SL730

CONTENTS
SECTION 1 GENERAL
Group 1 Safety Hints -------------------------------------------------------------------------------------------------------- 1-1

Group 2 Specifications ----------------------------------------------------------------------------------------------------- 1-10
Group 3 Operational Checkout Record Sheet --------------------------------------------------------------- 1-19
SECTION 2 POWER
POWER TRAIN SYSTEM
Group 1 Structure and Function -------------------------------------------------------------------------------------- 2-1

Group 2 Transmission ------------------------------------------------------------------------------------------------------ 2-2
Group 3 Torque Converter ----------------------------------------------------------------------------------------------- 2-35
Group 4 Axle --------------------------------------------------------------------------------------------------------------------- 2-40
SECTION 3 BRAKE SYSTEM
Group 1 Structure ------------------------------------------------------------------------------------------------------------- 3-1

Group 2 Air Brake Circuit ------------------------------------------------------------------------------------------------- 3-2
Group 3 Components Specification and Function -------------------------------------------------------- 3-3
SECTION 4 STEERING SYSTEM
Group 1 Hydraulic Circuit ------------------------------------------------------------------------------------------------- 4-1

Group 3 Operational Checks and Troubleshooting ------------------------------------------------------- 4-18
Group 4 Test and Adjustments ---------------------------------------------------------------------------------------- 4-24
SECTION 5 WORK EQUIPMENT
Group 1 Hydraulic Circuit ------------------------------------------------------------------------------------------------- 5-1

Group 3 Operational Checks and Troubleshooting ------------------------------------------------------- 5-21
Group 4 Test and Adjustments ---------------------------------------------------------------------------------------- 5-31
SECTION 6 ELECTRICAL SYSTEM
Group 1 Component Location ----------------------------------------------------------------------------------------- 6-1

Group 2 Electrical Circuit ------------------------------------------------------------------------------------------------- 6-3
Group 3 Monitoring System --------------------------------------------------------------------------------------------- 6-4
Group 4 Connector ----------------------------------------------------------------------------------------------------------- 6-11
0-9
FOREWORD
1. STRUCTURE
This service manual has been prepared as an aid to improve the quality of repairs by giving the
serviceman an accurate understanding of the product and by showing him the correct way to
perform repairs and make judgements. Make sure you understand the contents of this manual and
use it to full effect at every opportunity.
This service manual mainly contains the necessary technical information for operations performed in
a service workshop.
For ease of understanding, the manual is divided into the following sections.
Structure and function

This group explains the structure and function of each component. It serves not only to give an
understanding of the structure, but also serves as reference material for troubleshooting.
Operational checks and troubleshooting
This group explains the system operational checks and troubleshooting charts correlating problem to
remedy.
Tests and adjustments
This group explains checks to be amide before and after performing repairs, as well as adjustments
to be made at completion of the checks and repairs.
Disassembly and assembly
This group explains the order to be followed when removing, installing, disassembling or assembling
each component, as well as precautions to be taken for these operations.
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Contact your Hyundai distributor for the latest information.
0-1
2. HOW TO READ THE SERVICE MANUAL
Distribution and updating Revised edition mark (①②③…)
Any additions, amendments or other changes When a manual is revised, an edition mark is
will be sent to HYUNDAI distributors. recorded on the bottom outside corner of the
Get the most up-to-date information before you pages.
start any work.
Revisions
Filing method Revised pages are shown at the list of revised
1. See the page number on the bottom of the pages on the between the contents page and
page. section 1 page.
File the pages in correct order.
2. Following examples shows how to read the Symbols
page number. So that the shop manual can be of ample
Example 1 practical use, important places for safety and
3-3 quality are marked with the following symbols.
Section number (3. Power train
system)
Consecutive page number for Symbol Item Remarks
each section.
Special safety precautions are
3. Additional pages : Additional pages are necessary when performing the
indicated by a hyphen(-) and number after the work.
Safety
page number. File as in the example. Extra special safety precautions
10 - 4 are necessary when performing
10 - 4 - 1 the work because it is under
Added pages internal pressure.
10 - 4 - 2
10 - 5 Special technical precautions or
※ Caution
other precautions for preserving
standards are necessary when
performing the work.
0-2
3. CONVERSION TABLE
Method of using the Conversion Table
The Conversion Table in this section is provided to enable simple conversion of figures. For details of
the method of using the Conversion Table, see the example given below.
Example
1. Method of using the Conversion Table to convert from millimeters to inches
Convert 55 mm into inches.
(1) Locate the number 50 in the vertical column at the left side, take this as ⓐ, then draw a horizontal
line from ⓐ.
(2) Locate the number 5in the row across the top, take this as ⓑ, then draw a perpendicular line
down from ⓑ.
(3) Take the point where the two lines cross as ⓒ. This point ⓒ gives the value when converting
from millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.

(1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place
to the left) to convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) 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.
Millimeters to inches ⓑ
1mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
ⓒ
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
ⓐ
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
0-3
Millimeters to inches 1mm = 0.03937in
0 1 2 3 4 5 6 7 8 9
0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
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 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
0-4
Liter to U.S. Gallon 1ℓ = 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378

10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.6076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.631 25.625 25.889 26.153
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 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
0-5
kgf·m to lbf
kgf lbf·ftft 1kgf·m = 7.233lbf·ft
0 1 2 3 4 5 6 7 8 9
7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1

10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 396.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 10005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
0-6
kgf/cm2 to lbf/in2 1kgf / cm2 = 14.2233lbf / in2
0 1 2 3 4 5 6 7 8 9
14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0

10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 2863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 5603 2617 2631 2646 2660 2674 2688
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
0-7
TEMPERATURE
Fahrenheit-Centigrade Conversion.
A simple way to convert a fahrenheit temperature reading into a centigrade temperature reading or vice verse
is to enter the accompanying table in the center or boldface column of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
˚C ˚F ˚C ˚F ˚C ˚F ˚C ˚F
-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 117.8
-37.2 -35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
-26.7 -16 3.2 -6.7 20 68.0 12.8 55 131.0 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 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
-20.6 -5 23.0 -1.1 35 95.0 21.1 70 158.0 51.7 125 257.0
-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

-19.4 -3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
-18.9 -2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 172 347.0
0-8
SECTION 1 GENERAL
Group 1 Safety Hints --------------------------------------------------------------------------------------------------------1-1

Group 2 Specifications -----------------------------------------------------------------------------------------------------1-10
Group 3 Operational Checkout Record Sheet ---------------------------------------------------------------1-19
SECTION 1 GENERAL
GROUP 1 SAFETY HINTS
FOLLOW SAFE PROCEDURE

Unsafe wor k practices are dangerous.
Understand service procedure before doing
work; Do not attempt shortcuts.
WEAR PROTECTIVE CLOTHING

Wear close fitting clothing and safety equipment
appropriate to the job.
73031GE01
WARN OTHERS OF SERVICE WORK

Unexpected machine movement can cause
serious injury.
Before performing any work on the wheel load-
er, attach a 「Do Do Not Operate
Operate」 tag on the
right side controller lever.
830K1SH03E
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 the machine. Never mount or
dismount a moving machine. 73032E01
Be careful of slippery conditions on platforms,

steps, and handrails when leaving the machine.
1-1
PREPARE FOR EMERGENCIES
Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors,
ambulance ser vice, hospital, and fire
department near your telephone.
73031GE03
WORK IN CLEAN AREA

Before starting a job :
· Clean work area and machine.
· Make sure you have all necessary tools to do
your job.
· Have the right parts on hand.
· Read all instructions thoroughly; Do not
attempt shortcuts.
73031GE26
PROTECT AGAINST FLYING DEBRIS

Guard against injury from flying pieces of metal
or debris; Wear goggles or safety glasses.
73031GE04
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.
73031GE05
1-2
PARK MACHINE SAFELY
Before working on the machine:
· Park machine on a level surface.
· Lower bucket to the ground.
· Turn key switch to OFF to stop engine.
Remove key from switch.
· Move pilot control shutoff lever to locked
position.
· Allow engine to cool. 73031GE23
SUPPORT MACHINE PROPERLY

Always lower the attachment or implement to
the ground before you work on the machine. If
you must work on a lifted machine or attachment,
securely support the machine or attachment.
Do not support the machine on cinder blocks,
hollow tiles, or props that may crumble under
continuous load.
Do not work under a machine that is supported
solely by a jack. Follow recommended
procedures in this manual. 73031GE06
SERVICE COOLING SYSTEM SAFELY

Explosive 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.
73031GE07
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 tank outdoors.
73031GE08
1-3
Store flammable fluids away from fire hazards.
Do not incinerate or puncture pressurized
containers.
Make sure machine is clean of trash,
grease, and debris.
Do not store oily rags ; They can ignite and
burn spontaneously.
73031GE09
BEWARE OF EXHAUST FUMES

Prevent asphyxiation. Engine exhaust fumes
can cause sickness or death.
If you must operate in a building, be positive
there is adequate ventilation. Either use an
exhaust pipe extension to remove the exhaust
fumes or open doors and windows to bring
enough outside air into the area.
REMOVE PAINT BEFORE WELDING OR

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, avoid breathing the
dust. Wear an approved respirator.
· If you use solvent or paint stripper, remove
stripper with soap and water before welding.
Remove solvent or paint stripper containers
and other flammable material from area.
Allow fumes to disperse at least 15 minutes
before welding or heating. 73031GE10
1-4
ILLUMINATE WORK AREA SAFELY
Illuminate your work area adequately but safely.
Use a portable safety light for working inside or
under the machine. Make sure the bulb is
enclosed by a wire cage. The hot filament of an
accidentally broken bulb can ignite spilled fuel
or oil.
73031GE11
SERVICE MACHINE SAFELY

Tie long hair behind your head. Do not wear a
necktie, scarf, loose clothing or necklace when
you work near machine tools or moving parts.
If these items were to get caught, severe injury
could result.
Remove rings and other jewelry to prevent
electrical shorts and entanglement in moving
parts. 73031GE12
STAY CLEAR OF MOVING PARTS

Entanglements in moving parts can cause
serious injury.
To prevent accidents, use care when working
around rotating parts.
73031GE13
1-5
AVOID HIGH PRESSURE FLUIDS
Escaping fluid under pressure can penetrate the
skin causing serious injury.
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten
all connections before applying pressure.
Search for leaks with a piece of cardboard.
Protect hands and body from high pressure
73031GE14
fluids.
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be
surgically removed within a few hours or
gangrene may result.
73031GE15
AVOID HEATING NEAR PRESSURIZED

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 73031GE16
other materials.
PREVENT BATTERY EXPLOSIONS

Keep sparks, lighted matches, and flame away
from the top of battery. Battery gas can
explode.
Never check battery charge by placing a metal
object across the posts. Use a volt-meter or
hydrometer.
Do not charge a frozen battery; It may explode.
73031GE17
Warm battery to 16˚C (60˚F).
1-6
PREVENT ACID BURNS
Sulfuric acid in battery electrolyte is poisonous. It
is strong enough to burn skin, eat holes in
clothing, and cause blindness if splashed into
eyes.
1. Avoid the hazard by:
2. Filling batteries in a well-ventilated area.
3. Wearing eye protection and rubber gloves.
Avoiding breathing fumes when electrolyte
is added.
4. Avoiding spilling of dripping electrolyte.
5. Use proper jump start procedure.
1. If you spill acid on yourself:
2. Flush your skin with water.
Apply baking soda or lime to help neutralize
the acid.
3. Flush your eyes with water for 10-15 minutes.
Get medical attention immediately.
1. If acid is swallowed:
2. Drink large amounts of water or milk.
Then drink milk of magnesia, beaten eggs,
or vegetable oil.
73031GE18
3. Get medical attention immediately.
USE TOOLS PROPERLY

Use tools appropriate to the work. Makeshift
tools, parts, and procedures can create safety
hazards.
Use power tools only to loosen threaded tools
and fasteners.
For loosening and tightening hardware, use the
correct size tools. Avoid bodily injury caused by
73031GE19
slipping wrenches.
Use only recommended replacement parts.
(See Parts catalogue.)
1-7
SERVICE TIRES SAFELY
Explosive separation of a tire and rim parts can
cause serious injury or death.
Do not attempt to mount a tire unless you have the
proper equipment and experience to perform the job.
Always maintain the correct tire pressure. Do not
inflate the tires above the recommended pressure.
Never weld or heat a wheel and tire assembly.
The heat can cause an increase in air pressure
resulting in a tire explosion.
Welding can structurally weaken or deform the
wheel.
When inflating tires, use a clip-on chuck and
extension hose long enough to allow you to stand
to one side and not in front of or over the tire
assembly. Use a safety cage if available.
Check wheels for low pressure, cuts, bubbles, 73031GE24
damaged rims or missing lug bolts and nuts.
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.
73031GE25
DISPOSE OF FLUIDS PROPERLY

Improperly disposing of fluids can harm the
environment and ecology. Before draining any
fluids, find out the proper way to dispose of waste
from your local environmental agency.
Use proper containers when draining fluids. Do
not use food or beverage containers that may
mislead someone into drinking from them.
73031GE20
DO NOT pour oil into the ground, down a drain, or
into a stream, pond, or lake. Observe relevant
environmental protection regulations when
disposing of oil, fuel, coolant, brake fluid, filters,
batteries, and other harmful waste.
1-8
REPLACE SAFETY SIGNS
Replace missing or damaged safety signs.
See the machine operator's manual for correct
safety sign placement.
73031GE21
LIVE WITH SAFETY

Before returning machine to customer, make
sure machine is functioning properly, especially
the safety systems. Install all guards and
shields.
KEEP ROPS INSTALLED PROPERLY (option)

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 altered by welding, bending, drilling,
or cutting. A damaged ROPS should be 73031GE22
replaced, not reused.
1-9
GROUP 2 SPECIFICATION
1. MAJOR COMPONENT
Bucket Tire Head light Hydraulic tank Air cleaner Raidator
Boom Boom cylinder Main control valve Battery Counterweight
Bell crank Bucket cylinder Cab Main pump Precleaner Muffler Engine
Bucket link Front axle Steering cylinder Transmission Torque converter Rear axle Fuel tank
830K2SE01E
1-10
2. SPECIFICATIONS
1) WITH BOLT-ON CUTTING
B CUTTING EDGE TYPE BUCKET
F
I
4880
J
H
3775
C
40
G
48
570 95
D
0
E
A
830K2SE03E
Description Unit Specification

Operating weight kg (lb) 10200 (22490)
Struck 1.5 (2.0)
Bucket capacity m3 (yd3)
Heaped 1.8 (2.4)
Overall length A 6830 (22' 5")
Overall width B 2450 (8' 1")
Overall height C 3235 (10' 7")
Ground clearance D 370 (1' 3")
Wheelbase E mm (ft-in) 2850 (9' 4")
Tread F 1850 (6' 1")
Dump clearance at 45˚ G 2865 (9' 5")
Dump reach (full lift) H 1075 (3' 6")
Width over tires I 2300 (7' 7")
Dump angle J 45
degree (˚)
Roll back angle (carry position) K 49
Lift (with load) 5.2
Cycle time Dump (with load) sec 1.2
Lower (empty) 2.7
Maximum travel speed km/hr (mph) 39.5 (24.5)
Braking distance 13.1 (43' 0")
m (ft-in)
Minimum turning radius (center of outside tire) 4.90 (16' 1")
Gradeability degree (˚) 30
First gear 7.4 (4.6)
Second gear 13.3 (8.3)
Forward
Third gear 23.9 (14.9)
Travel speed km/hr (mph)
Fourth gear 39.5 (24.5)
Reverse
1-11
2) WITH TOOTH TYPE BUCKET
F
I
4880
J
H
3775
C
40
G
48
572 95
D
5
E
A
830K2SE04E
Description Unit Specification

Operating weight kg (lb) 10200 (22490)
Struck 1.4 (1.8)
Bucket capacity m3 (yd3)
Heaped 1.7 (2.2)
Overall length A 6940 (22' 9")
Overall width B 2480 (8' 2")
Overall height C 3235 (10' 7")
Ground clearance D 370 (1' 3")
Wheelbase E mm (ft-in) 2850 (9' 4")
Tread F 1850 (6' 1")
Dump clearance at 45˚ G 2790 (9' 2")
Dump reach (full lift) H 1150 (3' 9")
Width over tires I 2300 (7' 7")
Dump angle J 45
degree (˚)
Roll back angle (carry position) K 49
Lift (with load) 5.2
Cycle time Dump (with load) sec 1.2
Lower (empty) 2.7
Maximum travel speed km/hr (mph) 39.5 (24.5)
Braking distance 13.7 (43' 0")
m (ft-in)
Minimum turning radius (center of outside tire) 4.90 (16' 1")
Gradeability degree (˚) 30
Forward
Third gear 23.9 (14.9)
Travel speed km/hr (mph)
Fourth gear 39.5 (24.5)
Reverse
1-12
3. SPECIFICATION FOR MAJOR COMPONENTS
1) ENGINE
Item Specification
Model YC6J125Z-T20
Type 4-cycle turbocharged diesel engine.
Control type Mechanical control
Cooling method Water cooling
Number of cylinders and arrangement 6 cylinders, in-line
Firing order 1-5-3-6-2-4
Combustion chamber type Direct injection type
Cylinder bore × stroke 105×125 mm (4.1"×4.9")
Piston displacement 6494 cc (396 cu in)
Compression ratio 17.5 : 1
Rated gross horse power 92 kW / 2200 rpm
Maximum gross torque at 1400~1600 rpm 500 N·m
Engine oil quantity 16ℓ(4.2 U.S. gal)
Dry weight 650 kg (1430 lb)
High idling speed 2400±50 rpm
Low idling speed 725±50 rpm
Rated fuel consumption (at rated) 215 g/kW·hr
Starting motor 24 V-6 kW
Alternator 28 V-55 Amp
Battery 2×12 V×120 Ah
1-13
2) MAIN PUMP (+steering pump)
Item Specification
Type Fixed displacement gear pump
Capacity 100＋50 cc/rev
Maximum operating pressure 200 kgf/cm2 (2840 psi)
Rated oil quantity 169ℓ/min (44.6 U.S.gpm)
Rated speed 2200 rpm
3) MAIN CONTROL VALVE

Item Specification
Type 2 spool
Operating method Mechanical control
Main relief valve set pressure 160 kgf/cm2 (2280 psi)
Overload relief valve set pressure 180 kgf/cm2 (2560 psi)
4) CYLINDER
Item Specification
Boom cylinder Bore dia×Rod dia×Stroke Ø110×Ø65×785 mm
Bucket cylinder Bore dia×Rod dia×Stroke Ø160×Ø80×380 mm
Steering cylinder Bore dia×Rod dia×Stroke Ø 70×Ø45×412 mm
5) DYNAMIC POWER TRANSMISSION DEVICES
Item Specification
Model YJ315/BS428
Converter Single-stage, Single-phase
Type
Transmission Transmission Mechanical, hydraulic
Gear shift Forward fourth gear, reverse second gear
Control Mechanical single lever type
Drive devices 4-wheel drive
Axle Front Front fixed location
Rear Oscillation±12˚ of center pin-loaded
Wheels Tires 17.5-25, 14PR (L3)
Travel Four-wheel, dry-disc type, pneumatic
Brakes
Parking Disc type brake on transmission
Type Hydraulic, articulated
Steering
Steering angle 40˚ to both right and left angle, respectively
1-14
4. TIGHTENING TORQUE OF MAJOR COMPONENT
Torque
No. Descriptions Bolt size
kgf·m lbf·ft
1 Engine mounting bolt (2EA) M24×3.0 100 ± 15 723 ± 108
2 Engine mounting bolt (bracket) M12×1.75 10.7 ± 1.6 77.4 ± 11.6
Engine
3 Radiator mounting bolt M16×2.0 29.7 ± 4.5 215 ± 32.5
4 Fuel tank mounting bolt M16×2.0 29.7 ± 4.5 215 ± 32.5
5 Main pump housing mounting bolt M12×1.75 12.8 ± 3.0 92.6 ± 21.7
6 Main control valve mounting bolt M12×1.75 12.8 ± 3.0 92.6 ± 21.7
7 Steering unit mounting bolt M10×1.5 6.9 ± 1.4 49.9 ± 10.1
Hydraulic
8 Steering valve mounting bolt M10×1.5 6.9 ± 1.4 49.9 ± 10.1
system
9 Brake valve mounting bolt M8×1.25 2.5 ± 0.5 18.1 ± 3.6
10 Control lever mounting bolt M10×1.5 6.9 ± 1.4 49.9 ± 10.1
11 Hydraulic oil tank mounting bolt M16×2.0 29.7 ± 4.5 215 ± 32.5
12 Transmission mounting bolt M24×3.0 100 ± 15 723 ± 108
13 Transmission mounting bolt (bracket) M18×2.5 32.7 ± 4.9 237 ± 35.4
14 Power Torque converter housing mounting bolt M12×1.75 10.7 ± 1.6 77.4 ± 11.6
15 train Front axle mounting bolt, nut M30×2.0 200 ± 15 1447 ± 108
16 Tire mounting nut M20×1.5 61 ± 2.0 441 ± 14.5
17 Drive shaft joint mounting bolt, nut 1/2-20UNF 15.5 ± 0.5 112 ± 3.6
18 Counterweight mounting bolt M30×2.0 199 ± 29.9 1439 ± 216
19 Others Operator seat mounting bolt M8×1.25 3.4 ± 0.8 24.5 ± 5.8
20 Cab mounting bolt (4EA) M27×3.0 70 ± 10 506 ± 72.3
1-15
5. TORQUE CHART
Use following table for unspecified torque.
1) BOLT AND NUT
(1) Coarse thread

8T 10T
Bolt size
kg·m lb·ft kg·m lb·ft
M 6×1.0 0.85 ~ 1.25 6.15 ~ 9.04 1.14 ~ 1.74 8.2 ~ 12.6
M 8×1.25 2.0 ~ 3.0 14.5 ~ 21.7 2.73 ~ 4.12 19.7 ~ 29.8
M10×1.5 4.0 ~ 6.0 28.9 ~ 43.4 5.5 ~ 8.3 39.8 ~ 60
M12×1.75 7.4 ~ 11.2 53.5 ~ 79.5 9.8 ~ 15.8 71 ~ 114
M14×2.0 12.2 ~ 16.6 88.2 ~ 120 16.7 ~ 22.5 121 ~ 167
M16×2.0 18.6 ~ 25.2 135 ~ 182 25.2 ~ 34.2 182 ~ 247
M18×2.5 25.8 ~ 35.0 187 ~ 253 35.1 ~ 47.5 254 ~ 343
M20×2.5 36.2 ~ 49.0 262 ~ 354 49.2 ~ 66.6 356 ~ 482
M22×2.5 48.3 ~ 63.3 350 ~ 457 65.8 ~ 98.0 476 ~ 709
M24×3.0 62.5 ~ 84.5 452 ~ 611 85.0 ~ 115 615 ~ 832
M30×3.0 124 ~ 168 898 ~ 1214 169 ~ 229 1223 ~ 1655
M36×4.0 174 ~ 236 1261 ~ 1703 250 ~ 310 1808 ~ 2242
(2) Fine thread

8T 10T
Bolt size
kg·m lb·ft kg·m lb·ft
M 8×1.0 2.17 ~ 3.37 15.7 ~ 24.3 3.04 ~ 4.44 22.0 ~ 32.0
M10×1.25 4.46 ~ 6.66 32.3~48.2 5.93 ~ 8.93 42.9 ~ 64.6
M12×1.25 7.78 ~ 11.58 76.3 ~ 83.7 10.6 ~ 16.0 76.6 ~ 115
M14×1.5 13.3 ~ 18.1 96.2 ~ 130 17.9 ~ 24.1 130 ~ 174
M16×1.5 19.9 ~ 26.9 144 ~ 194 26.6 ~ 36.0 193 ~ 260
M18×1.5 28.6 ~ 43.6 207 ~ 315 38.4 ~ 52.0 278 ~ 376
M20×1.5 40.0 ~ 54.0 289 ~ 390 53.4 ~ 72.2 386 ~ 522
M22×1.5 52.7 ~ 71.3 381 ~ 515 70.7 ~ 95.7 512 ~ 692
M24×2.0 67.9 ~ 91.9 491 ~ 664 90.9 ~ 123 658 ~ 890
M30×2.0 137 ~ 185 990 ~ 1338 182 ~ 248 1314 ~ 1795
M36×3.0 192 ~ 260 1389 ~ 1879 262 ~ 354 1893 ~ 2561
1-16
2) PIPE AND HOSE (FLARE type)
Thread size (PF) 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
3) PIPE AND HOSE (ORFS type)

Thread size (UNF) 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
4) FITTING
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
1-17
6. RECOMMENDED LUBRICANTS
Use only oils listed below or equivalent.
Do not mix different brand oil.
Ambient temperature˚C(˚F)
Capacity
Service point Kind of fluid -20 -10 0 10 20 30 40
ℓ (U.S. gal)
(-4) (14) (32) (50) (68) (86) (104)
SAE 30
SAE 10W
Engine oil pan Engine oil 16 (4.2)
SAE 10W-30
SAE 15W-40
Transmission Gear oil 40 (10.6) ATF DEXRON Ⅲ
SAE 80W-90
Front : 15 (4.0)
Axle Gear oil
Rear : 15 (4.0)
SAE 85W-90
ISO VG 32
Tank :
90 (23.8)
Hydraulic tank Hydraulic oil ISO VG 46
System :
130 (34.3)
ISO VG 68
ASTM D975 NO.1

Fuel tank Diesel fuel 170 (44.9)
ASTM D975 NO.2
NLGI NO.1
Fitting
Grease As required
(grease nipple) NLGI NO.2
Mixture of
antifreeze Ethylene glycol base permanent type
Radiator 33 (8.7)
and water
50 : 50
·SAE : Society of Automotive Engineers ·NLGI : National Lubricating Grease Institute

·API : American Petroleum Institute ·ASTM : American Society of Testing and Material
·ISO : International Organization for Standardization ·ATF : Auto Transmission Fluid
1-18
GROUP 3 OPERATIONAL CHECKOUT RECORD SHEET
·Owner :
·Date :
·Hours :
·Serial No. :
·Technician :
※ Use this sheet to record operational

checkout results.
Perform the operational check before
installing any test equipment. 830K1CH01
OK NOT
Item Comments
OK
1. Cluster indicator and gauge checks (engine OFF)
· Gauge check □ □
· Battery check □ □
· Cluster indicator circuit check □ □
· Cluster turn signals and warning indicator check □ □
2. Transmission checks
· Transmission control lever and neutral □ □
3. Cluster indicator and gauge checks (engine running)
· Cluster display and alternator output checks □ □

· Transmission temperature gauge check □ □
· Transmission oil pressure gauge check □ □
· Brake air pressure gauge check □ □
· Engine coolant temperature gauge check □ □
1-19
4. Brake system and clutch cut off checks
· Park brake capacity check □ □

· Park brake transmission lockout check □ □
· Service brake capacity check □ □
· Brake system leakage check □ □
· Service brake pedal check □ □
· Service and park brake system drag check □ □
5. Driving checks
·Transmission noise check □ □

·1st and 2nd speed clutch pack drag check □ □
·Transmission pressure, pump flow and leakage check □ □
·Torque converter check □ □
·Engine power check □ □
6. Hydraulic system checks
·Hydraulic system warm up procedure □ □

·Hydraulic pump performance check □ □
·Control lever boom float check □ □
·Bucket rollback circuit relief valve check □ □
·Bucket dump circuit relief
Low pressure check □ □
High pressure check □ □
·Boom and bucket cylinder drift check □ □
7. Steering system checks
·Steering unit check □ □

·Steering system leakage check □ □
1-20
8. Accessory checks
·Operating lights check □ □

·Work light check □ □
·Brake light check □ □
·Cab light check □ □
·Horn circuit check □ □
·Windshield washer and wiper check □ □
·Defroster blower check □ □
·Heater/Air conditioner blower check □ □
·Heater functional check □ □
·Air conditioner functional check □ □
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 □ □
·Seat and seat belt check □ □
·Air intake filter door check □ □
·Engine side panels check □ □
·Radiator cap access door check □ □
·Frame locking bar check □ □
·Service decal check □ □
1-21
SECTION 2 POWER TRAIN SYSTEM
Group 1 Structure and function --------------------------------------------------------------------------------------- 2-1

Group 2 Transmission ------------------------------------------------------------------------------------------------------ 2-2
Group 3 Torque converter ------------------------------------------------------------------------------------------------ 2-35
Group 4 Axle --------------------------------------------------------------------------------------------------------------------- 2-40
SECTION 2 POWER TRAIN SYSTEM
GROUP 1 STRUCTURE AND FUNCTION
1. POWER TRAIN COMPONENT OVERVIEW
Ttansmission Upper shaft Torque converter Engine
Front axle
Front drive shaft Center drive shaft Rear drive shaft Rear axle
830KPT01E
The power train of the following components:

· Transmission
· Front, center, rear and upper drive shafts
· Front and rear axles
Engine power is transmitted to the transmission through the torgue converter.
The transmission is a hydraulically engaged four speed forward, two speed reverse countershaft type
power shift transmission. A disc type parking 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 rear axle is mounted on an oscillating pivot.
The power transmitted to front axle and rear axle is reduced by the pinion gear and ring gear of
differential. It been passes from the differential to the sun gear shaft (axle shaft) of final drive.
The power of the sun gear is reduced by a planetary mechanism and is transmitted through the
planetary hub to the wheel.
2-1
GROUP 2 TRANSMISSION
1. STRUCTURE AND WORKING PRINCIPLE OF TRANSMISSION

As illustrated in the page 2-3, figure 1, the transmission consists of transmission housing (1), large
end cover (2), reverse shaft assembly (3), input shaft assembly (5), countershaft assembly (6), output
shaft (8), range gear sleeve (9) and shoe brake (12).
A hydraulic clutch is attached each to reverse shaft assembly (3), input shaft assembly (5) and
countershaft assembly (6).
As illustrated in figure 2, a hydraulic clutch consists of clutch driving shaft (1), clutch housing (2),
piston (3), exterior friction plate (4), interior friction plate (5), return spring (6) and clutch emptying
valve (7). When flow of hydraulic oil enters head end of cylinder, piston is pushed to move forward
pressing drive and driven friction plate to make driving shaft and gear to rotate, cut off hydraulic oil,
and thus clutch emptying valve opens automatically to press spring (6) to return.
As illustrated in figure 2, the hydraulic clutch consists of 6 clutch drive plates and 5 driven plates. The
driven plate has a 0.5 mm crown and the crown side should face piston. Gap-clearance of piston ring
should be ground and its width within 0.05~0.1 mm.
Figure 2 Structure of hydraulic clutch
2-2
10
8
11, 12
2
1
Figure 1 Structure of transmission
1 Transmission housing 5 Input shaft assembly 9 Range gear sleeve

2 Large end cover 6 Countershaft assembly 10 Oil tray
3 Reverse shaft assembly 7 Rear output flange 11 Front output flange
4 Input shaft flange 8 Output shaft 12 Shoe brake
2-3
2. WORKING OF TRANSMISSION
As enumerated in figure 3, the transmission route is as follows:
Forward gear Ⅰ transmission route : 1 - 15 - 7 - 9 - 3 - 11 - 13 - 17 - 4
Forward gear Ⅱ transmission route : 1 - 8 - 10 - 16 - 3 - 11 - 13 - 17 - 4
Forward gear Ⅲ transmission route : 1 - 15 - 7 - 9 - 12 - 17 - 4
Forward gear Ⅳ transmission route : 1 - 8 - 10 - 9 - 12 - 17 - 4
Reverse gear Ⅰ transmission route : 1 - 8 - 6 - 14 - 2 - 5 - 9 - 3 - 11-13 - 17 - 4
Reverse gear Ⅱ transmission route : 1 - 8 - 6 - 14 - 2 - 5 - 9 - 12 - 17 - 4
1 Input shaft
2 Rear gear shaft
3 Countershaft
4 Output shaft
5 Reverse shaft gear wheel
6 Reverse gear pinion
7 First & third gear input shaft
8 Second & forth gear input gear
9 First & third gear countershaft
10 Second & forth gear countershaft
11 Low gear countershaft
12 High gear output shaft
13 Low gear output shaft
14 Reverse gear clutch III
15 First & second gear clutch I
16 Second & forth gear clutch II
17 High & Low gear sliding sleeve
Figure 3 Working of transmission
Lever Gear selector lever High · low speed Low speed High.low speed
Gear Ⅰ Ⅱ Ⅲ selector lever selector lever
Forward 1 ● Low speed High speed
2 ● F
3 ● High speed Gear selector lever
4 ● R
II
Reverse 1 ● F I
2 ● R III 830KPT19
2-4
3. TECHNICAL DATA
Max. input speed 2500 rpm
Max. input torque 91.4 kgf·m (661 lbf·ft)
Max. input power 82 kW
Type of transmission housing Countershaft, constant mesh, hydraulic fork
Transmission ratio Forward gear 1 3.82
gear 2 2.08
gear 3 1.09
gear 4 0.59
Reverse gear 1 3.05
gear 2 0.87
Oil for transmission AFT (DEXRON Ⅲ)

Oil pump CB32 (no in transmission box)
Operating pressure 1.4 ~ 1.6 MPa
Allowable oil temperature of oil tray 100˚C
Operating pressure of brake relief valve >0.55 MPa
2-5
4. WORKING AND CONSTRUCTION OF HYDRAULIC OPERATING SYSTEM
Working of hydraulic operating system is as illustrated in figure 4. The right half of double dot dash
line is torque converter while the left half incorporates transmission control valve, hydraulic cylinder
(clutch), filter and tank (including a tank and a tray).
When charging pump of torque converter runs, pump (2) is driven by driving gear, sucking oil from
tank to output hydraulic oil, which enters combined valve of torque converter. Combined valve block
of torque converter consists of a reducing valve (3) and an overflow valve (4). The flow that enters the
combined valve will ensure supply in priority for transmission control by reducing valve (3) and then
for torque converter via reducing valve.
Torque converter
T/M T/C
part part
Brake Cooler
valve
Control valve
Torque converter
valve block
Lubrication
Oil
cooling
Figure 4 Schematic diagram of oil system
1 Suction filtering device 4 Overflow valve

2 Transmission pump 5 Transmission control valve
3 Transmission pressure valve 6 Brake relief valve
Transmission oil pressure and inlet oil pressure of torque converter are controlled by reducing valve (3)
and overflow valve (4) respectively. Set pressure of reducing valve is 1.4~1.6 MPa while that of overflow
valve is 0.5~0.65 MPa. When inlet pressure of torque converter becomes higher than the set value of
overflow valve (4), the valve opens to overflow spray oil for transmission. The flow from outlet is directed
to transmission lubricating system after cooling. High pressure oil delivered from pump is controlled to
1.4~1.6 MPa by reducing valve, which then enters transmission control valve (5) via brake relief valve (6)
to control gear shift clutch.
2-6
5. TRANSMISSION CONTROL VALVE
M22×1.5
M22×1.5
M22×1.5
Figure 5 Transmission control valve assembly

ass’y
Transmission control valve includes brake relief valve and transmission control valve. Orifice A on the
valve body is connected to combined valve of transmission. When transmission valve spool moves, oil
under pressure from combined valve of torque converter can flow into orifice C, D or E (C for clutch Ⅰ,
D for clutch Ⅱ, E for clutch Ⅲ) to go forth or back for shift. Screw PT1/8” at E on the top of valve body is
for connection of output to reverse gear.
When the brake pedal is pressed down, compressed air from the brake master cylinder has an air
passage for brake valve spool to push the spool rod, cutting operating oil way (A and B is not
connected). At the time, transmission is in neutral to ensure reliable braking.
2-7
6. MOUNTING
Mount the transmission housing on the frame and fix with bolts. For mounting size, refer to the page
2-12.
1) CONNECTION
Input flange of transmission is connected with torque
converter by driving shaft. Front and rear flange of
transmission is connected to driving shaft and front & rear
axle respectively.
5 connections of transmission control valve are :
(1) Mounting sizes of transmission control valve lever are as
illustrated in the figure 5. After the lever is pulled to the most
outside gear, Neutral, gear I and gear II are gained in order
by moving inside. The sizes are Lmax=51 mm, Lmin=15 mm
and stroke per gear = 12 mm.
(2) Connection screw on the end of brake control valve is
connected to the air pipe of brake master cylinder.
(3) Inlet for transmission control is located in Ⅰ-Ⅰ as
illustrated in figure 5.
(4) Inlet for spray oil of transmission is located in Ⅱ-Ⅱ.
(5) Inlet for cooling transmission is located in Ⅲ-Ⅲ. (3) and (4)
is connected to each correct port on combined valve of
torque converter. (5) is connected to oil outlet of radiator.
For positions of shift rod of range gear, see attached figure
1. There are three gears. The outside is high gear, the
inside low gear, stroke between two adjacent gears is 15
mm. Connection sizes of handle are illustrated in figure 6. Figure 6
2) USING
After mounting the transmission on the frame, add AFT (DEXRON Ⅲ) for about 40 liter from the
filler and, 5 minutes after starting the engine, check the oil level for specified position on scale. After
each shift work, it’s required to check the oil level of transmission.
During operation of transmission, be careful to check that its operating pressure is within 1.4~1.6
MPa, oil temperature at outlet of torque converter doesn’t exceed 105˚C, and 115˚C in short time,
and that in the oil tray of transmission doesn’t exceed 100˚C.
Run in the transmission 12 hours after mounting on the frame, each 2 hours for 6 gears. The load in
run-in period should not exceed 70% of the rated value, and frequently check oil temperature, oil
level and tightness of bolts. After completion of run-in, clean the oil tray of transmission and oil-filter
strainer, and renew oil.
Moving into reverse gear from a forward gear, into a forward gear from reverse gear, or moving
between high and low gears must be conducted after parking.
Gear 1 and 2, or gear 3 and 4 can be changed with each other during travel.
2-8
7. MAINTENANCE AND TROUBLESHOOTING
1) MAINTENANCE
Maintenance is carried out after running for 10, 50, 250, 500,1000 and 2000 hours.
(1) 10 hours maintenance
maintenance
① Check oil level in transmission.
② Check transmission for normal operation and driving gear for noise.
③ Check the bolts and nuts for good tightness and check for oil leaks.
① Inspect operation and noise of transmission.
② Clean the filter.
maintenance
① Renew oil.
① Replace oil filter.
maintenance
① Inspect operation, input power, noise, oil temperature, oil leaks, etc.
② Clean air vent caps, fasten up screws and pipe fittings.
2-9
2) TROUBLESHOOTING
Problem Cause Remedy

Too low oil pressure or 1. Transmission gear pump does not supply oil Repair.
zero 2. Failed reducing valve of torque converter. Repair.
3. Stuck brake valve. Repair.
4. Oil leaks in oil circuit. Repair.
5. Failed piston packing of clutch. Service and repair.
6. Failed O-ring of transmission valve. Replace.
7. Seal ring is failed. Replace.
8. Emptying valve for clutch has fallen off. Check and repair.
Too high oil pressure 1. Malfunction in overflow valve for torque converter. Repair.
2. Clogged oil circuit. Clean.
3. Incorrect oil is used. Renew oil.
Too high oil temperature 1. Clogged oil cooler. Clean.
2. Water has gotten into the oil circuit. Renew oil.
3. Insufficient oil amount. Replenish oil.
4. Incorrect gear selection in operation. Change to low gear.
5. Hand brake can not be normally released or Adjust.
braking drag.
6. Clutch friction plate can not be separated Replace.
completely.
Engine runs but vehicle 1. Insufficient oil. See “Too low oil pressure
will not move trouble”.
2. Incorrect range gear selector fork position. Reengage gear.
3. Brake spool has not response. Check brake spool.
4. Clutch friction plate collision. Replace.
5. Malfunction in control valve for transmission. Repair.
Weak traction 1. Low oil pressure. See “Too low oil pressure
trouble”.
2. Clutch friction plate can not be separated Repair.
completely and dragging.
3. Insufficient oil supply. Replenish oil.
2-10
3) NOTES IN REPAIR OPERATION
Following cares should be taken to reassemble the transmission after disassembly:
(1) Paper gasket and large end cover paper gasket must be of 0.5 mm, or too much axial clearance
of bearing may be formed to lead to damaged gear.
(2) Adjustment of bearing clearance for input shaft, countershaft and reverse shaft.
Axial clearance must be readjusted when reassembling input shaft, countershaft and reverse
shaft after disassembly. Perform adjustment as followings:
① If clearance of input shaft is too little, thickness of paper gasket may be increased or that of shaft
bushing decreased.
② For adjustment of clearance for countershaft and reverse shaft, you may first loosen stop plate,
and fasten adjusting screw, and then loosen a lock groove position (back for 0.125 mm axial
clearance) and lock up the lock plate.
③ Normal axial play of input shaft, countershaft and reverse shaft
Normal axial play of input shaft, countershaft and reverse shaft should be 0.1~0.13 mm.
2-11
View K
7. STRUCTURE
Rear
Front
1) OUTSIDE VIEW
Range
Gear lever
Oil return port

Hi-Neutral-Lo
2-12
View K
Input flange A Flange C Output flange B
Pressure oil port
Oil spray port
Pressure tap Cooling oil port

2) TRANSMISSION HOUSING (1/2)
66
9
3
4 2
62
65
7
6
5 63
12
11
10 64
9
8 1
21 15
22 14
13
17
23 7
11 6
24 16
9
8
27 29
25 4
30
32
26 33
20 5
13
22 19 31
28 9
15 18
14 52
9 34
8 35
830KPT05
1 Housing 15 Stop plate 29 O-ring

2 Name plate 16 Input shaft end cover 30 Gasket
3 Rivet 17 Seal 31 Sump
4 Bracket 18 Middle shaft end cover 32 Suction pipe
5 Hexagon bolt 19 Gasket 33 Magnetic
6 Spring washer 20 Regulating ring 34 Oring
7 Hexagon nut 21 Nut 35 Plug
8 Hexagon bolt 22 Washer 52 Hexagon bolt
9 Washer 23 Connector 62 Housing cover
10 End cover 24 Washer plate 63 Cover sheet
11 Gasket 25 Strainer core 64 Semi circular rivet
12 Regulating ring 26 Bolt 65 Gasket
13 Regulating screw 27 Flange joint 66 Hexagon bolt
14 Hexagon bolt 28 Hexagon bolt
2-13
TRANSMISSION HOUSING (2/2)
67 52
46 9
54
56 53 67
44 45
57 55 48
9
39 43 52
59 58 42 9
68
60 41 45
61 40 44
38 43 67
22 42
47 52
37 9
36
46
45
44
43
51
51
8
9
50
49
830KPT06
8 Hexagon bolt 44 Washer 55 Vent plate

9 Washer 45 Bush 56 Sleeve
22 Washer 46 Input end cover 57 Plate
36 O-ring 47 Dowel pin 58 Sleeve
37 Pipe assy 48 Socket pin 59 Long screw
38 Hexagon bolt 49 Washer 60 Casing
39 Pipe & dipstick 50 Input sealing cover 61 Gasket
40 Seal 51 Input seal 67 Plug
41 O-ring 52 Hexagon bolt 68 Plug
42 Cover 53 Air vent
43 Bush 54 Square nut
2-14
3) OUTPUT SHAFT
7
18
7
6 17
5 16
17
4
3 15
1
2 2
1 13 3
14 4
13 5
12
11
21
8
6
11 24
10
9 12
13
20
13
19
23
22
830KPT07
1 Hexagon bolt 9 Hexagon bolt 17 Steel ball

2 Stop pad 10 Washer 18 Output shaft
3 Pressure plate 11 Ball bearing 19 Output gear
4 O-ring 12 Thrust ring 20 Ring
5 Output flange 13 Sliding bearing 21 Brake drum
6 Dust cover 14 Ring 22 Nut
7 Seal output 15 Gear 23 Spring washer
8 Output rear end cover 16 High-low sliding sleeve 24 Bolt
2-15
4) INTPUT SHAFT
13
12
11 14
8
9
10
9
8
33
32
6 31
7 25 26 30
5 29
4 23 5
22 28
3
12 27
24
21
20
19
18
17
16
15
830KPT08
1 Small ring nut 12 Outer end cover 23 Valve seat

2 Stop washer 13 External friction disc 24 Gear
3 Washer 14 Internal friction disc 25 Stop pad
4 Flange 15 Snap ring 26 Hexagon bolt
5 Taper roller bearing 16 Spring seat 27 Pin
6 Input shaft 17 Spring 28 Bush
7 Plug 18 Piston 29 Inner sealing sleeve
8 Hole ring 19 Sealing ring 30 Piston ring
9 Ball bearing 20 O - ring 31 Shaft end baffle
10 Gear 21 Clutch case assy 32 Stop pad
11 Snap ring 22 Steel ball 33 Hexagon bolt
2-16
5) INTERMEDIATE SHAFT
15
14
13
10
11
12 16
11
10
9
28
8 27
7
6 25
5 24
4
3
2
1 6
29
26
23
22
21
20
19
18
17
830KPT09
1 Hexagon bolt 11 Ball bearing 21 Sealing ring

2 Stop pad 12 Gear 22 O-ring
3 Shaft end baffle 13 Snap ring 23 Clutch case assy
4 Piston ring 14 Outer end cover 24 Steel ball
5 Inner sealing sleeve 15 External friction disc 25 Valve seat
6 Roller bearing 16 Internal friction disc 26 Gear
7 Gear 17 Snap ring 27 Stop pad
8 Plug 18 Spring seat 28 Hexagon bolt
9 Intermediate shaft 19 Spring 29 Pin
10 Hole ring 20 Pistion
2-17
6) REVERSE SHAFT
15
14
13
16
10
12 11
11
10
28
27
9
8 25
7 24
6 6
5 29
4
23
1 26
23
22
21
20
19
18
17
830KPT10
1 Hexagon bolt 11 Ball bearing 21 Sealing ring

2 Stop pad 12 Gear 22 O-ring
3 Shaft end baffle 13 Snap ring 23 Clutch case aasy
4 Piston ring 14 Outer end cover 24 Steel ball
5 Inner sealing sleeve 15 External friction disc 25 Valve seat
6 Roller bearing 16 Internal friction disc 26 Stop pad
7 Sleeve 17 Snap ring 27 Hexagon bolt
8 Plug 18 Spring seat 28 Stop pad
9 Reverse shaft 19 Spring 29 Pin
10 Hole ring 20 Piston
2-18
7) HIGH-LOW SPEED SHIFT FORK
1
2
3
4
5
6
7
13
12
11
10 9
830KPT11
1 Pin 6 Washer 11 Washer

2 Socket screw 7 Hexagon bolt 12 Steel ball
3 HIgh-low shift fork 8 Seal 13 Spring
4 Gasket 9 Fork shaft
5 Fork support 10 Plug
2-19
8) CONTROL VALVE
12
9
10 12
11
1
2 27
7 5 3
8 6 4
28
13 7
14
15
16
17
18
22 19
11
23 10
9
24
21
26
20
25
830KPT12
1 Screw 11 Regulating washer 21 Plug

2 Washer 12 Control sliding valve 22 Valve body
3 Spring 13 Dust cover 23 Gasket
4 Steel ball 14 Plug 24 Bottom plate
5 Dust cover 15 O-ring 25 Socket screw
6 Pressure tap 16 Cup 26 Screw
7 Washer 17 Brake sliding valve 27 Hexagon bolt
8 Plug 18 Spring 28 Washer
9 Snap ring 19 O-ring
10 Seal 20 Spring seat
2-20
9) PARKING VALVE
3
2
1 4
2
1
22
19 21
20
14
13
14
3 6
18
27
17 23
16
7
11
7 28
29
8
15
9 12 24
10
10
25
26
830KPT13
1 Parking brake bracket 11 Nut 21 Bolt

2 Cam plate 12 Hexagon bolt 22 Iron wire
3 Washer 13 Upper fixed plate 23 Regulating spring
4 Split pin 14 Semi circular rivet 24 Bracket
5 Axis pin 15 Lower fixed plate 25 Bolt
6 Set screw 16 Rivet 26 Washer
7 Set screw spring 17 Friction pad 27 Bracket
8 Set screw spring 18 Bracket 28 Hexagon bolt
9 Washer 19 Steel band 29 Spring washer
10 Nut 20 Bracket
2-21
8. DISASSEMBLY
1) DRAINAGE FOR TRANSMISSION
(1) Hoist transmission up and put an oil
container under it.
830KTM10
(2) Unscrew the M20×1.5 bolts on the oil

pan with a spanner and make drainage
fully.
M20×1.5 bolts
830KTM11
2) OIL PAN OF TRANSMISSION

(1) Unscrew 20 - M10×30 bolts in sequence
on the oil pan with a spanner. As
disassembly, two diagonal bolts should be
removed finally to prevent from injury to
people due to falling oil pan.
(2) Be careful of remaining oil in the oil pan
when the last two bolts are removed.
(3) Put the oil pan removed in a clean place.
830KTM12
M10×30 bolts
830KTM13
2-22
3) HAND BRAKE ASSY
(1) Remove 4 - M12×30 bolts on the left
bracket of hand brake with a spanner.
830KTM14
(2) Remove 4 - M8×25 bolts on the right

bracket of handbrake with a spanner.
(3) Pull the total hand brake assy out and put
it in a clean place.
830KTM15
4) REMOVING FRONT & REAR OUTPUT

FLANGE
(1) Remove the bolt lock plate at the front
output flange with a screwdriver and
unscrew 2 - M10×25 bolts inside the front
output flange with a spanner. After
taking the pressure plate and O-ring out,
pull the front output flange assy out and
place it in a clean place.
830KTM16
(2) Remove the bolt lock plate at the rear

output flange with a screwdriver and
unscrew 2 - M10×25 bolts inside the rear
output flange with a spanner. After
taking the pressure plate and O-ring out,
pull the rear output flange assy out and
place it in a clean place.
830KTM17
2-23
5) REMOVING INPUT FLANGE
(1) Release the lock of stop plate on the input
shaft with a screwdriver and use a special
tool or iron piece to remove M - 20×1.5
round nut. After taking the pressure plate
out, pull the input flange (flange assy) out
and put it in a clean place.
830KTM18
6) REMOVING GEAR SHIFT FORK (HI

AND LO SPEED)
SPEED
(1) Put the transmission level, release the set
screw lock on the gear shift fork mount
and unscrew the M10 set screw with M14
spanner.
(2) Unscrew 4 - M10×30 bolts on the fork
mount with a spanner and tap lightly
the mount assy out with a copper bar and
put it in a clean place. 830KTM19
830KTM20
7) REMVING OUTER END COVER OF

TRANSMISSION
(1) Put the transmission level with the input
side up.
(2) Unscrew 4 - M10×25 bolts on the end
covers of input shaft, intermediate shaft
and reverse shaft with a spanner and
then use 2 - M10×25 bolts to push the
three end covers out and put them in a
clean place. 830KTM21
(3) Unscrew 8 - M10×30 bolts on the rear

end cover of output shaft and use 2
M10×30 bolts to push the rear end cover
out and put it in a clean place.
2-24
(4) Turn the transmission for other side and
place it level.
(5) Unscrew 5 - M10×30 bolts on the oil inlet
end cover of gear I, gear II and reverse
gear with a spanner and then use 2-
M10×30 bolts to push the three end
cover out and put them in a clean place.
830KTM22
830KTM23
(6) Unscrew 4 - M10×25 bolts on the seal

cap of front output shaft with a spanner
and use 2 - M10×25 bolts to push it out
and put in a clean place.
830KTM24
(7) Unscrew 13 - M10×30 socket bolts on the

large end cover with a socket wrench
and then use 2 - M10×45 bolts to push it
out and put in a clean place.
830KTM25
2-25
8) REMOVING CLUTCHES
(1) Take 3 sets of clutch par ts out of
transmission box and put them in a clean
place and mark outer ring of bearing to
prevent from miss assembly.
830KTM26
830KTM27
(2) Set the input parts up as illustrated in the

figure and use a flat chisel to release two
bolt locks and then unscrew 2 - M8×16
bolts with a spanner and use a copper
bar to tap the input shaft out.
(3) Use a flat taper to release the bolt lock
onthe clutch assy and unscrew 8 -
M10×25 bolts with a spanner.
(4) Remove the retainer with a screwdriver,
830KTM28
and then the outer end cover 6 outer
friction plates and 5 inner plates in order.
(5) Use a tool to remove 60 retaining ring
from clutch case, and then inner spring
seat, spring and piston in order.
830KTM29
2-26
9) REMOVING OUTPUT SHAFT
(1) Use a copper bar to tap on to the front end
of transmission to make the front end
output shaft to fall out from front bearing,
and then take the output shaft parts out
and put in a clean place.
830KTM30
830KTM31
2-27
9. ASSEMBLY
1) ASSEMBING INPUT CLUTCH PARTS
13
12
11 14
8
9
10
9
8
33
32
6 31
7 25 26 30
5 29
4 23 5
22 28
3
12 27
24
21
20
19
18
17
16
15
830KPT08
(1) Check the clutch valve seat (23) and internal steel ball (22) for looseness.
(2) Use a spanner to screw up 8 - M10×25 bolts to fasten gear I part drive gear (24) to clutch case
assy (21).
(3) Put up glue and knock in 2 straight pins (27).
(4) Unscrew 8- M10×25 bolts with a spanner and put up 4 stop plates (25) and fasten up 8 - M10
×25 bolts and lock up 4 stop plates with flat taper.
(5) Fit the oil seal ring (19) into piston (18) groove with the broken opening toward gear.
(6) Fit O-ring (20) into place on clutch case.
(7) Tap the piston assy into the oil cylinder of clutch case with a tool.
(8) Assemble the spring (17) and spring seat (16) onto the shaft of the clutch case and use the
special tool to mount the circlip for shaft (6).
(9) Put up 6 outer plates (13) and 5 inner plates (14) alternatively, and assemble outer end cover (12)
and retainer (11) finally.
(10) Knock 2 annular ball bearing into the bore of gear I drive gear (10) and mount two retainer (8) to
set.
(11) Mount the gear I drive gear assy into the clutch assy.
(12) Insert input shaft (6) into the bore of gear I drive gear assy.
(13) Knock the bearing (5) onto the input shaft with the special tool and mark on the inner and outer
ring of the bearing.
(14) Turn and mount sleeve (28) and knock the inner ring of bearing and oil seal (29) onto the input
shaft respectively.
(15) Apply glue and knock stop plug (7) in and then assemble end plate (31) and then stop washer
(32) and fasten up 2 - M8×16 with a spanner and make the two sides lock of stop washer with a
flat taper.
2-28
2) ASSEMBLING INTERMEDIATE SHAFT CLUTCH PARTS
15
14
13
10
11
12 16
11
10
9
28
8 27
7
6 25
5 24
4
3
2
1 6
29
26
23
22
21
20
19
18
17
830KPT09
(1) Check the valve seat (25) of clutch case assy (23) and internal steel ball (24) for looseness.
(2) Use a spanner to screw up 8 - M10×25 bolts to fasten gear II drive gear (26) to clutch case
assy.
(3) Put up glue and knock in 2 straight pins (29).
(4) Unscrew 8 - M10×25 bolts with a spanner and put up 4 stop plates (27) and fasten up 8 - M10
(7) Tap the piston assy into the oil cylinder of clutch case with a tool.
(10) Knock two annular ball bearings (11) into the bore of gear II drive gear (12) and mount two
retainers (10) to set.
(11) Mount the gear II drive gear assy into the clutch assy.
(12) Insert intermediate shaft (9) into the bore of gear II drive gear assy.
(13) Push gear II idler gear (7) onto the spline of intermediate shaft and knock the bearing onto the
intermediate shaft with the special tool and mark on the inner and outer ring of the bearing.
(14) Knock inner seal (5) onto the intermediate shaft with special tool.
(15) Apply glue and knock stop plug (8) in and then assemble end plate (3) and then stop washer (2)
and fasten up 2 - M8×16 with a spanner and make the two sides lock of stop washer with a
flat taper.
(16) Put 2 piston rings (4) into inner seal groove.
2-29
3) ASSEMBLING REVERSE SHAFT CLUTCH PARTS
15
14
13
16
10
12 11
11
10
28
27
9
8 25
7 24
6 6
5 29
4
23
1 26
23
22
21
20
19
18
17
830KPT10
(1) Check the valve seat (25) of clutch case assy (23) and internal steel ball (24) 5 for looseness.
(2) Use M16 spanner to screw up 8 - M10×25 bolts to fasten reverse gear reverse gear (26) to clutch
case assy.
(3) Apply glue and knock in 2 straight pins (29).
(4) Unscrew 8-M10×25 bolts with a spanner and put up 4 stop plates (27) and fasten up 8 - M10
(7) Tap the piston assy into the cylinder of clutch case with a tool.
(10) Knock two annular ball bearings (11) into the bore of reverse drive gear (12) and mount two
retainers (10) to set.
(11) Mount the reverse drive gear assy into the clutch assy.
(12) Insert reverse gear shaft (9) into the bore of reverse drive gear assy.
(13) Push reverse gear sleeve (7) onto the reverse gear shaft and knock the bearing onto the reverse
gear shaft with the special tool and mark on the inner and outer ring of the bearing.
(14) Knock inner seal (5) onto the reverse gear shaft with special tool.
(15) Apply glue and knock stop plug (8) in and then assemble end plate (3) and then stop washer (2)
and fasten up 2 - M8×16 with a spanner and make the two sides lock of stop washer with a
flat taper.
(16) Put 2 piston rings (4) into inner seal groove.
2-30
4) ASSEMBLING OUTPUT SHAFT PARTS
(1) Mount four composite bearings to high
speed gear and low speed gear
respectively.
830KTM35
(2) Insert high and low speed sleeve gear,

high speed gear and bearing onto the
output shaft.
830KTM36
5) ASSEMBLY
(1) Mount the left bracket and right bracket of
handbrake at the output side of
transmission onto the transmission box
and set with four M8×25 bolts and
M12×30 bolts respectively.
(2) Mount the bearing outer rings into the
bearing bore respectively and mark.
830KTM37
(3) Mount the intermediate shaft assy, reverse

gear shaft assy and output shaft assy into
their correct place on the box.
830KTM38
2-31
(4) Mount bearing into the bore for bearing on
the large end cover.
830KTM39
(5) Mount the large end cover into the box

and put up a paper gasket in the middle.
(6) Assemble the outer seal into the oil inlet
end cover.
(7) Mount the oil inlet end covers in place on
the box watching oil orifice position.
830KTM40
(8) Assemble the front output flange and

handbrake assy.
830KTM41
830KTM42
2-32
(9) Assemble the low speed gear assy into
the box.
830KTM43
(10) Assemble the output shaft assy.
830KTM44
(11) Assemble rear end cover of output shaft

and rear output flange.
(12) Mount the output shaft rear end cover
and oil seal (45×62×12) on the box and
then input flange, and adjust the bearing
gap at the input side to meet requirements.
(13) Mount the intermediate shaft end cover
and reverse gear shaft end cover and
fasten up the screws and set the stop
830KTM45
plate.
(14) Mount the fork shaft in the fork bracket.

(15) Mount the fork bracket assy through the
holes on the box and fasten with 4 -
M10×30 bolts. Mount the for k for
high-low shift speed by inserting the fork
shaft into the fork hole and adjust the
p o s i t i o n o f fo r k s h a f t t o k e e p i t
perpendicularly and drill hole to match
assembly.
830KTM46
2-33
830KTM47
(16) Mount the oil pan and set with 20 -

M10×30 bolts.
830KTM48
(17) Mount the control valve assy and top

plate and connect with 8-M10×45 and
4 - M10×35 bolts
830KTM49
2-34
GROUP 3 TORQUE CONVERTER
1. FEATURES AND USE

Hydraulic torque converter is a single stage, single phase radial turbine hydraulic converter. In
addition to the structural features of general hydraulic torque converter, this product features three
output shafts and thus it can drive three different models of hydraulic pump or other components to
meet the requirements of engine.
2. WORKING
The pump pulley connects to engine flywheel by a connection wheel and flexible steel board. Driven
by mechanical energy from engine, the unit transforms the energy into hydraulic power, which drives
the turbine to be transformed into mechanical energy and outputted by power output members.
Guide pulley has functions to change direction of operating flow and give a counter torque to the flow
to change torque and speed.
The oil inlet valve consists of main pressure valve and an overflow valve. Function of the main
pressure valve is to ensure sufficient oil supply to torque converter and that oil pressure range in
speed change oil circuit of engine is within 1.30 ~ 1.50 MPa. The function of overflow valve is to build
up a compensatory pressure to the system and, by different loading of torque converter and variation
of internal pressure of hydraulic oil, automatically control the flow passing through the torque
converter to control the heat dissipating capacity of torque converter and provide overpressure
protection when the outlet port of torque converter is clogged.
3. TECHNICAL DATA
Limit input torque 69.3 kgf·m (502 lbf·t)
Nominal torque at zero-speed loading 5.8 kgf·m (42.2 lbf·t)
Nominal torque at high efficiency loading 6.1 kgf·m (44.1 lbf·t)
Torque ration at zero-speed loading 3.24
Max. efficiency 0.836
Width of high efficiency region 2.032
Net weight 159kg
Dimensions 470×530×530 mm
2-35
4. MOUNTING AND USAGE
1) MOUNTING
When mounting, ensure that centerline of rotation of torque converter coincide with that of
crankshaft of engine (see page 2-39).
2) USAGE
(1) Hydraulic torque converter uses AFT (DEXRON Ⅲ). Oil temperature should be within 85~100˚C,
and not exceed 110˚C normally.
(2) Before staring hydraulic torque converter, check each rotating part for smooth rotation and that if
there is seizure and collision. Mount the hydraulic torque converter on the vehicle and add a
suitable amount of hydraulic oil to the tank.
(3) Start the engine and make the hydraulic torque converter to run for 1~2 minutes at low speed.
Add oil to the tank again. Oil level should reach indicator line in running of hydraulic torque
converter. Keep in mind to bleed air for the oil supply system when adding oil.
(4) After starting hydraulic torque converter, run it in low speed and moderate speed in sequence,
then under load. Frequently watch its running and check if there is abnormal noise. Immediately
stop and check if abnormal. During operation, frequently check for variation of oil pressure and
temperature and ensure that are within normal range. When the hydraulic torque converter is in
use, be sure to check it at least once a week and, if oil level is below the line, add adequate
amount of oil promptly.
(5) It’s required to renew oil for hydraulic torque converter after 30~50 hours of operation and then
renew for second time after 500 hours of operation. After that, renew oil in the same time interval.
(6) For mechanic transmission, the driver should make timely gear shift to prevent the engine from
dying by sound heard during operation. No engine dying will occur if transmission of hydraulic
torque converter is matched rationally. However, the driver still needs to change gear timely by oil
temperature readings to prevent from overheated oil in low efficiency region of torque converter
that may cause damage to sealing pack.
2-36
5. OIL SUPPLY SYSTEM
Working principle of oil supply system of hydraulic torque converter.
1 Cooler
2 Hydraulic torque converter
3 Main pressure valve Opening pressure 1.3 ~ 1.5 MPa
4 Overflow valve Opening pressure 1.3 ~ 1.5 MPa
5 Flow Q ≥ 50 ℓ/min
2-37
6. TROUBLESHOOTING
Problem Cause Increase engine rpm
I n s u f f i c i e n t Engine rpm drops. Increase engine rpm.
power output Gas exists in hydraulic oil. Check transmission oil level.
Check for tightness of tubing system.
Check for deteriorated hydraulic oil.
Too high hydraulic oil temperature. Lower oil temperature.
Too low pressure of overflow valve of Check for sensitivity of motion of overflow valve and
hydraulic torque converter. hydraulic oil leaks.
Too high oil Too long time of operation in low Decrease external load or increase engine rpm.
temperature efficiency region.
Too low oil level in oil tank or gas exists Add hydraulic oil, check for tightness of the
in hydraulic oil. connections of piping, and check for deteriorated oil.
Oil does not meet requirements. Use oil as recommended in operator's manual.
Too low oil pressure in oil supply Repair hydraulic valve, increase oil pressure.
system.
Low water level in cooling system. Repair water tank.
Insufficient oil supply. Check oil supply system.
To o l o w o i l Back pressure valve failure. Replace back pressure valve.
pressure in oil Clogged oil feed tube. Check oil tubing.
supply system
Insufficient oil supply of transmission oil Check and repair oil pump, or replace.
pump.
Damaged or severely worn oil seal Replace oil seal.
inside hydraulic torque converter.
Too low oil level in oil tank. Add hydraulic oil.
Clogged suction filter. Clean or replace the filter.
Failed pressure gauge. Replace the pressure gauge.
Oil leakage Damaged reinforced oil seal. Replace the oil seal.
Damaged O-ring. Replace the O-ring.
2-38
Length of spline
Lifting hole Total 3 spots
7. OUTSIDE VIEW
Oil return port

View A
ter Total 3
o cen
T posi-
tions of
spline
Total
3 spots
2-39
Opening pressure
Oil overflow port
er
cent
Pressure To Oil overflow port
measuring
port
View A
Overflow pressure
Opening pressure
Torque converter oil supply system diagram

GROUP 4 AXLE
1. OUTLINE
1) PRODUCT SURVEY
The axle has two stages reduction structure. It has rational design structure, reliable use
performance, long duration of life, etc. It adopts caliper disc brake by pneumatic braking. Braking
moment is large and braking is stable and reliable.
2) MAIN PERFORMANCE AND TECHNICAL PARAMETERS
Main technical parameters
Axle model Max. input Wheel-end Braking
Max. load Total ratio Main ratio Oil pressure
torque ratio moment
235 kgf·m 979 kgf

ZL30 18500 kg 20.26 4.222 4.8 9.8 MPa
(1700 lbf·ft) (7080 lbf·ft)
3) THE STRUCTURAL CHARACTERISTICS AND WORKING PRINCIPLE

(1) Main structural
structural characteristics
The drive axle is two stages reduction transmission device. The first grade device adopts spiral
bevel gear to transmit. Drive axle bears large input torque and has capability of high transmission
efficiency and stable working. The second grade device adopts planetary reduction transmission
structure (NGW) type. Rigidity of whole movement of drive axle is well and output speed is
smooth. Between two grades device, we adopt full-floating axle shaft to connect and transmit
power. The structure has overcome that axle housing in the course of working distortion brings
the influence to axle shaft transmission.
(2) Working principle
Wheel reductor Axle shaft
Final drive Input flange

830K2AX100
2-40
Power torque of vehicle is inputted by drive shaft from input flange of drive axle. Final drive changes
rotary direction to drive driven spiral bevel gear and differential case to rotate after it does reduction
and differential. Differential case drives cross pin and planet bevel gears to transmit power to axle
shaft gears. Axle shaft gears transmit power to two sides wheel-end reductors by axle shafts, finally
transmit power to planet carriers after wheel-end reductors do reduction, thereby drive wheels to roll
ahead.
Transmission route of drive axle as follows:
Transmission
Power torque of vehicle → Input flange → Final drive → Differential → Axle shafts → Wheel-end
reductors → Wheels.
4) MAINTENANCE
(1) Must lubricate for new drive axle before it is mounted on vehicle.
Recommended the lubricant: SAE85W-90.
When refuel oil, should separately refuel it from oil inlets at bowl of the middle of axle housing and
at two sides wheel-end.
· Oil amount
Front axle : 18ℓ(4.8 U.S.gal)
Real axle : 18ℓ(4.8 U.S.gal)
(2) Maintenance
aintenance per 250 hours
① Inspect wear condition of braking discs and whether there are destructive wear on them.
② Inspect wear condition of braking plates. When the grooves on friction lining have been worn
down and don’t meet the requirement, should immediately replace.
③ Inspect whether oil level at axle housing meets the requirement. If oil level lowers, should refuel
oil in time.
(3) Maintenan
Maintenancece per 1000 hours
Lubricant in drive axle work per 1000 hours to replace once new oil.
(4) Maintenance per
per 2000 hours
Should disconnect drive axle to inspect when it has worked for 2000 hours.
① Inspect spiral bevel gear pair backlash, mesh and wear condition of final drive.
② Inspect wear condition of differential gears and bevel gear washers.
③ Inspect wear condition of wheel-end gears.
④ Inspect wear condition of wheel-end planet gear needle rollers and bearings.
2-41
(6) Requirement of inspection and debugging projects in the course of use
① Spiral bevel gear pair backlash is 0.2~0.3 mm. Mesh is >50% both face width and tooth depth.
Mesh is at teeth middle. Mesh leans to little end at empty load. Backlash and mesh are adjusted
by adding and reducing adjust shims at bearing seat and by adjust nuts at two sides bearings of
differential.
② Adjustment of bearing clearance on wheel-end hub: Turn locknut tight until hub only rotates with
difficulty, then reverse locknut 1/10 turn. Here, hub can rotate freely without jammed phenomenon,
obvious axial clearance and oscillatory phenomenon, turn locknut tight with screw last.
2-42
5) TROUBLESHOOTING
Parts
Problem Cause Remdy
names
Final drive Loud noise 1. Gear backlash is oversize Adjust gear backlash.
and 2. Bearing is worn. Replace bearing.
differential Housing body L u b r i c a t i o n i s b a d . N o Refuel lubricant to oil level.
early heats lubricant or lubricant is
excessive.
Periodic unusual sound 1 . G e a r a p p e a r s t o o t h Replace gear.
breakage.
2. There is eyewinker inside. Bleed the oil port to inspect.
3. Fasteners loose. Turn fasteners tight.
Differential failure Cross pin breakage. Replace cross pin.
Leakage 1. Oil seal ages and wears. Replace oil seal.
2. Sealant loses its efficiency. Scrape off old sealant and smear
afresh.
3. Fasteners loose Turn fasteners tight.
Wheel-end Wheel-end doesn't rotate 1. Axle shaft breakage. Replace axle shaft.
reductions 2. Differential system failure. Adjust and replace differential
system.
There is 1 . G e a r a p p e a r s t o o t h Replace gear.
unusual sound breakage.
2. There is eyewinker inside. Bleed the oil port to inspect.
Housing body early heats L u b r i c a t i o n i s b a d . N o Refuel lubricant to oil level.
lubricant or lubricant is
excessive.
Brake Braking failure 1. Oil line disconnects or is Connect or replace oil line.
clogged.
2. Piston O-ring ages and Replace O-ring.
wears.
3. Piston and piston cylinder Replace brake.
jam.
4. Hydraulic pressure isn't Inspect oil pump and exhaust gas in
enough. oil line.
Friction lining doesn't 1. Piston seal ring ages and Replace seal ring.
release wears.
2. Oil inlet joint looses. Turn oil inlet joint tight.
3. There is casting defect on Replace brake body and repair.
brake body.
6) TRANSPORTATION AND DEPOSIT

(1) Strictly prohibit to deposit drive axle in the open air. It should be deposited in the room with good
ventilation. If lubricant has molded and deteriorated, when use drive axle, should replace new oil.
(2) Can’t knock and savagely handle drive axle in the course of carry and turnover.
2-43
8) STRUCTURE
(1) Drive axle assembly
4 2
3
5
7
6
18
9 17
8 16
14
15
10
11
12
13
830KPT14
1 Wheel-end reductor 7 Screw plug 13 Nut

2 Axle housing assy 8 Screw plug 14 Washer
3 O-ring 9 O-ring 15 Bolt
4 Screw plug 10 Final drive assy 16 Bolt
5 Exhaust plug 11 Double end studs 17 Washer
6 O-ring 12 Washer 18 Disc brake assy
2-44
(2) Wheel-end reductor
20
19
18
17
12 16
11 1314
15
10
89
5
3 4
6 7
1 2 30 31
28
10
37
37
23 35 36
33
32
34
29
26
24 28
22 27
21
25
830KPT15
1 Screw plug 13 Steel ball 25 Ring gear

2 O-ring 14 Washer 26 Bearing
3 Bolt 15 Needle roller 27 Hub
4 Washer 16 Spacer 28 Rim bolt
5 Cover 17 Planetary pin 29 Straight pin
6 Retaining plate 18 Planetary gear 30 Washer
7 Adjusting mainstay 19 Washer 31 Bolt
8 Screw plug 20 Short axle shaft 32 Bearing
9 O-ring 21 Criclip 33 O-ring
10 Rim nut 22 Sun gear 34 Braking disc
11 Planetary carrier 23 Screw 35 Washer
12 O-ring 24 Lock nut 36 Bolt
37 Oil seal
2-45
(3) Final drive assembly
19
20 2221
21 24 33
32
23 25 31
30
26 29
28
27 33
30
18 29
17
16 40 33
42 32
13 31
30
12 40 29
11 38 42
10 39 28
8
7 36
6 15
4 14 41
23 40
42 39
1 40
9 1011 38
37
5 35
43 34
44
45
46
830KPT16
1 Cover 17 Bearing 33 Bolt

2 Nut 18 Adjust shim 34 Adjust nut
3 Washer 19 Adjust nut 35 Bearing
4 Baffle plate 20 Bearing 36 Bolt
5 O-ring 21 Nut 37 Right differential case
6 Input flange 22 Lock plate 38 Thrust washer
7 Oil seal 23 Lock plate 39 Axle shaft gear
8 Oil seal 24 Lock plate 40 Thrust wahser
9 Thrust washer 25 Differential case 41 Cross pin
10 Bolt 26 Driven bevel gear 42 Planetary bevel gear
11 Washer 27 Bolt 43 Final drive housing
12 Bolt 28 Diff bearing cap 44 Criclip
13 Bearing 29 Left differential case 45 Bearing
14 Adjust shim 30 Bolt 46 Driving gear
15 Spacer 31 Lock plate 46 Driving gear
16 Bearing seat 32 Lock plate
2-46
(4) Brake assembly
3
4
4
3
2 6
8
9
10
1 11
2
3 12
4
5
5 11
4 11
3 12
13
6 14
7
13
8
9 14
10
11
12
830KPT17
1 Outside brake 6 O-ring 11 Washer

2 Piston 7 Inside brake 12 Bolt
3 Square seal ring 8 Washer 13 Split pin
4 Dust shroud 9 Joint 14 Bolt pin
5 Braking plate 10 Exhaust plug
2-47
Group 1 Structure ------------------------------------------------------------------------------------------------------------- 3-1

Group 2 Air brake circuit --------------------------------------------------------------------------------------------------- 3-2
Group 3 Components specification and function ----------------------------------------------------------- 3-3
GROUP 1 STRUCTURE
1
7
830KBS01
1 Air brake valve 5 Safety valve

2 Air tank 6 Front axle
3 Air booster 7 Rear axle
4 Oil and water separator
3-1
GROUP 2 AIR BRAKE CIRCUIT
FRONT AXLE
REAR AXLE
E/G
AIR COMPRESSOR
830KBS01A
1 Air brake valve 5 Safety valve

2 Air tank 6 Auto water drain
3 Air booster 7 Brake lamp air pressure switch
4 Oil and water separator 8 Pressure switch and sensor
3-2
GROUP 3 COMPONENTS SPECIFICATION AND FUNCTION
1. BRAKE VALVE
1) USE AND STRUCTURE
As a main device of foot brake, this unit adopts high technology and can be applied to single circuit
braking system of machines.
2) WORKING PRINCIPLE
When the brake pedal (2) is pressed, the rod (3) presses the equalizing spring (4) to produce a
pressure, which then pushes the piston (6) to move down to make intake valve (7) to open allowing
compressed air to flow from inlet to outlet port. When brake pedal (2) is released, return spring (5)
pushes the piston (6) to move up to make intake valve to return to original position to close air flow
between inlet and outlet. Remaining pressure at outlet is vented through exhaust port.
3) TECHNICAL DATA
(1) Operating air pressure : 784 kPa
(2) Working temperature : -30 ~ +80˚C
(3) Working medium : air
4) MOUNTING AND CONNECTION SIZE

(1) Connection screw : M22×1.5 (3EA)
(2) Mounting : 4-ø9
(3) Dimensions : 136×136×335
5) CORRECT USE AND MAINTENANCE

(1) Notes in using
① Before mounting, remove the plugs for inlet and outlet, and be sure to have the pedal and valve
body are securely assembled. Valve clearance should be adjusted properly with adjusting screw
(pressure of surplus for the roller to press the rod should be less than 0.5 mm) and fasten up the
nut.
② Insert M8 bolts through 4-ø9 holes to make secure assembly.
③ When connecting with piping, distinguish inlet port from outlet. Marking “1” means, inlet, “2”
means outlet and “3” exhaust port.
(2) Notes in Maintenance
① There should be water draining and filtering devices in air circuit to secure a clean air source.
Anti-rust process is required for the brake tubes and air cylinder.
② A space should be secured for freely moving of the pedal.
③ When replacing a wearing part, use a part same with the worn, the damaged fastening pieces
(such as stop ring, bolt) must also be replaced. All parts should be assembled in correct position
securely and no other part be damaged. After replacing, do not assemble to the machine before
completing test.
④ The moving part of air brake valve should be served grease. If the brake doesn’t grip properly or
grips weakly, check the wearing parts of air brake valve and braking system.
3-3
6) TROUBLESHOTTING
Trouble Cause Remedy
Air leaks under no work. Worn rubber. Replace rubber or assembly.
Air leaks under work. Worn rubber. Replace rubber or assembly.
Unsmooth exhaust. Seizing of piston. Replace the assembly.
Improper adjustment of pedal Adjust the adjusting screw manually to the
roller and rod. extent that pedal roller is just contacting the rod.
(Pressure of surplus for the roller to press the
rod should be less than 0.5 mm)
7) STRUCTURE AND MOUNTING SIZE
View A
Air outlet
Air
intlet
Air outlet
850KBS10
1 Bolt 4 Equalizing spring 7 Intake valve

2 Pedal 5 Spring
3 Rod 6 Piston
3-4
2. SAFETY RELIEF VALVE
Safety relief valve automatically drains condensate inside the air cylinder of brake line and manual
drainage is also available.
Safety relief valve is used to automatically drain condensate inside the air cylinder of brake line by
variation of air pressure (air pressure drops 0.03~0.1 MPa) and manual drainage is also available
after parking for fast drainage.
3) TECHNICAL DATA
(1) Rated operating air pressure : 800 kPa
(3) Weight : 0.1 kg
(1) M22×1.5
(2) Exhaust port down.
To connect air cylinder
Manual drainage button
Exhaust port
850KBS13
3-5
3. SAFETY VALVE
Safety valve is used to ensure that charge pressure of air brake line does not exceed 900 kPa.
Compressed air flows in through air inlet and, when the pressure at inlet exceeds 850 kPa, the
safety valve A is actuated for air relief to protect the air brake line.
3) TECHNICAL DATA
(1) Safety operating pressure : 850~900 kPa
Inlet M16×1.5 is connecting screw.
5) NOTES IN USING
Adjusting bolt of safety valve has been already set as delivery and user is not permitted to adjust or
remove the part as his/her wish.
6) TROUBLESHOOTING
Leaks at valve port Damaged rubber of safety valve stem Replace safety valve assy
assy.
Adjusting bolt
Air outlet
Air inlet
850KBS14
3-6
4.OIL AND WATER SEPARATOR
1) STRUCTURE
Oil and water separator combined valve is applicable to brake system. This device features
automatic control of working pressure in brake system and auto drainage of oil and water after
filtering. Since the unit has a built-in protector, safe pressures can be guaranteed.
Air under pressure from compressor flows into the valve through air inlet and water and impurities
can be filtered off through a strainer. After filtering, the compressed air reaches the outlet through
one-way valve to charge the cylinder. When the pressure inside cylinder reaches opening pressure,
air that enters into top head overcomes resistance of pressure spring to push control valve assy to
move upward to open the exhaust valve at the lower part to discharge the air along with filtered
impurities and water into atmosphere and compressor becomes idle state. When the pressure
inside air cylinder drops to exhaust stop value and the air inside cavity of top head can not
overcome the pressure spring, control valve moves down, and the exhaust valve moves up by the
action of spring to stop exhaust valve and air supply to cylinder is restarted.
3) TECHNICAL DATA
(1) Opeing pressure : 784±20 kPa
(2) Exhaust stop pressure : 685 ~ 750 kPa
(3) Working temperatures : -30 ~ +100˚C
(4) Weight : 1.8 kg
(1) Mounting size : 2-M8×40 double end stud
(2) Connection size : Inlet (M22×1.5), outlet (M22×1.5)
(3) Dimensions : 150.5×128.5×220
5) CORRECT USE AND M MAINTENANCE
AINTENANCE
(1) Notes in using
① Before mounting, remove the plugs for inlet and outlet.
② Mount the unit on the mount plate with outlet down.
③ Pressure regulator screw and safety valve have been set as delivery and user is not permitted to
adjust or remove by his/her self.
(2) Notes in maintenance
① The length of pipe from air compressor to combined valve should not be less than 2 m, aperture
not less than ø12 to ensure fully cooling of hot air and condensing moisture in air.
② If severely worn wearing part or air leaks is found, immediately replace the wearing part.
③ When replacing a wearing part, use a part same with the worn, the damaged fastening pieces
(such as bolt and nut) must also be replaced. All parts should be assembled in correct position
securely and no other part be damaged. After replacing, do not assemble to the machine before
completing test.
3-7
6) TROUBLESHOOTING
Leaks
eaks at exhaust port. Polluted exhaust valve. Clean pipe line.
Damaged exhaust valve. Replace exhaust valve.
Leaks
eaks at top head vent Damaged diaphragm. Clean pipe line.
Damaged control piston O-ring. Replace control piston O-ring.
Air
outlet
Air inlet
850KBS16
3-8
Group 1 Hydraulic circuit --------------------------------------------------------------------------------------------------- 4-1

Group 2 Structure and function ----------------------------------------------------------------------------------------- 4-5
Group 3 Operational check and troubleshooting ------------------------------------------------------------ 4-18
Group 4 Test and adjustments ------------------------------------------------------------------------------------------ 4-24
GROUP 1 HYDRAULIC CIRCUIT
1. STEERING CIRCUIT
L R
7
P T
MCV B
6
T
T/C 10
11
8
9
830K3HC03E
1 Main pump 7 Steering unit 10 Air breather

5 Steering cylinder 8 Return filter 11 Hydraulic tank
6 Streering valve 9 Bypass valve
4-1
2. NEUTRAL
L R
7
P T
MCV B
6
T
T/C 10
11
8
9
830K3HC34
The steering wheel is not being operated so control spool (G) does not move.
The oil from the steering pump enters port P streeing unit (7) and returns to hydranlic tank through the
spool (G).
4-2
3. LEFT TURN
L R
7
P T
MCV B
6
T
T/C 10
11
8
9
830K3HC35
When the steering wheel is turned to the left, the spool (G) within the steering unit (7) connected with
steering colurm turns in left hand direction.
At this time, the oil discharged from the steering pump flows into the spool (G) of the steering unit (7)
and flows into the gerotor (H).
Oil flow from the gerotor flows back into the spool (G) where it is directed out the left work port (L) to the
respective chamber of the steering cylinders (5).
Oil returned from left and right cylinder returns to hydraulic tank through the spool (G) of the steering
unit.
When the above operation is completed, the machine turns to the left.
4-3
4. RIGHT TURN
L R
7
P T
MCV B
6
T
T/C 10
11
8
9
830K3HC36
When the steering wheel is turned to the right, the spool (G) within the steering unit (7) connected with
steering colurmn turns in right hand direction.
At this time, the oil discharged from the steering pump flows into the spool (G) of the steering unit (7)
and flows into the gerotor (H).
Oil flow from the gerotor flows back into the spool (G) where it is directed out the right workport (R) to
the respective chamber of the steering cylinders (5).
Oil returned from left and right cylinder returns to hydraulic tank through the spool (G) of the steering
unit.
When the above operation is completed, the machine turns to the right.
4-4
1. STEERING PUMP
LOADER PUMP
14
13
12
10 11
9
7 8
6
5
4
3
1 2
24
23
21 22
19 20
18
17
16
15
STEERING PUMP
830KSE15E
1 Snap ring 9 Side plate 17 Pump body

2 Oil seal 10 Drive gear 18 Rear cover
3 Front cover 11 Driven gear 19 Decal
4 Snap ring 12 Seal 20 Rivet
5 Bearing 13 Seal 21 Washer
6 Bushing 14 Middle body 22 Bolt
7 Seal 15 Seal 23 Seal
8 Seal 16 Shaft 24 Bolt
4-5
2. STEERING UNIT
1) STEERING GEAR
850KSE12
1 Spool 10 X-ring 19 Spacer

2 Centering spring 11 O-ring 20 O-ring
3 Sleeve 12 Front cap 21 Gerotor
4 Seal 13 Spring washer 22 Gerotor
5 Bearing 14 Bolt 23 Drive
6 Seal 15 Cap screw 24 Plate
7 O-ring 16 Washer 40 Pin
8 Housing 17 Bar 41 Ball
9 O-ring 18 End cap
4-6
2) OVERLOAD VELVE
850KSE13
25 Plug 31 Spring seat 36 Spool

26 O-ring 32 Plug (adjusting screw) 37 Ball
27 Housing 33 Plug 38 Poppet
29 Spool 34 Plug 39 Spring
30 Spring 35 O-ring
4-7
3) INSTRUCTION FOR USE OF STEERING GEAR AND COMBINED OVERLOAD VALVE
■ STEERING
STEERING GEAR
· When the cycloid rotary valve and non reaction type steering gear, the oil inlet and return port are
interconnected and two cavities of hydraulic cylinder are in close state. External force applied to
hydraulic cylinder is transmitted to steering wheel but driver will not feel shaking from rough road.
· Partial parameters of steering gear:
Max. operating pressure : 16 MPa
Max. counter pressure : 6.3 MPa
Constant counter pressure : ≤ 2.5 MPa
(1) Structure of steering gear
For structure of steering gear, refer to page 4-6.
The components of the system are as follows.
① Rotary follow-up valve consisting of spool, sleeve and valve body
Controls direction of oil flow and its spool is directly connected with steering wheel and column.
② Cycloidal
Cycloidal gear pair (a stator and a rotor)
Detects motor to keep direct proportion between flow entering into steering cylinder and
steering wheel angle as power steering and be the equal of hydraulic pump as manual steering.
③ Intermediate shaf
shaftt and yoke linking rotor and valve sleeve
Works to keep the valve sleeve synchronous with rotor as power steering while to transmit
torque as manual steering.
④ Spring
Spring leaf
Ensures the follow-up valve to return to center when not in steering.
⑤ One-way valvalve
ve between inlet and return port
As manual steering is made, this device allows the oil inside a chamber of steering cylinder to
be pressed into another chamber through return port by the cycloidal gear pair while, as power
steering is made, the device ensures that oil does not directly flow from P port into T port.
Port A and B are connected to two chambers of steering cylinder and port P connected to
hydraulic pump and port T to oil tank.
(2) Working principle of steering gear
When steering gear is on center, the valve spool and sleeve are located in center by action of
spring leaf. Flow from pump is directed to spool through two rows of small holes in valve sleeve
and the end of valve spool and then is backed to oil tank through port T.
When the wheel is turned to right (or left), the spool is driven to turn to right (or left). Since there is
a max. 10.5° turn between valve spool and sleeve, the spool has an angle of turn in reference to
the sleeve, and the oil groove of spool is connected to oil inlet of sleeve. The flow from pump goes
through valve sleeve, oil groove of spool, and further to rotor and stator from the sleeve to push
the rotor to turn in reference to stator and, at the same time, the flow from rotor and stator goes
through valve sleeve and is directed to a chamber of steering cylinder via port A (or B) to cause
the piston rod extending (contracting) to push the steering wheel to turn to right (or left), while the
flow in the other chamber of cylinder is directed to valve sleeve via port B (or A) and goes through
the return groove of spool and then return groove of sleeve to return to oil tank through port T.
Oil circuit becomes current from approx. 1.5˚ of relative angle between valve spool and sleeve
and rotation of the rotor causes oil to flow into cylinder. Oil amount is in direct proportion with
angle of steering wheel.
4-8
Manual steering :
Manual
When engine stops or steering pump is malfunctioned, this type of steering gear allows turning of
steering wheel manually by static pressure. When the steering wheel is turned to right (left), the
valve spool turns for 10.5˚ to drive the sleeve, intermediate shaft and rotor by yoke. At the time,
the stator and rotor work together as a pump. Rotation of rotor sucks oil out from port T and the
flow goes through one-way valve, valve sleeve and spool, into inlet cavity of rotor pump. Manual
turning of rotor pump pressurizes oil to make the flow to be directed to a chamber of steering
cylinder to extend the piston rod (contract) causing the wheels to turn to right (left). Flow in
another chamber goes via port B (A) through valve sleeve, spool, then is directed from the sleeve
to inlet cavity of rotor pump through one-way valve, being constantly supplied to large (small)
chamber to realize steering.
To guarantee realization of manual steering, the steering gear should not be mounted in a
position 0.5 m higher than oil level of oil tank for better oil suction effect.
(3) Using, disassembly and assembly
· Using steering gear
① Mounting
When mounting steering gear, be sure to keep in line with steering column (coaxial), and there
should be a clearance axially to prevent the valve spool to become stuck. After assembly, check
the steering wheel can return smoothly.
Oil line should be laid by marking of four ports: P is connected to pump, T to tank, A and B to left
and right chamber of steering cylinder respectively.
② Test operation
a. Before operation, clean the oil tank and refill to the max. level, loosen the steering cylinder
screw connector, run oil pump in slow speed to bleed to the extent no foam is seen in out
flowing oil.
b. Disconnect piston rod from steering arm, turn steering wheel to the left and right extremes (do
not stop at two extremes) and refill oil into tank to the max. level again.
c. Fasten up all the screw connections (do not fasten under hydraulic pressure), connect piston
rod to steering arm, check that system pressure meets the specified value as piston reaches
extremes, check steering system works normally in any operating conditions and, when
steering is not smooth, find out the reasons carefully, do not turn the wheel forcibly, nor
disassemble the steering gear in a hurry to prevent parts to be damaged.
③ Using and Maintenance
Check oil leaks daily, oil level in tank and operation, replace filter element and drawing liquid.
When any problem is found, never turn the steering wheel by two people together.
4-9
· Disassembly of steering gear
① Typically, there are two kinds of orders for disassembling a steering gear, i.e. solution A and
solution B.
a. Front cover → small snap ring → bearing → large snap ring → valve spool & sleeve → yoke
→ spring leaf, rear cover → stop → stator → rotor → intermediate shaft → partition disc →
steel ball → valve body.
b. Rear cover → stop → stator → rotor → intermediate shaft → partition disc → steel ball →
valve spool & sleeve → yoke → spring leaf → small snap ring → bearng → large snap ring →
front cover → valve body.
② Notes in disassembly
Be careful not to make the working or end surface of any part to be damaged or scratched when
disassembling. Do not put the rubber rings disassembled in gasoline to prevent from
deformation or deterioration due to reaction with gasoline.
· Assembly of steering gear
① Order of assembly: Valve spool → valve sleeve → yoke → spring leaf → large snap ring →
bearing → small snap ring → valve body → front cover → steel ball → partition disc →
intermediate shaft → rotor → stator → stop → rear cover.
② Notes when assembling
a. Clean all parts with gasoline or kerosene before assembling (except for rubber ring). Paint on
junction surfaces should be cleaned with acetone. Never use cotton fabrics or cloth to clean the
parts, but use soft brush or silk. It’s the best to use compressed air to blow clean. After
assembling steering gear, add 50~100 ml hydraulic oil via the oil filler, turn the valve spool to left
and right and check if there is problem before assembling to the machine.
b. Junction surface of valve body, partition disc, stator and rear cover must be highly clean and
there should no scratches or damages.
c. There is a mark each on the stator and shaft end and be careful to make correct assembly in
the matching positions of shaft notch and internal hole of spline.
d. Conforming washer must be used for rear cover bolt.
e. When fastening 7 bolts for rear cover, fasten in order and every other two bolts, fasten up
gradually to a torque of 4.1 ~ 5.1 kgf·m (29.7 ~ 36.9 Ibf·ft).
f. Port of P, T, A, B should must be connected in one-to-one correspondence.
4-10
6) TROUBLESHOOTING

Oil leaks Damaged O-ring at journal Replace O-ring.
and overflow valve.
Oil leaks at connections of Clean off dirt on junction surface, grind
valve body, partition disc, scratches, and fasten up screws
stator and rear cover. according to notes in assembly.
Steering is light under no load (or Pressure of overflow valve is Adjust the pressure of overflow valve
l i g h t l o a d ) b u t h e a v y w h e n lower than that of steering to a specified value, or clean the
increasing load system or overflow valve is overflow valve.
clogged.
Steering is light as slowly turning Insufficient oil supply of Select a suitable pump. Check hydraulic
while heavy as fast hydraulic pump. pump for normal operation ad check if
the volumetric efficiency is too little.
Steering is heavy as fast or slowly Malfunction of one -way If steel ball is missing, load ø8 steel
turning and no steering pressure. valve inside the valve body. ball. If steel ball is stuck by dirt, clean.
Foam is in oil, irregular sound is Air in steering system. Bleed air, check suction pipe for oil
heard, cylinder moves and stops leaks, and that if return pipe is under
from time to time oil level.
Steering is heavy Oil tank is not full, or oil Refill oil to specified level.
viscosity too high. Use recommended fluid.
Severe steering deviation. Cylinder Malfunction in t wo -way Clean two-way buffer valve, or replace
will not move as turning steering buffer valve (steel ball is spring.
wheel (or moves slowly) seized due to dirt, or spring
failure).
Disordered oil distribution. Steering Reversed locations of rotator Reassemble referring to notes in
wheel turns itself or shakes and intermediate shaft. assembly.
Obvious increase in vibration by Broken or deformed yoke, Replace yoke, replace intermediate
pressure. Further, the wheel could broken or deformed opening shaft. Substitution with other object is
not turn of intermediate shaft. forbidden.
Steering wheel could not return to Steering column and valve Troubleshoot after finding out the
center. Steering gear could not spool are not coaxial. cause.
unload when steering wheel stops
Steering column has pushed
turning
the valve spool to be stuck.
Too much steering column
rotating resistance.
Broken or deformed spring
leaf.
Steering cylinder moves little at first Too low oil level in oil tank Refill oil to specified level.
and then will not as manual steering (oil in cylinder has returned
to oil tank).
As power steering, cylinder piston Too much radial or axial Replace rotor and stator. If axial
reaches the ex treme and driver clearance at rotor and stator clearance has become too large, grind
could not feel the extreme clearly. due to long time of use. the end surface of stator.
Steering cylinder will not move as
manual steering
No manual steering Too high oil viscosity. Use recommended oil.
4-11
■ OVERLOAD VALVE
(1) Overview
The overload valve is a combined valve for full hydraulic steering gear, and can be directly
assembled to four port flanges of steering valve body to become integrated one.
(2) Structure and working principle
The overload valve consists of a one-way valve, overflow valve and two-way buffer valve, which
guarantee stable steering performance, safety and reliability.
· Featu
Features
res
① Compact design, easy installation, space efficiency.
② Flexible pressure regulation, no leaks.
③ Combined valve can simplify hydraulic system and has low costs.
· Struct
Structure
ure
① One-way valve has a taper structure, consists of a valve seat, spool and spring and is fitted to
inside of oil inlet of valve body. This valve features light resistance and good sealing. High
pressure oil from hydraulic pump must pass through one-way valve to reach steering valve body.
This one-way valve is designed to prevent operation of hydraulic system from being broken due
to deflection of steering wheel because of return of oil to pump due to oil pressure in cylinder
being higher than operating oil pressure that is caused by obstruction to steering wheel in
special situations. One-way valve needs not adjustment in normal use, but reverse oil leaks
should be prevented.
② Overflow valve is of differential and direct-acting type consisting of a differential valve seat, spool,
spring, pressure regulating bolt and locking bolt. This device is attached to oil inlet and return
port of overflow valve body featuring simple structure and stable operation. Its function is to
prevent from overload, control pressure difference between inlet and return side to assure stable
pressure. This device has also the function to unload and overflow and is called as safety valve.
This valve also features regulation by loosening locking bolt and turning regulating bolt. After
regulating pressure, fasten the locking bolt.
③ Two-way buffer valve includes two direct-acting overflow valves and consists of a spring, two ball
valve seats and two steel balls. This device is attached to the valve body to the each port of two
chambers of steering cylinder. The ports are connected to return port. The product features
simple structure and easy manufacture and repair, and functions as two safety valves to unload
and make oil returning when pressure in a chamber of cylinder increases as speedy steering or
vehicle travel encounters sudden variation in resistance to protect the oil circuit between steering
cylinder and steering gear, assuring safe and reliable steering. Opening pressure of the valve is
5~6 MPa higher than operating pressure of steering gear.
(3) Installation and requirements in using
① Installation
Be sure to make correct connection of four ports, i.e., P, T, A and B when installing the valve
block on the flange at the steering gear side.
Be careful to keep clean junction surface of flange and prevent dirt from entering into the system.
Four O-seal rings in between valve block and steering gear flange should be laid flat, two screws
fastened at even fastening torque, 40~50 N.m. Be sure that valve block is not twisted.
4-12
4) TROUBLESHOOTING
Steering is light under no Pressure of overflow valve inside valve Regulate the pressure in overflow
load (or little load) but block is lower than required steering valve.
heavy as load is increased. pressure.
Overflow valve is seized by dirt, or Clean overflow valve, replace spring or
spring or oil seal failed. seal ring.
Vehicle travel is deflected, Failed two-way buffer valve (steel ball Clean two-way buffer valve, replace
or cylinder will not move (or is stuck by dirt or spring failed), failed spring or seal ring.
slowly) when turning wheel. seal ring.
P r e s s u r e c o u l d n o t b e Broken spring. Replace spring.
r e g u l a t e d ( i n c r e a s e o r Poor sealing at valve port causes valve Set the spool and seat, or replace part.
decrease). constant open.
Valve spool is stuck due to burr or oil Remove, inspect and repair.
stain.
Unstable pressure, with Poor contact between valve spool and Set the valve spool and seat, or
f r e q u e n t n o i s e a n d seat. replace part.
vibration. Poor spool motion. Check valve spool for being stuck by
dirt.
Bent or too weak spring. Replace spring.
Dirty oil, clogged damping hole Change fluid, clean damping hole
Flow exceeds specified value. Replace with a larger flow valve.
4-13
3. STEERING VALVE
850KSE14
1 Body 4 O-ring 7 Plug

2 Snap ring 5 Spring 8 Damping plug
3 Spool 6 Spring seat
4-14
1) OVERVIEW
The steering valve is used for full hydraulic steering gear to ensure a stable fluid flow for steering
gear in case fluid flow from the pump and load of hydraulic system fluctuate and to meet the
requirements for steering performance and stable steering. In addition to above features, this valve
also divert a current of hydraulic oil to other hydraulic devices and, consequently, the system can
delete an oil pump and simple design is also available.
2) STRUCTURE AND WORKING PRINCIPLE
The steering valve consists of valve body, a spool, a spring and a damping plug.
The steering valve just works in one-way and extra oil than supply for steering system and overflow
from safety valve all returns to oil tank through port T.
3) REQUIREMENTS IN USING
(1) Installation : The steering valve should be mounted such that the axis of valve spool is level as far
as possible.
(2) After setting pressure, do not loosen the safety valve. Adjusting washer/shim of safety valve
should not be altered as user wishes. When change of washer/shim is required for variation, test
must be performed on a test bed.
(3) Difference of pressure between before and after constant orifice is already set as delivery, and do
not alter the valve spool spring optionally. If change of difference of pressure is required, be sure
to make adjustment on a test bed for setting min. constant flow.
(4) Nominal flow of oil pump supporting the steering valve is 1~3 times of that of steering valve. To
secure normal operation of vehicle and steering system, the flow of oil pump as low speed
operation should not be less than nominal flow of the steering valve.
(5) Return piping of steering valve should be short as far as possible. Inside diameter of return piping
should be relatively large.
4-15
4) TROUBLESHOOTING

Decrease in nominal stable Volumetric efficiency of supporting Replace or repair pump.
flow is less than the flow pump has increased, or the pump
required for steering gear for delivers a flow less than nominal stable
60 turn/min flow as low speed operation.
Hydraulic oil is not clean. The spool of Clean the filter element and change
steering valve or safety valve is stuck hydraulic oil.
due to impurities.
Broken or deformed spool spring or Replace spring.
safety spring.
Improper spool clearance of steering Repair or replace.
valve and increased inside leaks.
Damaged seal ring at safety valve Replace seal ring.
seat.
Increase in nominal stable The spool of steering valve is stuck Clean the filter element and change
flow is more than the flow due to impurities. hydraulic oil.
required for steering gear for Poor compression of spool spring of Check condition of assembly.
100 turn/min steering valve.
Clogged damping hole of valve spool. Clean the filter element and change
hydraulic oil.
Pressure of safety valve is Improper setting of opening pressure Under stable nominal flow, regulate the
on the low side or too high of safety valve. pressure of safety valve. Add or
subtract pressure regulating washer/
shim.
Compression of safety valve spring is Check the spring the mounting size.
on the low side or over compressed.
Safety valve spool and seat are not in Replace part.

close contact.
Oil seeps & leaks Damaged O-ring Replace O-ring.
4-16
4. STEERING CYLINDER
25
6
7
24
3
23
5
4
2
1 21
22
15
14
1
9
8
15
26
13
30 27
16
29
12
11
28
10
830KSE15A
1 Dust seal 10 O-ring 23 Cylinder head

2 Rod wiper 11 Piston ring 24 Bushing
3 O-ring 12 Wear ring 25 Back up ring
4 Rod seal 13 Screw 27 Clamp
5 Buffer ring 14 Joint bearing 28 Piston
6 O-ring 15 Snap ring 29 Nut
7 Snap ring 16 O-ring 30 Tube assy
8 Washer 21 Rod assy
9 Nut 22 Bushing
4-17
GROUP 3 OPERATIONAL CHECKS AND TROUBLESHOOTING
This procedure is designed so the service man can make a quick check of the steering system using
a minimum amount of diagnostic equipment. If you need additional information, prefer to structure
and function in group 2.
A location will be required which is level and has adequate space to complete the checks.
The engine and all other major components must be at operating temperature for some checks.
Locate system check in the left column and read completely, following this sequence from left to right.
Read each check completely before performing.
At the end of each check, if no problem is found (OK), that check is complete or an additional check
is needed. If problem is indicated (NOT OK), you will be given repair required and group location.
If verification is needed, you will be given next best source of information :
Chapter 2 : Troubleshooting
Group 4 : Tests and adjustments
4-18
※Hydraulic oil must be at operating temperature for these checks.
Item Description Service action
Steering unit check Run engine at low idle. OK
Check completed.
Turn steering wheel until frames
A
are at maximum right (A) and NOT OK
B
then left (B) positions. Go to next check.
LOOK : Frames must move
smoothly in both directions.
When steering wheel is stopped,
frames must stop.
FEEL : Excessive effort must not
be required to turn steering
wheel.
NOTE : It is normal for steering
to drift from stops when steering
wheel is released.
Steering system leakage Turn steering wheel rapidly until OK
check Right frames are against stops. Check completed.
Heat hydraulic oil to oper- Left
Hold approximately 2kgf on NO NOT T OK
ating temperature.
steering wheel. Do steering system leak-
Run engine at high idle.
age test in group 3 to
Count steering wheel revolutions
isolate the leakage.
for 1 minute.
Repeat test in opposite direction.
LOOK : Steering wheel should
rotate less than 5rpm.
NOTE : Use good judgment;
Excessive steering wheel rpm
does not mean steering will be
affected.
4-19
2. TROUBLESHOOTING
※ Diagnose malfunction charts are arranged from most probable and simplest to verify, to least
likely, more difficult to verify. Remember the following steps when troubleshooting a problem :
Step 1. Operational check out procedure (see group 3 in section 1)
Step 2. Operational checks (in this group)
Step 3. Troubleshooting
Step 4. Tests and adjustments (see group 4)

No steering Low oil level. Add recommended oil.
Restricted suction line. Check.
Failed hydraulic pump. Remove and inspect return filter for
metal pump particles.
Stuck steering valve spool. Remove and inspect steering valve spool.
Relief valve in steering unit stuck open. Do relief cartridge leakage test.
Failed hydraulic lines. Check.
Slow or hard steering Too much friction in the mechanical Lubricate bearings and joints of frame
parts of the machine. or cylinders or repair if necessary.
Check steering column installation.
Cold oil. Warm the hydraulic oil.
Worn hydraulic pump. Do hydraulic pump performance check.
Low system relief valve setting. Test and adjust if necessary.
Low overload relief valves setting. Test and adjust if necessary.
4-20
Constant steer ing to Air in system. Check for foamy oil.
maintain straight travel
Leakage in steering system. Do steering system leakage check.
Worn steering unit. Do steering unit neutral leakage test in
group 4.
Spring without spring force or broken. Replace springs.
Spring in overload relief valve broken. Replace overload relief valve.
Gear wheel set worn. Replace gear wheel set.
Cylinder seized or piston seals worn. Replace defects parts.
S l ow s t e e r i n g w h e e l Leakage in steering system. Do steering system leakage check.
movement will not cause
Worn steering unit gerotor. Do steering unit leakage check.
any frame movement
Steering wheel can be Leakage in steering system. Do steering system leakage check.
turned with frames
against steering stop
Steer ing wheel tur ns Broken steering column or splined of Remove and inspect.
with no resistance and steering unit.
causes no frame
Lack of oil in steering unit. Star t engine and check steering
movement
operation.
Leakage in steering system. Do steering system leakage test in
group 4.
Erratic steering Air in oil. Check for foamy oil.
Low oil level. Add recommended oil.
Loose cylinder piston. Remove rod to inspect piston.
Damaged steering unit. Remove and inspect.
Spongy or soft steering Air in oil. Check for foamy oil.
Low oil level. Add recommended oil.
Free play at steering Loose steering wheel nut. Tighten.
wheel
Worn or damaged splines on steering Inspect.
column or valve.
Steering unit binding or B i n d i n g i n s t e e r i n g c o l u m n o r Inspect.
steering wheel does not misalignment of column.
immediately return to
High return pressure. Check for a pinched or damaged return
neutral when released
line.
Contamination in steering unit. Inspect hydraulic filter for contamination.
Repair cause of contamination. Flush
hydraulic system.
4-21
Steering unit locks up Large particles of contamination in Inspect hydraulic filter for contamination.
steering unit. Repair cause of contamination. Flush
hydraulic system.
Worn or damaged steering unit. Repair or replace steering unit.
Abrupt steering wheel Improperly timed gerotor gear in steering Time gerotor gear.
oscillation unit.
Steering wheel turns by Lines connected to wrong port. Reconnect lines.
itself
Worn or damaged steering unit. Repair or replace steering unit.
Neutral position of Steering column and steering unit out of Align the steering column with steering
steering wheel cannot line. unit.
be obtained, i.e. there
Too little or no play between steering Adjust the play and, if necessary,
is a tendency towards
column and steering unit input shaft. shorten
"motoring"
the splines journal.
Pinching between inner and outer
spools. Contact the nearest service shop.
"Motoring" effect. Leaf springs are stuck or broken and Replace leaf springs.
The steering wheel can have therefore reduced spring force.
turn on its own
Inner and outer spools pinch, possibly Clean steering unit or contact the
due to dirt. nearest service shop.
Return pressure in connection with the Reduce return pressure.
reaction between differential cylinder
and steering unit too high.
Backlash Cardan shaft fork worn or broken. Replace cardan shaft.
Springs without spring force or broken. Replace springs.
Worn splines on the steering column. Replace steering column.
4-22
"Shimmy" effect Air in the steering cylinder. Bleed cylinder.
The steered wheels Find and remove the reason for air
vibrate collection.
(Rough tread on tires
Mechanical connections or wheel Replace worn parts.
gives vibrations.)
bearings worn.
Steering wheel can be Oil is needed in the tank. Fill with clean oil and bleed the system.
turned the whole time
Steering cylinder worn. Replace or repair cylinder.
without the steered
wheels moving Gear wheel set worn. Replace gear wheel set.
Spacer across cardan shaft forgotten. Install spacer.
Steering wheel can be One or both anticavitation valves are Clean or replace defect or missing
turned slowly in one or leaky or are missing in overload relief valves.
both directions without the valves.
steered wheels turning
One or both overload relief valves are Clean or replace.
leaky.
Steering is too slow and Insufficient oil supply to steering unit, Replace pump or increase number of
heavy when trying to turn pump defective or number of revolutions revolutions.
quickly too low.
Relief valve setting too low. Adjust valve to correct setting.
Relief valve sticking owing to dirt. Clean the valve.
"Kick back" in steering Fault in the system. Contact authorized man or shop.
wheel from system
Kicks from wheels
H e a v y k i c k - b a c k i n Wrong setting of cardan shaft and gear- Correct setting.
steering wheel in both wheel set.
directions
Turning the steering wheel Hydraulic hoses for the steering Connect lines to correct ports.
activates the steered cylinders have been switched around.
wheels opposite
Hard point when starting Oil is too thick (cold). Let machine run until oil is warm.
to turn the steering wheel
Too little steering force Pump pressure too low. Correct pump pressure.
4-23
GROUP 4 TESTS AND ADJUSTMENTS
1. HYDRAULIC OIL CLEAN UP PROCEDURE USING PORTABLE FILTER CADDY

※ Service equipment and tool.
·Portable filter caddy
·Two 3658 mm (12 ft) × 1" I.D. 100R1
hoses with 3/4 M NPT ends
·Quick disconnect fittings
·Discharge wand
·Various size fittings and hoses
※ Steering system uses oil from hydraulic
oil tank. Flush all lines in the steering
system.
Disassemble and clean major compon-
ents for steering system.
Steering components may fail if steering
system is not cleaned after hydraulic oil
tank contamination.
1) If hydraulic system is contaminated due to a
major component failure, remove and dis-
assemble steering cylinders to clean debris
from cylinders.
2) 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.
3) To minimize oil loss, pull a vacuum in
hydraulic oil tank using a vacuum pump.
Connect filter caddy suction line to drain
port at bottom of hydraulic oil tank using
connector. Check to be sure debris has not
closed drain port.
4) Put filter caddy discharge line into hydraulic
oil tank filter hole so end is as far away from
drain port as possible to obtain a through
cleaning of oil.
4-24
5) Start the filter caddy. Check to be sure oil
is flowing through the filters.
Operate filter caddy approximately 10 min-
utes so oil in hydraulic oil tank is circulated
through filter a minimum of four times.
※ Hydraulic oil tank capacity 95ℓ(25.0 U.S.
gal).
Leave filter caddy operating for the next
steps.
6) Start the engine and run it at high idle.
※ For the most effective results, cleaning
procedure must start with the smallest
capacity circuit then proceed to the next
largest capacity circuit.
7) Operate all functions, one at a time, through
a complete cycle in the following order:
clam, steering, bucket, and boom. Also
include all auxiliary hydraulic functions.
Repeat procedure until the total system
capacity has circulated through filter caddy
seven times, approximately 30 minutes.
Each function must go through a minimum
of three complete cycles for a through
cleaning for oil.
※ Filtering time for machines with auxiliary
hydraulic functions must be increased
because system capacity is larger.
8) Stop the engine. Remove the filter caddy.
9) Install a new return filter element.
10) Check oil level in hydraulic oil tank ; Add oil
if necessary.
4-25
2. TEST TOOLS
1) CLAMP-ON ELECTRONIC TACHOMET-
ER INSTALLATION
· Service equipment and tools
Tachometer B
A : Clamp on tachometer.
Remove paint using emery cloth and
connect to a straight section of injec- C
tion line within 100 mm (4in) of pump.
Finger tighten only-do not over tighten.
D
B : Black clip (-). Connect to main
frame. A
C : Red clip (+). Connect to transducer.
D : Tachometer readout. Install cable.
75795SE32
2) DIGITAL THERMOMETER INSTALLATION

· Service equipment and tools
Digital thermometer
A : Temperature probe.
Fasten to a bare metal line using a A
C
tie band. Wrap with shop towel.
B
B : Cable.
C : Digital thermometer.
75795SE33
4-26
3. STEERING SYSTEM RESTRICTION TEST
· SPECIFICATION
Oil temperature 45±5˚C (113±9˚F)
Engine speed High idle
Maximum pressure 3.0MPa (30 bar, 430psi)
at steering unit
· GAUGE AND TOOL
Gauge 0~7 MPa (0~70 bar, 0~1000 psi) 2EA
· This test will check for restrictions in the
steering system which can cause overheat-
ing of hydraulic oil.
1) Install temperature reader.
(see temperature reader installation proce-
dure in this group).
P
2) Heat hydraulic oil to specifications.

(see hydraulic oil warm up procedure at
A
page 5-33).
3) Connect fitting (A) and install gauge.
Do not operate steering or loader funct-
ions or test gauge may be damaged.
4) Run engine at specification and read pres-
sure gauges.
If pressure is more than specification at the
steering unit, inspect steering unit.
850KSE37
4-27
4. STEERING UNIT LEAKAGE TEST
· SPECIFICATION
Maximum leakage 15ℓ/min (4 gpm)
· GAUGE AND TOOL Cap fitting
Temperature reader
Measuring container (approx. 20ℓ) T
L
Stop watch R
1) Install frame locking bar to prevent machine

from turning.
(see temperature reader installation proce-
dure in this group).
(see hydraulic oil warm up procedure at
page 5-33).
4) Disconnect return hose from fitting.
Install cap fitting.
5) Run engine at specifications. Rotate steer-
ing wheel against locking bar using approxi-
mately 1.2 kgf·m of force.
Measure oil flow from return hose for 1 min-
ute.
Safety lock bar
6) Leakage is greater than specifications,
repair or replace steering unit.
830KSE38
4-28
5. STEERING UNIT PRESSURE TEST
· SPECIFICATION
Oil pressure 16 MPa
(160 bar, 1160 psi)
· GAUGE AND TOOL
Gauge 0~35 MPa (0~350 bar, 0~5000 psi)
Temperature reader
1) Connect gauge to test port.
2) Install temperature reader (see installation
procedure in this group). Test port
3) Install frame locking bar.

Steering cylinder
4) Heat hydraulic oil to specifications (see
hydraulic oil warm up procedure at page Relief valve
5-33).
5) Run engine at specifications and turn steer-
A
ing wheel rapidly hold approximately 22N B
(5lb 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.
6) Read pressure gauge. This is the steering
valve relief pressure.
7) If pressure in not to specification, remove Safety lock bar
the plug (A) from steering unit. Turn adjust-

ing screw (B) in relief cartridge using a hex
head wrench to adjust pressure.
If pressure cannot be adjusted to specifica-
tion, disassemble and inspect steering unit. 830KSE39
4-29
Group 1 Hydraulic circuit --------------------------------------------------------------------------------------------------- 5-1

Group 2 Structure and function ---------------------------------------------------------------------------------------- 5-8
Group 3 Operational checks and troubleshooting ---------------------------------------------------------- 5-21
Group 4 Test and adjustments ------------------------------------------------------------------------------------------ 5-31
GROUP 1 HYDRAULIC CIRCUIT
1. HYDRAULIC CIRCUIT
3 4
5
L R
7
2
B2
A2
Boom
B1
A1
P T
Bucket
B
6
T
P T
1
T/C
10
11
8
9
830K3HC01E
1 Main pump 5 Steering cylinder 9 Bypass valve

2 Main control valve 6 Steering valve 10 Air breather
3 Boom cylinder 7 Steering unit 11 Hydraulic tank
4 Bucket cylinder 8 Return filter
5-1
2. WORK EQUIPMENT HYDRAULIC CIRCUIT
3 4
B2
A2
Boom
B1
A1
Bucket
P T
1 Steering system
T/C
10
11
8
9
830K3HC02E
1 Main pump 8 Return filter

2 Main control valve 9 Bypass valve
3 Boom cylinder 10 Air breather
4 Bucket cylinder 11 Hydraulic tank
5-2
1) WHEN THE BOOM CONTROL LEVER IS IN THE RAISE POSITION
3 4
B2
Boom A2
B1
Bucket
A1
P T
1 Steering system
T/C
10
11
8
9
830K3HC21
· When the boom control lever is pulled back, the boom spool is moved to raise position.
· The oil from main pump (1) flows into main control valve (2) and then goes to the large chamber of
boom cylinder (3).
· The oil from the small chamber of boom cylinder (3) returns to hydraulic oil tank (11) through the
boom spool at the same time.
· When this happens, the boom goes up.
5-3
2) WHEN THE BOOM CONTROL LEVER IS IN THE LOWER POSITION
3 4
B2
Boom A2
B1
Bucket
A1
P T
1 Steering system
T/C
10
11
8
9
830K3HC22
· When the boom control lever is pushed forward, the boom spool is moved to lower position.
· The oil from main pump (1) flows into main control valve (2) and then goes to small chamber of
boom cylinder (3).
· The oil returned from large chamber of boom cylinder (3) returns to hydraulic tank (11) through the
boom spool at the same time.
5-4
3) WHEN THE BOOM CONTROL LEVER IS IN THE FLOAT POSITION
3 4
B2
A2
Boom
B1
Bucket
A1
P T
1 Steering system
T/C
10
11
8
9
830K3HC23
· When the boom control lever is pushed further forward from the lower position, then the boom
spool is moved to floating position.
· The work ports (A2), (B2) and the small chamber and the large chamber are connected to the
return passage, so the boom will be lowered due to it's own weight.
· In this condition, when the bucket is in contact with the ground, it can be move up and down in
accordance with the shape of the ground.
5-5
4) WHEN THE BUCKET CONTROL LEVER IS IN THE DUMP POSITION
3 4
B2
Boom A2
B1
Bucket
A1
P T
1 Steering system
T/C
10
11
8
9
830K3HC24
· If the bucket control lever is pushed forward, the bucket spool is moved to dump position.
· The oil from main pump (1) flows into main control valve (2) and then goes to the small chamber of
bucket cylinder (4).
· The oil at the large chamber of bucket cylinder (4) returns to hydraulic tank (11).
· When this happens, the bucket is dumped.
5-6
5) WHEN THE BUCKET CONTROL LEVER IS IN THE ROLL BACK ((retract
retract)) POSITION
3 4
B2
Boom A2
B1
Bucket
A1
P T
1 Steering system
T/C
10
11
8
9
830K3HC25
· If the bucket control lever is pulled back, the bucket spool is moved to roll back position.
· The oil from main pump (1) flows into main control valve (2) and then goes to the large chamber of
bucket cylinder.
· The oil at the chamber of bucket cylinder (4) returns to hydraulic tank (11).
· When this happens, the bucket roll back.
5-7
1. MAIN PUMP
1) STRUCTURE
LOADER PUMP
14
13
12
10 11
9
7 8
6
5
4
3
1 2
24
23
21 22
19 20
18
17
16
15
STEERING PUMP
830KSE15E
1 Snap ring 9 Side plate 17 Pump body

2 Oil seal 10 Drive gear 18 Rear cover
3 Front cover 11 Driven gear 19 Decal
4 Snap ring 12 Seal 20 Rivet
5 Bearing 13 Seal 21 Washer
6 Bushing 14 Middle body 22 Bolt
7 Seal 15 Seal 23 Seal
8 Seal 16 Shaft 24 Bolt
5-8
2) MOUNTING REQUIREMENTS FOR GEAR PUMP
(1) Before mounting the gear pump, check its normal rotating direction and for being suitable to
whole system.
(2) Entry of gear pump should keep clean and no pollution. Interfacing surface of entry and discharge
should not be damaged and good sealing with O-ring seal should be guaranteed.
(3) Check if the depth of mounting hole for gear pump is longer than the length of the shaft of pump
so to prevent potential impact to the shaft and gear pump from burning out. Key shaft should be
assembled normally.
3) NOTES IN USING
(1) It’s strictly prohibited for user to disassemble the product, or the manufacturer will not guarantee
the performance of product.
(2) Viscosity of oil is dependant to temperature. When oil temperature increases, its viscosity
decreases. Therefore, oil temperature should be maintained under 80˚C. To secure the gear pump
working normally under different operating temperature, selected oil should feature little change
by variation of temperature, and have good chemical durability and foam resistance. Use of ISO
VG46 (ISO VG32, ISO VG68) anti-wear hydraulic oil is recommended.
(3) No impurities from machine and corrosive substance should be in oil. There should be filtering
devices with a precision of 25 µm in the system where the gear pump is working for.
(4) For transmission of gear pump, the manners that may produce radial force to pump (such as
direct geared and pulley transmission) are not permitted. Shaft bushing or elastic coupling can be
used. Requirements for concentricity: not more than 0.05 mm for shaft bushing type, no more than
0.1 mm for coupling type. Axial force is not permitted.
(5) The entry and discharge of gear pump should be assembled securely and sealing be reliable. Or
air may be included and oil leaks caused to lower the performance of gear pump.
(6) Max. pressure and max. rate of gear pump means momentary peak values permitted during
operation. Long time of continued use of gear pump may shorten its life span.
(7) Check if the depth of mounting hole for gear pump is longer than the length of the shaft of pump
so to prevent potential impact to the shaft and gear pump from burning out.
(8) Before mounting the gear pump, check the rotating direction of pump meets requirement.
5-9
4) TROUBLESHOOTING

Noise in pump Air in system. Fasten up all the connectors.
Insufficient oil supply. Refill oil to an adequate level.
Cold oil. Run slowly.
Contaminated suction filter. Clean or replace the filter.
Too thin suction pipe. Use a larger pipe.
Suction pipe is clogged. Remove the obstruction.
Clogged air filter in oil tank. Clean or replace the air filter.
Poor concentricity of pump and Inspect.
input shaft.
Severe resonance with tank, Check piping, elements and bolts for
peripheral parts of piping. being securely fastened.
Pump lags in response or no Insufficient oil supply. Refill oil to an adequate level.
response Improper pressure setting of Regulate the pressure of relief valve.
relief valve.
Worn or damaged pump. Repair or replace.
Worn, leaking or stuck valve. Repair or replace.
High oil temperature Too low pressure setting at Regulate pressure of overflow valve.
overflow valve.
Too low viscosity of hydraulic oil. Use recommended hydraulic oil.
Too low oil level. Refill oil to an adequate level.
Small tank. Add an oil cooler or replace with larger
tank.
Worn or damaged pump. Repair or replace.
Foam forms in oil Air has entered into oil tank Fasten up all the connectors.
through suction pipe.
Incorrect selection of oil. Use recommended oil.
Too low oil level. Refill oil to an adequate level.
Worn or damaged lip seal for Replace the lip seal for main shaft.
main shaft.
5-10
Insufficient
nsufficient flow of pump or Damaged side plate. Replace side plate.
pressure
Air has entered into the system. Fasten up all the connectors.
Too high viscosity of oil. Use recommended oil.
Leaks occur even after replacing Contaminated oil. Change all the oil.
lip seal for main shaft Damaged lip seal for main shaft Replace drive gear shaft.
has damaged the sealing area of
drive gear.
Worn or damaged seal ring. Replace seal ring.
5) NOTICE IN PLACING ORDER
TURN RIGHT TURN LEFT

(CLOCKWISE) (COUNTER CLOCKWISE)
850K3HC52
5-11
2. MAIN CONTROL VALVE
1) STRUCTURE
16 17 18 19 20
15
14
13
12
11
10
9
8
7 21
6
5 22
4
3 23
2
1
24
25
26
27 15 14 12
29 28 13
34 33 32 31 30
830KSE17E
1 Bolt 14 Spring 27 O-ring kit

2 End cover 15 Poppet 28 Plug
3 Stopper 16 Plug 29 Body
4 Spring retainer 17 O-ring kit 30 Spool
5 Spring 18 Spring 31 Spacer
6 Spring retainer 19 Poppet 32 Spring
7 Spacer 20 Bolt 33 Ball
8 O-ring kit 21 Dust seal 34 Spool positioner
9 Spool 22 End cap 35 Washer
10 Relief valve 23 O-ring kit 36 Ring
11 Overload valve 24 Pin 37 Snap ring
12 Plug 25 Plug
13 O-ring 26 O-ring
5-12
SAFETY RELIEF VALVE
20 2 21 22 3 23 4 24 5 6 25
19 18 17 16 15 14 13 12 1 11
850KSE18
1 Seal 12 Back up seal 19 Adjust screw

2 Lock nut 13 Spring seat 20 Cap
3 Seal 14 Spring seat 21 Body
4 O-ring 15 Poppet 22 Washer
5 Seal 16 Spring 23 Spring seat
6 Seal 17 Housing 24 Spring seat
11 Seat 18 Nut 25 Spring
5-13
2) OVERVIEW
Multi-way directional valve is of integrated slide valve structure which includes 2 spools valve
(bucket and boom spool) and triple multi-way valve (service spool, bucket spool, boom spool). Oil
ways include parallel and series connection. Multi-way valve has also various service valves
(overflow valve, overload valve, makeup valve) attached. As a hydraulic device for main equipment
of large and medium loader, the valve features compact structure, reliable functions, high
performance, good sealing, and convenient repair.
3) MODEL IDENTIFICATION
DFS - XX -XX
Product code
Inner diameter
Series code
4) TECHNICAL DATA
Item Unit Specification

Nominated flow ℓ/min 160
Nominated pressure MPa 16
Pressure regulating range MPa 8 ~ 20
Center MPa <0.3
Pressure loss
Direction change MPa <0.6
Pressure regulating range of overload valve MPa 8 ~ 25
5-14
5) STRUCTURE AND WORKING PRINCIPLE
(1) Structure
Retract (roll back)

Neutral
Dump
Bucket
Boom
Float
Lower
Neutral
Lift
850K3HC51
(2) Working Principle
B2
A2
Boom
B1
A1
Bucket
P T
Hydraulic circuit
830K3HC50
The Multi-way directional valve has boom control lever and bucket control lever. The bucket lever
has three positions, i.e. neutral, roll back and dump. Boom lever has four positions, i.e., hold, raise,
lower and float. Port P is flow inlet, T is flow return port and port A1 and B1 are connected to large
and small chamber bucket cylinder respectively, and port A2 and B2 are to large and small
chamber of boom cylinder.
5-15
① Neutral position
When bucket control lever and boom control lever are in neutral positions, the flow from pump
returns from inlet port P to tank through middle oil way.
② Bucket roll back and dump
When bucket control lever is shifted to back, the flow from pump opens one-way valve, and is
directed to A1 cavity, then to large chamber of bucket cylinder to make the bucket roll back, while
the flow in small cavity returns through cavity B1. Similarly, when bucket lever is shifted to
forward, the flow from pump opens one-way valve, and is directed to cavity B1, then to small
chamber of bucket cylinder to make the bucket dump, while flow in large chamber return through
cavity A1.
③ Float of Boom
When the boom control lever is shifted to back, the flow from pump opens one-way valve, and is
directed to cavity A2, then to large chamber of boom cylinder to make the boom to raise, while
the flow in small chamber returns through cavity B2. Likewise, when the boom control lever is
shifted to forward, the flow from pump opens one-way valve, and is directed to cavity B2, then to
small chamber of boom cylinder to make the boom to lower, while the flow in large chamber
returns through cavity A2. When the control lever of boom is in lower, move it further to forward to
get in float position. At the time, all of inlet port P and large and small chambers of cylinder are
connected to return way, and become under low pressure, and the cylinder is floating by the
weight of working equipment and bearing force of ground.
④ Function of main relief valve, overload valve and makeup valve
Main relief valve controls pressure in system. When pressure in system exceeds rated pressure,
the main relief valve opens and the flow returns to tank to protect the hydraulic system against
over pressure. When the bucket receives external impact or is interfered with by other
mechanism, overload valve opens for safety. Makeup valve functions to make up oil for cylinder
to prevent a chamber to be evacuated.
6) MOUNTING AND AND USING
(1) When transporting, mounting, and storing the product, be careful that the product does not
receive impacts that may damage the machined surface or flange face.
(2) Never disassemble the product in dust before assembling to machine to prevent dust from
entering.
(3) Check that rated pressure, sliding function, oil-way type and other features conform to system
requirements.
(4) Mounting plate should be level, mounting screws fastened in even torque, and the valves should
be in good alignment.
(5) Operating fluid should be clean, cleanliness meeting NAS 1638 10 grade and up.
(6) Allowable oil temperature range: -20 ~ 80˚C, normal oil temperature 50±5˚C.
(7) Connect each port correctly and piping shall not be too thin, too long.
(8) Our company offers three-guarantees to the product for one year from delivery for any
malfunctions resulted from problem in workmanship in case the user would have observed the
provisions given with regard to storage, use, installation and transportation.
5-16
7) TROUBLESHOOTING
No. Problem Cause Remedy
Insufficient operating 1. Pressure of main relief valve is on 1. Regulate pressure of main relief
pressure low side. valve.
2. Spool of main relief valve is stuck. 2. Remove and clean, or replace

valve spool.
1 3. Damaged pressure regulating 3. Replace with new product.
spring.
4. Too much pressure loss in system 4. Replace piping, or regulate

line. pressure of main relief valve within
the allowable range of pressure.
Insufficient operating 1. Oil supply to system is insufficient. Check oil source and repair oil pump.
flow 2. Too much leaks inside valve.
a. Too high oil temperature, low a. Take measures to reduce oil
viscosity temperature.
2 b. Improper hydraulic oil. b. Change hydraulic oil.
c. Too much clearance between c. Replace slide valve to keep a
slide valve and valve body. reasonable clearing.
3. Main relief valve failure. 3. Repair or replace the main relief
Malfunction in return. 1. Damaged or deformed return 1. Replace with new product.

spring.
3
2. Dirt between valve lever and valve 2. Clean part.
body.
External seeps and 1. Damaged seal ring. 1. Replace with new product.
leaks 2. Loose fastening pieces. 2. Fasten related fastening piece.
3. Too high oil temperature, low 3. Takes measures to reduce oil
4
viscosity temperature.
4. Poor sealing on flange surface. 4. Check fastening and sealing of

related parts.
5-17
8) NOTES IN DISASSEMBLY
(1) Keep clean field for assembly. Dust and dirt shall be strictly prevented.
(2) Never clean rubber sealing pieces with gasoline.
(3) To prevent from damage to part, never knock a part with an iron object when disassembling.
(4) Be sure to clean all the parts with kerosene or cleaner before assembling.
(5) After assembling, be sure to perform test and only passed product can be used.
5-18
3. BOOM CYLINDER
6
28
8
7
8
29
9
10 30
12
11
13
31
25
13
27
21
10
26
27
14
12
11
1
2
3
22
4
23
16 24
15
5
830KWE20
1 Rod wiper 10 O-ring 23 Back up ring

2 Rod seal 11 Hexagon screw 24 Bushing
3 Buffer ring 12 Washer 25 Pipe assy - R
4 O-ring 13 Dust seal 26 Clamp
5 Snap ring 14 Bolt 27 Pipe assy - B
6 O-ring 15 Washer 28 Piston
7 Piston ring 16 Hexagon screw 29 Nut
8 Wear ring 21 Rod assy 30 Tube assy
9 Screw 22 Cylinder head 31 Bushing
5-19
4. BUCKET CYLINDER
17
31
17
21
1
2
3
12
13
22
4
24
25
7
5
28
29
8
29 10
11
30 26
6
14
15 16
9
14 23
15
34
10 17
33
11 32 31
27
6
17
830KWE21
1 Rod wiper 12 Hexagon screw 26 Rod pipe assy

2 Rod seal 13 Washer 27 Base pipe assy
3 Buffer ring 14 Nut 28 Piston
4 O-ring 15 Washer 29 Wear ring
5 Snap ring 16 Bolt 30 Nut
6 O-ring 17 Dust seal 31 Bushing
7 O-ring 21 Rod assy 32 Pipe band
8 Piston ring 22 Cylinder head 33 Clamp
9 Screw 23 Tube assy 34 Pipe band
10 Hexagon screw 24 Back up ring
11 Washer 25 Bushing
5-20
GROUP 3 OPERATIONAL CHECKS AND TROUBLESHOOTING
1. OPERATIONAL CHECKS
This procedure is designed so the mechanic can make a quick check of the system using a minimum
amount of diagnostic equipment. If you need additional information, read structure and function,
Group 2.
A location will be required which is level and has adequate space to complete the checks.
The engine and all other major components must be at operating temperature for some checks.
Locate system check in the left column and read completely, following the sequence from left to right.
Read each check completely before performing.
At the end of each check, if no problem is found (OK), that check is complete or an additional check is
needed. If problem is indicated (NOT OK), you will be given repair required and group location.
If verification is needed, you will be given next best source of information:
·Chapter 2 : Troubleshooting
·Group 4 : Tests and adjustments
5-21
※ Hydraulic oil must be at operating temperature for these checks.

Hydraulic system warm-up Hold a hydraulic function over OK
procedure relief to heat oil (don't keep relief Check completed.
condition over 5 seconds at a
time).
Refer to page 5-33.
Periodically cycle all hydraulic
functions to distribute warm oil.
Repeat procedure until oil is at
operating temperature.
FEEL : Hydraulic reservoir must
be uncomfortable to hold your
hand against.
(approximately 40 ~50˚C)
Hydraulic pump With bucket flat on ground, OK
performance check actuate boom raise. Time how Check completed.
long it takes to raise boom to full
Heat hydraulic oil to NOT OK
height.
operating temperature. C h e ck t h e hy d r a u l i c
Run engine at high idle. LOOK : Boom must raise to full pump.
height in less than 6~7 seconds.
IF OK
Do steering system
leakage check at page
4-24.
IF OK
Do main hydraulic pump
flow test at page 5-34.
Control valve lift check With bucket partially dumped, OK
Run machine at low idle. lower boom to raise front of Check complete.
machine.
NOT OK
Slowly move boom control lever Repair lift checks in
to boom lower position. loader control valve.
Slowly move bucket control lever
to bucket dump position.
LOOK : Boom must not raise
before moving down.
Bucket must not rollback before
dumping.
5-22
Bucket rollback circuit relief Position bucket at a 45˚ angle OK
valve check against an immovable object. Check complete.
Engage transmission in 2nd NOT OK
speed forward. Replace boom lower
check valve.
LOOK : Bucket angle must not
change.
Bucket dump circuit relief Raise front of machine which OK
valve low pressure check bucket at 45˚ angle. Go to next check.
Backdrag with bucket while NOT OK
observing bucket angle. Do loader system and
circuit relief valve test at
LOOK : Bucket must not rollback
page 5-36.
Boom cylinder and bucket S e t t h e b o o m a n d bu cke t OK
cylinder drift check horizontal, then stop the engine. Check complete.
H e a t hy d r a u l i c o i l t o Stop the engine, wait for 5 NOT OK
operating temperature. minutes, then start measuring. Go to next check.
B
Measure the amount the lift and
dump cylinder rods retract during
A
15 minutes. (unloaded bucket)
A : Retraction of boom cylinder
rod
B : Retraction of bucket cylinder
rod
B Boom cylinder must drift less
than 36 mm
A Bucket cylinder must drift less
than 33 mm
5-23
Boom cylinder leakage Dump bucket until teeth or cutting OK
check edge is perpendicular to the Drift is approximately the
ground. same between first and
H e a t hy d r a u l i c o i l t o
second measurement.
operating temperature. Raise boom until cutting edge is
about 1 m (3 ft) above ground.
Repair loader control
Stop engine. Measure drift from valve or circuit relief valve.
tooth or cutting edge to ground
for 1 minute. NOT OK
If drift is considerably less
Wait 10 minutes.
on second measurement,
Measure drift from tooth or repair cylinder.
cutting edge to ground for 1
minute.
LOOK : Compare the drift rate
between the first measurement
and the second measurement.
Bucket cylinder leakage Raise bucket about 1 m (3 ft) off OK
check ground with bucket level. Drift is approximately the
same between first and
H e a t hy d r a u l i c o i l t o Stop engine. Place a support
second measurement.
operating temperature. under boom.
Measure drift from tooth or Repair loader control
cutting edge to ground for 1 valve or circuit relief valve
minute. at page 5-36.
Wait 10 minutes.
NOT OK
Measure drift from tooth or Drift is considerably less
cutting edge to ground for 1 on second measurement.
minute.
Repair cylinder.
LOOK : Compare the drift rates
between the first measurement
and the second measurement.
Check valve of safety valve Put bucket level and position OK
leakage check about 1.2 m (4 ft) above ground. Check complete.
H e a t hy d r a u l i c o i l t o Place a piece of tape on cylinder
NOT OK
operating temperature. rod at least 51 mm (2 in) from rod
Check or replace safety
guide.
valve.
Run engine at low idle in safety-
release position.
LOOK : Bucket must not drift up.
Control lever check Stop engine. Turn key switch to OK
OFF position. Check completed.
Move bucket control lever to roll
NOT OK
back, dump positions and then
Repair bucket control
release.
lever.
LOOK : Lever must return to
neutral when released from roll
back, dump positions.
5-24
Cycle time check Function Operating condition. Maximum cycle time
H e a t hy d r a u l i c o i l t o Boom raise Bucket flat on ground to full 5.1 sec
operating temperature. height.
Boom lower Full height to level ground. 3.0 sec
Bucket dump Boom at full height. 1.1 sec
Bucket rollback Boom at full height. 1.5 sec
Steering [No. of Frame stop to frame stop. 6.1 turns
turns]
OK
Check complete.
NOT OK
Go to slow hydraulic
functions in group 3.
5-25
※ MEASURING BOOM AND BUCKET CYCLE TIME
1) MEASUREMENT CONDITION
·Coolant temperature : Inside operating range
·Steering position : Neutral
·Hydraulic temperature : 40~50˚C
·Bucket : Unloaded
·Engine speed : High idling
2) MEASU
MEASURING
RING TOOL
· Stop watch (1EA)
3) MEASURIN
MEASURING G PROCEDURE
(1) Lifting time of boom Lifting time of boom
Set the bucket near the maximum tilt back
position and at the lowest position on the
ground. Raise the bucket and measure
the time taken for bucket to reach the
maximum height of the boom.
830KWE35
(2) Lowering time of boom

Set the bucket horizontal with the boom at Lowering time of boom
the maximum height, lower the bucket
and measure the taken for the bucket to
reach the lowest position on the ground.
830KWE36
(3) Dumping time of bucket

Raise the boom to the maximum height Dumping time of bucket
Rollback time of bucket
and measure the time taken for the bucket
to move from the maximum tilt back
position to the maximum dump position
(4) Roll back time of bucket
Raise the boom to the maximum height
and measure the time taken for the bucket
to reach the maximum tilt back position. 830KWE37
5-26
2. TROUBLESHOOTING
※ Diagnose malfunction charts are arranged from most probable and simplest to verify, to least likely,
more difficult to verify. Remember the following steps when troubleshooting a problem :
Step 1. Operational check out procedure (see section 1)

Step 2. Operational checks (see group 3)
Step 3. Troubleshooting
Step 4. Tests and adjustments (see group 4)

Noisy hydraulic pump Low oil supply or wrong viscosity. Fill reservoir with recommended oil.
Plugged or pinched suction line. Clean or replace line.
Air in oil. Check for foamy oil.
Tighten connections.
Replace O-rings and or lines.
Plugged suction line. Inspect and clean suction line.
Loose or missing hydraulic line clamps. Tighten or replace clamps.
Hydraulic lines in contract with frame. Inspect and repair.
Worn or damaged pump. Do hydraulic pump performance check
in group 3. Do hydraulic pump flow test
in group 4.
No or Slow hydraulic Failed or worn hydrualic pump. Do performance check.
functions
Cold oil. Warm oil up.
Slow engine speed. Adjust engine speed.
Check high idle speed.
Suction line air leak. Check for foamy oil.
Low oil supply. Add recommended oil.
Wrong oil viscosity. Use recommended oil.
Oil leaking past cylinders or control Check cylinder drift in group 3.
valve.
Blocked or damaged line. Inspect lines.
Binding loader control valve (MCV) Inspect valve.

spool.
5-27
No steering or hydraulic Low oil level. Add recommended oil.
function
Failed hydraulic pump. Remove and inspect return filter for
metal pump particles.
No hydraulic functions Failed hydraulic pump. Remove and inspect return filter for
steering normal metal pump particles, or replace the
pump.
Stuck open port relief valve. Replace relief valve.
Boom float function Loader control valve (MCV) spool Do pressure reducing valve pressure
does not work binding in bore. test.
One hydraulic function Stuck open port relief valve. Replace relief valve.
does not work.
Oil leaking past cylinder packings. Do boom and bucket cylinder leakage
test in group 4.
Inspect lines for damage.
Blockage in oil lines or valve.
Disconnect and inspect lines for internal
blockage.
Loader control valve (MCV) spool stuck Inspect and repair valve.
in bore.
Low hydraulic power Leakage within work circuit. Do cylinder drift check in group 3.
Low system relief valve (main relief Do loader system and port relief valve
valve) setting. pressure test in group 4.
Low port relief valve setting. Do loader system and port relief valve
pressure test in group 4.
Leaking system relief valve. Remove and inspect valve.

Worn hydraulic pump. Do hydraulic pump performance check
in group 3.
5-28
Function drifts down Leaking cylinders. Do cylinder leakage checks in group 4.
Leaking seals in circuit relief valve (port Inspect seals. Replace relief valve.
relief valve) or valve stuck open.
Leaking loader control valve (MCV). Repair or replace valve section.
Boom drifts up Leakage in boom down spool. Remove and inspect boom down spool.
Boom down does not MCV spool stuck. Inspect and repair valve.
work (engine off)
Oil overheats Low oil viscosity in hot weather. Use recommended oil.
Excessive load. Reduce load.
Holding hydraulic system over relief. Reduce load.
Leakage in work circuit. Do boom and bucket cylinder leakage
test in group 4.
Plugged fins in oil cooler. Inspect and clean oil cooler.
Internally plugged oil cooler. Do hydraulic oil cooler restriction test.
Incorrect system or circuit relief valve Do loader system and circuit relief valve
setting. pressure test in group 4.
Restriction in oil lines or loader control Inspect for dented or kinked lines.
valve (MCV).
Malfunctioning steering unit. Do hydraulic system restriction test in
group 4.
Leaking system main relief valve. Do hydraulic system restriction test in
group 4.
Remove and inspect valve and seals.
Worn hydraulic pump (internal leakage). Do hydraulic pump performance check
in group 3.
Hydraulic oil foams Low oil level. Add recommended oil.
Wrong oil. Change to recommended oil.
Water in oil. Change oil.
Loose or faulty suction lines (air leak in Tighten or install new lines.
system).
5-29
※ Followings are general precautions for the hydraulic system and equipment.
1) Every structure has its limit of strength and durability. The relief valve is installed to limit the
pressure on the hydraulic equipment and protect various parts of the wheel loader from possible
damage. Therefore, never change the preset pressure of the relief valve unless absolutely
necessary.
2) Since the hydraulic equipment is built with precision, the presence of only the slightest amount of
dust and / or other particles in the hydraulic circuit might cause wear and/or damage, resulting in
unstable functions and/or damage, resulting in unstable functions and/or unexpected accidents.
Therefore, always keep hydraulic oil clean. Periodically, check the filter in the return circuit and
replace the element as necessary.
3) Extract about 200cc of hydraulic oil from the tank as a sample every 6 months. If possible, have it
analyzed by a specialist to confirm that the oil can still be used. Never extract the oil for sampling
until the oil temperature has become the normal operating temperature. Since the replacement
period varies depending on operating conditions, refer to Operator's Manual and change oil.
4) Should the equipment get damaged due to the presence of metal particles and/or foreign matter in
the circuit drain out the hydraulic oil and carry out flushing. Also, replace the filter element and
clean the hydraulic tank. Change the hydraulic oil entirely.
5) When checking the filter, if found metal particles in the element, drain out the hydraulic oil entirely,
flush the whole circuit, and then fill with new oil. The presence of metal particles may indicate
internal damage to the equipment. In such a case, check carefully before flushing, and repair or
replace as required.
6) To add and/or change the hydraulic oil, always use recommended oil. (Refer to the list of
recommended oils and lubricants at page 1-18, Recommended lubricants.)
lubricants. Never mix oil of
different makes of kinds.
7) To change the hydraulic oil, use a clean vessel and funnel for pouring it into the tank. Never use
cloth because it might cause the presence of lint in the circuit.
8) When removing the hydraulic equipment, be sure to put plugs or caps on hoses, tube lines and
ports. Also, enter mating marks for later identification.
9) Disassemble and/or assemble the hydraulic equipment only in a clean place free of dust. When
disassembling, be careful about the interchangeability of parts, and clean the disassembled parts
with pure and clean mineral cleansing oil. Clean the internal passages as well. After the parts
have dried, wipe them off with a clean lint-free cloth.
10) When overhauling the hydraulic equipment replace all O-rings, backup rings, etc. with new ones.
Assemble O-rings with grease or vaseline applied.
11) After installing the equipment, add more hydraulic oil to make up for that lost during disassembly.
12) Tighten joints correctly. Loose joints will cause the hydraulic oil to leak. If the oil leaks, the tank oil
level drops and air gets sucked in, so the pump will break down. Also loose joints in suction lines
will take air in and might cause abnormal noise, malfunction or damage to pumps.
5-30
GROUP 4 TESTS AND ADJUSTMENTS
1. HYDRAULIC OIL CLEAN UP PROCEDURE USING PORTABLE FILTER CADDY

※ Service equipment and tool
·Portable filter caddy
·Two 4000 mm × 1in 100R1 Hoses
·Quick disconnect fittings.
·Discharge wand
·Various size fittings.
※ Flush all lines in the steering system and
cut off system. Disassemble and clean
major components for steering system.
Steering components may fail if steering
system is not cleaned after hydraulic oil
tank contamination.
1) If hydraulic system is contaminated due to a
major component failure, remove and
disassemble steering cylinders to clean
debris from cylinders.
2) 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.
3) To minimize oil loss, pull a vacuum in
hydraulic oil tank using a vacuum pump.
Connect filter caddy suction line to drain
port at bottom of hydraulic oil tank using
connector. Check to be sure debris has not
closed drain port.
4) Put filter caddy discharge line into hydraulic
oil tank filler hole so end is as far away from
drain port as possible to obtain a thorough
cleaning of oil.
5-31
5) Start the filter caddy. Check to be sure oil is
flowing through the filters.
Operate filter caddy approximately 10
minutes so oil in hydraulic oil tank is
circulated through filter a minimum of four
times.
※ Hydraulic oil tank capacity : 95ℓ(25.0 U.S.
gal)
Leave filter caddy operation for the next
steps.
6) Start the engine and run it at high idle.
※ For the most effective results, cleaning
procedure must start with the smallest
capacity circuit then proceed to the next
largest capacity circuit.
7) Operate all functions, one at a time, through
a complete cycle in the following order :
Steering, bucket, and boom. Also include all
auxiliary hydraulic functions.
Repeat procedure until the total system
capacity has circulated through filter caddy
seven times, approximately 30 minutes.
Each function must go through a minimum
of three complete cycles for a through
cleaning for oil.
※ Filtering time for machines with auxiliary
hydraulic functions must be increased
because system capacity is larger.
8) Stop the engine. Remove the filter caddy.
9) Install a new return filter element.
10) Check oil level in reservoir; Add oil if

necessary.
5-32
2. TEST TOOLS
1) CLAMP-ON ELECTRONIC TACHOMETER
INSTALLATION
·Service equipment and tools
Tachometer B
A : Clamp on tachometer.
Remove paint using emery cloth and
connect to a straight section of injection C
line within 100 mm (4 in) of pump. Finger
Tighten only-do not over tighten.
D
B : Black clip ( - ). Connect to main frame.
C : Red clip (+). Connect to transducer. A
D : Tachometer readout. Install cable.
75795SE32
2) DIGITAL THERMOMETER INSTALLATION

·Service equipment and tools
Digital thermometer
A : Temperature probe.
Fasten to a bare metal line using a tie A
band. Wrap with shop towel. C
B : Cable. B
C : Digital thermometer.
75795SE33
3. HYDRAULIC OIL WARM UP PROCEDURE

1) Install temperature reader (see temperature
reader installation procedure in this group).
2) Run engine at high idle.
3) Hold a hydraulic function over relief to heat
the oil.
4) Periodically cycle all hydraulic functions to
distribute warm oil.
5) Heat oil to test specification (approx. 45˚C).
5-33
4. MAIN HYDRAULIC PUMP FLOW TEST
· SPECIFICATION
Engine speed 2200±25 rpm
Test pressure 160±5 bar (2280 psi)
Maximum pump flow 169ℓ/min (44.6 gpm)
· FLOW METER AND TOOL
Flow meter 300ℓ/min (79.3 gpm) Flow meter
Temperature reader
1) Make test connections. To MCV
(see temperature reader installation
procedure in this group)
(see hydraulic oil warm up procedure in this
group)
4) Run engine at test specifications.
5) Close flow meter loading valve to increase Main pump
pressure to test specifications.
6) Read flow meter.
7) If flow is below specifications, check suction
line and suction pressure for abnormality
before removing pump. 830KWE33
5-34
5. LOADER
L ADER SYSTEM AND PORT RELIEF
VALVE PRESSURE TEST
· SPECIFICATION
Oil temperature (40~50˚C)
Relief valve Engine speed Relief pressure
System 160±5 kg/cm2 M
Low
(M) (2280±70 psi)
Bucket 180±5 kg/cm2
Low
rollback (R) (2560±70 psi)
Bucket 120±5 kg/cm2
Low
dump (D) (1710±70 psi)
Bucket
· Gauge and tool Boom
Gauge 0~35 MPa (0~350 bar, 0~5000 psi) D
R
M : System (main) relief valve
R : Bucket rollback relief
D : Bucket dump relief
1) Install fitting and pressure gauge to test port
in pump delivery line.
MCV
group)
4) To check the system relief (M), run engine
at low idle. Lower boom to bottomed
position.
Slowly activate boom down function while
Hyd tank
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
160 kg/cm2 (2280 psi). Damage to the pump
will result from excessive pressure settings. 830KWE34
5-35
6. HYDRAULIC SYSTEM RESTRICTION
TEST
· SPECIFICATION
Maximum pressure
3 MPa (30 bar, 43 psi) at steering unit
Maximum pressure at main control valve
1 MPa (10 bar, 145 psi)
· GAUGE AND TOOL
Gauge 0~7 MPa (0~70 bar, 0~1000 psi) 2EA
This test will check for restrictions in the
hydraulic system which can cause
overheating of hydraulic oil.
1) Install temperature reader. T

Steering unit
group)
3) Connect fitting and gauge to steering valve.
4) Connect fitting and gauge to main control
valve.
Do not operate steering or loader funct- MCV
ions or test gauge may be damaged.
5) Run engine at specification and read
pressure gauges.
loader control valve, check for a kinked,
dented or obstructed hydraulic line. Check
loader control valve for a binding spool.
steering unit, inspect neutral condition of
the steering unit and priority valve for a
stuck spool. Make sure orifice plugs are
installed in ends of priority valve spool.
Check for plugged orifice in priority valve LS
port and dynamic signal orifice on the spool
of priority valve. 830KWE42
5-36
7. LOADER CYLINDER DRIFT TEST
· SPECIFICATION
Boom horizontal
Bucket horizontal
Bucket unloaded
Item Standard value
Retraction of boom
36 mm
cylinder rod
B
Retraction of bucket
33 mm
cylinder rod
· GAUG
GAUGE E AND TOOL
Stop watch A
Temperature reader
A : Retraction of boom cylinder rod
Put the safety lock lever in the lock
B : Retraction of bucket cylinder rod
position.
Do not go under the work equipment.
1) Set the boom and bucket horizontal, then

stop the engine.
2) Stop the engine, wait for 5 minutes, then
start measuring.
3) Measure the amount the boom and bucket
7577AWE31
cylinder rods retract during 5 minutes.
5-37
8. BOOM AND BUCKET CYLINDER LEAKAGE TEST
· SPECIFICATION
Engine speed Low idle
Maximum leakage 15 mℓ/min (1/2 oz/min)
· GAUGE AND TOOL
Temperature reader
Stop watch
Measuring container
1) Fasten temperature sensor to head end
port of cylinder to be tested. Cover sensor
with a shop towel.
2) Heat hydraulic oil to specifications (see
hydraulic oil warm up procedure in this
group).
Never work under raised equipment
unless it is supported with a hoist or
support stands.
3) Full extend the cylinder to be tested. If
testing the boom cylinders, restrain boom in
the fully raised position using a hoist or a
stand.
※ Check cylinders for leakage in the fully
extended position only. In the retracted
position contacts the end of the cylinder
and seals off piston seal leakage.
4) Remove and plug cylinder rod end hose or
line.
5) Run engine at slow idle. Activate control
lever to extend cylinder for 1 minute over
relief while measuring leakage for open
port.
If leakage is within specification, excessive
cylinder drift is caused by leakage in the
loader control valve or circuit relief valve. (770-3ATM) 6-56
5-38
9. CYCLE TIME TEST
· SPECIFICATION
Function Operating conditions Maximum cycle time (seconds)
Boom raise Bucket flat on ground to full height 5.1
Boom lower (float) Full height to ground level 3.0
Bucket dump Boom at full height 1.1
Bucket rollback Boom at full height 1.5
Steering (number of turns) Frame stop to stop 6.1 turns
5-39
10. HYDRAULIC OIL FILTER INSPECTION
PROCEDURE
1) Lower the bucket to the ground, stop the
engine, move the control lever back and
forth several times, and clean all over the
upper surface of the hydraulic oil tank.
2) Remove the bolts and take out the filter
case cover and O-ring.
3) Remove the spring and bypass valve.
4) Remove the filter element from the tank.
Cover
5) Check the element and the filter case O-ring
bottom for debris. Excessive amounts of Spring
brass and steel particles can indicate a By-pass valve
failed hydraulic pump or a pump failure in
Return filter
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.
(1) Clean the inside of the filter case.
(2) Place new element in the proper positions
inside the filter case.
(3) Install the bypass valve and spring. Make
sure the element stand upright, and check
for complete contact of the element
bottom with the filter case bottom.
(4) Install the O-ring and filter case covers.
Tighten them with bolt. Replace the O-ring
with new one if damaged. 830KWE40
5-40
Group 1 Component location -------------------------------------------------------------------------------------------- 6-1

Group 2 Electrical circuit ---------------------------------------------------------------------------------------------------- 6-3
Group 3 Monitoring system ----------------------------------------------------------------------------------------------- 6-4
Group 4 Connector ------------------------------------------------------------------------------------------------------------ 6-11
GROUP 1 COMPONENT LOCATION
1. LOCATION 1
9
Cab ceiling(LH)
1
10
Front
11
C
A
B
R
O
O
F
78
64
5 14
3 12
2 13
15
830K7EL02E
1 Beacon switch 7 Multi function switch 13 Battery volt meter and

2 Work lamp switch 8 Horn button hour meter
3 Front wiper/washer switch 9 Electric fan 14 Cigar lighter
4 Gear selector lever 10 Aircon and heater switch 15 Engine stop switch
5 Hazard switch 11 Radio and MP3 player
6 Cluster 12 Starting Switch
6-1
2. LOCATION 2
4
5 6
4
4
4
1 2 3
8
7
9
10
15
11
12
13
10 14
11
830K7EL02-1
1 Head lamp 6 Electric fan 11 Rear combi lamp

2 Horn 7 Coolant temperator sensor 12 Fuel sender
3 Multi function switch 8 Engine oil pressure sensor 13 Back buzzer
4 Work lamp 9 Work lamp 14 Battery relay
5 Beacon lamp 10 Battery 15 Air tank pressure switch
6-2
FRONT WIPER
CN-55
WORK LAMP SW WIPER SW HAZARD SW TURN LEVER
-
CN-56
1
2
8
7
7
8
1
5
9
9
9
2
0 I (6) (1) (11) (7) (5) 751H
M
+
I 0 H
BARO
30 L R 57/58 862 862 ROr
6
METER
B
284D
E
Pf
Hi
Lo
0,
I G15J
SOCKET
U LED
1
4
5
6
4
10
2
3
10
CN-53
10 10
1
6
4
2
1
SERVICE 2
3
7
9
3
7
9
3
7
9
5
3
2
6
2
6
2
6
1
4
5
8
1
4
5
8
1
4
5
8
10
10
-
CS-36
751G
BACKING
CS-35
CS-41
CN-21
CN-171
+
R
2
L
892 892 W
B
Y
B
B
Gr
R
R
R
G
W
7
Or
GAUGE
B
VOr
ROr
ROr
ROr
VOr
Or
BrW
BrW
TC TEMP
284C
G30
L H G15I
56b LP
261
311
261
301
293
352
363
360
362
226
234
211
211
360
362
352
56a
U LED
G26
G26
G26
G25
G06
290F
290C
(10)
500
(8) (9)
G06
G03 CN-54
1
G02
-
G01 751H
2
9
8
5
1
1
6
3
2
11
10
7
+
CS-45
878 878 Or
CS-11
GAUGE
15
EARTH4
B
Y
Y
R
284B
Or
GY
WB
VW
ROr
BrW
FUEL LEVEL
G15G
U LED
CN-22 B G02 CN-4

1
351
234
211
325
333
261
251
343
226
G26
Gr 361 361 Gr 363
M 2 1
FRONT
WASHER
CL-51A
223 223 Y
1
CR-30
87a
G15F B TURN LH
86 30
GROUP 2 ELECTRICAL CIRCUIT
B G01 913 913A RW
11
85
V 321 751E CHARGE
1 2 1 2
87
Y 320 320 Y 325
86 2 CL-51B
85 87 87a ROr 250A
30 CL-52A
HIGH BEAM
323 323 V
3
G15D B HIGH BEAM

CR-40
751E R
86 30 87a
B G01A 250 ROr 251 CN-56 872 Y 872 Y BRAKE LOW
1 2 1 2
10
85 3
GW 331 PRESSURE
87 CL-52B
VW 330 330 VW 333 226 Y
86 4 CL-26A
85 87 87a ROr 250 234 Or 472 472 VW
16
30
LOW BEAM
290 ROr 293 934 G 751D PARKING
5 CL-DL
863 ROr 572
CR-2
893 W 573
1 2
1 2 1 2
86 30 87a
13
B G01B 883 LW
85 CL-26B
VW 341 873 Y
87 CL-53A
GY 340 340 GY 343 914 RW 233 233 Or
4
86 6
85 87 87a W 350A W 352 904 Gr G15C TURN RH
350
HORN RY
30 7
924 Br 751D
879 Or 933 933 G ENGINE OIL
5
1 2 1 2
CR-11 211
BrW 210 210 BrW 473 VW
1 4 5 6 7 9 10 11 12 13 15 16
L 87 8 CL-53B
G R 225
UNIT
B 85
B G01C 324 V
E 86
285 LW
FLASHER
8R 600 752 R
3 14 2
CN-52
-
CN-37 751A
+
TEMP
20A WORK LMAP_FRONT GW 100 G26 B 903 903 Gr

8
1 12
ENGINE
20A WORK LMAP_REAR Gr 150 284 284A LW

COOLENT
2 14
20A STOP LAMP R 200 G15 G15A
3
8
U LED
20A HEAD LAMP ROr 250

8R 4 CN-51
20A WIPER & BACK BUZZER W 350 751
2
5
-
30A AIR-CON/HEATER 2R 400 751 R

6
+
20A
GAUGE BOARD SIDE
CIGAR Or 450 923 923 Br

TM OIL
7
9
SIDE
261
234
324
285
752
924
934
904
914
893
883
863
873
879
473
311
301
226
351
G25
30A
G26
SERVICE POWER1
DASH
8
R 500 284 LW
PRESSURE
20A COWL OPEN
FRONT
9
RL 530 G15
U LED
B
B
Y
Y
20A ILL LAMP
G
G
256
Br
ROr
Gr
Or
10
LW
WB
VW
RW
ROr
20A BEACON LAMP W 266
8R 11
10A SPARE1
LH
RH
9
16
15
9
8
7
6
5
4
3
2
1
14
13
12
12
10
11
12
11
15
14
13
16
10
10A SPARE2
1
2
8
7
9
CN-4
CN-5
13
10A SPARE3
Y
V
SPEAKER
14
R
SPEAKER
G
Or
Or
Br
Gr
LW
LW
30A
WB
VW
IGNITION SWITCH
ROr
2Or 650
ROr
RW
15
30A POWER RELAY 2Gr 680
RH
BEACON
16
FUSE BOX
5
6
10A ROOM LAMP, RADIO(+) Y 700

17
230
SIDE
876
471
280
750
922
932
902
912
891
881
861
871
321
260
310
300
220
354
10A TURN LAMP
G04
G01
R 225
10 10
3
7
9
2
6
18
1
4
5
8
1
2
2
1
CS-23
20A
CN-24
AIRCON(+)
CN-23
19
L 425
30A SPARE4
L
W
20
LW
W
GY
RW
OR
30A SPARE5
CONSOLE
21
10A GAUGE 24V R 750 CN-7
22
704
703
283
G14
702
705
267
111
10A RADIO(IG) G 800 267

8
23
20A SPARE6
24
20A SPARE7 CN-7
25
20A SPARE8 400 R
1
26
5A ILLUMINATION 1 LW 280
27
5A ILLUMINATION 2
CL-7
ROr 290 111 RW
28 2
800 G G13A B
1
280C LW
2 3
Br 270
BEACON
160 R
2Br 670
CN-27
700 Y 801 801 G
1 ACC
3R 550 266 W G14 B
2 5
2 ILL-
110 RW
4 5 6 8 7
3 NC
703 GY
4 SPK FRT RH-
MP3 PLAYER
702 L
CR-35 5 SPK FRT LH-
86 30 87a 6 TEL MUTE
B G01H
85 7 ANT 12V
2Br 670 701 701 Y
RELAY
87 8 BACK UP+
POWER
R 657 283 283 LW
6 3
86 9 ILL+
85 87 87a 2Gr 680
30 10 NC
704 OR
11 SPK FRT RH+
CR-21 12 REMOCON+
POWER CONNECT
86 30 87a 13 REMOCON GND

G01I 705 W
85 14 SPK FRT LH+
LAMP
Br 270
87 15 NC
R 260 G14A B
86 16 GND
85 87 87a ROr 256 CN-9
30
290A ROr
CLEARLENCE
7
CR-3 CL-1
341 VW 701A Y
3
86 30 87a 2
B G01J G14
85 1
LAMP
RW 110
ROOM
87
FRONT
G 300
86 AC-3
85 87 87a GW 100 321 V 411 411 R
1
30 2
FAN
WORK LAMP
G14 B
1
280C LW
CR-55 230 Or
2 6
86 30 87a CL-5
B G01K 111 111 RW
7
85 2
R 160 331 GW G13A B
REAR
87 1
CAB CHASSIS SIDE
L 310 220 Y
4 1
86
85 87 87a Gr 150
FRONT
30 CL-6
WORK LAMP
111A RW
CS-79 2
G13B B
1
CR-63 1
WORK LAMP
650 Or
2
86 30 87a
G01L
3
85
Br 203
6-3
4
87
1
G 205
5
86 CL-22
85 87 87a R 200B 667 R 161 R
6
4
30 2
STOP LAMP
2
G13A B
ENGINE STOP SW
7
6
1
8
CR-58
REAR
290E ROr
86 30 87a CL-23
9
WB 354 G02 B 161 R

10
9 10
85 2
L 380 G13B B
87 1
WORK LAMP
G14
BUZZER
86 CL-2
BACK-UP
85 87 87a W 350 G02 B
30
290E ROr G13
450 Or
CIGAR
CN-26
Y 871
EARTH7
1
R 200A
2 CS-2
650 2Or 1
BUZZER
H0 I
WARNING
2
0, I
660 R 4
H
3
4 1
B
START SWITCH
2
3
CN-11 5
BR ACC
AC CONTROLLER GND
B G30 2W
1 1 663 6
B G30
2 BLOWER MOTOR GND 2
5
2R 400 6
ST C
3 AC 24V 3
4 NC 4
CN-48
A
L 425
5 AC CONTROLLER B+ 5
Y 448 HRM(-)
6 AC COMP 6 750
BW 445 KEYSWITCH CL-3
7 AC CONDENSOR FAN 7 332A GW Y
NC 2 Lo
8 ROr 290 322 V
ILLUMINATION 8 R
NC 1 Hi
G15B G12B B B
CR-7 GND 3
448 912 RW CN-9
86 30 87a HRM(+)
ROr 447 447 750 LW 282 282 LW Br /Gr
CHINA
85 24V 2 1 C
LW 446 446
1 2 3 4 5 6 7 8
87
B E
NC
COMP
R 222 Y
RELAY
400 Y 222 G T
86 1 2
85 87 87a
AIR-CON
R
HOURMETER & VOLTMETER
400 444
650
657
660
G15
30
471
657
871
G02
G02
G02
CL-24
CN-20
CR-33 G12A B
1.2B
1.2R
1.2R
1
1.2Or
B
B
B
Y
86 87a 342A VW
30 2
VW
8
LOW
FAN BW 445
HORN
85
RELAY BrW 444
87
1
2
3
87
30
85
86
3
4
1
2
R CN-25
87a
AIRCON
400 G11B B
86 1
CS-26
85 87 87a
1
R 400
CR-79
CN-125
30 VW 342 342 VW
2
876
600
550
3
205
200
290
667
530
380
280
663
657
922
932
902
912
891
881
871
861
444
446
447
448
203
87a 87
30
HIGH
220A
230A
CONDENSOR
HORN
4
1
85
86
CL-4
L
Y
Y
Y
R
R
R
G
G
GW 332 332
W
GW
Br
Br
Or
Y
Or
Gr
GPS CONN.
8R
3R
RL
LW
2W
LW
LW
2 Lo
RW
4
3
2
ROr
ROr
ROr
BrW
R
V 322 322 V R
5 1 Hi
CN-125A
G11 B B
2
9
7
3
1
8
5
4
7
6
8
5
1
6
9
12
2
2
10
13
15
14
4
3
1
11
3
15
13
14
12
11
10
R 668
668
STOP
CN-2
CN-3
CN-1
G12
G11
Y
Y
R
R
R
G
G
ENGINE
ROr 292 292 ROr

W
Br /Gr
Y
Br
Br
BUZZER
Or
LEVER
Or
Gr
CHINA
8R
3R
RL
LW
2W
7 1 C
FRONT FRAME SIDE
ROr
LW
ROr
G11A B
BrW
PARKING
B E
CN-83 Or 232 232 Or G T
2
877
601
551
204
202
201
221
291
665
352
231
281
664
661
921
931
901
RW 911
890
LW 880
870
ROr 860
6
531
441
440
449
443
449 BrW
EARTH5
FAN
CL-25
M
G25 B
1 2
EARTH3
AC COND
CN-12 CN-29
CN-79
G10 2B 2B G08 440 Y 1
2
9 AC-1 AC-11
441 ROr
3
Pa
FUEL
2
1 2
8 WOr 39 WB 15
ENGINE SIDE
SWITCH
16 BW
1
PRESS
662 R R 665 INLET MOTOR(REC) 1 1

3
1
2 BW 38 BW 16
AIR-CON
2
INLET MOTOR(FRE) 2 2
4
M
L 37 3 LR 17
INLET M/ACT
TEMP MOTOR ACT(+) 3 3

CD-48 BOr 36 4 BG 18 5
TEMP MOTOR ACT(-) 4 4
CUT OFF SOL
7
CD-18 G 35 5 GL 19 6
G TEMP M/ACT(PBR) 5 5 15 WB
OIL
920 Br Br 921 880 LW 7

1 Y 34 6 Y 20
MOTOR ACT(REF) 6 6
Pa
930 G G 931
Pa
3 GY 33 GW 21 17 LR
PRESS
7
MODE M/ACT(DEF) 7 7
1
TM OIL
PRESS
1
ENGINE
WK BW 32 BG
SWITCH
8 22 20 Y
MODE M/ACT(FOOT) 8 8 2
WOr 31 WR 23
M
CD-8 MODE M/ACT(M+) 9

9
9 3
4
LW 30 10 LB 24 18 BG
900 Gr Gr 901 MODE M/ACT(M-) 10 10 4
Y 29 YB
2
4 25 19 GL
TEMP
11
MODE M/ACT(PBR) 11 11 5
5
TEMP M/ACT
LW 28 12 LG 26
BLOWER RELAY(LO) 12 12 6
YW 27 YBr
COOLENT
27 9A GB
7
13
E
666 W W 664 BLOWER RELAY(M1) 13 13 7

6 BOr 26 14 BG 28
BLOWER RELAY(M2) 14 14
YW 25 15 YB 29 1
CN-74
BLOWER RELAY(HI) 15 15
G
3
11 LW 24 16 LW 30 2
COMPRESSOR(DPS) 16 16
24V, 35A
21 GW
ST
~3
Y 23 17 LY 31 3
CONDENSER FAN 17 17
4
M
12 18
18 18
W
D+
B+
ALTERNATOR
5
MODE(D/FOOT)
B+
M
7
BrW 47 1 BR 1 6
5Y GND 1 1 22 BG
5L BrW 46 BR 2 7
15 R
2
GND 2 2
STARTER CN-45
RW 45 RW 3 23 WR
BW 910
1
3
910 BW BW 911 BATTERY(+) 3 3 1
44
AC & HEATER CONTROLLER
7 RW 4 RW 4 20A Y
CD-4 BATTERY(+) 4 4 2
G 43 G
M
5 5
201 R ILLUMINATION 5 5 3
4
R 42 6 RY 6 24 LB
202 G POWER IG 6 6 4
Pa
2
LAMP
STOP
7 25 YB
NC 7 7 5
5
G29 B G08A
MODE(VENT)
BW 41 BrR
SWITCH
5 8 8
442 VW LW 443 DUCT SENSOR(+) 8 8 6
COMP
1
GW 40 GB 9 9B GB
7
10 9
CD-3 DUCT SENSOR(GND) 9 9 7
OrW 52
AIR-CON
GB 10
REAR FRAME SIDE
10
CN-28 860 ROr REVERSE FAN SIG 10 10 26 LG
AIR
G 11 1 Lo 1
NC 11 11
Pa
870 Y 35 YW
WK 12 2 MH 3
NC 12 12 27 YBr
NC 13
13
13 3 ML 2
RESISTOR
14 36A L
4 Hi 4
PRESSURE
NC 14 14
AC-2 AC-22 29 YB
1 2 1
1.25LgB 9
1 33 R
1.25G 8 2
2 6B RY
CD-49 3
RELAY(HI)
552 3R 36 L
4 4 3
890 W
EARTH6
DUCT SENSOR
28 BG
C
1
669 R
601
551
1 2 1
5
6
31
30
33
10
33A R
32
TM TEMP
1,2
2
6A RY
8R
3R
2
3
RELAY(M2)
G25 35 YW
G
LY
2B
CS-74
2R
CN-71
RY
BR
4 4 3
LW
RW
G27 G09 B
1
3
1
2
G09 RL 32 2B
531 1 M
CN-95
2
6
7A 36 L
8
7
6
2
5
4
3
1
G08
2.0
2
5
0.85
BLOWER
G07
CN-11
661 G28
FUSIBLE LINK
4
MASTER SWITCH
G06B
8
7
6
5
4
3
2
1
EARTH2
COWL OPEN SWITCH
NO.
352
1
231
204
221
291
281
877
G28
G28
G28
204A
G27
661A
G06C
2
COWL OPEN
AIR CON
L
B
CR-1
B
B
Y
B
Br
Or
Or
LW
Br
MCU
ROr
R
B
BATT RY
FUSE(IG)
2
1
2
1
3
3
2
2
1
4
1
4
4
1
1
3
2
2
CD-2
CN-65
FUSE(Battery)
CL-16
ILLUMINATION
DO-2
CL-15
E
E
T
T
S
S
GND(BLOWER)
C
C
DIODE
DESTINATION
CONDENSOR FAN
BATTERY
GND(CONTROLLER)
DPS(COMPRESSOR)
BACK BUZZER
FUEL LEVEL SENSOR
REAR COMBI RH
REAR COMBI LH
EARTH1
830K7EL10
GROUP 3 MONITORING SYSTEM
1. CLUSTER
The gauges panel consists of gauges and monitors as shown below, to warn the operator in case
of abnormal machine operation or conditions for the appropriate operation and inspection.
·Gauges : Indicate operating status of the machine.
·Warning lamp : Indicate abnormality of the machine.
·Pilot lamp : Indicate operating status of the machine.
※ The monitor installed on this machine does not entirely guarantee the condition of the machine.
Daily inspection should be performed according to chapter 6, Maintenance in operator's manual.
※ When the monitor provides a warning immediately check the problem, and perform the required
action.
Fuel gauge Parking brake warning lamp

High beam pilot lamp Right turning pilot lamp
Left turning pilot lamp
Battery charging warning lamp Engine oil pressure

Brake air pressure warning lamp warning lamp
Engine coolant temperature gauge

T/M oil pressure gauge
Brake air pressure gauge T/M oil temperature gauge
830K3CD02K
6-4
1) FUEL GAUGE
(1) This gauge indicates the amount of fuel in the fuel tank.
(2) Fill the fuel when the indicator moves 0 point, refuel as soon as
possible to avoid running out of fuel.
※ If the gauge indicates below 0 point even though the machine
is on the normal condition, check the electric device as that
850K3CD04
can be caused by the poor connection of electricity or sensor.
2) ENGINE COOLANT TEMPERATURE GAUGE

Operating range (1) This gauge indicates the temperature of coolant.
·Red range : Above 100˚˚C (219˚˚F)
Red (2) If the indicator is in operating range, it is normal.
(3) Keep idling engine at low speed until the indicator is in the
operating range.
850K3CD05
(4) If the indicator is in the red range, turn OFF the engine, check
the radiator and engine.
3) TRANSMISSION OIL TEMPERATURE GAUGE

Operating range (1) This gauge indicates the temperature of transmission oil.
·Red range : Above 120˚˚C (225˚˚F)
Red (2) If the indicator is in operating range, it is normal.
(3) Keep idling engine at low speed until the indicator is in the
operating range.
850K3CD07 (4) If the indicator is in the red range, it means the transmission is
overheated. Be careful that the indicator does not move into
the red range.
4) TRANSMISSION OIL PRESSURE GAUGE

ing (1) This gauge indicates the pressure of transmission oil.
erat e
Op rang Red
(2) If the indicator is in operating range, it is normal.
(3) If the indicator is in the red range, stop the engine and check
the transmission system.
850K3CD08
6-5
5) BRAKE AIR PRESSURE GAUGE
Oper (1) This gauge indicates the air pressure of service brake.
ating
range ·Red range : Below 0.4 MPa
Red
(2) If the indicator is in operating range, it is normal.
(3) If the indicator is in the red range, keep idling engine at low
speed until the operating range indicates.
850K3CD06
6) DIRECTION PILOT LAMP

(1) This lamp flashes when the signal indicator lever is moved.
(2) When the lamp lights up, the alarm (50 dB) sounds.
77073CD10
7) HIGH BEAM PILOT LAMP

(1) This lamp works when the illuminating direction is upward.
(2) This lamp comes ON when the dimmer switch is operated,
e.g., when passing another vehicle.
77073CD12
8) PARKING BRAKE WARNING LAMP

(1) When the parking brake is actuated, the lamp lights ON.
※ Check the lamp is OFF before driving.
77073CD13
9) BRAKE AIR PRESSURE WARNING LAMP

(1) The lamp lights ON when the air pressure of service brake
drops below the normal range.
(2) When the lamp is ON, stop the engine and check for its cause.
※ Do not operate until any problems are corrected.
850K3CD16
6-6
10) ENGINE OIL PRESSURE WARNING LAMP
(1) This lamp is comes ON after starting the engine because of
the low oil pressure.
(2) If the lamp comes ON during engine operation, shut OFF
engine immediately. Check oil level.
77073CD18
11) BATTERY CHARGING WARNING LAMP

(1) This lamp is ON when key ON, it is turned OFF after starting
the engine.
(2) Check the battery charging circuit when this lamp comes ON
during engine operation.
77073CD22
6-7
2. SWITCHES
Front
Cab celing (LH) Beacon switch
Horn button
Multi function switch Starting switch
Hazard switch Engine stop switch
Front wiper/washer switch
Work lamp switch
Engine cover switch

830K3CD29E
1) STARTING SWITCH
(1) There are three positions, OFF, ON and START.
· (OFF) : None of electrical circuits activate.
· (ON) : All the systems of machine operate.
· (START) : Use when star ting the engine. Release key
immediately after starting.
77073CD41
6-8
2) HAZARD SWITCH
(1) Use for parking, or roading machine.
OFF
(2) Both turn signal lights will flash simultaneously.
ON
※ If the switch is left ON for a long time, the battery may be discharged.
77073CD42
3) WORK LAMP SWITCH

(1) This switch use to operate the front and rear work lamps by two step.
·First step : Front work lamp located on the cab comes ON.
·Second step : Rear work lamp located on the cowl comes ON.
77073CD46
4) FRONT WIPER AND WASHER SWITCH

(1) The switch use to operate the front wiper and washer by two step.
·First step : The front wiper operates.
·Second step : The washer liquid is sprayed and the front wiper is
operated only while pressing. If release the switch,
return to the first step position.
77073CD47
5) BEACON SWITCH (option)

(1) This switch turns ON the rotary light on the cab.
77073CD50
6) HORN BUTTON
(1) If you press the button on the top of the multifunction switch, the horn
Horn button will sound.
850K3CD28A
6-9
7) CAB LAMP SWITCH
(1) This switch turns ON the cab room lamp.
73033CD24
8) MULTI FUNCTION SWITCH

(1) Dimmer switch
① This switch is used to turn the head lights direction.
② Switch positions
Up
·Up : To flash for passing
M ·Middle : Head lights low beam ON
Down ·Down : Head lights high beam ON
③ If you release the switch when it's in up position, the switch will return
850K3CD30
to middle
(2) Turning switch

① This switch is used to warn or signal the turning direction of the
Left turning
machine to other vehicles or equipment.
② Push the lever up for turning left, pull the lever down for turning right.
Right turning
850K3CD31
9) ENGINE COVER SWITCH

(1) This switch is used to open or close the engine cover.
(2) Turn the staring switch to the ON position, press the button.
·Green button : Open the engine cover
Green
Red ·Red button : Close the engine cover
830K3CD46
10) ENGINE STOP SWITCH

(1) If the switch is pressed, the engine stops immediately.
830K3CD37
6-10
GROUP 4 CONNECTOR
1. MAIN HARNESS
Connector No. of
Type Destination Connector part no.
number pin
CL-2 HES 1 CIGAR S810-001202
S822-014000
S822-114000
CS-2 HES 6 START SWITCH S814-006000
CN-125 CHINA 4 GPS DJ7041-6.3-21
CN-125A CHINA 4 GPS DJ7041-6.3-11
CN-171 TYCO 2 SERVICE SOCKET 174198-1
CS-26 TYCO 3 PARKING BRAKE LEVER 174200-1
CS-79 SWF 10 ENGINE STOP SWITCH 174200-1
CN-22 - 2 FRONT WASHER MG640605
CR-55 HELLA 5 WORK LAMP (FR) RELAY 8JA003526-001
CR-3 WORK LAMP (RR) RELAY
CR-40 LOW BEAM RELAY
CR-2 HORN RELAY
CR-63 STOP LAMP RELAY
CR-35 POWER RELAY
CR-21 CLEARANCE LAMP RELAY
CR-30 HIGH BEAM RELAY
CR-33 AIRCON CONDENSOR FAN RELAY
CR-7 AIRCON COMPRESSOR RELAY
CR-58 BACK UP BUZZER RELAY
CR-11 FLASHER UNIT RELAY
CR-79 ENGINE STOP BUZZER
CN-37 - 20 FUSE BOX 21N8-20041
CN-26 TYCO 2 WARNING BUZZER 174198-1
CN-1 HES 2 REAR FRAME SIDE 1 S813-130200
CN-2 TYCO 15 REAR FRAME SIDE 2 368301-1
CN-3 TYCO 15 REAR FRAME SIDE 3 2-85262-1
CN-11 DEUTSCH 8 HEATER SIDE DT06-8S
EARTH4 KSC 2620 1 - R8-10
CN-9 CHINA 8 - DJ7081-6.3-21
CN-7 CHINA 8 - DJ7081-6.3-21
CN-4 TYCO 16 TO DASH 368047-1
CN-5 TYCO 15 TO DASH 85223-1
CN-48 MOLEX 8 HOURMETER & VOLTMETER 39-01-2085
6-11
2. CAB HARNESS
Connector No. of
number pin
CN-7 CHINA 8 CAB CHASSIS SIDE DJ7081-6.3-11
CL-7 TYCO 2 BEACON 174198-1
CN-23
KET 2 SPEAKER 7123-1520
CN-24
CL-1 - 3 ROOM LAMP MG651032
CN-27 - 16 RADIO & MP3 player PK145-16017
CL-5 DEUTSCH 2 WORK LAMP, FRONT DT06-2S
CL-6 DEUTSCH 2 WORK LAMP, FRONT DT06-2S
CL-22 DEUTSCH 2 WORK LAMP, REAR DT06-2S
CL-23 DEUTSCH 2 WORK LAMP, REAR DT06-2S
CS-23 SWF 10 BEACON SWITCH 593757
EARTH7 KSC 2620 1 RING TERMINAL R3-10
AC-3 - 2 FAN DJ7021-6-3-10
3. DASHBOARD HARNESS
Connector No. of
number pin
CS-11 TYCO 11 TURN LEVER 172497-1
CN-21 TYCO 6 FRONT WIPER 936257-1
CS-41 SWF 10 HAZARD SWITCH 593757
CN-56 TYCO 16 GAUGE BOARD SIDE 368047-1
CN-4 TYCO 16 TO MAIN 368050-1
CN-5 TYCO 15 TO MAIN 2-85262-1
CS-35 SWF 10 WIPER SWITCH 593757
CS-36 SWF 10 WORK LAMP SWITCH 593757
CS-45 SWF 2 BACK-UP SWITCH MATING WITH DJ7021-6.3-10
6-12
4. REAR FRAME HARNESS
Connector No. of
number pin
CD-49 KET 1 TM TEMP 710197
CD-48 KET 1 TM OIL PRESSURE 710197
CD-3 KET 1×2 AIR PRESSURE 710197
CD-4 KET 1×2 STOP LAMP SWITCH 710197
CN-65 DEUTSCH 2 BACK BUZZER DT06-2S
CL-16 HES 4 REAR COMBI-RH S814-004000
CL-15 HES 4 REAR COMBI-LH S814-004000
CN-29 - 2 AIRCON PRESSURE SWITCH MG 640795
CN-83 KUM 2 FAN PB625-02027
CN-95 HES 2 FUSIBLE LINK S813-130200
- 2 FUSIBLE LINK 21EA-40171
DO-2 - 2 DIODE S816-002002
- 2 DIODE 21EA-50550
CR-1 HES 1×2 BATTERY RELAY S820-104002
CN-1 HES 2 - S813-030200
CN-2 TYCO 15 - 2-85262-1
CN-3 TYCO 15 - 368301-1
CN-12 CHINA 12 - DJ7041-6.3-21
CN-71 CHINA 2 - DJ7041-6.3-21
CD-2 - 2 - S814-002000
CS-74 - 1 MASTER SWITCH (IF EQUIPPED) S820-205000
- 1 MASTER SWITCH (IF EQUIPPED) ST710287-2
5. FRONT HARNESS
Connector No. of
number pin
CN-9 CHINA 8 FRONT FRAME, SIDE DJ7081-6.3-11
CL-3 TYCO 3 COMBI-FRONT, LH 174200-1
CL-24 TYCO 2 HEAD LIGHT, LH 174198-1
CN-20 MOLEX 2 HORN-LOW 36825-0211
CN-25 MOLEX 2 HORN-HIGH 26825-0211
CL-4 TYCO 3 COMBI-FRONT, RH 174200-1
CL-25 TYCO 2 HEAD UGHT, RH 174198-1
6-13
6. GAUGE HARNESS
Connector
Type No. of pin Destination Connector part no.
number
CN-55 BARO METER

CN-53 TC TEMP GAUGE
SWF 2 913328
CN-54 FUEL LEVEL GAUGE
KSC2620 1×3 R 1.25-4
CN-52 ENGINE COOLANT TEMP
CN-51 TM OIL PRESSURE
CL-51 A,B TURN-LH, CHARGE

CL-52 A,B HIGH BEAM, BRAKE LOW PRESSURE
CHINA 2×2 DJ702256-6.3-21
CL-26 A,B PARKING
CL-53 A,B TURN-RH, ENGINE OIL PRESSURE
CN-56 TYCO 16 GAUGE BOARD 368050-1
7. ENGINE HARNESS
Connector
Type No. of pin Destination Connector part no.
number
CN-79 HES 3 FUEL CUT OFF SOL S818-020311
CD-18 KSC 2620 1 ENGINE OIL PRESSURE Rl.25-4
CD-8 TYCO 1 COOLANT TEMP Rl.25-4
ST710384-2
CR-23 KET 2×2 START RELAY
ST710589-2
KSC 2620 1 R14-12

CN-45 STARTER
KET 1 ST710246-2
KSC 2620 1 R14-8

CN-74 ALTERNATOR
KSC 2620 1 Rl.25-4
CN-12 TYCO 12 ENGINE SIDE DJ7121-6.3-11
KSC 2620 1 NMWP01F-B

CN-28 COMPRESSOR
KSC 2620 1 Rl.25-10
6-14
8. CONNECTION TABLE FOR CONNECTORS
1) 58-L TYPE CONNECTOR
No. of
Receptacle connector (female) Plug connector (male)
pin
1 1
S813-030100 S813-130100
1 2 1 2
S813-030200 S813-130200
6-15
2) PA TYPE CONNECTOR
No. of
pin
2 5 1 3
1 3 2 5
S811-005002 S811-105002
3 7 1 4
1 4 3 7
S811-007002 S811-107002
4 9
1 5
1 5
4 9
S811-009002 S811-109002
5 11 1 6
11
1 6 5 11
S811-011002 S811-111002
6-16
No. of
pin
6 13 1 7
13
1 7 6 13
S811-013002 S811-113002
1 9
8 17
17
1 9 8 17
S811-017002 S811-117002
10
1 21 1 11
21
1 11 1
10 21
S811-021002 S811-121002
6-17
3) J TYPE CONNECTOR
No. of
pin Receptacle connector (female) Plug connector (male)
1 2
1
2 12
S816-002001 S816-102001
2 3 1
3 1 2
S816-003001 S816-103001
3 1 4 2
4 2 3 1
S816-004001 S816-104001
8 5 2
6 3 1
8 5 2 6 3 1
S816-008001 S816-108001
6-18
4) SWP TYPE CONNECTOR
No. of
Receptacle connector (Female) Plug connector (male)
pin
1 1
S814-001000 S814-101000
2 1
1 2
S814-002000 S814-102000
3 1
2 1 23
S814-003000 S814-103000
2 4 1 3
1 3 2 4
S814-004000 S814-104000
6-19
No. of
3 6 1 4
3 6
1 4
S814-006000 S814-106000
4 8 1 5
4 8
1 5
S814-008000 S814-108000
4 12 1 9
12
4 12
1 9
S814-012000 S814-112000
3 14 11
1
14
1 11 3 14
S814-014000 S814-114000
6-20
5) CN TYPE CONNECTOR
No. of
1 1
S810-001202 S810-101202
2 2
1 1
S810-002202 S810-102202
3 2
1 2 1 3
S810-003202 S810-103202
2 4 1 3
1 3 2 44
S810-004202 S810-104202
6-21
No. of
3 6 1 4
1 4 3 6
S810-006202 S810-106202
4 8 1 5
1 5 4 8
S810-008202 S810-108202
6-22
6) ITT SWF CONNECTOR
No. of
2
10
1 10
9
SWF593757
7) MWP NMWP CONNECTOR

No. of
1
1
NMWP01F-B
6-23
8) DEUTSCH DT CONNECTORS
DT 06 - 3S - ★★★★
Modifications (see below)

Number of contacts (P : Pin, S : Socket)
04 : Receptacle, 06 : Plug
Deutsch connetors
※ Modification
E003 : Standard end cap - gray
E004 : Color of connector to be black
E005 : Combination - E004 & E003
EP04 : End cap
EP06 : Combination P012 & EP04
P012 : Front seal enhancement - connectors color to black for 2, 3, 4 & 6pin
No. of
1 2 2 1
2
DT06-2S DT04-2P
2 1 1 2
3 3
DT06-3S DT04-3P
4 1 1 4
3 2 2 3
DT06-4S DT04-4P
6-24
No. of
6 1 1 6
4 3 3 4
DT06-6S DT04-6P
4 5 5 4
1 8
8 1
DT06-8S DT04-8P
7 6
6 7
12
1 12 12 1
DT06-12S DT04-12P
6-25
9) ECONOSEAL J TYPE CONNECTORS
No. of
S816-001002 S816-101002
1 2 1
2
S816-002002 S816-102002
S816-003002 S816-103002
S816-004002 S816-104002
6-26
No. of
S816-006002 S816-106002
S816-008002 S816-108002
10
S816-010002 S816-110002
12
S816-012002 S816-112002
6-27
No. of
15
368301-1 2-85262-1
10) KET 090 CONNECTOR

No. of
1
2
MG610070
6-28
11) KET 090 WP CONNECTORS
No. of
1
2
MG640605
2 1
MG640795
12) CHINA CONNECTORS

No. of
2 1 1 2
4 3 3 4
DJ7041-6.3-11 DJ7041-6.3-21
8 4
5
8
DJ7081-6.3-21
6-29
13) TYCO CONNECTOR
No. of
2 1
282080-1
2
174198-1
5 11
11
1 6
172497-1
6-30

SL730

Uploaded by

SL730

Uploaded by

CONTENTS

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

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

SECTION 3 BRAKE SYSTEM

Group 1 Structure ------------------------------------------------------------------------------------------------------------- 3-1

SECTION 4 STEERING SYSTEM

Group 1 Hydraulic Circuit ------------------------------------------------------------------------------------------------- 4-1

SECTION 5 WORK EQUIPMENT

Group 1 Hydraulic Circuit ------------------------------------------------------------------------------------------------- 5-1

SECTION 6 ELECTRICAL SYSTEM

Group 1 Component Location ----------------------------------------------------------------------------------------- 6-1

Structure and function

2. Convert 550 mm into inches.

0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

Kilogram to Pound 1kg = 2.2046lb

0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84

0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378

Liter to U.K. Gallon 1ℓ = 0.21997 U.K.Gal

0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980

7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1

14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0

-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

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

FOLLOW SAFE PROCEDURE

WEAR PROTECTIVE CLOTHING

WARN OTHERS OF SERVICE WORK

USE HANDHOLDS AND STEPS

Be careful of slippery conditions on platforms,

WORK IN CLEAN AREA

PROTECT AGAINST FLYING DEBRIS

PROTECT AGAINST NOISE

SUPPORT MACHINE PROPERLY

SERVICE COOLING SYSTEM SAFELY

HANDLE FLUIDS SAFELY-AVOID FIRES

BEWARE OF EXHAUST FUMES

REMOVE PAINT BEFORE WELDING OR

SERVICE MACHINE SAFELY

STAY CLEAR OF MOVING PARTS

AVOID HEATING NEAR PRESSURIZED

PREVENT BATTERY EXPLOSIONS

USE TOOLS PROPERLY

damaged rims or missing lug bolts and nuts.

USE PROPER LIFTING EQUIPMENT

DISPOSE OF FLUIDS PROPERLY

LIVE WITH SAFETY

KEEP ROPS INSTALLED PROPERLY (option)

Bucket Tire Head light Hydraulic tank Air cleaner Raidator

Boom Boom cylinder Main control valve Battery Counterweight

Description Unit Specification

Description Unit Specification

3) MAIN CONTROL VALVE

5) DYNAMIC POWER TRANSMISSION DEVICES

(1) Coarse thread

(2) Fine thread

3) PIPE AND HOSE (ORFS type)

Thread size Width across flat (mm) kgf·m lbf·ft

Transmission Gear oil 40 (10.6) ATF DEXRON Ⅲ

ASTM D975 NO.1

·SAE : Society of Automotive Engineers ·NLGI : National Lubricating Grease Institute

※ Use this sheet to record operational

1. Cluster indicator and gauge checks (engine OFF)

· Transmission control lever and neutral □ □

3. Cluster indicator and gauge checks (engine running)

· Cluster display and alternator output checks □ □

· Park brake capacity check □ □

·Transmission noise check □ □

6. Hydraulic system checks

·Hydraulic system warm up procedure □ □

7. Steering system checks

·Steering unit check □ □