: 23 Nm Fasten fixing plate (2) with cap screws. Tightening torque: 46 Nm Fig.
Page 334 Assembly Screw in two 5870.204.007 [Locating pin]. Mount torque converter bell housing with two AA02.247.426 [Eyebolt] and a crane. Fig. 344 Screw in and tighten hexagon screws (1). Tightening torque: 65 Nm Fig. 345 Installing the converter Special tools: • AA02.676.915 Load ring Operating supplies and auxiliary materials: •...
Page 335 Assembly Position flexplate (1) on the input shaft. Apply 0666.690.022 [LOCTITE 262] to threads of the hexagon screws. Screw in and tighten hexagon screws. Tightening torque: 115 Nm Fig. 346 Place the input shaft with flexplate (2) on the converter. Apply 0666.690.022 [LOCTITE 262] to threads of the hexagon screws.
Page 336 Assembly Risk of crushing due to hydraulic tool. Slight to moderate injury possible. ð Do not reach into danger area. Use suitable tool to force the cover onto input shaft until contact is obtained. Fig. 349 Force screen sheet (1) onto yoke until contact is obtained.
Page 337 Assembly Slide yoke (1) onto input shaft until contact is obtained. Fig. 352 Position washer (1). Screw in and tighten hexagon screws (2). Tightening torque: 40 Nm Fig. 353 Risk of crushing due to moving parts. Slight or moderate injury possible. ð...
Page 338 Assembly Insert cap screws (1) into the holes and tighten nuts. Tightening torque: 46 Nm Fig. 355 Installing pump shaft Press ball bearing (2) onto pump shaft until contact is obtained. Set Axial clearance of the ball bearing 0.00 mm to 0.05 mm. Insert securing ring e.
Page 339 Assembly Insert pump shaft (1) into the transmission until contact is obtained. Insert the pump shaft in the gearing of the converter. Fig. 358 Insert securing ring. Fig. 359 Mounting cover plate (PTO) Grease O‑ring. Insert the O‑ring (1) into the countersink of the housing.
Page 340 Assembly Fix cover plate (1) with hexagon screws. Tightening torque: 46 Nm Fig. 361 Assembling and installing shift system Installing duct plate Special tools: • 5870.204.037 Fixing pin Insert converter safety valve (1) into the housing hole until contact is obtained. Fig.
Page 341 Assembly Bolt in screw plugs into the duct plate and tighten. Tightening torque: 25 Nm Tightening torque: 30 Nm Fig. 363 Screw in two 5870.204.037 [Fixing pin]. Slide on seal (1). Fig. 364 3-265...
Page 342 Assembly Fig. 365 Slide on duct plate (1). Fix duct plate with internal hexalobular bolts in the specified order. Tightening torque: 23 Nm Insert valves (1) in duct plate. Fig. 366 3-266...
Page 343 Assembly Insert compression springs (1) in holes (3). Insert pistons (2) in holes (3). Fig. 367 Assembling and mounting valve blocks Special tools: • 5870.204.063 Fixing pin • AA02.416.230 Driver tool • AA02.416.754 Driver tool • AA02.414.200 Driver tool • AA02.318.019 Torque wrench Bolt two 5870.204.063 [Fixing pin] into the duct plate.
Page 344 Assembly Insert the control piston (1) in the hole. Insert compression spring (2). Apply oil to O-ring Insert O-ring in the radial groove of the plug (3). Insert the plug (3) in the hole. Fig. 369 Press the plug inwards with AA02.416.230 [Driver tool] until contact is obtained and insert fixing plate (1).
Page 345 Assembly Push the plug inwards with the AA02.416.754 [Driver tool] until contact is obtained and insert the spring clip (1). Fig. 372 Push on valve block (1). Fig. 373 Push on intermediate plate (1). Fig. 374 3-269...
Page 346 Assembly Insert piston (1) in the hole. Insert compression spring (2). Fig. 375 Push the compression spring inwards with AA02.414.200 [Driver tool] until contact is obtained and insert the fixing plate (1). Fig. 376 Push on valve block (1). Fig. 377 3-270...
Page 347 Assembly Screw in and tighten the hexalobular driving screws (1). Tightening torque: 3 Nm Fig. 378 Fig. 379 Bolt in internal hexalobular bolts (1) to (19) and tighten with AA02.318.019 [Torque wrench] in the specified order. Tightening torque: 3 Nm and 60° additional angle (tightening torque must be between 7 Nm and 13 Nm) If the tightening torque is not within the range specified, fit a new screw.
Page 348 Assembly Tightening torque: 3 Nm and 45° additional angle (tightening torque must to be between 7 Nm and 13 Nm) If the tightening torque is not within the range specified, fit a new screw. ※ Installing the pressure controllers Pay attention to radial installation ※...
Page 349 Assembly Insert seal (1) in control unit (2). Fig. 382 Fig. 383 Bolt two 5870.204.063 [Fixing pin] into the duct plate. Slide on control unit. Bolt in internal hexalobular bolts and tighten in the specified order. Tightening torque: 9.5 Nm 3-273...
Page 350 Assembly Installing filter bypass valve Insert compression spring (2) and piston (3) in hole (1). Fig. 384 Screw in tappet switch with O‑ring (1) and tighten. Tightening torque: 30 Nm Fig. 385 Installing output flanges Special tools: • 5870.048.057 Driver tool Operating supplies and auxiliary materials: •...
Page 351 Assembly Installing output flange on gearshift side Carry out the following two work steps ※ immediately one after the other. Apply 0666.690.191 [PHÖNIX SPIRITUS] to outer diameter of the shaft sealing ring. Use 5870.048.057 [Driver tool ] to insert shaft seal (1) with seal lip facing the oil chamber.
Page 352 Assembly Fix output flange with washer (2) and hexagon screws (1). Tightening torque: 40 Nm Fig. 389 Installing output flange on input side Carry out the following two work steps ※ immediately one after the other. Apply 0666.690.191 [PHÖNIX SPIRITUS] to outer diameter of the shaft sealing ring.
Page 353 Assembly Insert O-ring (1) in the space between output shaft and output flange. Fig. 392 Fix output flange with washer (2) and hexagon screws (1). Tightening torque: 40 Nm Fig. 393 Installing the temperature sensors and the breather Screw in breather (1) and tighten. Tightening torque: 12 Nm Screw in and tighten temperature sensors with O-ring (2).
Page 354 Assembly Installing the speed sensors and pressure controller Insert speed sensors with sealing element (1) in housing holes. Fix speed sensors with cap screws. Tightening torque: 9.5 Nm Fig. 395 Insert the pressure controller with O-rings (1) in the 3 o'clock position in the housing hole. Fix pressure controller with cap screws.
Page 355 Assembly Installing cover plate (filler neck) Put on seal and cover plate (1). Screw in and tighten hexagon screws. Tightening torque: 23 Nm Fig. 398 Put on seal and cover plate (1). Screw in and tighten hexagon screws. Tightening torque: 23 Nm Fig.
Page 356 Assembly Installing the pressure filter Oil O‑rings (1) and insert them in the radial grooves on the filter head. Fig. 400 Fix filter head (1) with internal hexalobular bolts. Tightening torque: 34 Nm Fig. 401 Lightly oil the seal of the pressure filter. Screw in pressure filter (1) until contact is obtained with the sealing surface on the filter head.
Page 357 Assembly Adding oil Bolt in screw plug with O-ring (1) and tighten. Tightening torque: 80 Nm Prior to initial operation, fill transmission with oil according to Operating Instructions. Fig. 403 3-281...
Page 358 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 -------------------------------------------------------- 4-31 Group 3 Tests and Adjustments -------------------------------------------------------------------------------------- 4-38 Group 4 Disassembly and Assembly ------------------------------------------------------------------------------ 4-40...
Page 359: Section 4 Brake And Fan System
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 360 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 361 2. HYDRAULIC CIRCUIT 2. HYDRAULIC CIRCUIT 26 27 PARKING Return line Return line Main pump 940T34BS01 Fan & brake pump Accumulator Air breather Orifice Accumulator Return filter Fan motor 28 Pressure sensor 34 Bypass valve 11 Directional valve 29 Brake valve 43 Filter assy Oil cooler Pressure switch...
Page 362 SERVICE BRAKE RELEASED SERVICE BRAKE RELEASED 26 27 PARKING Return line Return line Main pump 940T34BS02 When the pedal of brake valve (29) 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 (31).
Page 363 SERVICE BRAKE OPERATED SERVICE BRAKE OPERATED 26 27 PARKING Return line Return line Main pump 940T34BS03 When the pedal of brake valve (29) 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 (25) enters the piston in the front and rear axles.
Page 364 PARKING BRAKE RELEASED PARKING BRAKE RELEASED 26 27 Parking brake switch PARKING Return line Parking brake solenoid Return line Main pump 940T34BS04 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 365 PARKING BRAKE OPERATED PARKING BRAKE OPERATED 26 27 Parking brake switch PARKING Return line Parking brake solenoid Return line Main pump 940T34BS05 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 366 FAN MOTOR OPERATED FAN MOTOR OPERATED 26 27 Priority valve PARKING Return line Return line Main pump 940T34BS06 When the brake accumulators are fully charged, the priority valve switches position and the oil is directed to hydraulic fan motor through directional valve (11). The flow of the oil causes fan motor (10) to rotate the fan blade.
Page 367 DIRECTIONAL VALVE OPERATED DIRECTIONAL VALVE OPERATED 26 27 Priority valve PARKING Return line Return line Main pump 940T34BS07 When the fan control switch is pressed A or M position, the solenoid valve in the directional valve (11) is energized and the flow of the oil is changed. The rotation of the fan is reversed to clear the radiators.
Page 368 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 369: Fan System Operation
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 370 4. BRAKE VALVE 4. BRAKE VALVE 1) 1) STRUCTURE STRUCTURE Right pedal and base assy(opt) Left pedal and base assy Pressure switch Test connection Port Port name Port size P1, P2 Pressure port PF 3/8 Hydraulic circuit T1, T2 Return port PF 3/8 BR1, BR2 Brake cylinder port...
Page 371 2) 2) OPERATION OPERATION (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 372 (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 373 5. CUT-OFF VALVE 5. CUT-OFF VALVE STRUCTURE STRUCTURE 1) 1) 970A4BS32 Priority valve Orifice Orifice Pressure control valve Check valve Coil, Solenoid valve Directional valve Hydraulic circuit 4-15...
Page 374 2) 2) OPERATION OPERATION The pressure control 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 pressure control 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 375 6. BRAKE ACCUMULATOR 6. BRAKE ACCUMULATOR 1) 1) STRUCTURE STRUCTURE 31LL-40020 31AC-10030 Item (item 27) (item 26) Diameter 167 mm 136 mm Mounting height 219 mm 159 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...
Page 376 (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 377: Technical Data
7. PRESSURE SENSOR AND SWITCH 7. PRESSURE SENSOR AND SWITCH STRUCTURE STRUCTURE 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 ± 5 PF 1/4"...
Page 378 2) 2) OPERATION OPERATION Purpose Purpose (1) (1) The pressure switches are used to visually or audibly warn the driver of the pressure within the system. (2) (2) Make contact / circuit closer Make contact / circuit closer The pressure switch can be fitted in the braking system or directly on one of its components. The system pressure acts on an absorption area within the switch, making an electrical contact as the pressure on that area is increased.
Page 379 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 4-21...
Page 380 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 381 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 382 (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 383 (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 384 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 385: Maintenance And Repair Work
5) 5) MAINTENANCE AND REPAIR WORK MAINTENANCE AND REPAIR WORK (1) (1) Maintenance and replacement of the lining pads Maintenance and replacement of the lining pads The brake, particularly the brake lining carriers, must be visually inspected at regular intervals. If the remaining lining thickness is too thin, these intervals must be reduced accordingly to prevent extensive damage to the brake or the brake disc.
Page 386 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 387 (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 388 ※ 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 389: 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 390 ※Hydraulic oil must be at operating temperature for these checks (refer to page 6-49). 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 391 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 392 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 393 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 394: Service Brake
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 395: Parking Brake Malfunctions
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 396: 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 397 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 398: 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 1) 1) STRUCTURE STRUCTURE 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 399: General Repair Guidelines
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 400 ※ 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 401 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 4-43...
Page 402 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 403 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 404 2. FAN MOTOR 2. FAN MOTOR STRUCTURE STRUCTURE 1) 1) 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 405 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 406 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 407 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 4-49...
Page 408 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 409 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 410 (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 4-52...
Page 411 (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 4-53...
Page 412 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 413: Motor Assembly
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 414 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 4-56...
Page 415 Pre-tension the spring using a suitable device. 7609A4BS65 7609A4BS66 Assemble piston with retaining plate. ※ Oil piston and slipper pad. 7609A4BS67 4-57...
Page 416 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 417 (11) Fit control plate. Assembly aid : Grease 7609A4BS70 (12) Fit the port plate and fix it with the bolts crosswise. 7609A4BS71 4-59...
Page 418: 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 ---------------------------------------------------- 5-8 Group 3 Tests and Adjustments ----------------------------------------------------------------------------------- 5-14 Group 4 Disassembly and Assembly -------------------------------------------------------------------------- 5-19...
Page 419: 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 piston pump supplying a load sensing steering system and an closed center loader system. The components of the steering system are : ・Main pump ・Steering unit...
Page 420 2. HYDRAULIC CIRCUIT 2. HYDRAULIC CIRCUIT Joystick steering RCV CONTROL UNIT Electronics Priority valve LS1 L R Return line Return line Return line 940T35SE01 Strainer Main pump Line check valve Main control vavle Motor pump (option) Accumulator 37 Check block (option) Pressure sensor Joystick steering vlave(opt) 16 Steering cylinder...
Page 421 NEUTRAL NEUTRAL Priority valve Return line Return line Return line 940T35SE02 The steering wheel is not being operated so control spool (G) does not move. The oil from the pump enters the priority valve in main control valve and the inlet pressure oil moves the spool (D).
Page 422 LEFT TURN LEFT TURN Priority valve Return line Return line Return line 940T35SE03 When the steering wheel is turned to the left, the spool (G) within the steering unit (17) connected with steering column turns in left hand direction. At this time, the oil discharged from the pump flows into the spool (G) of the steering unit (17) through the spool (D) of priority valve in main control valve and flows into the gerotor (H).
Page 423: Right Turn
RIGHT TURN RIGHT TURN Priority valve Return line Return line Return line 940t35SE04 When the steering wheel is turned to the right, the spool (G) within the steering unit (17) connected with steering column turns in right hand direction. At this time, the oil discharged from the pump flows into the spool (G) of the steering unit (17) through the spool (D) of priority valve in main control valve and flows into the gerotor (H).
Page 424 3. STEERIN 3. STEERING UNIT G UNIT Inlet check valve Internal check valve for limited manual steering Load sensing port Cylinder port shock valves Anti-cavitation valves for cylinder ports Spool Sleeve Gerotor Cap screw Spacer plate Drive Needle bearing End cap 940A5SE10...
Page 425: Steering Cylinder
4. STEERING CYLINDER 4. STEERING CYLINDER 1) 1) STRUCTURE STRUCTURE 9,8 12 6,5 7 11,10 13 14 15 16 17 25 24 22,23 19,20,21 7407SE07 Tube assy 10 O-ring 19 U-bolt Rod assy 11 Back up ring 20 Hexagon nut Gland 12 O-ring 21 Spring washer...
Page 426: Group 2 Operational Checks And Troubleshooting
GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING This procedure is designed so the service man can make a quick check of the steering sys- tem using a minimum amount of diagnostic equipment. If you need additional information, prefer to structure and function in group 1.
Page 427 ※Hydraulic oil must be at operating temperature for these checks (refer to page 6-49). 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 NOT OK NOT OK then left (B) positions.
Page 428: Troubleshooting
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 429 Problem Cause Remedy C o n s t a n t s t e e r i n g t o C o n s t a n t s t e e r i n g t o Air in system. Check for foamy oil.
Page 430 Problem Cause Remedy Steering unit locks up Steering unit locks up Large particles of contamination in Inspect hydraulic ﬁ lter for contamination. steering unit. Repair cause of contamination. Flush hydraulic system. ★ Do of MCV DLS port flow test. This oil Thermal shock ﬂ...
Page 431 Problem Cause Remedy "Shimmy" effect "Shimmy" effect Air in the steering cylinder. Bleed cylinder. T h e s t e e r e d w h e e l s T h e s t e e r e d w h e e l s Find and remove the reason for air vibrate vibrate...
Page 432: 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 4000 mm × 1" 100R1 Hoses ·Quick disconnect fittings ·Discharge wand ·Connectors...
Page 433 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 tank capacity : 130ℓ(34.3 U.S. gal) Leave filter caddy operating for the next steps.
Page 434 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 435 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 210 bar (3045 psi) at steering unit ・ GAUGE AND TOOL GAUGE AND TOOL Gauge 0~7 MPa (0~70 bar, 0~1000 psi) 2EA ・...
Page 436 4. STEERING UNIT LEAKAGE TEST 4. STEERING UNIT LEAKAGE TEST ・ SPECIFICATION SPECIFICATION Oil temperature 45±5˚C (113±9˚F) Engine speed High idle Cap fitting Maximum leakage 10ℓ/min ・ GAUGE AND TOOL GAUGE AND TOOL Temperature reader Measuring container (approx 20ℓ) Steering unit Stop watch Install frame locking bar to prevent machine from turning.
Page 437: 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 Screw 10, 11 Medium Standard Manual Steering Check Valve *Anti-cavitation valve parts will vary according to configuration. H940AC5SE01 Cap screw Centering pin 18 Roll pin End cap...
Page 438 INTRODUCTION INTRODUCTION Most repairs require the removal of the control unit from the vehicle. Cleanliness is extremely important. Clean the port areas thoroughly before disconnecting the hydraulic lines. Plug the control unit ports and cover open hydraulic lines immediately after they have been disconnected.
Page 439 4) 4) DISASSEMBLY DISASSEMBLY ※ Cleanliness is extremely important when Cleanliness is extremely important when Gerotor (Meter) End repairing a steering control unit. Work in repairing a steering control unit. Work in a clean area. Before disconnecting lines, a clean area. Before disconnecting lines, 25 mm clean port area of unit thoroughly.
Page 440 Remove gerotor. Be careful not to drop star. Remove seal from spacer plate. Gerotor Remove spacer plate. Seal Remove seal from housing. Pull drive and twist to remove drive Plate-Spacer assembly from housing. Seal (10) Remove housing from vise. ※ Do not bindspool and sleeve in housing.
Page 441 (11) Carefully remove bearing and races, anti- cavitation valves and manual steering check valve (roll pin and ball) from bolt holes by tipping housing gerotor side Dust Seal Manual Steering Check Valve (when applicable) down. Ball (12) Do not remove any valves other than Roll Pin manual steering check valve assembly and anti-cavitation valve assembly.
Page 442 5) 5) ASSEMBLY ASSEMBLY ※ Assembly cleanliness Assembly cleanliness Check all mating surfaces. Replace any parts that have scratches or burrs that could cause leakage. Clean all metal parts in clean solvent. Blow dry with air. Do not wipe dry with cloth or paper towel because lint or other matter can get into the hydraulic system and cause damage.
Page 443 ④ Insert sleeve into housing bore. H940AC5SE06 ⑤ Place o-ring on plunger. H940AC5SE07 ⑥ Align seal with plunger. Cross section "L" shape of seal should be upside down. H940AC5SE08 ⑦ Push seal onto plunger. Lip of seal should be between O-ring and plunger.
Page 444 ⑧ Align plunger with sleeve. H940AC5SE10 ⑨ Push plunger into sleeve until it bottoms out, rotate 1/4 turn. ⑩ While holding sleeve in housing, withdraw plunger. ⑪ Withdraw sleeve. H940AC5SE11 ⑫ Inspect seal installation. Seal and O-ring must both be within shaft seal counterbore of housing.
Page 445 Install two bearing races and thrust bearing as shown in right figure. H940AC5SE14 Assemble spool and sleeve carefully so that spring slots line up at the same end. Rotate spool while sliding parts together. Test for free rotation. Spool should rotate smoothly in sleeve with fingertip force applied at splined end.
Page 446 Installation of spring spacers and springs, hold spring retainer at an angle as shown (see 1), insert spring spacers and springs one at a time in sequence noted by reference numbers 2~9,(standard torque), 2~8(medium torque), 2~7 (lowtorque), then position spring retainer correctly over all these parts.
Page 447 (10) Position spool and sleeve assembly so that splined end of spool enters 14 hole end of housing first. ※ While inser ting spool and sleeve assembly into housing, make sure parts do not tilt out of position. Push assembly gently into place with slight rotating action.
Page 448 ※ Timing reference data Timing reference data Meter (Gerotor) Align star valleys (reference A) with Gerotor — Star Valley marked drive 1 and drive 2 (reference B). Seal Groove this Side Valleys must align with pin. Note parallel O-ring relationship of reference lines A, B, C, and Spacer Plate —...
Page 449 (19) Install 7 dry cap screws in end cap. Pretighten cap screws to 17Nm [150 lb-in], then torque screws to 28-34 Nm [250-300 lb-in] in sequence shown in the right figure. H940AC5SE23 5-31...
Page 450 2. STEERING CYLINDER 2. STEERING CYLINDER STRUCTURE STRUCTURE 1) 1) 9,8 12 6,5 7 11,10 13 14 15 16 17 25 24 22,23 19,20,21 7407SE07 Tube assy 10 O-ring 18 Pipe assy Rod assy 11 Back up ring 19 U-bolt Gland 12 O-ring 20 Hexagon nut...
Page 451 TOOLS AND TIGHTENING TORQUE TOOLS AND TIGHTENING TORQUE 2) 2) Tools Tools (1) (1) Tool name Remark Spanner Steel bar 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...
Page 452 3) 3) DISASSEMBLY DISASSEMBLY Remove cylinder head and piston rod Remove cylinder head and piston rod (1) (1) 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 453 ※ 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 454 Disassemble the piston assembly Disassemble the piston assembly (3) (3) ① Remove wear ring (16) and piston seal (15). ※ Exercise care in this operation not to damage the grooves. 7407ASE42 (4) (4) Disassemble gland assembly Disassemble gland assembly ① Remove back up ring (11), and O-ring 8,9 12 5,6 7 10,11 (10).
Page 455 ASSEMBLY ASSEMBLY 4) 4) (1) (1) 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. 7407ASE44 ② Coat dust wiper (8) with grease and fit Press here dust wiper (8) to the bottom of the hole of (Straight down)
Page 456 ⑥ Fit back up ring (11) to gland (3). ※ Put the backup ring in the warm water of 30~50˚C. ⑦ Fit O-ring (10) to gland (3). ⑧ Fit bushing (4) to gland (3). 7407ASE47 (2) (2) Assemble piston assembly Assemble piston assembly ※...
Page 457 (3) (3) Install piston and gland assembly Install piston and gland assembly ① Fix the piston rod assembly to the work Gland assembly Piston rod bench. ② Apply hydraulic oil to the outer surface of piston rod (2), the inner surface of piston and gland.
Page 458 (4) (4) Overall assemble Overall assemble Fix with a bar ① Place a V-block on a rigid work bench. Mount the cylinder tube assembly (1) on Lift it and fix the assembly by passing a bar through the clevis pin hole to lock the assembly.
Page 459 2. CENTER PIVOT PIN 2. 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 460 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 461 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). 74095SE16 (11) Remove bolt (19), washer (20) and then LOWER take out cover (17, 18) and shims (4, 5).
Page 462 4) 4) ASSEMBLY ASSEMBLY 6 22 19,20 19,20 Clearance A 14,15,26 Clearance B 20,23 UPPER UPPER LOWER 74095SE20 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 463: Troubleshooting
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. (bearing preload : 0.6 ~ 0.9 kgfㆍm) ;...
Page 464: Section 6 Work Equipment
SECTION 6 WORK EQUIPMENT SECTION 6 WORK EQUIPMENT Group 1 Structure and Function ----------------------------------------------------------------------------------- 6-1 Group 2 Operational Checks and Troubleshooting ----------------------------------------------------- 6-35 Group 3 Tests and Adjustments ----------------------------------------------------------------------------------- 6-45 Group 4 Disassembly and Assembly --------------------------------------------------------------------------- 6-57...
Page 465: Group 1 Structure And Function
SECTION 6 WORK EQUIPMENT SECTION 6 WORK EQUIPMENT GROUP 1 STRUCTURE AND FUNCTION GROUP 1 STRUCTURE AND FUNCTION 1. HYDRAULIC SYSTEM OUTLINE 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.
Page 466 2. HYDRAULIC CIRCUIT (HL940 T3, HL940XT T3) 2. HYDRAULIC CIRCUIT (HL940 T3, HL940XT T3) AUX1 BUCKET BOOM Main pump Fan & brake pump down rollback Main control valve dump Control Unit / Electro Hydraulic, Joystick steering Control unit Boom lowering valve...
Page 467 3. WORK EQUIPMENT HYDRAULIC CIRCUIT 3. WORK EQUIPMENT HYDRAULIC CIRCUIT WHEN THE RCV LEVER IS IN THE RAISE POSITION WHEN THE RCV LEVER IS IN THE RAISE POSITION Steering unit P port ACCU B3 A3 3(2) 6(4) 5(3) 2(1) ( ) : 2spool To MCV Aux Down Aux Up...
Page 468 2) 2) WHEN THE RCV LEVER IS IN THE LOWER POSITION WHEN THE RCV LEVER IS IN THE LOWER POSITION Steering unit P port B3 A3 ACCU 3(2) 2(1) 6(4) 5(3) ( ) : 2spool To MCV Aux Down Aux Up Dump Bucket In B/Down...
Page 469 3) 3) WHEN THE RCV LEVER IS IN THE FLOAT POSITION WHEN THE RCV LEVER IS IN THE FLOAT POSITION Steering unit P port B3 A3 ACCU 3(2) 6(4) 5(3) 2(1) ( ) : 2spool To MCV Aux Down Aux Up Dump Bucket In B/Down...
Page 470 4) 4) WHEN THE RCV LEVER IS IN THE DUMP POSITION WHEN THE RCV LEVER IS IN THE DUMP POSITION Steering unit P port ACCU B3 A3 3(2) 5(3) 2(1) 6(4) ( ) : 2spool To MCV Aux Down Aux Up Dump Bucket In B/Down...
Page 471 5) 5) WHEN THE RCV LEVER IS IN THE ROLL BACK WHEN THE RCV LEVER IS IN THE ROLL BACK (retract) POSITION POSITION Steering unit P port B3 A3 ACCU 3(2) 5(3) 2(1) 6(4) ( ) : 2spool To MCV Aux Down Aux Up Dump...
Page 472 4. MAIN PUMP 4. MAIN PUMP STRUCTURE STRUCTURE (1/2) 1) 1) 74096WE12 Port Port name Port size Pressure port SAE 1" Suction port SAE 2" L, L1 Case drain port 1 1/16-12UN Pilot pressure port 7/16-20UNF...
Page 473 STRUCTURE STRUCTURE (2/2) 1-28 74096WE11 Rotary group 15 Taper roller bearing 30 Locking screw 1-1 High speed rotary group 16 Taper roller bearing 31 Double break-off pin 1-2 Control plate 17 Bearing liner 33 Cylinder pin Adjusting piece 20 Shaft seal ring 51 Control valve Pump housing 22 O-ring...
Page 474 2) 2) FUNCTION 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.
Page 475 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 476 (1) (1) Upstroking 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...
Page 477 (2) (2) Destroking 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...
Page 478 (3) (3) Low pressure standby 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...
Page 479 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 480 (4) (4) High pressure stall 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...
Page 481 (5) (5) Adjustment of flow control Adjustment of flow control Flow compensator setting must be carried out following procedures and conditions. ① Conditions Conditions Engine is running (at high or low idle). RCV is operated slowly (example : Boom up). Pressure gauges are installed.
Page 482 5. EH (electro hydraulic) CONTROL BLOCK 5. EH (electro hydraulic) CONTROL BLOCK STRUCTURE STRUCTURE 1) 1) 10-4 10-5 10-6 Proportional pressure reducing valve 10-1 10-2 10-3 Filter screen EH21 EH18 EH17 EH20 EH19 EH22 Size Port 1 ~ 6 9/16-18UNF 9/16-18UNF 3/4-16UNF 10-4...
Page 483 6. MAIN CONTROL VALVE 6. MAIN CONTROL VALVE STRUCTURE STRUCTURE 1) 1) (boom cylinder head) Handling hole(M10) (accumulator)) ACCU Handling hole(M10) (boom cylinder rod) ACCU Hydraulic circuit 940A6WE31 Port Port name Port size Port Port name Port size From main pump 1 5/16-12UNF a3, b3 Auxiliary pilot port...
Page 484 2) 2) BOOM SECTION OPERATION BOOM SECTION OPERATION Component description Component description 940A6MI10 Spring pack Bridge Anti-rotation device (opt) Tankregen channel Housing Relief valve Pressure compensator 10 Snubber Spool 11 Low Leak poppet Check valve 12 4th position device 6-20...
Page 485 Boom neutral position Boom neutral position 940A6WE12 The spool is in neutral position, pump is in low pressure stand-by. The A and B ports are not connected to the pumps nor the tank. Boom raise position Boom raise position 940A6WE12 When the pilot pressure is led to the port b1, the oil from the pump flows to the cylinder port B1 and oil from the cylinder flows into the tank through the cylinder port A1.
Page 486 Boom lower position Boom lower position 940A6WE14 When the pilot pressure is led to the port a1, the oil from the pump flows to the cylinder port A1 and oil from the cylinder flows into the tank through the cylinder port B1. If pressure in A1 becomes too low, flow from the tank avoid fullfiled A1 through tank regen channel.
Page 487 3) 3) BUCKET SECTION OPERATION BUCKET SECTION OPERATION Component description Component description 940A6MI16 Spring pack Bridge Anti-rotation device (opt) Tankregen channel Housing Relief valve Pressure compensator 10 Snubber Spool Check valve 6-23...
Page 488 Bucket neutral position Bucket neutral position 940A6WE17 The spool is in neutral position, pump is in low pressure stand-by. The A and B ports are not connected to the pumps nor the tank. Bucket roll back Bucket roll back (retract) position position 940A6WE18 When the pilot pressure is led to the port b2, the oil from the pump flows to the cylinder port B2 and...
Page 489 Bucket dump position Bucket dump position 940A6WE19 When the pilot pressure is led to the port a2, the oil from the pump flows to the cylinder port A2 and oil from the cylinder flows into the tank through the cylinder port B2. If pressure in A2 becomes too low, flow from the tank fullfiled A2 through tank regen channel.
Page 490 7. SAFETY VALVE SAFETY VALVE STRUCTURE STRUCTURE 1) 1) 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 2) 2)
Page 491: Boom Cylinder
8. BOOM AND BUCKET CYLINDER 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 492: Bucket Cylinder
2) 2) BUCKET CYLINDER BUCKET CYLINDER 23,24 12,13 4,5 9,10 6,7 14 17 18,19 20 21 940A6WE22 Tube assembly 11 O-ring 21 Set screw Rod assembly 12 O-ring 22 Bolt Gland 13 Back up ring 23 Bushing Bushing 14 Piston 24 Dust seal Snap ring 15 Piston seal...
Page 493 9. HYDRAULIC OIL TANK 9. HYDRAULIC OIL TANK STRUCTURE STRUCTURE 1) 1) ・ 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. ・...
Page 494 2) 2) RETURN OIL FILTER BYPASS VALVE RETURN OIL FILTER BYPASS VALVE When the filter is clogged When the filter is clogged (1) (1) 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...
Page 495 3) 3) AIR BREATHER AIR BREATHER The air breather is equipped with the capacity to perform three functions simultaneously-as an air filter, breathing valve, and as a lubrication opening. Air breather Preventing negative pressure inside the Preventing negative pressure inside the (1) (1) tank tank...
Page 496 10. ACCUMULATOR 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 497 11. RIDE CONTROL SYSTEM 11. RIDE CONTROL SYSTEM (option) 1) ACCUMULATORS 1) ACCUMULATORS Pre-charging Pre-charging Use an inert gas such as nitrogen for pre-charging accumulator. ※ Do not use oxygen or shop air. Do not use oxygen or shop air. ※...
Page 498 Structure 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 499: 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, Group 1.
Page 500 ※Hydraulic oil must be at operating temperature for these checks (refer to page 6-49). Item Description Service action Hydraulic system warm-up Hydraulic system warm-up Hold a hydraulic function over procedure procedure relief to heat oil. (don't keep relief Check completed. condition over 5 seconds at a time) Run engine at high idle.
Page 501 Item Description Service action Bucket rollback circuit relief Bucket rollback circuit relief Position bucket at a 45˚ angle valve check valve check against an immovable object. Check complete. Engage transmission in 3rd speed NOT OK NOT OK forward. R e p l a c e b o o m l o w e r check valve.
Page 502 Item Description Service action Boom cylinder leakage Boom cylinder leakage Dump bucket until teeth or cutting check check edge is per pendicular to the Drift is approximately the ground. same between first and H e a t h y d r a u l i c o i l t o second measurement.
Page 503 Item Description Service action Bucket leveler Bucket leveler Position bucket fully dumped just (positioner) check (positioner) check above ground level. Check complete. Run engine at low idle. Move control lever to bucket NOT OK NOT OK leveler detent position and release. Do bucket leveler checks.
Page 504: Measurement Condition
※ MEASURING BOOM AND BUCKET CYCLE TIME 1) MEASUREMENT CONDITION 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 2) MEASURING TOOL ・...
Page 505 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 section 1) Step 2.
Page 506 Problem Cause Remedy No steering or hydraulic No steering or hydraulic Low oil level. Add recommended oil. function function Failed hydraulic pump. Remove and inspect return filter for metal pump particles. No hydraulic functions No hydraulic functions Failed hydraulic pump. Remove and inspect return filter for steering normal steering normal...
Page 507 Problem Cause Remedy Function drifts down 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.
Page 508 ※ Followings are general precautions for the hydraulic system and equipment. Every structure has its limit of strength and durability. The relief valve is installed to limit the pressure on the hydraulic equipment and protect various parts of the wheel loader from possible damage.
Page 509: 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 4000 mm × 1in 100R1 Hoses ・Quick disconnect fittings.
Page 510 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 : 130ℓ(34.3 ※...
Page 511 2. BOOM HEIGHT KICKOUT ADJUSTMENT 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 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 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 512 3. TEST TOOLS 3. TEST TOOLS CLAMP-ON ELECTRONIC TACHOMETER CLAMP-ON ELECTRONIC TACHOMETER INSTALLATION 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.
Page 513 4. HYDRAULIC OIL WARM UP PROCEDURE 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.
Page 514 5. MAIN HYDRAULIC PUMP FLOW TEST 5. MAIN HYDRAULIC PUMP FLOW TEST ・ SPECIFICATION SPECIFICATION Oil temperature 45±5˚C (113±9˚F) Engine speed 2230 rpm Test pressure 280±5 bar (3980 psi) Maximum pump flow 160ℓ/min (42.3 gpm) ・ FLOW METER GAUGE AND TOOL FLOW METER GAUGE AND TOOL Gauge 0~35 MPa (0~350 bar, 0~5000 psi) Temperature reader...
Page 515 6. L 6. LOADER SYSTEM AND PORT RELIEF ADER SYSTEM AND PORT RELIEF VALVE PRESSURE TEST VALVE PRESSURE TEST ・ SPECIFICATION SPECIFICATION Oil temperature (40~50˚C) Relief valve Engine speed Relief pressure 280±5 kg/cm System (M) High (3980±70 psi) Boom raise (U) Boom down (W) 340±10 kg/cm (4840±140 psi)
Page 516 7. HYDRAULIC SYSTEM RESTRICTION TEST 7. HYDRAULIC SYSTEM RESTRICTION TEST ・ SPECIFICATION SPECIFICATION Oil temperature 45±5˚C (113±9˚F) Engine speed High idle Maximum pressure 1 MPa (10 bar, 145 psi) at steering unit. Maximum pressure at main control valve 1 MPa (10 bar, 145 psi) ・...
Page 517 8. LOADER CYLINDER DRIFT TEST 8. LOADER CYLINDER DRIFT TEST ・ SPECIFICATION SPECIFICATION Oil temperature 45±5˚C (113±9˚F) Boom horizontal Bucket horizontal Bucket unloaded Item Standard value Retraction of boom 10 mm cylinder rod Retraction of bucket 36 mm cylinder rod GAUGE AND TOOL GAUGE AND TOOL ・...
Page 518 9. BOOM AND BUCKET CYLINDER LEAKAGE TEST 9. BOOM AND BUCKET CYLINDER LEAKAGE TEST ・ SPECIFICATION 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 GAUGE AND TOOL Temperature reader Stop watch Measuring container Fasten temperature sensor to head end...
Page 519 10. CYCLE TIME TEST 10. CYCLE TIME TEST ・ SPECIFICATION SPECIFICATION Oil temperature 45±5˚C (113±9˚F) Engine speed High idle Function Operating conditions Maximum cycle time (seconds) Boom raise Bucket flat on ground to full height Boom lower (float) Full height to ground level Bucket dump Boom at full height Bucket rollback...
Page 520 11. HYDRAULIC OIL FILTER INSPECTION 11. HYDRAULIC OIL FILTER INSPECTION PROCEDURE 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 521: Group 4 Disassembly And Assembly
GROUP 4 DISASSEMBLY AND ASSEMBLY GROUP 4 DISASSEMBLY AND ASSEMBLY 1. MAIN PUMP 1. MAIN PUMP STRUCTURE STRUCTURE (1/2) 1) 1) 1-28 74096WE11 Rotary group 15 Taper roller bearing 30 Locking screw 1-1 High speed rotary group 16 Taper roller bearing 31 Double break-off pin 1-2 Control plate 17 Bearing liner...
Page 522 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 523: Disassemble The Pump
4) 4) SEALING SEALING / CLEANING THE CONTROL CLEANING THE CONTROL VALVE VALVE Disassemble the control valve. ※ Measure dimension A and note down. Check sealing surface (1). 75796WE62 5) 5) DISASSEMBLE THE PUMP DISASSEMBLE THE PUMP Remove the control valve. 75796WE63 Mark the location of the connection plate on the housing.
Page 524 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 525 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 -61...
Page 526 (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 527 (14) Disassemble the guide of the opposite piston. 75796WE78 6) 6) INSPECT HINTS 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.
Page 528 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 529 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 530: Pump Assembly
(12) Check : Check running conditions of the opposite piston. 75796WE90 7) 7) ADJUSTMENT OF TAPER ROLLER ADJUSTMENT OF TAPER ROLLER 0~0.05mm BEARING SET BEARING SET Cast iron housing must have initial tension of the bearings: 0~0,05 mm, grind position A if necessary. Position A 75796WE91 8) 8)
Page 531 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 -67...
Page 532 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 533 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 -69...
Page 534 2. REMOTE CONTROL VALVE 2. REMOTE CONTROL VALVE 1) 1) STRUCTURE STRUCTURE Locite 262 11-1 12-1 11-2 12-2 4,3,1 11-3 12-3 12-4 11-4 11-5 11-6 4,3,1 20-1 7707WE64 Handle 11-4 Cardan 22 Intermediary plunger kit Push button 11-5 Armature 23 Intermediary plunger guide 3-1 Locking pin 11-6 Spring ring 25 Electric bracket...
Page 535: Rubber Boot
2) 2) DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY (1) (1) PUSH BUTTON PUSH BUTTON ※ The remote control valve does not need to be removed from the machine to perform this operation. Remove worn pushbutton using a small screwdriver. The installation of new elements is performed without any special tools; the parts are simply pressed into place.
Page 536 (4) (4) DETENT CARDAN BRACKET KIT DETENT CARDAN BRACKET KIT ※ Remove the 2 grommets (20-1) from the flange (20). ※ Place centering sleeves V & W to avoid damaging the cardan knuckles while loosening the nuts. ※ Unscrew the locking nut (5) using a 23mm open-end wrench.
Page 537 (8) (8) INTERMEDIARY PLUNGER KIT INTERMEDIARY PLUNGER KIT ① Undo the intermediary plunger guide (23). ② Remove and replace the intermediary plunger kit assembly (22). (9) (9) GUIDE / PLUNGER AND REGULATION UNIT GUIDE / PLUNGER AND REGULATION UNIT ※ Beware of the plungers that might jump out due to the spring return.
Page 538 3. MAIN CONTROL VALVE 3. MAIN CONTROL VALVE 1) 1) STARTING, MAXIMAL PRESSURE SET UP STARTING, MAXIMAL PRESSURE SET UP Break the locking cover with a pair of pliers. Decalibrate the LS pressure relief valve (19 mm open end spanner on counternut ;...
Page 539 2) LS PRESSURE RELIEF VALVE REPLACEMENT 2) LS PRESSURE RELIEF VALVE REPLACEMENT The control block does not need to be removed from the machine to perform this operation. Place all of the machine’s actuators connected to the control block in neutral position. Release stored pressure by operating all the spools.
Page 540 4) FLOW REGULATOR REPLACEMENT 4) FLOW REGULATOR REPLACEMENT Unscrew the flow regulator (22 mm open end spanner). ※ Reassembly reassemble parts in reverse order. - Torque : 2.04±0.20 kgf・m (14.8±1.48 lbf·ft) H940AC6SE06 H940AC6SE07 5) PRESSURE COMPENSATOR REPLACEMENT 5) PRESSURE COMPENSATOR REPLACEMENT Unscrew the compensator plug (12 mm socket wrench).
Page 541: Check Valve Replacement
6) CHECK VALVE REPLACEMENT 6) CHECK VALVE REPLACEMENT Unscrew one of the check valves (6 mm socket wrench). ※ Reassembly I n s t a l l t h e c h e c k va l ve o n t h e distribution element.
Page 542 8) COMPLET CONTROL BLOCK DISASSEMBLY/ASSEMBLY 8) COMPLET CONTROL BLOCK DISASSEMBLY/ASSEMBLY Remove the control block from the machine. Remove the 3 nuts (19 mm ring wrench). H940AC6SE18 Remove the final element. Separate the distribution elements. H940AC6SE19 Reassembly R e p l a c e t h e O - r i n g s b e t w e e n distribution elements, initial element and final element.
Page 543 SECTION 7 ELECTRICAL SYSTEM SECTION 7 ELECTRICAL SYSTEM Group 1 Component Location ----------------------------------------------------------------------------------------- 7-1 Group 2 Electrical Circuit -------------------------------------------------------------------------------------------------- 7-3 Group 3 Electrical Component Specification ------------------------------------------------------------------ 7-22 Group 4 Connectors --------------------------------------------------------------------------------------------------------- 7-29 Group 5 Troubleshooting ------------------------------------------------------------------------------------------------- 7-52...
Page 544: Section 7 Electrical System
SECTION 7 ELECTRICAL SYSTEM SECTION 7 ELECTRICAL SYSTEM GROUP 1 COMPONENT LOCATION GROUP 1 COMPONENT LOCATION 1. LOCATION 1 1. LOCATION 1 970SA7EL20 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 545 2. LOCATION 2 2. LOCATION 2 G IN IN E IS SI 960A7EL21 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 546 GROUP 2 ELECTRICAL CIRCUIT GROUP 2 ELECTRICAL CIRCUIT · · ELECTRICAL CIRCUIT (1/3) ELECTRICAL CIRCUIT (1/3) MCU 121 PIN MULTI FUNCTION SWITCH MONITOR CLUSTER CN-431 AAVM MONITOR 609A 0.75 MAIN ACC(24V) 0.75 MAIN GND FRONT 0.75 CAN2 HIGH WIPER 0.75 CAN2 LOW 0.75 TRIGGER 1...
Page 547 WATER IN FUEL 0.75 CD-45 J1939 CAN A+ 0.75 1.25 1.25 1.25 1.25 HARNESS-CUMMINS 0.75 (HL940 T3, HL955 T3, HL960 T3 ONLY) CN-93 0.75 0.75 POSITION 2 SIGNAL 0.75 0.75 0.75 0.75 POSITION 1 RETURN POSITION 1 SIGNAL POSITION 1 SUPPLY...
Page 548 0.75 0.75 BUCKET IN VV SOLENOID F 20 F 44 R 04 R 09 R 23 R 27 BUCKET IN CN-438: HL940 T3~HL960 T3 Operator BUCKET LEVELER CN-101A F 21 F 45 Presence EH-18 CN-443 0.75 0.75 AUX DOWN VV...
Page 549 MEMORANDUM MEMORANDUM...
Page 550: Check Point
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 (12)] Illumination relay [CR-210 (87)] Fuse box [CN-37 (23)] Switch and button indicator lamp Cigar lighter lamp [CL-02] I/conn [CN-01 (31)] I/conn [CN-24 (10)] Number plate lamp [CL-21 (2)]...
Page 551 ILLUMINATION CIRCUIT ILLUMINATION CIRCUIT DIFF LOCK SW FUSE BOX FUSE BOX CS-79 CR-210 EMERGENCY TEST SW RELAY CN-58A ILLUMINATION LIGHT RELAY CN-11 AC HARNESS ILLUMINATION CL-02 CS-75 PARKING SW HAZARD SW CS-17 CS-41 CN-01 CN-24 CL-21 PILOT CUT-OFF SW NUMBER PLATE LAMP CN-07...
Page 552 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 (11)] Driving relay [CR-211 (87)] Multi function switch [CS-11(8)] Multi function switch MIDDLE [CS-11(7)] I/conn [CN-05 (32)] I/conn [CN-12 (17)] LH Head light low beam ON [CL-03 (6)] RH Head light low beam ON [CL-04 (6)]...
Page 553: Head Light Circuit
HEAD LIGHT CIRCUIT HEAD LIGHT CIRCUIT DRIVING RELAY CR-211 DRIVING LIGHT RELAY CN-58A HEAD LIGHT-LH CLUSTER CL-03 HEAD LIGHT-RH HIGH BEAM RH TURN LH TURN BATT. 24V IG 24V CL-04 CN-12 CN-05 CAN2 LOW CAN2 HI CAN2-SHILD CN-56 MULTI FUNCTION SWITCH 960SA7EL05 ※...
Page 554 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-58A (88)] 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 555: Work Light Switch
WORK LIGHT SWITCH WORK LIGHT SWITCH WORK LAMP FRONT RY CR-03 WORK LAMP REAR RY CR-55 SPARE_ECO FEELING SIGNAL ILLUMINATION LIGHT RELAY DRIVING LIGHT RELAY WORK LAMP FRONT WORK LAMP REAR FUEL WARMER RELAY AIRCON RUN SIGNAL CN-58A CL-32 WORK LAMP CL-33 FRONT...
Page 556 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-02A (1)] ECM power relay [CR-30 (30)] Power relay [CR-35 (30)] ※...
Page 557 STARTING CIRCUIT STARTING CIRCUIT JOYSTIC STEERING MONITOR CLUSTER USB PLAYER POWER CONNECT CS-02A 1.25RG 1.25RG FUSE BOX 1.25G TURN LAMP 1.25W 1.25W START KEY SW POWER IG 1.25R 1.25R RADIO B+ 551 Br 1.25RB 1.25RB BATT TCU 24V B+ CS-02C AC/HEATER B+ 0.85B VPSb...
Page 558: Charging Circuit
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 559 CHARGING CIRCUIT CHARGING CIRCUIT FUSE BOX TURN LAMP START KEY SW RADIO B+ TCU 24V B+ AC/HEATER B+ CLUSTER 24V B+ MCU B+ RMCU B+ ECM POWER ROOM LP RS-01 SMART KET IG RESISTOR MONITOR IG 3W/300 CN-45 STARTER CN-36 CN-74 ALTERNATOR CN-04...
Page 560 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)] Parking solenoid ON (activated) Parking brake released (by hydraulic pressure) [CS-17 (2)→(1)] T/M control unit [CN-157 (21)]...
Page 561 ELECTRIC PARKING ELECTRIC PARKING, PILOT CUT OFF CIRCU , PILOT CUT OFF CIRCUIT IT PARKING SW PARKING RELAY CR-78 EC4a CS-17 ED1, NC ED2, NC ED3, JOYSTICK EA ED4, FNR-F ED5, FNR-N CN-04 ED6, FNR-R ED7, PARKBRAKE FB1 VMGa AU1(+5VDC) ED9, BRAKE PD1 ED10, BRAKE PD2 CN-X2...
Page 562 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 563 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_REAR WIPER PARK, PILOT CUT CR-04 AUTO GREASE AIR PRE-HEAT...
Page 564 HAZARD, TURN AND ROTARY CIRCUIT HAZARD, TURN AND ROTARY CIRCUIT BEACON RELAY CR-117 BEACON RELAY CN-58A CN-01 REAR COMBI CL-16 BEACON LAMP REAR COMBI CL-117 CN-07 CL-15 FLASHER UNIT CR-11 CLUSTER HIGH BEAM RH TURN LH TURN BATT. 24V IG 24V CN-56 CN-12 CN-05...
Page 565 GROUP 3 ELECTRICAL COMPONENT SPECIFICATION GROUP 3 ELECTRICAL COMPONENT SPECIFICATION Part name Symbol Specifications Check item Gravity 12V × 150Ah 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 566 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 N.O Type ∞Ω: normal (open) CD-10 Lock-up, ※...
Page 567 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 568 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 569 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 Voltage Alternator 24V 70A 3 FI normal : 24~28V 4 NC CN-74 Starter 24V-4.8kW...
Page 570 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 571 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 7-28...
Page 572 GROUP 4 CONNECTORS GROUP 4 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 573 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 CN-79A DEUTSCH Differential lock solenoid DT06-2S DT04-2D-E005 CN-93 DEUTSCH ECM (engine control module) DRC26-505-04 CN-94 DEUTSCH ECM power DT06-4S DEUTSCH Boom kick out, Bucket leveler DT06-3S...
Page 574 Connector part No. Connector No. of Type Destination number Female Male CN-177A Econoseal J I/conn (Front harness-Quick coupler harness) S816-003002 S816-103002 CN-178 DEUTSCH Quick coupler lock solenoid DT06-2S CN-196 PACKARD Fuel heater 2-967325-3 CN-203 Rear wiper motor 936257-1 CN-246 PTC power MG620659-5 CN-249 DEUTSCH...
Page 575 Connector part No. Connector No. of Type Destination number Female Male Switch CS-1 Door switch ST730018-3 CS-2 Start key switch MG610335-5 CS-4 CARLING Pilot cut off switch VC2-01 CS-11 Multi function switch MG610339-5 CS-12 Multi function switch MG610339-5 CS-13 Multi function switch ST730018-3 CS-17 CARLING...
Page 576 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 577 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 7-34...
Page 578 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 7-35...
Page 579 No. of Receptacle connector (female) Plug connector (male) S811-013002 S811-113002 S811-017002 S811-117002 S811-021002 S811-121002 7-36...
Page 580 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 7-37...
Page 581 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 7-38...
Page 582 No. of Receptacle connector (female) Plug connector (male) S814-006000 S814-106000 S814-008000 S814-108000 S814-012000 S814-112000 S814-014000 S814-114000 7-39...
Page 583 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 7-40...
Page 584 No. of Receptacle connector (female) Plug connector (male) S810-006202 S810-106202 S810-008202 S810-108202 7-41...
Page 585 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 586 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 587 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 588 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 589 No. of Receptacle connector (female) Plug connector (male) DT06-6S DT04-6P DT06-8S DT04-8P DT06-12S DT04-12P 7-46...
Page 590 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 7-47...
Page 591 No. of Receptacle connector (female) Plug connector (male) S816-006002 S816-106002 S816-008002 S816-108002 S816-010002 S816-110002 S816-012002 S816-112002 7-48...
Page 592 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 7-49...
Page 593 MONITOR CONNECTOR (21WD-11400) MONITOR CONNECTOR (21WD-11400) 7-50...
Page 594 CN-58A CAN2 LOW REVERSE DRIVE RELAY CAN2 HI AUTO GREASE RELAY RIDE CONTROL RELAY SPARE_ECO FEELING SIGNAL INPUT FRONT WASHER SIGNAL ILLUMINATION LIGHT RELAY INPUT FRONT INT SIGNAL DRIVING LIGHT RELAY WORK LAMP FRONT REAR WIPER WASHER REALY WORK LAMP REAR ATACH LOCK RELAY FUEL WARMER RELAY ATACH UNLOCK RELAY...
Page 595 GROUP 5 TROUBLESHOOTING GROUP 5 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.12, 17 are not blown out and ON/OFF of bulb.
Page 596 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 597 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 598 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 599 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 600 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 601 7. WHEN STARTING SWITCH "ON" DOES NOT OPERATE 7. WHEN STARTING SWITCH "ON" DOES NOT OPERATE ・Before carrying out below procedure, check all the related connectors are properly inserted the fuse No.2 is not blown out. CN-36 ・After checking, connect the disconnected connectors again immediately unless otherwise TURN LAMP START KEY SW specified.
Page 602 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.