PDF Service Manual Hyundai HL760-7A Wheel Loader - 4 MB

This is the service manual for the Hyundai HL760-7A Wheel Loader.

It provides in-depth information for technicians to perform maintenance, troubleshooting, and major repairs.

The manual includes detailed procedures, specifications, and wiring diagrams.

Following this guide ensures that all service work is performed correctly and to factory standards.

It is an essential tool for any shop servicing these machines.

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--- Page 1 ---
CONTENTS

SECTION 1 GENERAL
  Group 1 Safety Hints - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1
  Group 2 Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-10
  Group 3 Operational Checkout Record Sheet - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-23


SECTION 2 ENGINE
  Group 1 Structure and Function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1
  Group 2 Engine speed & stall rpm - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-7
  Group 3 Fan drive circuit for cooling system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-8


SECTION 3 POWER TRAIN SYSTEM
  Group 1 Structure and Function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1
  Group 2 Operational Checks and Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-69
  Group 3 Test and Adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-80
  Group 4 Disassembly and Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-83


SECTION 4 BRAKE SYSTEM
  Group 1 Structure and Function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1
  Group 2 Operational Checks and Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-24
  Group 3 Tests and Adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-32
  Group 4 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-34


SECTION 5 STEERING SYSTEM
  Group 1 Structure and Function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-1
  Group 2 Operational Checks and Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-15
  Group 3 Tests and Adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-23
  Group 4 Disassembly and Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-30


SECTION 6 WORK EQUIPMENT
  Group 1 Structure and Function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-1
  Group 2 Operational Checks and Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-35
  Group 3 Tests and Adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-46
  Group 4 Disassembly and Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-62


                                                                                                          0-9

--- Page 3 ---
SECTION 1 GENERAL

Group 1 Safety Hints - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1
Group 2 Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-10
Group 3 Operational Checkout Record Sheet - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-23

--- Page 4 ---
GROUP 2 SPECIFICATION

1. MAJOR COMPONENT


           Bucket     Boom       Tire   Head light     Hydraulic tank     Air cleaner    Battery


        Bucket cylinder      Boom cylinder Main control valve    Radiator Counterweight


    Bucket link     Bell crank    Steering cylinder   Cab   Precleaner      Muffler     Engine


                          Front axle    Main pump     Transmission      Rear axle Fuel tank


                                                                                                 7607A2SE01


                                               1-10

--- Page 5 ---
6. TORQUE CHART
 Use following table for unspecified torque.
 1) BOLT AND NUT
  (1) Coarse thread
                                        8T                                 10T
     Bolt size
                            kgf·m                 lbf·ft       kgf·m                lbf·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 × 3.5              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
                            kgf·m                 lbf·ft       kgf·m                lbf·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


                                                  1-20

--- Page 6 ---
(2) Lubrication for the power components


                                                                                            7607AEG05


1   From lubricating oil cooler                   6   To camshaft
2   Main lubricating oil rifle                    7   Crankshaft main journal
3   To valve train                                8   Oil supply to rod bearings
4   From main lubricating oil rifle               9   Directed piston-cooling nozzle
5   To piston-cooling nozzle                     10   To internal lubrication of air compressor


(3) Lubrication for the overhead


                                                                                            7607AEG06


1   Main lubricating oil rifle                   4    Rocker lever shaft
2   Rocker lever support                         5    Rocker lever bore
3   Transfer slot                                6    Rocker lever


                                           2-4

--- Page 7 ---
3. TRANSMISSION
 1) LAYOUT


                                           12


                                                                                1
                  11


                                                                                2
                  10


                                                                                3


                                                                                4
                                      9

                           15

                                                                                5


                                                                              6


                                     14

                                           8


                                           7

                           13
                                                                                      7607PT03


  1   Reverse clutch(KR)        6    Rear output flange      11   Converter
  2   Engine-dependent          7    Converter side output   12   Inductive transmitter
      power take-off                 flange                       for engine speed
  3   Forward clutch(KV)        8    Output shaft            13   4th clutch(K4)
  4   2nd clutch(K2)            9    Transmission pump       14   Converter relief valve
  5   3rd clutch(K3)            10   Input flange            15   1st clutch(K1)


                                               3-5

--- Page 8 ---
By the direct proportional selection with separate pressure modulation for each clutch, the
  pressures to the clutches, taking part in the gear change, are controlled. In this way, a hydraulic
  overlab of the clutches to be engaged and disengaged is achieved.
  This is leading to fast shiftings without traction force interruption.
  At the shifting, the following criteria are considered:
  - Speed of engine, turbine, central gear train and output.
  - Transmission temperature.
  - Shifting mode(Up-, down-, reverse shifting and gear engaging from neutral).
  - Load level(Full- and partial load, traction, coasting inclusive consideration of load cycles during the
    shifting).
  The system pressure valve is limiting the maximum control pressure to 16+2 bar and releases the
  main stream to the converter and lubricating circuit.
  A converter relief valve is installed in the converter inlet, which protects the converter against high
  internal pressures(Opening pressure 9bar).
  Within the converter, the oil transfers the power transmission according to the well-known
  hydrodynamic principle(See torque converter, page 3-3).
  In order to avoid cavitation, the converter must be always completely filled with oil.
  This is achieved by a converter back pressure valve, following the converter, with an opening
  pressure of about 3.5bar.
  The oil, escaping from the converter, is directed to a oil cooler.
  The oil is directed from the oil cooler to the transmission and from there to the lubricating-oil circuit
  so that all lubricating points are supplied with cooled oil.
  In the electro-hydraulic control unit there are 6 pressure regulators installed.


5) GEAR SELECTOR(DW-3)
  The gear selector is designed for the
  mounting on the left side of the steering
  column. The positions(Speeds) 1 to 4 are                                           F

  selected by a rotary motion, the driving                                     1
                                                                               2
                                                                               3
                                                                                     N
                                                                           4
                                                                                     R
  direction Forward(F)-Neutral(N)-Reverse(R)
  by tilting the gear selector lever.
  The gear selector is also available with
  integrated kickdown control knob.
  A neutral lock is installed as protection
  against inadvertent drive off.
                                                                                         N   D
  Position N - Gear selector lever blocked in
  this position.
  Position D - Driving.                                                                            73033TM17


                                                   3-15

--- Page 9 ---
Fault code No.                        Reason                               Effect (only when fault code is active)
                 SAE J1939 Multiplexing Remote Accelerator             The engine will not respond to the remote
                 Pedal or Lever Position Sensor Circuit -              throttle. Engine may only idle. The primary or
    288          Received Network Data In Error. The OEM               cab accelerator may be able to be used.
                 vehicle electronic control unit (VECU) detected a
                 fault with the remote accelerator.
    292          Auxiliary temperature Sensor Input 1 - Special        Possible engine power derate.
                 instructions.
                 Auxiliary temperature sensor input 1 circuit -        None on performance.
                 Voltage above normal, or shorted to high
    293          source. High signal voltage or open circuit
                 detected at the OEM auxiliary temperature
                 circuit.
                 Auxiliary temperature sensor input 1 circuit -        None on performance.
    294          Voltage below normal, or shorted to low source.
                 Low signal voltage detected at the OEM
                 auxiliary temperature circuit.
    296          Auxiliary pressure sensor input 1 - Special           Possible engine power derate.
                 instructions.
                 Auxiliary pressure sensor input 1 circuit - Voltage   None on performance.
    297          above normal, or shorted to high source. High
                 signal voltage detected at the OEM pressure
                 circuit.
                 Auxiliary pressure sensor input 1 circuit - Voltage   None on performance.
    298          below normal, or shorted to low source. Low
                 signal voltage or open circuit detected at the
                 OEM pressure circuit.
                 Real time clock power interrupt - Data erratic,       None on performance. Data in the ECM will
    319          intermittent, or incorrect. Real time clock lost      not have accurate time and date information.
                 power.
                 Injector solenoid driver cylinder 1 circuit -         Engine can possibly misfire or run rough.
                 Current below normal, or open circuit. High
    322          resistance detected on injector number 1 circuit
                 or no current detected at number 1 injector driver
                 or return pin when the voltage supply at the
                 harness is on.
                 Injector solenoid driver cylinder 5 circuit -         Engine can possibly misfire or run rough.
                 Current below normal, or open circuit. High
    323          resistance detected on injector number 5 circuit
                 or no current detected at number 5 injector driver
                 or return pin when the voltage supply at the
                 harness is on.
                 Injector solenoid driver cylinder 3 circuit -         Engine can possibly misfire or run rough.
                 Current below normal, or open circuit. High
    324          resistance detected on injector number 3 circuit
                 or no current detected at number 3 injector driver
                 or return pin when the voltage supply at the
                 harness is on.
                 Injector solenoid driver cylinder 6 circuit -         Engine can possibly misfire or run rough.
                 Current below normal, or open circuit. High
    325          resistance detected on injector number 6 circuit
                 or no current detected at number 6 injector driver
                 or return pin when the voltage supply at the
                 harness is on.


                                                        3-25

--- Page 10 ---
Fault code           Meaning of the fault code
  (Hex)           possible reason for fault detection           Reaction of the TCU              Possible steps to repair   Remarks

    27       S.C. to battery voltage or O.C. at No reaction, TCU uses default â§£Check the cable from TCU to
             converter output temperature sensor input temperature             the sensor
             The measured voltage is too high:          OP mode : Normal      â§£Check the connectors
             â§£Cable is defective and is contacted to                          â§£Check the temperature sensor
               battery voltage
             â§£Cable has no connection to TCU
             â§£Temperature sensor has an internal defect
             â§£Connector pin is contacted to battery
               voltage or is broken

    28       S .C. to ground at converter output No reaction, TCU uses default â§£Check the cable from TCU to
             temperature sensor input                      temperature          the sensor
             The measured voltage is too low:              OP mode : Normal    â§£Check the connectors
             â§£Cable is defective and is contacted to                           â§£Check the temperature sensor
                vehicle ground
             â§£Temperature sensor has an internal defect
             â§£Connector pin is contacted to vehicle ground

    31       S.C. to battery voltage or O.C. at engine OP mode : Substitute clutch control   â§£Check the cable from TCU to
             speed input                                                                      the sensor
             TCU measures a voltage higher than 7.00V                                        â§£Check the connectors
             at speed input pin                                                              â§£Check the speed sensor
             â§£Cable is defective and is contacted to
                battery voltage
             â§£Cable has no connection to TCU
             â§£Speed sensor has an internal defect
             â§£Connector pin is contacted to battery
                voltage or has no contact

    32       S.C. to ground at engine speed input      OP mode : Substitute clutch control   â§£Check the cable from TCU to
             TCU measures a voltage less than 0.45V at                                        the sensor
             speed input pin                                                                 â§£Check the connectors
             â§£Cable/connector is defective and is                                            â§£Check the speed sensor
               contacted to vehicle ground
             â§£Speed sensor has an internal defect


                                                                      3-35

--- Page 11 ---
Fault code           Meaning of the fault code
  (Hex)           possible reason for fault detection               Reaction of the TCU             Possible steps to repair             Remarks

    95       S.C. to battery voltage at relay starter No reaction                               â§£Check the cable from TCU to
             interlock                                       OP mode : Normal                    the starter interlock relay
             TCU detected a wrong voltage at the output                                         â§£Check the connectors from
             pin, that looks like a S.C. to battery voltage                                      starter interlock relay to TCU
             â§£Cable is defective and has no connection                                          â§£Check the resistance* of * See Chapter (9)
                to battery voltage                                                               starter interlock relay
             â§£Starter interlock relay has an internal defect
             â§£Connector pin is contacted to battery voltage

    96       O.C. at relay starter interlock                 No reaction                        â§£Check the cable from TCU to
             TCU detected a wrong voltage at the output OP mode : Normal                         the starter interlock relay
             pin, that looks like a O.C. for this output pin                                    â§£Check the connectors from
             â§£Cable is defective and has no connection                                           starter interlock relay to TCU
               to TCU                                                                           â§£Check the resistance* of * See Chapter (9)
             â§£Starter interlock relay has an internal defect                                     starter interlock relay
             â§£Connector has no connection to TCU

    97       S.C. to ground at park brake solenoid         No reaction                          â§£Check the cable from TCU to
             TCU detected a wrong voltage at the output OP mode : Normal                         the park brake solenoid
             pin, that looks like a S.C. to vehicle ground                                      â§£Check the connectors from
             â§£Cable is defective and is connection to                                            park brake solenoid to TCU
               vehicle ground                                                                   â§£Check the resistance* of park * See Chapter (9)
             â§£Park brake solenoid has an internal defect                                         brake solenoid
             â§£Connector pin is contacted to vehicle
               ground

    98       S .C. to battery voltage at park brake           No reaction                       â§£Check the cable from TCU to
             solenoid                                         Optional : (Some customers)        the park brake solenoid
             TCU detected a wrong voltage at the output       TCU shifts to neutral caused by   â§£Check the connectors from
             pin, that looks like a S.C. to battery voltage   park brake feed back               park brake solenoid to TCU
             â§£Cable is defective and is connection to         OP mode : Normal                  â§£Check the resistance* of park * See Chapter (9)
                battery voltage                                                                  brake solenoid
             â§£Park brake solenoid has an internal defect
             â§£Connector pin is contacted to battery
                voltage


                                                                          3-45

--- Page 12 ---
Fault code           Meaning of the fault code
  (Hex)           possible reason for fault detection          Reaction of the TCU         Possible steps to repair              Remarks

   D1        S.C. to battery voltage at power supply for See fault codes No.21 to 2C   â§£Check cables and connectors Fault codes No.21 to No.2C
             sensors                                                                    to sensors, which are supplied may be reaction of this fault
             TCU measures more than 6V at the pin AU1                                   from AU1
             (5V sensor supply)                                                        â§£Check the power supply at the
                                                                                        pin AU1(Should be appx. 5V)

   D2        S.C. to ground at power supply for See fault codes No.21 to 2C            â§£Check cables and connectors Fault codes No.21 to No.2C
             sensors                                                                    to sensors, which are supplied may be reaction of this fault
             TCU measures less than 4V at the pin AU1                                   from AU1
             (5V sensor supply)                                                        â§£Check the power supply at the
                                                                                        pin AU1(Should be appx. 5V)

   D3        Low voltage at battery                    Shift to neutral                â§£Check power supply battery
             Measured voltage at power supply is lower OP mode : TCU shutdown          â§£Check cables from batteries to
             than 18V(24V device)                                                       TCU
                                                                                       â§£Check connectors from
                                                                                        batteries to TCU

   D4        High voltage at battery                    Shift to neutral               â§£Check power supply battery
             Measured voltage at power supply is higher OP mode : TCU shutdown         â§£Check cables from batteries to
             than 32.5V(24V device)                                                     TCU
                                                                                       â§£Check connectors from
                                                                                        batteries to TCU

   D5        Error at valve power supply VPS1         Shift to neutral                 â§£Check fuse
             TCU switched on VPS1 and measured OP mode : TCU shutdown                  â§£Check cables from gearbox to
             VPS1 is off or TCU switched off VPS1 and                                   TCU
             measured VPS1 is still on                                                 â§£Check connectors from
             â§£Cable or connectors are defect and are                                    gearbox to TCU
               contacted to battery voltage                                            â§£Replace TCU
             â§£Cable or connectors are defect and are
               contacted to vehicle ground
             â§£Permanent power supply KL30 missing
             â§£TCU has an internal defect


                                                                     3-55

--- Page 13 ---
2) FRONT AXLE DIFFERENTIAL SECTION


                                                                8         10   9   6      12


                                                   11

                                                   12


                           6   10     9


                                                                            Torque
                 7                                                        proportioning
                                          Limited slip


                 1
                                                                     12

                12

                 8


                 5

                                                                 4
                 3


                                                                                           7607PT16


1   Roller bearing                          7    Clutch
2   Input flange                            8    Planetary gear
3   Bevel gear set                          9    Spider
4   Differential housing                    10   Bevel thrust washer of side gear
5   Adjusting screw                         11   Thrust washer of planetary gear
6   Side gear                               12   Half case


                                     3-64

--- Page 14 ---
Item                 Description                              Service action

                              LOOK/FEEL : Transmission
                              must shift to former(2nd or 3rd or
                              4th) gear.
                              NOTE : If gear selector lever kick
                              down switch or RCV lever switch
                              is pressed twice, transmission will
                              shift down the immediately back
                              to former gear.
Forward, reverse and          Park unit on level surface.           OK
4th speed clutch pack    1
                          2
                          3
                                                                    Check completed.
                              Apply service brakes.
                         4


drag check
                                                               NOT OK
※ Transmission must           Move gear selector lever to
                                                               If unit moves, repair
   be warmed up for           neutral.
                                                               transmission.
   this check.
                              Move gear selector lever to 1st.
Engine running.
                              Release parking brake and
                              service brakes.
                              Run engine at low idle.
                              LOOK : Unit must not move in
                              either direction.
                              NOTE : If unit moves forward,
                              either the forward pack or the 4th
                              speed pack is dragging.

Transmission shift            Run engine at approximately OK
modulation check         1
                          2
                              1300rpm.                    Check completed.
                          3


Engine running.
                         4


                              Put transmission in 1st forward, NOT OK
                              shift several times from forward to Go to unit shifts too fast,
                              reverse and reverse to forward. chapter 2 in this group.
                              Repeat check in 2nd gear.
                              LOOK : Unit must slow down and
                              change direction smoothly.

Torque converter check        Start engine. Apply service OK
                         1


                         4
                          2
                          3
                              brakes and release parking brake. Check completed.
                              Move gear selector lever to 3rd NOT OK
                              speed.                           If stall rpm are too low or
                                                               too high, problem may be
                              Move gear selector control lever
                                                               engine power or torque
                              to forward "F" position.
                                                               converter.
                              Increase engine speed to high
                                                               IF OK
                              idle.
                                                               Replace transmission
                              LOOK : Torque converter stall torque converter.
                              rpm must be within the following
                              range.
                              Stall rpm : 2110±70rpm
                              Move gear selector control lever
                              to neutral "N" position and run for
                              15 seconds.


                                  3-74

--- Page 15 ---
2) DELIVERY RATES

    Port                              Description                              Size

     15    Connection to the oil cooler                                   1 5/6″-12UNF-2B
     16    Connection from the oil cooler                                 1 5/6″-12UNF-2B


3) INDUCTIVE TRANSMITTER AND SPEED SENSOR

    Port                              Description                              Size

     21    Inductive transmitter               n turbine                     M18×1.5
     34    Speed sensor                        n output and speedometer          -
     47    Inductive transmitter               n central gear train          M18×1.5
     48    Inductive transmitter               n engine                      M18×1.5


4) CONNECTIONS

    Port                              Description                              Size

     49    Plug connection on the hydraulic control unit                         -
     68    Pilot pressure(Option)                                     J      M16×1.5
     69    System pressure(Option)                                    G      M16×1.5


                                              3-84

--- Page 16 ---
(2) Converter
 Η Loosen hexagon head screws and
     separate diaphragm from the converter.


                                                     75773TM060


 Θ Loosen hexagon head screws and
   separate drive shaft from the diaphragm.


                                                     75773TM061


 Ι Remove inductive transmitter(Engine).


                                                     75773TM062


 Κ Loosen hexagon head screws and
   remove converter bell.


                                                     75773TM063


                                              3-94

--- Page 17 ---
(7) Disassemble clutch K1, K2 and K3
 ö The following figures show the disassem-
     bly of clutch K3.
     The disassembly of the clutches K1 and
     K2 is similar.


 Η Squeeze rectangular ring out.
   Pull tapered roller bearing from the shaft.
   Remove the opposite tapered roller
   bearing accordingly.
   Grab sleeve(Bearing 33800) 5873 001 059
   Grab sleeve(Bearing 39500) 5873 002 038

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