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Hyundai HL955, Manual

The Hyundai HL955 is a powerful and versatile construction wheel loader designed for efficiency and durability. Enhance your productivity with this top-of-the-line equipment, and ensure smooth operation by accessing the comprehensive user manual. Download your free manual today from manualshive.com to make the most of your HL955.

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3-45

Fault code

J1939 SPN

J1939 FMI

Reason

Effect (only when fault code is active)

3382
3058

18

Engine exhaust gas recirculation (EGR) system 
- Data valid but below normal operating range - 
Moderately severe level.  Measured egr flow is 
lower than commanded.

Possible reduced engine performance.

3383
3058

16

Engine exhaust gas recirculation (EGR) system 
- Data valid but above normal operating range - 
Moderately severe Level. Measured EGR flow is 
higher than commanded.

Possible reduced engine performance.

3394
4766

18

Aftertreatment 1 diesel oxidation catalyst outlet 
gas temperature - Data valid but below normal 
operating range - Moderately severe level. The 
diesel oxidation catalyst outlet Temperature is 
below the operating limit

Possible frequent need for aftertreatment 
regeneration.

3396
3750

31

Diesel particulate filter 1 conditions not met for 
active regeneration - Condition exists. The 
aftertreatment temperatures are not warm 
enough for aftertreatment injection.

Possible frequent need for aftertreatment 
regeneration.

3418

191

19

Transmission output shaft speed - Received 
network data in error. The J1939 multiplexing 
controller has indicated a malfunction of the 
transmission output shaft speed sensor.

None on performance.

3422
4344

3

Aftertreatment diesel exhaust fluid line heater 3 
circuit - Voltage above normal or shorted to high 
source. High signal voltage detected at the 
diesel exhaust fluid line heater 3 circuit.

Possible reduced engine performance.

3423
4344

4

Aftertreatment diesel exhaust fluid line heater 3 
circuit - Voltage below normal, or shorted to low 
source. Low signal voltage detected at the 
diesel exhaust fluid line heater 3 circuit.

Possible reduced engine performance.

3425
4344

5

Aftertreatment diesel exhaust fluid line heater 3 
circuit - Current below normal or open circuit. 
Open circuit detected in the diesel exhaust fluid 
line heater 3.

Possible reduced engine performance.

3488

563

9

Anti-lock braking (ABS) controller - Abnormal 
update rate. No communication or an invalid 
data transfer rate has been detected on the 
J1939 data link between the ECM and the anti-
lock braking (ABS) controller.

None on performance.

3492

251

10

Real time clock - Abnormal rate of change. 
The real time clock indicates a stuck engine off 
timer.

None on performance.

3494
1081

7

Engine wait to start lamp - Mechanical system 
not responding or out of adjustment. Wait to 
Start lamp has malfunction.

None on performance.

3497
1761

17

Aftertreatment diesel exhaust fluid tank level - 
Data valid but below normal operating range - 
Least severe level. 
The aftertreatment diesel exhaust fluid tank 
level is low.

None on performance.

※ 

Some fault codes are not applied to this machine.

Summary of Contents for HL955

Page 1: ...ments 3 90 Group 4 Disassembly and Assembly 3 92 SECTION 4 BRAKE SYSTEM SECTION 4 BRAKE SYSTEM Group 1 Structure and Function 4 1 Group 2 Operational Checks and Troubleshooting 4 32 Group 3 Tests and Adjustments 4 39 Group 4 Disassembly and assembly 4 41 SECTION 5 STEERING SYSTEM SECTION 5 STEERING SYSTEM Group 1 Structure and Function 5 1 Group 2 Operational Checks and Troubleshooting 5 13 Group ...

Page 2: ...TEM SECTION 7 ELECTRICAL SYSTEM Group 1 Component Location 7 1 Group 2 Electrical Circuit 7 3 Group 3 Monitoring System 7 22 Group 4 Electrical Component Specification 7 69 Group 5 Connectors 7 76 Group 6 Troubleshooting 7 97 ...

Page 3: ...s not only to give an understanding of the structure but also serves as reference material for troubleshooting Operational checks and troubleshooting Operational checks and troubleshooting This group explains the system operational checks and troubleshooting charts correlating problem to remedy Tests and adjustments Tests and adjustments This group explains checks to be amide before and after perf...

Page 4: ...ributors Get the most up to date information before you start any work Filing method Filing method See the page number on the bottom of the page File the pages in correct order Following examples shows how to read the page number Example 1 3 3 Section number 3 Power train system Consecutive page number for each section Additional pages Additional pages are indicated by a hyphen and number after th...

Page 5: ...al point one place to the left to convert it to 55 mm Carry out the same procedure as above to convert 55 mm to 2 165 inches The original value 550 mm was divided by 10 so multiply 2 165 inches by 10 move the decimal point one place to the right to return to the original value This gives 550 mm 21 65 inches 1 2 1 2 3 1 2 3 Millimeters to inches Millimeters to inches 1mm 0 03937 in ⓑ ⓐ 0 1 2 3 4 5 ...

Page 6: ...6 3 425 3 465 3 504 90 3 543 3 583 3 622 3 661 3 701 3 740 3 780 3 819 3 858 3 898 Kilogram to Pound Kilogram to Pound 1kg 2 2046lb 0 1 2 3 4 5 6 7 8 9 0 2 20 4 41 6 61 8 82 11 02 13 23 15 43 17 64 19 84 10 22 05 24 25 26 46 28 66 30 86 33 07 35 27 37 48 39 68 41 89 20 44 09 46 30 48 50 50 71 51 91 55 12 57 32 59 5 61 73 63 93 30 66 14 68 34 70 55 72 75 74 96 77 16 79 37 81 57 83 78 85 98 40 88 18...

Page 7: ...2 455 22 719 22 983 23 247 23 511 90 23 775 24 040 24 304 24 568 24 832 25 096 25 631 25 625 25 889 26 153 Liter to U K Gallon Liter to U K Gallon 1ℓ 0 21997 U K Gal 0 1 2 3 4 5 6 7 8 9 0 0 220 0 440 0 660 0 880 1 100 1 320 1 540 1 760 1 980 10 2 200 2 420 2 640 2 860 3 080 3 300 3 520 3 740 3 950 4 179 20 4 399 4 619 4 839 5 059 5 279 5 499 5 719 5 939 6 159 6 379 30 6 599 6 819 7 039 7 259 7 479...

Page 8: ... 8 622 0 629 3 636 5 643 7 90 651 0 658 2 665 4 672 7 679 9 687 1 694 4 701 6 708 8 716 1 100 723 3 730 5 737 8 745 0 752 2 759 5 766 7 773 9 781 2 788 4 110 795 6 802 9 810 1 817 3 824 6 831 8 839 0 846 3 853 5 860 7 120 868 0 875 2 882 4 889 7 896 9 904 1 911 4 918 6 925 8 933 1 130 940 3 947 5 954 8 962 0 969 2 976 5 983 7 990 9 998 2 10005 4 140 1012 6 1019 9 1027 1 1034 3 1041 5 1048 8 1056 0...

Page 9: ...1266 90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408 100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550 110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693 120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835 130 1849 2863 1877 1892 1906 1920 1934 1949 1963 1977 140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119 150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262 160 2276 2290 2304...

Page 10: ...31 0 32 2 90 194 0 26 1 15 5 0 6 7 20 68 0 12 8 55 131 0 32 2 90 194 0 25 6 14 6 8 6 1 21 69 8 13 3 56 132 8 32 8 91 195 8 25 0 13 8 6 5 6 22 71 6 13 9 57 134 6 33 3 92 197 6 24 4 12 10 4 5 0 23 73 4 14 4 58 136 4 33 9 93 199 4 23 9 11 12 2 4 4 24 75 2 15 0 59 138 2 34 4 94 201 2 23 3 10 14 0 3 9 25 77 0 15 6 60 140 0 35 0 95 203 0 22 8 9 15 8 3 3 26 78 8 16 1 61 141 8 35 6 96 204 8 22 2 8 17 6 2 ...

Page 11: ...SECTION 1 GENERAL SECTION 1 GENERAL Group 1 Safety Hints 1 1 Group 2 Specifications 1 10 Group 3 Operational Checkout Record Sheet 1 23 ...

Page 12: ...orming any work on the wheel load er attach a Do Not Operate Do Not Operate tag on the right side controller lever USE HANDHOLDS AND STEPS USE HANDHOLDS AND STEPS Falling is one of the major causes of personal inju ry When you get on and off the machine always maintain a three point contact with the steps and handrails and face the machine Do not use any controls as handholds Never jump on or off ...

Page 13: ...s Wear goggles or safety glasses PROTECT AGAINST NOISE PROTECT AGAINST NOISE Prolonged exposure to loud noise can cause impairment or loss of hearing Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises WORK IN CLEAN AREA WORK IN CLEAN AREA Before starting a job Clean work area and machine Make sure you have all necess...

Page 14: ...ive release of fluids from pressurized cooling system can cause serious burns Shut off engine Only remove filler cap when cool enough to touch with bare hands HANDLE FLUIDS SAFELY AVOID FIRES HANDLE FLUIDS SAFELY AVOID FIRES Handle fuel with care It is highly flammable Do not refuel the machine while smoking or when near open flame or sparks Always stop engine before refueling machine Fill fuel ta...

Page 15: ...ng enough outside air into the area REMOVE PAINT BEFORE WELDING OR REMOVE PAINT BEFORE WELDING OR HEATING HEATING Avoid potentially toxic fumes and dust Hazardous fumes can be generated when paint is heated by welding soldering or using a torch Do all work outside or in a well ventilated area Dispose of paint and solvent properly Remove paint before welding or heating If you sand or grind paint av...

Page 16: ...ent in moving parts STAY CLEAR OF MOVING PARTS STAY CLEAR OF MOVING PARTS Entanglements in moving parts can cause serious injury To prevent accidents use care when working around rotating parts ILLUMINATE WORK AREA SAFELY ILLUMINATE WORK AREA SAFELY Illuminate your work area adequately but safely Use a portable safety light for working inside or under the machine Make sure the bulb is enclosed by ...

Page 17: ... FLUID LINES FLUID LINES Flammable spray can be generated by heating near pressurized fluid lines resulting in severe burns to yourself and bystanders Do not heat by welding soldering or using a torch near pressurized fluid lines or other flammable materials Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area Install fire resisting guards to protect hoses or ot...

Page 18: ...burn skin eat holes in clothing and cause blindness if splashed into eyes Avoid the hazard by Filling batteries in a well ventilated area Wearing eye protection and rubber gloves Avoiding breathing fumes when electrolyte is added Avoiding spilling of dripping electrolyte Use proper jump start procedure If you spill acid on yourself Flush your skin with water Apply baking soda or lime to help neutr...

Page 19: ...low pressure cuts bubbles damaged rims or missing lug bolts and nuts USE PROPER LIFTING EQUIPMENT USE PROPER LIFTING EQUIPMENT Lifting heavy components incorrectly can cause severe injury or machine damage Follow recommended procedure for removal and installation of components in the manual DISPOSE OF FLUIDS PROPERLY DISPOSE OF FLUIDS PROPERLY Improperly disposing of fluids can harm the environmen...

Page 20: ...t safety sign placement KEEP ROPS INSTALLED PROPERLY KEEP ROPS INSTALLED PROPERLY Make certain all parts are reinstalled correctly if the roll over protective structure ROPS is loosened or removed for any reason Tighten mounting bolts to proper torque The protection offered by ROPS will be impaired if ROPS is subjected to structural damage is involved in an overturn incident or is in any way alter...

Page 21: ...Tire Head light Hydraulic tank Radiator Counterweight Battery Main control valve Boom cylinder Boom Front axle Transmission Rear axle Steering cylinder Bucket link Main pump Engine Air cleaner Cab Bucket cylinder Bell crank 760F2SE01 1 MAJOR COMPONENT 1 MAJOR COMPONENT ...

Page 22: ...0 6 9 Dump clearance at 45 G 2840 9 4 Dump reach full lift H 1125 3 8 Width over tires I 2580 8 6 Dump angle J degree 48 Roll back angle carry position K 48 Cycle time Lift with load sec 5 8 Dump with load 1 2 Lower empty 3 8 Maximum travel speed km hr mph 38 5 24 0 Braking distance m ft in 13 42 8 Minimum turning radius center of outside tire 5 24 17 2 Gradeability degree 30 Breakout force kg lb ...

Page 23: ...rance at 45 G 3235 10 7 Dump reach full lift H 1150 3 8 Width over tires I 2580 8 6 Dump angle J degree 48 0386 45 0387 Roll back angle carry position K 48 Cycle time Lift with load sec 5 8 Dump with load 1 2 Lower empty 3 8 Maximum travel speed km hr mph 38 5 24 0 Braking distance m ft in 13 42 8 Minimum turning radius center of outside tire 5 32 17 2 Gradeability degree 30 Breakout force kg lb 1...

Page 24: ...ance at 45 G 2750 9 1 Dump reach full lift H 1175 3 10 Width over tires I 2580 8 6 Dump angle J degree 48 Roll back angle carry position K 48 Cycle time Lift with load sec 5 8 Dump with load 1 2 Lower empty 3 8 Maximum travel speed km hr mph 38 5 24 0 Braking distance m ft in 13 42 8 Minimum turning radius center of outside tire 5 24 17 2 Gradeability degree 30 Breakout force kg lb 13870 30580 Tra...

Page 25: ...t 45 G 3145 10 4 Dump reach full lift H 1235 4 1 Width over tires I 2580 8 6 Dump angle J degree 48 0386 45 0387 Roll back angle carry position K 48 Cycle time Lift with load sec 5 8 Dump with load 1 2 Lower empty 3 8 Maximum travel speed km hr mph 38 5 24 0 Braking distance m ft in 13 42 8 Minimum turning radius center of outside tire 5 32 17 2 Gradeability degree 30 Breakout force kg lb 13775 30...

Page 26: ...ential 970 2200 Rear axle include differential 760 2140 Tire 20 5 R25 L3 230 507 Hydraulic tank assembly 168 370 Fuel tank assembly 336 741 Main pump assembly 55 121 Fan brake pump assembly 12 26 Main control valve 2 spool 3 spool 34 41 75 90 Steering valve EHPS 10 22 Boom assembly HL955 980 2160 HL955 XT 1210 2670 Bell crank assembly 260 573 Bucket link 44 97 2 8 m3 bucket with bolt on cutting ed...

Page 27: ...in line Firing order 1 5 3 6 2 4 Combustion chamber type Direct injection type Cylinder bore stroke 107 124 mm 4 2 4 9 Piston displacement 6700 cc 408 cu in Compression ratio 17 3 1 Rated horse power Gross 200 hp at 2200 rpm Maximum torque at 1400 rpm 95 kgf m 685 lbf ft Engine oil quantity 18ℓ 4 8 U S gal Wet weight 520 kg 1146 lb High idling speed 2230 50 rpm Low idling speed 800 25 rpm Rated fu...

Page 28: ...230 rpm MAIN CONTROL VALVE MAIN CONTROL VALVE 4 4 Item Specification Type 2 spool Operating method Hydraulic pilot assist System pressure 280 kgf cm2 3980 psi Overload relief valve pressure 340 kgf cm2 4840 psi 300 kgf cm2 4270 psi Bucket dump ELECTRO HYDRAULIC BLOCK ELECTRO HYDRAULIC BLOCK 5 5 Item Specification Type Proportional pressure reducing vlave Control current 0 950 mA Resistance 10 5 Ω ...

Page 29: ...peed See the page 2 2 5 speed transmission opt Model ZF 5WG210 Type Converter Single stage double phase with lock up clutch Transmission Full automatic power shift Gear shift Forward fifth gear reverse third gear Control Electrical single lever type kick down system Travel speed Forward 1 2 3 4 5 6 4 11 1 17 1 26 6 40 0 km hr Reverse 1 2 3 6 7 11 7 28 0 km hr Axle Drive devices 4 wheel drive Front...

Page 30: ...0 500 72 0 97 2 521 703 86 4 116 625 839 M24 2 0 64 1 86 5 464 625 90 1 121 652 875 108 146 782 1056 M30 2 0 129 174 933 1258 181 245 1310 1772 217 294 1570 2126 Bolt size 8 8T 10 9T 12 9T kgf m lbf ft kgf m lbf ft kgf m lbf ft M 6 1 0 0 8 1 2 5 8 8 6 1 2 1 8 8 7 13 0 1 5 2 1 10 9 15 1 M 8 1 25 2 0 3 0 14 5 21 6 2 8 4 2 20 3 30 4 3 4 5 0 24 6 36 1 M10 1 5 4 0 6 0 29 0 43 3 5 6 8 4 40 5 60 8 6 8 10...

Page 31: ...9 3 8 22 5 36 2 1 2 27 9 5 68 7 3 4 36 18 130 1 41 21 152 1 1 4 50 35 253 Thread size Width across flat mm kgf m lbf ft 9 16 18 19 4 28 9 11 16 16 22 5 36 2 13 16 16 27 9 5 68 7 1 3 16 12 36 18 130 1 7 16 12 41 21 152 1 11 16 12 50 35 253 Thread size Width across flat mm kgf m lbf ft 1 4 19 4 28 9 3 8 22 5 36 2 1 2 27 9 5 68 7 3 4 36 18 130 1 41 21 152 1 1 4 50 35 253 ...

Page 32: ...ing bolt M10 1 5 6 9 1 4 50 10 1 12 Steering valve EHPS mounting bolt M8 1 25 2 5 0 5 18 1 3 6 13 Brake valve mounting bolt M8 1 25 2 5 0 5 18 1 3 6 14 Cut off valve mounting bolt M8 1 25 2 5 0 5 18 1 3 6 15 EH control block mounting bolt M8 1 25 2 5 0 5 18 1 3 6 16 Safety valve M10 1 5 6 9 1 4 50 10 1 17 Hydraulic oil tank mounting bolt M16 2 0 29 7 4 5 215 32 5 18 Power train system Transmission...

Page 33: ... Transmission Oil Diesel Exhaust Fluid DEF compatible with AdBlue Refer to below list SAE 30 SAE 10W SAE 10W 30 SAE 15W 40 ISO VG 46 HBHO VG 46 4 ISO VG 68 2ASTM D975 NO 1 ASTM D975 NO 2 2 NLGI NO 1 NLGI NO 2 Ethylene glycol base permanent type 50 50 2SAE 5W 40 2ISO VG 15 2Ethyleneglycolbasepermanenttype 60 40 50 30 20 10 0 10 20 30 40 58 22 4 14 32 50 68 86 104 SAE 10W 30 SAE 15W 40 Ultra low sul...

Page 34: ...k Battery check Monitor indicator circuit check Cluster turn signals and warning indicator check 2 Transmission axle and engine neutral start 2 Transmission axle and engine neutral start switch and reverse warning alarm switch checks switch and reverse warning alarm switch checks Transmission control lever and neutral Neutral start and reverse warning Alarm circuit checks 3 Monitor indicator and g...

Page 35: ...ion kick down system check 1st 2nd 3rd and 4th speed clutch pack drag check Transmission pressure pump flow and leakage check Transmission shift modulation check Torque converter check Engine power check 6 Hydraulic system checks 6 Hydraulic system checks Hydraulic system warm up procedure Hydraulic pump performance check Pilot control valve boom float check Boom down solenoid valve check Control ...

Page 36: ...ater Air conditioner blower check Heater functional check Air conditioner functional check Start aid system check 9 Cab components and vandal protection checks 9 Cab components and vandal protection checks Cab door latch check Cab door hold open latch check Cab door release button check Cab door lock check Cab door window check Cab window latch check Steering column adjustment check Seat and seat ...

Page 37: ...SECTION 2 ENGINE SECTION 2 ENGINE Group 1 Structure and Function 2 1 Group 2 Engine speed and Stall rpm 2 12 Group 3 Fuel warmer system 2 13 ...

Page 38: ...lled cylinder block and cylinder head are made of case iron and turbocharger is attached Starting motor Crankcase breather Flywheel housing Lubricating oil filter Exhaust outlet connection Water inlet connection Oil pan Vibration damper Lubricating oil filter cooler Lifting bracket Fuel filter ECM engine control module Fan drive Air intake connection Oil fill arrangement Lifting bracket Turbocharg...

Page 39: ...el supply to fuel gear pump 5 Fuel gear pump 6 To pressure side fuel filter 7 Pressure side fuel filter 8 To high pressure fuel pump 9 High pressure fuel pump 10 To fuel rail 11 Fuel rail 12 Fuel rail pressure relief valve 13 Common rail fuel return 14 High pressure fuel line to injector 15 High pressure connector 16 Injector 17 Fuel return from injectors 18 Combined fuel return 19 Fuel return to ...

Page 40: ... To lubricating oil pan 7 Lubricating oil cooler 8 Filter bypass valve 9 Filter bypass valve closed 10 Filter bypass valve open 11 To lubricating oil filter 12 Full flow lubricating oil filter 13 From lubricating oil filter 14 To main lubricating oil rifle s Lubrication for the turbocharger Lubrication for the turbocharger 1 1 7609A2EG12 1 Turbocharger lubricating oil supply 2 Turbocharger lubrica...

Page 41: ...bearing 5 To camshaft journal 6 Oil supply to rod bearings 7 Crankshaft cross drilling from the main bearing journal 8 J jet piston cooling nozzle 9 To accessory drive oil feed Lubrication for the overhead components Lubrication for the overhead components 3 3 7609A2EG14 1 Main lubricating oil rifle 2 Rocker lever support 3 Transfer slot 4 Rocker lever shaft 5 Rocker lever bore 6 Rocker lever ...

Page 42: ...2 5 Lubrication for the accessory drive Lubrication for the accessory drive 4 4 7609A2EG15 1 Oil supply to accessory drive 2 Oil feed from block Oil returns to pan through the gear housing ...

Page 43: ...s 5 Coolant flow from cylinder block to cylinder head 6 Coolant flow between cylinders 7 Coolant flow to thermostat housing 8 Thermostat open bypass passage closed 9 Coolant flow back to radiator 10 Thermostat closed bypass passage open 11 Coolant bypass passage in cylinder head 12 Coolant flow to water pump inlet 760F2EG17 1 Air compressor coolant supply line 2 Air compressor coolant return to co...

Page 44: ...lant return to the EGR cooler outlet tube 3 Coolant supply to the EGR cooler from the rear of the cylinder block 4 EGR cooler coolant return to the coolant inlet connection 5 De aeration port to coolant top tank 1 Coolant supply to aftertreatment DEF dosing valve and DEF tank 2 Coolant supply to cab heater 3 De aeration port to coolant top tank 760F2EG19 ...

Page 45: ...ger compressor outlet 4 Charge air cooler inlet 5 Charge air cooler outlet 6 Air intake connection adapter 7 Air intake connection 8 Intake manifold 9 Intake port 10 Intake valves 11 EGR connection tube 12 EGR cooled exhaust gases 13 Charge air cooled intake air 14 EGR valve 15 Air mixture to combustion cylinder ...

Page 46: ...7609A2EG21 1 Exhaust valves 2 Exhaust port 3 Exhaust manifold 4 Turbocharger 5 Turbocharger exhaust outlet 6 Exhaust inlet to EGR cooler 7 EGR cooler 8 Cooled exhaust outlet to EGR valve 9 EGR valve 10 EGR valve differential pressure sensor ...

Page 47: ...eatment DEF dosing valve 6 Aftertreatment DEF dosing valve 7 Decomposion reactor 8 Exhaust DEF mixture 9 Aftertreatment selective catalyst reduction SCR intake temperature sensor probe 10 Aftertreatment SCR catalyst 11 Aftertreatment SCR outlet temperature sensor probe 12 Exhaust flow exiting aftertreatment system 13 Aftertreatment DEF dosing valve coolant fittings 14 Aftertreatment inlet mono nit...

Page 48: ... only when aftertreatment DEF tank coolant valve is open 4 Aftertreatment DEF tank 5 Coolant return to engine 6 Aftertreatment DEF supply from aftertreatment DEF tank 7 Aftertreatment DEF flow to aftertreatment DEF dosing unit 8 Aftertreatment DEF dosing unit 9 Aftertreatment DEF return to aftertreatment DEF tank 10 Aftertreatment DEF flow to aftertreatment DEF dosing valve ...

Page 49: ...nvertor stall rpm Start the engine and lower the bucket on the ground as the figure Set the clutch cut off mode at the OFF position Press the brake pedal and accelerator pedal fully Shift the transmission lever to the 4th forward position Check the engine rpm at the above condition 2 2 Full stall rpm Full stall rpm Start the engine and raise the bucket approx 45 cm 1 5 ft as the figure Set the clu...

Page 50: ... 06 07 08 09 10 TURN LAMP START KEY SW RADIO B 30A 10A 10A 30 86 87 85 87a 86 85 87 30 87a 30 86 87 85 87a 86 85 87 30 87a 30 86 87 85 87a 86 85 87 30 87a 6 2 1 3 4 5 6 1 5 3 0 I 0 I H 4 2 B H BR ACC C 2 1 2 4 3 80A 40A 1 AIR PRE HEAT 17 22 21 23 24 25 26 16 12 33 CN 36 CN 39 CR 30 CR 35 EG ECM RY IGNITION RY CS 02 START SWITCH CS 75 BATTERY BATT RY CR 01 CS 74 MASTER SWITCH CN 352 CN 351 CN 01 FU...

Page 51: ...ER TRAIN SYSTEM SECTION 3 POWER TRAIN SYSTEM Group 1 Structure and Function fault code 3 1 Group 2 Operational Checks and Troubleshooting 3 78 Group 3 Test and Adjustments 3 90 Group 4 Disassembly and Assembly 3 92 ...

Page 52: ...g brake is located on the transmission The transmission outputs through universal joints to three drive shaft assemblies The front drive shaft is a telescoping shaft which drives the front axle The front axle is mounted directly to the loader frame The front axle is equipped with conventional differential as standard option Limited slip Hyd lock differential The rear axle is equipped with conventi...

Page 53: ...E 55 Filter pressure differential valve X Pressure regulator under voltage NFS Follow on slide D Vibration damper B Orifice P1 Proportional valve clutch K4 P2 Proportional valve clutch KR P3 Proportional valve clutch K1 P4 Proportional valve clutch K3 P5 Proportional valve clutch KV P6 Proportional valve clutch K2 Y1 Y6 Pressure regulator 7607APT18 1 Speed Forward Reverse Neutral Engaged clutch Po...

Page 54: ... valve Converter lock up clutch valve Converter lock up clutch X Pressure regulator under voltage NFS Follow on slide D Vibration damper B Orifice P1 Proportional valve clutch K4 P2 Proportional valve clutch KR P3 Proportional valve clutch K1 P4 Proportional valve clutch K3 P5 Proportional valve clutch KV P6 Proportional valve clutch K2 Y1 Y6 Pressure regulator 7609A3PT18 Speed Forward Reverse Neu...

Page 55: ...eel enters the turbine wheel and is there inversed in the direction of flow According to the rate of reversion the turbine wheel and with it also the output shaft is receiving a more or less high reaction torque The stator reaction member following the turbine has the task to reverse the oil streaming out of the turbine once more and to deliver it under the suitable discharge direction to the pump...

Page 56: ...ill Function of a hydrodynamic torque converter schematic view When the turbine speed is reaching about 80 of the pump speed the torque multiplication becomes 1 0 i e the turbine torque becomes equal to that of the pump torque From this point on the converter is working similar to a fluid clutch A stator freewheel serves to improve the efficiency in the upper driving range in the torque multiplica...

Page 57: ... pressure to lock up clutch valve 9 System pressure from lock up clutch valve to lock up clutch With closed converter lock up clutch the slip between pump and turbine wheel and consequently the hydraulic loss in the converter is equal to zero see figure A According to the turbine speed the converter lock up clutch is shifted automatically Via a proportional valve the pilot pressure is applied to t...

Page 58: ...flange 7 Converter side output flange 8 Output shaft 9 Transmission pump 10 Connection to engine 11 Converter 12 Inductive transmitter for engine speed 13 4th clutch K4 14 Converter relief valve 15 1st clutch K1 16 Parking brake 3 TRANSMISSION 3 TRANSMISSION LAYOUT LAYOUT 1 1 1 2 3 4 5 12 11 10 9 8 7 14 13 15 6 16 7577APT03 ...

Page 59: ... pump 6 Breather 7 Electrical hydraulic transmission control 8 Power take off Coaxial Engine dependent 9 Parking brake 10 Oil drain plug 11 Connection to engine 12 Output flange Converter side 13 Output flange Rear side 14 Temperature switch for oil temperature behind converter 15 Difference pressure switch for pressure filter 16 Solenoid valve for converter lock up clutch 5 speed T M only 7609A3P...

Page 60: ...orward Forward 1st Forward 1st In 1st forward forward clutch KV and 1st clutch K1 are engaged Forward clutch and 1st clutch are actuated by the hydraulic pressure applied to the clutch piston 3 3 1 1 OUTPUT INPUT IN KR K2 K4 K3 OUT KR KV K2 K3 K1 K4 OUTPUT GEAR PATTERN KV K1 7577APT04 F1 ...

Page 61: ...rward forward clutch KV and 2nd clutch K2 are engaged Forward clutch and 2nd clutch are actuated by the hydraulic pressure applied to the clutch piston INPUT OUT GEAR PATTERN KV IN KR K2 K4 K3 K1 KR KV K2 K3 K1 K4 OUTPUT OUTPUT 7577APT05 F2 ...

Page 62: ...rward forward clutch KV and 3rd clutch K3 are engaged Forward clutch and 3rd clutch are actuated by the hydraulic pressure applied to the clutch piston INPUT OUT GEAR PATTERN KV IN KR K2 K4 K3 K1 KR KV K2 K3 K1 K4 OUTPUT OUTPUT 7577APT06 F3 ...

Page 63: ...h forward 4th clutch K4 and 3rd clutch K3 are engaged 4th clutch and 3rd clutch are actuated by the hydraulic pressure applied to the clutch piston INPUT OUT GEAR PATTERN OUTPUT KV IN KR K2 K4 K3 K1 KR KV K2 K3 K1 K4 OUTPUT 7577APT07 F4 ...

Page 64: ...1st reverse reverse clutch KR and 1st clutch K1 are engaged Reverse clutch and 1st clutch are actuated by the hydraulic pressure applied to the clutch piston 2 2 INPUT OUT GEAR PATTERN OUTPUT KV IN KR K2 K4 K3 K1 KR KV K2 K3 K1 K4 OUTPUT 7577APT08 R1 ...

Page 65: ...verse reverse clutch KR and 2nd clutch K2 are engaged Reverse clutch and 2nd clutch are actuated by the hydraulic pressure applied to the clutch piston INPUT OUT GEAR PATTERN KV IN KR K2 K4 K3 K1 KR KV K2 K3 K1 K4 OUTPUT OUTPUT 7577APT09 R2 ...

Page 66: ...verse reverse clutch KR and 3rd clutch K3 are engaged Reverse clutch and 3rd clutch are actuated by the hydraulic pressure applied to the clutch piston INPUT OUT GEAR PATTERN KV IN KR K2 K4 K3 K1 KR KV K2 K3 K1 K4 OUTPUT OUTPUT 7577APT10 R3 ...

Page 67: ...sheet 8 Duct plate 9 Oscillation damper 10 Follow on slide 11 Pressure regulator Y4 Y5 Y6 Y3 Y2 Y1 1 2 3 4 5 6 5 3 A A B SECTION B B 2 6 1 4 8 7 Y5 11 9 10 SECTION A A 73033CV01 ELECTRO HYDRAULIC SHIFT CONTROL WITH PROPORTIONAL VALVE ELECTRO HYDRAULIC SHIFT CONTROL WITH PROPORTIONAL VALVE 4 speed transmission 4 speed transmission 4 4 1 1 ...

Page 68: ...sure regulator e g Y1 follow on slide and vibration damper The control pressure of 9 bar for the actuation of the follow on slides is created by the pressure reducing valve The pressure oil 16 2 bar is directed via the follow on slide to the respective clutch 1 Cable harness 2 Proportional valve 3 Intermediate plate duct plate 4 System pressure valve 16 2 bar 5 Pressure reducing valve 9 0 5 bar 6 ...

Page 69: ...in the converter the oil serves to transmit the power according to the well known hydrodynamic principle see torque converter page 3 3 To avoid cavitation the converter must be always completely filled with oil This is achieved by a converter back pressure back up valve rear mounted to the converter with an opening pressure of at least 4 3bar The oil escaping out of the converter is directed to a ...

Page 70: ...o plug connection on the electro hydraulic control unit 14 CAN Connection 15 Wiring 16 Cable to lock up clutch valve 5 speed transmission Description of the basic functions Description of the basic functions The powershift transmissions is equipped is electronic transmission control unit EST 37A developed for it The system is processing the desire of the driver according to the following criteria ...

Page 71: ...r clutch On a level road it is possible to start off also in higher gears Upshifting under load Upshifting under load will be then realized if the machine can still accelerate by it Downshifting under load Downshifting under load will be realized if more traction force is needed Upshifting in overrunning condition In the overrunning mode the upshifting will be suppressed by accelerator pedal idlin...

Page 72: ...f both components in the machine thus ensuring the correct mating Transmission and electronics It is imperative to respect the following test conditions Shifting position neutral Engine in idling speed Parking brake actuated Transmission in operating temperature After a replacement of the transmission the electrohydraulic control or the TCU in the machine the AEB cycle must be as well carried out ...

Page 73: ... main pump press Display failure 2 Control Function No automatic Emergency steering operation ECO gauge display failure 3 RMS Working hours accumulation failure Checking list 1 CN 58B 35 CD 39 B Checking Open Short 2 CN 58A 11 CD 39 A Checking Open Short 3 CN 58B 25 CD 39 C Checking Open Short 204 0 10 seconds continuous Boom cylinder head pressure Measurement Voltage 5 3 V 侑 4 10 seconds continuo...

Page 74: ...warning operation failure Checking list 1 CN 58B 22 CD 02 2 Checking Open Short 2 CN 58B 25 CD 02 1 Checking Open Short 318 8 In the startup conditions 30 seconds continuous Fan speed 10 rpm in the Remote cooling fan EPPR current reference value is in X Ma differ by model 侑 Results Symptoms 1 Monitor Cooling Fan revolutions display failure Checking list 1 CN 58A 15 CD 73 1 Checking Open Short 2 CN...

Page 75: ...A Checking Open Short 3 CN 58B 25 CD 03 C Checking Open Short 507 0 10 seconds continuous Parking oil pressure Measurement Voltage 5 3V 侑 4 10 seconds continuous Parking oil pressure Measurement Voltage 0 3V 侑 Results Symptoms 1 Monitor Parking oil Press display failure 2 Control Function No judgment Parking status Checking list 1 CN 58B 34 CD 26 B Checking Open Short 2 CN 58A 11 CD 26 A Checking ...

Page 76: ...Results Symptoms 1 Monitor Boom position sensor signal voltage display failure 2 Control Function No calibration angle sensor No calibration boom pressure Boom Detent operation failure Soft end stop Boom operation failure Lock up clutch operation failure Checking list 1 CN 58B 37 CN 100 B Checking Open Short 2 CN 58A 5 CN 100 C Checking Open Short 3 CN 58B 25 CN 100 A Checking Open Short 729 3 10 ...

Page 77: ...ration failure 844 2 10 seconds continuous Monitor Communication Data Error 侑 Results Symptoms 1 Control Function Monitor operation failure 850 2 When mounting the RMCU 90 seconds continuous RMCU Communication Data Error 侑 Results Symptoms 1 Control Function RMCU operation failure 861 2 When mounting the EHCU 10 seconds continuous EHCU Communication Data Error 侑 Results Symptoms 1 Control Function...

Page 78: ...eter invalid 2311 2 Boom joystick position signal error 2311 0 Boom joystick position input value above normal operation range 2311 1 Boom joystick position input value below normal operation range 2311 3 Boom joystick position input voltage above normal or shorted to high source 2311 4 Boom joystick position input voltage below normal or shorted to low source 2311 13 Boom joystick position contro...

Page 79: ...l operation range 2306 5 Bucket in EPPR valve input current below normal or open circuit 2306 6 Bucket in EPPR valve input current above normal or grounded circuit 2306 14 Bucket in EPPR valve block parameter invalid 2307 0 Bucket dump EPPR valve input value above normal operation range 2307 1 Bucket dump EPPR valve input value below normal operation range 2307 5 Bucket dump EPPR valve input curre...

Page 80: ...eering proportional valve start position error AAVM FAULT CODE AAVM FAULT CODE 1 3 1 3 Fault Code Description A01 AAVM Communication Error AAVM A02 AAVM Communication Error Front Camera A03 AAVM Communication Error Rear Camera A04 AAVM Communication Error Left Camera A05 AAVM Communication Error Right Camera A06 Manual Setting Fail A07 No MCU CID A08 MCU CID Format Error A09 AAVM Hardware Error AA...

Page 81: ...ing limit Engine power derate 125 102 18 Intake Manifold 1 Pressure Data valid but below normal operating range Moderately severe level Intake manifold pressure is below the minimum operating limit Engine power derate 131 91 3 Accelerator pedal or lever position sensor 1 circuit Voltage above normal or shorted to high source High voltage detected at accelerator pedal position number 1 circuit The ...

Page 82: ... Fan will stay ON if controlled by ECM 154 105 4 Intake manifold 1 temperature sensor circuit Voltage below normal or shorted to low source Low signal voltage detected at intake manifold air temperature circuit Fan will stay ON if controlled by ECM 155 105 0 Intake manifold 1 temperature Data valid but above normal operational range Most severe level Intake manifold air temperature signal indicate...

Page 83: ... on the 5 volt sensor supply circuit to the engine speed sensor Engine may run rough may stop running may not start or may be difficult to start 239 3511 3 Sensor supply 3 circuit Voltage above normal or shorted to high source High voltage detected on the 5 volt sensor supply circuit to the engine speed sensor Engine may run rough may stop running may not start or may be difficult to start 241 84 ...

Page 84: ...e 322 651 5 Injector solenoid driver cylinder 1 circuit Current below normal or open circuit Current detected at injector 1 when voltage is turned OFF Engine power derate 323 655 5 Injector solenoid driver cylinder 5 circuit Current below normal or open circuit Current detected at injector 5 when voltage is turned OFF The current to the injector is shut OFF Engine power derate 324 653 5 Injector s...

Page 85: ...low source Low voltage detected at sensor supply number 1 circuit Engine power derate 383 729 5 Engine intake air heater 1 circuit Current below normal or open circuit A malfunctioning engine intake air heater circuit has been detected Engine may not start or may be difficult to start 386 3509 3 Sensor supply 1 circuit Voltage above normal or shorted to high source High voltage detected at sensor ...

Page 86: ...re sensor circuit Voltage above normal or shorted to high source High signal voltage detected at the fuel rail 2 pressure sensor circuit Possible reduced engine performance 484 1349 4 Injector metering rail 2 pressure sensor circuit Voltage below normal or shorted to low source Low signal voltage detected at the fuel rail 2 pressure sensor circuit Possible reduced engine performance 515 3514 3 Sen...

Page 87: ...e on performance 597 167 18 Electrical charging system voltage Data valid but below normal operational range Moderately severe level Low battery voltage detected by the battery voltage monitor feature None on performance 649 1378 31 Engine oil change interval Condition exists Change engine oil and filter None on performance 687 103 18 Turbocharger 1 speed Data valid but below normal operational ra...

Page 88: ... 651 7 Injector solenoid driver cylinder 1 Mechanical system not responding or out of adjustment The ECM has detected an error with the injection timing or quantity Possible reduced engine performance 1141 652 7 Injector solenoid driver cylinder 2 Mechanical system not responding or out of adjustment The ECM has detected an error with the injection timing or quantity Possible reduced engine perfor...

Page 89: ...inder number 2 Possible reduced engine performance 1656 1325 31 Engine misfire cylinder 3 Condition exists Engine misfire has been detected in cylinder number 3 Possible reduced engine performance 1657 1326 31 Engine misfire cylinder 4 Condition exists Engine misfire has been detected in cylinder number 4 Possible reduced engine performance 1658 1327 31 Engine misfire cylinder 5 Condition exists E...

Page 90: ... high source High signal voltage detected at the aftertreatment diesel exhaust fluid tank heater circuit Possible reduced engine performance 1684 3363 4 Aftertreatment diesel exhaust fluid tank heater Voltage below normal or shorted to low source Low signal voltage detected at the aftertreatment diesel exhaust fluid tank heater circuit Possible reduced engine performance 1691 100 18 Aftertreatment...

Page 91: ...ignal voltage detected at the crankcase pressure circuit None on performance 1866 411 2 Exhaust gas recirculation valve delta pressure Data erratic intermittent or incorrect An error in the egr delta pressure signal was detected at initial key on or the sensor failed the autozero test possible reduced engine performance 1867 412 2 Engine gas recircuilation temperature Data erratic intermittent or ...

Page 92: ...mal operating range Most severe level The soot load of the aftertreatment diesel par ticulate filter has exceeded the recommended limits Engine protection derate is enabled Possible reduced engine performance 1938 3597 1 Ecu power output supply voltage 1 Data valid but below normal operational range Moderately severe level Low battery voltage detected by the VGT actuator Possible reduced engine pe...

Page 93: ...gnal voltage has been detected at the EGR valve position sensor circuit Possible reduced engine performance 2273 411 3 Exhaust gas recirculation valve delta pressure sensor circuit Voltage above normal or shorted to high source High signal voltage detected at the EGR differential pressure sensor circuit Possible reduced engine performance 2274 411 4 Exhaust gas recirculation valve delta pressure s...

Page 94: ...source Low signal voltage detected at EGR temperature circuit Possible reduced engine performance 2377 647 3 Fan control circuit Voltage above normal or shorted to high source Open circuit or high voltage detected at the fan control circuit The fan can stay on continuously or not not run at all 2387 641 7 VGT Actuator driver circuit motor Mechanical system not responding or out of adjustment The s...

Page 95: ...he soot load of the aftertreatment diesel particulate filter has exceeded the recommended limits Possible reduced engine performance 2646 110 32 Engine coolant temperature Condition exists The EGR valve was closed to reduce engine coolant temperature Possible reduced engine performance 2718 520325 31 Brake switch and accelerator pedal position incompatible Condition exists The ECM has detected the...

Page 96: ...e normal or shorted to high source High signal voltage detected at the aftertreatment diesel particulate filter outlet pressure sensor circuit Possible reduced engine performance 3134 3610 4 Aftertreatment diesel particulate filter outlet pressure sensor circuit Voltage below normal or shorted to low source Low signal voltage detected at the aftertreatment diesel particulate filter outlet pressure...

Page 97: ... 9 Aftertreatment Intake NOx sensor Abnormal update rate No communication or an invalid data transfer rate has been detected on the J1939 data link between the ECM and the aftertreatment intake NOx sensor Possible reduced engine performance 3235 4363 16 Aftertreatment SCR outlet temperature Data valid but above normal operating range Moderately severe level The SCR outlet temperature sensor readin...

Page 98: ...ut down 30 seconds after the red STOP lamps starts flashing 3254 3242 15 Aftertreatment diesel particulate filter intake temperature Data valid but above normal operating range Least severe level The aftertreatment diesel particulate filter intake temperature sensor reading has exceeded the maximum engine protection temperature limit Possible reduced engine performance 3255 3246 16 Aftertreatment ...

Page 99: ...al or shorted to high source High signal voltage detected at the catalyst intake temperature sensor circuit Possible reduced engine performance 3315 4765 2 Aftertreatment diesel oxidation catalyst intake temperature Data erratic intermittent or incorrect The aftertreatment diesel oxidation catalyst intake temperature sensor is not changing with engine operating conditions Possible reduced engine p...

Page 100: ...er efficiency Data valid but below normal operating range Moderately severe level The EGR cooler is not cooling the recirculated exhaust gas sufficiently None on performance 3343 5285 18 Engine charge air cooler efficiency Data valid but below normal operating range Moderately severe level The engine charge air cooler is not cooling the intake air flow sufficiently None on performance 3361 102 10 ...

Page 101: ...4 3 Aftertreatment diesel exhaust fluid line heater 3 circuit Voltage above normal or shorted to high source High signal voltage detected at the diesel exhaust fluid line heater 3 circuit Possible reduced engine performance 3423 4344 4 Aftertreatment diesel exhaust fluid line heater 3 circuit Voltage below normal or shorted to low source Low signal voltage detected at the diesel exhaust fluid line...

Page 102: ...ion or an invalid data transfer rate has been detected on the J1939 data link between the ECM and the accelerator pedal or lever idle validation switch Engine will only idle 3531 171 9 Ambient air temperature Abnormal update rate No communication or an invalid data transfer rate has been detected on the J1939 data link between the ECM and the ambient air temperature sensor Possible reduced engine ...

Page 103: ...t diesel exhaust fluid line heater relay Voltage below normal or shorted to low source Low signal voltage detected at the diesel exhaust fluid line heater relay Possible reduced engine performance 3567 5394 5 Aftertreatment diesel exhaust fluid dosing valve Current below normal or open circuit A circuit error has been detected in the aftertreatment diesel exhaust fluid dosing valve circuit Possibl...

Page 104: ...e 3596 4334 2 Aftertreatment diesel exhaust fluid pressure sensor Data erratic intermittent or incorrect The diesel exhaust fluid pressure sensor has reported a reading too high or low for the operating conditions Possible reduced engine performance 3649 5024 10 Aftertreatment Intake NOx sensor heater Abnormal rate of change The aftertreatment intake NOx sensor heater is unable to maintain its nor...

Page 105: ...r Abnormal rate of change The aftertreatment intake NOx sensor reading is not valid None on performance 3727 5571 7 High pressure common rail fuel pressure relief valve Mechanical system not responding or out of adjustment The fuel rail high pressure relief valve has opened at a lower than expected pressure Possible reduced engine performance 3737 1675 31 Engine starter mode overcrank protection C...

Page 106: ...g range Moderately severe level High battery voltage supply detected at the aftertreatment SCR intermediate NH3 sensor Possible reduced engine performance 3933 5851 18 Aftertreatment SCR Intermediate NH3 gas sensor power supply Data valid but below normal operating range Moderately severe level Low battery voltage supply detected at the aftertreatment SCR intermediate NH3 sensor Possible reduced e...

Page 107: ...etected at the aftertreatment diesel exhaust fluid dosing unit heater relay circuit Possible reduced engine performance 4157 4376 7 Aftertreatment diesel exhaust fluid return valve Mechanical system not responding or out of adjustment A stuck aftertreatment diesel exhaust fluid return valve has been detected None on performance 4158 5742 12 Aftertreatment diesel particulate filter temperature sens...

Page 108: ...rformance 4168 5745 3 Aftertreatment diesel exhaust fluid dosing unit heater Voltage above normal or shorted to high source The aftertreatment diesel exhasut fluid dosing unit heater is detected to be stuck on None on performance 4169 5745 5 Aftertreatment diesel exhaust fluid dosing unit heater Voltage below normal or shorted to low source The aftertreatment diesel exhasut fluid dosing unit heate...

Page 109: ... known Intermittent battery voltage supply detected at the after treatment SCR temperature sensor module Possible reduced engine performance 4279 5848 21 Aftertreatment 1 SCR Intermediate NH3 Data not rational Drifted low An in range low failure has been detected Possible reduced engine performance 4281 5848 2 Aftertreatment SCR Intermediate NH3 Data erratic intermittent or incorrect The aftertrea...

Page 110: ...temperature Data valid but above normal operating range Moderately severe level High SCR Intermediate temperature detected Progressive power and or speed derate increasing in severity from time of alert If the engine protection shutdown feature is enabled the engine will shut down 30 seconds after the red STOP lamps starts flashing 4526 521 2 Brake pedal position Data erratic intermittent or incor...

Page 111: ...ble reduced engine performance 4732 1761 13 Aftertreatment diesel exhaust fluid tank level sensor Out of calibration The received datalink message was not valid None on performance 4739 1761 11 Aftertreatment 1 diesel exhaust fluid tank level sensor Root cause not known An unknown error has been detected with the aftertreatment diesel exhaust fluid tank level sensor Possible reduced engine perform...

Page 112: ... 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 Transmis...

Page 113: ...ehicle ground Shift lever is defective TCU shifts transmission to neutral OP mode Transmission shutdown Check the cables from TCU to shift lever Check signal combinations of shift lever positions F N R Fault is taken back if TCU detects a valid signal for the direction at the shift lever 13 Logical error at engine derating device TCU detected no reaction of engine while derating device active Afte...

Page 114: ...sistance of customer specific function No 1 device 21 S C to battery voltage at clutch cut off input The measured voltage is too high Cable is defective and is contacted to battery voltage Clutch cut off sensor has an internal defect Connector pin is contacted to battery voltage Clutch cut off function is disabled OP mode Normal Check the cable from TCU to the sensor Check the connectors Check the...

Page 115: ...to vehicle ground No reaction TCU uses default temperature OP mode Normal Check the cable from TCU to the sensor Check the connectors Check the temperature sensor 31 S C to battery voltage or O C at engine speed input TCU measures a voltage higher than 7 00V at speed input pin Cable is defective and is contacted to battery voltage Cable has no connection to TCU Speed sensor has an internal defect ...

Page 116: ...battery voltage or O C at internal speed input TCU measures a voltage higher than 7 00V at speed input pin Cable is defective and is contacted to vehicle battery voltage Cable has no connection to TCU Speed sensor has an internal defect Connector pin is contacted to battery voltage or has no contact OP mode Substitute clutch control Check the cable from TCU to the sensor Check the connectors Check...

Page 117: ... zero and turbine speed or internal speed not equal to zero Speed sensor has an internal defect Sensor gap has the wrong size Special mode for gear selection OP mode Substitute clutch control If a failure is existing at turbine speed TCU shifts to neutral OP mode Limp home Check the sensor signal of output speed sensor Check the sensor gap of output speed sensor Check the cable from TCU to the sen...

Page 118: ...e Cluster controller is defective Interference on CAN Bus No reaction Check cluster controller Check wire of CAN Bus Check cable to controller 61 AEB request signal CAN signal for AEB request is defective I O controller is defective Interference on CAN Bus No reaction OP mode Normal Check I O controller Omron master Check wire of CAN Bus Check cable to I O controller Omron master 64 Sarting gear s...

Page 119: ... TCU Check the regulator resistance Check internal wire harness of the gearbox See page 3 74 73 O C at clutch K1 The measured resistance value of the valve is out of limit Cable connector is defective and has no contact to TCU Regulator has an internal defect TCU shifts to neutral OP mode Limp home If failure at another clutch is pending TCU shifts to neutral OP mode TCU shutdown Check the cable f...

Page 120: ... neutral OP mode Limp home If failure at another clutch is pending TCU shifts to neutral OP mode TCU shutdown 余 余 余 余 Check the cable from TCU to the gearbox Check the connectors from gearbox to TCU Check the regulator resistance Check internal wire harness of the gearbox See page 3 74 79 O C at clutch K3 The measured resistance value of the valve is out of limit  Cable connector is defective and...

Page 121: ...erating device Check the connectors from gearbox to TCU Check the regulator resistance Check internal wire harness of the gearbox See page 3 74 83 O C at clutch K4 The measured resistance value of the valve is out of limit  Cable connector is defective and has contact to TCU ÂRegulator has an internal defect TCU shifts to neutral OP mode Limp home If failure at another clutch is pending TCU shift...

Page 122: ...OP mode TCU shutdown Check the cable from TCU to the gearbox Check the connectors from gearbox to TCU Check the regulator resistance Check internal wire harness of the gearbox See page 3 74 89 O C at clutch KR The measured resistance value of the valve is out of limit Cable connector is defective and has no contact to TCU Regulator has an internal defect TCU shifts to neutral OP mode Limp home If ...

Page 123: ...o battery voltage Cable is defective and has no connection to battery voltage Starter interlock relay has an internal defect Connector pin is contacted to battery voltage No reaction OP mode Normal Check the cable from TCU to the starter interlock relay Check the connectors from starter interlock relay to TCU Check the resistance of starter interlock relay See page 3 74 96 O C at relay starter int...

Page 124: ...nnection solenoid TCU detected a wrong voltage at the output pin that looks like a S C to vehicle ground Cable is defective and is contacted to vehicle ground Difflock solenoid has an internal defect Connector pin is contacted to vehicle ground No reaction OP mode Normal Check the cable from TCU to the difflock solenoid Check the connectors from difflock solenoid to TCU Check the resistance of dif...

Page 125: ...e warning device Check the connectors from warning device to TCU Check the resistance of warning device See page 3 74 B1 Slippage at clutch K1 TCU calculates a differential speed at closed clutch K1 If this calculated value is out of range TCU interprets this as slipping clutch Low pressure at clutch K1 Low main pressure Wrong signal at internal speed sensor Wrong signal at output speed sensor Wro...

Page 126: ...ain pressure Wrong signal at internal speed sensor Wrong signal at turbine speed sensor Wrong size of the sensor gap Clutch is defective TCU shifts to neutral OP mode Limp home If failure at another clutch is pending TCU shifts to neutral OP mode TCU shutdown Check pressure at clutch KV Check main pressure in the system Check sensor gap at internal speed sensor Check sensor gap at turbine speed se...

Page 127: ...ve the defined threshold programmable No reaction or shift to neutral OP mode Normal C3 Overtemp converter output TCU measured a oil temperature at the converter output that is the allowed threshold No reaction OP mode Normal Cool down machine Check oil level Check temperature sensor C4 S C to ground at joystick status indicator TCU detected a wrong voltage at the output pin that looks like a S C ...

Page 128: ...voltage at battery Measured voltage at power supply is lower than 18V 24V device Shift to neutral OP mode TCU shutdown Check power supply battery Check cables from batteries to TCU Check connectors from batteries to TCU D4 High voltage at battery Measured voltage at power supply is higher than 32 5V 24V device Shift to neutral OP mode TCU shutdown Check power supply battery Check cables from batte...

Page 129: ... together with fault code F2 F2 Configuration lost TCU has lost the correct configuration and can t control the transmission Interference during saving data on non volatile memory TCU is brand new or from another vehicle Transmission stay neutral OP mode TCU shutdown Reprogram the correct configurat ion for the vehicle e g with cluster controller F3 Application error Something of this application ...

Page 130: ...attery G is connected to battery voltage Cable Cable Open circuit R12 R1P R1C R2P R2C Short cut to ground R12 0 R1C R2C 0 R1P R2P Short cut to battery R12 0 R1C R2C 0 R1P R2P 0 76043PT19 76043PT20 1 R G 2 1 2 TCU P Power supply Actuator Sensor C Chassis Ground U Bat MEASURING OF RESISTANCE AT ACTUATOR SENSOR AND CABLE MEASURING OF RESISTANCE AT ACTUATOR SENSOR AND CABLE Actuator Actuator 5 5 1 1 2...

Page 131: ... the bevel gear and is sent at right angles At the same time the speed is reduced and passes through the both differentials to the axle shafts The power of the axle shafts is further reduced by planetary gear type final drives and is sent to the wheels Front axle Front axle 1 1 Rear axle Rear axle 2 2 1 1 1 2 3 4 2 3 2 3 4 2 3 1 1 Input 4 Axle housing 2 Output 3 Brake 7579A3PT15 7579A3PT16 1 Input...

Page 132: ...ear Swing Pinion gear Side gear Side gear Carrier Pinion gear Ring gear When turning When turning When turning the rotating speed of the left and right wheels is different so the pinion gear and side gear inside the differential assembly rotate in accordance with the difference between the rotating speed of the left and right wheels The power of the carrier is then transmitted to the axle gear sha...

Page 133: ...o absorb the shock from the ground surface to the machine and at the same time they must rotate in contact with the ground to gain the power which drives the machine Various types of tires are available to suit the purpose Therefore it is very important to select the correct tires for the type of work and bucket capacity 1 2 7407APT10 ...

Page 134: ...vel and has adequate space to complete the checks The engine and all other major components must be at operating temperature for some checks Locate system check in the left column and read completely following the sequence from left to right Read each check completely before performing At the end of each check if no problem is found OK that check is complete or an additional check is needed If pro...

Page 135: ...cks neutral lock latch checks Engine OFF Move gear selector lever to each position NOTE NOTE Gear selector lever position changes slightly as steering column is tilted FEEL FEEL Lever must move freely through all positions Engage neutral lock Apply slight effort to move lever into forward F and reverse R LOOK LOOK Neutral lock must stay engaged OK OK Check completed NOT OK NOT OK Repair lock or re...

Page 136: ...selector lever kick down switch once LOOK FEEL LOOK FEEL Transmission must shift back to 2nd gear Shift to 3rd or 4th gear and press gear selector lever kick down switch once LOOK FEEL LOOK FEEL Transmission must not shift down Select T M shift mode to AL auto light mode Drive machine at approximately 90 speed of max speed in each gear 2nd or 3rd or 4th Shift to 2nd or 3rd or 4th gear in each forw...

Page 137: ...ning Run engine at approximately 1300 rpm Put transmission in 1st forward shift several times from forward to reverse and reverse to forward Repeat check in 2nd gear LOOK LOOK Unit must slow down and change direction smoothly OK OK Check completed NOT OK NOT OK Go to unit shifts too fast chapter 2 in this group Torque converter check Torque converter check Start engine Apply service brakes and rel...

Page 138: ...ck out procedure See group 3 in section 1 Step 2 Operational checks In this group Step 3 Troubleshooting Step 4 Tests and or adjustments See group 3 1 1 Problem Cause Remedy Transmission slippage Low oil level Wrong oil grade Restricted transmission pump suction screen Leak in transmission control valve or gasket Low transmission pump flow due to worn pump Weak or broken pressure regulat ing valve...

Page 139: ... purpose Do transmission element leakage test using system pressure Repair transmission See transmission pressure is low in this group Do brake pedal operational check Do service and park system drag checks Do torque converter stall test If engine pulldown in normal torque converter is good Drain transmission to determine if large pieces of metal contamination are present Inspect drive shafts and ...

Page 140: ...ontrol valve to transmission Transmission system pressure is low one or two gears Failed transmission pump Failed transmission control valve gasket Leakage in clutch piston or seal ring Do pump flow test Inspect transmission control valve for external leakage Remove control valve Inspect or replace gasket Disassemble and repair Transmission shifts too low Low oil level aeration of oil Low transmis...

Page 141: ...ke dragging Pinched restricted or leaking lube lines Machine operated in too high gear range Malfunction in temperature gauge or sensor Restricted air flow through oil cooler or radiator Failed oil cooler bypass valve In thermal bypass valve Failed thermal bypass valve Internally restricted oil cooler Leakage in transmission hydraulic system Malfunction in converter relief valve Low transmission p...

Page 142: ...e speed Failed universal joints on transmission drive shaft or differential drive shafts Add oil Check engine speed Check universal joints Machine lacks power and acceleration Engine high idle speed set too low Incorrect transmission oil Aerated oil Low transmission pressure Warped transmission clutch Torn transmission control valve gasket Brake drag Failed torque converter Low engine power Check ...

Page 143: ...nsmission pressure pump flow and leakage check Transmission pressure light comes ON for each shift Cold oil No time delay in monitor Restriction in modulation orifice Stuck PPC valve Low transmission pressure circuit Leak in transmission pressure circuit Failed transmission pump Clogged filter Warm oil to specification Do monitor check Remove orifice and inspect for restriction and or plugging Rem...

Page 144: ... Do brake check Remove and inspect pinion Check to ensure pinion housing was indexed Remove pinion gear housing and inspect ring and pinion gear Remove differential housing drain plug and inspect for metal particles Disassemble and inspect Do axle bearing adjustment check Remove differential Inspect repair Oil seeping from outer axle seal Excessive end play in axle Worn outer bearing and or cup Ov...

Page 145: ...shafts Worn front drive line support bearing Bent drive shaft Loose yoke retaining nuts drive shafts wobble at high speed Rear axle oscillating support Lack of lubrication Inspect Align drive shaft yokes Inspect repair Inspect all drive shafts Replace Inspect Replace Inspect repair Lubricate with proper grade of grease ...

Page 146: ...RE AND TEMPERATURE OIL PRESSURE AND TEMPERATURE 1 1 7609A3PT14 Port Description Size 51 Converter inlet opening pressure 11 2 bar H M10 1 0 52 Converter outlet opening pressure 4 3 3 bar M14 1 5 53 Forward clutch 16 2 bar KV B M10 1 0 55 Reverse clutch 16 2 bar KR E M10 1 0 56 1st clutch 16 2 bar K1 D M10 1 0 57 2nd clutch 16 2 bar K2 A M10 1 0 58 3rd clutch 16 2 bar K3 C M10 1 0 60 4th clutch 16 ...

Page 147: ...ransmitter n turbine M18 1 5 34 Speed sensor n output and speedometer 47 Inductive transmitter n central gear train M18 1 5 48 Inductive transmitter n engine M18 1 5 54 Filter contamination switch M14 1 5 Port Description Size 10 Breather M10 1 0 49 Plug connection on the hydraulic control unit 68 Pilot pressure option J M16 1 5 69 System pressure option G M16 1 5 SOLENOID VALVE SOLENOID VALVE 5 s...

Page 148: ...mbly truck 5870 350 000 Holding fixtures 5870 350 063 Clamping angles 5870 350 090 Drain oil prior to starting disassembly Disposal of oil according to legal requirements 1 1 Removal of filter Removal of filter Separate fine filter 1 from filter head by means of belt wrench Belt wrench 5870 105 005 1 1 7609ATM002 7609ATM003 Loosen Torx screws 2 and separate filter head 1 from transmission housing ...

Page 149: ...5873 042 002 Adjusting screws M6 5870 204 063 2 2 Remove gear shift control assy 1 and sealing plate 2 Adjusting screws M6 5870 204 063 Remove differential pressure switch for fine filter from duct plate 4 1 Switch with O ring 2 Piston 3 Compression spring Loosen hexagon nuts and Torx screws and separate duct plate 1 and seal 2 from housing rear part 7609ATM004 7609ATM005 7609ATM006 7609ATM007 2 1...

Page 150: ...ss 1 towards valve block 2 Pull converter safety valve 1 out of housing hole Loosen Torx screws 1 Socket wrench TX 27 5873 042 002 Separate duct plate 1 and sealing plate 2 from valve block 3 7609ATM008 7609ATM009 7609ATM010 7609ATM011 2 1 1 1 2 3 1 ...

Page 151: ...ove cover 2 Remove opposite cover 3 in the same way Socket wrenchTX 27 5873 042 002 Remove wiring harness 1 Loosen cylindrical screws 3 remove fixing plates and remove pressure controllers 2 Loosen cylindrical screws remove fixing plates and remove pressure controllers 1 on opposite side 1 1 1 1 2 2 3 3 ...

Page 152: ...6 7609ATM016 Separate housing from valve housing by loosening the adjusting screws equally Adjusting screws 5870 204 036 Remove individual parts 1 Pressure reducing valve 2 Vibration dampers 3 Follow on slide Remove individual parts of opposite side analogously 1 Main pressure valve 2 Vibration dampers 3 Follow on slide 7609ATM017 7609ATM018 7609ATM019 16 16 1 S 2 2 3 3 1 1 ...

Page 153: ...nstallation position of connecting housing 4 towards valve block 5 Loosen cylindrical screws 1 and remove lock up clutch valve Loosen screw neck 2 and remove O rings Loosen torx screws 3 and remove connecting housing Further disassembly steps see figure TM015 to TM019 3 3 7609ATM020 2 3 1 4 5 ...

Page 154: ...k 3 Breather 4 Inductive sensor n central gear chain 5 Inductive sensor n turbine 6 Inductive sensor n engine 7609ATM021 7609ATM022 2 1 4 3 1 2 DISASSEMBLY DISASSEMBLY Inductive sensor hall sensor breather oil Inductive sensor hall sensor breather oil filler and oil drain plug filler and oil drain plug 2 2 1 2 5 6 Loosen cylindrical screw 1 and remove speed sensor hall sensor Remove O ring 2 Speed...

Page 155: ...ure pump Engine connection oil pressure pump converter back pressure valve and converter back pressure valve and temperature sensor measuring point temperature sensor measuring point 63 after the converter 63 after the converter 3 3 1 1 7609ATM023 7609ATM024 2 1 3 1 Oil pressure pump Oil pressure pump Loosen bolted connection 1 converter bell housing oil feed housing and remove converter bell hous...

Page 156: ...gether with oil pressure pump from transmission housing front part Separate oil pressure pump 1 from oil feed housing 2 Remove O ring 1 Loosen cylindrical screws 2 7609ATM027 7609ATM026 7609ATM028 2 2 1 1 2 1 Check oil gear pump In case of wear marks in the pump housing cover or on the inner and outer rotor the complete oil pressure pump is to be replaced 1 Cover 2 Inner rotor 3 Outer rotor 4 Pump...

Page 157: ...Preload converter safety valve 1 by means of screw driver or assembly aid and remove locking plate 2 Assembly aid 5870 345 107 3 3 Remove individual parts of converter safety valve which are getting released 1 Pressure plate 2 Compression spring 3 Piston Remove temperature sensor 1 7609ATM031 7609ATM033 7609ATM032 2 2 3 1 1 1 ...

Page 158: ...f valve 2 out of the housing hole 7609ATM034 2 1 DISASSEMBLY DISASSEMBLY Without emergency steering pump Without emergency steering pump Loosen bolted connection cover 1 and cover front part 2 and remove cover 3 and 4 and seal 4 4 7609ATM035 2 4 3 1 ...

Page 159: ...e Loosen hexagon screws 1 remove washer and O ring Output flange on output side Output flange on output side Loosen hexagon screws 1 remove washer and O ring 2 2 Pull off output flange 1 and remove shaft seal 2 Pull off output flange 1 and remove shaft seal 2 5 5 1 1 7609ATM036 7609ATM038 7609ATM037 7609ATM039 2 1 1 2 1 1 ...

Page 160: ... the brake disc 2 can be rotated by hand HP hand operated pump 5870 287 007 MINIMESS coupling M12 1 5 5870 950 101 3 3 Loosen hexagon nut with open end wrench insert Open end wrench insert AA00 244 432 7609ATM040 7609ATM041 1 2 Loosen hexagon screws 2 and remove parking brake 1 see figure TM043 Loosen hexagon screws 2 of bolted brake disk output flange connection and remove brake disk 3 7609ATM042...

Page 161: ...3 105 Loosen hexagon screws 1 remove washer and O ring Pull off output flange 2 and remove shaft seal Remove cylindrical screw with washer 3 7609ATM044 1 2 3 ...

Page 162: ...sen bolted connection 2 between housing front and rear part and separate housing rear part by means of lifting device 7609ATM045 Loosen bolted connection 1 of oil screen sheets 7609ATM046 Remove output shaft 1 and lower oil screen sheet 2 from housing 7609ATM047 Remove all rectangular rings 1 from the clutches and all O rings 2 from the oil tubes 7609ATM048 2 3 4 6 6 1 1 2 1 1 2 1 2 ...

Page 163: ...input shaft 2 are only fixed by the gear chain 7609ATM050 Separate housing rear part incl clutches from housing front part by means of the lifting device and attaches it to the assembly truck 1 Clutch KV 2 Input shaft 3 Clutch KR 4 Pump shaft Clutches KV KR and input shaft are only fixed by the gear chain Attention must be paid that the non fixed components of the gear chain do not get loose 7609A...

Page 164: ...ter rings arrows from the housing front part If contrary to the recommendation the tapered roller bearings of clutches input and output are not replaced it is imperative to ensure the previous pairing bearing outer ring bearing inner ring Bearing outer ring and bearing inner ring must be marked 7609ATM054 9 1 2 Disengage retaining ring 1 and remove pump shafts 2 7609ATM055 10 Press ball bearing 1 ...

Page 165: ... recommendation the tapered roller bearings of clutches input and output are not replaced it is imperative to ensure the previous pairing bearing outer ring bearing inner ring Bearing outer ring and bearing inner ring must be marked The lubrication lines are rolled in 1 and 2 and are highly difficult to remove In case of damage use of the appropriate special tool is imperative for fitting or repla...

Page 166: ...f the shaft Forcing device 5870 026 100 Grab sleeve 5873 001 057 or Rapid grip 5873 011 011 DISASSEMBLY DISASSEMBLY Clutches KV KR K1 K2 K3 K4 input Clutches KV KR K1 K2 K3 K4 input and output shaft and output shaft See opposite picture K1 clutch K2 clutch K3 clutch K4 clutch KR clutch KV clutch AN input shaft 7 7 Snap out retaining ring 1 KV KR K4 K1 K3 AN 1 1 2 ...

Page 167: ...ler gear 1 by means of cut off device and pull it off the clutch shaft Cut off device 5870 300 024 Puller 5870 300 033 Snap retaining ring 2 out of the idler gear 1 and remove ball bearing 3 Remove needle cage 1 from the shaft 2 7609ATM064 7609ATM065 7609ATM066 7609ATM067 1 1 1 2 3 1 2 ...

Page 168: ... tapered roller bearing inner ring off the shaft Forcing device 5870 026 100 Grab sleeve 5873 001 057 or Rapid grip 5873 011 011 Unsnap snap ring 1 Remove end shim 1 and disc set 2 out the disc carrier 3 7609ATM068 7609ATM069 7609ATM070 7609ATM071 1 2 1 1 2 3 ...

Page 169: ...nsnap L ring Assembly aid 5870 345 088 1 Remove support shim 1 compression spring 2 and washer 3 7609ATM073 Lift piston 1 by means of compressed air out of the cylinder bore and remove it Remove both O rings 1 and 2 7609ATM074 7609ATM075 1 2 3 2 1 1 ...

Page 170: ... TM085 TM090 KR clutch KR clutch Remove stud bolt 1 and snap out piston ring 2 2 2 Pull tapered roller bearing inner ring off the shaft Forcing device 5870 026 100 Grab sleeve 5873 001 059 Snap out retaining ring 1 7609ATM076 7609ATM077 7609ATM078 7609ATM079 2 1 1 1 ...

Page 171: ...tch shaft Cut off device 5870 300 024 Puller 5870 300 033 Snap retaining ring 2 out of the idler gear 1 and remove ball bearing 3 Remove needle cage 1 from the shaft 2 7609ATM080 7609ATM081 7609ATM082 Turn shaft 2 by 180 and snap out piston ring 1 7609ATM083 1 1 2 3 1 1 2 2 ...

Page 172: ...device 5870 026 100 Grab sleeve 5873 001 057 or Rapid grip 5873 011 011 Unsnap snap ring 1 Remove end shim 1 and disc set 2 out the disc carrier 3 7609ATM084 7609ATM085 7609ATM086 7609ATM087 Preload compression spring 1 unsnap L ring Assembly aid 5870 345 088 1 1 3 2 1 ...

Page 173: ...and washer 3 7609ATM088 Lift piston 1 by means of compressed air out of the cylinder bore and remove it Remove both O rings 1 and 2 7609ATM089 7609ATM090 1 2 3 2 1 1 K1 clutch K1 clutch Remove stud bolt 1 and snap out piston ring 2 3 3 7609ATM091 1 2 ...

Page 174: ...g off the shaft Forcing device 5870 026 100 Grab sleeve 5873 001 059 Snap out retaining ring 1 7609ATM092 7609ATM093 Remove axial bearing assy 1 7609ATM094 1 1 Take off idler gear 1 remove needle cage 2 and axial bearing assy 3 7609ATM095 1 2 3 ...

Page 175: ...utch 1 see figure TM099 TM104 Turn shaft 2 by 180 and snap out piston ring 1 7609ATM096 7609ATM097 Pull tapered roller bearing inner ring off the shaft Basic tool 5873 002 001 Grab sleeve 5873 002 038 7609ATM098 1 1 2 Unsnap snap ring 1 7609ATM099 1 ...

Page 176: ...the disc carrier 3 Preload cup springs unsnap L ring 1 Assembly aid 5870 345 088 7609ATM100 7609ATM101 7609ATM102 Remove cup spring package 1 1 1 1 3 2 Lift piston 1 by means of compressed air out of the cylinder bore and remove it 7609ATM103 1 ...

Page 177: ... 2 1 K2 clutch K2 clutch Remove stud bolt 1 and snap out piston ring 2 4 4 Pull tapered roller bearing inner ring off the shaft Forcing device 5870 026 100 Grab sleeve 5873 001 059 Snap out retaining ring 1 7609ATM105 7609ATM106 7609ATM107 2 1 1 ...

Page 178: ...ATM108 1 Take off idler gear 1 remove needle cage 2 and axial bearing assy 3 Pull clutch 1 off the shaft Disassembly clutch 1 see figure TM113 TM118 Turn shaft 2 by 180 and snap out piston ring 1 7609ATM109 7609ATM110 7609ATM111 2 1 3 1 2 1 ...

Page 179: ...he shaft Forcing device 5870 026 100 Grab sleeve 5873 001 059 7609ATM112 Unsnap snap ring 1 Remove end shim 1 and disc set 2 out the disc carrier 3 Preload cup springs unsnap L ring 1 Assembly aid 5870 345 088 7609ATM113 7609ATM114 7609ATM115 1 1 3 2 1 ...

Page 180: ...ove cup spring package 1 1 Lift piston 1 by means of compressed air out of the cylinder bore and remove it Remove both O rings 1 and 2 7609ATM117 7609ATM118 2 1 1 7609ATM119 K3 clutch K3 clutch Snap out piston ring 1 5 5 1 ...

Page 181: ...aft Forcing device 5870 026 100 Grab sleeve 5873 001 059 Remove axial bearing assy 1 Take off idler gear 1 remove needle cage 2 and axial bearing assy 3 7609ATM121 7609ATM122 1 1 2 3 Pull clutch 1 off the shaft Disassembly clutch 1 see figure TM126 TM131 7609ATM123 1 ...

Page 182: ...ton ring 2 Pull tapered roller bearing inner ring off the shaft Basic tool 5873 002 001 Grab sleeve 5873 002 038 7609ATM124 7609ATM125 Unsnap snap ring 1 7609ATM126 2 1 1 Remove end shim 1 and disc set 2 out the disc carrier 3 7609ATM127 3 2 1 ...

Page 183: ...snap L ring 1 Assembly aid 5870 345 088 Remove cup spring package 1 7609ATM128 7609ATM129 7609ATM130 Lift piston 1 by means of compressed air out of the cylinder bore and remove it 1 1 1 Remove both O rings 1 and 2 7609ATM131 2 1 ...

Page 184: ...t piston ring 2 6 6 Pull tapered roller bearing inner ring off the shaft Forcing device 5870 026 100 Grab sleeve 5873 001 057 or Rapid grip 5873 011 011 Snap out 1 retaining ring 7609ATM134 1 1 2 Pull clutch 1 off the shaft Disassembly clutch 1 see figure TM140 TM145 7609ATM135 1 ...

Page 185: ...nd axial bearing assy 2 The gear 3 cannot be removed shrink fit Turn shaft 2 by 180 and snap out piston ring 1 7609ATM136 7609ATM137 7609ATM138 Pull tapered roller bearing inner ring off the shaft Forcing device 5870 026 100 Grab sleeve 5873 001 059 7609ATM139 2 1 1 2 3 2 1 ...

Page 186: ... snap ring 1 Remove end shim 1 and disc set 2 out the disc carrier 3 Preload cup springs unsnap L ring 1 Assembly aid 5870 345 088 7609ATM140 7609ATM141 7609ATM142 1 1 3 2 1 7609ATM143 Remove cup spring package 1 1 ...

Page 187: ...TM145 2 1 1 7609ATM146 Input shaft Input shaft Snap out piston ring 1 Turbine wheel shaft and drive gear 2 are fixed by a snap ring When separated the components will be destroyed 7 7 1 2 7609ATM147 Pull tapered roller bearing inner ring off the drive gear Basic tool 5873 001 000 Grab sleeve 5873 001 058 or Rapid grip 5873 011 014 ...

Page 188: ...eparate input shaft and gear 1 shrink fit 7609ATM148 1 7609ATM149 7609ATM150 Output shaft Output shaft Pull tapered roller bearing inner ring off the output shaft and remove oil screen sheet 1 Basic tool 5873 002 001 Grab sleeve 5873 002 038 8 8 Turn output shaft by 180 and pull off tapered roller bearing inner ring Basic tool 5873 002 001 Grab sleeve 5873 002 038 1 ...

Page 189: ...09ATM151 7609ATM152 7609ATM153 7609ATM154 8 8 1 1 2 1 1 2 1 3 Mount bearing inner ring 1 until contact is obtained Fit rectangular ring 40 2 5 2 Wear protective gloves Adjust bearing inner ring after cooling down Mount needle cage 60 68 20 1 onto the shaft and oil it Install ball bearing 50 90 18 2 into the idler gear 1 until contact is obtained and fix it by means of retaining ring 90 3 3 ...

Page 190: ...m 1 75 3 2 142 3 Check function of the drain valve see arrow There must be no jamming of the ball Place piston 1 into the disk carrier Observe installation position see figure 7609ATM155 7609ATM156 7609ATM157 Use a hand operated press to place piston into the disk carrier by means of the assembly aid Assembly aid 5870 345 088 7609ATM158 2 1 1 1 ...

Page 191: ...70 345 124 Inner installer and pressure piece It is always necessary to mount a new L ring Different clutches disc arrangements with relevant disc clearance can be installed depending on the parts manual The actually installed clutch and disc arrangement must be taken from the corresponding parts manual Figure no TM162 and TM163 illustrates the different disc arrangements Disk carrier with piston ...

Page 192: ...nd inner disks alternately into the disk carrier 4 as personated in TM163 1 Friction disk coated on one side 1 pcs 2 Outer disks 10 pcs 3 Inner disks 10 pcs Take care that the uncoated blank side of the friction disk 1 is showing towards the piston Number of friction surfaces 16 Mount end plate 1 and fix disk package by means of snap ring 2 e g thickness 2 65 mm recommended value Press on end plat...

Page 193: ...ed with an appropriate snap ring optional thicknesses 2 1 4 2 mm Install clutch until contact is obtained Mount inner disks onto the inner disk carrier by means of short left right rotations Wear protective gloves Heat up clutch inner diameter approx 120 C Fix clutch 1 by means of retaining ring 55 2 2 7609ATM166 7609ATM168 7609ATM167 7609ATM169 F L R 2 1 16 18 17 ...

Page 194: ...bearing inner ring approx 120 C Mount stud bolt 1 Tightening torque M10 8 8 16 1 73 kgf m 12 5 lbf ft Fit rectangular ring 40 2 5 2 Check closing and opening of the clutch by means of compressed air at the hole see arrow Closing and opening of the clutch must be clearly audible 7609ATM171 7609ATM170 7609ATM172 7609ATM173 19 21 20 1 2 1 ...

Page 195: ...utch KR Clutch Heat up bearing inner ring approx 120 C 7609ATM175 7609ATM176 7609ATM177 2 2 2 1 1 Mount bearing inner ring 1 until contact is obtained Fit rectangular ring 40 2 5 2 Wear protective gloves Adjust bearing inner ring after cooling down Mount needle cage 60 68 20 1 onto the shaft and oil it ...

Page 196: ...ess in preassembled idler gear 1 onto the shaft until contact is obtained Place both O rings 1 and 2 into the piston grooves and oil them 1 75 3 2 142 3 Check function of the drain valve see arrow There must be no jamming of the ball Place piston 1 into the disk carrier Observe installation position see figure 7609ATM179 7609ATM180 7609ATM181 2 1 1 1 ...

Page 197: ...nner installer see figure TM184 Preload compression spring by means of assembly aid S1 and pressure piece S2 until L ring has engaged into the annular groove Assembly aid S1 5870 345 088 Assembly fixture S S2 5870 345 124 Inner installer and pressure piece It is always necessary to mount a new L ring Disk carrier with piston retraction 1 Washer 2 Compression spring 3 Support shim 4 L ring 5 Disk c...

Page 198: ...ated in figure TM186 1 Friction disk coated on one side 1 pcs 2 Outer disks 10 pcs 3 Inner disks 10 pcs Take care that the uncoated blank side of the friction disk 1 is showing towards the piston Number of friction surfaces 20 Install outer and inner disks alternately into the disk carrier 4 as personated in figure TM187 1 Friction disk coated on one side 1 pcs 2 Outer disks 10 pcs 3 Inner disks 1...

Page 199: ...ad disk clearance Disk clearance 2 65 2 95 mm In case of deviations the disk clearance must be corrected with an appropriate snap ring optional thicknesses 2 1 4 2 mm Heat up clutch inner diameter approx 120 C 7609ATM190 7609ATM191 16 F Mount end plate 1 and fix disk package by means of snap ring 2 e g thickness 2 65 mm recommended value 7609ATM188 2 1 ...

Page 200: ...ft right rotations Wear protective gloves Fix clutch 1 by means of retaining ring 55 2 2 7609ATM192 7609ATM193 18 17 L R 2 1 Mount bearing inner ring 1 until contact is obtained Wear protective gloves Adjust bearing inner ring after cooling down Heat up bearing inner ring approx 120 C 7609ATM195 7609ATM194 19 20 1 ...

Page 201: ... opening of the clutch by means of compressed air at the hole see arrow Closing and opening of the clutch must be clearly audible 7609ATM196 7609ATM197 21 2 1 7609ATM198 Install sealing cap orifice 1 Wet contact surface with loctite Type No 262 22 1 Clutch K1 Clutch K1 Heat up bearing inner ring approx 120 C 7609ATM199 3 3 ...

Page 202: ...r cooling down Place both O rings 1 and 2 into the piston grooves and oil them 1 75 3 2 158 3 Check function of the drain valve see arrow There must be no jamming of the ball Place piston 1 into the disk carrier Observe installation position see figure 2 Use a hand operated press to place piston into the disk carrier by means of the assembly aid Assembly aid 5870 345 088 7609ATM203 ...

Page 203: ... S2 5870 345 124 Inner installer and pressure piece It is always necessary to mount a new L ring 7609ATM204 7609ATM205 Disk carrier with piston retraction 1 Cup spring package 2 L ring 3 Disk carrier 4 Piston with O rings 7609ATM206 2 1 S S1 S2 2 1 3 4 Install outer and inner disks alternately into the disk carrier 4 as personated in figure TM207 1 Friction disk coated on one side 1 pcs 2 Outer di...

Page 204: ...kg and set dial indicator to zero 7609ATM208 7609ATM209 F Then press end plate against the snap ring upwards and read disk clearance Disk clearance 2 35 2 65 mm In case of deviations the disk clearance must be corrected with an appropriate snap ring optional thicknesses 2 1 4 2 mm 7609ATM210 2 1 F 7609ATM211 Heat up clutch inner diameter approx 120 C ...

Page 205: ...and axial washer 55 78 1 3 and oil it Install chamfer see arrow of running disk 1 showing towards the axial cage 7609ATM212 7609ATM213 2 1 1 Mount needle cage 55 63 64 1 and oil it 7609ATM214 3 1 Install 1 idler Mount inner disks onto the inner disk carrier idler by means of short left right rotations 7609ATM215 16 L R 1 ...

Page 206: ...g disk 3 showing towards the axial cage Fix idler gear 1 and single parts by means of retaining ring 2 7609ATM216 7609ATM217 18 17 2 1 Heat up bearing inner ring approx 120 C 7609ATM218 19 1 3 2 Mount bearing inner ring 1 until contact is obtained Wear protective gloves Adjust bearing inner ring after cooling down 7609ATM219 20 1 ...

Page 207: ...mpressed air at the hole see arrow Closing and opening of the clutch must be clearly audible 7609ATM220 7609ATM221 21 2 1 Clutch K2 Clutch K2 Heat up bearing inner ring approx 120 C 7609ATM222 7609ATM223 4 4 1 2 Mount bearing inner ring 1 until contact is obtained Fit rectangular ring 40 2 5 2 Wear protective gloves Adjust bearing inner ring after cooling down ...

Page 208: ...n 1 into the disk carrier Observe installation position see figure 2 Use a hand operated press to place piston into the disk carrier by means of the assembly aid Assembly aid 5870 345 088 Mount inner installer S onto the disk carrier Install cup spring package 1 and L ring 2 Installation position cup spring package and L ring see figure TM229 Inner installer see figure TM228 7609ATM226 7609ATM227 ...

Page 209: ...Cup spring package 2 L ring 3 Disk carrier 4 Piston with O rings 7609ATM229 S1 S2 2 1 3 4 Install outer and inner disks alternately into the disk carrier 4 as personated in figure TM230 1 Friction disk coated on one side 1 pcs 2 Outer disks 7 pcs 3 Inner disks 7 pcs Take care that the uncoated blank side of the friction disk 1 is showing towards the piston Number of friction surfaces 14 7609ATM230...

Page 210: ...pwards and read disk clearance Disk clearance 1 75 2 05 mm see figure TM230 In case of deviations the disk clearance must be corrected with an appropriate snap ring optional thicknesses 2 1 4 2 mm 7609ATM233 F 7609ATM234 Heat up clutch inner diameter approx 120 C Mount clutch 1 until contact is obtained Wear protective gloves 7609ATM235 1 ...

Page 211: ...ATM236 2 1 Mount needle cage 55 63 50 1 and oil it 7609ATM237 3 1 Mount axial washer 55 78 1 1 axial cage 55 78 3 2 and running disk 55 78 5 3 and oil it Install chamfer see arrow of running disk 3 showing towards the axial cage Install 1 idler Mount inner disks onto the inner disk carrier idler by means of short left right rotations 7609ATM239 7609ATM238 L R 1 3 2 1 16 17 ...

Page 212: ...ng inner ring approx 120 C 7609ATM241 Mount bearing inner ring 1 until contact is obtained Wear protective gloves Adjust bearing inner ring after cooling down Mount stud bolt 1 Tightening torque M10 8 8 16 1 73 kgf m 12 5 lbf ft Fit rectangular ring 40 2 5 2 7609ATM242 7609ATM243 21 1 2 1 18 19 20 ...

Page 213: ...609ATM245 7609ATM246 7609ATM247 5 5 1 2 1 Mount bearing inner ring 1 until contact is obtained Fit rectangular ring 40 2 5 2 Wear protective gloves Adjust bearing inner ring after cooling down Mount stud bolt 3 Tightening torque M10 8 8 16 1 73 kgf m 12 5 lbf ft Place both O rings 1 and 2 into the piston grooves and oil them 1 75 3 2 142 3 Check function of the drain valve see arrow There must be ...

Page 214: ...rrier Install cup spring package 1 and L ring 2 Installation position cup spring package and L ring see figure TM252 Inner installer see TM251 Preload cup spring package by means of assembly aid S1 and pressure piece S2 until L ring has engaged into the annular groove Assembly aid S1 5870 345 088 Assembly fixture S S2 5870 345 124 Inner installer and pressure piece It is always necessary to mount ...

Page 215: ... 14 7609ATM253 7609ATM254 Install outer and inner disks alternately into the disk carrier 4 as personated in figure TM254 1 Friction disk coated on one side 1 pcs 2 Outer disks 7 pcs 3 Inner disks 7 pcs Take care that the uncoated blank side of the friction disk 1 is showing towards the piston Number of friction surfaces 12 2 2 1 1 4 4 3 3 Different clutches disc arrangements with relevant disc cl...

Page 216: ...ate with F approx 100 N 10 kg and set dial indicator to zero 7609ATM257 F Then press end plate against the snap ring upwards and read disk clearance Disk clearance 1 75 2 05 mm In case of deviations the disk clearance must be corrected with an appropriate snap ring optional thicknesses 2 1 4 2 mm Heat up clutch inner diameter approx 120 C 7609ATM258 ...

Page 217: ... 55 78 3 2 and axial washer 55 78 1 3 and oil it Install chamfer see arrow of running disk 1 showing towards the axial cage Install 1 idler Mount inner disks onto the inner disk carrier idler by means of short left right rotations Mount needle cage 55 63 50 1 and oil it 7609ATM262 7609ATM261 7609ATM260 L R 1 1 3 2 1 16 17 ...

Page 218: ...3 2 7609ATM264 Pay attention that the running disk is flush with the shaft see arrow collar to ensure that all inner disks are mounted on the idler gear teeth Heat up bearing inner ring approx 120 C 7609ATM265 Mount bearing inner ring 1 until contact is obtained Fit rectangular ring 40 2 5 2 Wear protective gloves Adjust bearing inner ring after cooling down 7609ATM266 2 1 18 19 20 ...

Page 219: ...Clutch K4 Clutch Heat up bearing inner ring approx 120 C 7609ATM268 7609ATM269 7609ATM270 6 6 1 2 1 Mount bearing inner ring 1 until contact is obtained Fit rectangular ring 40 2 5 2 Wear protective gloves Adjust bearing inner ring after cooling down Undercool shaft 1 approx 80 C heat up gear 2 approx 120 C and mount until contact is obtained Wear protective gloves 2 ...

Page 220: ... 80 2 5 1 Mount lower axial washer 55 78 1 1 axial needle cage 55 78 3 2 and upper axial washer 55 78 1 1 and oil it Upper and lower axial washer are identical Mount needle cage 55 63 50 1 and oil it Mount idler gear 1 7609ATM272 7609ATM273 7609ATM274 2 1 1 1 ...

Page 221: ...Place both O rings 1 and 2 into the piston grooves and oil them 1 75 3 2 142 3 Check function of the drain valve see arrow There must be no jamming of the ball Place piston 1 into the disk carrier Observe installation position see figure 7609ATM276 7609ATM277 1 Use a hand operated press to place piston into the disk carrier by means of the assembly aid Assembly aid 5870 345 088 7609ATM278 2 1 ...

Page 222: ...l cup spring package 1 and L ring 2 Installation position cup spring package and L ring see figure TM281 Inner installer see figure TM280 Preload cup spring package by means of assembly aid S1 and pressure piece S2 until L ring has engaged into the annular groove Assembly aid S1 5870 345 088 Assembly fixture S S2 5870 345 124 Inner installer and pressure piece It is always necessary to mount a new...

Page 223: ...learance Disk clearance 1 35 1 65 mm see figure TM282 In case of deviations the disk clearance must be corrected with an appropriate snap ring optional thicknesses 2 1 4 2 mm Press on end plate with F approx 100 N 10 kg and set dial indicator to zero Magnetic stand 5870 200 055 Dial indicator 5870 200 057 Heat up bearing inner ring approx 120 C 7609ATM285 7609ATM284 7609ATM286 18 F F 16 17 ...

Page 224: ...L R 1 Secure clutch by means of retaining ring 55 2 1 Mount bearing inner ring 1 until contact is obtained Wear protective gloves Adjust bearing inner ring after cooling down Fit rectangular ring 40 2 5 2 Mount stud bolt 3 Tightening torque M10 8 8 16 1 73 kgf m 12 5 lbf ft Heat up bearing inner ring approx 120 C 7609ATM288 7609ATM290 7609ATM289 22 21 1 1 3 2 19 20 ...

Page 225: ...tch must be clearly audible 7609ATM291 Input shaft Input shaft Undercool input shaft 1 approx 80 C heat up drive gear 2 approx 120 C and mount until contact is obtained Wear protective gloves 7 7 Secure drive gear by means of retaining ring 100 3 1 7609ATM292 7609ATM293 Heat up bearing inner ring approx 120 C 7609ATM294 1 2 1 ...

Page 226: ... ring after cooling down 7609ATM295 1 Heat up bearing inner ring approx 120 C Mount bearing inner ring 1 until contact is obtained Wear protective gloves Adjust bearing inner ring after cooling down Install snap ring 1 into the annular groove 2 of the turbine shaft 7609ATM296 7609ATM297 7609ATM298 1 1 2 ...

Page 227: ... up clutch 5 speed T M Mount turbine shaft 1 until the snap ring engages into the input shaft groove Turbine shaft is axially fixed Snap in and interlock rectangular ring 2 60 3 3 36 2 5 7609ATM300 1 2 3 Output shaft Output shaft Heat up bearing inner ring approx 120 C 7609ATM301 7609ATM302 8 8 1 Mount bearing inner ring 1 until contact is obtained Wear protective gloves Adjust bearing inner ring ...

Page 228: ...TM303 7609ATM304 1 Mount screen sheet 1 Heat up bearing inner ring approx 120 C Mount bearing inner ring 1 until contact is obtained Wear protective gloves Adjust bearing inner ring after cooling down 7609ATM305 1 ...

Page 229: ...lling tool 5870 600 003 Lubricant 5870 451 006 7609ATM306 9 9 1 1 2 The spare parts service supplies the lubri cating oil tube 1 only as a complete package with the housing front part Single parts delivery upon request only Assembly is only possible with the spe cial tool Rolling tool 5870 600 005 Lubricant 5870 451 006 7609ATM307 Mount O rings 22 3 into the annular groove of the oil tubes 1 and 2...

Page 230: ...609ATM310 1 2 Insert all bearing outer rings into the bearing holes of both housing parts Housing front part AN Input AB Output KV Forward clutch KR Reverse clutch K1 1st gear clutch K2 2nd gear clutch K3 3rd gear clutch K4 4th gear clutch Installation position see figure TM311 and TM312 7609ATM311 4 KR AN K4 K1 AB KV K2 K3 Mount O rings 22 3 into the annular groove of the oil tubes 1 and 2 and oi...

Page 231: ... See figure TM054 and TM055 7609ATM312 5 KV AN K2 K3 KR K4 K1 AB Due to the installation conditions the installation of single clutches without using the special tool is not possible Risk of injury Risk of injury Install clutches by means of housing rear part figure TM320 to TM321 Housing rear part will be removed again later Place KR clutch AN input shaft and KV clutch into the housing rear part ...

Page 232: ...ll bearing 45 85 19 1 onto the pump shaft 2 until contact is obtained Mount rectangular ring 60 3 3 Grease and centrically align rectangular ring Mount pump shaft 1 until contact is obtained Fix pump shaft by means of retaining ring 85 3 2 7609ATM317 7609ATM318 7609ATM319 10 11 12 K1 2 2 K4 1 1 3 ...

Page 233: ...0 13 K2 S KV AN KR K4 K1 K3 Pivot housing rear part 180 by using a lifting device 1 Clutch KV 2 Input shaft 3 Clutch KR 4 Pump shaft Clutch KV KR and input shaft are only fixed by the gear chain Attention must be paid that the non fixed components of the gear chain do not get loose 7609ATM321 2 1 3 4 14 Use the lifting device to bring the housing rear part into contact position with the housing fr...

Page 234: ...ws Mount O rings 22 3 2 into the annular groove of the oil tubes and oil them Mount all rectangular rings 4 grease and align them centrally Wet mounting face 3 with sealing agent loctite type No 574 7609ATM325 2 1 3 4 Carefully bring the housing front part into contact position with the housing rear part by using the lifting device Pay attention that both oil tubes are aligned with the holes in th...

Page 235: ...this step on all clutch shafts Driving element 5870 345 089 Crank handle 5870 280 007 7609ATM328 7609ATM329 2 1 3 Fix housing front and rear part by means of cylindrical screws 1 Tightening torque M10 8 8 50 4 69 kgf m 33 9 lbf ft Mount fixing plate 2 Mount stud bolts 3 Wet screw in thread with loctite type No 243 Tightening torque M8 10 9 25 1 53 kgf m 11 1 lbf ft 1 21 22 7609ATM330 1 The screw p...

Page 236: ...48 237 Use of the specified driver S ensures the exact installation position Fill space between sealing lip and dust lip with grease Wet outer diameter rubber coated with spirit 1 1 Press screen sheet 1 onto the input flange 2 Installation position shaft seal see figure TM332 1 Shaft seal 90 120 13 2 Gearbox housing rear section 3 Roller bearing 4 Output shaft 7609ATM331 7609ATM333 7609ATM332 10 1...

Page 237: ...ways necessary to use new hexagon screws Output flange output side with parking Output flange output side with parking brake brake Use driver S to mount shaft seal 90 120 13 with the sealing lip showing to the oil sump Driver 5870 048 237 Use of the specified driver S ensures the exact installation position Fill space between sealing lip and dust lip with grease Wet outer diameter rubber coated wi...

Page 238: ...king brake setting screw Tightening torque M10 8 8 16 4 89 kgf m 35 4 lbf ft Fix brake disk 1 at output flange by means of hexagon screws 2 and washers Tightening torque M10 10 9 25 6 93 kgf m 50 2 lbf ft Connect HP pump on port see arrow and apply approx 80 bar pressure to parking brake 3 and bring it in contact position HP hand operated pump 5870 287 007 MINIMESS coupling 5870 950 101 7609ATM338...

Page 239: ...TEM Clearance 0 5 1 5 mm Nom clearance 1 0 mm 7609ATM341 7609ATM342 Output flange on converter side Output flange on converter side Use driver S to mount shaft seal 90 120 13 with the sealing lip showing to the oil sump Driver 5870 048 237 Use of the specified driver S ensures the exact installation position Fill space between sealing lip and dust lip with grease Installation position shaft seal s...

Page 240: ...utput flange 2 until contact is obtained Insert O ring 48 4 into the space between output flange and shaft Fix output flange 1 by means of washer 2 and hexagon screws 3 Oil hexagon screws before the assembly Tightening torque M10 8 8 30 4 69 kgf m 33 9 lbf ft It is always necessary to use new hexagon screws 7609ATM344 7609ATM345 7609ATM346 3 1 2 4 5 1 2 3 1 2 ...

Page 241: ...verter back pressure valve The figure shows the single parts of the converter back pressure valve 1 Oil feed housing 2 Piston 3 Compression spring 4 Pressure plate 5 Locking plate Install pressure plate 4 with the pin Ø6 mm showing to the locking plate 5 11 11 1 1 Assemble single parts preload them with assembly aid S and fix them by means of locking plate 1 Assembly aid 5870 345 107 Mount tempera...

Page 242: ...M8 5870 204 011 2 2 Install two adjusting screws S and mount stator shaft 1 Pay attention to radial installation position Adjusting screws M10 5870 204 007 In case of wear marks in the pump housing or on the control disk the pump assy must be replaced Install outer rotor C h a m fe r s e e a r r ow t o s h ow downwards 7609ATM350 7609ATM351 7609ATM352 1 2 S 1 Install inner rotor Teeth see arrow to...

Page 243: ... showing downwards carefully insert the shaft seal 75 905 10 1 into the pump housing 2 until contact is obtained Wet outer diameter of shaft seal with spirit Driver 5870 055 070 Handle 5870 260 002 Oil sliding bearing see arrow before the assembly Mount inner installer S onto the stator shaft Mount preassembled transmission pump 1 Pay attention to radial installation position Inner installer see f...

Page 244: ...rews 2 Tightening torque M8 10 9 30 2 35 kgf m 17 0 lbf ft Tightening torque M8 10 9 45 2 35 kgf m 17 0 lbf ft Tightening torque M8 10 9 60 2 35 kgf m 17 0 lbf ft Fasten fixing plate 3 by means of cylindrical screws 4 Tightening torque M8 8 8 40 3 47 kgf m 25 1 lbf ft 7609ATM358 7609ATM359 1 Fix converter bell housing 1 by means of hexagon screws 2 Tightening torque M10 10 9 65 6 63 kgf m 47 9 lbf...

Page 245: ...ion Spot welded reinforcing rings with thread of the flex plate 2 to be arranged towards the outside see arrows Spot welded reinforcing disks of the flex plate 3 to be arranged towards the outside see arrows Mount washer 5 onto the hexagon screw M12 18 6 and fix flex plate Wet threads of hexagon screws with loctite type No 262 7609ATM362 Fix flex plate 1 by means of hexagon screws 2 Secure hexagon...

Page 246: ...cy REASSEMBLY without emergency steering steering Fit adjusting screws S and assemble seal 1 and cover 2 Fix cover by means of hexagon screws 1 Tightening torque M8 8 8 18 2 35 kgf m 17 0 lbf ft 12 12 1 2 7609ATM364 7609ATM365 1 2 S 1 ...

Page 247: ... Tightening torque M8 8 8 16 2 35 kgf m 17 0 lbf ft Mount screw plug M26 1 5 7 with O ring 23 2 Tightening torque M8 8 8 16 8 16 kgf m 59 0 lbf ft Bring cover 8 with seal into contact position with the housing front part and fix it by means of hexagon screws 9 Tightening torque M8 8 8 18 2 35 kgf m 17 0 lbf ft Mount oil drain plug with O ring 35 2 1 Tightening torque M38 1 5 8 16 kgf m 59 0 lbf ft...

Page 248: ... of the electro hydraulic control 14 14 7609ATM368 A A B Cover Housing Housing Valve block Cover Wiring harness Pressure reducing valve 9 bar Main pressure valve16 2 bar Y6 Y1 Y5 Y2 Y4 Y3 B 7609ATM369 7609ATM370 Proportional valve P5 Main press valve16 2 bar Vibration damper Valve block Follow on slide Press reducing valve 9 bar Pressure controller Duct plate Y5 Wiring harness ...

Page 249: ...opposite figure shows the following single parts 1 Pressure reducing valve 1EA piston and compr spring 2 Vibration damper 3EA piston and compr spring 3 Follow on slide 3EA piston and compr spring Install the single parts according to figure TM372 Preload compression springs of the follow on slides and preliminarily fix pistons by means of cylindrical pins Ø5 0 mm assembly aid see arrows S 7609ATM3...

Page 250: ...s of fixing plates 2 and Torx screws 3 Install fixing plate with the claw showing downwards Pay attention to the radial installation position of pressure controllers see figure Tightening torque M5 8 8 12 0 56 kgf m 4 06 lbf ft Reducing adapter 5870 656 056 Socket wrench TX 27 5873 042 002 7609ATM376 7609ATM377 Preassemble the opposite side Preassemble the opposite side The figure on the right sho...

Page 251: ...eans of Torx screws 1 Tightening torque M5 10 9 30 0 56 kgf m 4 06 lbf ft Adjusting screws 5870 204 036 Reducer 5870 656 056 Socket spanner TX 27 5873 042 002 7609ATM380 1 Mount the pressure regulators with O ring 13 5 2 1 and fasten them by means of fixing plates and cap screws Install the fixing plate with the neck showing downwards Observe radial installation position of the pressure regulators...

Page 252: ... 30 0 56 kgf m 4 06 lbf ft Reducer 5870 656 056 Socket spanner TX 27 5873 042 002 7609ATM385 S Fix the wiring harness by means of retaining clamp 1 Install the opposite cover Lock up clutch solenoid valve see figure TM396 TM397 5 speed T M 7609ATM384 7609ATM383 1 1 Flush mount screens 1 into the holes of the sealing plate see arrows Pay attention to the installation position screens to show upward...

Page 253: ...t a new seal plate Place duct plate 1 and fix it equally by means of Torx screws 2 Tightening torque M6 10 9 23 1 07 kgf m 7 74 lbf ft Socket wrench TX 27 5873 042 002 7609ATM387 7609ATM388 2 1 3 2 1 Insert converter safety valve 1 into the housing hole until contact is obtained 7609ATM390 1 Provide the screw plugs M10 1 with O rings 8 1 5 1 and install them Tightening torque 0 61 kgf m 4 43 lbf f...

Page 254: ...e M16 1 5 3 06 kgf m 22 1 lbf ft Socket wrench TX 40 5873 042 004 7609ATM391 7609ATM392 Fit two adjusting screws Adjusting screws 5870 204 063 Mount sealing plate 1 and electro hydraulic control unit 2 It is not permitted to reassemble the seal plate after opening the threaded joint shift unit gearbox housing In case of repair it is always necessary to mount a new seal plate 7609ATM394 Mount compr...

Page 255: ...3 Tightening torque M5 10 9 30 0 56 kgf m 4 06 lbf ft Torque wrench 5870 203 031 Socket wrench TX 27 5873 042 002 Reducing adapter 5870 656 056 Pay attention to installation position of connection housing see the markings applied during disassembly 2 2 Fix pressure controller 1 by means of cylindrical screws 2 Tightening torque M6 8 8 12 1 02 kgf m 7 38 lbf ft Fit screw necks 3 with O ring 11 3 2 ...

Page 256: ...tch valve to lock up clutch clutch valve to lock up clutch Fix screw in sleeve 1 Tightening torque 4 59 kgf m 33 2 lbf ft Adjusting screws 5870 204 036 Wet screw in thread with loctite type No 243 Fix pipes 2 with screw nut 3 and 4 Tightening torque screw nut 3 3 57 kgf m 25 8 lbf ft Tightening torque screw nut 4 4 59 kgf m 33 2 lbf ft 7609ATM399 1 4 3 2 Fitting of fine filter pressure filter Fitt...

Page 257: ...s Slightly oil the seal Turn in the filter until contact with the sealing surface is obtained and then tighten it by hand with approx 1 3 to 1 2 rotation Before putting the transmission into operation fill it with oil according to operation manual 7609ATM401 ...

Page 258: ...ssembly truck Assembly truck 5870 350 000 Fixtures 5870 350 077 Clamping brackets 5870 350 075 Support 5870 350 125 Before clamping the axle fully turn in the support Position axle first onto the two fixtures secure with clamping brackets and then unbolt the support until contact with the axle is obtained 1 1 1 1 2 FRONT AXLE 2 FRONT AXLE 7609AAX001 7609AAX002 7609AAX003 ...

Page 259: ...vice and loosen hexagon screws Then separate the output assy from the axle housing Load carrying device 5870 281 043 Fix the load carrying device with a wheel nut Pull stub shaft and sun gear shaft Pay attention to potentially releasing shim Fix output to assembly truck Assembly truck 5870 350 000 Fixture 5870 350 113 7609AAX007 7609AAX004 7609AAX005 7609AAX006 ...

Page 260: ... of the profile of the output shaft Lift the planetary carrier out of the brake housing by means of the lifting device Rear axle planetary carrier with 3 planetary gears Inner extractor 5870 300 019 Eye bolt 5870 204 073 Front axle planetary carrier with 4 planetary gears Inner extractor 5870 300 017 Eye nut 5870 204 076 7609AAX008 7609AAX009 7609AAX010 7609AAX011 ...

Page 261: ...oller bearing from the planetary carrier Rapid grip 5873 014 016 Basic tool 5873 004 001 Disengage retaining ring Pull off planetary gear Lift the end plate out of the brake housing 7609AAX012 7609AAX013 7609AAX014 7609AAX015 ...

Page 262: ...and press piston out of the brake housing by means of compressed air If necessary remove guide ring back up rings and grooved rings out of the annular grooves of the brake housing see arrows For the installation position of the single parts please also refer to the following sketch 16 17 18 7609AAX016 7609AAX017 7609AAX018 7609AAX019 ...

Page 263: ...t both bearing outer rings Resetting device 5870 400 001 7609AAX022 20 Lift the brake housing from the output shaft by means of the lifting device 7609AAX021 19 1 Brake housing 2 Guide ring 3 Back up ring 4 Grooved ring 5 Grooved ring 6 Back up ring 7 Slide ring seal 8 Output shaft 7609AAX020 ...

Page 264: ...ver to remove the slide ring seal from the output shaft Resetting device 5870 400 001 7609AAX023 Pull the tapered roller bearing from the output shaft Rapid grip 5873 014 013 Basic tool 5873 004 001 7609AAX024 21 22 ...

Page 265: ...eparate the axle housing from the axle drive housing Pay attention to releasing differential Loosen screw neck Pull the bearing outer ring out of the bearing hole and remove the shim behind Then remove the O ring see arrow Loosen the threaded connections and remove the releasing brake tube 2 2 7609AAX025 7609AAX026 7609AAX027 7609AAX028 ...

Page 266: ...mbly of the differential is described as of page 3 213 Press piston see arrow out of the axle housing see subsequent figure by means of compressed air This operation is only necessary for the hydraulic lock differential option Pull the bearing outer ring see arrow out of the housing hole and remove the shim behind 3 3 7609AAX029 7609AAX030 7609AAX031 7609AAX032 ...

Page 267: ...ench 5870 401 139 Clamping device 5870 240 002 Pull the input flange from the input pinion and use a lever to remove the shaft seal behind from the axle drive housing Press input pinion from the axle drive housing and remove the releasing tapered roller bearing Extractor 5870 000 065 Hexagon screw 2EA AA00 331 360 7609AAX035 7609AAX036 7609AAX033 7609AAX034 ...

Page 268: ...acer ring and pull the tapered roller bearing from the input pinion Gripping device AA00 684 425 Basic tool 5873 002 000 If necessary force both bearing outer rings out of the axle drive housing 7609AAX037 7609AAX038 ...

Page 269: ...piece 5870 100 075 Preload the housing cover compression spring by means of the press and disengage the retaining ring Then remove sliding sleeve and compression spring from the housing cover Pull both tapered roller bearings from the differential Crown wheel side Crown wheel side Grab sleeve 5873 012 016 Basic tool 5873 002 001 Opposite side Opposite side Grab sleeve 5873 003 029 Basic tool 5873 ...

Page 270: ... Disk carrier 5 Disk package Preload differential by means of the press loosen locking screws and housing cover Remove axle bevel gear with thrust washers from the differential housing 7609AAX044 7609AAX045 7609AAX043 Force out both slotted pins 7609AAX046 1 2 3 4 5 ...

Page 271: ... washers from the differential housing Pull the differential axle long and remove the releasing spider gears with thrust washers from the differential housing 7609AAX047 7609AAX048 Remove the axle bevel gear and the shim behind Press crown wheel from the differential carrier 7609AAX049 7609AAX050 ...

Page 272: ...b sleeve 5873 012 016 Basic tool 5873 002 001 Preload the differential by means of the press loosen locking screws and housing cover Remove axle bevel gear with thrust washers from the differential housing Preload the differential by means of the press loosen the hexagon screws and remove the releasing housing cover 7609AAX051 7609AAX052 7609AAX053 7609AAX054 ...

Page 273: ...the releasing spider gears with thrust washers from the differential housing Pull the differential axle long and remove the releasing spider gears with thrust washers from the differential housing 7609AAX056 7609AAX057 7609AAX055 Remove the axle bevel gear and the shim behind 7609AAX058 ...

Page 274: ...tion option Pull both tapered roller bearings from the differential Grab sleeve 5873 012 016 Basic tool 5873 002 001 Lift the axle bevel gear with pressure ring disk package and thrust washers out of the differential housing Preload the differential by means of the press loosen locking screws and housing cover 7609AAX060 7609AAX061 7609AAX062 ...

Page 275: ... of the differential housing 7609AAX063 Remove the second axle bevel gear Lift the pressure ring out of the differential housing and remove the disk package and thrust washers behind Press crown wheel from the differential carrier 7609AAX065 7609AAX066 7609AAX064 ...

Page 276: ...ential housing until contact is obtained Locating pins 5870 204 040 Insert axle bevel gear Insert spider gears with thrust washers into the differential housing and fix them with the spider shaft long Thrust washers must be positioned with the tabs see arrow being located in the recesses of the differential housing Insert thrust washer into the differential housing 5 5 7609AAX067 7609AAX068 7609AA...

Page 277: ...bs see arrow 1 being located in the recesses of the differential housing Pay attention to radial installation position of the spider shafts fixing holes arrow 2 Fix spider shafts short with slotted pins Flush mount slotted pins Mount second axle bevel gear 7609AAX072 7609AAX073 7609AAX071 Fix the thrust washers into the housing cover by means of grease 7609AAX074 1 2 ...

Page 278: ...AX076 Insert the premounted sliding sleeve into the housing cover Preload the compression spring by means of the press and engage the retaining ring into the annular groove of the sliding sleeve Setting of disk package Setting of disk package Premount single parts according to the adjacent sketch 1 Housing cover 2 Pressure piece 3 Cage 4 Lever 12EA 5 Disk carrier 6 Pressure ring 7 Inner disks 8 Ou...

Page 279: ... 0 1 mm B Contact face To obtain a correct measuring result The housing cover may only be supported on the contact face B Ensure that the assembly fixture is only supported on the disk package and not on the disk carrier 5 7609AAX079 7609AAX080 Position housing cover onto pressure piece see arrow Insert two hexagon screws into the housing cover to radially fix the disk package Pressure piece 5870 ...

Page 280: ...xagon screws Tightening torque M14 10 9 18 9 kgf m 136 lbf ft Pressure piece 5870 100 075 Heat both tapered roller bearings and insert until contact is obtained Adjust tapered roller bearing after cooling down 17 18 7609AAX083 7609AAX084 Fix axial roller cage see arrow to the sliding sleeve by means of grease 7609AAX085 19 ...

Page 281: ...tact is obtained Locating pins 5870 204 040 Insert axle bevel gear Insert spider gears with thrust washers into the differential housing and fix them with the spider shaft long Thrust washers must be positioned with the tabs see arrow being located in the recesses of the differential housing Insert thrust washer into the differential housing 7609AAX086 7609AAX087 7609AAX088 7609AAX089 ...

Page 282: ... with thrust washers into the differential housing and fix them with the two spider shafts short Thrust washers must be positioned with the tabs see arrow 1 being located in the recesses of the differential housing Pay attention to radial installation position of the spider shafts fixing holes arrow 2 Fix spider shafts short with slotted pins Flush mount slotted pins ...

Page 283: ... bolt with new locking screws Tightening torque M16 12 9 40 8 kgf m 295 lbf ft Attach the housing cover and preload the differential with the press Then fix the housing cover with hexagon screws Tightening torque M14 10 9 18 9 kgf m 136 lbf ft 7609AAX094 7609AAX095 Heat both tapered roller bearings and insert until contact is obtained Adjust tapered roller bearing after cooling down 7609AAX096 ...

Page 284: ...order starting with an outer disk The installation clearance of the internal parts is corrected by mounting outer disks with different thicknesses The difference in thickness between The difference in thickness between the left and the right disk package the left and the right disk package must only be 0 1 mm at maximum must only be 0 1 mm at maximum Place the pressure ring Insert thrust washer in...

Page 285: ...nsert the second pressure ring into the differential housing 7609AAX104 Insert the axle bevel gear until contact is obtained and install the inner disks with the teeth Preassemble the differential spider and insert it into the differential housing into the pressure ring ...

Page 286: ...ifference in thickness between the left and the right disk package the left and the right disk package must only be 0 1 mm at maximum must only be 0 1 mm at maximum Determine the installation clearance Determine the installation clearance 0 2 0 7 0 2 0 7 mm mm Measure dimension I from the mounting face of the differential housing to the plane face of the outer disk Dimension I e g 44 30 mm 7609AAX...

Page 287: ... the differential housing is obtained Locating pins 5870 204 040 Preload the differential by means of the press and bolt with new locking screws Tightening torque M16 12 9 40 8 kgf m 295 lbf ft Heat both tapered roller bearings and insert until contact is obtained Adjust tapered roller bearing after cooling down 7609AAX108 7609AAX109 7609AAX110 ...

Page 288: ...o obtain Determination of shim thickness to obtain a correct contact pattern a correct contact pattern The following measuring procedures must be carried out with utmost accuracy Inaccurate measurements lead to an incorrect contact pattern requiring an additional disassembly and reassembly of input pinion and differential Read dimension I from the axle drive housing Dimension I e g 221 10 mm Read ...

Page 289: ...assembly of input pinion Undercool the external bearing outer ring and insert it into the axle drive housing until contact is obtained Driver tool 5870 058 079 Handle 5870 260 004 7609AAX114 7609AAX115 7609AAX113 7609AAX116 Insert the determined shim e g s 1 00 mm into the housing hole Undercool the internal bearing outer ring and bring it into contact position in the housing hole by using the ass...

Page 290: ... been removed during disassembly e g s 8 18 mm A later check of the rolling torque however is absolutely necessary Heat the tapered roller bearing and insert it into the input pinion until contact is obtained 7609AAX117 7609AAX118 Insert the preassembled input pinion into the axle drive housing and insert the heated tapered roller bearing until contact is obtained Press the protection plate onto t...

Page 291: ...lling torque In case of deviations from the In case of deviations from the necessary rolling torque correct with a necessary rolling torque correct with a corresponding spacer AX118 page corresponding spacer AX118 page 3 234 as specified below 3 234 as specified below Insufficient rolling torque Insufficient rolling torque install thinner spacer ring install thinner spacer ring Excessive rolling t...

Page 292: ... value the required shims are allocated in the table below Any or deviation of the test dimension caused by production is also marked on the crown wheel rear side e g 20 or 10 or 10 or 20 In accordance with this deviation the required shims are allocated in the table below 1 Axle housing 2 Shim crown wheel side 3 Shim differential carrier side 4 Axle housing Shims for differential Crown wheel mark...

Page 293: ... Insert the determined shim e g s 1 1 mm into the hole of the axle housing and adjust the bearing outer ring see arrow until contact is obtained 16 17 18 7609AAX127 7609AAX128 7609AAX129 Mount two locating pins and bring the axle housing into contact position with the axle drive housing by means of the lifting device Locating pins 5870 204 024 Then preliminarily fix the axle housing with 4 hexagon...

Page 294: ...g Load carrying device 5870 281 083 22 By rotating the input flange roll crown wheel over the input pinion in both directions several times Then remove the axle housing again and lift the differential out of the axle drive housing Compare the obtained contact pattern In case of any contact pattern In case of any contact pattern deviation a measuring error was deviation a measuring error was made w...

Page 295: ...l 5870 048 233 The exact installation position of the shaft seal is obtained when using the specified driver tool Wet the outer diameter of the shaft seal with spirit directly before installation and fill the space between seal and dust lip with grease 24 Insert input flange and finally tighten by means of disk and slotted nut Tightening torque 122 kgf m 885 lbf ft Slotted nut wrench 5870 401 139 ...

Page 296: ... groove of the brake tube see arrow Mount two locating pins and bring the axle housing into contact position with the axle drive housing by using the lifting device Then fix the axle housing by means of hexagon screws Tightening torque M20 10 9 57 1 kgf m 413 lbf ft Locating pins 5870 204 024 After assembling the axle housing secure the axle with clamping brackets 7 7 7609AAX137 7609AAX138 7609AAX...

Page 297: ...ith threaded connection and hexagon nut see arrow Tightening torque 10 2 kgf m 73 8 lbf ft Provide screw plug with a new O ring and fit it Flush mount slotted pins Tightening torque 5 1 kgf m 36 9 lbf ft 7609AAX142 7609AAX141 ...

Page 298: ...en mount new new slide ring seal part 2 accordingly into the brake housing For the installation position of the seal please also refer to sketch page 3 244 The surface of the slide ring seal may not have any grooves scratches or other types of damage Take care that the sealing surface is parallel to the housing face The O rings must be mounted evenly into the locating hole and must not bulge out o...

Page 299: ...oaked with oil Insert back up rings and grooved rings into the annular grooves of the brake housing see arrows Pay attention to the installation position please also refer to sketch page 3 244 7609AAX149 7609AAX148 Clean the annular groove of the brake housing with spirit Then insert the guide ring into the annular groove see also the following sketch and fix it with loctite type No 415 at its ext...

Page 300: ... shaft 7609AAX151 Flush mount the slotted pins 6EA into the holes of the piston 7609AAX152 Insert the piston into the brake housing and carefully install with the fixing device until contact is obtained Fixing device AA00 680 530 Sufficiently oil seal surface of piston back up rings grooved rings and guide ring 7609AAX153 ...

Page 301: ...ton 7609AAX154 Insert cover and fix it by means of hexagon screws Tightening torque M8 10 9 3 47 kgf m 25 1 lbf ft 7609AAX156 7609AAX157 7609AAX155 Mount outer and inner disks For the number of disks and the disk arrangement please refer to the relating parts manual Insert end plate ...

Page 302: ...ve of the planetary gear Use packaging sleeve to facilitate assembly 1 Cylindrical roller bearing 2 Packaging sleeve 3 Snap ring 4 Planetary gear Heat bearing inner rings and insert the premounted planetary gears with large radius facing the planetary carrier downwards until contact is obtained Adjust bearing inner rings after cooling down Then fix planetary gears by means of retaining rings Heat ...

Page 303: ...ier with 4 planetary gears Inner extractor 5870 300 017 Eye nut 5870 204 076 7609AAX163 19 Setting of gap width output shaft Setting of gap width output shaft planetary carrier planetary carrier Bring planetary carrier with measuring disk and three old locking screws which were removed during disassembly into contact position Tightening torque 20 4 kgf m 148 lbf ft Measuring disk AA00 360 730 Pivo...

Page 304: ...new locking screws When using the cover with offset 0 07 mm the groove figure AX167 must be visible when the cover is installed Tighten locking screws successively with a tightening torque of 20 4 kgf m 148 lbf ft Then retighten the locking screws successively with a tightening torque of 51 kgf m 369 lbf ft 23 7609AAX168 Determined gap width Delta Offset to be used on the cover P No 0 30 0 24 mm 0...

Page 305: ...ng face of the brake housing to the front face of the stop bolt Dimension I e g 19 75 mm Gauge blocks 5870 200 066 Straightedge 5870 200 022 Insert stub shaft into the teeth of the axle bevel gear until contact is obtained Pay attention to the installation position mount the stub shaft with the long teeth showing to the differential Insert the sun gear shaft until contact is obtained 27 28 26 7609...

Page 306: ...e 5870 200 022 29 7609AAX174 CALCULATION EXAMPLE Dimension I 19 75 mm Dimension II 17 15 mm Difference 2 60 mm Required axial play e g 1 00 mm Difference shim e g s 1 60 Difference shim e g s 1 60 mm mm Insert sun gear shaft into the planetary carrier Fix determined shim s e g s 1 60 mm with grease into the sun gear shaft 30 31 7609AAX175 7609AAX176 ...

Page 307: ...tion with the axle housing Then fix the output by means of hexagon screws Tightening torque M18 10 9 39 8 kgf m 288 lbf ft Adjusting screws M18 15 5870 204 029 Load carrying device 5870 281 043 Fix load carrying device with wheel stud Grease O ring see arrow and install it to the axle housing Mount breather see arrow 32 34 33 35 7609AAX177 7609AAX179 7609AAX178 7609AAX180 ...

Page 308: ...tions Check brake hydraulics for leakages Check brake hydraulics for leakages Before starting the test completely breathe the brake hydraulics Then pressurize the brake temporarily 5EA with p 100 bar max High pressure test High pressure test Build up test pressure p 100 10 bar max and close connection to HP pump via shut off valve A pressure drop of max 2 2 bar is permissible during a 5 minute tes...

Page 309: ...rive housing 7577AAXR001 Mount axle on assembly truck Special tool Assembly truck 5870 350 000 Supporting bracket 2EA 5870 350 106 7577AAXR002 Drain oil from axle Use suitable reservoir environmental protection 7577AAXR003 Drain oil from both outputs Use suitable reservoir environmental protection 1 1 7577AAXR004 2 3 4 5 4 2 3 1 ...

Page 310: ...05 Replacement combi seal ring output Replacement combi seal ring output The combi seal ring output can also be replaced on the installed axle for this purpose remove output shaft For the installation of the combi seal ring refer to work steps on page 3 261 figure 7577AAXR030 032 Special tool Pry bar 5870 345 071 7577AAXR006 Output brake Output brake Disassemble brake tube 7577AAXR007 Take up outp...

Page 311: ...f axle bevel gear differential 7577AAXR009 Mount output assy on assembly truck Remove end plate 1 brake breather valve 2 and screw neck 3 Special tool Assembly truck 5870 350 000 Fixture 5870 350 112 7577AAXR010 Remove lid with O ring Special tool Pry bar 5870 345 071 7577AAXR011 Loosen locking screws and remove lid Pay attention to releasing planetary Pay attention to releasing planetary carrier ...

Page 312: ...xtractor 5870 300 019 Eye nut 5870 204 073 7577AAXR013 Snap out retaining ring Special tool Set of external pliers 5870 900 015 7577AAXR014 Pull off planetary gear Disassemble the remaining planetary gears in the same way Special tool Three armed puller 5870 971 002 7577AAXR015 ...

Page 313: ...g off the planetary carrier Special tool Grab sleeve 5870 003 033 Basic tool 5870 003 001 7577AAXR016 Take disc package out of brake housing 7577AAXR017 Loosen threaded joint 7577AAXR018 Remove lid cup spring and disk 7577AAXR019 ...

Page 314: ...5 8 7 0 4 0 0 001 7577AAXR020 Remove sealing elements arrows also refer to below sketch from annular grooves of brake housing 7577AAXR021 To the sketch 1 Brake housing 2 Guide ring 3 Support ring 4 Grooved ring 5 Grooved ring 6 Support ring 7577AAXR022 1 2 3 4 5 6 ...

Page 315: ...cial tool Lifting chain 5870 281 047 Eyebolts 5870 204 071 7577AAXR023 Remove screw neck 1 and breather valve 2 7577AAXR024 Lift off shaft seal by lever and remove both bearing outer rings from brake housing if required Special tool Pry bar 5870 345 071 7577AAXR025 1 2 16 17 18 ...

Page 316: ...3 260 Pull bearing inner ring from output shaft Special tool Rapid grip 5873 014 016 Basic tool 5873 004 001 7577AAXR026 If required disassemble wear sleeve arrow of combi seal ring 7577AAXR027 19 20 ...

Page 317: ...idering installation dimension X see detailed sketch figure 7577AAXR031 Wet contact faces of shaft seal brake housing with spirit right before assembly assembly aid Grease shaft seal around the dust and sealing lips Observe plane installation position of shaft seal use the specified driver to ensure an exact shaft seal installation position Special tool Driver tool 5870 051 065 1 Brake housing 2 O...

Page 318: ...g until contact Special tool Driver tool 5870 050 010 7577AAXR034 Press inside bearing outer ring into brake housing until contact Special tool Driver tool 5870 050 003 7577AAXR035 2 2 Apply sealing agent Loctite no 574 on contact faces of wear sleeve output shaft and mount wear sleeve part I combi seal ring considering installation dimension Y see detailed sketch figure 7577AAXR031 Special tool P...

Page 319: ...pirit Then insert guide ring into annular groove Ensure an exact contact position of the whole guide ring circumference after wards stick guide ring with glue Loctite no 415 on its endpoints Ensure a correct installation position of Ensure a correct installation position of the guide ring the guide ring Endpoints of guide ring to be in 12 o clock position in the axle installed in the machine radia...

Page 320: ...arefully bring piston in contact position 7577AAXR040 Inser t disc cup spring and lid considering the installation position see detail sketch 1 Disc 2 Cup spring 3 Lid 4 Hex screw 5 Brake housing 6 Piston 7 Slotted pin 7577AAXR041 Fix lid with hex screws evenly until contact is obtained cup spring pre load Finally tighten hex screws Tightening torque M8 10 9 3 47 kgf m 25 1 lbf ft 7577AAXR042 Deta...

Page 321: ... of a new planetary carrier or if disassembled Insert shim arrow 2 into planetary carrier until contact 7577AAXR044 Insert pre assembled planetary carrier Special tool Lifting chain 5870 281 047 Lifting device 5870 281 082 7577AAXR045 Fix planetary carrier with disc and new locking screws Do not reuse locking screws just one time installation is permitted 7577AAXR046 2 1 ...

Page 322: ...l times roller setting Tightening torque M18 12 9 51 kgf m 369 lbf ft 7577AAXR047 Apply a screw safety marking paint on correctly installed locking screws 7577AAXR048 Mount O ring arrow on lid 7577AAXR049 Insert pre assembled lid into output shaft Special tool Plastic hammer 5870 280 004 7577AAXR050 16 17 ...

Page 323: ...basis for the required equipment 7577AAXR051 Insert disc package considering disc arrangement and installation position of outer discs see sketch 7577AAXR051 7577AAXR052 Insert end plate Item 4 fix by means of grease assembly aid Ensure radial installation position driving tabs of end plate must be positioned in recessed grooves of the brake housing Special tool Locating screw 5870 204 078 7577AAX...

Page 324: ...o the pin of the planetary carrier until contact is obtained with the large radius bearing inner ring showing downwards arrow Adjust bearing after cooling down 7577AAXR054 7577AAXR055 Fix planetary gears with retaining ring Check contact position of retaining ring on groove base and readjust if required Special tool Set of external pliers 5870 900 015 7577AAXR056 Axial play setting of sun gear sha...

Page 325: ...ferential axle bevel gear until contact 7577AAXR060 Determine dimension II from mounting face brake housing axle housing to front face sun gear shaft Dimension II e g 19 00 mm CALCULATION EXAMPLE Dimension I 21 25 mm Dimension II 19 00 mm Difference 2 25 mm Required axial play e g average 1 25mm Result shim required e g s 1 00mm 7577AAXR061 Pull stub shaft with sun gear shaft out of axle housing I...

Page 326: ... housing 7577AAXR064 Take up output by means of lifting bracket Mount pre assembled sun gear stub shaft into teeth of planetary gears Special tool Lifting bracket 5870 281 043 7577AAXR065 5 5 Bring output assy into contact position with axle housing by mounting the stub shaft into the gearing of the axle bevel gear differential Pay attention to end plate see figure 7577AAXR053 page 3 267 7577AAXR0...

Page 327: ...h new O ring Tightening torque M24 1 5 5 1 kgf m 36 9 lbf ft Mount breather valve 2 Tightening torque 0 61 kgf m 4 4 lbf ft Install screw neck 3 with new O ring Tightening torque 3 7 kgf m 26 6 lbf ft 7577AAXR068 Install brake tube 1 Tightening torque Screw nut 2 10 2 kgf m 73 8 lbf ft Cylindrical screw 3 M8 8 8 2 3 kgf m 17 0 lbf ft 7577AAXR069 1 2 3 1 2 2 ...

Page 328: ...n to HP pump by means of a shutoff valve A pressure drop by max 3 3 bar is permissible during a 5 minute test duration Low pressure test Low pressure test Reduce testing pressure to p 5 bar and close shut off valve again No pressure drop is permitted during a 5 minute test duration Special tool HP pump 5870 287 007 Straight screw in connection 0637 842 518 Measuring fitting M18x1 5 5870 950 139 Oi...

Page 329: ...axle drive housing Secure axle by means of a support Secure axle by means of a support arrow risk of accident arrow risk of accident Take up axle housing half on crown wheel side with lifting chain see figure 757AAXR072 and loosen bolted connection axle housing axle drive housing Special tool Lifting chain 5870 281 047 Eyebolts 5870 204 071 Separate axle housing from axle drive housing Pay attenti...

Page 330: ...assembly aid Special tool Hot air blower 230 V 5870 221500 Hot air blower 115 V 5870 221501 7577AAXR074 Fix input flange by means of a clamping fork loosen hex nut Secure axle by means of a support Secure axle by means of a support risk of accident risk of accident Special tool Clamping fork 5870 240 025 7577AAXR075 2 2 Remove disc and pull off flange Remove screen sheet from output flange if requ...

Page 331: ...pinion out by means of press off tool and remove releasing bearing inner ring Special tool Press off tool 5870 280 044 7577AAXR078 Remove spacer ring from pinion 7577AAXR079 Pull bearing inner ring off the pinion Special tool Grab sleeve 5873 012 013 Basic tool 5873 002 001 7577AAXR080 ...

Page 332: ...ter ring Special tool Internal extractor 5870 300 019 Counter support 5870 300 020 Force bearing outer ring out of inner bearing hole pay attention to shim behind contact pattern bevel gear set Mark shim thickness position and bearing allocation assembly aid ...

Page 333: ...the corresponding spare parts list If a bevel gear set is specified the crown wheel must only be replaced together with the pinion 7577AAXR083 Only for assembly of new parts or if disassembled Mount O ring on axle housing part I and install axle drive housing pay attention to radial installation position Tightening torque M 18 1 5 10 9 39 8 kgf m 288 lbf ft 7577AAXR084 REASSEMBLY INPUT DIFFERENTIA...

Page 334: ...6 figure 7577AAXR082 into the inner bearing hole pinion bearing 7577AAXR085 Basic setting of pinion position Basic setting of pinion position Read dimension I production dimension axle drive housing from axle center to bearing contact inner bearing hole from the axle drive housing position see arrow Dimension I e g 182 81 mm 7577AAXR086 Read pinion dimension X pinion basic dimension e g 148 from p...

Page 335: ...LE e g Dimension I 182 81 mm Dimension II III 148 00 33 62 181 62 mm Result 1 19 mm Required shim S 1 20 mm Required shim S 1 20 mm Insert determined shim into the hole of the axle drive housing see figure 7577AAXR085 Special tool Digital depth gauge 5870 200 072 Gauge blocks 5870 200 066 7577AAXR088 Undercool bearing outer ring see arrow and bring it into contact position in the inner bearing hol...

Page 336: ...assembly e g s 8 7 mm If the originally installed shim was replaced contact pattern bevel gear set see page 3 278 figure 7577AAXR085 also install a spacer ring adjusted by the same correction value The required bearing rolling torque of 0 11 0 23kgf m without shaft seal however is decisive in case it is not achieved see bearing rolling torque check figure 7577AAXR094 correct the bearing rolling to...

Page 337: ... pinion Check rolling torque of the pinion bearing bearing Bearing rolling torque without shaft Bearing rolling torque without shaft seal 0 11 0 23 kgf seal 0 11 0 23 kgf m m Try to achieve upper value In case of a deviation from the required rolling torque correct it with a corresponding spacer ring see figure 7577AAXR079 page 3 280 Special tool Torque wrench 5870 203 031 Reducing adapter to 5870...

Page 338: ...in 5870 281 047 Eyebolts 5870 204 071 7577AAXR097 Bring axle housing to contact position by means of hex screw and temporarily fix it Rotate differential several times in both directions roller setting also see figure 7577AAXR099 Tightening torque M 18 10 9 39 8 kgf m 288 lbf ft 7577AAXR098 Contact pattern check of bevel gear Contact pattern check of bevel gear set set Cover some tooth flanks of c...

Page 339: ...im for correction see figure 7577AAXR085 page 3 278 7577AAXR100 If disassembled Insert shim s 2 into sun gear shaft 1 and mount stub shaft 3 If position was not allocated as specified in disassembly instructions on page 3 277 figure 7577AAXR072 and sun gear shaft clearance see page 3 268 figure 7577AAXR58 62 must be set on both output sides 7577AAXR101 Insert preassembled stub shafts into both out...

Page 340: ...sition complete axle half on the axle drive housing by mounting the stub shaft into the gearing of the axle bevel gear differential Pay attention to radial installation position of output towards axle drive housing Special tool Lifting chain 5870 281 047 Eyebolts 5870 204 071 7577AAXR105 Fix axle housing finally by means of hex screws Rotate differential several times in both directions roller set...

Page 341: ...bevel gear teeth Turn the pinioin gear and check the contact pattern WTHAX16 WTHAX17 Concave side Convex side Correct pattern Correct pattern ADJUSTMENT DJUSTMENT WTHAX18 Concave side Convex side Incorrect pattern high contact Incorrect pattern high contact WTHAX19 WTHAX20 Reduce the distance ...

Page 342: ...3 286 Incorrect pattern low contact Incorrect pattern low contact WTHAX21 WTHAX22 Concave side Convex side WTHAX23 Add the distance ...

Page 343: ...BRAKE AND FAN SYSTEM SECTION 4 BRAKE AND FAN SYSTEM Group 1 Structure and Function 4 1 Group 2 Operational Checks and Troubleshooting 4 32 Group 3 Tests and Adjustments 4 39 Group 4 Disassembly and Assembly 4 41 ...

Page 344: ...ed volume of oil for reserving brake system The oil through the accumulator flows to the brake valves The brake valve is a closed center design dual circuit operated by a pedal The front and rear brakes will operate simultaneously with only one brake pedal depressed The hydraulic fan system is used to meet the cooling requirements The hydraulic fan system controls the fan speed through the pump ou...

Page 345: ... brake line pressure In addition because these systems operate with hydraulic oil filtration can be utilized to provide long component life and low maintenance operation Because these systems are closed center by using a properly sized accumulator emergency power off braking that is identical to power on braking can be achieved These systems can be either dedicated where the brake system pump supp...

Page 346: ...PS A B D L S B P1 T1 P2 T2 A1 A2 T M 40 PS Return line Return line Main pump 41 2 Fan brake pump 15 Cut off valve 16 Accumulator 17 Accumulator 18 Pressure sensor 19 Brake valve 20 Pressure switch 21 Hydraulic tank 22 Air breather 23 Return filter 24 Bypass valve 25 Strainer 26 Oil cooler 29 Fan motor 30 Directional valve 40 Axle 41 Parking brake at T M 7609A4BS01 ...

Page 347: ...ed When the spool removes up the drain port is opened and the hydraulic oil in the piston of axles return to the tank 21 Therefore the service brake is kept released 22 21 23 24 26 2 29 18 17 16 15 20 19 25 16 30 18 18 Front Rear Parking A B P T T2 P B3 S3 T1 PP S2 B2 B1 S1 G1 G2 PS PS PS A B D L S B P1 T1 P2 T2 A1 A2 T M 40 PS Return line Return line Main pump 41 1 1 7609A4BS02 ...

Page 348: ...inlet port is opened and at the same time the hydraulic oil controlled the pressure level by the cut off valve 15 enters the piston in the front and rear axles Therefore the service brake is applied 22 21 23 24 26 2 29 18 17 16 15 20 19 25 16 30 18 18 Front Rear Parking A B P T T2 P B3 S3 T1 PP S2 B2 B1 S1 G1 G2 PS PS PS A B D L S B P1 T1 P2 T2 A1 A2 T M 40 PS Return line Return line Main pump 41 ...

Page 349: ...spring and pushes the piston rod This releases the brake Therefore the hydraulic oil pressure is applied to the parking brake piston through the solenoid valve and the parking brake is kept released 22 21 23 24 26 2 29 18 17 16 15 20 19 25 16 30 18 18 Front Rear Parking A B P T T2 P B3 S3 T1 PP S2 B2 B1 S1 G1 G2 PS PS PS A B D L S B P1 T1 P2 T2 A1 A2 T M 40 PS Return line Return line Main pump 41 ...

Page 350: ... parking brake return to the tank through the solenoid valve When the piston rod is returned by the force of the spring the parking brake is applied 22 21 23 24 26 2 29 18 17 16 15 20 19 25 16 30 18 18 Front Rear Parking A B P T T2 P B3 S3 T1 PP S2 B2 B1 S1 G1 G2 PS PS PS A B D L S B P1 T1 P2 T2 A1 A2 T M 40 PS Return line Return line Main pump 41 Parking brake solenoid Parking brake switch P A B ...

Page 351: ...directional valve 30 The flow of the oil causes fan motor 29 to rotate the fan blade The rotation of the fan forces cool air to flow through the cooler 22 21 23 24 26 2 29 18 17 16 15 20 19 25 16 30 18 18 Front Rear Parking A B P T T2 P B3 S3 T1 PP S2 B2 B1 S1 G1 G2 PS PS PS A B D L S B P1 T1 P2 T2 A1 A2 T M 40 PS Return line Return line Main pump 41 Priority valve 5 5 7609A4BS06 ...

Page 352: ...irectional valve 30 is energized and the flow of the oil is changed The rotation of the fan is reversed to clear the radiators 22 21 23 24 26 2 29 18 17 16 15 20 19 25 16 30 18 18 Front Rear Parking P T T2 P B3 S3 T1 PP S2 B2 B1 S1 G1 G2 PS PS PS D L B P1 T1 P2 T2 A1 A2 T M 40 PS Return line Return line Main pump 41 Priority valve A B B A S1 6 6 760F4BS07 ...

Page 353: ...KE PUMP 3 FAN AND BRAKE PUMP STRUCTURE STRUCTURE 1 1 L S B L1 L2 Hydraulic circuit S B L1 L L2 A VIEW A 7609A4BS30 Port Port name Port size B Delivery port SAE 3 4 S Suction port SAE 1 1 4 L L1 L2 Drain port 3 4 16UNF 2B ...

Page 354: ... movement of the pistons allows the maximum amount of oil to be drawn into the cylinder The pump will produce the maximum displacement The swashplate 3 angle is controlled by command current signal to control valve solenoid 6 The pump output pressure level can be set by the solenoid current When the solenoid current signal drops toward a zero value the pump output pressure level is the maximum FAN...

Page 355: ...ring 5 Cap screw 6 Washer 7 Housing 8 Lower spool 9 O ring 10 O ring 11 Upper spool 14 Housing 15 Spacer 16 Retaining ring 17 Retainer 18 Shim 19 Spring 20 Spring 21 Spring 22 Piston 23 Quad ring 24 O ring 25 Retainer 26 Cup 27 Boot 28 Left pedal and base assy 29 Sensor 30 Washer 31 Cap screw 32 Cover 33 Screw 34 Lever assy option 35 Right pedal and base assy option 1 1 75794BS07 ...

Page 356: ...base assy opt VIEW A A P1 P2 T2 T1 P1 T1 P2 T2 A1 A2 Test connection Pressure switch Hydraulic circuit 75794BS08 Port Port name Port size P1 P2 Pressure port 3 4 16UNF T1 T2 Return port 3 4 16UNF A1 A2 Brake cylinder port 3 4 16UNF Brake pressure specification 80 5 bar 1160 70 psi ...

Page 357: ...ce applied Spring assembly above the spools and the hydraulic pressure below the spool Balance of forces After output of the braking pressure spools 11 8 are in a partial braking position causing ports P1 P2 and ports T1 T2 to close and holding the pressure in ports A1 A2 Full braking position Full braking position When pedal is fully actuated end position of the brakes is reached and a connection...

Page 358: ...air work When working on the braking system always make sure that there is absolutely no pressure in the system Even when the engine is switched off there will be some residual pressure in the system When doing repair work make sure your environment is very clean Immediately close all open ports on the components and on pipes using plugs Replacing the complete actuating mechanism Replacing the com...

Page 359: ... 4 Hydraulic circuit 3 4 5 6 7 8 C2 C3 C5 C1 C6 FC C4 C2 FC C1 C4 C3 C5 C6 PS PS 2 2 2 1 Block 2 Check valve 3 Priority valve 4 Unload valve 5 1 Solenoid valve 5 2 Coil 6 Fixed orifice with compensated 7 Orifice 8 Bar 1 1 7609A4BS32 Part name Port size P PP SAE 3 4 T2 PF 1 2 T1 S1 S2 S3 B1 B2 B3 G1 PF 3 8 PS G2 PF 1 4 ...

Page 360: ...ority valve spring and pilot pressure brake priority pressure pushed priority spool to the upward Therefore full pump flow directly goes to the brake system in order to satisfy the demand of the brake system Pump flow goes through the following components orifice 7 check valve 2 shuttle valve 8 Brake failure pressure sensor at G1 port detects pressure in the brake accumulators When the pressure is...

Page 361: ... A is connected to the hydraulic circuit causing the diaphragm accumulator to be filled and the gas volume to be compressed as the pressure rises When the pressure falls the compressed gas volume will expand thus displacing the accumulated pressure fluid into the circuit The diaphragm bottom contains a valve disk D which if the diaphragm accumulator is completely empty closes the hydraulic outlet ...

Page 362: ...ient must be scrapped following the instructions under Disposal of the accumulator Disposal of the accumulator The amount of initial gas pressure can also be checked from the vehicle Start the vehicle s engine The pump will now supply oil to the accumulators Until the initial gas pressure is reached the hydraulic pressure in the accumulator will rise abruptly This is apparent from the gauge in the...

Page 363: ...09A4BS12 Item Type Medium G H1 mm H2 mm Adjusting range kgf cm2 Actuating pressure kgf cm2 Voltage V Parking pressure sensor Oil PF 1 4 45 12 5 0 200 100 5 Max 30 Charging pressure sensor Oil PF 1 4 45 12 5 0 200 100 5 Max 30 Brake priority pressure sensor Oil PF 1 4 45 12 5 0 200 100 5 Max 30 Brake stop pressure switch NO Oil PF 1 4 45 12 5 1 10 5 1 Max 32 H1 H2 G Connector 11 Hex 22 10 8x2 4 NO ...

Page 364: ...ontact as the pressure on that area is increased The current is now broken e g to deactivate a warning facility Installation requirements Installation requirements No special measures need to be taken Maintenance of the pressure switch Maintenance of the pressure switch No special maintenance beyond the legal requirements is necessary When using high pressure cleaners on the vehicle please make su...

Page 365: ...CTURE STRUCTURE 1 12 10 9 8 7 3 5 4 6 2 11 13 9 1 Housing 2 Pressure ring 3 Pressure bolt 4 Setting screw 5 Plate spring pack 6 Piston 7 Lining pad 8 Lining pad 9 Guiding pin 10 Rubber buffer 11 Adjusting screw 12 Lining spring 13 Counter nut 1 1 7609A4BS21 ...

Page 366: ... When the lining pad 7 comes into contact with the brake disc the reaction force displaces the brake on the guide pins 9 against the spring force of the rubber buffers 10 until the second lining pad 8 is also pressed against the brake disc The braking effect braking torque is dependent upon the frictional values of the brake linings The brake is released by complete pretensioning of the plate spri...

Page 367: ...brake Fitting the brake Rotate the screw cap 5 in a counter clockwise direction and unscrew it Release the lock nut 1 and turn the adjusting screw 2 counter clockwise until the pressure bolt 6 contacts the piston 9 with the flat surface Slide the brake over the brake disc in this condition Screw the two guide pins 7 into the gearbox in accordance with the fitting instructions Refer to page 3 171 C...

Page 368: ...sing a small amount of force after locking in position Release the counter nut 4 and then turn the setting screw 3 in a clockwise direction until the end surface of the setting screw 3 is in contact with the surface provided for setting Hold the setting screw 3 in position and lock using the counter nut 4 Remove the setting gauges from both sides of the brake disc The fitting procedure for the bra...

Page 369: ...e application pressure for clamping the setting gauges must be selected so that both gauges can be removed using a small amount of force after locking in position gauges can be removed using a small amount of force after locking in position Release the counter nut 4 and then turn the adjusting screw 3 in a clockwise direction until the end surface of the adjusting screw 3 is in contact with the su...

Page 370: ...tely free For emergency release a torque of min 7 1 For emergency release a torque of min 7 1 kgf m kgf m 51 6 51 6 lbf ft lbf ft is required on the setting screw is required on the setting screw 2 2 Screw on the lock nut 1 up to contact with the piston and apply a slight locking force to the setting screw 2 Screw on the screw cap 5 in a clockwise direction by a few threads dirt ingress protection...

Page 371: ...ing carrier must be replaced in accordance with the following instructions 5 5 1 S1 2 4 3 R S 5 1 Lock nut 2 Setting screw 3 Pressure bolt 4 Piston 5 Screw cap S Peg spanner S1 Screwdriver R Ring spanner 7609A4BS24 1 1 Place the machine on flat ground and secure against rolling away Release the parking brake by application of the required release pressure min 130 bar Rotate the screw cap 5 in a co...

Page 372: ... can be taken from the fitting instructions Refer to page 3 93 Check the pressure line A pressure line which is too short must be unscrewed in order to Check the pressure line A pressure line which is too short must be unscrewed in order to permit removal of the brake permit removal of the brake An emergency release of the parking brake must be carried out before releasing the An emergency release...

Page 373: ... of the parking brake Rotate the screw cap in a counter clockwise direction and unscrew it Release the lock nut 3 of the setting screw 2 Rotate the setting screw 2 in an counter clockwise direction until the pressure bolt 8 can be pushed completely into the piston 1 Unscrew lever the pressure bolt 8 with a suitable screwdriver until it contacts the piston 1 Actuate the brake valve and dissipate th...

Page 374: ...fitting If necessary also replace the dust protection cap 10 The dust protection cap 10 has a vulcanised in steel ring which is used to press it into the The dust protection cap 10 has a vulcanised in steel ring which is used to press it into the opening in the brake housing 4 opening in the brake housing 4 In order to replace this you will need to lever it out with a suitable tool and then replac...

Page 375: ... and has adequate space to complete the checks The engine and all other major components must be at operating temperature for some checks Locate system check in the left column and read completely following the sequence from left to right Read each check completely before performing At the end of each check if no problem is found OK that check is complete or an additional check is needed If proble...

Page 376: ...km hr and switch parking brake ON LOOK FEEL LOOK FEEL Machine must come to a stop within 2 meters 6 feet when parking brake is engaged at 8km hr Transmission must shift to neutral OK OK Check completed NOT OK NOT OK Inspect parking brake Go to group 3 Parking brake Parking brake transmission lockout transmission lockout check check Engine running Turn parking brake to ON Place transmission in 1st ...

Page 377: ...ter starting engine OK OK Check completed NOT OK NOT OK Check for brake circuit leakage Go to next page IF OK IF OK Install a cap on line connected to inlet of brake valve and repeat pump flow check If time does not decrease check for worn brake pump Service brake capacity Service brake capacity check check Engine running Select clutch cut off mode to OFF Apply service brakes release park brake an...

Page 378: ... indicator must not come ON OK OK Check completed NOT OK NOT OK Make sure brake pedal is not binding and keeping brakes partially engaged Bleed brakes in group 3 Check brake system pressure NOT OK NOT OK If light comes ON with e n g i n e r u n n i n g accumulator has lost it s charge Inspect and recharge accumulator Brake system leakage Brake system leakage check check Start engine and wait 30 se...

Page 379: ...ully release when feet are removed from pedals Drive machine at high speed for about 5 minutes Brake drag is indicated if brake areas in differential case are hot NOTE NOTE Observe parking brake If disk is hot parking brake drag is indicated OK OK Check completed NOT OK NOT OK Adjust park brake NOT OK NOT OK Check floor mat interfer ence to pedal or debris build up IF OK IF OK Check for brake pres...

Page 380: ...n brake piston seal Do brake accumulator check Do brake pump standby pressure test Do brake valve pressure test Bleed brakes Inspect brake surface material Do brake valve leakage test Check for an over filled differential Apply brakes and check for leakage from check plug It is normal for the oil level to be slightly above the check plug Aggressive brakes Aggressive brakes Internal restriction in ...

Page 381: ...test Do brake system components leakage tests Do brake pump flow test Do parking brake pressure test Problem Cause Remedy Brake will not hold Brake will not hold Pads not adjusted correctly Malfunctioning parking brake solenoid Worn brake disk and or brake pads Brake piston hangs up in bore Adjust parking brake Inspect and replace Disassemble inspect repair Remove and inspect Repair Brake disk ove...

Page 382: ...a 1 5 gradient with the bucket unloaded Depress the service brake place the gear selector lever in neutral then stop the engine Turn the parking brake switch ON then slowly release the service brake pedal and the machine must be kept stopped The measurement must be made with the machine facing either up or down the slope 1 2 3 2 2 2 2 ADJUSTMENT OF PARKING BRAKE ADJUSTMENT OF PARKING BRAKE Externa...

Page 383: ...d within a few hours or gangrene may result Doctors unfamiliar with this type of injury should reference a knowledgeable medical source Two people are required to bleed brake system oil one to operate brake valve and other to open and close bleed screws Install frame locking bar Engage parking brake Put a clear plastic tube on bleed screw to route low to hydraulic oil tank filler tube or container...

Page 384: ...top 5 Pump housing 6 Port plate 7 Swash plate 8 Drive shaft 10 Spring 12 Adjustment shim 14 Stop ring 15 Tapered roller bearing 16 Tapered roller bearing 17 Liner bearing 18 Liner bearing 19 Flat screw 20 Shaft seal ring 21 O ring 24 Kantseal ring 25 Retaining ring 27 Socket screw 31 Plug 33 Cylinder pin 41 Control valve 42 Gasket 43 Socket screw 51 Control piston 52 Locking screw 42 41 43 20 25 5...

Page 385: ...nd sliding surfaces for wear Re work of the sliding surfaces by using for example abrasive paper can damage the surface Fill the hydraulic pump with hydraulic oil before commissioning Protect the drive shaft Wrap the drive shaft with tape Remove the retaining ring Remove shaft seal to front 1 2 2 1 2 3 4 2 1 3 4 73096WE59 60 73096WE61 SEALING THE DRIVE SHAFT SEALING THE DRIVE SHAFT 1 Retaining rin...

Page 386: ...l and housing 73096WE62 7609A4BS28 Assembling of the sealing ring carefully down to the stop ring 2 73096WE61 Assemble the retaining ring circlip Visual check to ensure that the circlip is correctly located in the groove 3 SEALING THE CONTROL VALVE SEALING THE CONTROL VALVE Remove the control valve 4 4 1 73096WE64 Ø25 m Ø34 mm ...

Page 387: ... sealing surface 1 Replace gasket 2 2 7609A6WE100 Assemble control valve Tighten the bolts Tightening torque 1 58 kgf m 11 4 lbf ft 3 73096WE66 Check dimension A 4 7609A6WE101 1 2 A A 75796WE79 INSPECT HINTS INSPECT HINTS Renew all bearings 5 5 1 ...

Page 388: ...l wear grooves 3 Bearing seat 4 Splines for cylinder drive 5 Bearing seat 2 Check Sliding surface free of grooves 3 75796WE81 1 Check Bearing surfaces 4 75796WE82 75796WE83 Check That the retaining plate is free of grooves and that there is no wear in the slipper pad area 5 ...

Page 389: ...y 2 Pistons must only be replaced as a set 6 1 2 2 75796WE84 Check 1 Cylinder bores 2 Splines 7 1 2 75796WE85 Free of grooves no signs of wear 8 75796WE86 Check Cylinder sliding surface free of grooves no wear no embedded foreign particles That there are no scratches on the control plate Only replace them as a set 9 75796WE87 ...

Page 390: ... 2 Control plate 5 Motor housing 6 Port plate 7 Cam plate swash plate 8 Drive shaft 9 Shaft key 12 Adjustment shim 15 Tapered roller bearing 16 Tapered roller bearing 18 Bearing bushing 20 Shaft seal 22 O ring 25 Retaining ring circlip 27 Socket bolt 33 Cylinder pin 35 Cylinder pin 40 Screw 41 Screw 40 41 1 101 1 106 1 102 1 110 1 2 18 22 16 33 6 8 25 20 9 5 35 15 1 111 1 107 1 104 12 27 1 109 7 7...

Page 391: ...al Remove key Protect the drive shaft Remove the circlip Use installation tool or plastic strip for assembling seal Change the shaft seal and check its sliding surface drive shaft and housing grease the sealing ring 4 3 2 2 1 2 7609A4BS34 7609A4BS33 7609A4BS31 7609A4BS32 1 2 ...

Page 392: ...sembled together with the taper roller bearing from inside the taper roller bearing from inside the motor housing normally to get a secure motor housing normally to get a secure sealing condition If you decide to repair sealing condition If you decide to repair the motor in the shown way be very the motor in the shown way be very careful while handling so that the drive careful while handling so t...

Page 393: ...MBLE THE MOTOR Disassembly position Mark the location of the port plate on the housing Remove the port plate fixing bolts crosswise Remove the port plate Control plate can drop down hold tight 3 3 3 1 2 7609A4BS40 7609A4BS38 7609A4BS39 ...

Page 394: ...ontrol plate 4 7609A4BS41 Remove bearing outer ring with withdrawal tool Do not damage the sealing surface Disassemble the taper roller bearing near by port plate Remove the adjustment shim 6 5 7609A4BS43 7609A4BS42 ...

Page 395: ...ve the drive shaft to rear side Remove swash plate with special tool see the next figure 9 7 8 7609A4BS46 7609A4BS47 7609A4BS44 7609A4BS45 Loosen the swash plate with a slide hammer a small hook diameter 6 mm catches the end of the swash plate at the bottom 10 ...

Page 396: ...4 53 Press down bearing The external front bearing ring is pulled out of the pump housing 11 12 Disassemble circlip and shaft seal 13 7609A4BS50 7609A4BS48 7609A4BS49 ...

Page 397: ...4 54 Remove shaft seal and shim 14 7609A4BS51 7609A4BS52 7609A4BS53 Pre tension the spring using a suitable device Remove circlip Remove spring and pressure pins 15 16 ...

Page 398: ...o axial play 2 pistons must only be replaced as a set Check cylinder bores 1 and splines 2 Free of grooves no signs of wear Cylinder sliding surface free of grooves no wear no embedded foreign particles That there are no scratches on the control plate Only replace them as a set 3 4 4 4 1 2 7609A4BS54 7609A4BS56 7609A4BS55 7609A4BS57 1 2 2 1 2 ...

Page 399: ...S58 MOTOR ASSEMBLY MOTOR ASSEMBLY Fit the circlip into the housing Assemble shaft seal and shim against circlip Assembly of the shaft seal 1 against the safety ring 2 back up the shim 3 down to the seal ring 3 5 5 1 2 7609A4BS59 7609A4BS61 7609A4BS60 1 2 3 ...

Page 400: ...housing Shaft seal with pre assembled bearing into housing Protect splines of the shaft with plastic strip against damage of the seal lip 4 7609A4BS62 Assemble swash plate Fit pressure pins using an assembly aid 5 6 7609A4BS63 7609A4BS64 ...

Page 401: ...4 58 Pre tension the spring using a suitable device Assemble piston with retaining plate Oil piston and slipper pad 7 8 7609A4BS65 7609A4BS67 7609A4BS66 ...

Page 402: ...up Assembly aid Hold the pistons by using an O ring 9 7609A4BS68 7609A4BS69 Fit bearing 1 in port plate Fit cyilindrical pin 2 Fit O ring 3 Fit control plate 4 Assembly Hold the components in place with grease 10 1 2 3 4 ...

Page 403: ...4 60 Fit control plate Assembly aid Grease 11 7609A4BS70 7609A4BS71 Fit the port plate and fix it with the bolts crosswise 12 ...

Page 404: ...ON 5 STEERING SYSTEM SECTION 5 STEERING SYSTEM Group 1 Structure and Function 5 1 Group 2 Operational Checks and Troubleshooting 5 13 Group 3 Tests and Adjustments 5 21 Group 4 Disassembly and Assembly 5 28 ...

Page 405: ...mp flows to the priority valve of steering valve The priority valve of steering valve preferentially supplies flow on demand to the steering unit When the machine is steered the steering unit routes flow to the steering cylinders to articulate the machine When the machine is not being steered or if pump flow is greater than steering flow the priority valve supplies flow to the loader system That i...

Page 406: ... P T L R PS M 2 3 8 8 7 1 Main pump steering 6 Steering unit 7 Accumulator 8 Steering valve EHPS 8 Electric steering valve option 9 Joystick steering lever option 11 Shuttle valve 14 Steering cylinder 21 Hydraulic tank 22 Air breather 23 Return filter 24 Bypass valve 25 Strainer 27 Check valve 760F5SE01 28 Pressure sensor 31 Motor pump option 32 Check block option 33 Pressure sensor option 34 Chec...

Page 407: ... pressure oil moves the spool D to the right Almost all of pump flow goes to the loader system main control valve through the EF port and partly flows into the hydraulic tank 21 through the spool M MCV Return line Fan brake pump 6 14 22 21 1 11 39 9 25 27 27 28 RH LH CL CR L EF R P LS T Ps Ts ELECTRONICS 1 4 X1 X2 X3 S1 B2 L3 L4 B1 L1 L2 S1 S2 X1 X2 P T L R PS 2 3 8 8 7 D M G 23 24 1 1 760F5SE02 ...

Page 408: ...ty valve and then priority valve to be pushed to left side Consequently oil will flow via CF of priority valve to main spool That oil will 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 is concluded as flow rate which is kept in left chamber from steering unit Furthermore the rate controls speed of movement for c...

Page 409: ...ty valve and then priority valve to be pushed to left side Consequently oil will flow via CF of priority valve to main spool That oil will push steering cylinder rod out and it will cause wheel loader to be steered to right side The rate of movement of main steering spool is concluded as flow rate which is kept in right cham ber from steering unit Furthermore the rate controls speed of movement fo...

Page 410: ...ock valves Suction valves Hydraulic circuit 15 16 17 18 Controller Joystick CL CR L EF R P LS T Ps Ts ELECTRONICS 1 3 2 4 Joystick steering opt Joystick steering opt 1 1 1 To tank 2 To emergency system 3 To main control valve 4 From main pump 5 To steering unit P port 6 From steering unit T port 7 From steering unit L port 8 Shock suction valve left side 9 To steering cylinder left side 10 To stee...

Page 411: ...tarted EF port of the steering valve may be connected to the working hydraulic Maximum pressure on the EF port 250 bar The operating pressure in the loader system has not effected on the operation of the priority valve 18 of steering 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 priorit...

Page 412: ...ll 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 get to be increased If ...

Page 413: ...ill push steering cylinder rod out and it will cause wheel loader to be steered to right side The rate of movement of main steering spool 15 is concluded as flow rate which is kept in right 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 get to be increased ...

Page 414: ...mined setting at which point the spool shifts to restrict input flow from 1 reducing mode or to open flow from 2 to 3 relieving mode as needed to maintain the regulated pressure at 2 Relief valve Relief valve 5 5 FUNCTION FUNCTION The main relief valve is inside the steering valve and set the maximum circuit pressure of the steering circuit When the steering valve is being actuated if the steering...

Page 415: ...e steering cylinder in proportion to the angular rotation of the steering wheel Spool 9 is connected directly to the drive shaft of steering wheel It is connected to sleeve 7 by cross pin 3 not in contact with the spool when the steering wheel is at neutral and neutral posi tion spring 2 Cardan shaft 8 is meshed at the top with cross pin 3 and forms one unit with sleeve 7 At the same time it is me...

Page 416: ...he piston 13 is fastened to the rod 2 The piston uses a single wear ring 15 with a piston seal 14 to seal between the piston and tube The gland seals against the tube with two O rings The rod is sealed against the gland with a rod seal 6 2 2 1 Tube assembly 2 Rod assembly 3 Gland 4 Dust wiper 5 Retaining ring 6 Rod seal 7 Back up ring 8 Buffer ring 9 Du bushing 10 O ring 11 Back up ring 12 O ring ...

Page 417: ...e at operating temperature for some checks Locate system check in the left column and read completely following this sequence from left to right Read each check completely before performing At the end of each check if no problem is found OK that check is complete or an additional check is needed If problem is indicated NOT OK you will be give repair required and group location If verification is n...

Page 418: ...te less than 7 rpm NOTE NOTE Use good judgment Excessive steering wheel rpm does not mean steering will be affected OK OK Check completed NOT OK NOT OK Do steering system leakage test in group 3 to isolate the leakage Priority valve in steering Priority valve in steering valve low pressure valve low pressure check check Park machine on a hard surface Hold brake pedal down Run engine at high idle S...

Page 419: ... Failed main pump drive Stuck priority valve spool Broken priority valve spring Relief valve in steering valve stuck open Add recommended oil Remove and inspect return filter for metal pump particles Do main pump flow test Remove and inspect priority valve spool Remove and inspect spring Do relief cartridge leakage test in group 3 No hydraulic functions No hydraulic functions steering normal steer...

Page 420: ... Check for foamy oil Do steering system leakage check Do steering system leakage check Do steering unit neutral leakage test in group 3 Replace leaf springs Replace shock valve Replace gear wheel set Replace defects parts Slow steering wheel Slow steering wheel movement will not cause movement will not cause any frame movement any frame movement Leakage in steering unit gerotor Worn steering unit ...

Page 421: ...n Repair cause of contamination Flush hydraulic system Inspect hydraulic filter for contamination Repair cause of contamination Flush hydraulic system Steering unit locks up Steering unit locks up Worn or damaged steering unit Repair or replace steering unit Abrupt steering wheel Abrupt steering wheel oscillation oscillation Improperly timed gerotor gear in steer ing unit Time gerotor gear Steerin...

Page 422: ... possibly due to dirt Return pressure in connection with the reaction between differential cylinder and steering unit too high Oil is needed in the tank Steering cylinder worn Gear wheel set worn Spacer across cardan shaft forgotten Replace leaf springs Clean steering unit or contact the nearest service shop Reduce return pressure Fill with clean oil and bleed the system Replace or repair cylinder...

Page 423: ...ons without both directions without the steered wheels turn the steered wheels turn ing ing One or both shock valves are leaky or are missing in steering valve Clean or replace defective of missing valves Steering is too slow and Steering is too slow and heavy when trying to heavy when trying to turn quickly turn quickly Insufficient oil supply to steering unit pump defective or number of revoluti...

Page 424: ...eering wheel wheel Spring force in priority valve too weak Oil is too thick cold Replace spring by a stronger Let motor run until oil is warm Too little steering force Too little steering force possibly to one side possibly to one side only only Pump pressure too low Too little steering cylinder Piston rod area of the differential cylin der too large compared with piston diameter Correct pump pres...

Page 425: ...n debris from cylinders Install a new return filter element Clean fil ter housing before installing new element For a failure that creates a lot of debris remove access cover from hydraulic oil tank Drain and clean hydraulic oil tank of fill the specified oil to hydraulic oil tank through upper cover To minimize oil loss pull a vacuum in hydraulic oil tank using a vacuum pump Connect filter caddy ...

Page 426: ...largest capacity circuit Operate all functions one at a time through a complete cycle in the following order clam steering bucket and boom Also include all auxiliary hydraulic functions Repeat procedure until the total system capacity has circulated through filter caddy seven times approximately 30 minutes Each function must go through a minimum of three complete cycles for a through cleaning for ...

Page 427: ... is accurate enough for test work 2 TEST TOOLS 2 TEST TOOLS CLAMP ON ELECTRONIC TACHOMET CLAMP ON ELECTRONIC TACHOMET ER INSTALLATION ER INSTALLATION Service equipment and tools Tachometer A Clamp on tachometer Remove paint using emery cloth and connect to a straight section of injec tion line within 100 mm 4in of pump Finger tighten only do not over tighten B Black clip Connect to main frame C Re...

Page 428: ...ure reader see temperature reader installation proce dure in this group Heat hydraulic oil to specifications see hydraulic oil warm up procedure at page 6 55 Connect fitting and install gauge Do not operate steering or loader funct Do not operate steering or loader funct ions or test gauge may be damaged ions or test gauge may be damaged Run engine at specification and read pres sure gauges If pre...

Page 429: ...urning Install temperature reader see temperature reader installation proce dure in this group Heat hydraulic oil to specifications see hydraulic oil warm up procedure at page 6 55 Disconnect return hose from fitting Install cap fitting Run engine at specifications Rotate steering wheel against locking bar using approximately 1 2 kgf m of force Measure oil flow from return hose for 1 minute Leakag...

Page 430: ...force pressure on wheel with frames locked If steering wheel is turned slowly it will continue to with the frames locked This will give an incorrect pressure read ing If steering wheel continues to turn rapidly with the frames locked steering system leakage is indicated Read pressure gauge This is the steering valve relief pressure If pressure in not to specification turn adjusting screw in relief...

Page 431: ...all temperature reader see temperature reader installation proce dure in this group Heat hydraulic oil to specifications see hydraulic oil warm up procedure at page 6 55 Install plug A in Ts port Disconnect line from T port on steering valve Install plug in line Connect line B to steering valve Start engine and run at specification Measure oil leakage from T port If leakage is more than specificat...

Page 432: ...ad bushing 5 O ring 7 Bearing assembly 8 Ring 9 Cross pin 11 Cardan shaft 12 Set of springs 13 O ring 14 Distributor plate 15 Gearwheel set 17 End cover 18 Washer 20 Screw with pin 21 Screw GROUP 4 DISASSEMBLY AND ASSEMBLY GROUP 4 DISASSEMBLY AND ASSEMBLY 1 5 3 4 2 7 8 9 12 21 20 18 17 13 15 14 13 11 7607SE10 ...

Page 433: ...5 29 TOOLS TOOLS Holding tool Guide ring 2 2 1 Assembly tool for O ring and kin ring 2 Assembly tool for lip seal 3 Assembly tool for cardan shaft 4 780 3A 5 69 3 780 3A 5 69 4 7607SE08 7607SE09 ...

Page 434: ...orque wrench 0 7 1 kgf m 0 54 4 lbf ft 13 mm socket spanner 6 8 mm and 12 mm hexagon sockets 12 mm screwdriver 2 mm screwdriver 13 mm ring spanner 6 8 and 12 mm hexagon socket spanners Plastic hammer Tweezers 6 780 3A 5 70 1 780 3A 5 70 2 ...

Page 435: ... P R 780 3A 5 71 Screwed connection Max tightening torque kgf m lbf ft With cutting edge With copper washer With aluminum washer With O ring 1 4 BSP F 4 1 29 7 2 0 14 5 3 1 22 4 3 8 BSP F 6 1 44 1 2 0 14 5 5 1 36 9 1 2 BSP F 10 2 73 8 3 1 22 4 8 2 59 3 7 16 20 UNF 2 0 14 5 3 4 16 UNF 6 1 44 1 M 12 1 5 4 1 29 7 2 0 14 5 3 1 22 4 2 0 14 5 M 18 1 5 7 1 51 4 2 0 14 5 5 1 36 9 5 1 36 9 M 22 1 5 10 2 73...

Page 436: ...ing unit in the holding tool Screw out the screws in the end cover 6 off plus one special screw 4 4 1 Remove the end cover sideways 2 Lift the gearwheel set with spacer if fitted off the unit Take out the two O rings 3 Remove cardan shaft 4 780 3A 5 72 1 780 3A 5 72 2 780 3A 5 72 3 780 3A 5 72 4 ...

Page 437: ... Take care to keep the cross pin in the sleeve and spool horizontal The pin can be seen through the open end of the spool Press the spool inwards and the sleeve ring bearing races and needle bearing will be pushed out of the housing together 8 780 3A 5 73 1 780 3A 5 73 2 780 3A 5 73 3 780 3A 5 73 4 ...

Page 438: ...l screw from the end cover 10 A small mark has been made with a pumice stone on both spool and sleeve close to one of the slots for the neutral position springs see drawing If the mark is not visible remember to leave a mark of your own on sleeve and spool before the neutral position springs are disassembled Carefully press the spool out of the sleeve 11 780 3A 5 74 1 780 3A 5 74 2 780 3A 5 74 3 7...

Page 439: ...completely disassembled 14 Cleaning Clean all parts carefully in Shellsol K or the like Inspection and replacement Replace all seals and washers Check all p a r t s c a r e f u l l y a n d m a ke a ny replacements necessary Lubrication Before assembly lubricate all parts with hydraulic oil 780 3A 5 75 1 780 3A 5 75 2 780 3A 5 75 3 ...

Page 440: ...d press them into place 1 Line up the spring set 2 780 3A 5 76 4 Assemble the spool sleeve and make sure the marks on spool and sleeve are opposite each other see drawing page 5 36 3 780 3A 5 76 1 Press the springs together and push the neutral position springs into place in the sleeve 4 780 3A 5 77 2 7607SE06 ...

Page 441: ...Guide the ring down over the sleeve The ring should be able to move free of the springs 6 780 3A 5 77 3 780 3A 5 77 4 Fit the cross pin into the spool sleeve 7 Fit bearing races and needle bearing See the next page 8 780 3A 5 78 1 780 3A 5 78 2 ...

Page 442: ...n the inner bearing race must face the inner spool Installation instruction for O ring Turn the steering unit until the bore is horizontal Guide the outer part of the assembly tool into the bore for the spool sleeve 9 780 3A 5 78 4 Grease O ring with hydraulic oil and place them on the tool 10 780 3A 5 79 1 780 3A 5 79 2 5 4 3 2 1 7607SE07 ...

Page 443: ...nto position in the housing 12 780 3A 5 79 3 780 3A 5 79 4 Draw the inner and outer parts of the assembly tool out of the steering unit bore leaving the guide from the inner part in the bore 13 780 3A 5 80 1 Installation instructions for lip seal Installation instructions for lip seal Lubricate the lip seal with hydraulic oil and place it on the assembly tool 14 780 3A 5 80 2 ...

Page 444: ...ttom 15 780 3A 5 80 3 780 3A 5 80 4 Press and turn the lip seal into place in the housing 16 780 3A 5 81 1 With a light turning movement guide the spool and sleeve into the bore Fit the spool set holding the cross pin horizontal 17 780 3A 5 81 2 ...

Page 445: ...vertical again Put the check valve ball into the hole indicated by the arrow 19 780 3A 5 81 3 780 3A 5 81 4 Screw the threaded bush lightly into the check valve bore The top of the bush must lie just below the surface of the housing 20 780 3A 5 82 1 Grease the O ring with mineral oil approx viscosity 500 cSt at 20 C 21 780 3A 5 82 2 ...

Page 446: ...s parallel with the connection flange 23 780 3A 5 82 3 780 3A 5 82 4 Place the cardan shaft as shown so that it is held in position by the mounting fork 24 780 3A 5 83 1 Grease the two O rings with mineral oil approx viscosity 500 cSt at 20 C and place them in the two grooves in the gear rim Fit the gearwheel and rim on the cardan shaft 25 780 3A 5 83 2 ...

Page 447: ...ed in relation to the shaft slot as shown Turn the gear rim so that the seven through holes match the holes in the housing 26 26 Fit the spacer if any 27 780 3A 5 83 3 780 3A 5 83 4 Place the end cover in position 28 780 3A 5 84 1 Fit the special screw with washer and place it in the hole shown 29 780 3A 5 84 2 ...

Page 448: ...Tightening torque 3 1 0 6 kgf m 30 Place the dust seal ring in the housing 31 780 3A 5 84 3 780 3A 5 84 4 Fit the dust seal ring in the housing using special tool and a plastic hammer 32 780 3A 5 85 1 Press the plastic plugs into the connection ports Do not use a hammer 33 780 3A 5 85 2 22 4 4 3 lbf ft ...

Page 449: ... up ring 8 Buffer ring 9 Du bushing 10 O ring 11 Back up ring 12 O ring 13 Piston 14 Piston seal 15 Wear ring 16 O ring 17 Steel ball 18 Set screw 19 Spherical bearing 20 Retaining ring 21 O ring 22 Hexagon socket plug 23 Check valve 24 Spring 25 Cushion plunger 26 Parallel pin 1 19 20 12 11 16 13 14 15 20 2 19 5 4 7 6 9 3 10 8 22 24 23 17 18 26 25 21 21 ...

Page 450: ... Tightening torque 2 2 2 2 1 1 Tool name Remark Wrench For gland Driver Small and large sizes Torque wrench Capable of tightening with the specified torques Part name Item Size Torque kgf m lbf ft Gland 3 M70 2 56 6 405 43 4 Piston 13 M36 2 90 9 651 65 1 Set screw 18 M 8 1 25 2 0 2 14 5 1 4 ...

Page 451: ... pressure after the oil draining operation Loosen and remove the gland 3 Cover the extracted piston rod 2 with rag to prevent it from being accidentally damaged during operation Draw out gland 3 and piston rod 2 assembly together from cylinder tube 1 Since the piston rod assembly is heavy in this case lift the tip of the piston rod 2 with a crane or some means and draw it out However when piston r...

Page 452: ...ssembly Remove the set screw 18 and steel ball 17 Remove piston assembly 13 and O ring 16 2 2 Remove the gland 3 assembly from piston rod 2 If it is too heavy to move move it by striking the flanged part of gland 3 with a plastic hammer Pull it straight with gland assembly lifted with a crane Exercise care so as not to damage the lip of rod bushing 9 and packing 4 5 6 7 8 by the threads of piston ...

Page 453: ...e the grooves 3 3 Disassemble gland assembly Disassemble gland assembly Remove back up ring 11 and O ring 10 Remove O ring 12 Remove snap ring 5 and dust wiper 4 Remove back up ring 7 rod seal 6 and buffer ring 8 Exercise care in this operation not to damage the grooves Do not remove seal and ring if does not damaged 4 4 15 14 16 76095SE23 5 4 7 6 8 11 10 12 75795SE23 ...

Page 454: ...orrect direction that is shown in figure Fit back up ring 7 and rod seal 6 and buffer ring 8 to corresponding grooves in that order Coat each packing with hydraulic oil before fitting it Insert the backup ring until onside of it is inserted into groove 3 Press here Straight down Metal 4 Wrong Right 6 Push bar ASSEMBLY ASSEMBLY Assemble gland assembly Assemble gland assembly Check for scratches or ...

Page 455: ...3 Put the back up ring in the warm water of 30 50 C Fit O ring 10 12 to gland 3 Fit bushing 9 to gland 3 Assemble piston assembly Assemble piston assembly Check for scratches or rough surfaces If found smooth with an oil stone Coat the outer face of piston 13 with hydraulic oil Fit wear ring 15 to piston 13 Fit O ring 16 to piston 13 11 10 12 3 9 13 14 2 2 13 15 16 76095SE25 75795SE26 75795SE27 76...

Page 456: ...sembly Piston rod 3 3 75795SE29 Piston rod Piston assembly 18 17 757F5SE26 Overall assembly Overall assembly Place a V block on a rigid work bench Mount the cylinder tube assembly on it and fix the assembly by passing a bar through the clevis pin hole to lock the assembly Insert the piston rod assembly in to the cylinder tube assembly while lifting and moving the piston rod assembly with a crane B...

Page 457: ... in the figure in the disassembly and assembly procedures 1 1 25 26 6 10 28 2 4 5 19 20 3 13 22 23 24 UPPER 16 1 7 8 12 17 18 6 21 14 15 27 9 1 19 20 4 5 30 29 29 30 11 UPPER LOWER 1 Bearing 2 Cover 3 Cover 4 Shim 0 1 t 5 Shim 0 5 t 6 Bolt w washer 7 Pin 8 Collar 9 Collar 10 Plate 11 Pin 12 Dust seal 13 Dust seal 14 Shim 0 1 t 15 Shim 0 5 t 16 Bushing 17 Cover 18 Cover 19 Hexagon bolt 20 Hardened ...

Page 458: ...d plate 10 22 Take out upper pin 11 to the downside using a metal punch 1 2 Maintain the front frame horizontal level remove hexagon bolts 6 and then remove the plate 21 and shims 14 15 27 Take out lower pin 7 to the upside using a metal punch carefully Jack up or lifting the front frame 29 slightly the collar 9 protrudes over the rear frame Remove the collar 9 Lift the frame by passing the slingi...

Page 459: ...in the table below 1 2 3 4 5 3 3 Unit mm Remove bolt 19 washer 20 and then take out cover 17 18 and shims 4 5 Take out the dust seal 12 from the cover 17 18 Remove the bearing 1 and collar 8 29 19 20 17 18 4 5 12 12 8 LOWER 1 11 12 13 Remove bolt 19 washer 20 and then take out cover 2 and shims 4 5 Take out dust seal 13 from the cover 2 Remove the bearing 1 and dust seal 13 8 9 29 UPPER 19 20 2 29...

Page 460: ...l upper bearing in bore in upper front frame Place the cover 2 17 and hold in place with bolt 19 At this time adjust shims 4 5 to press the shoulder of bearing 1 against retainer ㆍ Adjustment method of clearance A Adjustment method of clearance A Install bearing 1 and cover 2 17 without shim 4 5 Install four of bolt 19 so that each bolt is separated by 90 degrees ㆍTightening torque 0 8 1 0 kgfㆍm 5...

Page 461: ...tment method of clearance B Adjustment method of clearance B Install pin 7 and plate 21 without shim 14 15 27 Install four of bolt 6 so that each bolt is separated by 90 degrees ㆍTighting torque 0 8 1 0 kgfㆍm 5 8 7 2 lbfㆍft Adjust shims in order to control the clearance B ㆍClearance B 0 1 0 2 mm ㆍShim thickness 0 1 mm 0 5 mm 2 0 mm Tighten the all the bolts 6 ㆍTightening Torque 9 8 15 8 kgfㆍm 70 9...

Page 462: ...SECTION 6 WORK EQUIPMENT Group 1 Structure and Function 6 1 Group 2 Operational Checks and Troubleshooting 6 41 Group 3 Tests and Adjustments 6 52 Group 4 Disassembly and Assembly 6 64 ...

Page 463: ...outes flow to the boom bucket or auxiliary cylinders not shown when the respective spools are shifted Flow from the main pump is routed to the main control valve where pump outlet pressure is reduced to pilot circuit pressure The main control valve flow to the remote control valve The remote control valve routed flow to either end of each spool valve section in the main control valve to control sp...

Page 464: ... B Down a2 b2 b1 B up B in a1 Dump b2 Aux down b2 Aux up To MCV 2 HYDRAULIC CIRCUIT HL955 HL955XTD 2 HYDRAULIC CIRCUIT HL955 HL955XTD 757F6WE01 1 Main pump 2 Fan brake pump 3 Main control valve 4 Fan motor 5 Directional valve 6 Oil cooler 7 Check valve 8 Controller opt 9 Boom lowering valve 10 Remote control block EH 11 FNR remote control lever 12 Remote control valve HYD 13 Safety valve 14 Suttle...

Page 465: ...22 19 EH EH HYD HYD 27 40 9 To MCV 8 1 4 3 2 HYDRAULIC CIRCUIT HL955 HL955XTD DIRECT STEERING OPT HYDRAULIC CIRCUIT HL955 HL955XTD DIRECT STEERING OPT 9556WE01 1 Main pump 2 Fan brake pump 3 Main control valve 4 Fan motor 5 Directional valve 6 Oil cooler 7 Check valve 8 Controller opt 9 Boom lowering valve 10 Remote control block EH 11 FNR remote control lever 12 Remote control valve HYD 13 Safety...

Page 466: ...n a2 b2 b1 B up B in a1 Dump b2 Aux down b2 Aux up To MCV 2 Spool 22 13 HYDRAULIC CIRCUIT HL955TM HYDRAULIC CIRCUIT HL955TM 757FTM6WE01 1 Main pump 2 Fan brake pump 3 Main control valve 4 Fan motor 5 Directional valve 6 Oil cooler 7 Check valve 8 Controller opt 9 Boom lowering valve 10 Remote control block EH 11 FNR remote control lever 12 Remote control valve HYD 13 Safety valve 14 Suttle valve 1...

Page 467: ... EH EH HYD HYD 27 40 9 To MCV 8 3 1 2 4 HYDRAULIC CIRCUIT HL955TM DIRECT STEERING OPT HYDRAULIC CIRCUIT HL955TM DIRECT STEERING OPT 955TM6WE01 1 Main pump 2 Fan brake pump 3 Main control valve 4 Fan motor 5 Directional valve 6 Oil cooler 7 Check valve 8 Controller opt 9 Boom lowering valve 10 Remote control block EH 11 FNR remote control lever 12 Remote control valve HYD 13 Safety valve 14 Suttle ...

Page 468: ...LS a2 b2 b1 a1 Pst B3 A3 b3 a3 T Dump Roll back Up Down Floating P Bucket Boom Aux PS PS 23 22 25 24 12 11 26 28 28 29 6 5 4 4 40 14 13 29 29 Control unit Electro Hydraulic Joysick steering 757F6WE02 1 Main pump 3 Main control valve 4 Remote control valve EH type 4 Remote control valve FNR type opt 5 Control unit 6 EH control block 11 Safety valve 12 Shuttle valve 13 Boom cylinder 14 Bucket cylind...

Page 469: ...to hydraulic oil tank 22 through the boom spool at the same time When this happens the boom goes up 1 T A1 P1 X1 X2 X3 S1 B2 L3 L4 B1 L1 L2 S1 S2 X1 X2 PS Aux Bucket Boom Joystick 4 1 EH20 EH19 EH22 EH21 P T 6 4 3 2 5 3 2 1 2 Spool EH18 EH17 To MCV a3 b3 a1 b1 a2 b2 Return line Fan brake pump Steering system Return line Steering valve EHPS EF port Steering valve EHPS LS port 3 LH RH B1 A1 B2 A2 LS...

Page 470: ...combines with the oil from the pump through the regeneration check valve and flows into the small chamber of the cylinder This prevents cylinder cavitation by the negative pressure when the pump flow cannot match the boom down speed Dump Roll back Up Floating Bucket Boom Aux Down Regeneration check valve 1 T A1 P1 X1 X2 X3 S1 B2 L3 L4 B1 L1 L2 S1 S2 X1 X2 PS Aux Bucket Boom Joystick 4 1 EH20 EH19 ...

Page 471: ... in contact with the ground it can be move up and down in accordance with the shape of the ground 1 T A1 P1 X1 X2 X3 S1 B2 L3 L4 B1 L1 L2 S1 S2 X1 X2 PS Aux Bucket Boom Joystick 4 1 EHCU EH20 EH19 EH22 EH21 P T 6 4 3 2 5 3 2 1 2 Spool EH18 EH17 To MCV a3 b3 a1 b1 a2 b2 Return line Fan brake pump Steering system Return line Steering valve EHPS EF port Steering valve EHPS LS port 3 LH B1 A1 B2 A2 LS...

Page 472: ...er of bucket cylinder combines with the oil from the pump and flows into the small chamber of the cylinder This prevents cylinder cavitation by the negative pressure when the pump flow cannot match the bucket dump speed 1 T A1 P1 X1 X2 X3 S1 B2 L3 L4 B1 L1 L2 S1 S2 X1 X2 PS Aux Bucket Boom Joystick 4 1 EH20 EH19 EH22 EH21 P T 6 4 3 2 5 3 2 1 2 Spool EH18 EH17 To MCV a3 b3 a1 b1 a2 b2 Return line F...

Page 473: ...ucket cylinder 14 returns to hydraulic tank 22 When this happens the bucket roll back 11 T A1 P1 X1 X2 X3 S1 B2 L3 L4 B1 L1 L2 S1 S2 X1 X2 PS Aux Bucket Boom Joystick 4 1 EH20 EH19 EH22 EH21 P T 6 4 3 2 5 3 2 1 2 Spool EH18 EH17 To MCV a3 b3 a1 b1 a2 b2 Return line Fan brake pump Steering system Return line Steering valve EHPS EF port Steering valve EHPS LS port 3 LH B1 A1 B2 A2 LS a2 b2 b1 a1 Pst...

Page 474: ... 1 L1 L2 B1 X1 L3 B2 X2 S1 L4 S2 E G B2 L3 L4 B1 L1 L2 S1 S2 X1 X2 Hydraulic circuit 75796WE88 Port Port name Port size B1 Pressure port SAE 1 B2 Pressure port SAE 1 S1 Suction port SAE 2 S2 Suction port SAE 1 1 2 L1 L3 Case drain port M22 1 5 L2 L4 Case drain port 7 8 14UNF 28 X1 X2 Pilot pressure port M14 1 5 ...

Page 475: ... 15 Taper roller bearing 16 Taper roller bearing 17 Bearing liner 20 Shaft seal ring 22 O ring 23 O ring 24 O ring 25 Retaining ring 27 Socket screw 28 Locking screw 30 Locking screw 33 Cylinder pin 36 O ring 51 Control valve 52 Flange cover 54 Seal screw 55 Seal screw 23 27 5 36 28 24 10 6 16 12 33 52 51 8 15 20 25 22 30 17 7 1 1 1 2 2 54 55 37 75796WE11 ...

Page 476: ...Control plate 56 Adjusting piece 57 Pump housing 58 Port plate 59 Swash plate 60 Drive shaft 61 Shim 62 Shim 63 Taper roller bearing 64 Taper roller bearing 65 Bearing liner 66 Shaft seal ring 68 O ring 69 Retaining ring 70 Socket screw 71 Locking screw 72 Locking screw 73 Cylinder pin 89 Control valve 90 Flange cover 93 Set screw ...

Page 477: ...flows to flow compensator spool 13 This spool keeps the pump output at a level that is necessary to fulfill the requirements for the system flow and for the pressure The pressure compensator spool 12 also limits maximum system pressure The pressure compensator spool 12 prevents damage to the steering and loader hydraulic components from excessive pressure The swivel angle of the pumps is controlle...

Page 478: ... the force of counter spring 6 The oil pressure than causes the pump to destoke Pressure and flow compensator valve 7 also controls the maximum output of pump pressure When steering and loader pressure rises above pressure compensator setting pressure compensator spool 12 overrides flow compensator spool 13 This causes the pump to destroke ...

Page 479: ...harge pressure this difference pressure causes spool 13 to move right As spool 13 moves right the spool 13 blocks the flow of supply oil to control piston 10 Pump swash plate 2 is controlled by pressure and flow as much as hydraulic system requests When the oil flow to control piston 10 is blocked the pilot oil in passage 22 drains to passage 23 The oil then flows past pressure compensator spool 1...

Page 480: ...sator spool 13 to move left Pump oil now flows through passage 15 The oil then flows past flow compensator spool 13 through passage 22 and then to control piston 10 The pump pressure behind control piston 10 is now greater than the combined force of counter piston 4 and of counter spring 6 The angle of swash plate 2 decreases This decreases the pump output and the system pressure When the lower fl...

Page 481: ... Before you start the engine counter spring 6 holds swash plate 2 at the maximum angle As the pump begins to turn oil begins to flow and pressure increases in the system Because of close centered steering control valve and close centered loader hydraulic system As this pressure increase the pressure pushes flow compensator spool 13 against spring 18 This causes flow compensator spool 13 to move le...

Page 482: ...eakage to the pump case The leakage to the pump case is a result of the cross drilled hole The pump maintains low pressure standby Low pressure standby pressure should not exceed 40 bar 580 psi Low pressure standby will vary in the same pump as the system leakage or the pump leakage increases The pump will upstroke slightly in order to compensate for the increasing leakage Control piston 10 will c...

Page 483: ...ore discharged pressure push flow compensator spool 13 left Supply oil now flows past flow compensator spool 13 and through passage 23 The oil flows past flow compensator spool 13 and into passage 22 The oil then flows to control piston 10 Pump swash plate 2 will be minimum displacement if the operator does not turn the steering wheel and RCV then the pump will return to low pressure standby High ...

Page 484: ...ng screw 1 of flow controller by tightening or loosing the screw 1 Flow setting ΔP Gauge A Gauge B Specification Steering pump 29 bar Loader pump 22 bar 5 B L L1 S X 2 1 52 bar rev 52 bar rev Gauge A Pressure compensator 75796WE38 Adjustment of pressure control Pressure compensator setting must be carried out following procedures and conditions Conditions Engine is running System is at relief cond...

Page 485: ...cted to port 3 tank When the inlet pressure fluctuates it provides an almost constant outlet pressure depending on the energization of the coil When the control current increases the coil solenoid exerts a force on the control piston which is proportional to the control current and thereby defines the regulated pressure at port 1 This setting is proportional to the control current Pressures at tan...

Page 486: ... 1 3 Type Closed center Load pressure Independent Flow Distribution 1 75796WE10 Port Port name Port size P From main pump 1 5 16 12UN T To hydraulic tank 1 5 16 12UN A1 B1 To bucket cylinder port 1 5 16 12UN A2 B2 To boom cylinder port 1 5 16 12UN a1 b1 Bucket pilot port 11 16 16UN a2 b2 Boom pilot port 11 16 16UN a3 b3 Auxiliary pilot port 11 16 16UN LS Load sensing port 9 16 18UNF Pst To RCV P p...

Page 487: ...0 70 50 75796WE13 11 Housing 30 O ring 31 O ring 50 Housing 60 Plate 61 Cylinder screw 70 Check valve 72 Spool 74 Locking screw 80 Pressure relief valve 83 Pressure relief valve 84 Flow control valve 86 Counter balance valve 87 Pressure reducing valve 133 Valve seat 134 Throttle bolt 135 Valve seat ...

Page 488: ...4 21 23 20 12 21 23 18 50 11 75796WE14 11 Housing 12 Cover 13 Cover 14 Cover 18 Cylinder screw 19 Cylinder screw 20 Cylinder screw 21 Throttle check valve 22 Throttle check valve 23 Threaded steel pipe fitting 30 O ring 40 Spool 41 Spool 42 Spool 50 Housing 90 Spring retainer 91 Compression spring 93 Spring retainer 94 Spring 95 Ring 96 Spring retainer ...

Page 489: ... back Up Down Floating P Bucket Boom Hydraulic circuit P T 6 3 1 2 8 5 4 7 3 4 6 7 5 75796WE15 function 2 1 Housing 2 Spool 3 Pressure compensator 4 Loader holding valve 5 Counter balance valve 6 Regeneration check valve 7 Port relief valve 8 Spring chamber ...

Page 490: ...spool 2 and the actuator connections A B The highest load pressure of all of the actuators involved is applied to all of the pressure compensators In parallel it is also applied to the pump If the pump flow is insufficient for all of the functions then all work movements are reduced in speed by the same ratio Loading holding Within each function axis a load holding valve 4 is fitted between the pr...

Page 491: ...on oil from the pump will be blocked Then the pumps are at low pressure stand by B2 A2 b2 a2 B1 A1 B2 A2 LS a2 b2 b1 a1 Pst T Dump Roll back Up Down Floating P Bucket Boom Hydraulic circuit P T 75796WE51 boom section operation Spool in neutral 3 1 ...

Page 492: ...pool moved to raise position Oil from the pump flows to the cylinder port B2 through the load holding valve and oil from the cylinder flows into the tank passage through the cylinder port A2 Load holding valve When the load pressure is higher than the pump pressure the load holding valve shuts off the passage between the high pressure feed passage and the center bypass passage and prevents the rev...

Page 493: ...e cylinder port A2 through the load holding valve and oil from the cylinder flows into the tank passage through the cylinder port B2 When the lowering speed of boom is faster the return oil from the large chamber of boom cylinder combines with the oil from the pump through regeneration check valve 6 and flows into the small chamber of the cylinder This prevents cylinder cavitation by the negative ...

Page 494: ...Pst T Dump Roll back Up Floating P Bucket Boom Hydraulic circuit 75796WE54 When the boom spool is located in float position the oil from the pump will be blocked The cylinder ports A2 B2 are connected to the tank passage so the boom will be lowered due to it s own weight ...

Page 495: ...on oil from the pump will be blocked Then the pumps are at low pressure standby B1 A1 b1 a1 P T B1 A1 B2 A2 LS a2 b2 b1 a1 Pst T Dump Roll back Up Down Floating P Bucket Boom Hydraulic circuit 75796WE55 Bucket section operation Spool in neutral 4 1 ...

Page 496: ... spool moved to rollback position Oil from the pump flows to the cylinder port B1 through the load holding valve and oil from the cylinder flows into the tank passage through the cylinder port A1 Load holding valve When the load pressure is higher than the pump pressure the load holding valve shuts off the passage between the high pressure feed passage and the center bypass passage and prevents th...

Page 497: ...ylinder port A1 through the load holding valve and oil from the cylinder flows into the tank passage through the cylinder port B1 When the dumping speed of bucket is faster the return oil from the large chamber of bucket cylinder combines with the oil from the pump through regeneration check valve 6 and flows into the small chamber of the cylinder This prevents cylinder cavitation by the negative ...

Page 498: ...CU PF 3 8 A1 Supply to RCV lever PF 1 4 T To hydraulic tank PF 1 4 operation This valve is used to cut off the pilot circuit When the pilot cut off switch in the cab is pressed to ON position the solenoid valve is activated and then the pilot oil flow into the pilot circuit The accumulator satisfied short term peak power demands and is a source of emergency power in case of main circuit pressure f...

Page 499: ... against the rod with a lip type buffer ring 8 and a rod seal 5 A dust wiper 9 cleans the rod when it is retracted BOOM CYLINDER 1 10 9 6 7 8 2 13 11 4 3 15 14 18 16 17 22 12 5 19 23 24 24 20 1 21 25 28 26 27 28 31 30 29 27 757F6WE17 1 Tube assembly 2 Rod assembly 3 Gland 4 Bushing 5 Snap ring 6 Rod seal 7 Back up ring 8 Buffer ring 9 Dust wiper 10 Snap ring 11 O ring 12 O ring 13 Back up ring 14 ...

Page 500: ...12 O ring 13 Back up ring 14 Piston 15 Piston seal 16 Wear ring 17 Dust ring 18 O ring 19 Back up ring 20 Lock nut 21 Set screw 22 Bolt 23 Bushing 24 Bushing 25 Dust seal 26 Dust seal 27 Band assembly 28 Pipe assembly 29 Pipe assembly 30 O ring 31 Bolt 2 23 2 25 25 10 9 7 8 6 3 4 22 13 12 18 14 17 19 15 20 21 28 30 30 1 31 24 26 26 16 29 31 27 11 5 757F6WE18 ...

Page 501: ... hydraulic return oil filter becomes clogged return filter bypass valve 6 acts to allow the oil to return directly to the hydraulic tank 1 This prevents damage to the hydraulic filter 5 The bypass valve 6 is also actuated when negative pressure is generated in the circuit 1 1 Hydraulic tank wa 2 Pipe wa 3 Sight gauge 4 Air breather 5 Element assembly 6 Bypass valve 7 Spring 8 O ring 9 Socket bolt ...

Page 502: ...ank is a pressurized sealed type so negative pressure is formed inside the hydraulic tank when the oil level drops during operations When this happens the difference in pressure between the tank and the outside atmospheric pressure opens the poppet in the breather and air from the outside is let into the tank or prevent negative pressure Preventing excessive pressure inside the tank When the hydra...

Page 503: ... the compressed nitrogen gas inside the accumulator sends pilot pressure to the control valve to actuate it and allow the boom and bucket to come down under their own weight Type of gas Nitrogen gas N2 Volume of gas 0 75ℓ 0 2 U S gal Charging pressure of gas 16 kg cm2 228 psi Max actuating pressure 128 kg m2 1820 psi 1 2 3 1 Diaphragm 2 Steel pressure vessel 3 Closure button 7803AWE56 ...

Page 504: ...the gauge starts showing the pressure in the accumulator Do not turn the T handle all the way down as it will damage the valve core Crack open nitrogen bottle valve D and slowly fill accumulator Shut off when gauge indicates desired pre charge Let the pre charge set for 10 to 15 minutes This will allow the gas temperature to stabilize If the desired pre charge is exceeded close nitrogen bottle val...

Page 505: ...a minute The lifting system must firstly be secured against lowering After carrying out maintenance work screw the bolt B and nut A Tightening torque A 2 04 kgf m 14 8 lbf ft 1 2 3 4 7609A6WE28 2 REMOVE FROM HYDRAULIC SYSTEM Structure 3 1 Body 2 Hydraulic cap 3 Gas cap 4 Piston 5 V O ring 5A V O ring back up washers 6 Piston ring piston 7 O ring 7A O ring back up washer 8 Gas valve 8A Gas valve O ...

Page 506: ... The engine and all other major components must be at operating temperature for some checks Locate system check in the left column and read completely following the sequence from left to right Read each check completely before performing At the end of each check if no problem is found OK that check is complete or an additional check is needed If problem is indicated NOT OK you will be given repair...

Page 507: ...operating temperature Run engine at high idle With bucket flat on ground actuate boom raise Time how long it takes to raise boom to full height LOOK Boom must raise to full height in less than 7 seconds OK Check completed NOT OK Go to priority valve in steering valve high pressure check at page 5 26 IF OK Do steer ing system leakage check at page 5 27 IF OK Do main hydraulic pump flow test at page...

Page 508: ...lly dumped lower boom to raise front of machine Push control lever to the float detent position and release lever LOOK Front of machine lower to the ground and valve must remain in float position when lever is released OK Check complete NOT OK Do pilot control valve pressure test in group 3 B o o m c y l i n d e r a n d bucket cylinder drift check Heat hydraulic oil to operating temperature Set th...

Page 509: ...oom Measure drift from tooth or cutting edge to ground for 1 minute Wait 10 minutes Measure drift from tooth or cutting edge to ground for 1 minute LOOK Compare the drift rates between the first measurement and the second measurement OK Drift is approximately the same between first and second measurement Repair loader control valve or circuit relief valve at page 6 57 NOT OK Drift is considerably ...

Page 510: ...ket leveler checks Boom height kickout check Run engine at low idle Position bucket flat on ground Move control lever to boom raise detent position and release LOOK Boom must raise to the set height and stop Control lever must return to neutral OK Check complete NOT OK Do boom height kickout check Cycle time check Heat hydraulic oil to operating temperature Run engine at high idle Function Boom ra...

Page 511: ...MEASURING PROCEDURE Lifting time of boom Lowering time of boom Dumping time of bucket Rollback time of bucket 1 LOWERING TIME OF BOOM Set the bucket horizontal with the boom at the maximum height lower the bucket and measure the taken for the bucket to reach the lowest position on the ground 2 DUMPING TIME OF BUCKET Raise the boom to the maximum height and measure the time taken for the bucket to ...

Page 512: ... Check for foamy oil Tighten connections Replace O rings and or lines Inspect and clean strainer in reservoir Tighten or replace clamps Inspect and repair Do hydraulic pump performance check in group 2 Do hydraulic pump flow test in group 3 No or Slow hydraulic functions Failed or worn hydrualic pump Cold oil Slow engine speed Suction line air leak Low oil supply Wrong oil viscosity Oil leaking pa...

Page 513: ... in group 3 One hydraulic function does not work Faulty pilot control valve RCV Stuck open port relief valve Oil leaking past cylinder packings Blockage in oil lines or valve Loader control valve MCV spool stuck in bore Do pilot control valve pressure test Inspect and repair valve Replace relief valve Do boom and bucket cylinder leakage test in group 3 Inspect lines for damage Disconnect and inspe...

Page 514: ...ystem over relief Leakage in work circuit Plugged fins in oil cooler Internally plugged oil cooler Incorrect system or circuit relief valve setting Restriction in oil lines or loader control valve MCV Malfunctioning steering valve Leaking system main relief valve Worn hydraulic pump internal leakage Use recommended oil Reduce load Reduce load Do boom and bucket cylinder leakage test in group 3 Ins...

Page 515: ... equipment get damaged due to the presence of metal particles and or foreign matter in the circuit drain out the hydraulic oil and carry out flushing Also replace the filter element and clean the hydraulic tank Change the hydraulic oil entirely When checking the filter if found metal particles in the element drain out the hydraulic oil entirely flush the whole circuit and then fill with new oil Th...

Page 516: ...cloth When overhauling the hydraulic equipment replace all O rings backup rings etc with new ones Assemble O rings with grease or vaseline applied After installing the equipment add more hydraulic oil to make up for that lost during disassembly Tighten joints correctly Loose joints will cause the hydraulic oil to leak If the oil leaks the tank oil level drops and air gets sucked in so the pump wil...

Page 517: ...ontaminated due to a major component failure remove and disassemble steering cylinders to clean debris from cylinders Install a new return filter element Inspect filter housing before installing new element For a failure that creates a lot of debris remove access cover from hydraulic oil tank Drain and clean hydraulic oil tank of fill the specified oil to hydraulic oil tank through upper cover To ...

Page 518: ...ext largest capacity circuit Operate all functions one at a time through a complete cycle in the following order Clam steering bucket and boom Also include all auxiliary hydraulic functions Repeat procedure until the total system capacity has circulated through filter caddy seven times approximately 30 minutes Each function must go through a minimum of three complete cycles for a through cleaning ...

Page 519: ...esired position above the midway point Then push icon A for 2 3 seconds The boom will return to the programmed position when the raise detent is activated and the boom is below the kickout position Lower kickout position To set the lower kickout lower the bucket to the desired position below the midway point Then push icon A for 2 3 seconds The boom will return to the programmed position when the ...

Page 520: ...not over tighten B Black clip Connect to main frame C Red clip Connect to transducer D Tachometer readout Install cable A C B D C B A DIGITAL THERMOMETER INSTALLATION Service equipment and tools Digital thermometer A Temperature probe Fasten to a bare metal line using a tie band Wrap with shop towel B Cable C Digital thermometer DISPLAY MONITOR TACHOMETER The display monitor tachometer is accurate...

Page 521: ...on approx 45 C 1 2 3 4 5 A B Ride control valve Ride control system option Attention Before carrying out any maintenance work the accumulators must be unloaded zero pressure For this loosen the nut A and bolt B counterclockwise with 10 mm spanner The accumulator will be unloaded zero pressure in less than a minute The lifting system must firstly be secured against lowering After carrying out maint...

Page 522: ...ections Install temperature reader see temperature reader installation procedure in this group Heat hydraulic oil to specifications see hydraulic oil warm up procedure in this group Run engine at test specifications Close flow meter loading valve to increase pressure to test specifications Read flow meter If flow is below specifications check suction line and suction pressure for abnormality befor...

Page 523: ...omed position Slowly activate boom down function while watching pressure gauge If pressure is not to specification loosen lock nut on system relief valve M and adjust to specification Do not adjust the system relief valve above 280 kg cm2 3980 psi Damage to the pump will result from excessive pressure settings 6 LOADER SYSTEM AND PORT RELIEF VALVE PRESSURE TEST 1 2 3 4 Relief valve Engine speed Re...

Page 524: ...tion Do not go under the work equipment Set the boom and bucket horizontal then stop the engine Stop the engine wait for 5 minutes then start measuring Measure the amount the boom and bucket cylinder rods retract during 15 minutes A Retraction of boom cylinder rod B Retraction of bucket cylinder rod 1 2 3 7577AWE31 Item Standard value Retraction of boom cylinder rod 7 mm Retraction of bucket cylin...

Page 525: ...tend the cylinder to be tested If testing the boom cylinders restrain boom in the fully raised position using a hoist or a stand Check cylinders for leakage in the fully extended position only In the retracted position contacts the end of the cylinder and seals off piston seal leakage Remove and plug cylinder rod end hose or line Run engine at slow idle Activate control lever to extend cylinder fo...

Page 526: ...e Minimum pressuer 30 bar Pressure range 35 50 bar GAUGE AND TOOL Gauge 0 7 MPa 0 70 bar 0 1000 psi Lower boom to ground Connect gauge to the pilot pressure port of function to be checked Install temperature reader see temperature reader installation procedure in this group Heat hydraulic oil to specification see hydraulic oil warm up procedure in this group 1 2 3 4 ...

Page 527: ...TD HL955TM Boom raise Bucket flat on ground to full height 5 8 5 8 Boom lower float Full height to ground level 3 9 3 9 Bucket dump Boom at full height 1 2 2 0 Bucket rollback Boom at full height 1 6 2 2 Steering No of turns Frame stop to stop 3 5 turns Function Operating conditions Maximum cycle time seconds Boom raise Bucket flat on ground to full height while holding steering over relief 10 ...

Page 528: ... process A rubber type of material can indicated cylinder packing or other packing failure The hydraulic oil filter in the filter case of the hydraulic oil tank should be replaced every 1000 operating hours or more often When the filter element is replaced please keep as follows Clean the inside of the filter case Place new element in the proper positions inside the filter case Install the bypass ...

Page 529: ...ed hub 12 Shim 15 Taper roller bearing 16 Taper roller bearing 17 Bearing liner 20 Shaft seal ring 22 O ring 23 O ring 24 O ring 25 Retaining ring 27 Socket screw 28 Locking screw 30 Locking screw 33 Cylinder pin 36 O ring 37 Side marker ring 51 Control valve 52 Gasket 54 Locking screw 55 Socket screw 23 27 5 36 28 24 10 6 16 12 33 52 51 8 15 20 25 22 30 17 7 1 1 1 2 2 54 55 37 75796WE11 ...

Page 530: ... Control plate 56 Adjusting piece 57 Pump housing 58 Port plate 59 Swash plate 60 Drive shaft 61 Shim 62 Shim 63 Taper roller bearing 64 Taper roller bearing 65 Bearing liner 66 Shaft seal ring 68 O ring 69 Retaining ring 70 Socket screw 71 Locking screw 72 Locking screw 73 Cylinder pin 89 Control valve 90 Flange cover 93 Set screw ...

Page 531: ...rasive paper can damage the surface Fill the hydraulic pump with hydraulic oil before commissioning Change the shaft seal and check its sliding surface drive shaft and housing grease the sealing ring 2 2 1 2 3 4 2 1 75796WE60 Assemble the sealing ring fitting tool holds the correct position of the sealing ring in the pump housing Assemble the circlip in the correct position 3 75796WE58 sealing the...

Page 532: ... the control valve Disassemble the control valve Measure dimension A and note down Check sealing surface 1 4 1 Mark the location of the connection plate on the housing 2 75796WE64 75796WE63 disassemble the pump Remove the control valve 5 1 ...

Page 533: ...late Distributor plate and adjustment piston can drop down 3 75796WE65 Remove distributor plate Take note of the orientation Remove bearing with withdrawal tool Do not damage the sealing surface 4 75796WE66 Remove the rotary group in a horizontal position 5 75796WE67 ...

Page 534: ...ells 6 75796WE68 Remove the circlip and the shaft seal 7 75796WE69 Remove the drive shaft through rear side 8 75796WE70 Pre tension the spring 1 using a suitable device Remove circlip 2 Remove spring 1 and pressure pins 3 9 1 2 3 75796WE72 ...

Page 535: ...t bearing out of housing press seat 10 75796WE74 Remove the control plate 11 75796WE75 Use bearing puller to remove outer bearing race of rear bearing press seat 12 75796WE76 Disassemble the guide of control piston Mounting position pilot valve side 13 75796WE77 ...

Page 536: ... 75796WE78 75796WE79 inspect hints Renew all bearings 6 1 1 2 3 4 5 6 75796WE80 Check 1 Wear on splines rust 2 Drive shaft seal wear grooves 3 Bearing seat 4 Splines for cylinder drive 5 Bearing seat 2 Check Sliding surface free of grooves 3 75796WE81 1 ...

Page 537: ...metal deposits on the sliding surface 1 and that there is no axial play 2 Pistons must only be replaced as a set 6 75796WE83 Check That the retaining plate is free of grooves and that there is no wear in the slipper pad area 5 1 2 2 75796WE84 Check 1 Cylinder bores 2 Splines 7 1 2 75796WE85 ...

Page 538: ...urface free of grooves no wear no embedded foreign particles That there are no scratches on the control plate Only replace them as a set 9 75796WE87 Check Mounting surface control plate undamaged 10 75796WE120 Check Check running conditions of the control piston 11 75796WE89 ...

Page 539: ...t of taper roller bearing set Cast iron housing must have initial tension of the bearings 0 0 05 mm grind position A if necessary 7 1 75796WE92 pump assembly Fit the seal into the housing Fit the circlip 8 1 75796WE93 Fit the drive with bearing from rear end Do not touch seal lip with edge of keyway or spline 2 ...

Page 540: ...6 75 Pre tension the spring using a suitable device 4 75796WE94 Fit pressure pins using an assembly aid 3 75796WE95 Assemble piston with retaining plate Oil piston and slipper pad 5 75796WE97 ...

Page 541: ...1 6 75796WE98 5 4 1 2 3 4a 75796WE99 Fit bearing 1 in connection plate Fit cyilindrical pin 2 Fit O rings 3 4 pieces Fit adjustment spool 4 and guide piston 4a Fit distributor plate 5 direction of rotation dependent Assembly Hold the components in place with grease 7 1 ...

Page 542: ...796WE100 For clockwise rotation pumps the distributor plate is off set by 4 to the right from the centre position Clockwise and anti clockwise rotation distributor plates are not identical 75796WE101 Fit connection plate and control valve 10 75796WE63 9 ...

Page 543: ...80 72 74 80 70 50 11 Housing 30 O ring 31 O ring 50 Housing 60 Plate 61 Cylinder screw 70 Check valve 72 Spool 74 Locking screw 80 Pressure relief valve 83 Pressure relief valve 84 Flow control valve 86 Counter balance valve 87 Pressure reducing valve 133 Valve seat 134 Throttle bolt 135 Valve seat 1 75796WE13 ...

Page 544: ...4 21 23 20 12 21 23 18 50 11 75796WE14 11 Housing 12 Cover 13 Cover 14 Cover 18 Cylinder screw 19 Cylinder screw 20 Cylinder screw 21 Throttle check valve 22 Throttle check valve 23 Threaded steel pipe fitting 30 O ring 40 Spool 41 Spool 42 Spool 50 Housing 90 Spring retainer 91 Compression spring 93 Spring retainer 94 Spring 95 Ring 96 Spring retainer ...

Page 545: ...bled or result in oil leakage or low performance When disassembled tag the components for identification so that they can be reassembled correctly Once disassembled O ring and back up rings are usually not to be used again Remove them using a wire with its end made like a shoe horn Be careful not to damage the slot If the components are left disassembled or half disassembled they may get rust from...

Page 546: ...2EA Tool Wrench 4 mm Tightening torque 0 85 kgf m 6 1 lbf ft 5 1 75796WE41 Remove the cover spring retainer spring and spool 75796WE42 1 Spool 2 Spring 2 Spring ratainer 4 Bolt 5 Cover 1 2 3 4 5 75796WE43 Port relief valve Tool Spanner 24 mm 75796WE44 2 ...

Page 547: ...6 82 Tightening torque 10 2 kgf m 73 8 lbf ft 75796WE45 Precharge valve Tool Spanner 24 mm 75796WE46 3 Tightening torque 6 1 kgf m 44 3 lbf ft 75796WE47 ...

Page 548: ...TEM SECTION 7 ELECTRICAL SYSTEM Group 1 Component Location 7 1 Group 2 Electrical Circuit 7 3 Group 3 Monitoring System 7 22 Group 4 Electrical Component Specification 7 69 Group 5 Connectors 7 76 Group 6 Troubleshooting 7 97 ...

Page 549: ...ick down button 2 Horn button 3 FNR switch 4 FNR select button 5 Hone button 6 Multi function switch 7 Hazard switch 8 Gear select lever 9 Radio USB player 10 Aircon heater switch 11 Monitor 12 Starting switch Starting button opt 13 Work load button 14 Pilot cut off switch 15 Parking brake switch 16 SCR switch 17 Differential lock switch opt 18 Emergency test switch 19 Engine control unit ECU 760F...

Page 550: ... Horn 3 Angle sensor 4 Work lamp 5 Machine control unit MCU 6 Transmission control unit TCU 7 Fuse and relay box 8 Master switch 9 Start relay 10 Fuel sender 11 Battery relay 12 Battery 13 Rear combi lamp 14 Number plate lamp 15 Camera opt 16 Work lamp 17 Control unit electro hydraulic joystick steering 19 Engine hood open switch 20 24V socket ...

Page 551: ...0A 01 02 03 04 05 06 07 08 09 10 13 14 15 16 17 18 19 20 21 22 11 10A 12 10A 10A 23 10A 24 R 15 R 11 R 12 R13 R 17 R 01 R 02 R 03 R 04 R 05 R 06 R 07 R 08 R 09 R 10 215 791 790 792 A2 1 3 0 2 0 AIR CONDITIONER HARNESS MAIN RELAY CR 35 R 17 716 ROr 716 TURN LAMP START KEY SW RADIO B 30A 10A 10A CN 36 ELEC STEERING PUMP RELAY WIF ANALOG INPUT NEUTRAL SIGNAL 24V ANTI RESTART RELAY PARKING OIL LOW PS ...

Page 552: ...N 36 ELEC STEERING PUMP RELAY SEAT BELT WARNING NEUTRAL SIGNAL 24V ANTI RESTART RELAY PARKING OIL LOW PS BRAKE OIL LOW PS ENINGE START SIGNAL SCANIA FUEL SENDOR HYD TEMP SENDER ALT LEVEL COOLING FAN EPPR COOLING FAN EPPR AIRCON RUN SIGNAL AIR FILTER GROUND_SENSOR TACHO SENSOR _REMOTE FAN TACHO SENSOR _REMOTE FAN CAN2 LOW CAN2 HI CN 58A POWER IG 24V BATTERY POWER 24V FUEL WARMER COUNT_WEIGHT_SET SW...

Page 553: ...2 46 75 76 5 622 646 645 642 643 YOr Or W WOr GW BATT 28 73 49 50 27 BATT 26 BATT 91 FORCED REGEN SWITCH 10AWG CABLE BATTERY EARTH Br 87 31 CAN A REGEN INHIBIT SWITCH HYD TEMP CD 01 711 693 W WOr 19 20 STARTER 15 R CN 74 AC COMP 1 ALTERNATOR FUEL HEATER 2 1 382 G Gr 536 246 246 B P G 3 U 1 2 3 FI 4 NC 1 2 3W 300 LW 382 LW 382 CN 128 RESISTOR RS 01 716 718 718 716 716 G53 G53 CR 23 CN 45 B M M 536 ...

Page 554: ...28 RESISTOR RS 01 716 718 718 716 716 G53 G53 CR 23 CN 45 B M M 536 G53A FROM BATTERY RELAY 708 708 ROr ROr ROr RW B B 1 25 1 25 1 25 2 0 2 0 LW 2 0 2 0 1 25 109 80R G53B 2 GLOW RELAY CN 80 PREHEATER 5 0 5 0R 709 CR 24 1 25 376 Y 44 44 45 39 C NC B J1939 CAN A A J1939 CAN A CAN A RESISTOR 33 CR R01 A1 ECU CN J2 A NC D J1939 CAN A C J1939 CAN A E NC F NC B NC CN 126 SERVICE TOOL 246 Gr 28 536 536 3...

Page 555: ...N J31 DEF DOSING IJT VALVE 9 5 4 3 10 8 7 4 1 CN 20 CN 21 NA DEF PUMP GROUND DEF PUMP SUPPLY DEF PUMP PWM DEF REVERSING VALVE HS RETURN 32 8 16 54 79 6 81 82 57 38 39 40 85 85 53 77 12 12 643 4 3 2 1 POWER 24V CAN_LO CAN_HI RETURN CN J7A NOx SENSOR 4 3 2 1 POWER 24V CAN_LO CAN_HI RETURN CN J7B NOx SENSOR 4 3 2 1 RETURN CAN_LO CAN_HI POWER 24V CN J10 SCR THERMISTOR CONT 4 3 2 1 RETURN CAN_LO CAN_HI...

Page 556: ...768 621 624 620 449 9 8 447 8 9 CAN H CAN L ANA IN 4 VCC OUT 1 5 4 CN 16 1 2 3 4 7 8 9 10 11 12 10 2 3 4 5 8 9 13 14 CN 15 7 6 EH 11A ELECTRONIC JOYSTICK 5 6 449 447 448 450 FNR SWITCH F N R 925 909 912 908 751 GROUND 0 7V 4 3V ROLLER 5V 10 8 9 ROLLER CS 85 STORE BUTTON 925 L 751 3 2 1 12 11 10 9 8 7 6 1 2 3 4 7 1 5 6 5 2 1 11 3 12 1 2 3 11 4 5 6 12 S1 S5 S6 S7 S8 S9 AUX HOLD HORN KD FNR NC NC R2 ...

Page 557: ...7 6 MEMORANDUM MEMORANDUM ...

Page 558: ...hter lamp CL 02 I conn CN 01 37 I conn CN 24 10 Number plate lamp CL 21 2 RH Combi clearance lamp ON CL 16 4 I conn CN 05 58 LH Head lamp ON CL 03 3 Fuse box CN 37 24 Switch indicator lamp Radio USB player CL 27 9 I conn CN 01 36 LH Combi clearance lamp ON CL 15 4 I conn CN 05 57 RH Head lamp ON CN 04 3 CHECK POINT CHECK POINT 1 1 GND Ground Engine Key switch Check point Voltage OFF ON GND relay i...

Page 559: ...0 3 6 5 2 9 10 7 5 6 3 8 7 8 ILLUMINATION LIGHT RELAY A13 ILLUMINATION 5 1 2 7 8 1 4 2 5 8 7 4 2 6 3 1 2 7 8 1 4 5 2 8 7 4 5 6 3 7 8 10 3 7 2 1 8 9 7 5 2 5 3 1 6 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 ACC ILL NC SPK FRT RH SPK FRT LH TEL MUTE ANT 12V BACK UP ILL NC SPK FRT RH REMOCON REMOCON GND SPK FRT LH NC GND 1 3 4 5 7 Or Or Or LOr G LOr G Or YOr Or R BW R BW R BW R BW Or Or YOr B Or B Or B ...

Page 560: ...ight low beam ON CL 03 6 RH Head light low beam ON CL 04 6 Multi function switch DOWN CS 11 6 I conn CN 05 31 CHECK POINT CHECK POINT 1 1 2 2 GND Ground LH Head light high beam ON CL 03 4 RH Head light high beam ON CL 04 4 Cluster high beam pilot lamp ON CN 56 5 Engine Key switch Check point Voltage OFF ON GND relay input GND relay output GND multi function input GND multi function output GND mult...

Page 561: ...E C 6 3 4 2 1 T 5 ABL YOr B CL 04 HEAD LIGHT LH 47 48 40 44 32 31 53 50 57 58 55 59 CN 05 Y Y 30 86 87 85 86 85 87 30 87a 87a G G YOr L CR 211 DRIVING RELAY DRIVING LIGHT RELAY A14 G CN 58A MCU Y Gr RW BY L BVi G Y J 1 4 3 5 2 6 I U f058 O C W O J I U f058 HO 7 Lo R L 3 2 BG BW BWG 4 C W 6 Hi C 8 WB B 5 B R O L F Lo Hi 1 2 3 4 5 6 1 2 3 5 6 7 8 4 1 2 3 4 5 6 8 9 14 7 15 16 IG 24V BATT 24V RH TURN ...

Page 562: ...LH Front work lamp ON CL 32 1 RH Front work lamp ON CL 33 1 Work lamp switch Work lamp switch select Rear MCU CN 58B B03 Rear work lamp relay CR 55 87 I conn CN 01 33 CHECK POINT CHECK POINT GND Ground 1 1 2 2 1 1 2 2 Engine Key switch Check point Voltage OFF ON GND work lamp power input GND work lamp power output GND front work lamp GND rear work lamp 20 25V I conn CN 24 12 LH Rear work lamp ON C...

Page 563: ...0A 20A 20A 10A 20A 30A 20A 30A 20A 20A 20A 20A 2 0 A 10A 10A 20A 10A 10A 20A 25 26 27 28 29 30 31 32 33 34 37 38 39 40 41 42 43 44 45 46 10A 35 30A 36 20A 10A 4710A 48 DEF SUPPLY HOSE HEATING 1 2 3 ECU B DEF SENSOR SPARE SPARE 10A 20A 10A 10A 49 50 51 5210A 5310A 54 GW Y AIRCON RUN SIGNAL FUEL WARMER A29 B14 B03 WORK LAMP REAR ECO FEELING SIGNAL B09 WORK LAMP FRONT A14 DRIVING LIGHT RELAY A13 ILLU...

Page 564: ... Master switch CS 75 1 2 When start key switch is in START position Start switch START CS 2 6 Start safety relay CR 05 30 87 I conn CN 04 20 I conn CN 13 7 Start relay CR 23 Starter terminal B and M connector of start motor CHECK POINT CHECK POINT 1 1 2 2 1 2 GND Ground ECM Electronic control module MCU Machine control unit TCU Transmission control unit Battery relay CR 1 ECM power relay CR 30 30 ...

Page 565: ... C AD2 B AD3 A D K AS R V B3 B2 B1 ED VP VM AD7 AD6 AD5 AD4 AD3 AD2 AD1 4 3 2 1 4 3 2 1 4 3 2 1 N R F OUTPUT SIGNAL A C D A B C D AD5 R AD4 F AD6 N B A B C G F H J D MCU_RS232 P_DUMP MCU_RS232_RX CAN_Lo CAN2_Lo BATTERY BATTERY MCU_RS232_TX CAN2_Hi CAN_Hi E A20 B32 B11 B33 A03 NEUTRAL SIGNAL 24V ANTI RESTART RELAY ALT LEVEL POWER IG 24V BATTERY RELAY 1 2 3 4 IG 24V GND CAN2 HI CAN2 LOW 23 1 3 4 5 7...

Page 566: ...NG FLOW Warning flow Warning flow Altermator CN 74 2 I conn CN 13 8 I conn CN 04 18 MCU CN 58B B33 Cluster charge warning lamp ON Charging flow Charging flow Alternator Starter CN 45 B Battery relay CR 01 Battery terminal Charging Fusible link CN 351 40A Master switch CS 74 1 2 I conn CN 01 16 17 Fuse box CN 36 39 Fusible link CN 352 80A I conn CN 01 21 26 Fuse box CN 38 39 CHECK POINT CHECK POINT...

Page 567: ...50 51 52 10A 53 54 TCU 24V B AC HEATER B CLUSTER 24V B MCU B RMCU B ROOM LP ECM POWER SPARE 02 SPARE 03 10A 10A 20A 20A 20A 20A 20A 01 02 03 04 05 06 07 08 09 10 11 20A 12 20A TURN LAMP START KEY SW RADIO B 30A 10A 10A DEF SENSOR AIR PRE HEAT 10A CN 36 CN 38 CN 39 FUSE BOX B P G 3 U 1 2 3 FI 4 NC 1 2 3W 300 7 8 18 20 6 7 4 17 22 21 23 24 25 26 16 12 33 14 32 2 13 23 CN 01 CN 04 CN 13 ALTERNATOR CN...

Page 568: ...d By spring force Pilot cut off ON Pilot cut off ON Fuse box CN 39 41 Pilot cut off switch ON Pilot cut off switch CS 4 5 4 I conn CN 05 11 I conn CN 12 12 Pilot cut off solenoid ON CN 68 activate Pilot cut off released Pilot cut off OFF Pilot cut off OFF Fuse box CN 39 41 Pilot cut off switch OFF Pilot cut off solenoid CN 68 OFF Pilot cut off applied CHECK POINT CHECK POINT 1 1 1 1 2 2 3 3 4 4 GN...

Page 569: ...A 49 50 51 5210A 5310A 54 FUSE BOX WIPER CN 39 1 2 1 2 1 2 3 4 6 7 8 9 10 11 5 12 CN 12 13 14 A B C CD 05 CN 68 CN 71 PILOT CUT SOL PARKING SOL BRAKE PEDAL PS_CLUTCH CUTOFF S G Y L 1 2 3 12 13 14 17 11 18 CN 05 19 20 21 22 23 24 25 26 10 16 15 27 28 29 18 EUPR DIAGNOSTIC 15 SDDK DIAGNOSTIC 24 VMGA1 GROUND_BRAKE PEDAL 37 AU1 5V SUPPLY_BRAKE PEDAL 38 EU1 SIGNAL SENSOR_BRAKE PEDAL 29 ED11 21 ED10 PAR...

Page 570: ...perating high Auto parking when switch OFF Switch OFF Fuse box CN 39 40 Wiper relay Hi CR 4 3 4 Front wiper motor CN 21 1 2 Multi function switch CS 12 5 4 Wiper relay Lo CR 26 4 3 Front wiper motor CN 21 5 Wiper motor stop Rear wiper and washer switch Rear wiper switch on monitor MCU CN 58B B16 Rear wiper relay CR 25 5 3 I conn CN 07 8 Rear wiper motor CN 203 5 Rear wiper motor operating MCU CN 5...

Page 571: ...15 37 36 38 39 30 31 28 27 IGNITION RELAY CONTOR 24V OUT REAR WIPER SPEED REALY AUTO GREASE RELAY REAR WIPER WASHER REALY ATACH LOCK RELAY ATACH UNLOCK RELAY BEACON RELAY MIRROR HEAT REALY FRONT WIPER 1ST SPEED REALY INPUT FRONT WASHER SIGNAL INPUT FRONT INT SIGNAL A30 B05 B08 B19 B07 B18 B17 B16 A39 B09 B15 A40 RIDE CONTROL RELAY B06 CN 39 FUSE BOX CN 203 REAR WIPER CN 07 MCU CN 58A CN 58B CR 25 ...

Page 572: ...STOP LAMP HORN HEAT MIRROR FUEL WARMER 1 CIGARLIGHTER COWL OPEN FUEL WARMER 2 43 44 27 47 31 39 38 13 4 32 1 2 3 4 C T E S 1 2 3 4 C T E S GOr Or GOr OrW OrW B GOr B CN 01 CL 16 CL 15 REAR COMBI RH REAR COMBI LH Y Gr RW BY L BVi G Y J 1 4 3 5 2 6 I O C W O J I HO 7 Lo R L 3 2 BG BW BWG 4 C W 6 Hi C 8 WB B 5 B R O L F Lo Hi 1 2 3 4 5 6 1 2 3 5 6 7 8 4 2 9 10 3 6 5 2 9 10 7 5 6 3 8 7 8 86 87 85 87 8...

Page 573: ...on Gauges Indicate operating status of the machine Warning lamps Indicate abnormality of the machine Pilot lamps Indicate operating status of the machine LCD Indicates selected the driving speed and direction The cluster installed on this machine does not entirely guarantee the condition of the The cluster installed on this machine does not entirely guarantee the condition of the machine Daily ins...

Page 574: ...ange even though the machine is on the normal condition check the electric device as that can on the normal condition check the electric device as that can be caused by the poor connection of electricity or sensor be caused by the poor connection of electricity or sensor 760F3CD04 760F3CD05 Engine coolant temperature gauge Engine coolant temperature gauge 3 3 This gauge indicates the temperature o...

Page 575: ...lamp Steering warning lamp primary Steering warning lamp emergency Brake fail warning lamp Battery charging warning lamp Emergency warning lamp SCR system cleaning warning lamp Stop engine warning lamp Check engine warning lamp HEST warning lamp Water in fuel warning lamp T M oil temp warning lamp Engine overheat warning lamp Fuel level warning lamp SCR system cleaning inhibit warning lamp 760F3CD...

Page 576: ...e the primary element after 4 times cleanings Replace the primary element after 4 times cleanings This warning lamp operates and the buzzer sounds when the temperature of hydraulic oil is over 106 C 223 F Check the hydraulic oil level when the lamp is turned ON and the buzzer sounds Check for debris between oil cooler and radiator If you want to stop buzzer sound just touch the icon If you want to...

Page 577: ... If you want to stop buzzer sound just touch the icon 77073CD16 77073CD18 77073CD22 Primary Primary This lamp indicates that the primary steering has failed When the indicator comes ON and the action alarm sounds steer the machine immediately to a convenient location and stop the machine Stop the engine and investigate the cause If you want to stop buzzer sound just touch the icon If you want to s...

Page 578: ...MCU and engine ECM on the engine is abnormal or if the cluster received specific fault code from engine ECM Check the communication line between them If the communication line is OK then check the fault codes on the monitor If you want to stop buzzer sound just touch the icon If you want to stop buzzer sound just touch the icon Check engine warning lamp Check engine warning lamp 760F3CD56 12 12 Th...

Page 579: ... will be ON when a stationary manual SCR sys tem cleaning is not performed Stop the engine immediatary Please contact your Hyundai service center or local dealer This warning lamp lights ON or blinks when the SCR system cleaning is needed as table below SCR SCR selective catalytic reduction system cleaning warning lamp system cleaning warning lamp 7609A3CD52 16 16 This warning lamp indicates when ...

Page 580: ...Manual SCR system cleaning This warning lamp indicates when illuminated that exhaust temperatures are high due to SCR system cleaning The lamp will also illuminate during a manual SCR system cleaning When this lamp is illuminated be sure the exhaust pipe outlet is not directed at any surface or material that can melt burn or explode When this lamp is illuminated the exhaust gas temperature When th...

Page 581: ...ion DEF AdBlue level Check engine Stop engine On Off Off The DEF AdBlue level has fallen below the initial warning level 10 Blink Off Off The DEF AdBlue level has fallen below the critical warning level 5 Blink On Off The DEF AdBlue level has fallen below the initial derate level 2 5 The engine power will be limited automatically Blink On On This is happened when 30 minutes elapsed with empty cond...

Page 582: ...F before driving Check the lamp is OFF before driving 77073CD12 77073CD13 High beam pilot lamp High beam pilot lamp 1 1 Parking brake pilot lamp Parking brake pilot lamp 2 2 The lamp comes ON when FNR select button on the optional FNR remote control lever is pressed Refer to page 7 67 Refer to page 7 67 7807A3CD24 FNR select pilot lamp FNR select pilot lamp option 3 3 This lamp lights ON when joys...

Page 583: ...used by the poor connection of electricity or sensor 6 LF LR Limp home gear Oil temperature too low no gear available Warm up engine transmission WS Warning sump temperature Alternate between WS and actual gear direction while driving in neutral only displayed WS if no fault is detected Cool down transmission WT Warning torque c o n v e r t e r temperature Alternate between WS and actual gear dire...

Page 584: ... input value Please refer to switch page 7 59 for selection and change of menu and input value Display type can be changed by operator See page 7 54 for details Display type can be changed by operator See page 7 54 for details 1 1 TYPE A default Main display Main menu Press Sub menu TYPE B 1 6 7 13 10 11 12 8 9 Tap 1 2 3 4 5 9 8 6 7 10 11 12 13 5 4 3 2 760F3CD11 1 1 Clock 2 Buzzer 3 Wiper speed 4 ...

Page 585: ...ormation Change display information 2 2 1 2 5 3 4 760F3CD08 1 760F3CD08A 1 Machine monitoring 760F3CD07E 1 Buzzer stop In main display you can check the data and setup what you want by touching each window area or icon Machine monitoring Machine monitoring To display the item in main display select two items of them Priority in the machine monitoring display Priority in the machine monitoring disp...

Page 586: ...play screen Refer to page 7 49 Engine mode and operation history Engine mode and operation history Set the engine mode A Refer to page 7 39 Set Hour meter ODO meter B Refer to page 7 48 760F3CD08K 1 Transmission mode Transmission mode Set the clutch cut off A shift B and torque con verter lock up mode C Refer to page 7 40 760F3CD08L 1 760F3CD08M 1 A B A B C ...

Page 587: ...r settings of machine User can apply or save the setting of monitor easily Active fault Active fault Display the fault code of MCU ECU TCU EHCU Refer to page 7 48 Maintenance Maintenance Elapsed time change or replace cycle can be changed Refer to page 7 51 Help Help Read the monitor manual as a PDF file on the monitor Smart terminal Smart terminal The menu features a smartphone and operates the m...

Page 588: ...an check the fault message and move the mainte nance screen by touching relevant area 760F3CD17 1 760F3CD18 1 Machine monitoring warning Machine monitoring warning Warning sign red icon will be shown when the tem perature of hydraulic oil cooling water transmission oil or battery voltage is not normal state Case of warning sign 4 4 760F3CD19 1 Communication error Communication error MCU could not ...

Page 589: ...ory Machine information Hyd Coolant and T M oil temp Battery voltage Hour meter ODO meter Active Logged fault MCU ECU TCU EHCU General record Hourly record Daily record Mode record TCU ECU MCU RMCU EHCU Monitor Cluster 3 Machine security Maintenance Service menu Change A S phone number Software update ESL system setting Change password Smart key Elapsed time Cycle Maintenance history Sensor monito...

Page 590: ... 760F3CD24F 1 Engine mode Engine mode The operator can adjust the machine s performance Econo Maximum fuel efficiency for general loading Standard General digging and loading operation Power Maximum power output for hard digging operation or hill climb Engine speed Engine speed Setting engine low idle rpm ...

Page 591: ...ch FNR RCV Joystick steering 760F3CD29C 760F3CD29B 760F3CD29A Clutch cut off C C O mode 760F3CD26B 760F3CD26A L mode M mode H mode Left brake pedal 760F3CD27 Four modes are available for operator s preference and job condition OFF The clutch cut off function is disable L Low The clutch is disengaged early for short distance and rapid loading M Medium The clutch is disengaged normally for general d...

Page 592: ... lock together through a direct lock up clutch 760F3CD32B 760F3CD32A Shift mode Shift mode Four modes are available for operator s preference and job condition Manual Machine is operated by selected gear on lever AL Auto Light Automatic shifting point is fast for long distance transportation and fuel efficiency AN Auto Normal Automatic shifting point is normal without automatic kick down to 1st ge...

Page 593: ...page 7 62 for details Refer to page 7 62 for details 15 0 5 15 760F3CD126 Weighing system Weighing system The weight indication in bucket is calculated by measuring boom position and boom pressure The weight is 0 0 ton when the boom is placed at below 15 The weight is indicated when the boom is placed at the range 5 15 The weight is calculated when the boom is placed at above 5 and boom is lowered...

Page 594: ...functions are operated Save position Refer to page 4 22 in operator s manual Auxiliary attachment max flow level Auxiliary attachment max flow level mode option mode option If the machine is equipped with auxiliary attachment auxiliary attachment flow can be easily adjusted and controlled Set the oil flow level from 0 to 15 level by using button 760F3CD34B 760F3CD34A 760F3CD35B 760F3CD35A 760F3CD3...

Page 595: ...760F3CD40B 01 760F3CD40A 1 760F3CD40D 1 760F3CD40C 1 Speedometer frequency setting Speedometer frequency setting mode mode 760F3CD73B 760F3CD73A 1 Press speedometer setting bar or for 3 seconds Only for the service person Do not adjust arbitrary Only for the service person Do not adjust arbitrary Using button Using button To change the pulse value press or To change the position press Automatic Ma...

Page 596: ...fore delivery of the machine When angle sensor is replaced or actual value is different compared to setting value this function can be done Bell crank angle Boom angle Bucket cylinder stroke Detent setting switch 760F3CD128 The calibration must be carried out as follows Lower the boom at maximum low position and press NEXT button or bucket must be max tilting position Raise boom at maximum high po...

Page 597: ... sensor need to be checked Press START button after following the instruction After a few minutes Calibration fail or Calibration success message will be shown Press complete button then process be ended Using button Using button Using instead of NEXT complete button Boom pressure calibration Boom pressure calibration It is used when bucket weight is changed or measured weight is inaccurate The ca...

Page 598: ...play during AEB mode Display during AEB mode Symbol Meaning ST Start AEB K1 K4 KV KR Calibrating clutch K1 K4 KV or KR respectively OK Calibration for all clutches finished Spanner and Kx Kx couldn t be calibrated AEB finished E Engine speed too low Raise engine speed E Engine speed too high Lower engine speed T Transmission oil temperature too low Heat up transmission T Transmission oil temperatu...

Page 599: ...play the item in main display select the item in main display See the page 7 34 760F3CD41B 1 760F3CD41A 1 760F3CD42B 1 760F3CD42A 1 Display the fault code of MCU ECU TCU EHCU and delete logged fault Refer to service manual for HCESPN FMI of engine and transmission Refer to service manual for HCESPN FMI of engine and transmission Not define will be indicated in case of that there s no fault Not def...

Page 600: ...r and monitor can be checked 760F3CD46B 760F3CD46A 1 Dispaly the fuel consumption history General record average fuel rate and a days fuel used Hourly record Daily record Mode record Fuel consumption history Fuel consumption history 760F3CD141A 760F3CD141 760F3CD141C 760F3CD141E 760F3CD141G ...

Page 601: ...fic time Specific Specific time time If set specific time to 5 minutes ESL system is activated after 5 minutes Therefore the password does not need to restart engine within 5 minutes Default passwor Default password 00000 d 00000 Change password Change password Input 5 to 10 digits Smart key opt Smart key opt Manage usage Set the using or not of smart key If you using smart key ESL function always...

Page 602: ...000 侏2 5000 3 Pilot line filter element 1000 4 Hydraulic oil return filter 1000 5 Engine oil filter 500 6 Fuel filter element 500 7 Fuel pre filter 500 8 Hydraulic tank air breather 1000 9 Radiator coolant 2000 10 Transmission oil and filter 1000 11 Axle oil front and rear 1500 12 Aircon heater outer filter 1000 13 Crankcase Breather Filter 2000 14 DEF AdBlue supply module filter 4500 15 DEF AdBlu...

Page 603: ... Speed limit setting 20 40 km h 5 km h intervals Weighing system compensation Weighing system compensation Calibration workload depending on work tool Only for the service person Do not adjust arbitrary Only for the service person Do not adjust arbitrary EHCU I O information EHCU I O information Real time monitoring joystick stroke EPPR current Service menu Service menu 760F3CD74B 1 760F3CD74A 1 7...

Page 604: ...ime for daylight If you set the time for daylight the rest time will be night Using button Using button Changing brightness by or input data by Clock setting Clock setting Set the time hour minute and AM or PM Temperature C F Speed km h mph Weight ton lb Pressure bar Mpa kgf m2 psi Using button Using button Move to other item by Unit setting Unit setting 760F3CD77B 760F3CD77A 1 760F3CD78B 1 760F3C...

Page 605: ...should put radio mode into Aux mode Display style Display style Language Language Set the display type A or B User can select preferable language and all display are changed the selected language 13 multiple language available 760F3CD79B 760F3CD79A 1 760F3CD81B 760F3CD81A 1 760F3CD81C 1 760F3CD81D 760F3CD81E 1 ...

Page 606: ...lay order Display order Set the channel sequence of each camera Active when the reverse gear is selected Active when the reverse gear is selected If transmission engages the reverse gear R1 R3 the camera mode is displayed automatically in main display If the camera was not equipped this menu is not useful In main display if the is touched or switch is pushed the first ordered display camera will b...

Page 607: ... coolant temperature is above 30 C or when 10 minutes have passed since starting the engine 75793CD31 Warming up pilot lamp Warming up pilot lamp 1 1 This lamp lights ON for the first five seconds after starting the engine 75793CD17 Seat belt pilot lamp Seat belt pilot lamp 2 2 This lamp lights ON when start switch is turned clockwise to the ON position Light will turn off after approximately 5 45...

Page 608: ... This lamp lights ON when the boom float is activated 7807A3CD24 Float mode pilot lamp Float mode pilot lamp 6 6 Auto ride control Auto ride control This lamp lights ON when the automatic ride control function is activated ON Conditional speed ON Conditional speed setting Refer to page 7 61 Refer to page 7 61 75793CD33 Ride control pilot lamp Ride control pilot lamp option Manual ride control Manu...

Page 609: ...1 Refer to page 7 41 760F3CD94 Torque converter lock up pilot lamp Torque converter lock up pilot lamp option 9 9 This lamp is turned ON when the coolant temperature is below 10 C 50 F or the hydraulic oil temperature 20 C 68 F The automatic fuel warming is cancelled when the engine coolant temperature is above 60 C and the hydraulic oil tem perature is above 45 Csince the start switch was ON posi...

Page 610: ...zzer Wiper Wiper Camera Camera Menu Menu Machine monitoring Machine monitoring Fuel rate Fuel rate Engine mode Operation history Engine mode Operation history Transmission mode Transmission mode Quick menu Quick menu Move to selected setting screen by using enter switch Move to selected setting screen by using enter switch When keypad is not pressed for 3 seconds convert screen to main display Whe...

Page 611: ...e green pilot lamp is turned ON 6 6 760F3CD83 1 Work lamp switch Work lamp switch This switch use to operates the front and rear work lamps Front Front Front work lamp located on the cab comes ON The green pilot lamp is turned ON Front Rear Front Rear Front work lamp located on the cab and rear work lamp located on the cowl come ON The green pilot lamp is turned ON 7 7 760F3CD84 1 This switch is u...

Page 612: ... automatic ride control automatically turns on when the travel speed exceeds a preset speed forward backward 1 15 km h The blue pilot lamp is turned ON Ride control switch Ride control switch option 10 10 760F3CD87A 1 760F3CD87B 1 ON Always ON Always Select ON Always ON Always in order to turn on the system for ride control regardless speed The ride control will smooth the ride of the machine duri...

Page 613: ...760F3CD115C 1 760F3CD115D 1 Error detection Error detection Set error detection ON OFF Refer to the page 7 42 for details Refer to the page 7 42 for details Rear wiper and washer switch Rear wiper and washer switch 12 12 760F3CD89 1 This switch use to operates the rear wiper and washer When pressing the switch the mode is changed sequence base OFF intermittent Low OFF Intermittent Intermittent The...

Page 614: ...ON OFF Save position Save position Set the boom kickout and bucket leveler Refer to page 4 22 The green pilot lamps are turned ON The green pilot lamps are turned ON Fine modulation switch Fine modulation switch 16 16 760F3CD67 ON ON Remote control lever provide the operator with precise control of the work equipment bucket and boom cylinders can be con trolled precisely The green pilot lamp is tu...

Page 615: ...tch in cold weather the fuel warm If you turn ON the starting switch in cold weather the fuel warm er is automatically operated to heat the fuel by sensing the cool er is automatically operated to heat the fuel by sensing the cool ant temperature Start the engine in 1 2 minutes after turning ant temperature Start the engine in 1 2 minutes after turning ON the starting switch More time may take acc...

Page 616: ...etermine if the emergency steering and the emergency steering lamp are functional When the switch is pressed the emergency steering pump motor will run The emergency steering lamp will light If the emergency steering lamp does not light do not operate the machine 1 2 EMERGENCY TEST SWITCH option 4 760F3CD52 M A Manual Auto OFF DIFFERENTIAL LOCK SWITCH option 5 760F3CD30 This switch is used to appl...

Page 617: ...to allow cleaning HEST lamp will be illuminated during the entire SCR system clean ing Refer to the page 7 29 for ditails Refer to the page 7 29 for ditails This switch can be move to the SCR system cleaning position This switch can be move to the SCR system cleaning position only when the safety button is pulled to backward only when the safety button is pulled to backward Also this switch return...

Page 618: ...er FNR select button FNR select button If the select button is pressed the indication lamp on the cluster will be ON and this FNR switch will start to operate When the engine is running the machine is on standstill 0 When the engine is running the machine is on standstill 0 speed parking brake is released gear selector lever is in the speed parking brake is released gear selector lever is in the n...

Page 619: ...not operate with the switch in ON J If the wiper does not operate with the switch in ON J Ⅰ Ⅱ posi posi tion turn the switch OFF O immediately and check the cause tion turn the switch OFF O immediately and check the cause If the switch remains ON motor failure can result If the switch remains ON motor failure can result 1 1 MULTI FUNCTION SWITCH MULTI FUNCTION SWITCH 13 13 O J Ⅰ Ⅱ 73033CD29 Dimmer...

Page 620: ...ox 50Ω connected Ω Fusible link 24V Resistance between ring termi nal and each connector pin 0Ω normal Start key B BR 24V 1A B ACC 24V 10A B ST 20V 40A Resistance between each pin Key off Ω for each pin Key on 0Ω for pin 1 2 1 3 Start 0Ω for pin 1 5 Pressure switch N C Type Resistance 0Ω normal close Pressure switch N O Type Resistance Ω normal open 6 1 2 3 4 5 6 1 5 3 0 I 0 I H 4 2 B H BR ACC ST ...

Page 621: ...k resistance about 24Ω Fuel sender Resistance at fuel levels full level 200Ω 9 12 level 500Ω 6 12 level 800Ω 3 12 level 1100Ω empty 1300Ω Room lamp 24V 10W Resistance normal 1 2Ω Relay 5pin 24V 20A Resistance normal about 160Ω for pin 85 86 0Ω for pin 30 87 Ω for pin 30 87 1 2 Pa 1 2 1 2 30 86 87 85 87a 86 85 87 30 87a 3 2 1 CL 1 CD 2 CN 43 CN 136 CN 154 CN 155 CD 10 CN 68 CN 177 CN 71 CN 178 CN 7...

Page 622: ...ff position Ωbetween pin 1 5 and 2 6 0Ωbetween pin 5 7 and 6 8 Work lamp Number plate lamp Work lamp 24V 70W Number plate lamp 24V 10W Resistance normal 1 2Ω Beacon lamp 24V 70W H1 TYPE Resistance normal 1 1Ω 1 2 C 1 2 7 1 4 5 2 8 7 6 4 3 1 8 5 2 CN 123 LH CN 124 RH CL 1 CL 5 CL 6 CL 21 CL 22 CL 23 1 2 CL 7 M 3 2 5 1 4 2 1 5 3 4 CR 2 CR 4 CR 25 CR 26 CR 37 CR 58 CR 79 CR 115 CR 117 CR 136 CR 302 C...

Page 623: ... 27 2 kgf cm Radio USB player 24V 20W 20W Resistance Power ON 4Ω 4Ω for pin 1 6 4 8 Back up buzzer 24V 0 5A 110dB Resistance normal 5 2Ω Washer pump 24V 2 5A Resistance normal 26 4 Ω for pin1 2 24V 12V 7 10 11 12 3 1 2 4 5 6 8 9 20A 13mA 2 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 ACC ILL GND SPK FRT RH SPK FRT LH TEL MUTE ANT 12V BACK UP ILL NC SPK FRT RH REMOCON REMOCON GND SPK FRT LH NC GND 1 2 ...

Page 624: ...Denso 24V 95A Voltage normal 24 28V Starter Denso PA90L 24V 7 8kW Operating or not Aircon compressor 24V 79W Resistance normal 13 4Ω Start relay 24V 300A Coil resistance normal 1 2Ω Switch connection Ωat normal open position 0Ωwhen engaged Lo Hi M 5 4 E 3 Pf 2 B 1 2 3 4 5 6 1 B A 1 M M B P L G 3 U 1 2 3 FI 4 NC CN 21 FR CN 102 RR CL 2 CN 74 CN 45 1 CN 28 CR 23 ...

Page 625: ...rmal about 5MΩ Flasher unit 24V 85 190 C M 50dB Head lamp 24V 75W 70W H4 TYPE 24V 4W T4W Resistance normal a fewΩ Combi lamp rear 24V 5W R5W 2 24V 21W P21W Master switch Continuous capaci ty 180Amp Push in capacity 1000Amp 2 1 M 2 CS 1 CS 55 86 87 85 87 85 T 86 Lo Hi E C 6 3 4 2 1 T 5 ABL CL 15 CL 16 4 3 2 1 C T E S CL 3 CL 4 CR 11 2 1 2 1 CS 74 CS 75 ...

Page 626: ...7 75 Part name Symbol Specifications Check item Warning buzzer 24V 200mA 90 5dB ℓm Preheater 24V 200A Resistance 0 25 0 12Ω Resistor 4W Resistance A B 120Ω CN 26 2 1 A B C A B CN 80 CN 99 ...

Page 627: ... 15 KET 11 I conn RH console harness Main harness MG651350 MG641353 CN 16 KET 14 I conn RH console harness Main harness MG651110 MG641113 CN 18 DEUTSCH 12 LH seat console DT06 12S DT04 12P CN 19 Econoseal J 6 I conn Emer steer harness Front harness S816 006002 S816 106602 CN 21 AMP 6 Front wiper motor 936257 1 CN 24 DEUTSCH 12 Grill harness DT06 12S CN 26 250 2 Warning buzzer S810 002202 CN 26A AM...

Page 628: ...D10 9 96P CN 128 NMWP 1 Aircon compressor PB625 01027 CN 129 KET 2 Receiver drier MG640795 CN 134 AMP 6 Diagnostic TCU 1 480705 0 CN 136 AMP 2 Ride control solenoid 85202 1 CN 136A Econoseal J 2 I conn Ride control harness Front harness S816 002002 S816 102002 CN 137 AMP 1 12V socket 174198 1 CN 138 AMP 12 DC DC Converter 1 967622 1 CN 139 AMP 1 12V socket 174198 1 CN 149 DEUTSCH 2 Mirror heat LH ...

Page 629: ... CN J17 AMP 4 DOC temp sensor 4 1418390 1 CN J26 BOSCH 12 DEF supply module 2 1703639 1 CN J27 DEUTSCH 2 DEF heater valve DT06 2S CN J28 BOSCH 2 Hose heating PR line 1 928 403 874 CN J29 BOSCH 2 Hose heating back line 1 928 403 874 CN J30 BOSCH 2 Hose heating suction line 1 928 403 874 CN J31 BOSCH 2 DEF dosing inlet valve 1 928 403 874 Relay CR 1 Ring term Battery relay S820 104002 CR 2 AMP 5 Hor...

Page 630: ...S 79 VC2 01 10 Differential lock switch 21HN 56300 CS 85 85L KET 2 Workload switch MG610070 MG620074 CS 86 86L KET 2 Kick down switch MG610070 MG620074 CS 87 87L KET 2 Horn switch MG610070 MG620074 CS 88 88L KET 2 FNR select switch MG610070 MG620074 CS 105 VC2 01 10 SCR switch 21HN 56300 Light CL 1 KET 3 Room lamp MG651032 CL 2 KET 3 Cigar lighter S822 014000 S822 114000 CL 3 DEUTSCH 6 Head light ...

Page 631: ...DT06 3S CD 27 AMP 2 Turbin pick up sensor 85202 1 CD 39 DEUTSCH 3 Main pump pressure switch DT06 3S CD 40 DEUTSCH 3 Steering pump pressure switch DT06 3S CD 43 AMP 2 Lock up proportional valve 282027 CD 45 DEUTSCH 2 WIF sensor DT06 2S EP06 CD 46 AMP 3 Output speed sensor 282087 CD 47 AMP 2 Gear chain sensor 85202 5 CD 48 AMP 2 Oil filter restriction sensor 282080 CD 49 AMP 2 Converter temp sensor ...

Page 632: ...TABLE FOR CONNECTORS 2 CONNECTION TABLE FOR CONNECTORS 58 L TYPE CONNECTOR 58 L TYPE CONNECTOR 1 1 No of pin Receptacle connector female Plug connector male 1 2 1 S813 030100 1 S813 130100 1 2 S813 030200 1 2 S813 130200 ...

Page 633: ...811 105002 3 7 1 4 S811 007002 1 4 3 7 S811 107002 4 9 1 5 S811 009002 1 5 4 9 S811 109002 5 11 1 6 S811 011002 1 6 5 11 S811 111002 7 9 11 PA TYPE CONNECTOR PA TYPE CONNECTOR 2 2 No of pin Receptacle connector female Plug connector male ...

Page 634: ...83 13 6 13 1 7 S811 013002 17 21 1 7 6 13 S811 113002 8 17 1 9 S811 017002 1 9 8 17 S811 117002 1 21 1 11 1 11 1 21 S811 121002 S811 021002 No of pin Receptacle connector female Plug connector male 10 10 ...

Page 635: ...or female Plug connector male 2 3 4 8 1 2 2 1 2 3 1 3 1 2 3 1 4 2 4 2 3 1 6 3 1 8 5 2 8 5 2 6 3 1 S816 002001 S816 102001 S816 003001 S816 103001 S816 004001 S816 104001 S816 008001 S816 108001 J TYPE CONNECTOR J TYPE CONNECTOR 3 3 2 1 ...

Page 636: ...le connector Female Plug connector male 1 1 S814 001000 2 3 4 1 S814 101000 2 1 1 2 S814 002000 S814 102000 3 2 1 1 2 3 S814 003000 S814 103000 2 4 1 3 1 3 2 4 S814 004000 S814 104000 SWP TYPE CONNECTOR SWP TYPE CONNECTOR 4 4 ...

Page 637: ... 1 4 1 4 3 6 S814 006000 S814 106000 4 8 1 5 1 5 4 8 S814 008000 S814 108000 4 12 1 9 1 9 4 12 S814 012000 S814 112000 3 14 1 11 1 11 3 14 S814 014000 S814 114000 No of pin Receptacle connector female Plug connector male ...

Page 638: ...3 4 1 S810 101202 2 1 S810 002202 2 1 S810 102202 3 1 2 S810 003202 2 1 3 S810 103202 2 4 1 3 S810 004202 1 3 2 4 S810 104202 CN TYPE CONNECTOR CN TYPE CONNECTOR 5 5 No of pin Receptacle connector female Plug connector male 4 ...

Page 639: ...7 88 No of pin Receptacle connector female Plug connector male 6 3 6 1 4 S810 006202 8 1 4 3 6 S810 106202 1 5 4 8 S810 108202 4 8 1 5 S810 008202 ...

Page 640: ...TT SWF CONNECTOR 6 1 2 11 12 SWF589790 1 4 3 6 6189 0133 HW090 SEALED CONNECTOR HW090 SEALED CONNECTOR 7 7 2 1 2 PH805 02028 MWP02F B CONNECTOR MWP02F B CONNECTOR 8 8 6 6 No of pin Receptacle connector female Plug connector male No of pin Receptacle connector female Plug connector male ...

Page 641: ...f pin Receptacle connector female Plug connector male 2 1 2 85202 1 AMP TIMER CONNECTOR AMP TIMER CONNECTOR 10 10 No of pin Receptacle connector female Plug connector male 12 1 7 6 12 174045 2 AMP 040 MULTILOCK CONNECTOR AMP 040 MULTILOCK CONNECTOR 11 11 12 1 24 36 13 25 344111 1 12 24 36 1 13 25 344108 1 344111 1 344108 1 ...

Page 642: ...tor female Plug connector male 2 1 2 MG640795 No of pin Receptacle connector female Plug connector male 10 1 2 9 10 SWF593757 ITT SWF CONNECTOR ITT SWF CONNECTOR 13 13 No of pin Receptacle connector female Plug connector male 1 1 NMWP01F B MWP NMWP CONNECTOR MWP NMWP CONNECTOR 14 14 ...

Page 643: ...RS DT 06 3S 15 15 Modifications see below Number of contacts P Pin S Socket 04 Receptacle 06 Plug Deutsch connetors Modification E003 Standard end cap gray E004 Color of connector to be black E005 Combination E004 E003 EP04 End cap EP06 Combination P012 EP04 P012 Front seal enhancement connectors color to black for 2 3 4 6pin 4 4 2 3 1 DT06 4S 4 1 3 2 DT04 4P ...

Page 644: ...7 93 No of pin Receptacle connector female Plug connector male 6 6 1 4 3 DT06 6S 6 1 4 3 DT04 6P 5 4 8 1 8 5 4 8 1 DT06 8S 12 DT04 8P 6 7 1 12 DT06 12S 7 6 12 1 DT04 12P ...

Page 645: ...n Receptacle connector female Plug connector male 1 2 3 4 S816 101002 S816 102002 S816 103002 S816 104002 ECONOSEAL J TYPE CONNECTORS ECONOSEAL J TYPE CONNECTORS 16 16 2 1 S816 001002 S816 002002 S816 003002 S816 004002 ...

Page 646: ...7 95 No of pin Receptacle connector female Plug connector male 6 8 10 12 S816 106002 S816 108002 S816 110002 S816 112002 S816 006002 S816 008002 S816 010002 S816 012002 ...

Page 647: ...ug connector male 2 12040753 METRI PACK TYPE CONNECTOR METRI PACK TYPE CONNECTOR 17 17 368301 1 No of pin Receptacle connector Female Plug connector Male 40 1 2 3 4 5 6 7 8 9 10 31 32 33 34 35 36 37 38 39 40 11 21 20 30 1 5 6 10 31 40 11 21 20 30 35 36 DRC26 40SA B C DEUTSCH MCU CONNECTOR DEUTSCH MCU CONNECTOR 18 18 ...

Page 648: ...nd ON OFF of bulb After checking connect the disconnected connectors again immediately unless otherwise specified GROUP 6 TROUBLESHOOTING GROUP 6 TROUBLESHOOTING YES NO 1 CN 56 CLUSTER FUSE CN 37 No 17 1 CN 57 MONITOR Check voltage 760F7EL24 YES 20 30 V NO 0 V Cause Remedy Defective cluster Defective monitor Disconnection in wiring harness or poor contact between CN 56 1 CN 57 1 and fuse No 17 Rep...

Page 649: ...ied Cause Remedy Defective controller Disconnection in wiring harness or poor contact between CN 58B B33 andCN 4 18 Disconnection in wiring harness or poor contact between CN 14 18 and alternator terminal 2 Defective alternator Replace Repair or replace after clean Repair or replace after clean Replace Check voltage between alternator terminal 2 and chassis Check voltage between CN 4 18 and chassi...

Page 650: ...ontact between CN 12 13 and CN 5 14 Disconnection in wiring harness or poor contact between CN 12 13 and CN 71 2 Difective parking switch Disconnection in wiring harness or poor contact between CS 17 2 and Fuse No 41 Replace Repair or replace after clean Repair or replace after clean Repair or replace after clean Replace Repair or replace after clean Check voltage between CN 71 2 and chassis NO Vo...

Page 651: ...ediately unless otherwise specified Cause Remedy DefectiveT M control unit Disconnection in wiring harness or poor contact between CN 157 21 and CS 17 1 Defective switch Disconnection in wiring harness or poor contact between CS 17 2 and fuse No 41 Replace Repair or replace after clean Replace Repair or replace after clean Check voltage between CN 157 21 and chassis NO Voltage 20 30V Parking switc...

Page 652: ...herwise specified Wiring diagram See page 7 17 Cause Remedy Defective clutch cut off mode switch Defective T M control unit Defective T M control unit Defective parking switch Disconnection wiring harness or poor contact between CN 157 21 and CS 17 1 Replace Replace Replace Replace Repair or replace after clean Is voltage between CN 157 21 and chassis 20 28V Is there continuity between CS 17 1 and...

Page 653: ...nnected connectors again immediately unless otherwise specified Check voltage CS 12 6 Voltage 20 30V Starting switch ON Wiper switch 1st Voltage 20 30V Starting switch ON Wiper switch 1st YES NO MULTI FUNCTION SWITCH CS 12 CS 11 CS 5 7 6 5 4 3 2 1 8 1 2 3 4 5 6 J I II O C W O J I II R L C B R O L F Lo Hi BWG C Hi Y Gr RW BY L BVi G 1 4 3 5 2 6 HO 4 W 6 Y 7 Lo 3 2 BG BW 8 WB 5 B Gr LOr 3 1 5 2 4 CR...

Page 654: ... 20A 20A 10A 10A 20A 10A 10A 20A 37 38 39 40 41 42 43 44 45 46 10A 47 10A 48 DEF SUPPLY HOSE HEATING 1 2 3 ECU B SPARE SPARE 10A 20A 10A 10A 49 50 51 52 10A 53 54 TCU 24V B AC HEATER B CLUSTER 24V B MCU B RMCU B ROOM LP RADIO IG RMCU IG CLUSTER IG LH STEER LEVER EHCU IG MCU IG KEY OFF TCU IG ECM POWER SPARE 02 SPARE 03 ILLUMINATION ILLUMINATION ECU IG 10A 10A 20A 20A 20A 20A 20A 10A 20A 20A 20A 10...

Page 655: ... 87a 87a CR 03 WORK LAMP FRONT RY 1 2 1 2 12 11 10 1 2 3 4 5 6 CN 24 CL 45 WORK LAMP RH CL 46 WORK LAMP LH 13 4 2 32 14 33 12 16 17 25 CN 01 26 BEACON WORK LAMP_REAR ILL LAMP HEAD LAMP BACK BZ STOP LAMP HORN AIR CON HEATER 1 FUEL WARMER 2 SEAT HEAT AIR RIDE WIPER PARK PILOT CUT AUTO GREASE FAN REVERSE ATT RIDE CONTROL SPARE 12V CONVERTOR WORK LAMP_FRONT AIR PRE HEAT HEAT MIRROR FUEL WARMER 1 CN 38...

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