DL250 (K1023773e)
DL250 (K1023773e)
DL250 (K1023773e)
Shop Manual
K1023773E
Serial Number 5001 and Up
DOOSAN reserves the right to improve our products in a continuing process to provide the best
possible product to the market place. These improvements can be implemented at any time with no
obligation to change materials on previously sold products. It is recommended that consumers
periodically contact their distributors for recent documentation on purchased equipment.
This documentation may include attachments and optional equipment that is not available in your
machine's package. Please call your distributor for additional items that you may require.
Illustrations used throughout this manual are used only as a representation of the actual piece of
equipment, and may vary from the actual item.
Specifications
Specification for DL250 ....................................................................... SP000866
General Maintenance
General Maintenance Procedures ...................................................... SP000097
Standard Torques ................................................................................ SP000813
Drive Train
Transmission and Torque Converter.................................................. SP000867
Transmission Error Codes (ZF).......................................................... SP001056
Front Axle (ZF-MT-L 3085)................................................................. SP000868
Rear Axle (ZF-MT-L 3075) ................................................................. SP000869
Drive Shaft ........................................................................................... SP000870
Brake
Service Brake....................................................................................... SP000871
Brake Supply Valve............................................................................. SP000872
Parking Brake ...................................................................................... SP000873
Brake Pedal Valve............................................................................... SP000874
Accumulator.......................................................................................... SP000875
Steering
Steering ................................................................................................ SP000876
Cushion Valve...................................................................................... SP000328
Emergency Steering ............................................................................ SP000877
Table of Contents
Page I
Frame
Articulation Center ............................................................................... SP000878
Counterweight....................................................................................... SP000130
Tank
Oil Tank................................................................................................ SP000879
Fuel Tank ............................................................................................. SP000880
Hydraulics
Cylinders............................................................................................... SP001027
Main Pump........................................................................................... SP001035
Main Control Valve.............................................................................. SP000881
Load Isolation System......................................................................... SP000882
Cooling System.................................................................................... SP000883
Pilot System ......................................................................................... SP000884
Hydraulic Schematic DL250................................................................ SP000886
Electrical System
Air Conditioner ..................................................................................... SP001211
Electrical System ................................................................................. SP000924
Electrical Schematic DL200/ DL250................................................... SP000925
Table of Contents
Page II
1Safety
SP000865
WHEEL LOADER SAFETYSP000865
Wheel Loader
Safety
Edition 1
Safety Precautions............................................... 5
Applicable Models................................................ 5
To the Operator of a Wheel Loader ................. 6
General Safety Essentials................................. 10
Location of Safety Labels................................. 10
Unauthorized Modifications ............................... 11
General Hazard Information.............................. 11
Before Starting Engine ...................................... 19
Machine Operation ............................................ 23
Maintenance ....................................................... 31
Battery ................................................................ 40
Towing ................................................................ 42
Shipping and Transportation ............................. 43
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
DANGER!
Unsafe use of the wheel loader could lead to serious injury
or death. Operating procedures, maintenance and
equipment practices or traveling or shipping methods that
do not follow the safety guidelines on the following pages
could cause serious, potentially fatal injuries or extensive
damage to the machine or nearby property.
CAUTION!
This word is used on safety messages and safety labels and
indicates potential of a hazardous situation that, if not
avoided, could result in minor or moderate injury. It may
also be used to alert against a generally unsafe practice.
WARNING!
This word is used on safety messages and safety labels and
indicates potential of a hazardous situation that, if not
avoided, could result in serious injury or death. It may also
be used to alert against a highly unsafe practice.
DANGER!
This word is used on safety messages and safety labels and
indicates an imminent hazard of a situation that, if not
avoided, is very likely to cause death or extremely serious
injury. It may also be used to alert against equipment that
may explode or detonate if handled or treated carelessly.
Accessory Applications
This wheel loader has been designed primarily for moving
earth with a bucket. For use as a grapple or for other object
handling, contact DOOSAN. Lifting-work applications are
permitted in approved lift configuration, to rated capacity
only, with no side-loading (unless prohibited by local
regulation). Do not use machine for activities for which it
was not intended. Do not use bucket for lifting work, unless
lift slings are used in approved configuration.
LOCATION OF SAFETY
LABELS
Location of safety labels (decals) can vary from unit to unit.
Refer to appropriate Operation and Maintenance Manual,
and Parts Manual for your unit.
There are several specific warning signs on this machine.
The exact location of hazards and the description of the
hazards are reviewed in the appropriate Operation and
Maintenance Manual.
Please become familiarized with all warning signs.
Make sure that all of the warning signs are legible. Clean
the warning signs or replace the warning signs if you cannot
read the words. Replace the illustrations if the illustrations
are not visible. When you clean the warning signs, use a
cloth, water and soap. Do not use solvent, gasoline, or other
harsh chemicals to clean the safety signs. Solvents,
gasoline, or other harsh chemicals could loosen the
adhesive that secures the warning sign. Loose adhesive will
allow the warning sign to fall off.
Replace any safety sign that is damaged, or missing. If a
safety sign is attached to a part that is replaced, install a
safety sign on the replacement part.
GENERAL HAZARD
INFORMATION
Safety Rules
Only trained and authorized personnel can operate and
maintain the machine.
Follow all safety rules, precautions and instructions when
operating or performing maintenance on the machine.
Do not operate the machine if you are not feeling well, if
you are taking medication that makes you feel sleepy, if you
have been drinking, or if you are suffering from emotional
problems. These problems will interfere with your sense of
judgement in emergencies and may cause accidents.
When working with another operator or with a person on
work site traffic duty, be sure that all personnel know the
nature of the work and understand all hand signals that are
to be used.
Always observe strictly any other rules related to safety.
Safety Features
Be sure that all guards and covers are installed in their
proper position. Have guards and covers repaired
immediately if damaged.
Be sure that you understand the method of use of safety
features such as transmission lever neutral lock and the
seat belt, and use them properly.
Never remove any safety features. Always keep them in
good operating condition.
Failure to use safety features according to the instructions in
the Operation and Maintenance Manual could result in
serious bodily injury.
HAOA060L
Figure 6
Accumulator
The pilot control system is equipped with an accumulator.
For a brief period of time after the engine has been shut
down, the accumulator will store a pressure charge that may
enable hydraulic controls to be activated. Activation of any
controls may enable the selected function to operate under
force of gravity.
When performing maintenance on the pilot control system,
the hydraulic pressure in the system must be released as
describe in Operation and Maintenance Manual.
The accumulator is charged with high-pressure nitrogen gas,
so it is extremely dangerous if it is handled in the wrong
way. Always observe the following precautions;
• Do not drill or make any holes in the accumulator
or expose it any flame, fire or heat source.
• Do not weld on the accumulator, or try attaching
anything to it.
• When carrying out disassembly or maintenance of
the accumulator, or when disposing of the
accumulator, the charged gas must be properly
released. Contact your DOOSAN distributor.
• Wear safety goggles and protective gloves when
working on an accumulator. Hydraulic oil under
pressure can penetrate the skin and cause
serious injuries.
Engine Ventilation
Engine exhaust gases can cause loss of judgment, loss of
alertness, and loss of motor control. These gases can also
cause unconsciousness, serious injury and fatal accidents.
Make sure of adequate ventilation before starting engine in
any enclosed area.
You should also be aware of open windows, doors or
ductwork into which exhaust may be carried, or blown by
wind, exposing others to danger.
ARO1770L
Figure 11
IMPORTANT
If you need more information or have any questions or
concerns about safe operating procedures or working the
wheel loader correctly in a particular application or in the
specific conditions of your individual operating
environment, please consult your local DOOSAN
representative.
Figure 14
Movement Alarms
If wheel loader is equipped with an audible travel movement
alarm, test alarm on a daily basis. Audible alarm should
sound as soon as travel system is engaged.
HDO1042L
Figure 17
Figure 19
IMPORTANT
When hydraulic system maintenance or service work must
be performed, be aware that accumulators in system store
fluid under pressure after system has been shut down. To
release hydraulic pressure in accumulators, operate control
with engine "OFF" until accumulator pressure is completely
dissipated.
HAAD4050
Figure 21
HAOC920L
Figure 22
HDO1037L
Figure 24
Use of Lighting
When checking fuel, oil, battery electrolyte, or window
washing fluid, always use lighting with anti-explosion
specifications. If such lighting equipment is not used, there
is danger of explosion.
If work is carried out in dark places without using lighting, it
may lead to injury, so always use proper lighting.
Even if the place is dark, never use a lighter or flame
instead of lighting. There is danger of fire. There is also
HDO1040L
danger that the battery gas may catch fire and cause and
Figure 25
explosion.
Burn Prevention
When checking the radiator coolant level, shut down engine,
let the engine and radiator cool down, then check the
coolant recovery tank. If the coolant level in the coolant
recovery tank is near the upper limit, there is enough
coolant in the radiator.
Loosen the radiator cap gradually to release the internal
pressure before removing the radiator cap.
If the coolant level in the coolant recovery tank is below the
lower limit, add coolant.
Cooling system conditioner contains alkali. Alkali can cause
personal injury. Do not allow alkali to contact the skin, the
eyes, or the mouth.
Allow cooling system components to cool before you drain
the cooling system.
Hot oil and hot components can cause personal injury. Do
not allow hot oil or hot components to contact the skin.
Remove the hydraulic tank filter plug only after the engine
has been stopped. Make sure that the hydraulic tank filter
plug is cool before you remove it with your bare hand.
Remove the hydraulic tank filter plug slowly to relieve
pressure.
Relieve all pressure in the hydraulic oil system, in the fuel
system, or in the cooling system before you disconnect any HAAE1980
lines, fittings, or related items.
Figure 26
Batteries give off flammable fumes that can explode.
Do not smoke while you are checking the battery electrolyte
levels.
Electrolyte is an acid. Electrolyte can cause personal injury.
Do not allow electrolyte to contact the skin or the eyes.
Always wear protective glasses when you work on batteries.
WARNING!
When you connect or disconnect connectors between ECU
and Engine or connector between ECU and the machine,
always disconnect the source power to protect damage of
the ECU.
If you don't observe this procedure, the ECU would be
gamaged or the engine would operate abnormally.
WARNING!
Failure to obtain prompt medical assistance could result in
gangrene or other serious damage to tissue.
WARNING!
Improper lifting can allow load to shift and cause personal
injury or damage to the machine.
Specification
for DL250
Edition 1
Safety Precautions............................................... 5
Applicable Models................................................ 5
Component Locations .......................................... 6
General Specifications ......................................... 8
Engine Performance Curves ............................. 10
Working Range and Dimensions...................... 12
Working Capacities............................................ 15
Bucket Capacity............................................................ 15
Tipping Load ................................................................. 15
Material Weight .................................................. 15
Approximate Weight of Workload Materials ............... 15
CAUTION!
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good
working order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
1 2 3 4
5 6 7
18 17 11 20 19 10 22 23 24
26 8 25
44 12 13 14 15
30 28 27
43 42 39 40 36 38 37 16 41 35 34 33 32 31 21 29 FG006184
Figure 1
80
70
TORQUE (kg.m)
60
POWER OUTPUT (ps)
150
100
160
150
140
P
B(D)
F
Q
40
62
I
K
C
H
b
15
FG006688
Figure 3
Dump Height, to tooth (H) 2,730 mm (8' 11") 2,700 mm (8' 10")
Dump Reach, to Tooth (I) 1,200 mm (3' 11") 1,210 mm (3' 11")
Dump Height to Bucket Pivot (K) 3,886 mm (12' 9") 3,856 mm (12' 8")
E F
A
C
B
D
FG006689
Figure 4
Reference Reference
Description Description
Number Number
A 1,566 mm (5' 2") E 1,500 mm (4' 11")
B 2,406 mm (7' 11") F 753 mm (2' 6")
C 3,692 mm (12' 1") a 46°
D 8,135 mm (26' 8") b 43°
Bucket Capacity
Standard toothed bucket has a capacity of 2.5 m3 (3.25 yd3).
An optional bucket equipped with a cutting edge and no
teeth has a capacity of 2.6 m3 (3.38 yd3).
Tipping Load
Static Tipping Load with bucket in Over Front position is
12,200 kg (26,895 lb). With bucket in Fully Turned position,
Static Tipping Load is 10,200 kg (22,486 lb).
MATERIAL WEIGHT
The data below describes weight of a cubic meter (cubic
yard) of many types of workload materials.
401 kg/m3
Charcoal --------------------- ---------------------
(695 lb/yd3)
449 kg/m3
Coke, foundry size --------------------- ---------------------
(756 lb/yd3)
897 kg/m3
Coal, anthracite --------------------- ---------------------
(1,512 lb/yd3)
1,522 kg/m3
Dolomite, crushed --------------------- ---------------------
(2,565 lb/yd3)
1,522 kg/m3
Earth, DRY, packed --------------------- ---------------------
(2,565 lb/yd3)
1,762 kg/m3
Earth, WET, muddy --------------------- ---------------------
(2,970 lb/yd3)
1,522 kg/m3
Limestone, crushed --------------------- ---------------------
(2,565 lb/yd3)
1,602 kg/m3
Limestone, fine --------------------- ---------------------
(2,705 lb/yd3)
1,282 kg/m3
Phosphate, rock --------------------- ---------------------
(2,160 lb/yd3)
929 kg/m3
Salt --------------------- ---------------------
(1,566 lb/yd3)
529 kg/m3
Snow, light density --------------------- ---------------------
(891 lb/yd3)
1,522 kg/m3
Sand, DRY, loose --------------------- ---------------------
(2,565 lb/yd3)
1,922 kg/m3
Sand, WET, packed --------------------- ---------------------
(3,240 lb/yd3)
1,362 kg/m3
Shale, broken --------------------- ---------------------
(2,295 lb/yd3)
529 kg/m3
Sulphur, broken --------------------- ---------------------
(1,620 lb/yd3)
IMPORTANT
Weights are approximations of estimated average
volume and mass. Exposure to rain, snow or ground
water; settling or compaction due to overhead weight
and chemical or industrial processing or changes due to
thermal or chemical transformations could all increase
value of weights listed in table.
General
Maintenance
Procedures
Edition 1
Safety Precautions............................................... 5
Applicable Models................................................ 5
Welding Precautions and Guidelines ................. 6
Hydraulic System - General Precautions........... 7
Maintenance Service and Repair Procedure..... 9
General Precautions ....................................................... 9
Hydraulic System Cleanliness and Oil Leaks . 10
Maintenance Precautions for Hydraulic System
Service .......................................................................... 10
Oil Leakage Precautions.............................................. 11
Cleaning and Inspection ................................... 12
General Guidelines ....................................................... 12
Bearing inspection ........................................................ 13
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
WARNING!
Structural elements of the machine may be built from a
variety of steels. These could contain unique alloys or may
have been heat treated to obtain particular strength
characteristics. It is extremely important that welding
repairs on these types of steel are performed with the
proper procedures and equipment. If repairs are performed
incorrectly, structural weakening or other damage to the
machine (that is not always readily visible) could be caused.
Always consult DOOSAN After Sales Service before
welding on integral components (loader arm, frames, car
body, track frames, turntable, attachment, etc.) of the
machine. It is possible that some types of structurally
critical repairs may require Magnetic Particle or Liquid
Penetrant testing, to make sure there are no hidden cracks
or damage, before the machine can be returned to service.
CAUTION!
Always perform welding procedures with the proper safety
equipment on hand. Adequate ventilation and a dry work
area are absolutely essential. Keep a fire extinguisher
nearby and always wear protective clothing and the
recommended type of eye protection.
HYDRAULIC SYSTEM -
GENERAL PRECAUTIONS
Always maintain oil level in the system at recommended
levels. Assemblies that operate under heavy loads, at high
speed, with extremely precise dimensional tolerances
between moving parts - pistons and cylinders, or shoes and
swash plates, for example - can be severely damaged if oil
supply runs dry.
Assemblies can be run dry and damaged severely in a very
short time when piping or hoses are disconnected to repair
leaks and/or replace damaged components. Hoses that are
inadvertently switched during disassembly (inlet for outlet
and vice versa), air introduced into the system or
assemblies that are low on oil due to neglect or careless
maintenance, could all produce sufficient fluid loss to cause
damage.
IMPORTANT
Hydraulic system operating conditions (repetitive cycling,
heavy work loads, fluid circulating under high-pressure)
make it extremely critical that dust, grit or any other type of
contamination be kept out of the system. Observe fluid and
filter change maintenance interval recommendations and
always preclean any exterior surface of the system before it
is exposed to air. For example, the reservoir fill cap and
neck area, hoses that have to be disassembled, and the
covers and external surfaces of filter canisters should all be
cleaned before disassembly.
General Precautions
Fluid level and condition should always be checked
whenever any other type of maintenance service or repair is
being performed.
NOTE: If the unit is being used in an extreme temperature
environment (in sub-freezing climates or in high
temperature, high humidity tropical conditions),
frequent purging of moisture condensation from the
hydraulic reservoir drain tap should be a regular and
frequent part of the operating routine. In more
moderate, temperate climates, draining reservoir
sediment and moisture may not be required more
than once or twice every few months.
Inspect drained oil and used filters for signs of abnormal
coloring or visible fluid contamination at every oil change.
Abrasive grit or dust particles will cause discoloration and
darkening of the fluid. Visible accumulations of dirt or grit
could be an indication that filter elements are overloaded
(and will require more frequent replacement) or that
disintegrating bearings or other component failures in the
hydraulic circuit may be imminent or have already occurred.
Open the drain plugs on the main pump casings and check
and compare drain oil in the pumps. Look for evidence of
grit or metallic particles.
Vibration or unusual noise during operation could be an
indication of air leaking into the circuit (Refer to the
appropriate Troubleshooting section for component or unit for
procedures.), or it may be evidence of a defective pump.
The gear type pilot pump could be defective, causing low
pilot pressure, or a main pump broken shoe or piston could
be responsible.
NOTE: If equipped, indicated operating pressure, as shown
on the multidisplay digital gauge on the Instrument
Panel ("F-Pump" and "R-Pump") will be reduced as a
result of a mechanical problem inside the pump.
However, pressure loss could also be due to
cavitation or air leakage, or other faults in the
hydraulic system.
Check the exterior case drain oil in the main pumps. If no
metallic particles are found, make sure there is no air in the
system. Unbolt and remove the tank return drain line from
the top part of the swing motor, both travel motors and each
main pump. If there is air in any one of the drain lines,
carefully prefill the assembly before bolting together the
drain line piping connections. Run the system at low rpm.
IMPORTANT
Make sure that cleaning solvents will be compatible with
rubber materials used in the hydraulic system. Many
petroleum based compounds can cause swelling,
softening, or other deterioration of system sealing
elements, such as O-rings, caps and other seals.
Figure 1
General Guidelines
All parts must be clean to permit an effective inspection.
During assembly, it is very important that no dirt or foreign
material enters unit being assembled. Even minute particles
can cause malfunction of close fitting parts such as thrust
bearing, matched parts, etc.
WARNING!
Care should be exercised to avoid inhalation of vapors,
exposure to skin and creating fire hazards when using
solvent type cleaners.
Bearing inspection
The conditions of the bearing are vital to the smooth and
efficient operation of the machinery. When any component
containing bearings is disassembled, always carefully
examine the condition of the bearings and all of its
components for wear and damage.
Once the bearing is removed, clean all parts thoroughly
using a suitable cleaning solution. If the bearing is
excessively dirty soak the bearing assembly in a light
solution and move the bearing around until all lubricants and
or foreign materials are dissolved and the parts are
thoroughly clean.
When drying bearings, moisture free compressed air can be
used. Be careful not to direct the air in a direction which will
force the bearing to dry spin while not being properly
lubricated.
Normal Bearing
Smooth even surfaces with no discoloration or marks.
Figure 2
Bent Cage
Cage damage due to improper handling or tool usage.
Figure 3
Figure 4
Galling
Metal smears on roller ends due to overheat, lubricant
failure or overload.
Replace bearing - check seals and check for proper
lubrication.
Figure 5
Figure 6
Figure 7
Misalignment
Outer race misalignment due to foreign object.
Clean related parts and replace bearing. Make sure races
are properly seated.
Figure 8
Indentations
Surface depressions on race and rollers caused by hard
particles of foreign materials.
Clean all parts and housings, check seals and replace
bearings if rough or noisy.
Figure 9
Figure 10
Brinelling
Surface indentations in raceway caused by rollers either
under impact loading or vibration while the bearing is not
rotating.
Replace bearing if rough or noisy.
Figure 11
Cage Wear
Wear around outside diameter of cage and roller pockets
caused by abrasive material and inefficient lubrication.
Replace bearings - check seals.
Figure 12
Figure 13
Figure 14
Smears
Smearing of metal due to slippage caused by poor fitting,
lubrication, overheating, overloads or handling damage.
Replace bearings, clean related parts and check for proper
fit and lubrication.
Replace shaft if damaged.
Figure 15
Figure 16
Heat Discoloration
Heat discoloration can range from faint yellow to dark blue
resulting from overload or incorrect lubrication.
Excessive heat can cause softening of races or rollers.
To check for loss of temper on races or rollers, a simple file
test may be made. A file drawn over a tempered part will
grab and cut metal, whereas a file drawn over a hard part
will glide readily with no metal cutting.
Replace bearing if over heating damage is indicated. Check
seals and other related parts for damage.
Figure 17
Stain Discoloration
Discoloration can range from light brown to black caused by
incorrect lubrication or moisture.
if the stain can be removed by light polishing or if no
evidence of overheating is visible, the bearing can be
reused.
Check seals and other related parts for damage.
Figure 18
Standard
Torques
Edition 1
Standard Torques
Safety Precautions............................................... 5
Applicable Models................................................ 5
Torque Values for Standard Metric Fasteners.. 6
Torque Values for Standard U.S. Fasteners..... 7
Type 8 Phosphate Coated Hardware ................ 9
Torque Values for Hose Clamps ..................... 10
Torque Values for Split Flanges ...................... 11
Torque Wrench Extension Tools ...................... 12
Torque Multiplication .................................................... 12
Other Uses for Torque Wrench Extension Tools ...... 14
Tightening Torque Specifications (Metric) .................. 15
CAUTION!
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good
working order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
Grade
Dia. x Pitch
(mm)
3.6 4.6 4.8 5.6 5.8 6.6 6.8 6.9 8.8 10.9 12.9
(4A) (4D) (4S) (5D) (5S) (6D) (6S) (6G) (8G) (10K) (12K)
0.15 0.16 0.25 0.22 0.31 0.28 0.43 0.48 0.50 0.75 0.90
M5 x Std.
(1.08) (1.15) (1.80) (1.59) (2.24) (2.02) (3.11) (3.47) (3.61) (5.42) (6.50)
0.28 0.30 0.45 0.40 0.55 0.47 0.77 0.85 0.90 1.25 1.50
M6 x Std.
(2.02) (2.16) (3.25) (2.89) (3.97) (3.39) (5.56) (6.14) (6.50) (9.04) (10.84)
0.43 0.46 0.70 0.63 0.83 0.78 1.20 1.30 1.40 1.95 2.35
M7 x Std.
(3.11) (3.32) (5.06) (4.55) (6.00) (5.64) (8.67) (9.40) (10.12) (14.10) (16.99)
0.70 0.75 1.10 1.00 1.40 1.25 1.90 2.10 2.20 3.10 3.80
M8 x Std.
(5.06) (5.42) (7.95) (7.23) (10.12) (9.04) (13.74) (15.18) (15.91) (22.42) (27.48)
0.73 0.80 1.20 1.00 1.50 1.35 2.10 2.30 2.40 3.35 4.10
M8 x 1
(5.28) (5.78) (8.67) (7.23) (10.84) (9.76) (15.18) (16.63) (17.35) (24.23) (29.65)
1.35 1.40 2.20 1.90 2.70 2.35 3.70 4.20 4.40 6.20 7.20
M10 x Std.
(9.76) (10.12) (15.91) (13.74) (19.52) (19.99) (26.76) (30.37) (31.18) (44.84) (52.07)
1.50 1.60 2.50 2.10 3.10 2.80 4.30 4.90 5.00 7.00 8.40
M10 x 1.25
(10.84) (11.57) (18.08) (15.18) (22.42) (20.25) (31.10) (35.44) (36.16) (50.63) (60.75)
2.40 2.50 3.70 3.30 4.70 4.20 6.30 7.20 7.50 10.50 12.50
M12 x Std.
(17.35) (18.08) (26.76) (23.86) (33.99) (30.37) (45.56) (52.07) (54.24) (75.94) (90.41)
2.55 2.70 4.00 3.50 5.00 4.50 6.80 7.70 8.00 11.20 13.40
M12 x 1.25
(18.44) (19.52) (28.93) (25.31) (36.16) (32.54) (49.18) (55.69) (57.86) (81.00) (96.92)
3.70 3.90 6.00 5.20 7.50 7.00 10.00 11.50 12.00 17.00 20.00
M14 x Std.
(26.76) (28.20) (13.23) (37.61) (54.24) (50.63) (72.33) (83.17) (86.79) (122.96) (144.66)
4.10 4.30 6.60 5.70 8.30 7.50 11.10 12.50 13.00 18.50 22.00
M14 x 1.5
(29.65) (31.10) (47.73) (41.22) (60.03) (54.24) (80.28) (90.41) (94.02) (133.81) (159.12)
5.60 6.00 9.00 8.00 11.50 10.50 15.50 17.90 18.50 26.00 31.00
M16 x Std.
(40.50) (43.39) (65.09) (57.86) (83.17) (75.94) (112.11) (129.47) (133.81) (188.05) (224.22)
6.20 6.50 9.70 8.60 12.50 11.30 17.00 19.50 20.00 28.00 35.50
M16 x 1.5
(44.84) (47.01) (70.16) (62.20) (90.41) (81.73) (122.96) (141.04) (144.66) (202.52) (256.77)
7.80 8.30 12.50 11.00 16.00 14.50 21.00 27.50 28.50 41.00 43.00
M18 x Std.
(56.41) (60.03) (90.41) (79.56) (115.72) (104.87) (151.89) (198.90) (206.14) (296.55) (311.01)
9.10 9.50 14.40 12.50 18.50 16.70 24.50 27.50 28.50 41.00 49.00
M18 x 1.5
(65.82) (68.71) (104.15) (90.41) (133.81) (120.79) (177.20) (198.90) (206.14) (296.55) (354.41)
11.50 12.00 18.00 16.00 22.00 19.00 31.50 35.00 36.00 51.00 60.00
M20 x Std.
(83.17) (86.79) (130.19) (115.72) (159.12) (137.42) (227.83) (253.15) (260.38) (368.88) (433.98)
12.80 13.50 20.50 18.00 25.00 22.50 35.00 39.50 41.00 58.00 68.00
M20 x 1.5
(92.58) (97.64) (148.27) (130.19) (180.82) (162.74) (253.15) (285.70) (296.55) (419.51) (491.84)
15.50 16.00 24.50 21.00 30.00 26.00 42.00 46.00 49.00 67.00 75.00
M22 x Std.
(112.11) (115.72) (177.20) (151.89) (216.99) (188.05) (303.78) (332.71) (354.41) (484.61) (542.47)
17.00 18.50 28.00 24.00 34.00 29.00 47.00 52.00 56.00 75.00 85.00
M22 x 1.5
(122.96) (133.81) (202.52) (173.59) (245.92) (209.75) (339.95) (44.76) (405.04) (542.47) (614.80)
20.50 21.50 33.00 27.00 40.00 34.00 55.00 58.00 63.00 82.00 92.00
M24 x Std.
(148.27) (155.50) (238.68) (195.29) (289.32) (245.92) (397.81) (419.51) (455.67) (593.10) (655.43)
23.00 35.00 37.00 31.00 45.00 38.00 61.00 67.00 74.00 93.00 103.00
M24 x 2.0
(166.35) (253.15) (267.62) (224.22) (325.48) (202.52) (441.21) (484.61) (535.24) (672.66) (744.99)
NOTE: Torque values listed throughout this manual are lubricated (wet) threads; values should be
increased 1/3 for nonlubricated (dry) threads.
Heat Treated Material Grade 5 and Grade 8
Grade 5 Grade 8
Thread Size (3 Radial Dashes On Head) (6 Radial Dashes On Head)
Foot Pounds Newton Meter Foot Pounds Newton Meter
(ft lb) (Nm) (ft lb) (Nm)
1/4" - 20 6 8 9 12
1/4" - 28 7 9 11 15
5/16" - 18 13 18 18 24
5/16" - 24 15 20 21 28
3/8" - 16 24 33 34 46
3/8" - 24 27 37 38 52
7/16" - 14 38 52 54 73
7/16" - 20 42 57 60 81
1/2" - 13 58 79 82 111
1/2" - 20 65 88 90 122
9/16" - 12 84 114 120 163
9/16" - 18 93 126 132 179
5/8" - 11 115 156 165 224
5/8" - 18 130 176 185 251
3/4" - 10 205 278 290 393
3/4" - 16 240 312 320 434
7/8" - 9 305 414 455 617
7/8" - 14 334 454 515 698
1" - 8 455 617 695 942
1" - 14 510 691 785 1064
1 1/8" - 7 610 827 990 1342
1 1/8" - 12 685 929 1110 1505
1 1/4" - 7 860 1166 1400 1898
1 1/4" - 12 955 1295 1550 2102
1 3/8" - 6 1130 1532 1830 2481
1 3/8" - 12 1290 1749 2085 2827
1 1/2" - 6 1400 2034 2430 3295
1 1/2" - 12 1690 2291 2730 3701
1 3/4" - 5 2370 3213 3810 5166
2" - 4 1/2 3550 4813 5760 7810
NOTE: If any bolts and nuts are found loose or at
values less than what the chart states, it is
recommended that the loose bolt and/or nut be
replaced with a new one.
Torque
Radiator, Air Cleaner, Boots,
Hydraulic System
Etc.
Clamp Type And Size
Kilogram Kilogram
Inch Pounds Inch Pounds
Meter Meter
(in lb) (in lb)
(kg•m) (kg•m)
"T" Bolt (Any Diameter) 0.68 - 0.72 59 - 63 ------- ------
Worm Drive - Under
44 mm (1-3/4 in) Open 0.2 - 0.3 20 - 30 0.5 - 0.6 40 - 50
Diameter
Worm Drive - Over
44 mm (1-3/4 in) Open 0.5 - 0.6 40 - 50 ------- ------
Diameter
Worm Drive - All
0.6 - 0.7 50 - 60 0.5 - 0.6 40 - 50
"Ultra-Tite"
Bolt Torque
Flange Bolt
Kilogram Meter Foot Pounds
Size (*) Size
(kg•m) (ft lb)
1/2" 5/16" 2.1 - 2.5 15 - 18
3/4" 3/8" 3.0 - 3.7 22 - 27
1" 3/8" 3.7 - 4.8 27 - 35
1 - 1/4" 7/16" 4.8 - 6.2 35 - 45
1 - 1/2" 1/2" 6.4 - 8.0 46 - 58
2" 1/2" 7.6 - 9.0 55 - 65
2 - 1/2" 1/2" 10.9 - 12.6 79 - 91
3" 5/8" 19.1 - 20.7 138 - 150
3 - 1/2" 5/8" 16.2 - 18.4 117 - 133
Torque Multiplication
A wrench extension tool can be used to increase the
tightening force on a high capacity nut or bolt.
For example, doubling the distance between the bolt and the
back (handle) end of the torque wrench doubles the
tightening force on the bolt. It also halves the indicated
reading on the scale or dial of the torque wrench. To
accurately adjust or convert indicated scale or dial readings,
use the following formula:
I = A x T / A + B where:
I = Indicated force shown on the torque wrench scale or
dial. Figure 1
T = Tightening force applied to the nut or bolt (actual Torque).
A = Length of the torque wrench (between the center of the
nut or bolt and the center of the handle).
B = Length of the extension.
As an example, if a 12" extension is added to a 12" torque
wrench, and the indicated torque on the dial reads
"150 ft lb," the real force applied to the bolt is 300 ft lb:
A x T 12 x 300 3600
I = = = = 150
A + B 12 + 12 24
CAUTION!
Disassembly, overhaul and replacement of components
on the machine, installation of new or replacement parts
and/or other service-related maintenance may require the
use of thread or flange sealing assembly compound.
Use the information on this page as a general guide in
selecting specific formulas that will meet the particular
requirements of individual assembly installations.
DOOSAN does not specifically endorse a specific
manufacturer or brand name but the following table of
"Loctite" applications is included for which
cross-references to other makers' products should also
be widely available.
IMPORTANT
Use primer "T" or "N" for all cold weather assembly of
fastener adhesives, with Thread locker sealers 222, 242/
243, 262, 271, 272, or 277.
Breakaway Cure
Product Application Color Removal Strength (in lb)
of Sealer Alone
Low strength for 6 mm (1/4") or
222 Purple Hand tools 45
smaller fasteners.
242 or Medium strength for 6 mm (1/4")
Blue Hand tools 80
243 and larger fasteners.
High strength for high grade Heat/260°C (500°F)
262 fasteners subject to shock, stress Red Remove HOT 160
and vibration. (NO solvent)
Extra high strength for fine thread
Heat/260°C (500°F)
271 fasteners up to 25 mm (1") Red 160
Remove HOT
diameter.
High temperature/high strength for
Heat/316°C (600°F)
272 hostile environments to 232°C Red 180
Remove HOT
(450°F).
Extra high strength for coarse
Heat/260°C (500°F)
277 thread fasteners 25 mm (1") Red 210
Remove HOT
diameter and larger.
V. "Loctite" Adhesives
Transmission
and Torque
Converter
Edition 1
Safety Precautions............................................... 7
Applicable Models................................................ 7
General................................................................. 8
Transmission and Torque Converter................ 10
Powershift Transmission .............................................. 11
Transmission Control.................................................... 11
The Chart of Measuring Points and Connection
4 WG-190 ..................................................................... 13
Oil Circuit Diagram 4WG-190 ..................................... 15
Transmission Electrical Components................ 18
TCU (Transmission Control Unit) ................................ 20
Transmission Control Valve ......................................... 20
Transmission Oil Temperature Sensor ....................... 20
Engine Pickup Sensor ................................................. 21
Central Gear Pickup Sensor ....................................... 21
Turbine Pickup Sensor ................................................ 21
Output Speed Sensor .................................................. 22
Shift Lever Switch (DW-3)........................................... 22
Forward, Reverse Switch Lever (Optional) ................ 23
Finger Tip Work Lever ................................................ 24
Auto Selector Switch.................................................... 25
Display........................................................................... 26
Transmission Faults Codes............................... 27
Fault Display ................................................................. 27
CAN - Message ........................................................... 27
Description of Fault Codes.......................................... 27
Abbreviations................................................................. 28
Definition of Operation Modes .................................... 28
Table of Fault Codes................................................... 29
Measurement of Resistance at Actuator/sensors and
Cable ............................................................................. 29
Transmission Electrical Circuits ........................ 30
CAUTION!
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good
working order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
11
1
10 3 2
12
7 4
13
11
10
8 5
6
9 10
FG008077
Figure 1
Item DL250
Model 4WG-190 (Full Auto)
Type 3-Element, 1-Stage, Single-phase,
E/G mounted with flexible plate
Oil Cooler Water-cooled (multi-plate) and Air-cooled
Torque Converter Charging Pump 105 lpm at 2,000 rpm
Hydraulic Pump P.T.O 1 : 1
T/C Size ∅ 340 mm (13.39 in)
Stall Ratio 3.06
Safety Relief 11 Bar (160 psi)
Type Full Power Shift, Counter shaft
Speeds 4 Forward / 3 Reverse
Ratio F: 3.745 / 2.184 / 1.072 / 0.636
Transmission R: 3.555 / 1.981 / 1.017
Power Shift Control 16 - 18 bar (232 - 261 psi)
Pressure
Shift Control Electric Shift with Proportional Valve
Oil Capacity 45 l (11.8 U.S. gal)
Dry Weight 505 kg (1,113 lb)
Front 7 C Mechanics
Output Flange
Rear 6 C Mechanics
Transmission Control
Transmission control, See “The Chart of Measuring Points
and Connection 4 WG-190” on page -13., Electrohydraulic
unit on page -14 and “Oil Circuit Diagram 4WG-190” on
page 1-15.
The transmission pump, necessary for the oil supply of
converter, and the transmission control, is input-side
mounted from outside, together with stator shaft and oil
supply flange, on transmission. The drive is realized by the
pump-wheel flange of converter.
The feed rate of pump is Q = 105 lpm at nEngine = 2000
min-1.
This pump is sucking the oil through the coarse filter out of
oil sump and delivers it through the ZF-Fine filter can be
fitted also externally from transmission - to system pressure
valve.
ZF-Fine filter
Grade of filtration according to ISO 4572: β30 ≥ 75 β15 = 25
β10 = 5.0
Filter area at least: 3,900 cm2
Dust capacity according to ISO 4572 at least: 40 g
The six clutches of transmission are selected via the 6
proportional valves P1 to P6.
The proportional valve (pressure regulator unit) consist of
pressure regulator (e.g. Y1). follow-on slide and oscillation
damper.
Marking on
No. Denomination of Position Connection
Valve Block
Measuring Points for Pressure Oil and Temperature
51 Converter Inlet - Opening pressure 9 bar (130 M10 x 1 H
psi)
52 Converter Exit - Opening pressure 3.5 bar (51 M14 x 1.5
psi)
53 Clutch Forward 16+2 bar (230 - 260 psi) KV M10 x 1 B
55 Clutch Reverse 16 +2 bar (230 +29 psi) KR M10 x 1 E
56 Clutch 16 +2 bar (230 +29 psi) K1 M10 x 1 D
57 Clutch 16 +2 bar (230 +29 psi) K2 M10 x 1 A
58 Clutch 16 +2 bar (230 +29 psi) K3 M10 x 1 C
60 Clutch 16 +2 bar (230 +29 psi) K4 M10 x 1 F
63 Converter Exit
M14 x 1.5
Temperature 100°C, Short-time 120°C
65 System Pressure 16 +2 bar (230 +29 psi) K4 M10 x 1 K
Measuring points for Delivery Rates
15 Connection to Heat Exchanger 1 5/16" -
12UNF-2B
16 Connection from Heat Exchanger 1 5/16" -
12UNF-2B
Inductive Transmitters and Speed Sensor
21 Inductive Transmitter n Turbine M18 x 1.5
34 Speed Sensor n Output and Speedometer -------
47 Inductive Transmitter n Central Gear Train M18 x 1.5
48 Inductive Transmitter n Engine M18 x 1.5
Connections
49 Plug Connection on Hydraulic Control Unit
68 Pilot Pressure (Optional) M16 x 1.5 J
69 System Pressure (Optional) M16 x 1.5 G
CODE
FG008638
Figure 3
LEGEND:
= System Pressure
= Pilot Pressure
AMS1111L
SP000867
Transmission and Torque Converter SP000867
Page 17
TRANSMISSION ELECTRICAL
COMPONENTS
20
30
13
21 10
40
50
0 km/h
10 18
19
17
14
20
3 2 1
15
16
1-4 A
MAN 2-4
3
9
2
11
12 4
6 7
FG004369
Figure 5
AJS0200L
Figure 6
2 2
• Pressure: 0.8 kg/cm → 8.3 kg/cm (11 - 118 psi)
FG005184
3. The contained temperature sensor detects the Figure 7
temperature of control valve and transmits the electrical
signal to TCU, and serves TCU determines gears to
change.
• Neutral: At temperature less than -30°C
• 1st or 2nd gear: At temperature less than -10°C
• Normal Operation: At temperature greater than
-10°C
• N: Neutral
• R: Reverse KD
N
• 1,2,3,4: Shift Step
SHIFT SWITCH
* Forward shift range: 1 - 4
LEVER LOCK KEY
* Reverse shift range: 1 - 3 R (N/D)
2. Kick-down (Down Shift) Switch AJS0270L
Figure 13
• KD: Kick-down Switch
3. Lever Lock Key
• N: Neutral (The lever is not moved.)
• D: Driving (The lever is released.)
4. Switch Circuit
B A AD3 (B3)
1 2 G B AD2 (B2)
1 2 L X1
C AD1 (B1)
1 2 V
D AD7 (KD)
R A ED1 (+/VP)
2 Gr
1 D AD6 (N)
3 2
1
3 Y B AD4 (F) X2
1 2
3 P C AD5 (R)
AJS0280L
Figure 14
D C B A
(AD5) PINK
X2
(AD4) YELLOW
(VP) RED
(AD7) VIOLET
D C B A
(AD1) BLUE
X1
(AD2) GREEN
(AD3) BLACK
AJS0290L
Figure 15
6. Switch Connection
ED1 VP
AD1 B1
AD2 B2
AD3 B3
AD4 V
AD5 R
AD6 AS
AD7 KD
AJS0300L
Figure 16
12 11 10 9 8 7
DEUTSCH
1 2 3 4 5 6
FG004371
Figure 18
3-Lever (Optional)
AUX. BUCKET BOOM
1. Horn Switch
H KD
• H: Horn Switch
2. Kick-down (Down Shift) Switch
• KD: Kick-down Switch
12 11 10 9 8 7
DEUTSCH
1 2 3 4 5 6
FG004372
Figure 19
1
12 1
RETURN TO DIG
12 MAGNET
2
11 2
FLOAT
11 MAGNET
3
10 3
RAISE
10 MAGNET
4
HORN
9
5
DOWN SHIFT
8
FG004373
Figure 20
7 6
8 5
DEUTSCH
9 4
10 3
11 2
12 1
FG004374
Figure 21
Fault Display h
left right
g
character character
BAR
CAN - Message FG004442
The TCU sends the fault code of a detected fault in the Figure 23
specified CAN - message, while the fault is active.
If more than one fault is detected, the fault code scrolls.
Abbreviations
O.C. Open Circuit
S.C. Short Circuit
OP-Mode OPeration Mode
TCU Transmission Control Unit
ABS Anti Blocking System
ASR Anti Slipping Regulation
EEC Electronic Engine Controller
PTO Power Take Off
CCO Clutch Cut Off
Normal
There is no failure detected in transmission system or failure
has no or slight effects on transmission control. TCU will
work without or in special cases with little limitations. (see
following table)
Limp-home
The detected failure in the system has strong limitations to
transmission control. TCU can engage only one gear in
each direction. In some cases only one direction will be
possible. TCU will shift the transmission into neutral at the
first occurrence of the failure. First, the operator must shift
the gear selector into neutral position. If output speed is less
than a threshold for neutral to gear and the operator shifts
the gear selector into forward or reverse, the TCU will select
the limp-home gear. If output speed is less than a threshold
for reversal speed and TCU has changed into the limp-home
gear and the operator selects a shuttle shift, TCU will shift
immediately into the limp-home gear of the selected
direction. If output speed is greater than the threshold, TCU
will shift the transmission into neutral. The operator has to
slow down the vehicle and must shift the gear selector into
neutral position.
Actuator
open circuit:R12 ≈ R1G ≈ R2G ≈ ∞
1
short cut to ground:R12 ≈ R;R1G ≈ 0, R2G ≈ R or R 1G ≈ R,
R2G ≈ 0(for S.C. to ground, G is connected to vehicle R
ground)
short cut to battery:R12 ≈ R;R1G ≈ 0, R2G ≈ R or R1G ≈ R, 2
G
R2G ≈ 0(for S.C. to battery, G is connected to battery
voltage).
HBOE640I
Figure 24
Cable
UBat
open circuit:
R12 ≈ R1P ≈ R 1C ≈ R 2P ≈ R2C ≈ ∞ P (power supply)
TCU
short cut to ground: Actuator /
1 2
Sensor
R12 ≈ 0;R1C ≈ R2C ≈ 0,R1P ≈ R2P ≈ ∞
C (chassis)
short cut to battery:
R12 ≈ 0,R1C ≈ R2C ≈ ∞,R1P ≈ R2P ≈ 0 Gnd
HBOE650I
Figure 25
17
(8)
10 20 K3 Y4
(N) 87a 87a K4 Y1
18 87
30 30
87 +
85 86 86 85 - 21
11
1-4 2-4 1
23 5
22 68 14 2-1 2-3
87a
30 52
87 30
86 8 16
85 8 36 (CN1-4) SIG. 15
53 21 2 4
57
3
12 62 2
VPS1 7 13 11
+
Y2 2 10
4 1 9
Y1 1 56
Y3 3 32
Y4 4 55 15 2 1
3 Y5 5 9 18 4 26 3
KICK 1 2 3 4
Y6 6 51 DOWN STEP STEP STEP STEP F N R
TEMP 8 39 45 X2-A VP
TEMP 9 46 67 X2-D AD6
X1-A AD3
23 49
22 X1-D
63 X1-C
AD7 2
AD1
17 65 X1-B AD2
43 X2-B AD4
64 X2-C AD5
A 25
26 CC-TV
B
C
27 59
4P CONN(4) 9
28
12 19 44 F 7 0
27 (ENGINE) 35 N 5 I
3
41 31 R II
(TURBINE) 10 9
42
(CENTRAL
3 29
GEAR CHAIN)
EST-37A
3 28
1
AUTO(1-4) 29
AUTO(2-4) 20 2 F 2-LEVER (OPT)
5
TML 1 2 3 1 4 N
PST
MANUAL 2 7
AUTO(1-4) R
AUTO(2-4)
MONO-LEVER (OPT)
25 66 1
F/R SELECT 7 5
L11 7
ELEC. STEERING 7 10 9
L14
1 6
7 0
NC 3
1
30 NO
C 3 5 I
1 II
2 9
3 31 19
10
87a 28
30
3 87 87a 87a
2 30 30
85 86 87 87
1
85 86 86 85
PVED
7
34 33
4
5 8 32
6
35 ELECTRIC STEERING (OPT) 9
FG008639
Figure 26
Traveling Circuits
Shift Lever Position TCU Input TCU Output T/M Control Valve
Neutral 45, 67, 20 (12, 13) -
1st Gear 45, 20, 43, 63 (12, 13) - 32, 9 Y3, Y5
2nd Gear 45, 20, 43 (12, 13) - 9, 51 Y5, Y6
Forward
3rd Gear 45, 20, 43, 65 (12, 13) - 55, 9 Y4, Y5
4th Gear 45, 20, 43, 63, 65 (12, 13) - 56, 55 Y2, Y4
1st Gear 45, 20, 64, 63 (12, 13) - 10, 32 Y1, Y3
Reverse 2nd Gear 45, 20, 64 (12, 13) - 10, 51 Y1, Y6
3rd Gear 45, 20, 64, 65 (12, 13) - 32, 9 Y1, Y4
(8)
17 10 4
(N) 87a
18 87
30 11
85 86 1 8
1-4 2-4 1
52 14 2-1 2-3
19
BATT 14 23
36 (CN1-4) 16
68 SIG. 15
21 2
12
VPS1 7 13 3
+
62 2
Y2 2 10 11
Y1 1 56
4 1 9
Y3 3 32
Y4 4 55
3 Y5 5 9 EST-37A
KICK 1 2 3 4
Y6 6 51 DOWN STEP STEP STEP STEP F N R
TEMP 8 39 45 X2-A VP
TEMP 9 46 67 X2-D AD6
49 X1-A AD3
23 22 X1-D
17 63 X1-C
AD7 2
AD1
65 X1-B AD2
19 43 X2-B AD4
(ENGINE) 64 X2-C AD5
41
12 (TURBINE)
42
(CENTRAL
3
GEAR CHAIN)
7 6
AUTO(1-4) 29 66 1
5
AUTO(2-4) 20 7
10 9
PST TML 1 2 3 1
MANUAL 2
5 AUTO(1-4)
AUTO(2-4)
FG005186
Figure 27
(8)
17 10 4
(N) 87a
18 87
30 11
85 86 1 8
1-4 2-4 1
52 14 2-1 2-3
19
BATT 14 23
36 (CN1-4) SIG. 15 16
68
21 2
12
VPS1 7 13 3
+
62 2
Y2 2 10 11
Y1 1 56
4 1 9
Y3 3 32
Y4 4 55
3 Y5 5 9 EST-37A
KICK 1 2 3 4
Y6 6 51 DOWN STEP STEP STEP STEP F N R
TEMP 8 39 45 X2-A VP
TEMP 9 46 67 X2-D AD6
49 X1-A AD3
23 22 X1-D
17 63 X1-C
AD7 2
AD1
65 X1-B AD2
19 43 X2-B AD4
(ENGINE) 64 X2-C AD5
41
12 (TURBINE)
42
(CENTRAL
3
GEAR CHAIN)
7 6
AUTO(1-4) 29 66 1
5
AUTO(2-4) 20 7
10 9
PST TML 1 2 3 1
MANUAL 2
5 AUTO(1-4)
AUTO(2-4)
FG005187
Figure 28
17 10 4
(N) 87a
18 87
30 11
85 86 1 8
1-4 2-4 1
52 14 2-1 2-3
19
BATT 14 23
36 (CN1-4) SIG. 15 16
68
21 2
12
VPS1 7 13 3
+
62 2
Y2 2 10 11
Y1 1 56
4 1 9
Y3 3 32
Y4 4 55
3 Y5 5 9 EST-37A
KICK 1 2 3 4
Y6 6 51 DOWN STEP STEP STEP STEP F N R
TEMP 8 39 45 X2-A VP
TEMP 9 46 67 X2-D AD6
49 X1-A AD3
23 22 X1-D
17 63 X1-C
AD7 2
AD1
65 X1-B AD2
19 43 X2-B AD4
(ENGINE) 64 X2-C AD5
41
12 (TURBINE)
42
(CENTRAL
3
GEAR CHAIN)
7 6
AUTO(1-4) 29 66 1
5
AUTO(2-4) 20 7
10 9
PST TML 1 2 3 1
MANUAL 2
5 AUTO(1-4)
AUTO(2-4)
FG005188
Figure 29
(8)
17 10 4
(N) 87a
18 87
30 11
85 86 1 8
1-4 2-4 1
52 14 2-1 2-3
19
BATT 14 23
36 (CN1-4) SIG. 15 16
68
21 2
12
VPS1 7 13 3
+
62 2
Y2 2 10 11
Y1 1 56
4 1 9
Y3 3 32
Y4 4 55
3 Y5 5 9 EST-37A
KICK 1 2 3 4
Y6 6 51 DOWN STEP STEP STEP STEP F N R
TEMP 8 39 45 X2-A VP
TEMP 9 46 67 X2-D AD6
49 X1-A AD3
23 22 X1-D
17 63 X1-C
AD7 2
AD1
65 X1-B AD2
19 43 X2-B AD4
(ENGINE) 64 X2-C AD5
41
12 (TURBINE)
42
(CENTRAL
3
GEAR CHAIN)
7 6
AUTO(1-4) 29 66 1
5
AUTO(2-4) 20 7
10 9
PST TML 1 2 3 1
MANUAL 2
5 AUTO(1-4)
AUTO(2-4)
FG005189
Figure 30
17 10 4
(N) 87a
18 87
30 11
85 86 1 8
1-4 2-4 1
52 14 2-1 2-3
19
BATT 14 23
36 (CN1-4) SIG. 15 16
68
21 2
12
VPS1 7 13 3
+
62 2
Y2 2 10 11
Y1 1 56
4 1 9
Y3 3 32
Y4 4 55
3 Y5 5 9 EST-37A
KICK 1 2 3 4
Y6 6 51 DOWN STEP STEP STEP STEP F N R
TEMP 8 39 45 X2-A VP
TEMP 9 46 67 X2-D AD6
49 X1-A AD3
23 22 X1-D
17 63 X1-C
AD7 2
AD1
65 X1-B AD2
19 43 X2-B AD4
(ENGINE) 64 X2-C AD5
41
12 (TURBINE)
42
(CENTRAL
3
GEAR CHAIN)
7 6
AUTO(1-4) 29 66 1
5
AUTO(2-4) 20 7
10 9
PST TML 1 2 3 1
MANUAL 2
5 AUTO(1-4)
AUTO(2-4)
FG005190
Figure 31
(8)
17 10 4
(N) 87a
18 87
30 11
85 86 1 8
1-4 2-4 1
52 14 2-1 2-3
19
BATT 14 23
36 (CN1-4) SIG. 15 16
68
21 2
12
VPS1 7 13 3
+
62 2
Y2 2 10 11
Y1 1 56
4 1 9
Y3 3 32
Y4 4 55
3 Y5 5 9 EST-37A
KICK 1 2 3 4
Y6 6 51 DOWN STEP STEP STEP STEP F N R
TEMP 8 39 45 X2-A VP
TEMP 9 46 67 X2-D AD6
49 X1-A AD3
23 22 X1-D
17 63 X1-C
AD7 2
AD1
65 X1-B AD2
19 43 X2-B AD4
(ENGINE) 64 X2-C AD5
41
12 (TURBINE)
42
(CENTRAL
3
GEAR CHAIN)
7 6
AUTO(1-4) 29 66 1
5
AUTO(2-4) 20 7
10 9
PST TML 1 2 3 1
MANUAL 2
5 AUTO(1-4)
AUTO(2-4)
FG005191
Figure 32
17 10 4
(N) 87a
18 87
30 11
85 86 1 8
1-4 2-4 1
52 14 2-1 2-3
19
BATT 14 23
36 (CN1-4) SIG. 15 16
68
21 2
12
VPS1 7 13 3
+
62 2
Y2 2 10 11
Y1 1 56
4 1 9
Y3 3 32
Y4 4 55
3 Y5 5 9 EST-37A
KICK 1 2 3 4
Y6 6 51 DOWN STEP STEP STEP STEP F N R
TEMP 8 39 45 X2-A VP
TEMP 9 46 67 X2-D AD6
49 X1-A AD3
23 22 X1-D
17 63 X1-C
AD7 2
AD1
65 X1-B AD2
19 43 X2-B AD4
(ENGINE) 64 X2-C AD5
41
12 (TURBINE)
42
(CENTRAL
3
GEAR CHAIN)
7 6
AUTO(1-4) 29 66 1
5
AUTO(2-4) 20 7
10 9
PST TML 1 2 3 1
MANUAL 2
5 AUTO(1-4)
AUTO(2-4)
FG005192
Figure 33
(8)
17 10 4
(N) 87a
18 87
30 11
85 86 1 8
1-4 2-4 1
52 14 2-1 2-3
19
BATT 14 23
36 (CN1-4) SIG. 15 16
68
21 2
12
VPS1 7 13 3
+
62 2
Y2 2 10 11
Y1 1 56
4 1 9
Y3 3 32
Y4 4 55
3 Y5 5 9 EST-37A
KICK 1 2 3 4
Y6 6 51 DOWN STEP STEP STEP STEP F N R
TEMP 8 39 45 X2-A VP
TEMP 9 46 67 X2-D AD6
49 X1-A AD3
23 22 X1-D
17 63 X1-C
AD7 2
AD1
65 X1-B AD2
19 43 X2-B AD4
(ENGINE) 64 X2-C AD5
41
12 (TURBINE)
42
(CENTRAL
3
GEAR CHAIN)
7 6
AUTO(1-4) 29 66 1
5
AUTO(2-4) 20 7
10 9
PST TML 1 2 3 1
MANUAL 2
5 AUTO(1-4)
AUTO(2-4)
FG005193
Figure 34
Downshift
Overview
1. There are two downshift switches down Figure 35, and
it is possible for operators to select one of them
according to the condition.
2. If the downshift switch is depressed during the machine
moving, downshifting takes place automatically. As a
result, fast digging and moving is possible. But at the
manual mode the kick-down can only be activated.
3. If a change or traveling direction takes place or the
downshift switch is depressed a second time, FG004391
downshifting is released automatically. Figure 35
11
1 8
1-4 2-4 1
52 14 2-1 2-3
19
BATT 14 23
36 (CN1-4) SIG. 15 16
68
21 2
12
VPS1 7 13 3
+
62 2 4
Y2 2 10 11
Y1 1 56
4 1 9
Y3 3 32
Y4 4 55
3 Y5 5 9 EST-37A
KICK 1 2 3 4
Y6 6 51 DOWN STEP STEP STEP STEP F N R
TEMP 8 39 45 X2-A VP
TEMP 9 46 67 X2-D AD6
49 X1-A AD3
23 22 X1-D
17 63 X1-C
AD7 2
AD1
65 X1-B AD2
19 43 X2-B AD4
(ENGINE) 64 X2-C AD5
41
12 (TURBINE)
42
(CENTRAL
3
GEAR CHAIN)
7 6
AUTO(1-4) 29 66 1
5
AUTO(2-4) 20 7
10 9
PST TML 1 2 3 1
MANUAL 2
5 AUTO(1-4)
AUTO(2-4)
FG005194
Figure 36
With the auto selector switch (Figure 37) is in the "O" and
the forward second gear is selected, if either downshift 1-4 A
switch (Figure 35) is activated, a pulse is sent to the "22"
transmission controller. This signal energizes solenoid
MAN 2-4
valves, (Y3 and Y5), which shifts the transmission to the
forward first gear. When either switch (Figure 35) is selected
a second time, the transmission pulse signal of the "22"
terminal is interrupted and solenoid valve, Y5 and Y6, are
energized and the transmission returns to the forward
second gear.
FG004375
Figure 37
11
1 8
1-4 2-4 1
52 14 2-1 2-3
19
BATT 14 23
36 (CN1-4) SIG. 15 16
68
21 2
12
VPS1 7 13 3
+
62 2 4
Y2 2 10 11
Y1 1 56
4 1 9
Y3 3 32
Y4 4 55
3 Y5 5 9 EST-37A
KICK 1 2 3 4
Y6 6 51 DOWN STEP STEP STEP STEP F N R
TEMP 8 39 45 X2-A VP
TEMP 9 46 67 X2-D AD6
49 X1-A AD3
23 22 X1-D
17 63 X1-C
AD7 2
AD1
65 X1-B AD2
19 43 X2-B AD4
(ENGINE) 64 X2-C AD5
41
12 (TURBINE)
42
(CENTRAL
3
GEAR CHAIN)
7 6
AUTO(1-4) 29 66 1
5
AUTO(2-4) 20 7
10 9
PST TML 1 2 3 1
MANUAL 2
5 AUTO(1-4)
AUTO(2-4)
FG005195
Figure 38
When the auto selector switch (Figure 38) is in the "I" position,
the "29" terminal of transmission controller is energized. This
allows the transmission to automatically upshift and downshift
gears depending on the load and on the engine speed.
If either downshift switch (Figure 35) is activated, a pulse
signal is sent to the "22" terminal of transmission controller.
This signal shifts the transmission to the next lowest gear.
Automatic
Downshift Switch "Activated"
Gear Selection
Fourth Gear Downshift to Third Gear
Third Gear Downshift to Second Gear
Second Gear Downshift to First Gear
First Gear Remains in First Gear
11
1 8
1-4 2-4 1
52 14 2-1 2-3
19
BATT 14 23
36 (CN1-4) SIG. 15 16
68
21 2
12
VPS1 7 13 3
+
62 2 4
Y2 2 10 11
Y1 1 56
4 1 9
Y3 3 32
Y4 4 55
3 Y5 5 9 EST-37A
KICK 1 2 3 4
Y6 6 51 DOWN STEP STEP STEP STEP F N R
TEMP 8 39 45 X2-A VP
TEMP 9 46 67 X2-D AD6
49 X1-A AD3
23 22 X1-D
17 63 X1-C
AD7 2
AD1
65 X1-B AD2
19 43 X2-B AD4
(ENGINE) 64 X2-C AD5
41
12 (TURBINE)
42
(CENTRAL
3
GEAR CHAIN)
7 6
AUTO(1-4) 29 66 1
5
AUTO(2-4) 20 7
10 9
PST TML 1 2 3 1
MANUAL 2
5 AUTO(1-4)
AUTO(2-4)
FG005196
Figure 39
Automatic
Downshift Switch "Activated"
Gear Selection
Fourth Gear Downshift to Third Gear
Third Gear Downshift to Second Gear
Second Gear Downshift to First Gear
First Gear Remains in First Gear
Figure 40
CAUTION!
When the machine is traveling or working in the place
of inclination, the transmission cutoff switch (Figure 40)
must be placed in position 'O' for the purse of using
engine braking and the normal braking function at the
same time.
17 10 4
(N) 87a
18 87
30 11
85 86 1 8
1-4 2-4 1
52 14 2-1 2-3
19
BATT 14 23
36 (CN1-4) SIG. 15 16
68
21 2
12
VPS1 7 13 3
+
62 2
Y2 2 10 11
Y1 1 56
4 1 9
Y3 3 32
Y4 4 55
3 Y5 5 9 EST-37A
KICK 1 2 3 4
Y6 6 51 DOWN STEP STEP STEP STEP F N R
TEMP 8 39 45 X2-A VP
TEMP 9 46 67 X2-D AD6
49 X1-A AD3
23 22 X1-D
17 63 X1-C
AD7 2
AD1
65 X1-B AD2
19 43 X2-B AD4
(ENGINE) 64 X2-C AD5
41
12 (TURBINE)
42
(CENTRAL
3
GEAR CHAIN)
7 6
AUTO(1-4) 29 66 1
5
AUTO(2-4) 20 7
10 9
PST TML 1 2 3 1
MANUAL 2
5 AUTO(1-4)
AUTO(2-4)
FG005197
Figure 41
19
6
13
0
3
14 5 I
1 II
9 14 BATT
10
11
1-4 2-4 1
23 5
22 68 14 2-1 2-3
87a
30 52
87 30
85 86 8 36 (CN1-4)
8 16
SIG. 15
53 21 2 4
57
3
62 2
11
4 1 9
KICK 1 2 3 4
DOWN STEP STEP STEP STEP F N R
45 X2-A VP
67 X2-D AD6
X1-A AD3
22 X1-D
63 X1-C
AD7 2
AD1
65 X1-B AD2
19 43 X2-B AD4
(ENGINE) 64 X2-C AD5
41
12 (TURBINE)
42
(CENTRAL
GEAR CHAIN) 3
AUTO(1-4) 29
AUTO(2-4) 20
PST TML 1 2 3 1
MANUAL 2
5 AUTO(1-4)
AUTO(2-4)
FG004390
Figure 43
Introduction
AEB Starter
Start
BOS0360L
Figure 44
Figure 45
Inner Section
Figure 46
Reference Reference
Description Description
Number Number
1 Clutch Shaft "KR" 9 Transmission Pump
2 Power Take-off; Coaxial; 10 Flexible Plate
Engine-dependent 11 Converter
3 Clutch Shaft "KV" 12 Input Transmitter for Engine
4 Clutch Shaft "K2" Speed
5 Clutch Shaft "K3" 13 Clutch Shaft "K4"
6 Output Flange - Rear 14 Converter Relief Valve
7 Output Flange - Converter Side 15 Clutch Shaft "K1"
8 Output Shaft
3
3
4
3
8
5
7 6
FG008067
Figure 47
Reference Reference
Description Description
Number Number
1 Lifting Lugs 5 Model Identification Plate
2 Flexible Plate 6 output Flange - Converter Side
3 Transmission Suspension Bores 7 Oil Drain Plug with Magnetic
M20 Insert M38x1.5
4 Attachment Possibility for 8 Attachment Possibility for Oil
Emergency Steering Pump (Not Filter Pipe with Oil Dipstick
Used) (Converter Side)
1 2 3 4 5
12
11 9
10
BZS0060L
Figure 48
Reference Reference
Description Description
Number Number
1 Flexible Plate 8 Parking Brake
2 Converter 9 Output Flange - Rear
3 Converter Bell Housing 10 Oil Drain Plug with Magnetic
4 Breather Insert M38x1.5
5 Transmission - Case Cover 11 Output Flange - Converter Side
6 Filter Head 12 Transmission Case
7 Box Filter (Fine Filter)
1 2
6
4
HOT
BZS0070L
Figure 49
Reference Reference
Description Description
Number Number
1 Lifting Lugs 6 Output Flange - Rear
2 Power Take-off; Coaxial; 7 Parking Brake
Engine-dependent 8 Box Filter (Fine Filter)
3 Electrohydraulic Control 9 Filter Head
4 Oil Filter Pipe
5 Transmission Suspension Bores
M20
Gearshift System
Figure 50
Figure 52
Figure 53
Figure 54
Figure 56
Clutch KV
Figure 57
Figure 58
Figure 59
Figure 60
Figure 61
Figure 62
Figure 63
Figure 64
IMPORTANT
Different versions in relation to position of cable
harness are possible.
In this connection, pay attention to Specifications of
Vehicle Manufacturer.
Figure 65
Figure 66
Figure 67
Figure 68
Figure 69
Figure 70
Figure 71
Figure 72
Figure 73
Figure 74
Figure 75
Figure 76
Figure 77
Figure 78
Reference
Description
Number
1 Vibration Damper (3x
Spool and
Compression Spring)
2 Follow On Site (3x
Spool and
Compression Spring)
3 Pressure Reducing
Valve (1x Spool and Figure 79
Compression Spring)
Figure 80
Figure 83
Figure 84
Reference
Description
Number
1 Main Pressure Valve
(1x Spool and
Compression Spring.)
2 Follow On Slide (3x
Spool and
Compression Spring)
Figure 85
3 Vibration Damper (3x
Spool and
Compression Spring)
Figure 87
Figure 88
Figure 89
Figure 90
Figure 91
Figure 92
Figure 93
Figure 94
Figure 95
Figure 96
Figure 97
Figure 98
Figure 99
Figure 100
Figure 101
Figure 102
Figure 103
Figure 104
Figure 105
Figure 106
Figure 107
Figure 108
Figure 109
Figure 110
Figure 111
Figure 112
Figure 113
Figure 114
Figure 115
Figure 116
Figure 117
Figure 118
Figure 119
Figure 120
Figure 121
Figure 122
13. Remove socket head screws, output shaft and two oil
collecting plate.
Figure 123
Figure 124
Reference
Description
Number
AN Input
KV Clutch - Forward
KR Clutch - Reverse
K1 Clutch - 1st Speed
K2 Clutch - 2nd Speed Figure 125
K3 Clutch - 3rd Speed
K4 Clutch - 4th Speed
Figure 126
Figure 127
Figure 128
Figure 129
Figure 130
IMPORTANT
If contrary to ZF-Recommendation the tapered roller
bearing of clutches and of input and output are not
replaced, the allocation (inner bearing races to
outer bearing races) must at least be maintained.
Figure 131
Mark inner bearing races and outer bearing races
accordingly to each other.
Figure 132
Figure 133
Figure 134
Figure 135
Figure 136
Figure 137
Figure 138
Figure 139
Figure 140
Figure 141
Figure 142
Figure 143
Figure 144
Figure 146
Figure 147
Figure 148
Figure 149
Figure 150
Figure 151
Figure 152
Figure 153
Figure 154
Figure 155
Figure 156
Figure 157
Figure 158
Figure 159
Figure 160
IMPORTANT
To ensure the correct installation of the oil tubes, the
use of the indicated special tool (S) is imperative.
Figure 161
IMPORTANT
The pipe end must be maximally plane with the
housing face. If necessary, equalize projection of
pipe.
Figure 162
(S) Rolling tool - 5870 600 003
(S) Rolling tool - 5870 600 005
(S) Rolling tool - 5870 600 007
Figure 163
Figure 164
IMPORTANT
The pipe end must be maximally plane with the
housing face. If necessary, equalize projection of
pipe.
Figure 165
Figure 166
Figure 167
Figure 169
Figure 170
Figure 171
Reference
Description
Number
1 Plate Carrier
2 Piston
3 Outer Plate - One
Sided Coated (1 Piece)
4 Inner Plates (10
Pieces)
Figure 172
5 Outer Plate - Coated
On Both Sides (10
Pieces)
6 Retaining Ring
(Optional
S = 2.1 - 4.2 mm
{0.08 - 0.17 in})
7 End Shim
IMPORTANT
Install outer plate (3) with the uncoated side facing
the piston.
Figure 173
Figure 174
Figure 175
IMPORTANT
Use oil according to the list of lubricants TE-ML 03.
Figure 177
Figure 178
Figure 179
Figure 180
Figure 181
Figure 182
Figure 183
Figure 184
Figure 185
Figure 186
Figure 187
Figure 188
Figure 189
Figure 190
Figure 191
Figure 192
Figure 193
Figure 194
IMPORTANT
The plate arrangement of Clutch-K1is not identical
with Clutch-K2 and K3. In this connection see
Figure 195.
Reference
Description
Number
1 Plate Carrier
2 Piston
Figure 195
3 Outer Plate - One Sided
Coated (1 Piece)
4 Inner Plates (9 Pieces)
5 Outer Plate - Coated on
Both Sides (9 Pieces)
6 Retaining Ring (Optional
s = 2.1 - 4.2 mm
(0.08 - 0.17 in))
7 End Shim
Reference
Description
Number
1 Plate Carrier
2 Piston
3 Outer Plate - One Sided
Coated (1 Piece)
4 Inner Plates (7 Pieces)
5 Outer Plate - Coated on
Both Sides (7 Pieces)
6 Retaining Ring (Optional
s = 2.1 - 4.2 mm
(0.08 - 0.17 in))
7 End Shim
IMPORTANT
Install outer plate (3) with the uncoated side facing
the piston.
Figure 197
Figure 198
11. Press on end shim with about 100 N (10 kg {22 lb}),
apply dial indicator and set it at zero (Figure 199).
12. Push end shim using screwdriver against retaining ring
until seated (upward) and read plate clearance on dial
indicator (Figure 200).
NOTE: In case of a deviation from required plate
clearance, correct with corresponding retaining
ring (s= 2.1 - 4.2 mm (0.08 - 0.17 in)).
Figure 199
IMPORTANT
Use oil according to the list of lubricants TE-ML 03
Figure 201
Figure 202
Figure 203
IMPORTANT
Only if the running disk is overlapping with the
shaft collar is ensured that all inner plates are
accommodated.
Figure 204
Figure 205
Figure 206
Figure 207
Figure 208
Figure 209
Figure 210
Figure 211
Figure 212
Figure 213
Figure 214
Reference
Description
Number
1 Plate Carrier
2 Piston
3 Outer Plate - One
Sided Coated (1 Piece)
4 Inner Plates (9 Pieces)
5 Outer Plate - Coated
on Both Sides (9
Pieces)
6 Retaining Ring Figure 215
(Optional
s = 2.1 - 4.2 mm
(0.08 - 0.17 in))
7 End Shim
IMPORTANT
Install outer plate (3) with the uncoated side facing
the piston.
Figure 216
Figure 217
Figure 218
IMPORTANT
Use oil according to the list of lubricants TE-ML 03.
Figure 220
Figure 221
Figure 222
Figure 223
Figure 224
CAUTION!
Use safety gloves.
Figure 225
Figure 226
Figure 227
Figure 228
Figure 229
Figure 230
Figure 231
Figure 232
Figure 233
Figure 234
Figure 235
Figure 236
Reference
Description
Number
AN Input
KV Clutch - Forward
KR Clutch - Reverse
K1 Clutch - 1st Speed
K2 Clutch - 2nd Speed Figure 237
K3 Clutch - 3rd Speed
K4 Clutch - 4th Speed
AB Output
Figure 238
Figure 239
Reference
Description
Number
AN Input
KV Clutch - Forward
KR Clutch - Reverse
K1 Clutch - 1st Speed
K2 Clutch - 2nd Speed
K3 Clutch - 3rd Speed
K4 Clutch - 4th Speed
AB Output Figure 240
IMPORTANT
Before the installation of the clutches and the drive
shaft, grease rectangular rings and align them
centrally.
Figure 241
Figure 242
Figure 243
5. Position Clutch-K2.
Figure 244
Figure 245
Figure 246
Figure 247
Figure 248
12. Grease O-rings on two oil tubes (see also Figure 163).
Wet mounting face with sealing compound Loctite
#574.
13. Position preassembled housing cover using lifting
device carefully on gearbox housing until seated
(Figure 249).
NOTE: Pay attention to overlapping of the oil tubes with
the bores in housing cover.
(S) Lifting chain - 5870 281 047
Figure 249
Figure 250
Figure 251
Figure 252
Figure 253
Figure 254
Figure 255
Figure 256
Figure 257
Figure 258
Figure 259
Figure 260
Figure 261
Reference
Description
Number
1 Piston
2 Compression Spring
3 Pressure Plate
4 Lock Plate
Figure 262
NOTE: Install pressure plate with spigot (∅6 mm
(0.24 in)) facing lock plate.
2. Install components according to Figure 262, preload
and attach using lock plate.
3. Install new O-ring on plug (Arrow) and install it.
NOTE: Torque limit (M14 x 1.5) 2.55 kg•m (18.44 ft lb).
Figure 263
Figure 264
Figure 265
Figure 266
4. Insert O-ring (Arrow) into the annular groove and oil it.
Figure 267
Figure 268
Figure 269
Figure 270
Figure 271
Figure 272
Figure 273
Figure 274
Figure 275
Figure 277
Figure 278
Figure 279
Figure 280
10. Mount gasket and fasten cover using hex head screws.
NOTE: Torque limit (M8/8.8) 2.35 kg•m (16.96 ft lb).
Figure 281
Figure 282
Reference
Description
Number
1 Gasket
2 Duct Plate
3 Gasket Figure 283
4 Intermediate Plate
5 Gasket
Figure 284
Figure 285
Figure 286
Figure 287
Figure 288
Reference
Description
Number
34 Speed Sensor
N-Output and
Speedometer
Figure 289
21 Inductive Transmitter
N-Turbine
47 Inductive Transmitter
N-Central Gear Train
48 Inductive Transmitter
N-Engine
Figure 290
Figure 291
IMPORTANT
Pay attention to different setting dimensions. Setting
dimension corresponds to distance between contact
face-inductive transmitter and tooth tip, see Figure 292.
Figure 292
Figure 293
Figure 294
Dimension I 30.10 mm
(1.1850 in)
Required Gap (0.03 - - 0.60 mm
0.08 mm (0.0012 - (0.0236 in)
0.0031 in)) e.g
Gives Installation = 29.50 mm
Dimension (1.1614 in)
EXAMPLE L:
Dimension II 30.00 mm
(1.1811 in)
Installation Dimension - 29.50 mm
(1.1614 in)
Difference = Shim = 0.50 mm
(0.0197 in)
Figure 295
Reference
Description
Number
1 Speed Sensor
2 Plate
3 O-ring
Figure 297
IMPORTANT
Before putting transmission into service, carry out
oil filling according to Operation and Maintenance
Manual.
Figure 298
Figure 299
Transmission
Error Codes (ZF)
Edition 1
Safety Precautions............................................... 5
Applicable Models................................................ 5
Introduction ........................................................... 6
Abbreviations........................................................ 6
Display.................................................................. 7
Description of Fault Codes............................................ 7
Display During Operation .................................... 8
Display During AEB-Mode ................................ 10
Definition of Operating Modes.......................... 12
Normal........................................................................... 12
Substitute Clutch Control ............................................. 12
Limp-home .................................................................... 12
Transmission shut Down ............................................. 12
TCU Shut Down ........................................................... 13
Table of Fault Codes ........................................ 14
Table of Fault Codes - ERGO-Control............ 33
Measurement of Resistance at Actuator/sensors
and Cable......................................................... 36
Actuator ......................................................................... 36
Cable ............................................................................. 36
CAUTION!
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good
working order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
ABBREVIATIONS
Throughout this section the following abbreviations are used
to indicate various conditions.
Abbreviations
O.C. Open Circuit
S.C. Short Circuit
Op-Mode OPeration Mode
TCU Transmission Control Unit
EEC Electronic Engine Controller
PTO Power Take Off
Reference Description
BAR
Letter
FG004442
a, f Automatic Range
(Upshifting and Figure 1
Downshifting)
b, c, d, e Preselected Gear
Kx
Engine speed too low, ---------------
E
→ raise engine
Engine speed too high. ---------------
E
→ lower engine speed.
Transmission oil temperature too ---------------
T
low.
→ Heat up transmission
Transmission oil temperature too ---------------
T
high.
→ Cool down transmission
FT Transmission temperature not in Transmissions stays in neutral, you
defined range during calibration have to restart the TUC (ignition off/on)
FB Operating mode not NORMAL or Transmissions stays in neutral, you
transmission temperature sensor have to restart the TUC (ignition off/on)
defective or storing of Calibrated
values to EEPROM-has failed.
FO Outputspeed_not_zero Transmissions stays in neutral, you
have to restart the TUC (ignition off/on)
FN Shift lever not in Neutral position Transmissions stays in neutral, you
have to restart the TUC (ignition off/on)
Normal
There is no failure detected in transmission system or failure
has no or slight effects on transmission control. TCU will
work without or in special cases with little limitations. (See
“Table of Fault Codes” on page -14.)
Limp-home
The detected failure in the system has strong limitations to
transmission control. TCU can engage only one gear in
each direction. In some cases only one direction will be
possible.
TCU will shift the transmission into neutral at the first
occurrence of the failure. First, the operator must shift the
gear selector into neutral position.
If output speed is less than a threshold for neutral to gear
and the operator shifts the gear selector into forward or
reverse, the TCU will select the limp-home gear.
If output speed is less than a threshold for reversal speed
and TCU has changed into the limp-home gear and the
operator selects a shuttle shift, TCU will shift immediately
into the limp-home gear of the selected direction.
If output speed is greater than the threshold, TCU will shift
the transmission into neutral. The operator has to slow down
the vehicle and must shift the gear selector into neutral
position.
Fault Meaning of the Fault Code Reaction of the TCU Possible Steps to Remarks
Code (Possible reason for fault Repair
(hex) detection.)
11 Logical error at gear range TCU shifts Check cables from Failure cannot be
signal. transmission to TCU to shift lever. detected in systems
neutral. with DW2/DW3 shift
TCU detected a wrong signal Check signal
lever.
combination for gear range. Op-Mode: combinations of shift
transmission shut lever positions for Fault is taken back if
• Cable from shift lever to TCU
down. gear range. TCU detects a valid
is broken.
signal for position.
• Cable is defective and is
contacted to battery voltage or
vehicle ground.
• Shift lever is defective.
12 Logical error at direction select TCU shifts Check cables from Fault is taken back if
signal. transmission to TCU to shift lever. TCU detects a valid
neutral. signal for direction at
TCU detected a wrong signal Check signal
shift lever.
combination for direction. Op-Mode: combinations of shift
transmission shut lever positions F-N-R.
• Cable from shift lever to TCU
down.
is broken.
• Cable is defective and is
contacted to battery voltage or
vehicle ground.
• Shift lever is defective.
13 Logical error at engine derating After selcting neutral, Check engine This fault is reset
device. TCU changes to OP- derating device. after power up of
Mode limp home. TCU.
TCU detected no reaction of
engine while derating device Only DL500
activ.
15 Logical error at direction select TCU shifts Check the cables Fault is taken if TCU
signal 2. shift lever. transmission to neutral from TCU to shift detects a valid
if selector activ lever2. neutral signal for the
TCU detected a wrong signal
direction at the shift
combination for the direction. OP-Mode: Check signal
lever.
transmission shutdown combinations of shift
• Cable from shift lever 2 to
if selector activ. lever positions F-N-R
TCU is broken.
• Cable is defective and is
contacted to battery voltage or
vehicle ground.
• Shift lever is defective.
B7 Overtemp sump.
BC Overspeed output.
F2 Configuration lost.
F3 Application error.
F5 Clutch failure
Actuator
Open circuit:R12 ≈ R1G ≈ R2G ≈ ∞ 1
Figure 2
Cable
UBat
open circuit:
R12 ≈ R1P ≈ R 1C ≈ R 2P ≈ R2C ≈ ∞ P (power supply)
TCU
Actuator /
short cut to ground: 1 2
Sensor
Front Axle
(ZF-MT-L 3085)
Edition 1
CAUTION!
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good
working order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
Outline
Front Axle
Frame-Fixed
Type
Semifloating
26,900 kg
Max. Static Load
(59,200 lb)
Drive Flange 6C
FG006692
Figure 1 DRIVE AXLE ASSEMBLY
Reference 6
Description 4
Number 5
6 4
1 Oil Drain Hole M24x1.5
Axle Casing
2 Oil Drain Hole M24x1.5
Outputs
3 Oil Filler Hole M36x1.5
4 Brake Bleeder 2
1 3
5 Bleeder 2
FG006694
6 Check Hole
(Wear for Multidisk Brake) Figure 2
4 6
6 4 5
2
2 3 1
FG006696
Figure 3
Oil drain
Remove drain plugs 1 and 2 and drain oil.
Oil filling
Provide drain plugs (M24x1.5) with new O-ring and
install them.
Tightening torque MA = 7.14 kg•m (51.63 ft lb).
Bleeders
At initial operation and during the oil change intervals,
clean Bleeder 3 and 5 and make a functional check.
Brake
For the pneumatic-hydraulic or via an accumulator system
-operated brake actuation following oils are permissible:
1.Motor oils SAE 10W according to specification MIL-L
2104 C, MIL-L 46152, API-CC, CD, SC, SD, SE
2.ATF-Oils Type A, Suffix A, Dexron of II D
Figure 4
Following to this provide level plug with a new O-ring and "X"
install it!
Tightening torque MA = 7.14 kg•m (51.63 ft lb)
FG008078
Figure 5
Figure 6
Reference
Description
Number
1 Axle Type
2 Axle Serial No.
3 ZF Parts - List No.
4 Total-ratio of Axle / Version With or Without
ZF multidisk Self Locking Differential
5 Type of Lubricant
6 Lubricant Specifications
Figure 7
Figure 8
Figure 9
Figure 11
Figure 12
Figure 13
Figure 22
Figure 23
Figure 24
Figure 25
Figure 26
Figure 27
Figure 28
Figure 29
Figure 30
Figure 31
Figure 32
Figure 33
Figure 34
Figure 35
Figure 36
Figure 37
Figure 38
Figure 39
Figure 40
Figure 41
Figure 42
Figure 43
Figure 44
Figure 45
Figure 46
Figure 47
Figure 48
Figure 49
Figure 50
Reference
Description
Number
1 Brake Housing
2 Guide Ring
3 Support Ring
4 U-ring
5 U-ring
6 Support Ring
7 Output Shaft
Figure 51
Figure 52
Figure 53
Figure 54
Figure 55
Figure 56
Figure 57
Figure 58
Figure 59
Figure 60
Figure 61
Figure 62
Figure 63
Reference
Description
Number
1 Brake Housing
2 Shaft Seal
* Grease Filling
Figure 64
Figure 65
Figure 66
Figure 67
Reference
Description
Number
1 Brake Housing
2 Guide Ring
3 Support Ring
4 U-ring
5 U-ring
6 Support Ring
7 Output Shaft
Figure 68
Figure 69
Figure 70
Figure 71
13. Press gripping rings (4x, see arrows) onto pins until
seated on assembly fixture (S).
NOTE: The exact installation dimension (see Figure 74)
of gripping rings is obtained when using
specified assembly fixture.
NOTE: Pay attention to installation position, install
gripping rings with orifices offset by 180° to
each other.
Figure 72
Figure 73
Reference
Description
Number
1 Pin
2 Gripping Rings
3 Cup Springs
4 Support Shim
5 Retaining Ring
X Installation Dimension
Gripping Rings 10.5
+0.3 mm
Figure 74
Figure 75
Figure 76
Figure 77
Figure 78
Reference
Description
Number
1 Brake Housing
2 Retaining Ring
3 Slotted Pin
4 Support Shim
5 Piston
X Installation Dimension
4.0 - 0.5 mm
Figure 79
Figure 80
Figure 81
Figure 82
Figure 83
23. Grease both O-rings (see arrows) and insert them into
annular grooves of ring gear.
Figure 84
Figure 85
25. Heat inner bearing races and install them until seated
with big radius showing to planet carrier (downwards).
NOTE: Subsequently install inner bearing races after
cooling down.
Figure 86
Figure 87
Figure 88
Figure 89
30. Insert stub shaft into spline of axle bevel gear until
seated.
Figure 91
Figure 92
Figure 93
EXAMPLE
Figure 94
Figure 95
Figure 96
Figure 97
Figure 98
Figure 99
Figure 100
Figure 101
Figure 104
Figure 105
Figure 106
Figure 107
Figure 108
Figure 109
Figure 110
Figure 111
Figure 112
Figure 113
Figure 114
Figure 115
Figure 116
Figure 117
Figure 118
Figure 119
Figure 120
Figure 121
Figure 122
Figure 123
Figure 124
Figure 125
Figure 126
Figure 127
Figure 128
Figure 129
Figure 130
Figure 131
Figure 132
Figure 133
Figure 134
Figure 135
Reference
Description
Number
1 Vent Valve
2 Connection Part
3 O-ring
4 Rectangular Ring
Figure 137
Figure 138
Figure 139
Figure 140
Figure 141
Figure 142
Reference
Description
Number
1 O-ring
2 Screw Plug
3 Vent Valve
Figure 143
9. Install plug.
Tightening torque MA = 7.14 kg•m (51.63 ft lb)
Figure 144
Figure 145
Figure 146
EXAMPLE "A"
Figure 147
Figure 148
EXAMPLE "B"
Figure 149
Figure 150
Figure 151
Figure 152
Figure 153
Figure 154
Figure 155
Figure 156
9. Assemble washer.
Figure 157
Figure 158
Figure 160
Figure 161
Figure 162
Figure 163
Figure 164
Figure 165
Figure 166
Figure 167
Figure 168
Figure 169
Figure 170
Figure 171
EXAMPLE "D"
Figure 172
Figure 173
Figure 174
Figure 175
Figure 176
Figure 177
Figure 178
Figure 179
Figure 180
Figure 181
Figure 183
Figure 184
Figure 185
Figure 187
Figure 188
Figure 189
Figure 190
Figure 191
Rear Axle
(ZF-MT-L 3075)
Edition 1
CAUTION!
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good
working order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
Outline
Rear Axle
Trunnion Mounting
Type
Semifloating
20,800 kg
Max. Static Load
(45,800 lb)
Drive Flange 6C
FG006692
Figure 1 DRIVE AXLE ASSEMBLY
Reference 6
Description 4
Number 5
6 4
1 Oil Drain Hole M24x1.5
Axle Casing
2 Oil Drain Hole M24x1.5
Outputs
3 Oil Filler Hole M36x1.5
4 Brake Bleeder 2
1 3
5 Bleeder 2
FG006694
6 Check Hole
(Wear for Multidisk Brake) Figure 2
4 6
6 4 5
2
2 3 1
FG006696
Figure 3
Oil drain
Remove drain plugs 1 and 2 and drain oil.
Oil filling
Provide drain plugs (M24x1.5) with new O-ring and
install them.
Tightening torque MA = 7.14 kg•m (51.63 ft lb).
Bleeders
At initial operation and during the oil change intervals,
clean Bleeder 3 and 5 and make a functional check.
Brake
For the pneumatic-hydraulic or via an accumulator
system-operated brake actuation following oils are
permissible:
1.Motor oils SAE 10W according to specification MIL-L
2104 C, MIL-L 46152, API-CC, CD, SC, SD, SE
2.ATF-Oils Type A, Suffix A, Dexron of II D
Figure 4
Following to this provide level plug with a new O-ring and "X"
install it!
Tightening torque MA = 7.14 kg•m (51.63 ft lb)
FG008078
Figure 5
Figure 6
Reference
Description
Number
1 Axle Type
2 Axle Serial No.
3 ZF Parts - List No.
4 Total-ratio of Axle / Version With or
Without ZF multidisk Self Locking
Differential
5 Type of Lubricant
6 Lubricant Specifications
Figure 7
Figure 8
Figure 9
Figure 11
Figure 12
Figure 13
Figure 22
Figure 23
Figure 24
Figure 25
Figure 26
Figure 27
Figure 28
Figure 29
Figure 30
Figure 31
Figure 32
Figure 33
Figure 34
Figure 35
Figure 36
Figure 37
Figure 38
Figure 39
Figure 40
Figure 41
Figure 42
Figure 43
Figure 44
Figure 45
Figure 46
Figure 47
Figure 48
Figure 49
Figure 50
Reference
Description
Number
1 Brake Housing
2 Guide Ring
3 Support Ring
4 U-ring
5 U-ring
6 Support Ring
7 Output Shaft
Figure 51
Figure 52
Figure 53
Figure 54
Figure 55
Figure 56
Figure 57
Figure 58
Figure 59
Figure 60
Figure 61
Figure 62
Figure 63
Reference
Description
Number
1 Brake housing
2 Shaft seal
* Grease filling
Figure 64
Figure 65
Figure 66
Figure 67
Reference
Description
Number
1 Brake Housing
2 Guide Ring
3 Support Ring
4 U-ring
5 U-ring
6 Support Ring
7 Output Shaft
Figure 68
Figure 69
Figure 70
Figure 71
13. Press gripping rings (4x, see arrows) onto pins until
seated on assembly fixture (S).
NOTE: The exact installation dimension (see Figure 74)
of gripping rings is obtained when using
specified assembly fixture.
NOTE: Observe installation position, install gripping
rings with orifices offset by 180° to each other.
Figure 72
Figure 73
Reference
Description
Number
1 Pin
2 Gripping Rings
3 Cup Springs
4 Support Shim
5 Retaining Ring
X Installation Dimension
Gripping Rings 10.5
+0.3 mm
Figure 74
Figure 75
Figure 76
Figure 77
Figure 78
Reference
Description
Number
1 Brake Housing
2 Retaining Ring
3 Slotted Pin
4 Support Shim
5 Piston
X Installation Dimension
4.0 - 0.5 mm
Figure 79
Figure 80
Figure 81
Figure 82
Figure 83
23. Grease both O-rings (see arrows) and insert them into
annular grooves of ring gear.
Figure 84
Figure 85
25. Heat inner bearing races and install them until seated
with the big radius showing to planet carrier
(downwards).
NOTE: Subsequently install inner bearing races after
cooling down.
Figure 86
Figure 87
Figure 88
Figure 89
30. Insert stub shaft into spline of axle bevel gear until
seated.
Figure 91
Figure 92
Figure 93
EXAMPLE
Figure 94
Figure 95
Figure 96
Figure 97
Figure 98
Figure 99
Figure 100
Figure 101
Figure 103
Figure 104
Figure 105
Figure 106
Figure 107
Figure 108
Figure 109
Figure 110
Figure 111
Figure 112
Figure 113
Figure 114
Figure 115
Figure 116
Figure 117
Figure 118
Figure 119
Figure 120
Figure 121
Figure 122
Figure 123
Figure 124
Figure 125
Figure 126
Figure 127
Figure 128
Figure 129
Figure 130
Figure 131
Figure 132
Figure 133
Figure 134
Figure 135
Figure 136
Reference
Description
Number
1 Vent Valve
2 Connection Part
3 O-ring
4 Rectangular Ring
Figure 138
Figure 139
Figure 140
Figure 141
Figure 142
Figure 143
Reference
Description
Number
1 O-ring
2 Screw Plug
3 Vent Valve
Figure 144
9. Install plug.
Tightening torque MA = 7.14 kg•m (51.63 ft lb)
Figure 145
Figure 146
Figure 147
EXAMPLE "A"
Figure 148
Figure 149
EXAMPLE "B"
EXAMPLE "C"
Figure 150
Figure 151
Figure 152
Figure 153
Figure 154
Figure 155
Figure 156
Figure 157
Figure 158
Figure 159
Figure 161
Figure 162
Figure 163
Reference
Description
Number
1 Differential housing
2 Sealing cover
3 Installation dimension
2.0 ± 0.5 mm
Figure 164
Figure 165
Figure 166
Figure 167
Figure 168
Figure 169
Figure 170
Figure 171
Figure 172
Figure 173
Figure 174
Figure 175
Figure 176
Figure 177
Figure 178
Figure 179
Figure 180
Figure 181
Figure 182
Figure 183
Figure 184
Figure 185
Figure 187
Figure 188
Figure 189
Figure 191
Figure 192
Figure 193
Figure 194
Figure 195
Drive Shaft
Edition 1
Drive Shaft
Safety Precautions............................................... 5
Applicable Models................................................ 5
Drive Shaft Weight ......................................................... 6
Drive Shaft Coupling Dimension ................................... 6
Drive Shaft, Tightening Torque ..................................... 6
CAUTION!
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good
working order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
REAR AXLE
2 3
FRONT AXLE FG006697
Figure 1
Service Brake
Edition 1
Service Brake
Safety Precautions............................................... 5
Applicable Models................................................ 5
General Description ............................................. 6
Service Brake System......................................... 8
CAUTION!
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good
working order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
2 1
6
5
7
9 FG008070
Figure 1
CLOSES 3 Bar
STOP
FRONT AXLE
L.H Brake valve BR1 BR2 2
OPENS 25 Bar
T/M DISCONNECT
REAR AXLE
T/M
P1 T1 P2 T2
E/G 7
5 8
R.H Brake pedal 12
0.46 BAR
30B 30B
15B
0.75L 65bar 0.75L 0.32L
parking brake
(PFO1/4) (PFO3/8) (PFO3/8) (PFO3/8)
TP1
(PFO3/8)
A1 LPWS P1 P2 A2 A3 (PFO1/4)
1.5 BAR
15
C3-1 C3-2
4.0 C2 C3-3
TP2 PILOT
(PFO3/8)
TANK (PFO1/4)
2
0.5" 28 kgf/cm
C4
0.5"
20 abs.
FO
(PFO1/2)
SAFETY 13
C3 PARK
(PFO3/8)
C1
(PFO1/2)
C6 C5
LPWS 11
14
2
T 160 kgf/cm
OIL COOLER PK
10 1" 3/4" 3/4" M
(PFO1/2)
(PFO1/4)
23ccr A4 T1 T2
(PFO3/8)
(PFO3/8) (PFO1/4)
30B
BRAKE/FAN/PILOT P
3/4"
* TUV only 0.75L
PUMP
3
19.8 cm/rev L
7/16" 90±5 Bar
STEER PUMP 1200±50 rpm BRAKE & PILOT & FAN MOTER SUPPLY VALVE
3
63.8 cm/rev
FAN MOTOR
LOADER PUMP
3
58.3 cm/rev
PUMP
FG008071
Figure 2
Reference Reference
Description Description
Number Number
1 Rear Axle 9 Brake Valve
2 Transmission Cutoff Switch 10 Brake Pump
3 Front Axle 11 Pilot Supply Line
4 Brake 12 Low Pressure Warning Switch
5 Brake Pedal 13 Parking Brake Valve
6 Stop Light Switch 14 Low Pressure Warning Switch
7 Parking Brake 15 Brake and Pilot Filter
8 Accumulators : Brake
Brake Supply
Valve
Edition 1
Safety Precautions............................................... 5
Applicable Models................................................ 5
Brake, Pilot & Fan Motor Supply Valve............ 6
Specifications .................................................................. 7
CAUTION!
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good
working order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
TP1 PA
C3-1 A1 A1-1
A4
4
3 10
4
P1
5 5
PI
C3-4
TP2
6 LP
PK 6
C2 F0
T1
C4
C1 C6
C5
P2 A3
7
1
2 4
4
T2
C3-2 A2 A2-2
M F1 C3-3
PART NO.
LOT NO.
AOS0560L
Figure 1 Brake & Fan Motor Supply Valve
Reference Reference
Description Description
Number Number
1 Body (200*127*79) 6 Coil (C4, C5)
2 Sequence (C1) 7 Relief (C6)
3 Reducing (C2) 8 Plug
4 Check (C3-1, C3-2, C3-3, C3-4) 9 Plug
5 Solenoid (C4, C5) 10 Orifice (∅4.0-M8*1.25)
C3-1 C3-2
A4 4.0 C2 C3-3
TP2 PI
28 kgf/cm
C4
SAFETY
FO
C1 C3-4
PA
120 kgf/cm
F1
C5 PK
C6
M 160 kgf/cm
T1 T2
FG009147
Figure 2 Hydraulic Circuit
Specifications
Item Specifications
Max. Operating Pressure 210 kg/cm2 (3,000 psi)
Rated Flow 57 l/min (15.05 gpm)
Setting Pressure C1 120 ± 2 kg/cm2 (1,710 ± 28 psi)
(Input P:180 kg/cm2(2,560 psi),
Q:57 ipm (15.05 gpm)
C2 28 ± 2 kg/cm2 (398 ± 28 psi)
(Input P:120 kg/cm2(1,710 psi),
Q:20 ipm (5.3 gpm)
C6 160 ± 2 kg/cm2 @ 40 lpm
(2,276 ± 28 psi @ 10.56 gpm
C3 Cracking Pressure 2.40 kg/cm2 (34.1 psi)
Port Size F0, F1, M PF 1/2 O-ring
TP1, TP2, T2 PF 1/4 O-ring
LP, LK ∅30 PF 1/4 BSP
All other ports PF 3/8 O-ring
Parking Brake
Edition 1
Parking Brake
Safety Precautions............................................... 5
Applicable Models................................................ 5
General Description ............................................. 6
Functional Characteristics and Maintenance
Instructions
for Spring Loaded Sliding Caliper Brakes ................... 8
1. Functional Characteristics of Spring Loaded Sliding
Caliper Brakes ................................................................ 8
2. Mounting and Basic Setting Regulations............... 10
3. Adjusting Regulations .............................................. 11
4. Emergency Release of Parking Brake .................. 11
5. Maintenance and Repair Work............................... 12
6. General..................................................................... 14
CAUTION!
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good
working order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
1 2 3
FG006707
Figure 1
Reference Reference
Description Description
Number Number
1 Transmission 3 Parking Brake Disk
2 Parking Brake
16
20 4 3 13 14 8 10 15 7 11 12 FG008072
Figure 2
Figure 3
6. General
Any discovered defects or damage to parts not listed here
must naturally be repaired or replaced using original parts.
For any other information not contained in these instructions
or for more detailed instructions, please contact the vehicle
or brake manufacturer.
Brake Pedal
Valve
Edition 1
Safety Precautions............................................... 5
Applicable Models................................................ 5
General Description ............................................. 6
Theory of Operation ....................................................... 6
Specification .................................................................... 8
CAUTION!
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good
working order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
Theory of Operation
The brake pedal valve is attached to, and operated by, the
brake pedal. See Figure 1. The valve contains two spools.
See Figure 2. One spool ports fluid to the brake pistons in
the front axle, and the other spool ports fluid to the brake
pistons in the rear axle. Maximum system operating
pressure is 60 ± 3 bars (870 ± 44 psi). If something in one
of the circuits should fail, the other circuit will continue to
operate.
18 1.5
0
24
40
LOCK PLATE
T1
BL1
P1
BR1
T2
BL2
P2
BR2
BR2 BR1
P2 T2 P1 T1
FG008844
Figure 1
4
1 5
P2 T2 P1 T1
3
6
BR BR BL
BL
2 BR2 BR1
P2 T2 P1 T1
AJS0740L
Figure 2
Reference Reference
Description Description
Number Number
1 Primary Control Spool 4 Upper Spring
2 Secondary Control Spool 5 Main Control Spring
3 Lower Spring 6 Working Element
Accumulator
Edition 1
Accumulator SP000875
Page 1
MEMO
Accumulator SP000875
Page 2
Table of Contents
Accumulator
Safety Precautions............................................... 5
Applicable Models................................................ 5
General Description ............................................. 6
Specifications .................................................................. 8
Accumulator SP000875
Page 3
MEMO
Accumulator SP000875
Page 4
SAFETY PRECAUTIONS
CAUTION!
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good
working order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
Accumulator SP000875
Page 5
GENERAL DESCRIPTION
1
FG006708
Figure 1
Reference Reference
Description Description
Number Number
1 Brake Accumulator - 2ea 2 Pilot Accumulator
Reference
Description
Number
1 Shell
2 Diaphragm
3 Poppet
4 Fluid Port Figure 2
Accumulator SP000875
Page 6
Accumulators are solidly constructed to resist the high
operating pressures of the fluids they contain. There are
only three main moving parts: a valve assembly at the top
allows adding or expelling gas from the compressible,
precharged upper chamber; a valve assembly at the bottom
of the accumulator for passing hydraulic fluid in and out,
and an elastic diaphragm to separate the two chambers.
The flexible diaphragm changes shape to conform to the
changing pressures and volumes of the two fluids in the
upper and lower chambers.
There are six possible positions the diaphragm can be in
and they are as follows: Pressure Fluid Nitrogen
Accumulator SP000875
Page 7
4. When system oil is at highest working pressure and
the accumulator fills to maximum reserve capacity, the
flexible diaphragm is pushed up into the top of the
upper chamber.
The highest working pressure is sometimes referred to
as the "P3" pressure and can also be referenced on
the manufacturer's data label on the exterior of the
accumulator.
5. If system oil pressure begins to fall off or is
momentarily checked or interrupted, the energy stored
on the other side of the diaphragm, in the form of
compressed gas, pushes oil back out of the lower
chamber, maintaining oil pressure of the circuit.
6. With minimal system pressure, an equilibrium point may
be reached in which accumulator precharge pressure
and hydraulic system oil pressure achieve a rough
balance. In this condition a minimal amount of oil is
stored in the accumulator.
Specifications
System Charge Pressure Volume
30 kg/cm2 750 cc
Brake
(430 psi) (45.77 in3)
Accumulator SP000875
Page 8
1Steering
SP000876
STEERING SP000876
Steering
Edition 1
Steering SP000876
Page 1
MEMO
Steering SP000876
Page 2
Table of Contents
Steering
Safety Precautions............................................... 5
Applicable Models................................................ 5
General Description ............................................. 6
Power Steering System ................................................. 6
EHPS Valve .................................................................... 8
Parts List....................................................................... 10
Steering Spool at Neutral Position ............................. 12
Steering Spool Operated ............................................. 14
Pressure Reducing Valves .......................................... 16
Steering Unit................................................................. 18
Function......................................................................... 18
Function .............................................................. 20
Picture of Components in the EHPS ......................... 20
Steering SP000876
Page 3
MEMO
Steering SP000876
Page 4
SAFETY PRECAUTIONS
CAUTION!
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good
working order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
Steering SP000876
Page 5
GENERAL DESCRIPTION
2 3
6
FG006709
Figure 1
Reference Reference
Description Description
Number Number
1 Cushion Valve 4 Main Pump
2 Steering Unit 5 EHPS Valve
3 Main Block Valve 6 Steering Cylnder
Steering SP000876
Page 6
3
L R
BRAKE/PILOT/FAN PUMP
3
19.8 cm /rev
TPU EF
0.75 STEER
O.25"
C1 UNIT
PUMP C2
P T
160
ELECTRIC STEER
1"
P-controller
HT
0.75
2 4
LE
RE
PE
1 3
EF
TE (PF3/4) 12 BAR
Ps
30 BAR (PF1/2)
190 BAR
Ts
TPS (PF1/2)
O.25" P(PF3/4) T(PF1/2)
6
80X 40X450
STEERING CYL.
15BAR 15BAR CUSHION V/V
1
FG008074
Reference Reference
Description Description
Number Number
1 Cushion Valve 4 Main Pump
2 Steering Unit 5 EHPS Valve
3 Main Block Valve 6 Steering Cylnder
Steering SP000876
Page 7
EHPS Valve
Figure 1
Steering SP000876
Page 8
Reference Reference
Description Description
Number Number
1 To Tank 10 To Steering Cylinder
2 To Emergency System (Right Side)
3 To Main Pump 11 Shock and Suction Valve
(Right Side)
4 From Main Pump
12 From Steering Unit R-port
5 To Steering Unit P-port
13 Relief Valve
6 From Steering Unit T-port
14 Check Valve
7 From Steering Unit L-port
15 Main Steering Spool
8 Shock and Suction Valve
(Left Side) 16 Pressure Reducing Valve
9 To Steering Cylinder (Left 17 Metering Spool
Side) 18 Priority Spool
Steering SP000876
Page 9
Parts List
Figure 2
Reference Reference
Description Description
Number Number
1 Valve Block 51 Threaded Plug
2 Spool W. Spring 52 Threaded Plug
3 Spool W. Spring, 60 Cover, Spring Housing
Reduction Valve 61 O-ring
4 Spool, Metering 62 O-ring
5 Compress Spring 63 Screw
7 Spool, Dynamic / Intern PP 65 Plug
8 Throttle Screw 66 Cover
9 Compress Spring 67 Screw
15 Pipe W. O-ring 80 Shock Valve PVLP
16 Plug W. O-ring, Pipe 81 Spring Conically
20 Plug W. O-ring 82 Plug with. O-ring
21 Bush W. Plug, Reduction Valve 85 Check Valve
22 Plug W. O-ring, LS 90 Valve Seat
23 Plug W. O-ring, PP 91 Pilot Cone
25 Plug W. O-ring, Shuttle 92 Spring OSV
26 Ball, 1/2 94 Adjustment Screw, PVB/PVP
37 Label 95 Plug OSV
40 Plug 150 Packing,
50 Threaded Plug EHPS Type 1&2 M/ELAKTIV
Steering SP000876
Page 10
Description of operation of EHPS with integrated priority
valve
Figure 3 shows a diagram of the steering system.
The system includes the following Sauer-Danfoss
components:
One steering unit, type OSPCX CN and one steering valve,
type 0 EHPS valve
The following valves are integrated in the EHPS (position
numbers refer to numbers on drawing Figure 1)
Figure 3
Steering SP000876
Page 11
Steering Spool at Neutral Position
Figure 4
In neutral position, the oil will pass from the pump across
the integrated priority valve (18) in the EHPS valve for
discharge through the EF port. When the steering unit is in
neutral, flow through it is blocked and all flow through the
priority valve (18) in EHPS valve is directed out the EF port
and passed to the main control valve.
When the engine is turned off, the priority valve spool (18)
is pushed to the right by the spring.
The passage to the EF port is blocked while the passage to
the CF port is open.
When the machine is started, EF port of the EHPS valve
may be connected to the working hydraulic. Maximum
pressure on the EF port = 270 bar.
The operating pressure in the loader system has not
effected on the operation of the priority valve (18) of EHPS
valve. Independently of operation of the loader actuated in relief,
the priority valve (18) will not shift until the machine is steered.
A part of flow through the priority valve spool (18) will flow
to P port of steering unit through the pressure reducing
valve. Also, flow as pilot signal of steering through the
priority valve spool (18) passes from the P port through the
Dynamic orifice and into the LS line. It flows to the tank
through the LS orifice in main spool.
In neutral position, the main spool will be in its center
position. This means that knocks and impacts from the
cylinder are not transmitted to the steering unit. The EHPS
valve is thus of the nonreactive type.
Steering SP000876
Page 12
Steering Spool Operated
1. Turning Left
Figure 5
When the steering wheel is turned to the left, the pressure
oil from the steering unit will fill the left side chamber of
main steering spool (15), and the main steering spool (15)
moves to the right.
At the same time of moving of the main steering spool (15),
LS signal will be blocked.
If LS signal of main steering spool (15) is blocked, it cause the
to pressure increase in the left chamber of the priority valve (18A)
and then the priority valve (18) will be pushed to the right side.
Consequently, oil will flow via CF from the priority valve to
the main spool.
Oil will now push steering cylinder rod out and it will cause
wheel loader to be steered to left side.
The rate of movement of main steering spool (15) is
concluded as flow rate, which is kept in left chamber from
steering unit. Furthermore, the rate controls speed of
movement for cylinder.
When the cylinder reaches to end position, pressure of oil
flowing through main steering spool (15) will increase. If the
oil pressure increase up to the setting of relief valve, the
relief valve will be activated. This results in decreasing
pressure in the left chamber of priority valve (18A), and will
push the priority valve (18) to right side. The oil flow to
cylinder will be blocked.
Steering SP000876
Page 13
2. Turning Right
Figure 6
Steering SP000876
Page 14
Pressure Reducing Valves
Figure 7
Steering SP000876
Page 15
Pilot Relief Valve
Figure 8
Reference Reference
Description Description
Number Number
1 Plastic Plug 4 Thrust Pad
2 Adjustment Screw 5 Valve Seat
3 Spring
Steering SP000876
Page 16
Steering Unit
Figure 9
Reference Reference
Description Description
Number Number
1 Bearing 7 Sleeve
2 Neutral Position Spring 8 Cardan Shaft
3 Cross Pin 9 Spool
4 Housing 10 Check Valve
5 Gear Wheel 11 Distributor Plate
6 Gear Rim 12 End Cover
Function
The steering unit consists of a rotary valve and a rotary
metering unit.
Via a steering column the steering unit is connected to the
steering wheel of the vehicle.
When the steering wheel is turned, oil is directed from the
steering system pump via the rotary valve (spool and
sleeve) and rotary metering (gear wheel set) to the cylinder
ports L or R, depending on the direction of turn. The rotary
meter, meters the oil flow to the steering cylinder in
proportion to the rotation of the steering wheel.
Steering SP000876
Page 17
Exploded View of a Steering Unit
Figure 10
Steering SP000876
Page 18
FUNCTION
The main relief valve is inside the EHPS valve, and set the
maximum circuit pressure of the steering circuit. When the
EHPS valve is being actuated, and the steering circuit goes
up above the set pressure of this valve, oil will be relieved,
and the priority valve spool will be actuated, and the oil will
be drained to EF port.
Figure 11
Priority spool.
Position 18.
Figure 12
Metering spool.
Position 17.
Figure 13
Steering SP000876
Page 19
Relief valve.
Position 13.
Figure 14
Shock valve
Position 10.
Figure 15
Pressure reducing valve
Position 16.
Figure 16
Shuttle valve
Figure 17
Figure 18
Steering SP000876
Page 20
EHPS house.
Reference
Description
Number
1 Metering Spool Position 17
2 Main Spool Position 15
(Behind End Cover)
3 Pressure Reduction Valve
Position 16
(Behind End Cover)
4 Priority Spool Position 18
Figure 19
Steering SP000876
Page 21
Steering SP000876
Page 22
SP000328
CUSHION VALVE SP000328
Cushion Valve
Edition 1
Cushion Valve
Safety Precautions............................................... 5
Applicable Models................................................ 5
Cushion Valve...................................................... 6
Cushion Valve Operation ............................................... 6
Specifications .................................................................. 6
Parts List......................................................................... 7
CAUTION!
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good
working order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
Function
The cushion valve absorbs any excessive peak pressure
that maybe generated during initial movement of the steering
wheel or during a change in steering direction. The cushion
valve also prevents excessive high-pressure and shock that
can result from steering load inertia.
Working Principle
If a high-pressure oil is fed back to port R, it pushes spring
(3) and opens poppet (2). This operation directs the
high-pressure oil to port L through the center hole in spool
(12) and the check valve poppet in port L part. At the same
time, oil reaches the pressure room of the plug through
orifice (8). This operation closes the passage from port R to
port L. This releases the pressure and prevents machine
shock by intercepting oil. If a low-pressure oil flows, the
cushion operation is not necessary. It is due to the speed of
closing spool (12) is faster than the speed of opening
poppet (2), therefore, the cushion valve does not work.
Specifications
General
Max. Pressure 210 bar (3,046 psi)
Main Relief Pressure 15 bar (218 psi)
Hydraulic Oil ISO VG 46 WR or SIMILAR
Hydraulic Oil Temperature -20°C - +90°C
Environments
Atmospheric Temperature -30°C - +45°C
Vibration 3 - 5G/ 30 Hz
Shock 10G
Figure 1
Reference Reference
Description Description
Number Number
1 Body 10 Spring
2 Seat Valve 11 Back up Ring
3 Poppet 12 O-ring
4 Spring 13 O-ring
5 Plug 14 O-ring
6 Spring 15 Plug
7 Spool 16 Plug
8 Plug 17 Orifice
9 Poppet
Emergency
Steering
Edition 1
Emergency Steering
Safety Precautions............................................... 5
Applicable Models................................................ 5
General Description ............................................. 6
Emergency Steering Function Test............................... 8
Emergency Steering Automatic Test ............................ 8
Pump & DC Motor ............................................ 10
CAUTION!
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good
working order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
7 8
10 9
1
FG006710
Figure 1
Reference Reference
Description Description
Number Number
1 Pump & DC Motor 6 Oil Tank
2 Steering Pump 7 Steering Unit
3 Check Valve 8 Block Valve
4 Pressure Sensor 9 Steer Cylinder
5 Pump 10 Cushion Valve
B 62 Bar
R2 6B BR
M 10ccr
EMR.STEERING S/W
AJO0011L
30 15
20 20
10
40
10 25
5
50 30
0 0
km/h x100r/min
CHECK
STOP
F/R
1 FG006741
Figure 4
18.00 450
16.00 400
14.00 350
12.00 300
AMPS
GPM
10.00 250
8.00 200
6.00 150
4.00 100
2.00 50
0.00 0
0 500 1000 1500 2000 2500 3000 3500
PSI
Flow, 10 cc Amps, 10 cc
FG005128
Figure 5
Figure 6
Reference Reference
Description Description
Number Number
1 Retaining Ring 7 DC Motor
2 Shaft Seal 8 Start Sw Kit
3 Backup Ring 9 Gasket
4 Seal 10 Lock Washer
5 O-ring 11 Mounting Screw
6 Valve Assembly 12 Pump Assembly
Articulation
Center
Edition 1
Articulation Center
Safety Precautions............................................... 5
Applicable Models................................................ 5
General Description ............................................. 6
Maintenance Standard ................................................... 7
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
CAUTION!
When the loader is steered, the area near the center hinge
pins becomes so narrow that you might get caught between
the front and rear frames. Before trying to service the
loader, make sure to set the frame lock plate.
Before moving (traveling) the loader, make sure the frame
lock plate is set to the original position.
FG006713
Figure 1
DETAIL B
S=1/2
(LOWER HINGE BEARING)
DETAIL A
S=1/2
(UPPER HINGE BEARING)
AOS0170L
Figure 2
Counterweight
Edition 1
Counterweight SP000130
Page 1
MEMO
Counterweight SP000130
Page 2
Table of Contents
Counterweight
Safety Precautions............................................... 5
Applicable Models................................................ 5
Specifications ....................................................... 6
Counterweight ...................................................... 6
Counterweight SP000130
Page 3
MEMO
Counterweight SP000130
Page 4
SAFETY PRECAUTIONS
CAUTION!
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good
working order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
Counterweight SP000130
Page 5
SPECIFICATIONS
NOTE: Weight.
COUNTERWEIGHT
AJS0620L
Figure 1
Counterweight SP000130
Page 6
1Tank
SP000879
OIL TANK SP000879
Oil Tank
Edition 1
Oil Tank
Safety Precautions............................................... 5
Applicable Models................................................ 5
General Description ............................................. 6
Parts List......................................................................... 6
Specifications .................................................................. 7
CAUTION!
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good
working order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
Parts List
1 7
2 8
3 9
10
4
5 11
6
12
13
14
16 15
FG006714
Figure 1
Specifications
Oil Tank
Type Pressurized Sealing
Capacity (System) 158 liters (42 U.S. gal.)
Air Breather
Open Pressure 0.40 kg/cm2 (5.7 psi)
Vacuum pressure 0.035 kg/cm2 (0.5 psi) at 900 liters/min. (238 U.S. gal./min.)
Return Filter
Filtration Rating 10 μ
Pressure Drop 0.25 kg/cm2 (3 psi) at 600 liters (159 U.S. gal.), 20 cSt
Filtration Efficiency Over 99.5 %
Suction Filter
Filtration Rating 177 μ
Bypass Valve
Cracking Pressure 1.5 kg/cm2 (21 psi) at 40 liters (10.5 U.S. gal.), 20 cSt
Pressure Drop 2.0 kg/cm2 (28 psi) at 40 liters (10.5 U.S. gal.), 20 cSt
Fuel Tank
Edition 1
Fuel Tank
Safety Precautions............................................... 5
Applicable Models................................................ 5
General Description ............................................. 6
Parts List......................................................................... 6
Specifications .................................................................. 7
CAUTION!
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good
working order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
Parts List
2
4
3
5
1
12 11 10
FG008845
Figure 1
Reference Reference
Description Description
Number Number
1 Fuel Tank 7 Hose; Engine Oil Drain
2 Fuel Pipe 8 O-ring
3 Packing 9 Cover
4 Fuel Cap 10 Sender Cover
5 Fuel Strainer 11 Fuel Sender
6 Drain Cock 12 Step
Figure 2
Cylinders
Edition 1
Cylinders SP001027
Page 1
MEMO
Cylinders SP001027
Page 2
Table of Contents
Cylinders
Safety Precautions............................................... 5
Applicable Models................................................ 5
General Description ............................................. 6
Theory of Operation ....................................................... 7
Parts List......................................................................... 8
Troubleshooting, Testing and Adjustment........ 14
Disassembly ....................................................... 17
Cleaning and Inspection (Wear Limits and
Tolerances)......................................................... 19
Reassembly ........................................................ 19
Cylinders SP001027
Page 3
MEMO
Cylinders SP001027
Page 4
SAFETY PRECAUTIONS
CAUTION!
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good
working order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
Cylinders SP001027
Page 5
GENERAL DESCRIPTION
The machine contains boom cylinders, buckets cylinders and
steering cylinders. Each cylinder contains a cylinder tube,
piston rod, piston, and cylinder head. See Figure 1. The
piston is held to piston rod by a nut. A dust seal protects
the U-ring and oil seal from dirt and also prevents oil from
leaking out of the cylinder.
Figure 1
Reference Reference
Description Description
Number Number
1 Retaining Ring 10 Seal O-ring
2 Dust Seal 11 Piston
3 U-ring 12 Spring
4 Seat O-ring 13 Cylinder Tube
5 Port (A) 14 O-ring, Backup Ring
6 Cushion Plate 15 Bushing
7 Wear Ring 16 Cylinder Head
8 Piston Nut 17 Bolt
9 Port (B) 18 Piston Rod
Cylinders SP001027
Page 6
Theory of Operation
1. Piston 1
2. Oil Path A
3. Oil Path B
F1 = P x πB2
4
4. Rod Diameter
Q1 = S x π(B2)
4
Q2 = S x π(B2-R2)
4
Q1 > Q 2 0332
Figure 4
Cylinders SP001027
Page 7
Parts List
29
23
25 24
20
19
22
26
27
14
28
16
15
17
18
11
12
13
7
21 6
9 5
8
10
29
BAS0170L
Figure 5
Cylinders SP001027
Page 8
Reference Reference
Description Description
Number Number
1 Tube Assembly 16 Wear Ring
2 Steel Bushing 17 Dust Ring
3 Rod Assembly 18 O-ring
4 Steel Bushing 19 Piston Nut
5 Rod Cover 20 Lock Ring
6 DU-bushing 21 Socket Hex Bolt
7 Retaining Ring 22 Pipe Assembly
8 U-packing 23 O-ring
9 Backup Ring 24 Spring Washer
10 Dust wiper 25 Hex Bolt
11 O-ring 26 Pipe Clamp
12 Backup Ring 27 Spring Washer
13 O-ring 28 Hex Bolt
14 Piston 29 Grease Fitting Seal Kit
15 Glyd Ring
Cylinders SP001027
Page 9
Lift Hydraulic Cylinder
33 2
22
23
21
30 24
32
29
30
31
26 25
27
28
19
18
13
15
14
17 7
20 10
12 11
6
5
8 4
7
9
BAS0180L
Figure 6
Cylinders SP001027
Page 10
Reference Reference
Description Description
Number Number
1 Tube Assembly 18 Piston Nut
2 Steel Bushing 19 Lock Ring
3 Rod Assembly 20 Socket Hex Bolt
4 Rod Cover 21 Pipe Assembly
5 DU-bushing 22 O-ring
6 Retaining Ring 23 Spring Washer
7 U-packing 24 Hex Bolt
8 Backup Ring 25 Pipe Assembly
9 Dust wiper 26 O-ring
10 O-ring 27 Spring Washer
11 Backup Ring 28 Socket Hex Bolt
12 O-ring 29 Pipe Clamp
13 Piston 30 Spring Washer
14 Glyd Ring 31 Hex Bolt
15 Wear Ring 32 Hex Bolt
16 Dust Ring 33 Grease Fitting Seal Kit
17 O-ring
Cylinders SP001027
Page 11
Steering Hydraulic Cylinder
27
27
23
24
26
1
25
21
22
20
19
14
16
15
18 17
10
11
6
12
13
5
7
8
9
27
BAS0190L
Figure 7
Cylinders SP001027
Page 12
Reference Reference
Description Description
Number Number
1 Tube Assembly 15 Glyd Ring
2 Steel Bushing 16 Wear Ring
3 Rod Assembly 17 Dust Ring
4 Steel Bushing 18 O-ring
5 Rod Cover 19 Piston Nut
6 DU-bushing 20 Lock Ring
7 U-packing 21 Cushion Plunger
8 Backup Ring 22 Stop Ring
9 Dust wiper 23 Check Valve
10 O-ring 24 Spring
11 Backup Ring 25 Plug
12 O-ring 26 O-ring
13 Washer 27 Grease Fitting Seal Kit
14 Piston
Cylinders SP001027
Page 13
TROUBLESHOOTING, TESTING
AND ADJUSTMENT
Problem Possible Cause Remedy
Oil leaking between cylinder head Foreign material in U-ring (3). Remove foreign material.
(16) and piston rod (18). (Index Scratches in U-ring (3). Replace U-ring (3).
nos. refer to Figure 1)
Damage to U-ring (3). Replace U-ring (3).
Foreign material in dust seal (2). Remove foreign material.
Scratches to dust seal (2). Replace dust seal.
Damage to dust seal (2). Replace dust seal.
Foreign material in seal O-ring Remove foreign material.
(4).
Scratches in seal O-ring (4). Replace O-ring (4).
Damage to seal O-ring (4). Replace O-ring (4).
Scratches on sealing surface of If scratches are not deep,
piston rod (18). hone with an oil stone and
lubricate. If scratches are
deep, replace piston rod (18).
Deep scratches on inner surface Replace bushing.
of bushing (15).
Oil leaking between cylinder head Damage to O-rings (14). Replace O-rings (14).
(16) and cylinder tube (13).
Oil leaking from welded area of Damage to welded area. Replace cylinder tube (13).
cylinder tube (13).
Oil leaking between cylinder head Foreign material in U-ring (3, Remove foreign material.
(16) and piston rod (18). (Index Figure 1)
nos. refer to Figure 1). Scratches in U-ring (3, Figure 1). Replace U-ring (3).
Damage to U-ring (3, Figure 1). Replace U-ring (3).
Foreign material in dust seal (2, Remove foreign material.
Figure 1).
Scratches in dust seal (2, Figure Replace dust seal (2).
1).
Damage to dust seal (2, Figure Replace dust seal (2).
1).
Foreign material in seal O-ring Remove foreign material.
(4, Figure 1).
Scratches in seal O-ring (4, Replace O-ring (4).
Figure 1).
Damage to seal O-ring (4, Figure Replace O-ring (4).
1).
Scratch on sealing surface of If scratches are not deep,
piston rod (18, Figure 1). hone with an oil stone and
lubricate. If scratches are
deep, replace piston rod (18).
Deep scratches on inner surface Replace bushing.
of bushing (15, Figure 1).
Oil leaking between cylinder head Damage to O-rings (14, Figure Replace O-rings (14).
(16) and cylinder tube (13). 1).
Cylinders SP001027
Page 14
Problem Possible Cause Remedy
Oil leaking from welded area of Damage to welded area. Replace cylinder tube (13).
cylinder tube (13).
Cylinder drops from pull of gravity. Light scratches on sealing Hone out scratches with oil
surface of cylinder tube (13, stone.
Figure 1).
Deep scratches on sealing Replace cylinder tube (13).
surface of cylinder tube (13,
Figure 1).
Deep scratches on sealing Replace O-rings (10).
surface of piston O-rings (10,
Figure 1).
Foreign material in U-ring (3, Remove foreign material.
Figure 1).
Scratches in U-ring (3, Figure 1). Replace U-ring (3).
Damage to U-ring (3, Figure 1). Replace U-ring (3).
Nylon wear rings (7, Figure 1) Replace nylon wear rings (7).
twisted.
Nylon wear rings (7, Figure 1) Replace nylon wear rings (7).
scratched.
Nylon wear rings (7, Figure 1) Replace nylon wear rings (7).
have other damage.
Slow bucket and boom movements. Reduced oil flow due to dirty Disassemble and clean parts.
filter or dirty intake line.
Air drawn into circuit through Tighten intake connections.
loose connections.
Reservoir oil level too low. Fill reservoir to correct level.
Relief valve pressure setting Adjust relief valve pressure.
incorrect.
Damaged pump shaft or pump Replace damaged parts.
drive sleeve.
Pump worn or damaged Replace worn or damaged
internally. parts.
Relief valve sticking. Disassemble and inspect
cartridge. Clean or replace
cartridge.
Air in pressure line. Perform cylinder bleeding
procedure to remove air.
Tighten or replace pressure
line.
Damaged pipe or hose. Replace pipe or hose.
Worn cylinder seals. Replace worn parts.
Cylinders SP001027
Page 15
Problem Possible Cause Remedy
Low-pressure, shown by weak Reduced oil flow due to dirty Disassemble and clean parts.
upward movement of boom and filter or dirty intake line.
bucket. Reservoir oil level too low. Fill reservoir to correct level.
Relief valve pressure setting Adjust relief valve pressure.
incorrect.
Pump worn or damaged Replace worn or damaged
internally. parts.
Relief valve sticking. Disassemble and inspect
cartridge. Clean or replace
cartridge.
Worn cylinder seals. Replace worn parts.
Low pump output due to dirty Remove and clean pump
discharge pipes. discharge pipes.
Relief valve spring is weak. Replace worn parts.
Relief valve poppet worn.
Cylinder drops when control valve Worn plunger in control valve. Replace plunger.
is in neutral. Stuck overload relief valve due to Replace worn parts.
worn seat surface.
Loose pipes or joints. Tighten parts.
Worn piston seal on hydraulic Replace seal.
cylinder.
Vibration or excessive noise. Excessive resistance in pump Inspect intake line and clean
intake line. or replace as necessary.
Air being drawn into intake line. Inspect pipe joints and tighten.
Chattering relief valve. Change oil, replace valve.
Air bubbles in oil. Wrong type of operating oil. Drain and fill with proper type
of oil.
Oil level too low. Raise to proper level.
Air trapped in system. Perform cylinder bleeding
procedure to remove air.
Frequent rubber hose damage. System pressure too high. Adjust relief valve pressure.
Hoses breaking due to contact Restrain hoses to prevent
with another machine parts. contact.
Cylinders SP001027
Page 16
DISASSEMBLY
NOTE: Keep on hand a container large enough to hold all of
the oil in cylinder being repaired. When cylinder rod
and head are removed, oil will run out of cylinder.
NOTE: Dispose of drained fluids according to local
regulations.
1. Use an allen wrench to remove bolts that hold cylinder
head to cylinder tube. See Figure 8.
Figure 8
Figure 9
Figure 10
Cylinders SP001027
Page 17
4. Remove piston nut (1, Figure 11), piston assembly (2),
cushion flange (3), and cylinder head assembly (4).
Reference
Description
Number
1 Piston Nut
2 Piston Assembly
3 Cushion Flange
Cylinder Head
4
Assembly
Figure 11
Figure 12
Reference
Description
Number
1 Retaining Ring
2 Dust Seal
Figure 13
Reference
Description
Number
1 U-Packing
2 O-ring
3 Ring
Figure 14
Cylinders SP001027
Page 18
CLEANING AND INSPECTION
(WEAR LIMITS AND
TOLERANCES)
For general cleaning and inspection procedures, refer to
"General Maintenance Procedures" section.
REASSEMBLY
NOTE: Check cylinder head grooves for U-packing and dust
seal. If edges of grooves are sharp or have burns,
use an oil stone to smooth surface. See Figure 15.
Figure 15
Figure 16
Cylinders SP001027
Page 19
2. Install split backup ring into its groove by compressing
ring. See Figure 17. Make sure that ends of ring do
not overlap.
NOTE: The U-packing can be installed by hand or by
using a seal installing jig. The jig should be
made of copper, aluminum, or plastic. If a jig is
used, be sure that jig does not have sharp
edges that could damage U-packing.
Figure 17
Figure 18
Figure 19
Cylinders SP001027
Page 20
5. Check to be sure that U-packing and backup ring are
correctly installed by pushing with your hand on inner
diameter of U-packing. See Figure 20.
NOTE: There are 2 backup rings used on outside of
cylinder head. One backup ring is continuous.
The other backup ring is open, split by an
angled cut.
Figure 20
Reference
Description
Number
1 Split Backup Ring
Continuous Backup
2
Ring
Figure 21
Figure 22
Figure 23
Cylinders SP001027
Page 21
9. Use a seal installing jig to install dust seal into cylinder
head. See Figure 24. Install retaining ring.
Figure 24
Figure 25
Figure 26
Cylinders SP001027
Page 22
12. Insert one end of backup ring into its groove. See
Figure 27. Use your hand to slide other end of ring
into groove.
Figure 27
13. Use warm water to expand slipper seal. See Figure 28.
This will make seal easier to install. Set slipper seal in
60°C -100°C (140°F - 212°F) water for 5 minutes or
longer.
Figure 28
14. Insert one end of slipper seal, (1, Figure 29) into its
groove. Use your hand to slide other end of slipper
seal into groove.
WARNING!
Before piston is inserted into cylinder tube, make
sure that slipper seal is no longer expanded. If seal
is still expanded, it could catch on threaded portion
of cylinder tube. An expanded seal could also jam
inside cylinder tube. Figure 29
Cylinders SP001027
Page 23
15. Install two backup rings, (1, Figure 30). One ring fits
on either side of slipper seal (2).
Reference
Description
Number
1 Backup Ring
2 Slipper Seal
Figure 30
Figure 31
17. Set cylinder rod (1, Figure 32) into a repair fixture (2).
Securely clamp rod to fixture. Exercise caution to
prevent nicks or scratches to chrome plated areas of
rod. chrome plated area is oil sealing surface of rod.
Reference
Description
Number
1 Cylinder Rod
2 Repair Fixture
Figure 32
Cylinders SP001027
Page 24
18. Slide cylinder head assembly (1, Figure 33) onto
cylinder rod (2). Use caution to prevent threads on rod
from damaging seal inside cylinder head.
Reference
Description
Number
1 Cylinder Head
2 Cylinder Rod
Figure 33
19. Install cushion flange (1, Figure 34) on cylinder rod (2).
Slide piston assembly (3) onto cylinder rod (2).
Reference
Description
Number
1 Cushion Flange
2 Cylinder Rod
3 Piston Assembly
Figure 34
20. Install piston nut (1, Figure 35) and tighten it with an
impact wrench. Then use a torque wrench to tighten
nut (1) to specified torque.
After nut has been tightened, check to see that cushion
flange moves.
Figure 35
21. Slide rod assembly into cylinder tube. Align punch mark
(1, Figure 36) with port (2) in cylinder tube. This will
align hole (3) in cylinder head with port (2).
Reference
Description
Number
1 Punch Mark
2 Port
3 Hole
Figure 36
Cylinders SP001027
Page 25
22. Install bolts in cylinder head and tighten them to torque
specified in bolt torque chart. See Figure 37. Double
check to make sure that hole in cylinder head is align
with port in cylinder tube.
NOTE: After rebuilding a cylinder, or after loosening a
cylinder hydraulic line, air must be bled from
hydraulic system. To bleed air from system, first
extend and retract a cylinder (or pair of
cylinders) about 5 times at low engine rpm. Stop
cylinder about 100 mm (4 in) short of full
extension and full retraction. Then fully extend
and retract cylinder about 5 times, also at low Figure 37
engine rpm.
Cylinders SP001027
Page 26
SP001035
MAIN PUMP SP001035
Main Pump
Edition 1
Main Pump
Safety Precautions............................................... 5
Applicable Models................................................ 5
General Description ............................................. 7
Theory Of Operation ...................................................... 7
Parts List......................................................................... 8
Service Kits................................................................... 10
Dimensions.................................................................... 11
Specification .................................................................. 12
Model Number Code Series T6DC ....................... 12
Specifications ........................................................... 12
Special Tools ..................................................... 13
Seal Driver .................................................................... 13
Protective Cone ............................................................ 13
Disassembly ....................................................... 14
Reassembly ........................................................ 18
CAUTION!
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good
working order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
Theory Of Operation
The hydraulic pump is a triple vane pump which contains
three pumping sections. The first pumping section supplies
oil for the front attachment. The second pumping section
supplies oil for the steering cylinders. Surplus oil which is
not necessary for the steering function is directed into
control valve to join the first pump's oil by the priority valve.
The third pump section, is the pilot pump, used for brakes
and pilot line operation.
Figure 1
Figure 2
Figure 3
Reference
Kit Code Number Remark
Number
1 P1 Cartridge (B17) S24-40164-0 Rotor, vane, holdout pins, port-plates
2 P2 Cartridge (B20) S24-77212
3 P3 Cartridge (B20) S24-94162
- Seal Kit S24-76934 All seals included: shaft seal,
(S1-0.7bar) square-rings, O-rings
4 Shaft and Bearing S24-76933 Shaft, bearing, retaining ring
Assembly (Code 3)
Main Pump
12.45
R 73,8
Figure 4
7.9
6.35 MAX
Dimensions
38
76.7
82.7
106.4
127,00
126,95
64,3
147.4
17,5
80.7
2.3×45°
1.3×45°
87.1
181
211
22.25
30.2 SHAFT CODE 3
SAE C splined shaft
Class 1 - J498 b
12/24 d.p. - 14 teeth
30° pressure angle
flat root side fit
47.65
58.7
147.4
PRESSURE SAE#8
PRESSURE 19.1
PRESSURE 31.75
FG005325
Page 11
SP001035
Specification
Reference Reference
Description Description
Number Number
1 Modification 6 Type of Shaft
2 Seal Class 7 Cam Ring for "P3"
3 Design Letter 8 Cam Ring for "P2"
4 Porting Combination 9 Cam Ring for "P1"
5 Direction of Rotation 10 Series
Specifications
Specification
Item
Main Pump Steering Pump Pilot Pump
Model Number T67CCAY-B17-B20-B20-3R41-B1MY
Type Vane
58.3 cc/rev 63.8 cc/rev 19.8 cc/rev
Displacement
(3.56 in3/rev) (3.89 in3/rev) (1.208 in3/rev)
Seal Driver
A seal driver is required to install shaft seal in the pump
mounting cap.
NOTE: 1. Material: 4140 or equivalent.
2. Remove all burrs and break sharp edges: 0.25/
0.13R.
3. Length 19 mm ("A" dia) to be heat treated Rc 50/
55.
NOTE: A dia: 34.90 - 34.75
B dia: 57.10 - 56.92
C: 145
Figure 6
Tool ref.: SS2
Protective Cone
A protective cone is to be used when installing shaft
assembly in the mounting cap. The protective cone prevents
damaging the lips of the shaft seal during insertion.
NOTE: 1. Material: TEFLON preferred.
2. Remove all burrs and break sharp edges: 0.25/
0.13 R.
NOTE: A: 60
B dia: 35.00 - 34.95
C dia: 31.33 - 31.25
Tool ref.: CP14
Figure 7
Figure 8
Figure 9
Figure 10
Figure 11
Figure 12
Figure 13
Figure 14
Figure 15
Figure 16
Figure 17
Figure 18
Figure 19
Figure 20
WARNING!
Replace all seals and backup rings with new ones.
Make sure the dowel pin(s) (10) are properly
inserted in corresponding hole in housing (13).
Figure 21
Figure 22
WARNING!
When inserting P1 cartridge in mounting cap, make
sure the white teflon backup ring is not damaged
and securely in place.
WARNING!
Make sure the dowel pin is properly inserted in the
corresponding hole in housing (13).
Figure 24
Figure 25
Figure 26
Figure 27
WARNING!
Make sure rotation is as per required.
Figure 28
Figure 29
Figure 30
Figure 31
Figure 32
Main Control
Valve
Edition 1
Safety Precautions............................................... 5
Applicable Models................................................ 5
General Description ............................................. 6
Specifications ....................................................... 8
Parts List ............................................................ 10
Disassembly ....................................................... 12
Order of Replacement ................................................. 12
Cleaning and Inspection (Wear Limits and
Tolerances)......................................................... 14
Reassembly ........................................................ 15
Reassembly Order........................................................ 16
Valve Maintenance ............................................ 18
Main Relief Valve ......................................................... 18
Overload Relief Valve .................................................. 20
Anticavatation Valve ..................................................... 22
Valve Adjustment ............................................... 24
Installation .......................................................... 25
Operation ............................................................ 25
CAUTION!
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good
working order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
(1)
(2)
(2)
T1
P1
(3)
Pb1 (2) Pa1
B1 A1
Pb2 Pa2
B2 A2 (2)
(2)
Pb3 Pa3
B3 A3
FG006715
Figure 1
200 BAR
(2)
BUCKET
a1 b1
BUCKET CYLINDER
BOOM
a2
b2
BOOM CYLINDER
A2 275 BAR
(RAISE)
B2
(LOWER)
OPTION
a3 b3
Reference Reference
Description Description
Number Number
a1 Bucket Crowd Valve Port A2 Boom Up Port
b1 Bucket Dump Valve Port (to Boom Cylinder Tube)
a2 Boom Up Valve Port B2 Boom Lower Port
(to Boom Cylinder Rod)
b2 Boom Down Valve Port
A3 Option Cylinder Port
a3 Option Valve Port
(to Option Cylinder Rod)
b3 Option Valve Port
B3 Option Cylinder Port
A1 Bucket Crowd Port (to Option Cylinder Tube)
(to Bucket Cylinder Tube)
(1) Main Relief Valve
B1 Bucket Dump Port
(2) Overload Relief Valve
(to Bucket Cylinder Rod)
(3) Anticavitation Check Valve
Figure 3
Types Description
A Must replaced when Disassembly / Reassembly, supplied in repair
kit.
B Supplied as spare parts for quality warranty or assembly.
C Supplied as single item.
D Cannot be supplied.
Order of Replacement
Reference numbers are those shown in Figure 3.
1. Remove overload relief valves (27, 28, and 29) from
valve housing.
2. Remove main relief valve (30) from valve housing.
3. Remove anticavatation valve (31) from valve housing.
NOTE: Do not disassemble relief valve and
anticavatation valve unless problems are found
in them, because they should be replaced as
assemblies. They should be removed according
to “Valve Maintenance” on page 1-18, and
“Anticavatation Valve” on page 1-22. Provided,
that overload relief valve whose setting
pressure is higher than that of main relief valve
should not be removed because its adjustment
is impossible. Match mark parts, for proper
orientation and location during reassembly.
4. Loosen socket head bolt (13) and remove long caps (9
and 10) along with O-rings (12) on flange (of bucket
and boom spools).
5. Remove bucket spool (2) and boom spool, as
assemblies, from valve housing (1).
NOTE: Take care to prevent any dent or scratches on
surface of spool when taking it out.
Disassembly
1. Remove plug (2), spring (7), poppet (4) and sleeve (3)
from relief valve cartridge housing (1).
2. Remove adjustment lock nut assembly (13) and remove
pilot poppet (6) and spring (8).
3. Remove O-rings and backup rings from all pieces.
NOTE: Do not remove pilot seat (5) that is attached to
the plug body by crimping.
Figure 6
Reassembly
1. Install O-ring (9) and backup ring (10) on pilot seat (5).
2. Install O-ring (11) on plug (2).
3. Install O-ring (11) on relief valve cartridge housing (1).
4. Install sleeve (3), main poppet (4), spring (7) and pilot
seat (5) (with plug) in relief valve cartridge housing (1).
Tighten plug (2) to a torque of 10 - 11 kg•m (69 -
80 ft lb).
5. Insert pilot poppet (6) and spring (8) in plug (2).
Position O-ring (14) on plug (2). Install adjustment lock
nut assembly (13) in plug. Temporarily tighten lock nut.
6. Insert main relief valve assembly in valve housing and
tighten to a torque of 9 - 11 kg•m (69 - 80 ft lb).
NOTE: Adjust pressure as described in “Main Relief
Valve Adjustment” on page 1-24.
Disassembly
1. Remove plug (2), springs (7 and 8), piston (5), main
poppet (4), and sleeve (3) from relief valve cartridge
housing (1).
2. Loosen adjustment lock nut assembly (10) and remove
spring (9) and pilot poppet (6).
3. Remove O-rings and backup rings from all pieces.
Figure 7
Reassembly
1. Install O-ring (12) and backup ring (13) on plug (2).
2. Install O-ring (16) and backup ring (17) on main poppet
(4).
3. Install O-ring (14) on plug (2).
4. Install O-ring (14) on relief valve cartridge housing (1).
5. Slide piston (5) into main poppet (4), and then into
sleeve (3).
6. Install sleeve (3) into relief valve cartridge housing (1).
7. Set springs (7 and 8) in position on piston (5) and
sleeve (3).
8. Carefully install plug (2) in relief valve cartridge housing
(1), making sure that springs (7 and 8) are properly
seated. Tighten plug (2) to a torque of 8 - 9 kg•m (58
- 65 ft lb).
9. Insert pilot poppet (6) and spring (9) in plug (2).
Position O-ring (11) on plug (2). Install adjustment lock
nut assembly (10) in plug. Temporarily tighten lock nut.
10. Install overload relief valve assembly in valve housing
and tighten to a torque of 8 - 9 kg•m (58 - 65 ft lb).
NOTE: Adjust pressure as described in “Overload
Relief Valve Adjustment” on page 1-24.
Disassembly
1. Remove plug (6) from poppet sleeve (1).
NOTE: Do not disassemble main poppet (2). It is
connected to spring seat (4) and by C-pin (5)
which keeps it assembled to other parts.
2. Remove O-ring (7) and backup ring (8) from poppet
sleeve (1).
3. Remove O-ring (9) from plug (6)
Figure 8
OPERATION
1. First, check if valve arrangement is correct and oil is
clean. Check for leakage by increasing pressure
gradually (inching device with low idle).
2. Use hydraulic oil specified in the Operation and
Maintenance Manual.
3. Do not increase pressure of relief valve above its
nominal pressure value.
4. Start normal work cycle operations only after sufficiently
warming up the pilot circuit.
NOTE: When operating at low temperatures, use the
following procedures to prevent the valve from
sticking, due to heat shock of spool:
5. Do not move main relief valve or overload relief valve
abruptly and successively in case of pilot operation, but
operate the system slowly so that the oil in hydraulic
actuators flows smoothly and increases its temperature
evenly.
6. Do not try minute or composite operation at low
temperatures which may cause heat in some parts.
Load Isolation
System
Edition 1
Safety Precautions............................................... 5
Applicable Models................................................ 5
General Description ............................................. 6
Over View ....................................................................... 7
Hydraulic Circuit ............................................................. 8
Function........................................................................... 9
Maintenance and Service work ..................................... 9
LIS Valve-RSM2 ........................................................... 10
Characteristic Curve ..................................................... 10
Parts List....................................................................... 11
Accumulator .................................................................. 12
CAUTION!
Follow all safety recommendations and safe shop practices
outlined in the front of this manual or those contained
within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
7 8
1 6
FG006718
Figure 1
T X2
MX
3 4
Lifting cylinder
7 2
3
4 1 2
1
B A
8
Control block
FG008846
Figure 2
Reference Reference
Description Description
Number Number
1 LIS Valve (RSM2) 5 Emergency Drain Screw
2 Valve spool 6 Accumulator
3 3/2-way Directional Valve, 7 Lift Cylinder
Solenoid Operated 8 Control Valve
4 Pressure Relief Valve
(EC Design Tested)
CAUTION!
The safety technical requirements of the vehicle have to be
taken into account!
Before carrying out any maintenance work the
accumulators must be unloaded. (zero pressure).
Specification
General
Installation Optional
Ambient Temperature Range -20°C ~ +80°C
Weight 15 kg
Hydraulic
Ports A, B 420 bar
Max. Operating Pressure Port X2 350 bar
Port T 30 bar
Max. Nominal Flow Ports A, X2 150 l/min
Pressure Fluid Mineral Oil (HL, HLP) to DIN 51524
Viscosity range 10 ~ 380 mm2/s
Degree of Contamination
ISO 4406 (C) class 20/18/15
(Max. Permissible)
Electrical
Control Voltage 12V , 24V
Power Consumption (Solenoid) 14.4 W
Characteristic Curve
(measured with HLP 68, Oil = 40 ± 5°C)
Figure 3
Figure 4
Reference Reference
Description Description
Number Number
10 Housing 130 Compression Spring
20 Piston 140 Compression Spring
40 Socket 160 Plug
70 Spring Disc 170 Plug
80 Valve Seat 190 Plug
90 Valve Seat 230 Cheese Head Screw
100 Throttle Pin 260 FTWE
110 Grubscrew 270 DBDS
Specification
General
Ambient Temperature
-53°C ~ +204°C
Range
Weight 28.7 kg
Hydraulic
Max. Operating Pressure 280 bar
Capacity (Oil) 4 liters
Parts List
Figure 5
Reference Reference
Description Description
Number Number
01 Accumulator Body 08 Gas Valve Body
02 Hydraulic Cap 8A Gas Valve O-ring
03 Gas Cap 09 Protective Strap
04 Piston 9A Protective Screw
05 V O-ring 10 Name Plate
5A Backup Washer 13 Port Protector
07 End Seal O-ring 15 Mounting Bracket Assembly
7A Backup Washer
Cooling
System
Edition 1
Cooling System
Safety Precautions............................................... 5
Applicable Models................................................ 5
General................................................................. 6
Cooling System.................................................... 7
Circuit ........................................................................... 8
Specifications .................................................................. 9
Checking Hydraulic Function ......................................... 9
Fan Motor .......................................................... 11
Cooling Fan : Bi-directional motor with speed control
...................................................................................... 12
Cooling Fan Maximum Speed..................................... 13
Time Limit of Reverse Fan Solenoid Valve .............. 13
Proportional Pressure Relief Cartridge ....................... 13
Proportional inverse pressure relief valve .................. 14
Parts List....................................................................... 16
Solenoid Operated Spool Valve .................................. 17
Check Valve ................................................................. 17
Cooling Fan : Bi-directional Motor .......................... 17
CAUTION!
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good
working order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
10 5 9
2
4
6 7 8
FG006719
Figure 1
Reference Reference
Description Description
Number Number
1 Radiator Assembly 6 Transmission
2 Fan Guard 7 Transmission Oil Filter
3 Fan Motor (Rear Side) 8 Block Valve
4 Cooling Fan (Rear Side) 9 Oil Tank
5 Engine 10 Radiator Cap
Figure 2
Reference Reference
Description Description
Number Number
1 Engine 6 Cooling Fan
2 Cooling Pump 7 Temperature Sensor
3 Cooler 8 Temperature Sensor
4 Electronic Unit (ECU) 9 Transmission
5 Fan Motor
Figure 3
4
2
5
1
FG004236
Figure 4
Reference Reference
Description Description
Number Number
1 Fan Motor 4 Drain Line
2 Fan Guard 5 Outlet Line
3 Inlet Line 6 Pressure Check Port
WARNING
A modifying program of the control unit is permitted by
an authorized person.
3 2 1
T
3/4"
23ccr
4
P
1/2"
L
7/16" FG004935
Figure 5
Reference Reference
Description Description
Number Number
1 Motor 3 Prop. Pressure Relief Cartridge
2 Solenoid Operated Spool Valve 4 Check Valve
Figure 6
Reference Reference
Description Qty. Description Qty.
Number Number
1 Front Bearing 1 9 Idler Gear 1
2 Seal 2 10 Valve Cover 1
3 Bearing Block 2 11 Bolt 4
4 O-ring 2 Prop. Relief Valve
12 1
5 Dowel Pin 4 Catridge
6 Gear Housing 1 Solenoid Operated
13 1
Spool Valve
7 Coupling 1
14 Check Valve Catridge 1
8 Drive Gear 1
ON
REVERSE
FAN S/V
OFF
FG005765
Figure 7 Time Chart
Function
The principal function of the pilot operated PRV is controls
the motor speed from idle to max. speed by infinitely
adjusting the applied solenoid current. Further, the PRV
protects the motor from over pressurization. Due to the fail
safe function, maximum PRV pressure is automatically set
when solenoid de-energized (motor runs at max. speed =
max. cooling power). Increasing solenoid current results in
decreasing induced spring force, thereby reducing valve
opening pressure (motor speed decreases). The nominal
pressure is factory set, not adjustable. Because of the pilot
operation, the minimal adjustable pressure drop across the
valve is slightly higher than for direct operated RV at the
same flow.
NOTE: In the case of bidirectional motor with pressurized
outlet port, the back pressure is added to the nominal
PRV setting (due to the internal PRV drain).
Screw-in cartridge
• Pilot operated
• Nominal pressure adjustable + 20 % / - 30 %
• Qmax = 100 l/min
• Pmax = 400 bar
• PN max = 200 bar
General Specifications
Hydraulic Specifications
Electrical Control
Figure 8
Figure 9
Reference Reference
Description Description
Number Number
10 Coil KJ35/16 - G24 40 O-ring Viton ID 18.77x1.78
20 Retaining Nut M16x1x9.2 50 O-ring Viton ID 15.60x1.78
25 Hexagon Nut M8x1 60 Backup Ring RD 14.6x17.5x1.4
30 O-ring Viton ID 14.00x1.78
WARNING!
A modifying pressure of the proportional relief valve is
permitted by an authorized person.
Check Valve
The AC check valve prevents cavitation and erosion during
motor speed deceleration and spin-down.
Figure 10
TANK
T
3/4"
23ccr
4
P
1/2"
L
7/16"
FAN MOTOR
5
3
FG006721
Figure 11
Reference Reference
Description Description
Number Number
1 Motor 4 Check Valve
2 Solenoid Operated Spool Valve 5 Cooler Pump
3 Pressure Relief Cartridge
Reference Reference
Description Qty. Description Qty.
Number Number
1 Front Bearing 1 9 Idler Gear 1
2 Seal 2 10 Valve Cover 1
3 Bearing Block 2 11 Bolt 4
4 O-ring 2 12 Relief Valve Catridge 1
5 Dowel Pin 4 13 Solenoid Operated 1
6 Gear Housing 1 Spool Valve
7 Coupling 1 14 Check Valve Catridge 1
8 Drive Gear 1
Pilot System
Edition 1
Pilot System
Safety Precautions............................................... 5
Applicable Models................................................ 5
Overview............................................................... 6
Function ................................................................ 7
Block Diagram ..................................................... 8
FNR Lever + 2 Spool Control Valve ........................... 8
FNR Lever + 3 Spool Control Valve ........................... 8
Finger-tip 2 Lever + 2 Spool Control Valve................ 9
Finger-tip 3 Lever + 3 Spool Control Valve................ 9
Walvoil FNR Joystick ........................................ 10
Specification .................................................................. 10
Parts List....................................................................... 11
Finger-tip Joystick .............................................. 12
Specification .................................................................. 12
Parts List....................................................................... 13
CAUTION!
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good
working order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
8 1
6 5
7
FG006724
Figure 1
Reference Reference
Description Description
Number Number
1 Oil Tank 5 Main Control Valve
2 Pilot Control Valve 6 Aux. Control Valve
3 Brake & Pilot Supply Valve 7 Pilot Accumulator
4 Pilot Plate 8 Brake & Pilot Filter
Figure 2
Figure 3
Specification
Hydraulic Fluid ISO VG #46 or SIMILAR
Ambient Temperature -29 ~ +93 °C
Hyd. Oil Temperature -20 ~ +100 °C
Vibration 3 -5G/ 30Hz
Shock 10G
Supply Pressure 28 kg/cm2 (398 psi)
Supply Flow 42 lpm
Contamination NAS 9 Grade after Flushing
Reference
Description
Number
P Brake & Pilot Supply
Valve (PL port)
T Tank Return
1 Boom Up
2 Bucket Crowd
3 Boom Down
4 Bucket Dump
5 Option
6 Option
Figure 4
Figure 5
OIL TANK
T B1 B2 a1 a2
P A1 A2 b1 b2
PL
FG006726
Figure 6
Figure 7
Specification
Supply Pressure Max. 100 bar (1450 psi)
Control Pressure Max. 28 kg/cm2 (398 psi)
Breakaway Pressure 4.5 bar
Return-line Pressure Max. 3 bar (44 psi)
Control Flow Max. 15 l/min (4 USgpm)
Hysteresis Max. 0.5 bar (7.3 psi)
Ambient Temperature -40 ~ +60 °C
Hyd. Oil Temperature -20 ~ +70 °C
Leakage Max. 20 cm3/min
(From pump connection to tank with the spool in neutral position and a supply pressure of
40 bar)
System Voltage 24V
Reference
Description
Number
P Brake & Pilot Supply
Valve (’PL’ port)
T Tank Return
A1 Bucket Dump
A2 Boom Down
A3 Aux. (A port)
B1 Bucket Crowd
B2 Boom Up
B3 Aux. (B port)
Figure 8
Figure 9
1Hydraulic
Schematic
DL250
Edition 1
Safety Precautions............................................... 5
Applicable Models................................................ 5
DL250 ................................................................... 7
CAUTION!
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good
working order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
P
2
3/8", Brake P=60–3kgf/cm
3/8", Brake P=60–3kgf/cm 2
T
CLOSES 3 Bar
STOP
* JOYSTICK VALVE * OPTIONAL EQUIPMENT
(3-SPOOL OPT) Kick-down Horn
OPENS 25 Bar
T/M DISCONNECT
REAR AXLE DUMP CROWD AUTO RETURN RAISE LOWER OPT OPT
TO DIG
E/G
T
P
R.H Brake pedal
4 3 2 1 5 6
0.46 BAR
30B 30B
15B
0.75L 65bar 0.75L
parking brake
0.32L
(PFO1/4) (PFO3/8) (PFO3/8) (PFO3/8)
TP1 JOYSTICK VALVE
(PFO3/8) A1 LPWS P1 P2 A2 A3 (PFO1/4)
1.5 BAR (STD) Kick-down Horn
C3-1 C3-2
0.5" 28 kgf/cm2 C4
0.5"
FO SAFETY
20 abs. (PFO1/2)
T
C3 PARK P
(PFO3/8)
2 4 3 1
100 L/MIN FI 120 kgf/cm 2
(PFO1/2) C1
LPWS
C6 C5
T 160 kgf/cm2
OIL COOLER 3/4" 3/4" M
PK
(PFO1/4)
1" (PFO1/2) P
23ccr A4 T1 T2
(PFO3/8) (PFO3/8) (PFO1/4)
30B
P 200 BAR
BRAKE/FAN/PILOT * TUV only 0.75L
PUMP 3/4"
3
19.8 cm/rev L
7/16" 90–5 Bar
STEER PUMP 1200–50 rpm BRAKE & PILOT & FAN MOTER SUPPLY VALVE
3
63.8 cm/rev
FAN MOTOR BUCKET
LOADER PUMP a1 b1
3
58.3 cm/rev
BUCKET CYL.
BLOCK (DUMP)
VALVE
P1 P3 BOOM
a2 b2
1.25 1.25"
C3 TPM BOOM CYL.
0.25"
TPU
< EF
STEER
O.25" 0.75
UNIT 275 BAR
C1 (LOWER/FLOAT)
C2 A2
P T
140x 80X777 (RAISE)
160 B2
<
(LOWER)
C 4L
PRE CHARGER: 20 BAR
1"
P-controller
HT 0.75 X2 T
B 62 Bar
R2 6B BR
M 10ccr
EMR.STEERING S/W
15BAR 15BAR
CUSHION V/V
< <
FG006727
Figure 1
Air Conditioner
Edition 1
Air Conditioner
Safety Precautions............................................... 5
Applicable Models................................................ 5
General Description ............................................. 6
Refrigerant Circulation ......................................... 8
Control Panel ..................................................... 10
Control Specifications ........................................ 11
Temperature Level Control and Display .......... 12
Air Discharge According to Path Selection ..... 13
Air-conditioning System Circuit Diagram.......... 16
Troubleshooting .................................................. 18
Weight of R134a Gas Used In Machines....... 20
Refrigerant System Repairs .............................. 21
Refrigerant Safe Handling Procedures ....................... 21
Repair and Replacement Procedure........................... 22
Refrigerant Recovery.................................................... 24
Vacuuming Refrigerant System ................................... 24
Leakage Check............................................................. 26
Refrigerant Charging .................................................... 26
Inspecting System for Leakage................................... 28
CAUTION!
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good
working order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
FG009195
Figure 1
The heater and air conditioner are combined into one blower
unit in the right control stand of operator's seat. If
necessary, the operator can control inner temperature using
the operation panel installed in the top of the right side
door.
WARNING!
All service and inspection of the air-conditioning system
should be performed with the starter switch in the "O" AJS0530L
(OFF) position. Figure 2
4
7
3
HBOI020L
Figure 3
Reference Reference
Description Description
Number Number
1 Evaporator 5 Compressor
2 Expansion Valve 6 Blower Fan
3 Condenser 7 Receiver Dryer
4 Condenser Fan
WARNING!
Refrigerant gas is pressurized and sealed in the
air-conditioning system. Special precautions are required
for the proper recharging or release of refrigerant.
Release of refrigerant into the atmosphere is strictly
regulated by law. Make sure that you are in compliance
with all mandated federal, state and municipality
requirements, before starting any service or repair of the
air conditioner. Refrigerant gas used in the system must
meet or exceed specifications for R134a refrigerant, or
any subsequently issued environmentally mandated
standard.
FG004455
Figure 4
HDA6048L
Figure 5
50%
MAX HOT
0%
HDA6049L
Figure 6
LOW RELAY
HDA6050L
Figure 7
COMP OFF
1.5 C 4.0 C
HDA6051L
Figure 8
FG009196
Figure 9
Foot + Rear
FG009197
Figure 10
FG009198
Figure 11
3
5 2
B A
3 II
10 9
15-1 15-2
15 + -
M
14
LED 1~12
7
8 87a
30
3 11 HIGH
5 12 MID
- + 87
M 8 13 LOW
85 86 18 9 REC
19 10 FRE
10 M
15-6
MODE SELECT
23 7 VENT
AIR MODE
9 21 17 DEF
87a
RECIRCLE/FRESH 20 8 FOOT 15-7
30 BLOWER SPEED
M
87 TEMP. CONTROL
85 86 14 3 (WARM)
15 2 (COOL) M
2 4
9 16 5
15-8
4 1
DEF 2 7 1 6
10 M FOOT
3 6
15-9
26 16
CN7 HRS 26P
CN1 AMP MIC 13P + 250 4P
14
11 15
HRS NO.GT7A-26PD-DS 26P AMP MIC 13P
6 5 4 3 2 1
13 13 12 11 10 9 8 7 6 5 4 3 2 1
12 26 25 24 23 22 21 20 19 18 17 16 15 14
13 12 11 10 9 8 7
(CN7) (CN1)
FG004394
Figure 12
Figure 13
WARNING!
Always wear protective glasses and gloves when
handling refrigerant. If refrigerant comes in contact with
the skin or eyes, immediately flush with clean, running
water and consult a physician.
Select a clean and well ventilated area to work.
The refrigerant container is under high-pressure and
should be stored below 40°C (104°F). Be careful not to
drop the container from a high location
The contents are under high-pressure and should not be
used with compressed air or near an open flame.
UNION NUT
TORQUE WRENCH
CORRECT WRONG
WRONG
WRONG
CORRECT
O - RING POSITION
HDA6066L
Figure 14
RECOVER REFRIGERANT
RUN SYSTEM
Reference
Description
Number
1 Handle
2 Hose Connection
3 Mounting Disk
Reference
Description
Number
Refrigerant Leak
1
Detection Device
WARNING!
For accurate refrigerant leak detection, perform leak
detection procedure in a well ventilated area.
Refrigerant Charging
1. Perform the vacuuming procedure, vacuum holding and
leaking tests as described in the proceeding headings.
NOTE: First charge the refrigerant system with 100 g
(3.5 ounces) of refrigerant with the engine off.
Then using the manifold gauges as a guide fully
charge the system with the engine running.
When exchanging refrigerant containers, press
the manifold gauge low side valve to eliminate
air from the charging hose.
2 Low-pressure Side
3 High-pressure Side
4 From Receiver
5 Refrigerant Supply
Container
5
2. Charge the system by opening the manifold gauge low HDA6072L
side valve. Figure 21
Initial charge amount: 100 g (3.5 ounces).
3. If refrigerant does not flow freely into system, try
starting engine first before operating air conditioner.
• Temperature control switch setting: Maximum
Cooling
• Blower Speed Setting: Hi (3 step)
• Engine Speed: 1,300 - 1,500 rpm
WARNING!
When charging refrigerant system with the engine
running;
• Always keep refrigerant supply container in
the upright position.
Never open the high side pressure valve.
Reference
Description
Number Figure 22
1 Pressure
2 High-pressure
3 Low-pressure
4 Compressor Stop
Inspection Procedure
1. High-pressure side.
Compressor outlet → condenser inlet → receiver dryer
inlet → air conditioner unit inlet
2. Low-pressure side.
Compressor inlet → air conditioner unit outlet
3. Compressor.
Compressor shaft area, bolt hole area and magnetic
clutch area.
4. Receiver dryer.
Pressure switch and plug area.
Electrical
System
Edition 1
Electrical System
Safety Precautions............................................... 5
Applicable Models................................................ 5
Overview............................................................... 6
Electric Supply System ....................................... 7
Engine Starting Circuit ........................................ 9
Operation During Start Process .................................... 9
Operation After Start Process ..................................... 12
Engine Preheating System ............................... 15
Engine Stop System ......................................... 16
Charging System ............................................... 17
Monitoring System ............................................. 18
Instrument Panel .......................................................... 19
Function Check............................................................. 20
Monitoring System Schematic ..................................... 20
Operation....................................................................... 22
Windshield Wiper ............................................... 28
Front windshield wiper ................................................. 28
Rear Windshield wiper ................................................. 30
Lighting System ................................................. 32
Light Circuit................................................................... 32
ECU System ...................................................... 36
ECU Electric Circuit ..................................................... 37
ECU System Component............................................. 38
Engine Fault Code ............................................ 41
Cooling Fan Control System ............................ 45
Outline ........................................................................... 45
Diagram......................................................................... 46
Electrical Diagram ........................................................ 47
Parts of Cooling Fan Control System ........................ 48
Operation of Cooling Fan Control System................. 50
CAUTION!
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good working
order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
Symbol Color
W White
G Green
Or Orange
B Black
L Blue
Lg Light green
R Red
Gr Gray
P Pink
Y Yellow
Br Brown
V Violet
BR
E
8
R B+ I
B+
I(L)
REG. - + - +
7
FIELD F+
F-
1
E
GND
FG006702
Reference Reference
Description Description
Number Number
1 Battery 5 Starter Switch
2 Battery Relay 6 Fuse Box
3 Fusible Link 7 Alternator
4 Circuit Breaker 8 Diode
67
11
F ACC
N C
R B
R2
BR
5 R1
3
6
2
4
B A
BR
E
12
R B+ I
12
B+
I(L) - + - +
REG. 10
1
FIELD F+
F-
E
#6
#4
(CONN.1) (CONN.3)
FG006703
Figure 2 STARTER CIRCUIT (1) - WHILE STARTING
67
11
F ACC
N C
R B
R2
BR
5 R1
3
6
2
4
B A
BR
E
12
R B+ I
12
B+
I(L) - + - +
REG. 10
1
FIELD F+
F-
E
#6
#4
(CONN.1) (CONN.3)
FG008325
Figure 3
6
4
2
ACC C B A
B 5
R2 BR
9
R1 BR E
12
CN2-1
7 1
STARTER SWITCH CONNECTION
-
TML D H
PST B BR R1 R2 C ACC
OFF
PREHEAT 10
ON
START +
FG008326
Figure 4 ENGINE PREHEAT CIRCUIT
Reference Reference
Description Description
Number Number
1 Battery 7 Air Heater Relay
2 Battery Relay 8 Engine Control Unit (ECU)
3 Fusible Link 9 Preheat Indicator Light
4 Circuit Breaker 10 Air Heater
5 Starter Switch 11 Engine Thermo Sensor
6 Fuse Box 12 Diode
ACC C
6 B 5 4 2
R2 B A
BR
R1 7
BR
E
1-40
1-05
1-06
1-10
1-11 - + - +
8
1-02
1-03
STARTER SWITCH CONNECTION
1-08
1
TML 1-09 #1~#6
PST B BR R1 R2 C ACC
OFF
PREHEAT 9
ON
START
FG008327
Reference Reference
Description Description
Number Number
1 Battery 6 Fuse Box
2 Battery Relay 5 Diode
3 Fusible Link 8 Engine Control Unit (ECU)
4 Circuit Breaker 9 Injector Solenoid
5 Starter Switch
6
3
9
8
CN1-1
4 2
B A
1
CHARGE CN2-5 4 2 BR
L5
E
BUZZER CIRCUIT
6 8
R B+ I
8
7
B+
10 9 I(L)
13
REG. 7 - + - +
FIELD F+
10 F-
1
E
GND
FG008328
Figure 6 CHARGING CIRCUIT
Reference Reference
Description Description
Number Number
1 Battery 6 Fuse Box
2 Battery Relay 7 Alternator
3 Fusible Link 8 Diode
4 Circuit Breaker 9 Gauge Panel
5 Starter Switch 10 Control Unit
17 2
+
3
-
B+
16 W
D+C
15 5
20
30 15
20
6
10
40
10 25
5
50 30
0 0
km/h x100r/min
CHECK
STOP
F/R
7
J O
I II
12 10 11 9 8
FG006500
Figure 7
Reference Reference
Description Description
Number Number
1 Instrument Panel 10 Turn Signal Light Switch
2 Battery 11 High Beam Switch
3 Alternator 12 Working Light Switch
4 Speed Sensor 13 Brake Oil Pressure Switch
5 Coolant Temperature Sensor 14 Parking Brake Pressure Switch
6 Fuel Sensor 15 Transmission Cutoff Switch
7 Transmission Oil Temperature 16 Control unit
Sensor 17 Engine Control Unit (ECU)
8 Air Cleaner Indicator
9 Hazard Warning Light Switch
9 8 1 7 2 16 17
30 15
20 20
10 10 18
40
10 25
5
11 19
50 30
0 0
km/h x100r/min
12 20
F/R
13 21
14 15 4 5 6 22
HOURS
1
10 3
Figure 8
1 25 24
R B+ I B A
CN1 AMP MIC 13P
+ SIG CN1-4 B+ BR
SPEED -
I(L) E
+ S CN1-3
TACHO -
REG. 9
+ S CN1-6
WATER - 11 FIELD F+
TEMP F-
+ S CN1-7 E - + - +
FUEL - 12 12V 150AH 23 12V 150AH
+ S CN1-8 GND
T/M OIL - 13
TEMP CN1-13
10 27
2-3 1-4 CN3-8 3
HOUR 1
26
2
2-4 2-1 CN3-1
CN3-4
CN3-3 21
2
ILLUMINATION
CN1-9
CN1 AMP MIC 13P
CN1-1
CHARGE CN2-5 3 1
L5
SPARE CN2-4 4 2
L4
MIRROR HEATING CN2-12
L12 BUZZER CIRCUIT
BRAKE OIL PRESS
L10
CN2-10 6
8
3
PARK BRAKE CN2-16 7 22
L16
AIR CLEANER CN2-2 87a
L2 4 30
SPARE CN2-3 10 9 87
L3
F/R SELECT CN2-11 13 85 86
L11
REVERSE FAN CN2-13
L13
CN1-10 20
WORKING
L9
CN2-9 8
TURN SIGNAL (R)
L8
CN2-8 7
TURN SIGNAL (L)
L6
CN2-6 6
HI BEAM
L7
CN2-7 5
ELEC. STEERING CN2-14
L14 36
EMG STEERING CN2-15 14
L15
CN1-2 7 19
PREHEAT CN2-1
L1
CN1-5
E/G DIAGNOSTIC CN2-17
L17 1-13
CN1-11
1-56
CN2 AMP MIC 17P
1-22
1-56
15
14
1-33
18
17 FG008329
Figure 9
Instruments
Sensor Specification
Function Display Input
Input Specification
Terminal
10 km/h- 704 Hz
20 km/h- 1407 Hz
30 30 km/h- 2111 Hz
20
40 CN1-4 40 km/h- 2814 Hz
Speedometer 10
CN1-5 *ƒ = 70.36 V [Hz]
50
0 km/h ƒ : Frequency of T/M
Controller
v : Speed [km/h]
500 rpm - 100 Hz
1000 rpm - 200 Hz
15
20 1500 rpm - 300 Hz
10
2000 rpm - 400 Hz
Tachometer 25 CN1-3
5
2500 rpm - 500 Hz
30
0 *ƒ = 0.2 N [Hz]
x100r/min
ƒ: Frequency
N : Engine rpm
ALTERNATOR "I"
Hour Meter
Terminal voltage (24V)
HAOA601L
(1/2)
EMPTY FULL
EMPTY - Above 90 Ohm
Fuel Level
CN1-7 1/2 - 38 Ohm
Gauge
FULL - Below 10 Ohm
120 C
50 C 150 C
50°C - Above 188 Ohm
Transmission Oil
Temperature CN1-8 120°C - 21 Ohm
Gauge
150°C - Below 0.7 Ohm
Input
Description Symbol Operation Remarks
Terminal
Lights up while the air
heater is heated.
Forward /
Reverse F/R CN2 - 11
Initial Operation
Input
Item Output (Operation and initial setting mode)
(Terminal)
Initial Operation CN 1-1 • All warning lights are turned "ON" and turned "OFF" after 2
seconds.
(Except for turn signal indicator, high beam indicator, working
light indicator and transmission cutoff indicator and
emergency steering indicator.
• Warning buzzer is activated and turned "OFF" after 2
seconds.
• Monitoring system displays present condition.
5
1
2
MIRROR HEATING
L12 6
AIR CLEANER
L2 7 8
F/R SELECT 3 1
L11
REVERSE FAN 4 2 I
L13
CHARGE
L4
6
BUZZER CIRCUIT 3
L5
7 8
BRAKE OIL PRESS 87a
L10 30 4
PARK BRAKE 10 9 87
L16
13 85 86
13 12 11 10 9 8 7
FG008076
Figure 10
Reference Reference
Description Description
Number Number
1 Instrument Panel 7 Pilot Buzzer
2 Starter Switch 8 Alternator
3 Forward Lever Switch 9 Brake Oil Pressure Switch
4 Reverse Lever Switch 10 Parking Brake Pressure Switch
5 Fuse Box 11 Alarm Relay 2
6 Control Unit
Characteristic of Operation
Input Output
All warning lights are turned
1 When the starter switch is "ON." "ON" and turned "OFF"
after 2 - 2.5 seconds.
Battery warning light turns
is below 12 ± 1 V
When "I" terminal voltage "ON," L5
2
of alternator Battery warning light turns
is above 12 ± 1 V
"OFF," L5
Warning buzzer sounds
Brake oil pressure switch is "ON."
When "I" terminal voltage immediately
3 of alternator is above Forward or Reverse lever switch is "ON"
12 ±1 V Warning buzzer sounds
and Parking brake pressure switch is
immediately
"ON."
6
+ (R) -
P
+ (F) -
P
1
7
2
CN5-6 15(53a)
CN5-8 53c
CN4-2 H
CN5-7 J
H CN5-3 53b
L CN5-1 53
87a CN5-4 31b
S
5 LO 30
HI 87 TML J 0 I II OFF ON OFF ON
M SW WIPER WASHER HORN
STOP B 86 85
- RUN
E
3
4 1
2
5 4 3
FG004463
Figure 11
Reference Reference
Description Description
Number Number
1 Fuse Box 2 5 Wiper Motor
2 Wiper Washer Switch 6 Washer Tank
3 Wiper Relay 7 Diode
4 Wiper Timer
3
B
+
STOP RUN E
2
M L 2
4 II
-
S 6 0
5 I 7
10 9
5 5
5
+ (R) -
P
+ (F) - 4
P
FG004464
Figure 12 REAR WINDSHIELD WIPER 1ST ACTION CIRCUIT
Reference Reference
Description Description
Number Number
1 Fuse Box 1 4 Washer Tank
2 Wiper/washer Switch 5 Diode
3 Wiper Motor
3
B
+
STOP RUN E 2
M L 2
4 II
-
S 6 0
5 I 7
10 9
5 5
5
+ (R) -
P
+ (F) - 4
P
FG004465
Figure 13 REAR WINDSHIELD WIPER STOP CIRCUIT
Reference Reference
Description Description
Number Number
1 Fuse Box 1 4 Washer Tank
2 Wiper/washer Switch 5 Diode
3 Wiper Motor
Light Circuit
22
87a
30 28
87 87a 29
30 87a
(RR) 85 86 87 30
87
(FR) 23 85 86
85 86
19 (RL) 21
20 1
5 0
(FL) 7 6 I 2
(CR)
10 9 3 II
24 9 10 27 -
18 (CL)
18 +
17
1
CN2-9 L9 WORKING
CN2-7 HI BEAM
L7
CN2-6 TURN SIGNAL (L)
L6
CN2-8 TURN SIGNAL (R)
L8 B 26
CN1-2
2 E B ACC
7
L
1 8 3
10 11 5 87a
30
7 87 0
6 I 2
2 85 86
6 3 II
1 5 4 6 3 2 2 3 6 4 5 1 8 9 10
10 9
(clearanc)
(turn sig)
(turn sig)
18 TML N
(high)
(high)
(low)
(low)
CN4-8
49a
CN4-4 R
CN4-1 L
CN4-5
56
4
CN4-6
56b
CN4-7
56a
CN4-9
15/1
25
(clearanc)
(clearanc)
(back up)
(back up)
(turn sig)
(turn sig)
(stop)
(stop)
9
C A B E F D D F E B A C 87a
30
87
F
85 86
14 16 15 R
5
FG004467
Figure 14 LIGHT CIRCUIT
30
20
40
7 10
0 50
Km/h
e-doctor
ECU
1
14P
10
3 2 1
7 6 5 4
11 10 9 8
14 13 12
FG005280
Figure 15
Reference Reference
Description Description
Number Number
1 ECU (Engine Control Unit) 7 Tacho Meter
3 Electronic Accelerator Pedal 8 Transmission Controller
4 Engine Diagnostic Connector 10 Fuse Box
5 Engine Check Warning Light
ECU CONNECTOR
DIAGNOSTIC CONN. 14P
12 17 18 35
36 53
3 2 1
7 11 54 71
7 6 5 4
1 6 72 89
11 10 9 8
14 13 12
ECU
ENGINE VEHICLE
CONN CONN
GAUGE PANEL
3 2-32 1-30 0.5BW DIAGNOSTIC LAMP (-)
OIL PRESSURE P& 4 2-27
SENSOR 1-22 0.5YB DIAGNOSTIC LAMP (+)
(ODFT)
t 1 2-42 PREHEAT LAMP (-)
1-56 0.5LB
(0 281 002 420) 2 2-28 CIRCUIT BREAKER
V
+ FUSE 2 (1)
1-33 0.5WG TACHO S
- TACHO
3 2-33 10A
BOOST PRESSURE P& 4 2-34
SENSOR 1-65 0.85YR
(LDFT)
t 1 2-25
(0 281 002 576) 2 2-36
V
ECONOMIC-MODE SW
1 2-23 1-62 0.85YL 1
5
CRANKSHAFT SPEED SENSOR N 2 2-19 7
(TONE WHEEL WITH SLOTS) ACCELERATOR PEDAL
(0 281 002 662)
V 1-77 0.5R A 10 9
0.5B
1-79 0.5G B PT POSITION
2 2-09 SENSOR
1-78 0.5B C
CAMSHAFT SPEED SENSOR N 1 2-10 1-48 0.5Or E IDLE
(TONE WHEEL WITH PINS) VALIDATION
(0 281 002 662) V F
0.5BL D
1 2-15
COOLANT TEMPERATURE t 1-29 0.5BL 0.5BL
2 2-26
SENSOR V
FUEL TEMPERATURE 2 E/G EMERGENCY STOP SW
SENSOR
t 2 3
1 2-35 1-87 0.5R
(0 281 002 209) V
DIAGNOSTIC SW
3 2-13 0.5BL
1-85 0.5WB 1
RAIL PRESSURE SENSOR P 2 2-14 5
(RGS3) 7
(0 281 002 534) V 1 2-12
0.5B 10 9
(CONN.2)
1-35 0.5Y CAN B H
(CONN.3) (CONN.1)
GROUND TO FRAME
FG006729
Figure 16
14P
3 2 1
7 6 5 4
11 10 9 8
14 13 12
FG005201
Figure 18
Figure 19
FG004339
Figure 23
ACCELERATOR ASS’Y
A 0.5R
POSITION PT B 0.5B
SENSOR
C 0.5W
IDLE E 0.5G
VALIDATION
F 0.5L
D 0.85Or
FOOT PEDAL
DETAIL "A"
D A
E B
"A"
F C
HI
Sig 3 LO
Sig 2 HI LO
PEDAL SENSOR IDLE VALIDATION SW. 100%
Diagnostic
Region
WHITE BLACK RED BLUE ORANGE GREEN 91%
OV C B A +VE F D E
C.W. C.W. 73%
70.63%
A 15.4%
B THROTTLE POSITION SIGNAL BLACK 10.92%12.56%
Vct + 0.03 X Vspan
E 9%
C THROTTLE POSITION RETURN WHITE 3%
F 0%
48.3 W.O.T
Diagnostic
53.3 MIN
0 Datum -2.7
-15.2
-11.9
-7.4
45.8%
D COMMON ORANGE
58.3
-5.2 C.T
D Region
44
Degrees Travel
E OFF IDLE POSITION (NO) GREEN
PEDAL SENSOR F ON IDLE POSITION (NC) BLUE Driver Travel
Sensor Rotation
FG006510
Figure 24
Outline
It controls the speed of cooling fan according to temperature of
coolant or transmission oil.
Its reverse rotation function can be used for cleaning.
Information on temperature of coolant and transmission oil are
sent to the cooling fan controller via communication line (CAN).
9 10
3
1
4
ECU
5
6 3 1
4 2
7
11
FG005241
Figure 25
Reference Reference
Description Description
Number Number
1 Cooling Fan Controller 8 ECU
2 Reverse Rotation Lamp 9 Transmission Controller (TCU)
3 Cooling Fan Reverse Switch 10 Transmission Oil Temperature
4 Cooling Fan Proportional Valve Sensor
5 Reverse Rotation Solenoid 11 Coolant Temperature Sensor
6 Fuse Box
7 Fan Check Connector
14
6
15 13
ACC C B A
B
AMP 040 36P R2 BR
R1 BR E
10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11 16 15 14 13 12 11 10 9 16 17
(CN12) (CN11)
- + - +
2 12
CN1-1
CN2-13
L13
9
10
8
1-35 J1939 (+) 25
1-34 J1939 (-) 26 120 OHM
1-33 27
1-53 28
1-52
1-51
11
1
CN11
CN12-1
CN12-4
CN11-1 CN12-2
4
CN11-2
5
CN11-3 CN12-11
6
7 11
CN12-12
BATTERY (+) CN11-4
1
12 CN11-5
BATTERY (-) 2
13
18 3
CN11-6 3
CN11-7 CN11-13 1
4
5
CN12-13 7
4 CN12-14
10 9
CN12-19
5 CN12
FG005183
Figure 26
Reference Reference
Description Description
Number Number
1 Cooling Fan Controller 10 Transmission Oil Temperature
2 Reverse Rotation Lamp Sensor
3 Cooling Fan Reverse Rotation 11 Coolant Temperature Sensor
Switch 12 Battery
4 Cooling Fan Proportional Valve 13 Battery Relay
5 Reverse Rotation Solenoid 14 Fuse Lamp Link
6 Fuse Box 15 Circuit Braker
7 Engine Diagnostic Connector 16 Start Switch
8 ECU 17 Diode
9 Transmission Controller (TCU) 18 Fan Check Connector
Figure 28
FG004939
Figure 29
Figure 30
FG004492
Figure 31
Communication Monitoring
1. Communication port
A. SAE J1939 datalink
B. CAN H, CAN L, SHIELD
2. Communication failure
A. E0, E1, or E2 is shown on the controller display.
B. If there shows no error message, it means normal
operation.
Current Current
< Transmission Oil Temperature vs. current > < Coolant Temperature vs. current >
FG008075
Figure 32
Rotation
LED
All the segments light up for one second when power is first
supplied to the controller.
Block Diagram
3
5
6
8
4
FG004925
Figure 33 EMERGENCY STEERING SYSTEM BLOCK DIAGRAM
Reference Reference
Description Description
Number Number
1 Fuse Box 6 Emergency Steering Indicator
2 Emergency Steering Switch 7 Transmission Controller
3 Emergency Steering Timer 8 Battery
4 Emergency Steering Pressure 9 Main Steering Pressure Switch
Switch
5 Emergency Steering Pump
operation is following.
FG004921
Figure 34
4
A B
5 C
1 4 D
S0
6 S3
8
7 S1 3
2
7
1
8 S2 6
E1 (28V) 9 S4 9 5
SPEED
3
FG004923
Figure 36
Reference Reference
Description Description
Number Number
1 Emergency Steering Timer 6 Starter Switch "START"
2 Emergency Steering Indicator 7 Main Steering Pressure Switch
3 Transmission Controller (TCU) 8 Emergency Steering Pressure
4 Emergency Steering Pump Switch
5 Starter Switch "ON" 9 Emergency Steering Switch
AJS0480L
Figure 37 EMERGENCY STEERING PUMP
WARNING AJO0011L
A
11
C
5
- + D P
8
E
2
1 10 5 1
0
2 I 6 9 10
II 3
10 9
4
9 3
4 3bar
1 7
6
8
10bar
3
C 7
ACC 36 2
B 9 5 6
12
FG004924
Figure 39 EMERGENCY STEERING SYSTEM CIRCUIT
Reference Reference
Description Description
Number Number
1 Fuse Box 8 Diode
2 Emergency Steering Switch 9 Transmission Controller
3 Emergency Steering Timer 10 Headlight Switch
4 Main Steering Pressure Switch 11 Battery
5 Emergency Steering Pump 12 Starter Switch
6 Emergency Steering Indicator 13 Emergency Steering Pressure
7 Emergency Steering Pressure Switch
Switch
Electric Circuit
7 2 87a
11 30
87
10
+ 2 85 86
O 1
-
5 12
7
10 9 4
8
1 6
12
87a 3 87a
30 10 30
87
11 87
+ 85 86 86
O
12 85
- 12
1
9 5 3
+
O
-
FG004461
Figure 40 ELECTRIC DETENT CIRCUIT
Reference Reference
Description Description
Number Number
1 Fuse Box 2 7 Float Magnetic
2 Float Kick-out Switch 8 Return to Dig Magnetic
3 Raise Relay 9 Raise Proximity Switch
4 Float Relay 10 Float Proximity Switch
5 Return to Dig Relay 11 Return to Dig Proximity Switch
6 Raise Magnetic 12 Diode 3ea
HA0O2027
Figure 41
MAIN POWER
CIRCUIT
AJS0510L
Figure 42
1Electrical
Schematic
DL200/ DL250
Edition 1
Safety Precautions............................................... 5
Applicable Models................................................ 5
DL200/ DL250...................................................... 7
CAUTION!
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good
working order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
DIODE 3
(ENG STOP) CN2-4 2.5RG 18B
L4 B 23D 0.85L CIGAR LIGHTER
AMP 040 36P 11C 4C
P E
+
CHARGE CN2-5 107A 0.5W 0.5W 107B 3 1 26B 0.85R STOP RUN E 0.85B 1.25WG
L5 REAR WIPER SW 2RW 0.85BY
11B
10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 ECU CON.3 (16-PIN) ECU CON.2 ( PIN) (ENG MAINTENANCE) CN2-3 4 2 9C 0.5RW M L 24A 0.85LW 1.25B 0.85B
0.85LW 24C 4 II 2 0.85B 0.85WL 209B CC-TV - 0.85BY
20 19 18 17 16 15 14 13 12 11 16 15 14 13 12 11 10 9 CYLINDER CONN. ENGINE CONN. L3 TIME DELAY - DA2-1 4P CONN(1)
BRAKE OIL PRESS CN2-10 110A 0.5YL 0.5YL 110B 6 S 181B 0.85Y 1.25W 1.25W + 3W
5 1 0.85YB 25A 6 0
L10 BUZZER CIRCUIT
1.25WR
0.85WL
1.25RB
1.25RY
0.85RY
(CN12) (CN11)
1.25W
181A 25B 7
0.85L
32D 5 0.85B 151B
2RW
2RG
2RY
PARK BRAKE 111A 111B 7 I
CN2-16 0.5Lg 0.5Lg
0.85RG
L16 24B 10 1.25WR 1.25WR
REAR WIPER MOTOR 9
CN1-10 115A 0.85LR 8 57B 0.5BrW 2 60E 0.5WR 3Y
197A 143A 152A 20A 106A 14A 23A 41A 114A 209A 151A 81A 6A 11D
EMG STEERING (OPTION) ELEC. STEERING CN2-14 187F 0.5LY 0.85B 13
DA2-2
6 0.5B EMG STEERING
L14 DA2-3 9 10 11 12 13 14 1 2 3 4 5 6 7 8 8 STARTER
B 0.85L 23C 32B 0.85BR 32C 0.85BR TIMER
7 3 5B C 24V 4.5KW
EMG STEERING CN2-15 205B 0.5RW 0.85LR 115B 10 9 183B 0.85LB 30A 20A 15A 15A 15A 15A 10A 10A 10A 10A 10A 10A 10A 10A
L15 2WR 2WR 2WR
A 60R B
STARTER 149C 17 18 2C 15 16
WORKING CN2-9 0.5RL 0.5RL 0.5RL 123B 0.85RY 4G 5W 5W 4D 2B B
C 13G 0.85LR L9 WINDOW WASHER 15R 157A
EMG STEERING PUMP 0.5GR 0.5GR HORN (H)
13H TURN SIGNAL (R) CN2-8 84C 0.5GR H.F 0.85B 0.85RG
P D 207A L8 0.85L 23B + (R) - 32A 0.85BR FUSE BOX 2 FUSE BOX 1
0.85W 0.5GL 0.5GL P 5W 5W BLINKER 60R
1.25WR
0.85LR
0.85BY
DIODE 5 TURN SIGNAL (L) CN2-6 85C 0.5GL UNIT
L6 0.5R 0.5R 81B
E + (F) - 123C 0.85RY 4F 60BC 4E B
60B 0.85BR 96B 0.85B 11A
207B HI BEAM CN2-7 87B 0.5R P HORN (L) 15 16 0.85WR 17 18 15B 3WR
ACC
EMG STEERING SW L7 0.85YL 110C 0.85B L.F 0.85B E 0.85B C A
BRAKE OIL PRESS SW
65bar 10A 10A 10A 10A 10A 10A 10A 10A 30A 20A 15A 15A 15A 15A 13A
CN1-2 0.85B
0.85B 1 5 206B 0.85BR 111C 0.85BR 96C 8 4 0.85B B
0.85Lg 0.85B 1 2 3 4 5 6 7 8 9 10 11 12 13 14
PARK BRAKE PRESS SW L 10A BR 60B
PREHEAT CN2-1 153C 0.5WL 65bar 82A 6B 0.85Br
10 9 60M 0.5WR L1 DA2-4 26A 89A 33A 184A 92A 16A 17A 63A 59A 45A 105A 19B 19A R2
0.85BR 0.85BR 0.85GY 7A
0.5B CN1-5 113A 0.5LB
0.85WR
0.85WL
0.5G
0.85LB
1.25R 1.25R R1 FUSIBLE LINK 2
0.85RW
0.85LR
0.85BR
1.25LR
E/G DIAGNOSTIC 108B 0.5YB STARTER SWITCH
2RW
2RW
CN2-17 1.25RB 1.25RB 2RW
2RG
2RL
2RL
9 206A L17
0.85YB 0.85YB 0.85YB 2RW (K1001654A) 3WR 3R
208B 0.85WB 208A 3 4 207C 0.85W CN1-11 156A
MAIN STEERING 0.85B 0.85LR 0.85LR 0.85LR 5W 5W 5W 15A 1C
PRESS SW EMG STEERING 0.5BW 0.5G
3bar 1 13F 0.85LR CN2 AMP MIC 17P 2WR 0.5RW 0.85Br
TIMER FUSIBLE LINK 1
0.85B 204B 0.85WG 204A 6 8 11D 0.85BY C
STARTER SW FLOAT RELAY 2LR 2LR
EMG STEERING 10bar 0.85B 5 7 205A 0.5RW 0.5RW
34C 87a 0.85RW 0.85RW 0.5RW 2WR 2R
PRESS SW 0.85RY 0.85RY 30 33B 0.85RB 0.85Br
2 27C 0.5G 0.5G 34A 87 2RL 2RL 2RL 1.25LR 7B 60R 2A 1B
7
ELECTRIC STEERING 0.5LY DA1-3 2 0.5G
3 0.85RY 85 86 33C 0.85RB STOP LAMP SW (L) 0.85WL 0.85WL
EMG STEERING 0.85LR 11 3W
34B 0.85GW 88A 89B 0.85GY 1.25RG DIODE 2
174A 2R 3R
DIAGNOSTIC (-) 0.5BW 34B’ 5bar 0.85WR 0.85WR 0.85WR CIRCUIT BREAKER BATTERY RELAY
FLOAT 8A
ELECTRIC STEERING (OPTION) 1/2 DIAGNOSTIC (+) 0.5YB
MAGNET 0.85GY
5W 8W 8W
B A
0.85RG
0.5LB 1
1.25LR
PREHEAT (-)
0.5RW
0.5RW
0.85LY 83A HEAD LAMP RELAY LAMP SWITCH
HEAD LAMP(L) HEAD LAMP(R)
2RW
2RW
0.5LY 0.5LY HORN RELAY 4B 3B 3A
2LR
0.5WL 5 82B 0.85GY (2544-9033 ) (2549-9109 ) 1A
PREHEAT (+) 0.85LB 1.25BrW
21W 3W 70W 70W 70W 70W 3W 21W 0.85RY
SAUER-DANFOSS SUPPLY PART NC
C ELECTRIC STEERING 0.85YB
FLOAT KICK-OUT ASSEMBLY (OPTION) 87a
30 92B
7
87a 1.25RG +(2190-2036D4) 1.25BrW 8C BR
ELEC. STEERING RELAY 1 0.85YL NO 87 30 59B 0
JOY-STICK 184B TACHO 0.5WG 123A 83B 2 E
(JS-120) 185A 0.5LY 1.25WY 62A 87 60A
87a 185C (FLOAT KICK-OUT) 6 196A 6 I 2 1.25B
188A 1 30 ELEC. STEERING RELAY 2 ARM REST REVERSE FAN 0.5GB 85 86 0.5BrY
+ 33M 0.85RB FLOAT KICK-OUT SW 1 5 4 6 3 2 2 3 6 4 5 1 85 86 61B 81C 8B
0.85LY 87 87a CUT-OFF SWITCH 0.5WR 60T 8 0.5B 0.5WY 61A 3 II
189A 2 F/R SELECT 0.5LG 0.5B 95C 60R
30 173A 1 85B 16C 16D 87C 86B 86C 87D 17D 17C 84D
0.5WL
0.85LY
0.85YL O 173B 0.85W 60B 9 10
0.85B
60B 60R
0.85B
187C 86 187A 87 5 174B 0.85RY 10 9
190A 3 85 0.5B
0.85WR
0.85RW
0.85RW
0.85WR
185D
0.85WL
0.85WL
0.85GR
0.85GL
- 0.85B 0.5WR DIODE 1
0.85R
0.85R
7 0.85LB
187B 85 86 0.85LgB 185B 196B
0.85WR
0.85WR
0.85RW
0.85WL
0.85WL
CC-TV
0.85BR
60U
0.5BrW
0.5B
0.5GR
0.85G
0.5GL
0.5GL
0.5B 186E 186B 0.5BrY HAZARD SWITCH
0.5R
7 PROXIMITY SW 10 9 60 4P CONN(2)
2RL
0.5B 0.5WR 9B
(clearanc)
(clearanc)
0.85Lg 3 190B
(turn sig)
(turn sig)
187G 0.5B ELEC. STEERING SW 83C 83D - + - +
SW TURN SIGNAL
(high)
(high)
HEAD LAMP
(low)
(low)
0.85LgR 2 189B 8 0.85LY (RAISE) 1 2 12V 100AH 12V 100AH
0.85B 0.85LgB DA3-1 TML N
0.85LgW 1 188B + 33K 0.85RB 0.85RB 3 4 DA3-2
0.85GY 82C CN4-8
0.85LY 0.85LY 0.85RY 49a BATTERY
PVED O 38B 0.85RY 85B 84B
0.5GR 0.85GR 0.85GR 84A CN4-4
4 163B J1939 (+) 0.5Y R
- 0.85B
RETURN TO DIG RAISE 0.85GL 0.85GL 0.85GL 85A CN4-1 AVX 8W
5 164B J1939 (-) 0.5YB L COMBINATION
MAGNET MAGNET
RETURN TO DIG RELAY RAISE RELAY 0.85RW 0.85RW 1.25WY 62B CN4-5 SWITCH (R) AVX 1.25WG
6 165B J1939 DATALINK SHIELD 37A 56
(RETURN TO DIG) 1 0.85G 87a 33F 33D 87a 0.85R 3 0.85R 0.85R 0.85RW 86A CN4-6 0.5RW AVX 2RW
12 30 0.85RB 30 56b
+ 33L 0.85RB 0.85B 0.85RB 10 0.85R 87A CN4-7
35B 37B 0.85WR
35A 87 87 56a 9A 4A 18A
O 36B 0.85WG 35B’ 37B’ 0.85GW 0.85RG 59C CN4-9 0.85WL I B+ R
ECU 85 86 0.85RB 0.85RB 86 85 15/1
- 0.85B 92F CN5-6 15B
1.25LR
0.5LB 0.85LB
0.5RW
2 6 5 1 0.85RY 15(53a) 0.5 uF
0.5Br
36A 33G 33E 38A
2RW
2RW
2LR
(clearanc)
ENGINE VEHICLE 153B 157B
(turn sig)
35C 37C 0.85BR 0.85BR 96A CN5-8 B+
(stop)
DA1-2 53c
0.85WL (clearanc)
0.85GL (turn sig)
(stop)
0.5BrY 0.85BrY 95B CN4-2 -
3 2-32 0.85WG 0.85B H
156B 1-30 0.5BW DIAGNOSTIC (-) 0.85RB 0.85B 0.85B I(L)
OIL PRESSURE P& 0.85WR
HORN SWITCH 2 0.5BL 94A CN5-7
200A
4 2-27 0.5YB DIAGNOSTIC (+) J
0.85GW
108A 1-22
0.85GR
0.85WR
0.85GW
SENSOR 0.5WR 0.5WR 0.5WR
(ODFT)
t 1 2-42 PREHEAT (-)
92D 95A 0.85BrY H 97B 0.85RY 97A CN5-3
53b REG.
113B 1-56 0.5LB 0.5BrW 0.5BrW 0.85B TRIO DIODE
L 98B 98A CN5-1
(0 281 002 420) 2 2-28 28B 1-33 0.5WG TACHO
LIS ASSEMBLY (OPTION) 85E 88B 16B 58C 60X 58D 17B 88C 84E 0.85LB 4 9
43A
0.85YB
53
V C A B E F D D F E B A C 0.85W 0.85BrL 100B CN5-4 FIELD
SAFETY START RELAY BACK UP RELAY (ON JOYSTICK)-L S 101A 0.85Y 31b F+
LIS SOL-VALVE LO
LIS SELECT SW 0.5BrW 57A 87a 87a TML J 0 I II OFF ON OFF ON 154A D H
+ F-
3 2-33 (K ) 0.85LY 30 45B 0.5RL 45D 30 HI
DOWN SHIFT SW 15L E
BOOST PRESSURE P& 4 2-34 127C
87 87 58A 0.85RY
21W 21W 5W 21W 21W
M STOP SW WIPER WASHER HORN 0.85BG
SENSOR 0 92E
t 3 33J 85 86 45C 0.5RL 0.85WL 41B 46A 0.85V B 0.85L 172A 172B
0.85RB 0.5Gr 0.5P 85 86 45E 0.5RL LICENCE LAMP
- RUN
(LDFT) 1 2-25 127B 5 I 145A REAR COMBI LAMP REAR COMBI LAMP 1 GND
5 8 0.5BL 94B PREHEAT RELAY ALTERNATOR 99
(0 281 002 576) 146A E 0.85B AIR HEATER
2 2-36 124A 1 II 8B
V (ON JOYSTICK)-R 24V 60A
2RL
ACCELERATOR PEDAL 0.85LY 9 60 0.5BL 94C 2
0.5B 10 0.5WR 0.85RL 0.85RY 58B 101B 87a WIPER TIMER
160A 1-77 0.5R 160B A + WIPER MOTOR 30 100A 0.85BrL 94D ALTERNATOR 80A(OPTION)
1 2-23 0.85B - 0.5BL 3
161B 1-79 0.5G 161A B POSITION 0.85WG 0.85LB 92C 87
CRANKSHAFT SPEED SENSOR N 2 2-19
PT
SENSOR
LIS RELAY 0.5P PILOT CUT OFF SW
162B 1-78 0.5B 162A C 87a 0.85RY 146B 5 14 56A PILOT CUT OFF 0.85W
(TONE WHEEL WITH SLOTS) BACK BUZZER 44B 0.85BW 44A 1 1 85 86 93B 93A AIRCON UNIT
30 SOL-VALVE 0.5B 0.5L 4
(0 281 002 662)
V 158A 1-48 0.5Or 158B E IDLE 33H 0.85RB 0.85RB
0.5Gr 145B 52 23 14C 0.85RW 5 41C 0.85WL 0.85WL 41D 5
127A 87
VALIDATION DA5-1 7 7 42A 0.85Or 0.85Or PARKING BRAKE 0.5B 5 BLOWER
F 0.85RY 124B 30 68 14D 0.85RW WIPER RELAY 15
126A 85 86 125B 0.85LR 1 3 44C RELEASE SOL-VALVE 2LR 63D + -
2 42B M
2-09 0.5BL 169A D 0.85LR 125A 8 36 27B 0.85G 0.85B 10 9 60F 0.5WR 0.5WR 60G 9 10 0.5B
N 2RW 0.85LR 63E 14
CAMSHAFT SPEED SENSOR 1 2-10 0.5B
0.85LR 125C 53 0.85RL 45P 3 DA5-2
(TONE WHEEL WITH PINS) 169D 1-29 0.5BL 0.5BL 0.85BL 0.85BL 42C 2RW
(0 281 002 662) V 0.85BL 126B 57 TRANSMISSION 62 141A 0.85YR 0.85YR 141B 2 SPEED SENSOR PARKING BRAKE SW
4 2
FG006730
Figure 1
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