Service Guide

for WHEEL LOADER

page 0
Ⅰ. HYDRAULIC SYSTEM

page 1
1.General System HL730-7 and HL740-7

page 2
Main Control Valve HL740-7

Bucket Spool
Boom & Float Spool

Main Relief Valve

page 3
Boom Raise 1 HL740-7
Boom Lower 2

page 4
2-1.Boom Float 3 HL740-7

page 5
 HL757/760-7

2-SPOOL TYPE

SECUND. RELIEF VALVE S

PRESSURE CHECK PORT

MAKE UP VALVE (CHECK V/V)

3-SPOOL TYPE
BOOM SPOOL

BUCKET SPOOL

MAIN RELIEF VALVE

BOOM SPOOL

BUCKET SPOOL

AUX SPOOL

MAIN RELIEF VALVE

page 6
2-2.MCV Operation Boom Control (1/2) HL757/760-7
1. NEUTRAL 2. BOOM UP

page 7
MCV Operation Boom Control(2/2) HL757/760-7
3. BOOM DOWN 2. BOOM FLOAT

P MIN = 13~14 BAR

FOR BOOM FLOAT

page 8
3.Ride Control System (Load Suspension) ALL MODELS

A. OPERATION
RIDE CONTROL VALVE

ACCUMULATOR GROUP

RIDE CONTROL SWITCH

ON

OFF

Remark
“AUTO” or “ON” appears on the cluster display in case of (1) & (2)

page 9
3-1.Hydraulic Circuit ALL MODELS

Electric circuit: see chapter 9

page 10
4.Pilot Oil Supply Unit ALL MODELS
PILOT OIL SUPPLY UNIT

(Pre-set 45 bar)

30 bar
HL760-7
30 bar

(45 bar)

page 11
5.Safety Valve ALL MODELS

FEED LINE JOYSTICK

page 12
6.Joystick(Remote Control Valve) ALL MODELS

BOOM KICK OUT & BUCKET POSITIONING SYSTEM : see chapter 9

page 13
7.Steering System HL 730-7 & HL 740-7

A : 1st Steering Pump

EMERGENCY
B : Loader Pump
STEERING PUMP
(mounted on
transmission.) (5 bar)

page 14
Orbitrol Valve

Priority Valve

Steering Pump

Steering Cylinder

page 15
7-1.HL730-7 & HL740-7 Steering Pump

Pump Access through Cab Floor

Make Capacity GPM

HL730-7 : David Bown
HL740-7 : David Brown

page 16
7-2.Orbitrol Steering Valve HL730-7 & HL740-7

page 17
L R

T P

page 18
L R

T P

page 19
7-3.Overload Relief Valve HL730-7 & HL740-7

page 20
7-4.HL730-7 & HL740-7Priority Valve

CF

EF
LS

page 21
page 22
page 23
B. HL17, HL25, HL35, HL750, 760
¦ Steering pressure adjusting point : relief valve inside of Priority valve.

Not e; O ne turn of
a djusting sc rew is
7 0kg/? (10 00psi)
approx.

Sec tion of view of Priority valve for HL17, HL25, HL750,HL7 60

- Shot down the engine after lower the bucket on the ground.
- Remove connecting hose and fitting (“T” port).
- Insert the Hexagonal wrench(7/32 inch) to the relief valve.
- Turn the Hex.wrench clockwise to increase and turn anti-clockwise to decrease
the steering pressure.
- Assemble the fitting and hose at relief valve.
- Check again the steering pressure.

page 24
7-5.Steering Neutral HL 740-7 & HL 730-7

page 25
7-6.Left Turn HL730-7 & HL740-7

page 26
7-7.Right Turn HL730-7 & HL740-7

page 27
7-8.Steering Circuit HL757-7, HL760-7

STEERING VALVE
(EHPS)

29 Emergency pump
30 Emergency Priority valve
31 Check valve
32 Check valve
33 Emergency steering PS, NO (CD 40)
34 Steering PS, NC (CD39)

(10bar)

STEERING PUMP

WORK EQUIPMENT PUMP

EMERGENCY
STEERING PUMP (5 bar)
(mounted on transm.)

page 28
Steering PS, NC (CD39)

Emergency
steering PS, NO (CD 40)

page 29
7-9.Steering Piping HL757/760-7

P EF
LS
FROM EMERGENCY
PRIORITY VALVE

page 30
7-10.Steering Valve (1/2) HL757/760-7

ORBITROL

SHOCK & SUCTION VALVES

(LEFT & RIGHT)

MAIN STEERIN SPOOL

PILOT PRESSURE VALVE

(METERING SPOOL)

PRESSURE REDUCING VALVE (30Bar)

PRIORITY SPOOL MAIN STEERING RELIEF VALVE (210bar)

page 31
Steering Valve (2/2) (CONSIDER ENGINE RUNNING)
HL757/760-7
1. NEUTRAL 2. STEERING LEFT

P(30bar)

to tank

(PLS = 0 bar) (PLS = P)

“PRIORITY”

30 bar

“PRIORITY”
210 bar

to emergency to emergency
priority valve priority valve Remark - in case of maximum steering (end of stroke):
When the main steering relief valve opens, oil at left side of the
priority valve will flow over the relief valve towards the tank; this
results in bigger force at right side and by consequence the priority
is given again to port EF
page 32
7-11.Cushion Valve (1/2) HL757/760-7
The cushion valve eliminates steering jerk motion. Shocks will
be prevented by relieving of high pressuer in the steering lines.

RELIEF ASSY
PLUG 13 PLUG 13

Ck Ck Ck

1 SPRING FOR
(shimms) BOTH SIDES

RELIEF ASSY PLUG 13

Ck SPOOL

pressure
test “T”

page 33
Cushion Valve (2/2) HL757/760-7

Ck Ck

pressure
test “T”
Ck RELIEF ASSY

Steering
Cyl

page 34
7-12.Cushion Valve

- Function : absorb shock or vibration which is created possibly, when

loader travel uneven rough ground or when loader tire hit
against rock, stockpile of soil and etc during travel.

1)Install manual hydraulic pump and gauge as

figure at steering cylinder.
2)Remove plug No.13 at cushion valve.
3)Operate pump and check the pressure
when oil comes out from No.13

page 35
7-13.Steering Unit HL757/760-7

page 36
page 37
 HL757-7A
8.Brake System
A. CIRCUIT

BRAKE
PEDAL

50bar

CUT-OFF
VALVE
7bar

170bar PRESSURE SENSORS ON BRAKE CIRCUIT:

19 (CD26)
18 (CD3)
17 (CD4)
20 (CD5)

BRAKE
LINE FILTER

BRAKE
PUMP to fan motor
page 38
8-1.Brake Circuit HL730/HL740-7

A. CIRCUIT

BRAKE
PEDAL

Pilot Supply
unit
CUT-OFF
VALVE

170bar PRESSURE SENSORS ON BRAKE CIRCUIT:

19 (CD26)
18 (CD3)
17 (CD4)
20 (CD5)

BRAKE
LINE FILTER

BRAKE
PUMP to fan motor
page 39
8-2.Brake Piping ALL MODELS

FRONT AXLE

REAR AXLE
BRAKE PUMP

FAN PUMP

ENGINE SIDE

page 40
8-3.Cut-Off Valve ALL MODELS

Relief
CV1 CV2 valve

Charging/brake
(CD3)
Cut-off valve For verifying the accumulator pressure, do next:
1. Empty accu’s by pushing several times on the brake pedal (engine off)
150b max
CV3 2. Unscrew “charging press switch CD3, and mount pressure gauge (thread M10)
Parking (CD26) 120b min
3. Start engine, check pressure

PARKING
SOLENOID
BRAKE LINE FILTER
P (replace strainer ~ 250 hrs)

BRAKE LINE FILTER

A3

PS1 parking PS1 parking

(NC, CD26) (NC, CD26)

CV3
PS charging/brake
(NC, CD3)

PS charging/brake
(NC, CD3)
CV1 CV2

PARKING
SOLENOID Cut-off valve
Relief Cut-off valve
valve

Relief
valve parking sol, CN71

page 41
8-4.Brake Pedal ALL MODELS

PS clutch cut-off, CD5

FRONT BRAKE PRESS

REAR BRAKE PRESS

PS brake stop, CD4

page 42
8-5.HL730-7 & HL740-7 Parking Brake

Park Brake

Foot Brake

page 43
 ALL MODELS
The parking brake is engaged:
- when the machine is NOT operated PARKING BRAKE
- when (in case of machine operation) the parking
switch is put in OFF-position)

In case of demounting the brake:

Remove the cover and loosen the nut

PARKING SWITCH

Electric parking circuit: see chapter 9

HL760-7

Before adjusting gap:

- start engine
- parking switch in OFF position
- block the wheels so that the machine
cannot move

page 44
HL757-7, HL760-7

page 45
9.Electrically Controlled Hyd. Motor Fan Cooling System

Fan speed sensing factor

- coolant temperature (proportional sensing),
70(800rpm)→90℃(1,150rpm)
- engine Intake air temperature (on-off sensing), 70 ℃ ↑
- hydraulic oil temperature (on-off sensing), 95℃↑
- transmission oil temperature (on-off sensing), 90℃↑

Fan speed condition at engine high idle

- if the temperature of factors is low, the fan speed is max 800rpm
- if the temperature of factors is high, the fan speed is max 1150rpm

page 46
9-1.Fan Speed VS Engine Speed

Engine speed Fan speed Fan speed Fan speed

(rpm) at below 70℃ at 80℃ at over 90℃

800 600 600 600

900 625 650 670
1000 650 700 740
1100 675 750 810
1200 700 800 880
1300 725 850 950
1400 750 900 1020
1500 775 950 1090
1600 800 980 1150
1700 800 980 1150
1800 800 980 1150
1900 800 980 1150

page 47
 ALL MODELS

MCU
Relief Valve
+
-

FAN MOTOR
HL770-7

(±200 mA)

(±700 mA)

Screw A

릴리프 밸브 최대 Fan RPM:

압력
HL730/740-7 1100 rpm
점검 HL757 1200 rpm
HL760/770-7 1150 rpm
포트

page 48
9-2.Hyd. Circuit

Direction Control

Speed Control

page 49
Ⅱ. POWER TRAIN

page 50
1.Transmission
Zf full automatic ERGOPOWER transmissions

HL730-3 HL740-3 HL757-7

(#848~)

HL760-3 HL770-3 HL780-3

(#1302~) (#1171~) (#141~)

HL760-7 HL770-7

page 51
1.1 Electric Control System
EST37
CONTROL UNIT

HL757-7, HL760-7 HL770-7

page 52
 (1)

(2)

OPERATION

In automatic mode are 2 settings possible (mode 1 or

mode 2) . Refer to page 6 for activating the prefered
setting)

AUTOMATIC SHIFT: CHOOSE BETWEEN MODE 1 & 2:

MODE 1 AUTOMATIC SHIFT RANGE = [1 <--> 4 GEAR]

MODE 2 AUTOMATIC SHIFT RANGE = [2 <--> 4 GEAR]

page 53
 (or quick shift) KICK DOWN SWITCH (OR QUICK SHIFT)

The kick down switch can be programmed in 2 ways (mode 1 or mode 2) . QUICK SHIFT FUNCTION : CHOOSE BETWEEN MODE 1 & 2:
Refer to page 6 for activating the prefered setting)
MODE 1 PUSHING QUICK SHIFT BUTTON RESULTS

Pushing the switch results in linking PIN ED7 of the transmission controller to ALWAYS IN SHIFTING DOWN: 2 --> 1
the ground.
MODE 2 PUSHING QUICK SHIFT BUTTON RESULTS

IN SHIFTING DOWN & UP: 2 --> 1 --> 2 --> 1

GEAR SELECTOR CONNECTORS (CN121, CN122)

ARE SITUATED BEHIND FRONT WIPER PANEL:

Declucth electric mechanism: see page 70

page 54
1.2 Operating Modes of EST37

error codes table in service manual)

AEB Procedure see page 60

“ “

page 55
1.3 Section View
4WG-210 (~190) (HL760-7/HL757-7) 4WG-260/310 (HL770-7/HL780-3)

CONTROL VALVE
BLOCK

CONTROL VALVE
BLOCK

CONVERTOR RELIEF VALVE

page 56
1.4 Installation View
HL757-7, HL760-7 HL770-7A

(PTO, main
(PTO, main pump conn.)
pump conn.)

Coarse filter

page 57
1.5 Hydraulic Circuits
A. HL757-7, HL760-7

(inside block)

see page 58

page 58
B. HL770-7A

Full close : 500mA

Full open :
(inside block)
100mA(8.4bar)

see page 58

page 59
1.6 Shift Management Load Upshift,Coast Downshift

Input speed
16bar
Pressure

Offgoing clutch

10bar
Oncoming clutch

4bar

Fast filling
Fill compensation Take over Slipping phase New gear

page 60
1.7 Correct Clutch Filling

Fast fill time

Clutch filling
Pressure

depending on
- Size of clutch
Fills clutch
chamber - Clutch gap

Compensating time
Compensating pressure
Fast fill time
depending on
tolerances in
Moves piston
- Pressure regulator
towards discs
- Booster valve
pressure
Fast fill

- Clutch spring
- Clutch seal ring

Time

Compensating pressure

page 61
1.8 Determination Compensating Pressure

n Turbine

2 Seconds

Increase by 0.1 bar

Clutch pressure

Time
Pressure

page 62
1.9 Determination Fast Fill Time

n Turbine
Increase
by 0.01sec

Fast
fill time

0.15 sec

Time

page 63
1.10 Transmission Measuring Points
A. HL757-7, HL760-7 RIGHT SIDE VIEW

BACK SIDE VIEW

ENG
(T-transm CD-15)

LEFT SIDE VIEW

SEE ALSO PAGE 57

Emergency
(Output speed)
Steering pump

Not Conn. CD-27

Not Conn. CD-51
CD-50
CD-17

47 VENT
21
TRANSMISSION CONVERTOR
48

CD-15

page 64
B. HL770-7A
FRONT SIDE VIEW

RIGHT SIDE VIEW

(T-transm CD-15)

BACK SIDE VIEW

(Output speed)

SEE ALSO PAGE 57

Not Conn.
Not Conn.

CD-15

CD-50
CD-17
CD-51
CD-27

page 65
1.11 Electro Hydraulic Control Block
A. SECTIONAL VIEW

PROPORIONAL VALVE
(SEE NEXT PAGE)

page 66
1.12 Proportional Valve
Pressure regulator part
SECTION B - B

Current Connection
Clutch Neutral : at 100 mA
Clutch Active: at 500 mA

(NFS, BOOSTER Valve)

Pressure regulator part

ScreenFilter
(to Tank)

EXAMPLE OF FILL PRESSURE AND CURRENT AS FUNCTION OF TIME

ScreenFilter

(TO NFS)

(9 bar)
K2 (press) K1 (press)

9 bar
Amp2 Amp1
Operating pressure
(TO NFS)

page 67
1.13 Picture View of Valve Block

(SUMP) TEMP
SENDER

SCREEN FILTERS
INSIDE PLATE

page 68
1.14 AEB (Automatic Filling Parameter Determination)
A. DESCRIPTION

Before starting the AEB cycle :

1) warm up the transmission (T transm > 80°C)
2) move shift lever to Neutral position
3) engage parking brake
4) make sure that RPM is between 900 - 1000
How to operate AEB procedure
On the display: - select Menu / Adjustment
- push “AEB” during 2 seconds

Now, “K1, K2, K3, K4, KV, KR” and finally “OK” should be displayed on the screen successively
If not so, refer to the AEB table on next page and make sure that all parameters are OK . Then, try again

page 69
Display During AEB Mode (1/2)

page 70
Display During AEB Mode (2/2)

page 71
1.15 Data Transmitters & Proportional Valves All Loaders

page 72
1.16 Transmission Error Codes List

FIND DETAILED INFORMATION ABOUT TRANSMISSION ERROR CODES IN THE

HL757-7, HL760-7 SERVICE MANUAL, AT PAGE 3-27
HL770-7 SERVICE MANUAL, AT PAGE PAGE 3-20

page 73
* * Transmission temp. is lower then -12 °C

page 74
2. HL730-7 & HL740-7 Axle Assemblies Front Brake

Parking piston

Oil Passage

Service piston

page 75
2.1 HL730-7 & HL740-7 Axle Assembly Front brake Adjustment

Oil
Passage

-> Loose 3 turns to anticlockwise after

completely tighten the screws

page 76
2.2 HL730-7 & HL740-7 Axle Assembly Front Brake Checking

page 77
2.3 Axles / Final Drive HL757-7, HL760-7, HL770-7A

6 7 8 9
10
5

11

19

18

17 12

13

16
14
15

page 78
HL757-7, HL760-7, HL770-7A

page 79
Ⅲ. ELECTRIC SYSTEM

page 80
1. Electric system
1-1. Location
1-2. Parking system
1-3. Clutch cut-off system
1-4. Kick-out system
1-5. Ride control system
1-6. Emergency steering system

2. Cluster monitoring

3. Lights/Wiper circuit

HL730-7
HL740-7
HL757-7
HL760-7
HL770-7
HL780-7

page 81
1. Electric system ALL MODELS

1-1. Electric components location

1) Electric wire code
Cluster Machine Control Unit & Relay bord color code electric wires
Transmission Control Unit & Fuse box Y Yellow
G Green
Engine Control Unit L Blue
Gr or GY Gray
W White
Br or BR Brown
Or or OR Orange
V Violet
B Black
R Red

Example:
BrL (Br/L) = Brown wire with blue
stripe on it

page 82
2) Cluster Pin Lay-Out 3) Electric Throttle Pedal

Safety Device
permanent
ignition
Neutral Accel.
Remark: PIN 9, 10, 20: For program resetting
PIN 14, 15: MCU communication lines

page 83
4) CLUSTER Gauge specification

page 84
5) Controllers ALL MODELS

3 controllers are connected to each

other for optimal machine control

Transmission Control Unit (TCU) (EST37) Machine Control Unit (MCU) Engine Control Unit (ECU) (CumminsECM)

CN92
(HYUNDAI ATTACHMENT)

CN52 CN58 CN59 SENSOR CONNECTOR 50 p (2 PLUGS)

page 85
6) Free Connectors ALL MODELS

DIAGNOSIS / PROGRAMMING

CN98 RESISTOR 120 Ohm ( = CN99 on eng.harness)

CUMMINS DIAGNOSIS
CN139

CN97 DATA CABLE

CN98 MCU HYUNDAI PROGRAM UPGRADE/DIAGNOSIS

CN97
CN53 CN95 DATA CABLE
CLUSTER HYUNDAI PROGRAM UPGRADE
CN138
CN53 DATA CABLE
TCU Zf PROGRAM UPGRADE/DIAGNOSIS

OTHERS:

CN138 12V DC-DC CONVERTER (OPTION)

CN139 12V SOCKET (OPTION)

CN111 TWO LEVELER (JOYSTICK OPTION)

CN95

page 86
1-2. Electric Parking System ALL MODELS

- MACHINE ‘NOT’ OPERATED NO VOLTAGE PARKING BRAKE ALWAYS ENGAGED

PARKING BRAKE RELEASED

- MACHINE (IGNITION) ‘ON’
24V PARKING SOLENOID

PARKING SWITCH OFF

24V

CONTROLLER
OFF (MACHINE
PARK PS CONTROL UNIT)
NC,(CD-26)

24V 0V
PARKING SIG
PIN 2

24V EST 37
(TRANSMISSION
CONTROL UNIT)

24V TRANSMISSION OPERATIVE

ED 10
PIN 21
PARKING SWITCH ON

24V

0V
0V
PARKING BRAKE ENGAGED & TRANSMISSION IN NEUTRAL
ON
0V

page 87
1-3. Electric Declutch System ALL MODELS

CONTROLLER
(MACHINE
CONTROL UNIT)

24V
CLUTCH CUT OFF SW
PIN 10
24V

CLUTCH CUT OFF PS

PIN 29

ON

CLUTCH CUT-OFF SWITCH

BRAKE PEDAL PUSH EST 37
: 25Kg/cm2 (TRANSMISSION
CONTROL UNIT)

24V
ED 9
PIN 66
CLUTCH CUT-OFF PS
NO (CD-5)

TRANSMISSION IN NEUTRAL

page 88
1-4. Electric Boom & Bucket Positioning System ALL MODELS

Two proximate switches, mounted on the front structure of the

Fuse RCV / 24V machine, make sure that the joystick is “locked” in the position
“boom up or bucket in”, as long as the boom or bucket has not
reached the target position.

86 30 Proximate switch BOOM KICK OUT

B
BOOM UP RY
E
CR-41
S

85 87 87a Proximate switch

BOOM KICK OUT

86 30

B
BUCKET RY
E
CR-40
S
Proximate switch BUCKET LEVELLER
85 87 87a Proximate switch
BUCKET LEVELLER

Coils inside joystick housing

(1) (2) (3)
automize next operations:
BUCKET IN (1)
BOOM UP (2)
BOOM DOWN (FLOAT) (3)
CN114 CN111 Optional plug
LED
24V Max. 6mm

page 89
1-5. Electric Ride Control System ALL MODELS
- ’Auto’ position (Higher than 9.5Km)
Ride control v/v

Fuse 24V

1 AUTO = SPEED DEPENDING

2 OFF
3 ON
RIDE CONTROL
SWITCH

1 EST37
TRANSMISSION
CONTROL UNIT

2
8 (VPS2)

RIDE
CONTROL RY
3

57 (ADM5)

signal from speed sensor

page 90
1-5. Electric Ride Control System
- ’ON’ position

Ride control v/v

Fuse 24V

1 AUTO
2 OFF
3 ON, CONTINUOUSLY
RIDE CONTROL
SWITCH

1
EST37
TRANSMISSION
CONTROL UNIT

2
8 (VPS2)

RIDE
CONTROL RY
3

57 (ADM5)

signal from speed sensor

page 91
1-6. Electric Emergency Steering system

CONTROLLER (MACHINE CONTROL UNIT)

Fuse
Option

STEERING P/P PS
STEERING RY

STEERING PS
EMERGENCY
STEERING
PUMP
32 15 3
CR-37
(EMERGERNCY
STEERING TEST SW )

(NO, 5Kg/cm2)

(STEERING PS,NC :
10Kg/cm2 )

page 92
2. Cluster monitoring
The display be be configured like TYPE1 or TYPE 2:
2-1. LCD LAY-OUT (Go to menu group “adjustment-display” for this setting)

DISPLAY MENU BUTTONS

Scroll between meu items

EXPLANATION OF DISPLAY ELEMENTS

page 93
2-2. MENU EXPLANATION (1/3)
EXAMPLE: ACTIVATING JOB TIME MEASUREMENT

AUTOMATIC SHIFT: CHOOSE BETWEEN MODE 1 & 2:

MODE 1 AUTOMATIC SHIFT RANGE = [1 <--> 4 GEAR]

MODE 2 AUTOMATIC SHIFT RANGE = [2 <--> 4 GEAR]

AUXILARY SWITCHES INSIDE MENU PERMIT TO ACTIVATE

ABOVE FUNCTIONS WHEN STANDARD SWITCHES ARE DEFECT
(AUTO SELECT & CLUCTH CUT-OFF)

page 94
2-2. MENU EXPLANATION (2/3)

SEMI AUTO:
MODE 1 : 2->1->2->1
MODE 2 : 2->1->2->1
FULL AUTO:
MODE 1 : 4->3->4->3
3->2->3->2
MODE 1 : 4->3->2->1

page 95
2-2. MENU EXPLANATION (3/3)

(see p. 60)
MODEL

Refer to next page

Refer to next page

Refer to next page

WARNING LAMP

If the warning lamp lights up and the buzzer alarms, there might be an error:
to check this, do next steps on the menu:
MENU - DIAGNOSTICS - MACHINE - FAULT CODE: for viewing Machine errors codes
MENU - DIAGNOSTICS - ENGINE - FAULT CODE: for viewing Engine errors codes)
MENU - DIAGNOSTICS - TRANSMISSION - FAULT CODE: for viewing Machine errors codes)

Explanation of the codes : see next pages

page 96
2-3. ERROR CODES LIST
1) MACHINE ERROR CODES LIST (HYUNDAI)

When displaying the code, read the error description

by pushing on the “enter” button:

page 97
2) ENGINE ERROR CODES LIST (CUMMINS QSB/QSC) (1/3)

page 98
2) ENGINE ERROR CODES LIST (CUMMINS QSB/QSC) (2/3)

page 99
2) ENGINE ERROR CODES LIST (CUMMINS QSB/QSC) (3/3)

page 100
3) TRANSMISSION ERROR CODES LIST (Zf)

FIND DETAILED INFORMATION ABOUT TRANSMISSION ERROR CODES IN THE

HL757-7, HL760-7 SERVICE MANUAL, AT PAGE 3-27
HL770-7 SERVICE MANUAL, AT PAGE PAGE 3-20

page 101
2-4. SYMBOLS TRANSMISSION WARNING

* * Transmission temp. is lower then -12 °C

page 102
3. Lights/Wiper circuit (1) CLEARANCE LIGHT(STAND) + NUMBERPLATE LAMP + ILL. OF CLUSTER & SWITCHBOARD
(2) SAME LIKE (1) , BUT WITH HEAD LIGHT
SWITCH BOARD
(1) FRONT WORK LIGHTS
(2) SAME LIKE (1) , BUT WITH REAR WORK LIGHTS
REMARK Æ ONLY FUNCTIONS WHEN CLEARANCE LIGHTS ARE ACTIVATED

MULTI FUNCTION SWITCH:

SEE NEXT PAGE
HAZARD SW
1, 2 1, 2 (4 DIRECTION LIGHTS)

REAR
WORK LIGHTS

1, 2

NUMBERPLATE LAMP
(1) REAR WIPER, CONTINUOUS SPEED
(2) +REAR WASHER OPERATION,DURING PUSH

FRONT
WORK LIGHT STOP LIGHT -S

DIRECTION
LIGHT - T
BEACON SW, AT
LEFT UPPER SIDE
HEAD LIGHT - Lo DIRECTION -FOR ROTATOR LAMP
CLEARANCE LIGHT (+ HIGH BEAM LIGHT Hi) LIGHT ON ROOF (OPTION) CLEARANCE LIGHT (STAND) - C
(STAND) - C FRONT

page 103
3-1. MULTIFUNCTION SWITCH

HORN

FRONT WASHER OPERATION, DURING

PUSH (AUTOMATICALLY FRONT WIPER WILL
WORK 2,3 TIMES AS WELL)

-HIGH BEAM FLASH LIGHT FRONT WIPER OPERATION

-LEFT & RIGHT DIRECTION LIGHT
-HIGH BEAM LIGHT (ONLY OPERATIVE
WHEN HEAD LIGHT IS “ON”)
J = INTERMITTENTLY
(INTERVAL ADJUSTABLE VIA MENU ON CLUSTER:
Æ MENU/ ADJUSTMENT/WIPER INTERMITTENCE)

I, II = CONTINUOUS SPEEDS (1.,2)

page 104
3-2. ILLUMINATION CIRCUIT
(CLEARANCE LIGHT,...)
FRONT

REAR

S
T
C

CLEARANCE LIGHT (STAND) - C

S T C S T C
FRONT FRONT
REAR REAR

page 105
3-3. HEAD LIGHT CIRCUIT

FRONT

FRONT FRONT

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3-4. WORK LIGHT CIRCUIT

REAR REAR WORKLAMP

ON HL740-7
FRONT

FRONT FRONT
REAR REAR

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3-5. HAZARD, TURN AND ROTARY CIRCUIT
REAR DIRECTION LIGHT - T
REAR

6. HAZARD, TURN AND ROTARY CIRCUIT OPTION

REAR

FRONT

FRONT

FRONT
DIRECTION
LIGHT - T
OPTION
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3-6. WIPER AND WASHER CIRCUIT

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3-7. ELECTRIC COMPONENT SPECIFICATION (1/4) ALL MODELS

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3-7. ELECTRIC COMPONENT SPECIFICATION (2/4) ALL MODELS

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3-7. ELECTRIC COMPONENT SPECIFICATION (3/4) ALL MODELS

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3-7. ELECTRIC COMPONENT SPECIFICATION (4/4) ALL MODELS

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3-8. SYMBOLS & ABBREVIATIONS
The requiered circuits can be found in next books:
Electric Circuit Handbook : part nr. 91E2-30990
ON HYDRAULIC CIRCUITS: Hydraulic Circuit Handbook : part nr. 91E2-30980
MCV Main Control Valve
MR Main Relief Valve
RCV Remote Control Valve
(Joystick)
Dr Drain
Pi Pilot Pressure (30b)

ON ELECTRIC CIRCUITS:
BZ Buzzer
CN Connector
ILL. Illumination
NC Not Connected
INT Intermittent Signal (Wiper Mot)
Ry Relay
ACC Acceleration
CR Relay Connector
SOL Solenoid
AC Air Conditioner
ACT Actuator
COMP Compressor
MCU Machine Control Unit
GND Ground
TCU Transmission Control Unit
I (IG) Ignition
ECU Engine Control Unit (Cummins) =
S Start
ECM Electronic Control Unit Module (Cummins)
E Earth
OEM Original Equipment Manufacturer = Hyundai
B+ Battery Plus
PCB Printed Circuit Board
SW Switch
LH Left Hand Side
PS Pressure Switch
RH Right Hand Side

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