Wheel Loader Sl730

SECTION 1 GENERALSECTION 1 GENERAL

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

Group 2 Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-10

Group 3 Operational Checkout Record Sheet - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-19

1-1

SECTION 1 GENERALSECTION 1 GENERAL

FOLLOW SAFE PROCEDUREFOLLOW SAFE PROCEDURE

Unsafe work pract ices are dangerous. Understand service procedure before doing work; Do not attempt shortcuts.

WEAR PROTECTIVE CLOTHINGWEAR PROTECTIVE CLOTHING

Wear close fitting clothing and safety equipment appropriate to the job.

WARN OTHERS OF SERVICE WORKWARN OTHERS OF SERVICE WORK

Unexpected machine movement can cause serious injury.Before performing any work on the wheel load-er, attach a 「Do Not OperateDo Not Operate」 tag on the right side controller lever.

USE HANDHOLDS AND STEPSUSE 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.Be careful of slippery conditions on platforms, steps, and handrails when leaving the machine.

GROUP 1 SAFETY HINTSGROUP 1 SAFETY HINTS

73031GE01

73032E01

830K1SH03E

1-2

PREPARE FOR EMERGENCIESPREPARE FOR EMERGENCIES

Be prepared if a fire starts.

Keep a first aid kit and fire extinguisher handy.

Keep emergency numbers for doctors, ambulance serv ice, hospi ta l , and f i re department near your telephone.

PROTECT AGAINST FLYING DEBRISPROTECT AGAINST FLYING DEBRIS

Guard against injury from flying pieces of metal or debris; Wear goggles or safety glasses.

PROTECT AGAINST NOISEPROTECT AGAINST NOISE

Prolonged exposure to loud noise can cause impairment or loss of hearing.

Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises.

WORK IN CLEAN AREAWORK 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.

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1-3

SUPPORT MACHINE PROPERLYSUPPORT 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.

SERVICE COOLING SYSTEM SAFELYSERVICE 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.

HANDLE FLUIDS SAFELY-AVOID FIRES HANDLE FLUIDS SAFELY-AVOID FIRES

Handle fuel with care; It is highly flammable. Do not refuel the machine while smoking or when near open flame or sparks. Always stop engine before refueling machine.Fill fuel tank outdoors.

PARK MACHINE SAFELYPARK 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.

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· 73031GE23

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73031GE08

1-4

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.

BEWARE OF EXHAUST FUMESBEWARE 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 REMOVE PAINT BEFORE WELDING OR HEATINGHEATING

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.

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73031GE10

1-5

SERVICE MACHINE SAFELYSERVICE 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.

STAY CLEAR OF MOVING PARTSSTAY CLEAR OF MOVING PARTS

Entanglements in moving parts can cause serious injury.

To prevent accidents, use care when working around rotating parts.

ILLUMINATE WORK AREA SAFELYILLUMINATE 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.

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1-6

AVOID HIGH PRESSURE FLUIDSAVOID 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 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.

AVOID HEATING NEAR PRESSURIZED AVOID HEATING NEAR PRESSURIZED FLUID LINESFLUID 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 other materials.

PREVENT BATTERY EXPLOSIONSPREVENT 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. Warm battery to 16˚C (60˚F).

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1-7

USE TOOLS PROPERLYUSE 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 slipping wrenches.

Use only recommended replacement parts.(See Parts catalogue.)

PREVENT ACID BURNSPREVENT 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.

Avoid the hazard by:Filling batteries in a well-ventilated area.Wearing eye protection and rubber gloves.Avoiding breathing fumes when electrolyte is added.Avoiding spilling of dripping electrolyte.Use proper jump start procedure.

If you spill acid on yourself:Flush your skin with water.Apply baking soda or lime to help neutralize the acid.Flush your eyes with water for 10-15 minutes. Get medical attention immediately.

If acid is swallowed:Drink large amounts of water or milk.Then drink milk of magnesia, beaten eggs, or vegetable oil.Get medical attention immediately.

1.2.3.

4.5.

1.2.

3.

1.2.

3.73031GE18

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1-8

SERVICE TIRES SAFELYSERVICE 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, damaged rims or missing lug bolts and nuts.

USE PROPER LIFTING EQUIPMENTUSE PROPER LIFTING EQUIPMENT

Lifting heavy components incorrectly can cause severe injury or machine damage.

Follow recommended procedure for removal and installation of components in the manual.

DISPOSE OF FLUIDS PROPERLYDISPOSE 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.

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.

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1-9

LIVE WITH SAFETYLIVE WITH SAFETY

Before returning machine to customer, make sure machine is functioning properly, especially the safety systems. Install all guards and shields.

REPLACE SAFETY SIGNSREPLACE SAFETY SIGNS

Replace missing or damaged safety signs. See the machine operator's manual for correct safety sign placement.

KEEP ROPS INSTALLED PROPERLY 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 replaced, not reused.

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GROUP 2 SPECIFICATIONGROUP 2 SPECIFICATION

1. MAJOR COMPONENT1. MAJOR COMPONENT

830K2SE01E

Bucket

Boom

Bell crank

Bucket link

Muffler

Fuel tank

Engine

Battery

Tire

Boom cylinder

Bucket cylinder

Front axle

Head light

Main control valve

Cab

Steering cylinder

Main pump

Transmission Torque converter

Counterweight

RaidatorHydraulic tank Air cleaner

Precleaner

Rear axle

1-11

2. SPECIFICATIONS2. SPECIFICATIONS

WITH BOLT-ON CUWITH BOLT-ON CUTTING EDGE TYPE BUCKETTTING EDGE TYPE BUCKET1)1)

5700

4880

3775

G K

HJ

AE

D

C

F IB

4895

40

830K2SE03E

Description Unit Specification

Operating weight kg (lb) 10200 (22490)

Bucket capacityStruck

m3 (yd3)1.5 (2.0)

Heaped 1.8 (2.4)

Overall length A

mm (ft-in)

6830 (22' 5")

Overall width B 2450 (8' 1")

Overall height C 3235 (10' 7")

Ground clearance D 370 (1' 3")

Wheelbase E 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 Jdegree (˚)

45

Roll back angle (carry position) K 49

Cycle time

Lift (with load)

sec

5.2

Dump (with load) 1.2

Lower (empty) 2.7

Maximum travel speed km/hr (mph) 39.5 (24.5)

Braking distancem (ft-in)

13.1 (43' 0")

Minimum turning radius (center of outside tire) 4.90 (16' 1")

Gradeability degree (˚) 30

Travel speed

Forward

First gear

km/hr (mph)

7.4 (4.6)

Second gear 13.3 (8.3)

Third gear 23.9 (14.9)

Fourth gear 39.5 (24.5)

ReverseFirst gear 9.2 (5.7)


1-12

WITH TOOTH TYPE BUCKETWITH TOOTH TYPE BUCKET2)2)

5725

4880

3775

G K

HJ

AE

D

C

F IB

4895

40

830K2SE04E

Description Unit Specification

Operating weight kg (lb) 10200 (22490)

Bucket capacityStruck

m3 (yd3)1.4 (1.8)

Heaped 1.7 (2.2)

Overall length A

mm (ft-in)

6940 (22' 9")

Overall width B 2480 (8' 2")

Overall height C 3235 (10' 7")

Ground clearance D 370 (1' 3")

Wheelbase E 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 Jdegree (˚)

45

Roll back angle (carry position) K 49

Cycle time

Lift (with load)

sec

5.2

Dump (with load) 1.2

Lower (empty) 2.7

Maximum travel speed km/hr (mph) 39.5 (24.5)

Braking distancem (ft-in)

13.7 (43' 0")

Minimum turning radius (center of outside tire) 4.90 (16' 1")

Gradeability degree (˚) 30

Travel speed

Forward

First gear

km/hr (mph)

7.4 (4.6)


Third gear 23.9 (14.9)

Fourth gear 39.5 (24.5)

ReverseFirst gear 9.2 (5.7)


1-13

3. SPECIFICATION FOR MAJOR COMPONENTS3. SPECIFICATION FOR MAJOR COMPONENTS

ENGINEENGINE1)1)

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

1-14

MAIN CONTROL VALVEMAIN CONTROL VALVE3)3)

MAIN PUMPMAIN PUMP (+steering pump)2)2)

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

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)

CYLINDERCYLINDER4)4)

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

DYNAMIC POWER TRANSMISSION DEVICESDYNAMIC POWER TRANSMISSION DEVICES5)5)

Item Specification

Transmission

Model YJ315/BS428

TypeConverter Single-stage, Single-phase

Transmission Mechanical, hydraulic

Gear shift Forward fourth gear, reverse second gear

Control Mechanical single lever type

Axle

Drive devices 4-wheel drive

Front Front fixed location

Rear Oscillation±12˚ of center pin-loaded

Wheels Tires 17.5-25, 14PR (L3)

BrakesTravel Four-wheel, dry-disc type, pneumatic

Parking Disc type brake on transmission

SteeringType Hydraulic, articulated

Steering angle 40˚ to both right and left angle, respectively

1-15

4. TIGHTENING TORQUE OF MAJOR COMPONENT4. TIGHTENING TORQUE OF MAJOR COMPONENT

No. Descriptions Bolt sizeTorque

kgf·m lbf·ft

1

Engine

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

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

Hydraulicsystem

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

8 Steering valve mounting bolt M10×1.5 6.9 ± 1.4 49.9 ± 10.1

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

Powertrain

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 Torque converter housing mounting bolt M12×1.75 10.7 ± 1.6 77.4 ± 11.6

15 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

Others

Counterweight mounting bolt M30×2.0 199 ± 29.9 1439 ± 216

19 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

1-16

5. TORQUE CHART5. TORQUE CHART

Use following table for unspecified torque.

Fine threadFine thread

BOLT AND NUTBOLT AND NUT

Coarse threadCoarse thread(1)(1)

1)1)

(2)(2)

Bolt size8T 10T

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

Bolt size8T 10T

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

1-17

FITTINGFITTING4)4)

PIPE AND HOSE PIPE AND HOSE (FLARE type)2)2)

PIPE AND HOSE PIPE AND HOSE (ORFS type)3)3)

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

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

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

1-18

6. RECOMMENDED LUBRICANTS6. RECOMMENDED LUBRICANTS

Use only oils listed below or equivalent. Do not mix different brand oil.

Service point Kind of fluidCapacity

ℓ (U.S. gal)

Ambient temperature C̊ ( F̊)

-20(-4)

-10(14)

0(32)

10(50)

20(68)

30(86)

40(104)

Engine oil pan Engine oil 16 (4.2)

Transmission Gear oil 40 (10.6)

Axle Gear oil Front : 15 (4.0) Rear : 15 (4.0)

Hydraulic tank Hydraulic oil

Tank : 90 (23.8) System : 130 (34.3)

Fuel tank Diesel fuel 170 (44.9)

Fitting (grease nipple)

Grease As required

Radiator

Mixture of antifreezeand water

50 : 50

33 (8.7)

SAE 30

SAE 10W

SAE 10W-30

SAE 15W-40

SAE 80W-90

ISO VG 32

ISO VG 46

ISO VG 68

ASTM D975 NO.1

ASTM D975 NO.2

NLGI NO.1

NLGI NO.2

Ethylene glycol base permanent type

ATF DEXRON Ⅲ

SAE 85W-90

·SAE·API·ISO

:::

Society of Automotive EngineersAmerican Petroleum InstituteInternational Organization for Standardization

:::

National Lubricating Grease InstituteAmerican Society of Testing and MaterialAuto Transmission Fluid

·NLGI·ASTM·ATF

1-19

GROUP 3 OPERATIONAL CHECKOUT RECORD SHEETGROUP 3 OPERATIONAL CHECKOUT RECORD SHEET

·Owner ·Date ·Hours ·Serial No. ·Technician

:

:

:

:

:

Use this sheet to record operational Use this sheet to record operational checkout results.checkout results.Perform the operational check before Perform the operational check before installing any test equipment.installing any test equipment.

ItemOK

Comments

1. Cluster indicator and gauge checks (engine OFF)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 checks2. Transmission checks

· Transmission control lever and neutral □ □

3. Cluster indicator and gauge checks (engine running)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 □ □

NOTOK

※

830K1CH01

1-20

4. Brake system and clutch cut off checks4. 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 checks5. 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 checks6. 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 checks7. Steering system checks

·Steering unit check □ □

·Steering system leakage check □ □

1-21

8. Accessory checks8. 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 checks9. 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 □ □

SECTION 2 POWER TRAIN SYSTEM 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

2-1

GROUP 1 STRUCTURE AND FUNCTION GROUP 1 STRUCTURE AND FUNCTION SECTION 2 POWER TRAIN SYSTEM POWER TRAIN SYSTEM

Front axle

Ttansmission Upper shaft EngineTorque converter

Front drive shaft Center drive shaft Rear drive shaft Rear axle

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.

1. POWER TRAIN COMPONENT OVERVIEW1. POWER TRAIN COMPONENT OVERVIEW

830KPT01E

2-2

GROUP 2 TRANSMISSIONGROUP 2 TRANSMISSION

1. STRUCTURE AND WORKING PRINCIPLE OF TRANSMISSION1. 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

2-3

Figure 1 Structure of transmission

10

9

8

7

6

5

4

3

2

1

11, 12

1 Transmission housing 2 Large end cover 3 Reverse shaft assembly 4 Input shaft flange

5 Input shaft assembly 6 Countershaft assembly 7 Rear output flange 8 Output shaft

9 Range gear sleeve 10 Oil tray 11 Front output flange 12 Shoe brake

2-4

Gear Lever Gear selector lever High · low speed

selector leverⅠ Ⅱ Ⅲ

Forward 1 ● Low speed

2 ● F

3 ● High speed

4 ● R

Reverse 1 ● F

2 ● R

2. WORKING OF TRANSMISSION2. 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

Gear selector lever

High low speedselector lever

.Low speed

High speed

III

III 830KPT19

2-5

3. TECHNICAL DATA3. TECHNICAL DATA

Max. input speedMax. input torqueMax. input powerType of transmission housingTransmission ratio Forward gear 1 gear 2 gear 3 gear 4 Reverse gear 1 gear 2 Oil for transmission Oil pumpOperating pressure Allowable oil temperature of oil trayOperating pressure of brake relief valve

2500 rpm91.4 kgf·m (661 lbf·ft)82 kW Countershaft, constant mesh, hydraulic fork3.82 2.081.09 0.593.05 0.87

AFT (DEXRON Ⅲ)CB32 (no in transmission box)1.4 ~ 1.6 MPa 100˚C>0.55 MPa

2-6

Figure 4 Schematic diagram of oil system

1 Suction filtering device 2 Transmission pump 3 Transmission pressure valve

4 Overflow valve 5 Transmission control valve 6 Brake relief valve

4. WORKING AND CONSTRUCTION OF HYDRAULIC OPERATING SYSTEM 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.

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.

Control valve

Torque converter

Cooler

Torque converter

valve block

Lubrication

Brakevalve

T/Mpart

T/Cpart

Oilcooling

2-7

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.

Figure 5 Transmission control valve ass’y

5. TRANSMISSION CONTROL VALVE5. TRANSMISSION CONTROL VALVE

assembly

M22×1.5

M22×1.5

M22×1.5

2-8

6. MOUNTING6. MOUNTINGMount the transmission housing on the frame and fix with bolts. For mounting size, refer to the page

2-12.

CONNECTIONCONNECTION 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 :

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. Connection screw on the end of brake control valve is connected to the air pipe of brake master cylinder.Inlet for transmission control is located in Ⅰ-Ⅰ as illustrated in figure 5.Inlet for spray oil of transmission is located in Ⅱ-Ⅱ.

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

1)1)

USINGUSINGAfter 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)2)

(1)

(2)

(3)

(4)(5)

2-9

7. MAINTENANCE AND TROUBLESHOOTING7. MAINTENANCE AND TROUBLESHOOTING

MAINTENANCEMAINTENANCEMaintenance is carried out after running for 10, 50, 250, 500,1000 and 2000 hours.

10 hours ma10 hours maintenanceintenanceCheck oil level in transmission. Check transmission for normal operation and driving gear for noise. Check the bolts and nuts for good tightness and check for oil leaks.

250 250 hours maintenancehours maintenanceInspect operation and noise of transmission. Clean the filter.

500 hours mai500 hours maintenancentenanceRenew oil.

1000 hours 1000 hours maintenancemaintenance Replace oil filter.

2000 hours maint2000 hours maintenanceenance Inspect operation, input power, noise, oil temperature, oil leaks, etc. Clean air vent caps, fasten up screws and pipe fittings.

1)1)

(1)(1)①

②

③

(2)(2)

①

②

(3)(3)

(4)(4)

①

(5)(5)

①

①

②

2-10

TROUBLESHOOTINGTROUBLESHOOTING

Problem Cause Remedy

Too low oil pressure or

zero

1. Transmission gear pump does not supply oil

2. Failed reducing valve of torque converter.

3. Stuck brake valve.

4. Oil leaks in oil circuit.

5. Failed piston packing of clutch.

6. Failed O-ring of transmission valve.

7. Seal ring is failed.

8. Emptying valve for clutch has fallen off.

Repair.

Repair.

Repair.

Repair.

Service and repair.

Replace.

Replace.

Check and repair.

Too high oil pressure 1. Malfunction in overflow valve for torque converter.

2. Clogged oil circuit.

3. Incorrect oil is used.

Repair.

Clean.

Renew oil.

Too high oil temperature 1. Clogged oil cooler.

2. Water has gotten into the oil circuit.

3. Insufficient oil amount.

4. Incorrect gear selection in operation.

5. Hand brake can not be normally released or

braking drag.

6. Clutch friction plate can not be separated

completely.

Clean.

Renew oil.

Replenish oil.

Change to low gear.

Adjust.

Replace.

Engine runs but vehicle

will not move

1. Insufficient oil.

2. Incorrect range gear selector fork position.

3. Brake spool has not response.

4. Clutch friction plate collision.

5. Malfunction in control valve for transmission.

See “Too low oil pressure

trouble”.

Reengage gear.

Check brake spool.

Replace.

Repair.

Weak traction 1. Low oil pressure.

2. Clutch friction plate can not be separated

completely and dragging.

3. Insufficient oil supply.

See “Too low oil pressure

trouble”.

Repair.

Replenish oil.

2)2)

2-11

NOTES IN REPAIR OPERATIONNOTES IN REPAIR OPERATIONFollowing cares should be taken to reassemble the transmission after disassembly:

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. 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:

If clearance of input shaft is too little, thickness of paper gasket may be increased or that of shaft bushing decreased.

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.

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.

3)3)

(1)

(2)

①

②

③

2-12

Vie

w K

Fron

tR

ear

Fla

nge

CIn

put f

lang

e A

Hi-N

eutra

l-LoR

ange

G

ear

leve

r

Vie

w K

Oil

retu

rn p

ort

Out

put f

lang

e B

Pre

ssur

e oi

l por

t

Pre

ssur

e ta

pC

oolin

g oi

l por

t

Oil

spra

y po

rt

7. STRUCTURE7. STRUCTURE

OUTSIDE VIEWOUTSIDE VIEW1)1)

2-13

966

62

65

23

67

5

98

1514

1011

12

1611

17

9

521415

13

89

1918

20

2822

29

26

27

2423

2221

76

5

4

3435

31

30

1

4

89

13

25

3332

63

64

1 Housing 2 Name plate 3 Rivet 4 Bracket 5 Hexagon bolt 6 Spring washer 7 Hexagon nut 8 Hexagon bolt 9 Washer 10 End cover 11 Gasket 12 Regulating ring 13 Regulating screw 14 Hexagon bolt

15 Stop plate 16 Input shaft end cover 17 Seal 18 Middle shaft end cover 19 Gasket 20 Regulating ring 21 Nut 22 Washer 23 Connector 24 Washer plate 25 Strainer core 26 Bolt 27 Flange joint 28 Hexagon bolt

29 O-ring 30 Gasket 31 Sump 32 Suction pipe 33 Magnetic 34 Oring 35 Plug 52 Hexagon bolt 62 Housing cover 63 Cover sheet 64 Semi circular rivet 65 Gasket 66 Hexagon bolt

830KPT05

TRANSMISSION HOUSING TRANSMISSION HOUSING (1/2)2)2)

2-14

58

57

53

55

5456

6160

59 68

489

44

46

45

43

679

52

67

529

45

6744

4243

529

4645

4443

89

50

5151

49

3736

3942

4038

22

47

41

830KPT06

TRANSMISSION HOUSING TRANSMISSION HOUSING (2/2)

8 Hexagon bolt 9 Washer 22 Washer 36 O-ring 37 Pipe assy 38 Hexagon bolt 39 Pipe & dipstick 40 Seal 41 O-ring 42 Cover 43 Bush

44 Washer 45 Bush 46 Input end cover 47 Dowel pin 48 Socket pin 49 Washer 50 Input sealing cover 51 Input seal 52 Hexagon bolt 53 Air vent 54 Square nut

55 Vent plate 56 Sleeve 57 Plate 58 Sleeve 59 Long screw 60 Casing 61 Gasket 67 Plug 68 Plug

2-15

830KPT07

12

34

5

6

7

7

910

8

11

1213

1413

15

16

18

17

17

19

1320

1312

11

6

21

54

32

1

24

2223

OUTPUT SHAFTOUTPUT SHAFT3)3)

1 Hexagon bolt 2 Stop pad 3 Pressure plate 4 O-ring 5 Output flange 6 Dust cover 7 Seal output 8 Output rear end cover

9 Hexagon bolt 10 Washer 11 Ball bearing 12 Thrust ring 13 Sliding bearing 14 Ring 15 Gear 16 High-low sliding sleeve

17 Steel ball 18 Output shaft 19 Output gear 20 Ring 21 Brake drum 22 Nut 23 Spring washer 24 Bolt

2-16

830KPT08

1516

1718

19

21

24

20

28

27

529

303132

33

2322

2625

1 23

45

6

89

109

8

11

12

13

14

7

INTPUT SHAFTINTPUT SHAFT4)4)

1 Small ring nut 2 Stop washer 3 Washer 4 Flange 5 Taper roller bearing 6 Input shaft 7 Plug 8 Hole ring 9 Ball bearing 10 Gear 11 Snap ring

12 Outer end cover 13 External friction disc 14 Internal friction disc 15 Snap ring 16 Spring seat 17 Spring 18 Piston 19 Sealing ring 20 O - ring 21 Clutch case assy 22 Steel ball

23 Valve seat 24 Gear 25 Stop pad 26 Hexagon bolt 27 Pin 28 Bush 29 Inner sealing sleeve 30 Piston ring 31 Shaft end baffle 32 Stop pad 33 Hexagon bolt

2-17

12 3

45

67

8

9

1011

12

1110

13

14

15

16

1718

1920

2122

23

26

29

6

2425

2728

INTERMEDIATE SHAFTINTERMEDIATE SHAFT5)5)

830KPT09

1 Hexagon bolt 2 Stop pad 3 Shaft end baffle 4 Piston ring 5 Inner sealing sleeve 6 Roller bearing 7 Gear 8 Plug 9 Intermediate shaft 10 Hole ring

11 Ball bearing 12 Gear 13 Snap ring 14 Outer end cover 15 External friction disc 16 Internal friction disc 17 Snap ring 18 Spring seat 19 Spring 20 Pistion

21 Sealing ring 22 O-ring 23 Clutch case assy 24 Steel ball 25 Valve seat 26 Gear 27 Stop pad 28 Hexagon bolt 29 Pin

2-18

830KPT10

12 3

45

67

8

9

1011

12 1110

1314

15

16

1718

1920

21

2322

26

296

2524

27 28

REVERSE SHAFTREVERSE SHAFT6)6)

1 Hexagon bolt 2 Stop pad 3 Shaft end baffle 4 Piston ring 5 Inner sealing sleeve 6 Roller bearing 7 Sleeve 8 Plug 9 Reverse shaft 10 Hole ring

11 Ball bearing 12 Gear 13 Snap ring 14 Outer end cover 15 External friction disc 16 Internal friction disc 17 Snap ring 18 Spring seat 19 Spring 20 Piston

21 Sealing ring 22 O-ring 23 Clutch case aasy 24 Steel ball 25 Valve seat 26 Stop pad 27 Hexagon bolt 28 Stop pad 29 Pin

2-19

830KPT11

67

1312

1110

4

5

21

3

8

9

HIGH-LOW SPEED SHIFT FORKHIGH-LOW SPEED SHIFT FORK7)7)

1 Pin 2 Socket screw 3 HIgh-low shift fork 4 Gasket 5 Fork support

6 Washer 7 Hexagon bolt 8 Seal 9 Fork shaft 10 Plug

11 Washer 12 Steel ball 13 Spring

2-20

830KPT12

12

1211

109

1314

1516

17

22

23

24

26

25

78

5

76

1

2

34

27

28

1110

20

21

1918

9

CONTROL VALVECONTROL VALVE8)8)

1 Screw 2 Washer 3 Spring 4 Steel ball 5 Dust cover 6 Pressure tap 7 Washer 8 Plug 9 Snap ring 10 Seal

11 Regulating washer 12 Control sliding valve 13 Dust cover 14 Plug 15 O-ring 16 Cup 17 Brake sliding valve 18 Spring 19 O-ring 20 Spring seat

21 Plug 22 Valve body 23 Gasket 24 Bottom plate 25 Socket screw 26 Screw 27 Hexagon bolt 28 Washer

2-21

830KPT13

1

21

2

3

5

4

3 6

1314

19

7

7

8

910

10

11

12

15

2526

24

1617

18

2829

27

23

1420

21

22

PARKING VALVEPARKING VALVE9)9)

1 Parking brake bracket 2 Cam plate 3 Washer 4 Split pin 5 Axis pin 6 Set screw 7 Set screw spring 8 Set screw spring 9 Washer 10 Nut

11 Nut 12 Hexagon bolt 13 Upper fixed plate 14 Semi circular rivet 15 Lower fixed plate 16 Rivet 17 Friction pad 18 Bracket 19 Steel band 20 Bracket

21 Bolt 22 Iron wire 23 Regulating spring 24 Bracket 25 Bolt 26 Washer 27 Bracket 28 Hexagon bolt 29 Spring washer

2-22

Unscrew the M20×1.5 bolts on the oil pan with a spanner and make drainage fully.

830KTM10

M20×1.5 bolts

830KTM11

830KTM12M10×30 bolts

8. DISASSEMBLY8. DISASSEMBLY

DRAINAGE FOR TRANSMISSIONDRAINAGE FOR TRANSMISSIONHoist transmission up and put an oil

container under it.

1)1)(1)

(2)

OIL PAN OF TRANSMISSIONOIL PAN OF TRANSMISSION

Unscrew 20 - M10×30 bolts in sequence on the oi l pan with a spanner. As disassembly, two diagonal bolts should be

removed finally to prevent from injury to people due to falling oil pan. Be careful of remaining oil in the oil pan when the last two bolts are removed. Put the oil pan removed in a clean place.

2)2)

(1)

(2)

(3)

830KTM13

2-23

830KTM14

HAND BRAKE ASSYHAND BRAKE ASSY

Remove 4 - M12×30 bolts on the left bracket of hand brake with a spanner.

3)3)

(1)

830KTM15

Remove 4 - M8×25 bolts on the right bracket of handbrake with a spanner.

Pull the total hand brake assy out and put it in a clean place.

(2)

(3)

830KTM16

REMOVING FRONT & REAR OUTPUT REMOVING FRONT & REAR OUTPUT FLANGEFLANGE

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.

4)4)

(1)

830KTM17

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.

(2)

2-24

830KTM18

REMOVING INPUT FLANGEREMOVING INPUT FLANGE

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.

5)5)

(1)

830KTM19

REMOVING GEAR SHIFT FORK (HI REMOVING GEAR SHIFT FORK (HI AND LO SPEEDAND LO SPEED)

Put the transmission level, release the set screw lock on the gear shift fork mount and unscrew the M10 set screw with M14 spanner. 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.

6)6)

(1)

(2)

830KTM20

830KTM21

REMVING OUTER END COVER OF REMVING OUTER END COVER OF TRANSMISSIONTRANSMISSION

Put the transmission level with the input side up. 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. 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.

7)7)

(1)

(2)

(3)

2-25

830KTM22

Turn the transmission for other side and place it level.

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.

(4)

(5)

830KTM23

830KTM24

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.

(6)

830KTM25

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.

(7)

2-26

830KTM26

REMOVING REMOVING CLUTCHESCLUTCHES

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.

8)8)

(1)

830KTM27

830KTM28

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.

Use a flat taper to release the bolt lock onthe clutch assy and unscrew 8 - M10×25 bolts with a spanner.

Remove the retainer with a screwdriver, and then the outer end cover 6 outer friction plates and 5 inner plates in order.

Use a tool to remove 60 retaining ring from clutch case, and then inner spring seat, spring and piston in order.

(2)

(3)

(4)

(5)

830KTM29

2-27

830KTM30

REMOVING OUTPUT SHAFTREMOVING OUTPUT SHAFT

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.

9)9)

(1)

830KTM31

2-28

9. ASSEMBLY9. ASSEMBLY

ASSEMBING INPUT CLUTCH PARTSASSEMBING INPUT CLUTCH PARTS

Check the clutch valve seat (23) and internal steel ball (22) for looseness. Use a spanner to screw up 8 - M10×25 bolts to fasten gear I part drive gear (24) to clutch case assy (21). Put up glue and knock in 2 straight pins (27). 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. Fit the oil seal ring (19) into piston (18) groove with the broken opening toward gear. Fit O-ring (20) into place on clutch case. Tap the piston assy into the oil cylinder of clutch case with a tool. 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). Put up 6 outer plates (13) and 5 inner plates (14) alternatively, and assemble outer end cover (12)

and retainer (11) finally. Knock 2 annular ball bearing into the bore of gear I drive gear (10) and mount two retainer (8) to

set. Mount the gear I drive gear assy into the clutch assy. Insert input shaft (6) into the bore of gear I drive gear assy. Knock the bearing (5) onto the input shaft with the special tool and mark on the inner and outer ring of the bearing. Turn and mount sleeve (28) and knock the inner ring of bearing and oil seal (29) onto the input shaft respectively. 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.

(1)(2)

(3)(4)

(5)(6)(7)(8)

(9)

1516

1718

19

21

24

20

28

27

529

303132

33

2322

2625

1 23

45

6

89

109

8

11

12

13

14

7

830KPT08

(10)

(11)(12)(13)

(14)

(15)

1)1)

2-29

Check the valve seat (25) of clutch case assy (23) and internal steel ball (24) for looseness. Use a spanner to screw up 8 - M10×25 bolts to fasten gear II drive gear (26) to clutch case assy. Put up glue and knock in 2 straight pins (29). Unscrew 8 - M10×25 bolts with a spanner and put up 4 stop plates (27) and fasten up 8 - M10 ×25 bolts and lock up 4 stop plates with flat taper. Fit the oil seal ring (21) into piston (20) groove with the broken opening toward gear. Fit O-ring (22) into place on clutch case. Tap the piston assy into the oil cylinder of clutch case with a tool. Assemble the spring (19) and spring seat (18) onto the shaft of the clutch case and use the special tool to mount the circlip for shaft (9). Put up 6 outer plates (15) and 5 inner plates (16) alternatively, and assemble outer end cover (14) and retainer (13) finally. Knock two annular ball bearings (11) into the bore of gear II drive gear (12) and mount two retainers (10) to set. Mount the gear II drive gear assy into the clutch assy. Insert intermediate shaft (9) into the bore of gear II drive gear assy. 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. Knock inner seal (5) onto the intermediate shaft with special tool. 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.Put 2 piston rings (4) into inner seal groove.

(1)(2)

(3)(4)

(5)(6)(7)(8)

(9)

12 3

45

67

8

9

1011

12

1110

13

14

15

16

1718

1920

2122

23

26

29

6

2425

2728

830KPT09

(10)

(11)(12)(13)

(14)(15)

(16)

ASSEMBLING INTERMEDIATE SHAFT CLUTCH PARTSASSEMBLING INTERMEDIATE SHAFT CLUTCH PARTS2)2)

2-30

Check the valve seat (25) of clutch case assy (23) and internal steel ball (24) 5 for looseness. Use M16 spanner to screw up 8 - M10×25 bolts to fasten reverse gear reverse gear (26) to clutch

case assy. Apply glue and knock in 2 straight pins (29). Unscrew 8-M10×25 bolts with a spanner and put up 4 stop plates (27) and fasten up 8 - M10 ×25 bolts and lock up 4 stop plates with flat taper. Fit the oil seal ring (21) into piston (20) groove with the broken opening toward gear. Fit O-ring (20) into place on clutch case. Tap the piston assy into the cylinder of clutch case with a tool. Assemble the spring (19) and spring seat (18) onto the shaft of the clutch case and use the special tool to mount the circlip for shaft (9). Put up 6 outer plates (15) and 5 inner plates (16) alternatively, and assemble outer end cover (14)

and retainer (13) finally. Knock two annular ball bearings (11) into the bore of reverse drive gear (12) and mount two retainers (10) to set.

Mount the reverse drive gear assy into the clutch assy. Insert reverse gear shaft (9) into the bore of reverse drive gear assy. 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. Knock inner seal (5) onto the reverse gear shaft with special tool. 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.Put 2 piston rings (4) into inner seal groove.

(1)(2)

(3)(4)

(5)(6)(7)(8)

(9)

12 3

45

67

8

9

1011

12 1110

1314

15

16

1718

1920

21

2322

26

296

2524

27 28

830KPT10

(10)

(11)(12)(13)

(14)(15)

(16)

ASSEMBLING REVERSE SHAFT CLUTCH PARTSASSEMBLING REVERSE SHAFT CLUTCH PARTS3)3)

2-31

830KTM35

ASSEMBLING OUTPUT SHAFT PARTSASSEMBLING OUTPUT SHAFT PARTS

Mount four composite bearings to high speed gear and low speed gear respectively.

4)4)

(1)

830KTM36

Insert high and low speed sleeve gear, high speed gear and bearing onto the output shaft.

(2)

830KTM37

ASSEMBLYASSEMBLY

Mount the left bracket and right bracket of handbrake a t the ou tpu t s ide o f transmission onto the transmission box and set with four M8×25 bolts and M12×30 bolts respectively.

Mount the bearing outer rings into the bearing bore respectively and mark.

5)5)

(1)

(2)

830KTM38

Mount the intermediate shaft assy, reverse gear shaft assy and output shaft assy into their correct place on the box.

(3)

2-32

830KTM39

Mount bearing into the bore for bearing on the large end cover.

(4)

830KTM40

Mount the large end cover into the box and put up a paper gasket in the middle.

Assemble the outer seal into the oil inlet end cover.

Mount the oil inlet end covers in place on the box watching oil orifice position.

(5)

(6)

(7)

830KTM41

Assemble the front output flange and handbrake assy.

(8)

830KTM42

2-33

830KTM43

Assemble the low speed gear assy into the box.

(9)

830KTM44

Assemble the output shaft assy.(10)

830KTM45

Assemble rear end cover of output shaft and rear output flange.

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. Mount the intermediate shaft end cover and reverse gear shaft end cover and fasten up the screws and set the stop plate.

(11)

(12)

(13)

830KTM46

Mount the fork shaft in the fork bracket.

Mount the fork bracket assy through the holes on the box and fasten with 4 - M10×30 bolts. Mount the fork for high-low shift speed by inserting the fork shaft into the fork hole and adjust the pos i t i on o f fo r k sha f t t o keep i t perpendicularly and drill hole to match assembly.

(14)

(15)

2-34

830KTM47

830KTM48

Mount the oil pan and set with 20 - M10×30 bolts.

(16)

830KTM49

Mount the control valve assy and top plate and connect with 8-M10×45 and 4 - M10×35 bolts

(17)

2-35

GROUP 3 TORQUE CONVERTERGROUP 3 TORQUE CONVERTER

1. FEATURES AND USE 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 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 DATA3. 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

2-36

4. MOUNTING AND USAGE 4. MOUNTING AND USAGE

MOUNTING MOUNTING When mounting, ensure that centerline of rotation of torque converter coincide with that of

crankshaft of engine (see page 2-39).

USAGE USAGE Hydraulic torque converter uses AFT (DEXRON Ⅲ). Oil temperature should be within 85~100˚C, and not exceed 110˚C normally. 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.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. 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. 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. 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.

1)1)

2)2)(1)

(2)

(3)

(4)

(5)

(6)

2-37

5. OIL SUPPLY SYSTEM5. 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 MPa5 Flow Q ≥ 50 ℓ/min

2-38

6. TROUBLESHOOTING6. TROUBLESHOOTING

Problem Cause Increase engine rpm

Insuf f i c ien t

power output

Engine rpm drops. Increase engine rpm.

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

hydraulic torque converter.

Check for sensitivity of motion of overflow valve and

hydraulic oil leaks.

Too high oi l

temperature

Too long time of operation in low

efficiency region.

Decrease external load or increase engine rpm.

Too low oil level in oil tank or gas exists

in hydraulic oil.

Add hydraulic oil, check for tightness of the

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

system.

Repair hydraulic valve, increase oil pressure.

Low water level in cooling system. Repair water tank.

Insufficient oil supply. Check oil supply system.

Too l ow o i l

pressure in oil

supply system

Back pressure valve failure. Replace back pressure valve.

Clogged oil feed tube. Check oil tubing.

Insufficient oil supply of transmission oil

pump.

Check and repair oil pump, or replace.

Damaged or severely worn oil seal

inside hydraulic torque converter.

Replace oil seal.

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.

Damaged O-ring.

Replace the oil seal.

Replace the O-ring.

2-39

7. OUTSIDE VIEW7. OUTSIDE VIEW

Ove

rflow

pre

ssur

e

Tota

l 3

posi

-tio

ns o

f sp

line

Ope

ning

pre

ssur

e

Torq

ue c

onve

rter o

il su

pply

sys

tem

dia

gram

V

iew

A

Vie

w A

Ope

ning

pre

ssur

e

Pre

ssur

e m

easu

ring

port

Lifti

ng h

ole

Oil

over

flow

por

t

To c

ente

r

Oil

retu

rn p

ort

Tota

l3

spot

s

Oil

over

flow

por

t

Tota

l 3 s

pots

Leng

th o

f spl

ine

To c

ente

r

2-40

GROUP 4 AXLEGROUP 4 AXLE

1. 1. OUTLINEOUTLINE

PRODUCT SURVEYPRODUCT SURVEYThe 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.

MAIN PERFORMANCE AND TECHNICAL PARAMETERSMAIN PERFORMANCE AND TECHNICAL PARAMETERS

THE STRUCTURAL CHARACTERISTICS AND WORKING PRINCIPLE THE STRUCTURAL CHARACTERISTICS AND WORKING PRINCIPLE

Main sMain structural characteristicstructural 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.

Working principleWorking principle

1)1)

2)

3)3)

(1)(1)

(2)(2)

Axle model

Main technical parameters

Max. loadMax. input

torqueTotal ratio Main ratio

Wheel-endratio

Braking moment

Oil pressure

ZL30 18500 kg235 kgf·m

(1700 lbf·ft) 20.26 4.222 4.8

979 kgf (7080 lbf·ft)

9.8 MPa

Wheel reductor Axle shaft

Final drive Input flange

830K2AX100

2-41

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.

TransmissTransmission route of drive axle as follows:ion route of drive axle as follows:Power torque of vehicle → Input flange → Final drive → Differential → Axle shafts → Wheel-end reductors → Wheels.

MAINTENANCE MAINTENANCE 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 amountFront axle : 24ℓ(6.3 U.S.gal)Real axle : 24ℓ(6.3 U.S.gal)

Maintenance per 250 hoursaintenance per 250 hoursInspect wear condition of braking discs and whether there are destructive wear on them.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.Inspect whether oil level at axle housing meets the requirement. If oil level lowers, should refuel oil in time.

MaintenanMaintenance per 1000 hoursce per 1000 hours Lubricant in drive axle work per 1000 hours to replace once new oil.

Maintenance peMaintenance per 2000 hoursr 2000 hours Should disconnect drive axle to inspect when it has worked for 2000 hours.Inspect spiral bevel gear pair backlash, mesh and wear condition of final drive.Inspect wear condition of differential gears and bevel gear washers.Inspect wear condition of wheel-end gears.Inspect wear condition of wheel-end planet gear needle rollers and bearings.

4)4)(1)

(2)(2)

·

①②

③

(3)(3)

(4)(4)

①②③④

2-42

Requirement of inspection and debugging projects in the course of useSpiral 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.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.

(6)①

②

2-43

Parts names

Problem Cause Remdy

Final drive anddifferential

Loud noise 1. Gear backlash is oversize2. Bearing is worn.

Adjust gear backlash.Replace bearing.

Housing bodyearly heats

Lubr ica t ion is bad. No lubr icant or lubr icant is excessive.

Refuel lubricant to oil level.

Periodic unusual sound 1. Gear appears too th breakage.2. There is eyewinker inside.3. Fasteners loose.

Replace gear.

Bleed the oil port to inspect.Turn fasteners tight.

Differential failure Cross pin breakage. Replace cross pin.

Leakage 1. Oil seal ages and wears.2. Sealant loses its efficiency.

3. Fasteners loose

Replace oil seal.Scrape off old sealant and smear afresh.Turn fasteners tight.

Wheel-end reductions

Wheel-end doesn't rotate 1. Axle shaft breakage.2. Differential system failure.

Replace axle shaft.Adjust and replace differential system.

There is unusual sound

1. Gear appears too th breakage.2. There is eyewinker inside.

Replace gear.

Bleed the oil port to inspect.

Housing body early heats Lubr ica t ion is bad. No lubr icant or lubr icant is excessive.

Refuel lubricant to oil level.

Brake Braking failure 1. Oil line disconnects or is clogged.2. Piston O-ring ages and wears.3. Piston and piston cylinder jam.4. Hydraulic pressure isn't enough.

Connect or replace oil line.

Replace O-ring.

Replace brake.

Inspect oil pump and exhaust gas in oil line.

Friction lining doesn't release

1. Piston seal ring ages and wears.2. Oil inlet joint looses.3. There is casting defect on

brake body.

Replace seal ring.

Turn oil inlet joint tight.Replace brake body and repair.

TROUBLESHOOTINGTROUBLESHOOTING5)5)

TRANSPORTATION AND DEPOSITTRANSPORTATION AND DEPOSITStrictly 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.Can’t knock and savagely handle drive axle in the course of carry and turnover.

6)6)(1)

(2)

2-44

4

35

67

8

9

10

1112

13

1514

1716

1

2

18

830KPT14

STRUCTURESTRUCTUREDrive axle assemblyDrive axle assembly

8)8)(1)(1)

1 Wheel-end reductor 2 Axle housing assy 3 O-ring 4 Screw plug 5 Exhaust plug 6 O-ring

7 Screw plug 8 Screw plug 9 O-ring 10 Final drive assy 11 Double end studs 12 Washer

13 Nut 14 Washer 15 Bolt 16 Bolt 17 Washer 18 Disc brake assy

2-45

21 2224

23

27

25

2826

29

3233

35 36

3737

303128

43

98

1 2

76

10

1112

141315

1617

1918

20

5

34

10

830KPT15

Wheel-end reductorWheel-end reductor(2)(2)

1 Screw plug 2 O-ring 3 Bolt 4 Washer 5 Cover 6 Retaining plate 7 Adjusting mainstay 8 Screw plug 9 O-ring 10 Rim nut 11 Planetary carrier 12 O-ring

13 Steel ball 14 Washer 15 Needle roller 16 Spacer 17 Planetary pin 18 Planetary gear 19 Washer 20 Short axle shaft 21 Criclip 22 Sun gear 23 Screw 24 Lock nut

25 Ring gear 26 Bearing 27 Hub 28 Rim bolt 29 Straight pin 30 Washer 31 Bolt 32 Bearing 33 O-ring 34 Braking disc 35 Washer 36 Bolt 37 Oil seal

2-46

87

64321

5

9 1011

1011

1213

1415

1617

18

4645

44 43

4042

40

4240

3938

3938

37

3534

2928

3031

3233

28

2930

3132

33

2930

33

4240

41

27

26

2524

21212220

19

23

36

830KPT16

Final drive assemblyFinal drive assembly(3)(3)

1 Cover 2 Nut 3 Washer 4 Baffle plate 5 O-ring 6 Input flange 7 Oil seal 8 Oil seal 9 Thrust washer 10 Bolt 11 Washer 12 Bolt 13 Bearing 14 Adjust shim 15 Spacer 16 Bearing seat

17 Bearing 18 Adjust shim 19 Adjust nut 20 Bearing 21 Nut 22 Lock plate 23 Lock plate 24 Lock plate 25 Differential case 26 Driven bevel gear 27 Bolt 28 Diff bearing cap 29 Left differential case 30 Bolt 31 Lock plate 32 Lock plate

33 Bolt 34 Adjust nut 35 Bearing 36 Bolt 37 Right differential case 38 Thrust washer 39 Axle shaft gear 40 Thrust wahser 41 Cross pin 42 Planetary bevel gear 43 Final drive housing 44 Criclip 45 Bearing 46 Driving gear 46 Driving gear

2-47

23

45

54

3

6

7

89 10

11

12

23

4

43

6

89

1011

12

1413

1413

1

12

1111

23

45

54

3

6

7

89 10

11

12

23

4

43

6

89

1011

12

1413

1413

1

12

1111

830KPT17

Brake assemblyBrake assembly(4)(4)

1 Outside brake 2 Piston 3 Square seal ring 4 Dust shroud 5 Braking plate

6 O-ring 7 Inside brake 8 Washer 9 Joint 10 Exhaust plug

11 Washer 12 Bolt 13 Split pin 14 Bolt pin

SECTION 3 BRAKE SYSTEM SECTION 3 BRAKE SYSTEM

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

Group 2 Air brake circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-2

Group 3 Components specification and function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-3

3-1

GROUP 1 GROUP 1 STRUCTURESTRUCTURESECTION 3 BRAKE SYSTEM SECTION 3 BRAKE SYSTEM

1

2

3

3

4

7

6

5

1 Air brake valve 2 Air tank 3 Air booster 4 Oil and water separator

5 Safety valve 6 Front axle 7 Rear axle

830KBS01

3-2

GROUP 2 GROUP 2 AIR BRAKE CIRCUITAIR BRAKE CIRCUIT

AIR COMPRESSOR

REAR AXLE

FRONT AXLE

E/G

830KBS01A

1 Air brake valve 2 Air tank 3 Air booster 4 Oil and water separator

5 Safety valve 6 Auto water drain 7 Brake lamp air pressure switch 8 Pressure switch and sensor

3-3

GROUP 3 COMPONENTS SPECIFICATION AND FUNCTIONGROUP 3 COMPONENTS SPECIFICATION AND FUNCTION

1. BRAKE VALVE1. BRAKE VALVE

USE AND STRUCTURE 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.

WORKING PRINCIPLE 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.

TECHNICAL DATATECHNICAL DATAOperating air pressure : 784 kPa Working temperature : -30 ~ +80˚CWorking medium : air

MOUNTING AND CONNECTION SIZE MOUNTING AND CONNECTION SIZE Connection screw : M22×1.5 (3EA) Mounting : 4-ø9Dimensions : 136×136×335

CORRECT USE AND MAINTENANCE CORRECT USE AND MAINTENANCE Notes in using

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. Insert M8 bolts through 4-ø9 holes to make secure assembly.When connecting with piping, distinguish inlet port from outlet. Marking “1” means, inlet, “2” means outlet and “3” exhaust port.

Notes in Maintenance 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. A space should be secured for freely moving of the pedal. 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. 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.

1)1)

2)2)

3)3)

4)4)

5)5)

(1)(2)(3)

(1)(2)(3)

(1)①

②③

①

②③

④

(2)

3-4

TROUBLESHOTTINGTROUBLESHOTTING6)6)

Trouble Cause Remedy

Air leaks under no work.Air leaks under no work. Worn rubber. Replace rubber or assembly.

Air leaks under work.Air leaks under work. Worn rubber. Replace rubber or assembly.

Unsmooth exhaust.Unsmooth exhaust. Seizing of piston. Replace the assembly.

Improper adjustment of pedal roller and rod.

Adjust the adjusting screw manually to the 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)

STRUCTURE AND MOUNTING SIZESTRUCTURE AND MOUNTING SIZE7)7)

1 Bolt 2 Pedal 3 Rod

4 Equalizing spring 5 Spring 6 Piston

7 Intake valve

850KBS10

View A

Air outlet

Air intlet

Air outlet

3-5

Exhaust port

Manual drainage button

To connect air cylinder

2. SAFETY RELIEF VALVE2. SAFETY RELIEF VALVE

USE AND STRUCTURE USE AND STRUCTURE Safety relief valve automatically drains condensate inside the air cylinder of brake line and manual drainage is also available.

WORKING PRINCIPLE WORKING PRINCIPLE 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.

TECHNICAL DATATECHNICAL DATARated operating air pressure : 800 kPa Working temperature : -30 ~ +80˚CWeight : 0.1 kg

MOUNTING AND CONNECTION SIZEMOUNTING AND CONNECTION SIZEM22×1.5Exhaust port down.

STRUCTURE AND MOUNTING SIZESTRUCTURE AND MOUNTING SIZE

1)1)

2)2)

3)3)

4)4)

5)5)

(1)(2)(3)

(1)(2)

850KBS13

3-6


Leaks at valve port Leaks at valve port Damaged rubber of safety valve stem assy.

Replace safety valve assy

3. SAFETY VALVE3. SAFETY VALVE

USE AND STRUCTURE USE AND STRUCTURE Safety valve is used to ensure that charge pressure of air brake line does not exceed 900 kPa.

WORKING PRINCIPLEWORKING PRINCIPLECompressed 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.

TECHNICAL DATATECHNICAL DATASafety operating pressure : 850~900 kPa Working temperature : -40 ~ +80˚C

MOUNTING AND CONNECTION SIZEMOUNTING AND CONNECTION SIZEInlet M16×1.5 is connecting screw.

NOTES IN USINGNOTES IN USINGAdjusting 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.


1)1)

2)2)

3)3)

4)4)

5)5)

6)

(1)(2)

Air outlet

Air inlet

Adjusting bolt


850KBS14

3-7

4.OIL AND WATER SEPARATOR 4.OIL AND WATER SEPARATOR

STRUCTURE 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.

WORKING PRINCIPLEWORKING PRINCIPLEAir 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.

TECHNICAL DATA TECHNICAL DATA Opeing pressure : 784±20 kPa Exhaust stop pressure : 685 ~ 750 kPa Working temperatures : -30 ~ +100˚CWeight : 1.8 kg

MOUNTING AND CONNECTION SIZEMOUNTING AND CONNECTION SIZEMounting size : 2-M8×40 double end studConnection size : Inlet (M22×1.5), outlet (M22×1.5)Dimensions : 150.5×128.5×220

CORRECT USE AND MCORRECT USE AND MAINTENANCEAINTENANCENotes in using Before mounting, remove the plugs for inlet and outlet. Mount the unit on the mount plate with outlet down. Pressure regulator screw and safety valve have been set as delivery and user is not permitted to adjust or remove by his/her self.

Notes in maintenance 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. If severely worn wearing part or air leaks is found, immediately replace the wearing part. 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.

1)1)

2)2)

3)3)

4)4)

(1)(2)(3)(4)

(1)(2)(3)

5)5)(1)①②③

(2)①

②③

3-8


Leaks at exhaust port.eaks at exhaust port. Polluted exhaust valve. Clean pipe line.

Damaged exhaust valve. Replace exhaust valve.

Leaks at top head venteaks at top head vent Damaged diaphragm. Clean pipe line.

Damaged control piston O-ring. Replace control piston O-ring.


Air outlet

Air inlet


850KBS16

SECTION 4 STEERING SYSTEMSECTION 4 STEERING SYSTEM

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

4-1

1

5

6

10

11

89

P T

L

A

B

T

T/C

MCV

R7

GROUP 1 GROUP 1 HYDRAULIC CIRCUITHYDRAULIC CIRCUITSECTION 4 STEERING SYSTEMSECTION 4 STEERING SYSTEM

1. STEERING CIRCUIT1. STEERING CIRCUIT

1 Main pump 5 Steering cylinder 6 Streering valve

7 Steering unit 8 Return filter 9 Bypass valve

10 Air breather 11 Hydraulic tank

830K3HC03E

4-2

1

5

6

10

11

89

P T

L

A

B

T

T/C

MCV

R7

G

2. NEUTRAL2. NEUTRAL

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).

830K3HC34

4-3

1

5

6

10

11

89

P T

L

A

B

T

T/C

MCV

R

G

7

H

3. LEFT TURN3. LEFT TURN

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.

830K3HC35

4-4

1

5

6

10

11

89

P T

L

A

B

T

T/C

MCV

R7

G

H

4. RIGHT TURN4. RIGHT TURN

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.

830K3HC36

4-5

GROUP 2 STRUCTURE AND FUNCTIONGROUP 2 STRUCTURE AND FUNCTION

1 23

4 56 7 8 9

10 1112

13

14

15

1617

1819 20 21 22

2324

STEERING PUMP

LOADER PUMP

1. STEERING PUMP1. STEERING PUMP

830KSE15E

1 Snap ring 2 Oil seal 3 Front cover 4 Snap ring 5 Bearing 6 Bushing 7 Seal 8 Seal

9 Side plate 10 Drive gear 11 Driven gear 12 Seal 13 Seal 14 Middle body 15 Seal 16 Shaft

17 Pump body 18 Rear cover 19 Decal 20 Rivet 21 Washer 22 Bolt 23 Seal 24 Bolt

4-6

2. STEERING UNIT2. STEERING UNIT

STEERING GEARSTEERING GEAR

1 Spool 2 Centering spring 3 Sleeve 4 Seal 5 Bearing 6 Seal 7 O-ring 8 Housing 9 O-ring

10 X-ring 11 O-ring 12 Front cap 13 Spring washer 14 Bolt 15 Cap screw 16 Washer 17 Bar 18 End cap

19 Spacer 20 O-ring 21 Gerotor 22 Gerotor 23 Drive 24 Plate 40 Pin 41 Ball

850KSE12

1)1)

4-7

25 Plug 26 O-ring 27 Housing 29 Spool 30 Spring

31 Spring seat 32 Plug (adjusting screw) 33 Plug 34 Plug 35 O-ring

36 Spool 37 Ball 38 Poppet 39 Spring

850KSE13

OVERLOAD VELVEOVERLOAD VELVE 2)2)

4-8

INSTRUCTION FOR USE OF STEERING GEAR AND COMBINED OVERLOAD VALVEINSTRUCTION FOR USE OF STEERING GEAR AND COMBINED OVERLOAD VALVE

■ STEERIN STEERING GEAR G 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

Structure of steering gearStructure of steering gear For structure of steering gear, refer to page 4-6. The components of the system are as follows.

Rotary Rotary follow-up valve consisting of spool, sleeve and valve bodyfollow-up valve consisting of spool, sleeve and valve bodyControls direction of oil flow and its spool is directly connected with steering wheel and column.

CycCycloidal gear pairloidal 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.

Intermediate shafIntermediate shaft and yoke linking rotor and valve sleevet and yoke linking rotor and valve sleeveWorks to keep the valve sleeve synchronous with rotor as power steering while to transmit torque as manual steering.

SprSpring leafing leafEnsures the follow-up valve to return to center when not in steering.

One-way valOne-way valve between inlet and return portve between inlet and return portAs 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.

Working principle of steering gearWorking 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.

3)3)

·

·

(1)(1)

①

②

③

④

⑤

(2)(2)

4-9

ManManual steering :ual steering : 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.

Using, disassembly and assemblyUsing, disassembly and assemblyUsing steering gearUsing steering gearMounting 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. Test operation 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. 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. 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.

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.

(3)(3)·

①

②

③

a.

b.

c.

4-10

Disassembly of steering gearDisassembly of steering gearTypically, there are two kinds of orders for disassembling a steering gear, i.e. solution A and solution B. 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. 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.

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 gearAssembly of steering gear 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. Notes when assemblingClean 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. Junction surface of valve body, partition disc, stator and rear cover must be highly clean and there should no scratches or damages. 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. Conforming washer must be used for rear cover bolt. 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). Port of P, T, A, B should must be connected in one-to-one correspondence.

·

·

①

②

a.

b.

①

②a.

b.

c.

d.e.

f.

4-11



Oil leaksOil leaks Damaged O-ring at journal and overflow valve.

Replace O-ring.

Oil leaks at connections of valve body, partition disc, stator and rear cover.

Clean off dirt on junction surface, grind scratches, and fasten up screws according to notes in assembly.

Steering is light under no load (or Steering is light under no load (or l i g h t l o a d ) b u t h e a v y w h e n l i g h t l o a d ) b u t h e a v y w h e n increasing loadincreasing load

Pressure of overflow valve is lower than that of steering system or overflow valve is clogged.

Adjust the pressure of overflow valve to a specified value, or clean the overflow valve.

Steering is light as slowly turning Steering is light as slowly turning while heavy as fastwhile heavy as fast

Insufficient oil supply of hydraulic pump.

Select a suitable pump. Check hydraulic pump for normal operation ad check if the volumetric efficiency is too little.

Steering is heavy as fast or slowly Steering is heavy as fast or slowly turning and no steering pressure. turning and no steering pressure.

Malfunct ion of one-way valve inside the valve body.

If steel ball is missing, load ø8 steel

ball. If steel ball is stuck by dirt, clean.

Foam is in oil, irregular sound is Foam is in oil, irregular sound is heard, cylinder moves and stops heard, cylinder moves and stops from time to timefrom time to time

Air in steering system. Bleed air, check suction pipe for oil leaks, and that if return pipe is under oil level.

Steering is heavySteering is heavy Oil tank is not full, or oil viscosity too high.

Refill oil to specified level. Use recommended fluid.

Severe steering deviation. Cylinder Severe steering deviation. Cylinder will not move as turning steering will not move as turning steering wheel (or moves slowly)wheel (or moves slowly)

Malfunct ion in two-way buffer valve (steel ball is seized due to dirt, or spring failure).

Clean two-way buffer valve, or replace spring.

Disordered oil distribution. Steering Disordered oil distribution. Steering wheel turns itself or shakeswheel turns itself or shakes

Reversed locations of rotator and intermediate shaft.

Reassemble referring to notes in assembly.

Obvious increase in vibration by Obvious increase in vibration by pressure. Further, the wheel could pressure. Further, the wheel could not turnnot turn

Broken or deformed yoke, broken or deformed opening of intermediate shaft.

Replace yoke, replace intermediate shaft. Substitution with other object is forbidden.

Steering wheel could not return to Steering wheel could not return to center. Steering gear could not center. Steering gear could not unload when steering wheel stops unload when steering wheel stops turningturning

Steering column and valve spool are not coaxial.

Troubleshoot after finding out the cause.

Steering column has pushed the valve spool to be stuck.

Too much steering column rotating resistance.

Broken or deformed spring leaf.

Steering cylinder moves little at first Steering cylinder moves little at first and then will not as manual steeringand then will not as manual steering

Too low oil level in oil tank( oil in cylinder has returned to oil tank).

Refill oil to specified level.

As power steering, cylinder piston As power steering, cylinder piston reaches the extreme and driver reaches the extreme and driver could not feel the extreme clearly. could not feel the extreme clearly. Steering cylinder will not move as Steering cylinder will not move as manual steeringmanual steering

Too much radial or axial clearance at rotor and stator due to long time of use.

Replace rotor and stator. If axial clearance has become too large, grind the end surface of stator.

No manual steeringNo manual steering Too high oil viscosity. Use recommended oil.

6)6)

4-12

■ OVERLOAD VALVEOVERLOAD VALVE

OverviewOverview 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.

Structure and working principleStructure 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.

FeatuFeatures res Compact design, easy installation, space efficiency. Flexible pressure regulation, no leaks. Combined valve can simplify hydraulic system and has low costs.

StructStructure ure 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. 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. 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.

Installation and requirements in usingInstallation and requirements in usingInstallation 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.

(1)(1)

(2)(2)

·

①②③

①

②

③

·

(3)(3)①

4-13



Steering is light under no Steering is light under no load (or l i t t le load) but load (or l i t t le load) but heavy as load is increased. heavy as load is increased.

Pressure of overflow valve inside valve block is lower than required steering pressure.

Regulate the pressure in overflow valve.

Overflow valve is seized by dirt, or spring or oil seal failed.

Clean overflow valve, replace spring or seal ring.

Vehicle travel is deflected, Vehicle travel is deflected, or cylinder will not move (or or cylinder will not move (or slowly) when turning wheel. slowly) when turning wheel.

Failed two-way buffer valve (steel ball is stuck by dirt or spring failed), failed seal ring.

Clean two-way buffer valve, replace spring or seal ring.

Pressure cou ld not be Pressure cou ld not be regu la ted ( increase or regu la ted ( increase or decrease). decrease).

Broken spring. Replace spring.

Poor sealing at valve port causes valve constant open.

Set the spool and seat, or replace part.

Valve spool is stuck due to burr or oil stain.

Remove, inspect and repair.

Unstable pressure, with Unstable pressure, with f r e q u e n t n o i s e a n d f r e q u e n t n o i s e a n d vibration.vibration.

Poor contact between valve spool and seat.

Set the valve spool and seat, or replace part.

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)4)

4-14

3. STEERING VALVE3. STEERING VALVE

850KSE14

1 Body 2 Snap ring 3 Spool

4 O-ring 5 Spring 6 Spring seat

7 Plug 8 Damping plug

4-15

OVERVIEW 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.

STRUCTURE AND WORKING PRINCIPLE 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.

REQUIREMENTS IN USINGREQUIREMENTS IN USINGInstallation : The steering valve should be mounted such that the axis of valve spool is level as far

as possible. 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. 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.

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. Return piping of steering valve should be short as far as possible. Inside diameter of return piping should be relatively large.

1)1)

2)2)

3)3)(1)

(2)

(3)

(4)

(5)

4-16



Decrease in nominal stable Decrease in nominal stable flow is less than the flow flow is less than the flow required for steering gear for required for steering gear for 60 turn/min60 turn/min

Volumetric efficiency of supporting pump has increased, or the pump delivers a flow less than nominal stable flow as low speed operation.

Replace or repair pump.

Hydraulic oil is not clean. The spool of steering valve or safety valve is stuck due to impurities.

Clean the filter element and change hydraulic oil.

Broken or deformed spool spring or safety spring.

Replace spring.

Improper spool clearance of steering valve and increased inside leaks.

Repair or replace.

Damaged seal ring at safety valve seat.

Replace seal ring.

Increase in nominal stable Increase in nominal stable flow is more than the flow flow is more than the flow required for steering gear for required for steering gear for 100 turn/min100 turn/min

The spool of steering valve is stuck due to impurities.

Clean the filter element and change hydraulic oil.

Poor compression of spool spring of steering valve.

Check condition of assembly.

Clogged damping hole of valve spool. Clean the filter element and change hydraulic oil.

Pressure of safety valve is Pressure of safety valve is on the low side or too highon the low side or too high

Improper setting of opening pressure of safety valve.

Under stable nominal flow, regulate the pressure of safety valve. Add or subtract pressure regulating washer/shim.

Compression of safety valve spring is on the low side or over compressed.

Check the spring the mounting size.

Safety valve spool and seat are not in close contact.

Replace part.

Oil seeps & leaksOil seeps & leaks Damaged O-ring Replace O-ring.

4-17

23

54

2

324

7625

30

12

2811

10

21

29

13

26

15

98

14

15

1

22

1

1627

4. STEERING CYLINDER4. STEERING CYLINDER

830KSE15A

1 Dust seal 2 Rod wiper 3 O-ring 4 Rod seal 5 Buffer ring 6 O-ring 7 Snap ring 8 Washer 9 Nut

10 O-ring 11 Piston ring 12 Wear ring 13 Screw 14 Joint bearing 15 Snap ring 16 O-ring 21 Rod assy 22 Bushing

23 Cylinder head 24 Bushing 25 Back up ring 27 Clamp 28 Piston 29 Nut 30 Tube assy

4-18

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

GROUP 3 OPERATIONAL CHECKS AND TROUBLESHOOTINGGROUP 3 OPERATIONAL CHECKS AND TROUBLESHOOTING

4-19

※Hydraulic oil must be at operating temperature for these checks.

Item Description Service action

Steering unit checkSteering unit check Run engine at low idle.

Turn steering wheel until frames are at maximum right (A) and then left (B) positions.

LOOKLOOK :: Frames must move smoothly in both directions.

When steering wheel is stopped, frames must stop.

FEEL :FEEL : Excessive effort must not be required to turn steering wheel.

NOTE :NOTE : It is normal for steering to drift from stops when steering wheel is released.

OKOKCheck completed.

NOT OKNOT OKGo to next check.

Steering system leakage Steering system leakage checkcheckHeat hydraulic oil to oper-ating temperature.Run engine at high idle.

Turn steering wheel rapidly until frames are against stops.

Hold approximately 2kgf on steering wheel.

Count steering wheel revolutions for 1 minute.

Repeat test in opposite direction.

LOOKLOOK :: Steering wheel should rotate less than 5rpm.

NOTE :NOTE : Use good judgment; Excessive steering wheel rpm does not mean steering will be affected.


NONOT OKT OKDo steering system leak-age test in group 3 to isolate the leakage.

Right

Left

AB

4-20

2. TROUBLESHOOTING2. TROUBLESHOOTINGDiagnose malfunction charts are arranged from most probable and simplest to verify, to least 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 :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. TroubleshootingStep 4. Tests and adjustments (see group 4)

※


No steeringNo steering Low oil level.

Restricted suction line.

Failed hydraulic pump.

Stuck steering valve spool.

Relief valve in steering unit stuck open.

Failed hydraulic lines.

Add recommended oil.

Check.

Remove and inspect return filter for metal pump particles.

Remove and inspect steering valve spool.

Do relief cartridge leakage test.

Check.

Slow or hard steeringSlow or hard steering Too much friction in the mechanical parts of the machine.

Cold oil.

Worn hydraulic pump.

Low system relief valve setting.

Low overload relief valves setting.

Lubricate bearings and joints of frame or cylinders or repair if necessary.Check steering column installation.

Warm the hydraulic oil.

Do hydraulic pump performance check.

Test and adjust if necessary.

Test and adjust if necessary.

4-21


Constant steer ing to Constant steer ing to maintain straight travelmaintain straight travel

Air in system.

Leakage in steering system.

Worn steering unit.

Spring without spring force or broken.

Spring in overload relief valve broken.

Gear wheel set worn.

Cylinder seized or piston seals worn.

Check for foamy oil.

Do steering system leakage check.

Do steering unit neutral leakage test ingroup 4.

Replace springs.

Replace overload relief valve.

Replace gear wheel set.

Replace defects parts.

S low s teer ing wheel S low s teer ing wheel movement will not cause movement will not cause any frame movementany frame movement


Worn steering unit gerotor.

Do steering system leakage check.

Do steering unit leakage check.

Steering wheel can be Steering wheel can be t u r n e d w i t h f r a m e s t u r n e d w i t h f r a m e s against steering stopagainst steering stop

Leakage in steering system. Do steering system leakage check.

Steer ing wheel turns Steer ing wheel turns with no resistance and with no resistance and c a u s e s n o f r a m e c a u s e s n o f r a m e movementmovement

Broken steering column or splined of steering unit.

Lack of oil in steering unit.


Remove and inspect.

Star t engine and check steer ing operation.

Do steering system leakage test in group 4.

Erratic steeringErratic steering Air in oil.

Low oil level.

Loose cylinder piston.

Damaged steering unit.



Remove rod to inspect piston.

Remove and inspect.

Spongy or soft steeringSpongy or soft steering Air in oil.

Low oil level.



Free play at steering Free play at steering wheelwheel

Loose steering wheel nut.

Worn or damaged splines on steeringcolumn or valve.

Tighten.

Inspect.

Steering unit binding or Steering unit binding or steering wheel does not steering wheel does not immediately return to immediately return to neutral when releasedneutral when released

B ind ing i n s tee r i ng co lumn o r misalignment of column.

High return pressure.

Contamination in steering unit.

Inspect.

Check for a pinched or damaged returnline.

Inspect hydraulic fi lter for contamination.Repair cause of contamination. Flush hydraulic system.

4-22


Steering unit locks upSteering unit locks up Large particles of contamination in steering unit.

Worn or damaged steering unit.

Inspect hydraulic fi lter for contamination.Repair cause of contamination. Flushhydraulic system.

Repair or replace steering unit.

Abrupt steering wheel Abrupt steering wheel oscillationoscillation

Improperly timed gerotor gear in steering unit.

Time gerotor gear.

Steering wheel turns by Steering wheel turns by itselfitself

Lines connected to wrong port.

Worn or damaged steering unit.

Reconnect lines.

Repair or replace steering unit.

N e u t r a l p o s i t i o n o f N e u t r a l p o s i t i o n o f steering wheel cannot steering wheel cannot be obtained, i.e. there be obtained, i.e. there is a tendency towards is a tendency towards "motoring""motoring"

Steering column and steering unit out ofline.

Too little or no play between steering column and steering unit input shaft.

Pinching between inner and outer spools.

Align the steering column with steeringunit.

Adjust the play and, if necessary, shortenthe splines journal.

Contact the nearest service shop.

"Motoring" effect."Motoring" effect.The steering wheel can The steering wheel can turn on its ownturn on its own

Leaf springs are stuck or broken and have therefore reduced spring force.

Inner and outer spools pinch, possibly due to dirt.

Return pressure in connection with the reaction between differential cylinder and steering unit too high.

Replace leaf springs.

Clean steering unit or contact the nearest service shop.

Reduce return pressure.

BacklashBacklash Cardan shaft fork worn or broken.

Springs without spring force or broken.

Worn splines on the steering column.

Replace cardan shaft.

Replace springs.

Replace steering column.

4-23


"Shimmy" effect"Shimmy" effectThe s teered whee ls The s teered whee ls vibratevibrate(Rough tread on tires gives vibrations.)

Air in the steering cylinder.

Mechanical connections or wheel bearings worn.

Bleed cylinder.Find and remove the reason for air collection.

Replace worn parts.

Steering wheel can be Steering wheel can be turned the whole time turned the whole time w i thou t t he s tee red w i thou t t he s tee red wheels movingwheels moving

Oil is needed in the tank.

Steering cylinder worn.

Gear wheel set worn.

Spacer across cardan shaft forgotten.

Fill with clean oil and bleed the system.

Replace or repair cylinder.

Replace gear wheel set.

Install spacer.

Steering wheel can be Steering wheel can be turned slowly in one or turned slowly in one or both directions without the both directions without the steered wheels turningsteered wheels turning

One or both anticavitation valves are leaky or are missing in overload relief valves.

One or both overload relief valves are leaky.

Clean or replace defect or missing valves.

Clean or replace.

Steering is too slow and Steering is too slow and heavy when trying to turn heavy when trying to turn quicklyquickly

Insufficient oil supply to steering unit, pump defective or number of revolutions too low.

Relief valve setting too low.

Relief valve sticking owing to dirt.

Replace pump or increase number of revolutions.

Adjust valve to correct setting.

Clean the valve.

"Kick back" in steering "Kick back" in steering wheel from systemwheel from systemKicks from wheelsKicks from wheels

Fault in the system. Contact authorized man or shop.

H e av y k i ck - b a ck i n H e av y k i ck - b a ck i n steering wheel in both steering wheel in both directionsdirections

Wrong setting of cardan shaft and gear-wheel set.

Correct setting.

Turning the steering wheel Turning the steering wheel activates the steered activates the steered wheels oppositewheels opposite

Hydraulic hoses for the steer ing cylinders have been switched around.

Connect lines to correct ports.

Hard point when starting Hard point when starting to turn the steering wheelto turn the steering wheel

Oil is too thick (cold). Let machine run until oil is warm.

Too little steering forceToo little steering force Pump pressure too low. Correct pump pressure.

4-24

GROUP 4 TESTS AND ADJUSTMENTSGROUP 4 TESTS AND ADJUSTMENTS

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 hosesSteering 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.

If hydraulic system is contaminated due to a major component failure, remove and dis-assemble steering cylinders to clean debris from cylinders.

Install a new return filter element. Clean fil-ter housing before installing new element.

For a failure that creates a lot of debris, remove access cover from hydraulic oil tank. Drain and clean hydraulic oil tank of fill the specified oil to hydraulic oil tank through upper cover.

To minimize oil loss, pull a vacuum in hydraulic oil tank using a vacuum pump. Connect filter caddy suction line to drain port at bottom of hydraulic oil tank using connector. Check to be sure debris has not closed drain port.

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.

※

※

1)

2)

※

3)

4)

1. HYDRAULIC OIL CLEAN UP PROCEDURE USING PORTABLE FILTER CADDY1. HYDRAULIC OIL CLEAN UP PROCEDURE USING PORTABLE FILTER CADDY

4-25

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.

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.

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.

Stop the engine. Remove the filter caddy.

Install a new return filter element.

Check oil level in hydraulic oil tank ; Add oil if necessary.

5)

※

6)※

7)

※

8)

9)

10)

4-26

DIGITAL THERMOMETER INSTALLATIONDIGITAL THERMOMETER INSTALLATIONService equipment and toolsDigital thermometer

A : Temperature probe. Fasten to a bare metal line using a tie band. Wrap with shop towel.

B : Cable. C : Digital thermometer.

·

2. TEST TOOLS2. TEST TOOLS

CLAMP-ON ELECTRONIC TACHOMET-CLAMP-ON ELECTRONIC TACHOMET-ER INSTALLATIONER INSTALLATION

Service equipment and toolsTachometer

A : Clamp on tachometer.Remove paint using emery cloth and connect to a straight section of injec-tion line within 100 mm (4in) of pump. Finger tighten only-do not over tighten.

B : Black clip (-). Connect to main frame.

C : Red clip (+). Connect to transducer. D : Tachometer readout. Install cable.

1) 1)

2) 2)

A

C

B

D

CB

A

·

75795SE32

75795SE33

4-27

3. STEERING SYSTEM RESTRICTION TEST3. STEERING SYSTEM RESTRICTION TEST

SPECIFICATIONSPECIFICATIONOil temperature 45±5˚C (113±9˚F)Engine speed High idleMaximum pressure 3.0MPa (30 bar, 430psi)at steering unit

GAUGE AND TOOLGAUGE AND TOOLGauge 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.

Install temperature reader.(see temperature reader installation proce-dure in this group).

Heat hydraulic oil to specifications.(see hydraulic oil warm up procedure at page 5-33).

Connect fitting (A) and install gauge.

Do not operate steering or loader funct-Do not operate steering or loader funct-ions or test gauge may be damaged.ions or test gauge may be damaged.

Run engine at specification and read pres-sure gauges.

If pressure is more than specification at the steering unit, inspect steering unit.

1)

2)

3)

4)

·

·

·

850KSE37

P

A

4-28

4. STEERING UNIT LEAKAGE TEST4. STEERING UNIT LEAKAGE TEST

SPECIFICATIONSPECIFICATIONOil temperature 45±5˚C (113±9˚F)Engine speed High idleMaximum leakage 15ℓ/min (4 gpm)GAUGE AND TOOLGAUGE AND TOOLTemperature readerMeasuring container (approx. 20ℓ)Stop watch

Install frame locking bar to prevent machine from turning.

Install temperature reader.(see temperature reader installation proce-dure in this group).

Heat hydraulic oil to specifications.(see hydraulic oil warm up procedure at page 5-33).

Disconnect return hose from fitting.Install cap fitting.

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.

Leakage is greater than specifications, repair or replace steering unit.

1)

2)

3)

4)

5)

6)

·

· Cap fitting

TLR

Safety lock bar

830KSE38

4-29

5.5. STEERING UNIT PRESSURE TESTSTEERING UNIT PRESSURE TEST

SPECIFICATIONSPECIFICATIONOil temperature 45±5˚C (113±9˚F)Engine speed High idleOil pressure 16 MPa

GAUGE AND TOOLGAUGE AND TOOLGauge 0~35 MPa (0~350 bar, 0~5000 psi)Temperature reader

Connect gauge to test port.

Install temperature reader (see installation procedure in this group).

Install frame locking bar.

Heat hydraulic oil to specifications (see hydraulic oil warm up procedure at page 5-33).

Run engine at specifications and turn steer-ing wheel rapidly hold approximately 22N (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.

Read pressure gauge. This is the steering valve relief pressure.

If pressure in not to specification, remove 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.

1)

2)

3)

4)

5)

※

6)

7)

·

·

Test port

Steering cylinder

Safety lock bar

Relief valve

AB

830KSE39

(160 bar, 1160 psi)

SECTION 5 WORK EQUIPMENT SECTION 5 WORK EQUIPMENT

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

5-1

GROUP 1 HYDRAULIC CIRCUIT GROUP 1 HYDRAULIC CIRCUIT SECTION 5 WORK EQUIPMENT SECTION 5 WORK EQUIPMENT

1. HYDRAULIC CIRCUIT1. HYDRAULIC CIRCUIT

1 Main pump 2 Main control valve 3 Boom cylinder 4 Bucket cylinder

5 Steering cylinder 6 Steering valve 7 Steering unit 8 Return filter

9 Bypass valve 10 Air breather 11 Hydraulic tank

1

2

3 4

10

11

89

P T

A1

B1

A2

B2

T/C

5

6

P T

L

A

B

T

R7

Boom

Bucket

830K3HC01E

5-2

1

2

3 4

10

11

89

P T

A1

B1

A2

B2

T/C

Steering system

Boom

Bucket

2. WORK EQUIPMENT HYDRAULIC CIRCUIT2. WORK EQUIPMENT HYDRAULIC CIRCUIT

1 Main pump 2 Main control valve 3 Boom cylinder 4 Bucket cylinder

8 Return filter 9 Bypass valve 10 Air breather 11 Hydraulic tank

830K3HC02E

5-3

WHEN THE BOOM CONTROL LEVER IS IN THE RAISE POSITIONWHEN THE BOOM CONTROL LEVER IS IN THE RAISE POSITION

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.

··

·

·

1

2

3 4

10

11

89

P T

A1

B1

A2

B2

T/C

Steering system

Boom

Bucket

1)1)

830K3HC21

5-4

WHEN THE BOOM CONTROL LEVER IS IN THE LOWER POSITIONWHEN THE BOOM CONTROL LEVER IS IN THE LOWER POSITION

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.

··

·

1

2

3 4

10

11

89

P T

A1

B1

A2

B2

T/C

Steering system

Boom

Bucket

2)2)

830K3HC22

5-5

WHEN THE BOOM CONTROL LEVER IS IN THE FLOAT POSITIONWHEN THE BOOM CONTROL LEVER IS IN THE FLOAT POSITION

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.

·

·

·

1

2

3 4

10

11

89

P T

A1

B1

A2

B2

T/C

Steering system

Boom

Bucket

3)3)

830K3HC23

5-6

WHEN THE BUCKET CONTROL LEVER IS IN THE DUMP POSITIONWHEN THE BUCKET CONTROL LEVER IS IN THE DUMP POSITION

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.

1

2

3 4

10

11

89

P T

A1

B1

A2

B2

T/C

Steering system

Boom

Bucket

4)4)

830K3HC24

··

··

5-7

WHEN THE BUCKET CONTROL LEVER IS IN THE ROLL BACK (WHEN THE BUCKET CONTROL LEVER IS IN THE ROLL BACK (retractretract) POSITION) POSITION

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.

··

··

1

2

3 4

10

11

89

P T

A1

B1

A2

B2

T/C

Steering system

Boom

Bucket

5)5)

830K3HC25

5-8

GROUP 2 GROUP 2 STRUCTURE AND FUNCTIONSTRUCTURE AND FUNCTION

1. MAIN PUMP1. MAIN PUMP

STRUCTURESTRUCTURE1)1)

1 23

4 56 7 8 9

10 1112

13

14

15

1617

1819 20 21 22

2324

STEERING PUMP

LOADER PUMP

830KSE15E

1 Snap ring 2 Oil seal 3 Front cover 4 Snap ring 5 Bearing 6 Bushing 7 Seal 8 Seal

9 Side plate 10 Drive gear 11 Driven gear 12 Seal 13 Seal 14 Middle body 15 Seal 16 Shaft

17 Pump body 18 Rear cover 19 Decal 20 Rivet 21 Washer 22 Bolt 23 Seal 24 Bolt

5-9

MOUNTING REQUIREMENTS FOR GEAR PUMPMOUNTING REQUIREMENTS FOR GEAR PUMP Before mounting the gear pump, check its normal rotating direction and for being suitable to

whole system. 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. 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.

NOTES IN USING NOTES IN USING It’s strictly prohibited for user to disassemble the product, or the manufacturer will not guarantee

the performance of product. 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. 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. 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. 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. 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. 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.Before mounting the gear pump, check the rotating direction of pump meets requirement.

2)2)

3)3)

(1)

(2)

(3)

(1)

(2)

(3)

(4)

(5)

(6)

(7)

(8)

5-10



Noise in pumpNoise 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 input shaft.

Inspect.

Severe resonance with tank, peripheral parts of piping.

Check piping, elements and bolts for being securely fastened.

Pump lags in response or no Pump lags in response or no responseresponse

Insufficient oil supply. Refill oil to an adequate level.

Improper pressure setting of relief valve.

Regulate the pressure of relief valve.

Worn or damaged pump. Repair or replace.

Worn, leaking or stuck valve. Repair or replace.

High oil temperature High oil temperature Too low pressure setting at overflow valve.

Regulate pressure of 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 oilFoam forms in oil Air has entered into oil tank through suction pipe.

Fasten up all the connectors.

Incorrect selection of oil. Use recommended oil.

Too low oil level. Refill oil to an adequate level.

Worn or damaged lip seal for main shaft.

Replace the lip seal for main shaft.

4)4)

5-11


Insufficient flow of pump or nsufficient flow of pump or pressurepressure

Damaged side plate. Replace side plate.

Air has entered into the system. Fasten up all the connectors.

Too high viscosity of oil. Use recommended oil.

Leaks occur even after replacing Leaks occur even after replacing lip seal for main shaftlip seal for main shaft

Contaminated oil. Change all the oil.

Damaged lip seal for main shaft has damaged the sealing area of drive gear.

Replace drive gear shaft.

Worn or damaged seal ring. Replace seal ring.

NOTICE IN PLACING ORDERNOTICE IN PLACING ORDER5)5)

TURN RIGHT (CLOCKWISE)

TURN LEFT (COUNTER CLOCKWISE)

850K3HC52

5-12

2. MAIN CONTROL VALVE2. MAIN CONTROL VALVE

STRUCTURESTRUCTURE1)1)

830KSE17E

1 Bolt 2 End cover 3 Stopper 4 Spring retainer 5 Spring 6 Spring retainer 7 Spacer 8 O-ring kit 9 Spool 10 Relief valve 11 Overload valve 12 Plug 13 O-ring

14 Spring 15 Poppet 16 Plug 17 O-ring kit 18 Spring 19 Poppet 20 Bolt 21 Dust seal 22 End cap 23 O-ring kit 24 Pin 25 Plug 26 O-ring

27 O-ring kit 28 Plug 29 Body 30 Spool 31 Spacer 32 Spring 33 Ball 34 Spool positioner 35 Washer 36 Ring 37 Snap ring

1

23

45

67

89

1011

1213

1415 16 17 18 19 20

21

22

23

2425

2612

1329 28 27 15 14

3034 33 32 31

5-13

220 21 22 3 423 24 5 6 25

1111213141516171819

SAFETY RELIEF VALVESAFETY RELIEF VALVE

1 Seal 2 Lock nut 3 Seal 4 O-ring 5 Seal 6 Seal 11 Seat

12 Back up seal 13 Spring seat 14 Spring seat 15 Poppet 16 Spring 17 Housing 18 Nut

19 Adjust screw 20 Cap 21 Body 22 Washer 23 Spring seat 24 Spring seat 25 Spring

850KSE18

5-14

OVERVIEWOVERVIEWMulti-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.

MODEL IDENTIFICATION MODEL IDENTIFICATION

DFS - XX -XX

TECHNICAL DATATECHNICAL DATA

Product code Inner diameterSeries code

Item Unit Specification

Nominated flow ℓ/min 160

Nominated pressure MPa 16

Pressure regulating range MPa 8 ~ 20

Pressure lossCenter MPa <0.3

Direction change MPa <0.6

Pressure regulating range of overload valve MPa 8 ~ 25

2)2)

3)3)

4)4)

5-15

P T

A1

B1

A2

B2

Hydraulic circuit

Bucket

Boom

STRUCTURE AND WORKING PRINCIPLE STRUCTURE AND WORKING PRINCIPLE StructureStructure

5)5)(1)(1)

Working Principle

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.

(2)

Dum

pFl

oat

Low

erN

eutra

lLi

ft

Neu

tral

Ret

ract

(rol

l bac

k)

Bucket

Boom

830K3HC50

850K3HC51

5-16

Neutral positionNeutral 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. Bucket roll back and dumpBucket 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. Float of BoomFloat 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. Function of main relief valve, overload valve and makeup valveFunction 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.

MOUNTING AMOUNTING AND USINGND USING 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. Never disassemble the product in dust before assembling to machine to prevent dust from entering. Check that rated pressure, sliding function, oil-way type and other features conform to system requirements.

Mounting plate should be level, mounting screws fastened in even torque, and the valves should be in good alignment. Operating fluid should be clean, cleanliness meeting NAS 1638 10 grade and up. Allowable oil temperature range: -20 ~ 80˚C, normal oil temperature 50±5˚C. Connect each port correctly and piping shall not be too thin, too long.

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.

①

②

③

④

6)6)(1)

(2)

(3)

(4)

(5)(6)(7)(8)

5-17

No. Problem Cause Remedy

1

Insufficient operating pressure

1. Pressure of main relief valve is on low side.

1. Regulate pressure of main relief valve.

2. Spool of main relief valve is stuck. 2. Remove and clean, or replace valve spool.

3. Damaged pressure regulating spring.

3. Replace with new product.

4. Too much pressure loss in system line.

4. Replace piping, or regulate pressure of main relief valve within the allowable range of pressure.

2

Insufficient operating flow

1. Oil supply to system is insufficient. Check oil source and repair oil pump.

2. Too much leaks inside valve.

a. Too high oil temperature, low viscosity

a. Take measures to reduce oil temperature.

b. Improper hydraulic oil. b. Change hydraulic oil.

c. Too much clearance between slide valve and valve body.

c. Replace slide valve to keep a reasonable clearing.

3. Main relief valve failure. 3. Repair or replace the main relief

3

Malfunction in return. 1. Damaged or deformed return spring.

1. Replace with new product.

2. Dirt between valve lever and valve body.

2. Clean part.

4

External seeps and leaks

1. Damaged seal ring. 1. Replace with new product.

2. Loose fastening pieces. 2. Fasten related fastening piece.

3. Too high oil temperature, low viscosity

3. Takes measures to reduce oil temperature.

4. Poor sealing on flange surface. 4. Check fastening and sealing of related parts.


5-18

NOTES IN DISASSEMBLY NOTES IN DISASSEMBLY Keep clean field for assembly. Dust and dirt shall be strictly prevented. Never clean rubber sealing pieces with gasoline. To prevent from damage to part, never knock a part with an iron object when disassembling. Be sure to clean all the parts with kerosene or cleaner before assembling. After assembling, be sure to perform test and only passed product can be used.

8)8)(1)(2)(3)(4)(5)

5-19

628

8

78

30

27

11

13

3113

10

29

21

12

322

234

2416

9

5

11

10

25

26

1412

12

15

27

3. BOOM CYLINDER3. BOOM CYLINDER

1 Rod wiper 2 Rod seal 3 Buffer ring 4 O-ring 5 Snap ring 6 O-ring 7 Piston ring 8 Wear ring 9 Screw

10 O-ring 11 Hexagon screw 12 Washer 13 Dust seal 14 Bolt 15 Washer 16 Hexagon screw 21 Rod assy 22 Cylinder head

23 Back up ring 24 Bushing 25 Pipe assy - R 26 Clamp 27 Pipe assy - B 28 Piston 29 Nut 30 Tube assy 31 Bushing

830KWE20

5-20

21

12

3

424

255

22

12

728

29

8

29

30

9

17

3117

31

17

13

23

101126

6

17

15

33

14

627

1514

16

34

32

1011

4. BUCKET CYLINDER4. BUCKET CYLINDER

1 Rod wiper 2 Rod seal 3 Buffer ring 4 O-ring 5 Snap ring 6 O-ring 7 O-ring 8 Piston ring 9 Screw 10 Hexagon screw 11 Washer

12 Hexagon screw 13 Washer 14 Nut 15 Washer 16 Bolt 17 Dust seal 21 Rod assy 22 Cylinder head 23 Tube assy 24 Back up ring 25 Bushing

26 Rod pipe assy 27 Base pipe assy 28 Piston 29 Wear ring 30 Nut 31 Bushing 32 Pipe band 33 Clamp 34 Pipe band

830KWE21

5-21

GROUP 3 OPERATIONAL CHECKS AND TROUBLESHOOTINGGROUP 3 OPERATIONAL CHECKS AND TROUBLESHOOTING

1. OPERATIONAL CHECKS1. 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

5-22

※ Hydraulic oil must be at operating temperature for these checks.


Hydraulic system warm-up Hydraulic system warm-up procedureprocedure

Run engine at high idle.Refer to page 5-33.

Hold a hydraulic function over relief to heat oil (don't keep relief condition over 5 seconds at a time).

Periodically cycle all hydraulic functions to distribute warm oil.

Repeat procedure until oil is at operating temperature.

FEELFEEL : Hydraulic reservoir must be uncomfortable to hold your hand against.(approximately 40 ~50˚C)


Hydraulic pump Hydraulic pump performance checkperformance check

Heat hydraulic oil to operating temperature.Run engine at high idle.

With bucket flat on ground, actuate boom raise. Time how long it takes to raise boom to full height.

LOOKLOOK : Boom must raise to full height in less than 6~7 seconds.


NOT OKNOT OKCheck the hydrau l ic pump.

IF OKIF OKDo s tee r i ng sys tem leakage check at page4-24.

IF OKIF OKDo main hydraulic pump flow test at page 5-34.

Control valve lift checkControl valve lift checkRun machine at low idle.

With bucket partially dumped, lower boom to raise front of machine.

Slowly move boom control lever to boom lower position.

Slowly move bucket control lever to bucket dump position.

LOOKLOOK : Boom must not raise before moving down.

Bucket must not rollback before dumping.

OKOKCheck complete.

NOT OKNOT OKRepair lift checks in loader control valve.

5-23


Bucket rollback circuit relief Bucket rollback circuit relief valve checkvalve check

Position bucket at a 45˚ angle against an immovable object.

Engage transmission in 2nd speed forward.

LOOKLOOK : Bucket angle must not change.

OKOKCheck complete.

NOT OKNOT OKReplace boom lower check valve.

Bucket dump circuit relief Bucket dump circuit relief valve low pressure checkvalve low pressure check

Raise front of machine which bucket at 45˚ angle.

Backdrag with bucket while observing bucket angle.

LOOKLOOK : Bucket must not rollback

OKOKGo to next check.

NOT OKNOT OKDo loader system and circuit relief valve test at page 5-36.

Boom cylinder and bucket Boom cylinder and bucket cylinder drift checkcylinder drift check

Heat hydrau l i c o i l to operating temperature.

Se t the boom and bucke t horizontal, then stop the engine.

Stop the engine, wait for 5 minutes, then start measuring.

Measure the amount the lift and dump cylinder rods retract during 15 minutes. (unloaded bucket)

A : Retraction of boom cylinder rodB : Retraction of bucket cylinder rod

Boom cylinder must drift less than 36 mm

Bucket cylinder must drift less than 33 mm

OKOKCheck complete.

NOT OKNOT OKGo to next check.

B

A

A

B

5-24


Boom cylinder leakage Boom cylinder leakage checkcheck


Dump bucket until teeth or cutting edge is perpendicular to the ground.

Raise boom until cutting edge is about 1 m (3 ft) above ground.

Stop engine. Measure drift from tooth or cutting edge to ground for 1 minute.

Wait 10 minutes.

Measure drift from tooth or cutting edge to ground for 1 minute.

LOOKLOOK : Compare the drift rate between the first measurement and the second measurement.

OKOKDrift is approximately the same between first and second measurement.

Repair loader control valve or circuit relief valve.

NOT OKNOT OKIf drift is considerably less on second measurement, repair cylinder.

Bucket cylinder leakage Bucket cylinder leakage checkcheck


Raise bucket about 1 m (3 ft) off ground with bucket level.

Stop engine. Place a support under boom.


Wait 10 minutes.


LOOKLOOK : Compare the drift rates between the first measurement and the second measurement.

OKOKDrift is approximately the same between first and second measurement.

Repair loader control valve or circuit relief valve at page 5-36.

NOT OKNOT OKDrift is considerably less on second measurement.

Repair cylinder.

Check valve of safety valve Check valve of safety valve leakage checkleakage check


Put bucket level and position about 1.2 m (4 ft) above ground.

Place a piece of tape on cylinder rod at least 51 mm (2 in) from rod guide.Run engine at low idle in safety-release position.

LOOKLOOK : Bucket must not drift up.

OKOKCheck complete.

NOT OKNOT OKCheck or replace safety valve.

Control lever checkControl lever check Stop engine. Turn key switch to OFF position.

Move bucket control lever to roll back, dump positions and then release.

LOOKLOOK : Lever must return to neutral when released from roll back, dump positions.


NOT OKNOT OKRepair bucket control lever.

5-25


Cycle time checkCycle time check

Heat hydrau l i c o i l to operating temperature.Run engine at high idle.

Function

Boom raise

Boom lower

Bucket dump

Bucket rollback

Steering [No. of turns]

Operating condition.

Bucket flat on ground to full height.

Full height to level ground.

Boom at full height.

Boom at full height.

Frame stop to frame stop.

Maximum cycle time

5.1 sec

3.0 sec

1.1 sec

1.5 sec

6.1 turns

OKOKCheck complete.

NOT OKNOT OKGo to slow hydraulicfunctions in group 3.

5-26

※ MEASURING BOOM AND BUCKET CYCLE TIME

MEASURINMEASURING PROCEDUREG PROCEDURELifting time of boomLifting time of boomSet 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.

MEASUREMENT CONDITIONMEASUREMENT CONDITION·Coolant temperature : Inside operating range ·Steering position : Neutral·Hydraulic temperature : 40~50 C̊·Bucket : Unloaded·Engine speed : High idling

MEASUMEASURING TOOLRING TOOL · Stop watch (1EA)

Lifting time of boom

Lowering time of boom

Dumping time of bucketRollback time of bucket

Lowering time of boomLowering time of boomSet the bucket horizontal with the boom at the maximum height, lower the bucket and measure the taken for the bucket to reach the lowest position on the ground.

Dumping time of bucketDumping time of bucketRaise the boom to the maximum height and measure the time taken for the bucket to move from the maximum tilt back position to the maximum dump position

Roll back time of bucketRoll back time of bucketRaise the boom to the maximum height and measure the time taken for the bucket to reach the maximum tilt back position.

830KWE35

830KWE36

830KWE37

1)1)

(1)(1)

2)2)

3)3)

(2)(2)

(3)(3)

((4)4)

5-27

2. TROUBLESHOOTING2. 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. TroubleshootingStep 4. Tests and adjustments (see group 4)

※


Noisy hydraulic pumpNoisy hydraulic pump Low oil supply or wrong viscosity.

Plugged or pinched suction line.

Air in oil.

Plugged suction line.

Loose or missing hydraulic line clamps.

Hydraulic lines in contract with frame.

Worn or damaged pump.

Fill reservoir with recommended oil.

Clean or replace line.

Check for foamy oil.Tighten connections.Replace O-rings and or lines.

Inspect and clean suction line.

Tighten or replace clamps.

Inspect and repair.

Do hydraulic pump performance checkin group 3. Do hydraulic pump flow test in group 4.

No or Slow hydraulicNo or Slow hydraulicfunctionsfunctions

Failed or worn hydrualic pump.

Cold oil.

Slow engine speed.

Suction line air leak.

Low oil supply.

Wrong oil viscosity.

Oil leaking past cylinders or control valve.

Blocked or damaged line.

Binding loader control valve (MCV) spool.

Do performance check.

Warm oil up.

Adjust engine speed.Check high idle speed.



Use recommended oil.

Check cylinder drift in group 3.

Inspect lines.

Inspect valve.

5-28


No steering or hydraulicNo steering or hydraulicfunctionfunction

Low oil level.



Remove and inspect return filter for metal pump particles.

No hydraulic functionsNo hydraulic functionssteering normalsteering normal


Stuck open port relief valve.

Remove and inspect return filter for metal pump particles, or replace the pump.

Replace relief valve.

Boom float function Boom float function does not workdoes not work

Loader control valve (MCV) spool binding in bore.

Do pressure reducing valve pressure test.

One hydraulic function One hydraulic function does not work.does not work.

Stuck open port relief valve.

Oil leaking past cylinder packings.

Blockage in oil lines or valve.

Loader control valve (MCV) spool stuck in bore.

Replace relief valve.

Do boom and bucket cylinder leakage test in group 4.

Inspect lines for damage.Disconnect and inspect lines for internal blockage.

Inspect and repair valve.

Low hydraulic powerLow hydraulic power Leakage within work circuit.

Low system relief valve (main relief valve) setting.

Low port relief valve setting.

Leaking system relief valve.

Worn hydraulic pump.

Do cylinder drift check in group 3.

Do loader system and port relief valve pressure test in group 4.

Do loader system and port relief valve pressure test in group 4.

Remove and inspect valve.

Do hydraulic pump performance check in group 3.

5-29


Function drifts downFunction drifts down Leaking cylinders.

Leaking seals in circuit relief valve (port relief valve) or valve stuck open.

Leaking loader control valve (MCV).

Do cylinder leakage checks in group 4.

Inspect seals. Replace relief valve.

Repair or replace valve section.

Boom drifts upBoom drifts up Leakage in boom down spool. Remove and inspect boom down spool.

Boom down does not Boom down does not work (engine off)work (engine off)

MCV spool stuck. Inspect and repair valve.

Oil overheatsOil overheats Low oil viscosity in hot weather.

Excessive load.

Holding hydraulic system over relief.

Leakage in work circuit.

Plugged fins in oil cooler.

Internally plugged oil cooler.

Incorrect system or circuit relief valve setting.

Restriction in oil lines or loader control valve (MCV).

Malfunctioning steering unit.

Leaking system main relief valve.

Worn hydraulic pump (internal leakage).

Use recommended oil.

Reduce load.

Reduce load.

Do boom and bucket cylinder leakage test in group 4.

Inspect and clean oil cooler.

Do hydraulic oil cooler restriction test.

Do loader system and circuit relief valve pressure test in group 4.

Inspect for dented or kinked lines.

Do hydraulic system restriction test in group 4.

Do hydraulic system restriction test in group 4.Remove and inspect valve and seals.

Do hydraulic pump performance check in group 3.

Hydraulic oil foamsHydraulic oil foams Low oil level.

Wrong oil.

Water in oil.

Loose or faulty suction lines (air leak in system).


Change to recommended oil.

Change oil.

Tighten or install new lines.

5-30

Followings are general precautions for the hydraulic system and equipment.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.

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.

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 ManualOperator's Manual and change oil.

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.

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.

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.Recommended lubricants.) Never mix oil of different makes of kinds.

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.

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.

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.

When overhauling the hydraulic equipment replace all O-rings, backup rings, etc. with new ones. Assemble O-rings with grease or vaseline applied.

After installing the equipment, add more hydraulic oil to make up for that lost during disassembly.

Tighten joints correctly. Loose joints will cause the hydraulic oil to leak. If the oil leaks, the tank oil level drops and air gets sucked in, so the pump will break down. Also loose joints in suction lines will take air in and might cause abnormal noise, malfunction or damage to pumps.

※1)

2)

3)

4)

5)

6)

7)

8)

9)

10)

11)

12)

5-31

1. HYDRAULIC OIL CLEAN UP PROCEDURE USING PORTABLE FILTER CADDY1. 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.

If hydraulic system is contaminated due to a major component failure, remove and disassemble steering cylinders to clean debris from cylinders.

Install a new return filter element. Inspect filter housing before installing new element.For a failure that creates a lot of debris, remove access cover from hydraulic oil tank. Drain and clean hydraulic oil tank of fill the specified oil to hydraulic oil tank through upper cover.

To 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.

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.

※

※

1)

2)

※

3)

4)

GROUP 4 TESTS AND ADJUSTMENTSGROUP 4 TESTS AND ADJUSTMENTS

5-32

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.

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.

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.

Stop the engine. Remove the filter caddy.

Install a new return filter element.

Check oil level in reservoir; Add oil if necessary.

5)

※

6)※

7)

※

8)

9)

10)

5-33

2.2. TEST TOOLS TEST TOOLS

CLAMP-ON ELECTRONIC TACHOMETER CLAMP-ON ELECTRONIC TACHOMETER INSTALLATIONINSTALLATION·Service equipment and tools

Tachometer A : Clamp on tachometer.

Remove paint using emery cloth and connect to a straight section of injection line within 100 mm (4 in) of pump. Finger Tighten only-do not over tighten.

B : Black clip ( - ). Connect to main frame.C : Red clip (+). Connect to transducer.D : Tachometer readout. Install cable.

A

C

B

D

CB

A

DIGITAL THERMOMETER INSTALLATIONDIGITAL THERMOMETER INSTALLATION·Service equipment and tools Digital thermometerA : Temperature probe.

Fasten to a bare metal line using a tie band. Wrap with shop towel.

B : Cable.C : Digital thermometer.

1)1)

2)2)

75795SE32

75795SE33

3. HYDRAULIC OIL WARM UP PROCEDURE3. HYDRAULIC OIL WARM UP PROCEDURE

Install temperature reader (see temperature reader installation procedure in this group).

Run engine at high idle.

Hold a hydraulic function over relief to heat the oil.

Periodically cycle all hydraulic functions to distribute warm oil.

Heat oil to test specification (approx. 45 C̊).

1)

2)

3)

4)

5)

5-34

4. MAIN HYDRAULIC PUMP FLOW TEST4. MAIN HYDRAULIC PUMP FLOW TEST

SPECIFICATIONSPECIFICATIONOil temperature 45±5˚C (113±9˚F)Engine speed 2200±25 rpmTest pressure 160±5 bar (2280 psi)Maximum pump flow 169ℓ/min (44.6 gpm)

FLOW METER AND TOOLFLOW METER AND TOOLFlow meter 300ℓ/min (79.3 gpm)Temperature reader

Make test connections.

Install temperature reader.(see temperature reader installation procedure in this group)

Heat hydraulic oil to specifications.(see hydraulic oil warm up procedure in this group)

Run engine at test specifications.

Close flow meter loading valve to increase pressure to test specifications.

Read flow meter.

If flow is below specifications, check suction line and suction pressure for abnormality before removing pump.

·

·

1)

2)

3)

4)

5)

6)

7)

To MCV

Flow meter

Main pump

830KWE33

5-35

SPECIFICATIONSPECIFICATIONOil temperature (40~50 C̊)

Gauge and toolGauge 0~35 MPa (0~350 bar, 0~5000 psi)M : System (main) relief valveR : Bucket rollback reliefD : Bucket dump relief

Install fitting and pressure gauge to test port in pump delivery line.



To check the system relief (M), run engine at low idle. Lower boom to bottomed position.Slowly activate boom down function while watching pressure gauge. If pressure is not to specification, loosen lock nut on system relief valve (M) and adjust to specification.

Do not adjust the system relief valve above 160 kg/cm2 (2280 psi). Damage to the pump will result from excessive pressure settings.

5. L5. LOADER SYSTEM AND PORT RELIEF ADER SYSTEM AND PORT RELIEF VALVE PRESSURE TEST VALVE PRESSURE TEST

·

·

1)

2)

3)

4)

※

Relief valve Engine speed Relief pressure

System (M)

Low 160±5 kg/cm2

(2280±70 psi)

Bucketrollback (R)

Low 180±5 kg/cm2

(2560±70 psi)

Bucketdump (D)

Low 120±5 kg/cm2

(1710±70 psi)

MCV

Hyd tank

BucketBoom

M

DR

830KWE34

5-36

6. HYDRAULIC SYSTEM RESTRICTION 6. HYDRAULIC SYSTEM RESTRICTION TESTTEST

SPECIFICATIONSPECIFICATIONOil temperature 45±5˚C (113±9˚F)Engine speed High idleMaximum pressure

Maximum pressure at main control valve

GAUGE AND TOOLGAUGE AND TOOLGauge 0~7 MPa (0~70 bar, 0~1000 psi) 2EAThis test will check for restrictions in the hydraul ic system which can cause overheating of hydraulic oil.



Connect fitting and gauge to steering valve.

Connect fitting and gauge to main control valve.Do not operate steering or loader funct-Do not operate steering or loader funct-ions or test gauge may be damaged.ions or test gauge may be damaged.

Run engine at specification and read pressure gauges.

If pressure is more than specification at the loader control valve, check for a kinked, dented or obstructed hydraulic line. Check loader control valve for a binding spool.

If pressure is more than specification at the 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.

·

·

1)

2)

3)

4)

5)

T

Steering unit

MCV

830KWE42

1 MPa (10 bar, 145 psi)

3 MPa (30 bar, 43 psi) at steering unit

5-37

B

A

7. LOADER CYLINDER DRIFT TEST7. LOADER CYLINDER DRIFT TEST

SPECIFICATIONSPECIFICATIONOil temperature 45±5˚C (113±9˚F)Boom horizontalBucket horizontalBucket unloaded

GAUGGAUGE AND TOOLE AND TOOLStop watchTemperature reader

Put the safety lock lever in the lock position.Do not go under the work equipment.

Set the boom and bucket horizontal, then stop the engine.

Stop the engine, wait for 5 minutes, then start measuring.

Measure the amount the boom and bucket cylinder rods retract during 5 minutes.

A : Retraction of bucket cylinder rod

B : Retraction of boom cylinder rod

·

·

1)

2)

3)7577AWE31

Item Standard value

Retraction of boomcylinder rod

36 mm

Retraction of bucketcylinder rod

33 mm

5-38

SPECIFICATIONSPECIFICATIONOil temperature 45±5˚C (113±9˚F)Engine speed Low idleMaximum leakage 15 mℓ/min (1/2 oz/min)GAUGE AND TOOLGAUGE AND TOOLTemperature readerStop watchMeasuring container

Fasten temperature sensor to head end port of cylinder to be tested. Cover sensor with a shop towel.

Heat hydraulic oil to specifications (see hydraulic oil warm up procedure in this group).Never work under raised equipment Never work under raised equipment unless it is supported with a hoist or unless it is supported with a hoist or support stands.support stands.

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.

Remove and plug cylinder rod end hose or line.

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.

·

·

1)

2)

3)

※

4)

5)

8. BOOM AND BUCKET CYLINDER LEAKAGE TEST8. BOOM AND BUCKET CYLINDER LEAKAGE TEST

(770-3ATM) 6-56

5-39

9. CYCLE TIME TEST9. CYCLE TIME TEST

SPECIFICATIONSPECIFICATIONOil temperature 45±5˚C (113±9˚F)Engine speed High idle

·

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

5-40

CoverO-ringSpring

By-pass valve

Return filter

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.

Remove the bolts and take out the filter case cover and O-ring.

Remove the spring and bypass valve.

Remove the filter element from the tank.

Check the element and the filter case bottom for debris. Excessive amounts of brass and steel particles can indicate a failed hydraulic pump or a pump failure in process. A rubber type of material can indicated cylinder packing or other packing failure.The hydraulic oil filter in the filter case of the hydraulic oil tank should be replaced every 1000 operating hours or more often. When the filter element is replaced, please keep as follows.

Clean the inside of the filter case.

Place new element in the proper positions inside the filter case.

Install the bypass valve and spring. Make sure the element stand upright, and check for complete contact of the element bottom with the filter case bottom.

Install the O-ring and filter case covers. Tighten them with bolt. Replace the O-ring with new one if damaged.

10. HYDRAULIC OIL FILTER INSPECTION 10. HYDRAULIC OIL FILTER INSPECTION PROCEDUREPROCEDURE

1)

2)

3)

4)

5)

※

(1)

(2)

(3)

(4)

830KWE40

SECTION 6 ELECTRICAL SYSTEMSECTION 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

6-1

GROUP 1 COMPONENT LOCATIONGROUP 1 COMPONENT LOCATIONSECTION 6 ELECTRICAL SYSTEMSECTION 6 ELECTRICAL SYSTEM

1

2

546

7

14

1312

15

9

10

11

3

8

Front

Cab ceiling(LH)

CAB ROOF

1 Beacon switch 2 Work lamp switch 3 Front wiper/washer switch 4 Gear selector lever 5 Hazard switch 6 Cluster

13 Battery volt meter and hour meter 14 Cigar lighter 15 Engine stop switch

7 Multi function switch 8 Horn button 9 Electric fan 10 Aircon and heater switch 11 Radio and MP3 player 12 Starting Switch

1. LOCATION 11. LOCATION 1

830K7EL02E

6-2

1 2 3

4

5 6

9

10

1110 14

1213

11

15

7

8

4

4

4

1 Head lamp 2 Horn 3 Multi function switch 4 Work lamp 5 Beacon lamp

11 Rear combi lamp 12 Fuel sender 13 Back buzzer 14 Battery relay 15 Air tank pressure switch

6 Electric fan 7 Coolant temperator sensor 8 Engine oil pressure sensor 9 Work lamp 10 Battery

2. LOCATION 22. LOCATION 2

830K7EL02-1

6-3

B

B Gr

RW

R LG GW

CR

-3

CR

-55

WORK LAMPFRONT

WORK LAMPREAR

110

300

100

160

310

150

G01

J

G01

K

HORN RY

B GY

W

CR

-2

VW

341

340

350A

G01

B

FUSE BOX

CN

-37

600

400

100

150

200

250

350

500

700

670

750

800

290

280

270

8R GW

Gr

R RO

rW 2R R Y 2B

r

R Br

G LW RO

r

W

B

R

BrW

BrW

Or

Y

B

VOr

HA

ZA

RD

SW

Lo

Hi

M 5

4

E 3

Pf 2

B 1

CN-211

2

3

4

5

6

CS-41

FR

ON

T W

IPE

R

226

234

290F

211

211

G26

360

G25

362

352

ROr

R

B

L

G

CS-36

293

301

311

261

G26

WO

RK

LA

MP

SW

CN

-26

1 2

WARNINGBUZZER

Y R

871

200A

R BBrW

CR

-11

FLASHERUNIT

210

225

G01

C

B

M

1 2

CN

-22

FRONTWASHER

Gr

361

G02

POWERRELAY

CR

-35

BG

01H

670

657

680

R

LOW BEAMHIGH BEAM CLEARLENCELAMP

CR

-21

STOP LAMP

CR

-63

CR

-30

CR

-40

CN

-56

V32

1

Y32

0

RO

r25

0A

GW

331

VW

330

RO

r25

0 Or

450

3R55

0

2Or

650

2Gr

680

Br

270

R26

0

RO

r25

6

G20

5

Br

203

R20

0B

Br203

G

3R

8R600

550

205

R200

Y220A

ROr290

Or230A

LW280

2W663

R65729

0AR

Or

230

Or

321

V

331

GW

341

VW

220

YR40

0

G80

0

280C

LW Y70

0

110

RW

R75

2

285

LW

234

Or

324

V

226

Y

226

343GY

R 261

ROr 251

VW 333

Y 325

BrW 211

Or 234

ROr

G26

G01

L

G01

I

G01

A

G01

G01

G02

G03

G06

GAUGE BOARD SIDE

904

Gr

914

RW

873

Y

883

LW

893

W

863

RO

r

934

G

RHCONSOLESIDE

Y871

861

881

891

912

902

932 G

Gr

RW

W

ROr

LW

2Gr

2Br

B B

Y

B

1 3154 5 6 7 9 10 11 12 13 14 82

EARTH4

RL

530

530 RL

21 3 4 5 6 7 8

HR

M(-

)

KE

YS

WIT

CH

NC

NC

GN

D

HR

M(+

)

24V

NC

CN

-48

HOURMETER & VOLTMETER

750

750

G15

B

912

RW

BACK-UPBUZZER

CR

-58

WB

380

W35

0

354

L

280C

LW

2R

1 2 3 4 65 8 7 7 3 15 42 6

START SWITCH

CS

-22O

r65

0

660

663

2WRB Or

CL-

2

450

290E

G02

CIGAR

RO

r

CS-35B G26

290C

VOr 362

R 360

Gr 363

W 352

WIP

ER

SW

ROr

2

1

Or 500

G06B

CN-171SERVICESOCKET

CN-5

B

Y

B

1

2

3

4

5

13

1211

10

9

87654321

ROr863

873

883

893

914

904

934 G

Gr

RW

W

Y

LWROr 861

871

881

891

912

902

932GGr

RW

W

Y

LW

750

280

230

260

321

220

300

310

G04

G01

210

350

340

290

330

361

320

250

225

R

256

RO

r

380 L

876 Or

876Or

471 VW

VW 471

879 Or

473 VW

266

W

W26

6

816

879

Or

473

VW

G26

752

285

234

261324

226

301 G

311 L

G25

363

325

251

333

293

343

352

211

Gr

Y

RO

r

VW

RO

r

GY

W BrW

CN

-56

CN

-7

CN

-9

CN

-4

CN-4

6

7

8

9

10

1112

131415

14

15

16

16

8R 8R

FRONTDASHSIDE

R

LW

Or

ROrV

G30

R 261

ROr

B

ENGINE STOP SW

CS

-79

650

290E

667

G02

RO

r

667 R

24V, 35A

CS-26

PARKINGLEVER

G02 B

CS-45

BACKING351WB

G26B

351 WB 354WB

R16

0

CR-79871 Y

G02 B

657 R

G02 B

922 Br

924 Br Br 922

924

Br

ENGINESTOPBUZZER

1

2

3

4

1.2OrCN-125

650

1.2R660

1.2BG15

1.2R657

1

2

3

4

CN-125A

R 668

R 668

GPS CONN.

CS-74

MASTER SWITCH

1

2

3

5

6

7

8

4

CS-11

9

TU

RN

LE

VE

R

H(5)

R(1

1)(1

) L

LP(1

0)56

a(9

)56

b(8

)

30(6)

57/5

8(7

)

1011

LH

15

9 10

1

2

3

4

5

6

7

8

9

10

26

8

7

R

B

BATT RYCR-1

DO-2

BATTERY

3R

8R1

2

CN-95

601

551

FUSIBLE LINK

661A

G06C

Y

Br

Br

L

Or

B

B

B

CL-16

1

2

REAR COMBI LH

CL-15REAR COMBI RH

CN-65

BACK BUZZER

291 ROr

221

204

281 LW

231

204A

352

G28

G28

G28

PaPa

CD

-4

STOPLAMPSWITCH

CD

-3

CD

-49

TM TEMPAIRPRESSURE

R 661

2W 664

LW 281

231Or

291ROr

Y 221

201R

G 202

Br 204

R66

5

664

W

661

R20

1

202

G

3R

8R 601

551

G28

G07

G08

G08

G06

B

REAR FRAME SIDE

ENGINE SIDE

ROr

Y

LW

W

RW

Gr

G

Br 921

931

901

911

890

880

870

860

921

931

901

911

BW

Gr

GBr

860

870

890

WYRO

r

2B

12

34

56

8

8

13

4

56

79

1

2

9 8 2 1 3 4 56 711 12 10

CN

-12

DIODE

EARTH1

EARTH2EARTH5

EARTH6

BC

N-7

1G

09

COWL OPEN

G09

531

RL

COWL OPEN SWITCH

CN-3

7

CN-22

11

121415

1013

CN-1

L 352

12

CD-2877

G27 B

Or

FUEL LEVEL SENSOR

9

10

11

12

13

14

15

CD

-48

TM OILPRESSSWITCH

LW88

0

Pa

531RL

877Or

G27

G WK

0.85

2.0

G25

R 665

STARTER CN-45

B+

MM

15 R

CN-74

ALTERNATOR

W66

6

B+

D+

G

~ 3

U W

E

FUELCUT OFF SOL

CN

-79

12Pa

CD

-8

CD

-18

COOLENTTEMPENGINE

OILPRESS

R66

2

G10

920

930

900

910

BW

Gr

GBr

BW 910

2B

5L5Y

ST

G WK

20A

1

20A

2

20A

3

20A

4

30A

6

20A

7

30A

8

20A

9

20A

10

20A

11 12

10A

13 14

30A

15 16

10A

17

10A

18

20A

19

30A

20 21 22

10A

23

20A

24

20A

25

20A

26

5A27

20A

5

5A28

WO

RK

LM

AP

_FR

ON

T

WO

RK

LM

AP

_RE

AR

ST

OP

LA

MP

HE

AD

LA

MP

WIP

ER

& B

AC

K B

UZ

ZE

R

AIR

-CO

N/H

EA

TE

R

CIG

AR

SE

RV

ICE

PO

WE

R1

CO

WL

OP

EN

ILL

LAM

P

TU

RN

LA

MP

IGN

ITIO

N S

WIT

CH

PO

WE

R R

ELA

Y

RO

OM

LA

MP

, RA

DIO

(+)

AIR

CO

N(+

)

GA

UG

E 2

4V

RA

DIO

(IG

)

ILLU

MIN

AT

ION

1

ILLU

MIN

AT

ION

2

30A

BE

AC

ON

LA

MP

10A

10A

SP

AR

E1

SP

AR

E4

SP

AR

E6

SP

AR

E2

SP

AR

E5

SP

AR

E7

SP

AR

E3

SP

AR

E8

30A

10A

BL E

8587 86

G

1

5

9

10

1 2 3 4 5 6 7 8 9 10

2

6

21

1

2

33

11

22

30

86

87

85

87a 86

8587

30

87a

EARTH7

B

OR

GY

BL WOR

GY

YG

12

CL-

1

CN-24

CL-

5

12

CL-

6

WORK LAMPFRONT

RW

111

BG

13A

RW

111A

BG

13B

Y70

1A

705

801

283

704

G14

702

701

703

G14

A

704

703

12

ROOMLAMP

SPEAKERRH

SPEAKERLH

12

AC

-3

BG

14

R41

1

FAN

411

801

283

701

111

G13G14

CAB CHASSIS SIDE

12 3 45 6 78

CL-

7

12R

W11

1

BG

13A

BEACON BEACON

LW

LW 283

G14

G14

267

267W

111RW

1

2

W

L

CN-23

705

7022

1

CS-23

B Or

232

G11

A

VGW

B

CL-

433

2

322

G11

VW VW

B B

HORNHIGH

1 2

CN

-20

1 2

CN

-25

342

G11

B

342A

G12

A

Y22

2

VGW

B

CL-

333

2A

322

G12

B

HORNLOW

RO

r29

2

232

Or

V32

2

332

GW

VW

342

Y22

2

282

LWLW

282

RO

r29

2

G12

FRONT FRAME SIDE

2 3 4 5 678

CN

-9

1

G11

CL-

24CL-

22

12

CL-

23

WORK LAMPREAR

R16

1

BG

13A

R16

1

BG

13B

12

EA

RT

H3

CL-

25

CN

-11

1 2 3 4 5 6 7 8

B B 2R L Y RO

r

LW R RRO

rG30

G30

400

425

448

290

446

400

400

447

R RBW

400

400

445

CR

-33

BW

445

1 2 3 4 5 6 7 8

AC

CO

NT

RO

LLE

R G

ND

AC

24V

AC

CO

NT

RO

LLE

R B

+

ILLU

MIN

AT

ION

AC

CO

MP

AC

CO

ND

EN

SO

R F

AN

BLO

WE

R M

OT

OR

GN

D

CR

-7

NC

A

448

447

446

444

444

BrW

AIR-CONCOMPRELAY

AIRCONCONDENSORFANRELAY

L42

5

Y

ROr

448

447

446

444 BrW

LW

21 1 221 1 221 1 2

CN

-55

CN

-53

CN

-54

CL-

51A

CL-

52A

CL-

53A

CN

-52

CN

-51

TM OILPRESSURE

ENGINECOOLENTTEMP

BAROMETER

TC TEMPGAUGE

FUEL LEVELGAUGE

223

323

233

284

751

751

R

751A

751D

751E

751G

751H

284

LW

284A

284B

284C

284D

223

323

233

LWOr

VY

751H

G15

J

G15

I

G15

G

751E

G15

G15

G15

A

G15

C

G15

D

G15

F

862

RO

r86

2

892

892

W

878

Or

878

913A

913

872

872

YY

933

G93

3

903

903

Gr

923

923

BrB RW

B R

21 1 2

CL-

26A

472

472

VW

751D

6 7 15 1 11 3 10 16 13 4 5 12 14 8 2 9

U+-

CL-

51B

CL-

52B

CL-

26B

CL-

53B

TU

RN

LH

CH

AR

GE

HIG

H B

EA

M

BR

AK

E L

OW

PR

ES

SU

RE

PA

RK

ING

TU

RN

RH

EN

GIN

E O

IL

LED U+- LED U+- LED U+- LED U+- LED

4561 2 3

7A

4

3

1

2

M

21

21

3R R

552

669

CN

-29

AIR-CONPRESSSWITCH

Y44

0

RO

r44

1

2

Pa

1CN

-83

AC CONDFAN

BrW

449

BG

25

21

M

BrW 449

443LWROr 441

440Y

443

G08

ALW

G29

B

1

CN

-28

442

VW

AIR-CONCOMP

15

9 10

1

2

3

4

5

6

7

8

9

10

26

8

7

MP3 PLAYER POWER CONNECT

CN

-27

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

AC

C

ILL-

NC

SP

K F

RT

RH

-

SP

K F

RT

LH

-

TE

L M

UT

E

AN

T 1

2V

BA

CK

UP

+

ILL+

NC

SP

K F

RT

RH

+

RE

MO

CO

N+

RE

MO

CO

N G

ND

SP

K F

RT

LH

+

NC

GN

D

Lo Hi EC

2 11 2T

3

CHINA

Y B

Br

/Gr

GBR

Lo Hi EC

2 11 2T

3

CHINA

Y B

Br

/Gr GBR

1

2

3

CN-11

4

5

DESTINATIONNO.

1

2

3

4

5

6

7

8

GND(BLOWER)

MCU

DPS(COMPRESSOR)

CONDENSOR FAN6

7

8

RELAY(M2)

DUCT SENSOR

GB

9B

YB

25

LB24

Y20

A

WR

23

L36

2B32

L36

A

YB

r27

YW

35

LG26 35

YW

6AR

Y

33A

R

28B

G

3R

W

RELAY(HI)

36L

6BR

Y

33R

29Y

B

BR

1B

R2

RW

4G

5R

Y6

BrR

8G

B9

BR1,22B32RY6RW10

LW30LY31G5

AIR CON

GND(CONTROLLER)

FUSE(IG)

FUSE(Battery)

ILLUMINATION

2R33

1 2 3 4 5 6 7 8 9 10 11 12 13 14

GN

D

GN

D

BA

TT

ER

Y(+

)

BA

TT

ER

Y(+

)

ILLU

MIN

AT

ION

PO

WE

R IG

NC

DU

CT

SE

NS

OR

(+)

DU

CT

SE

NS

OR

(GN

D)

RE

VE

RS

E F

AN

SIG

NC

NC

NC

NC

RESISTOR

BLOWER

MODE(VENT)

1.25

G

91.

25Lg

B

8

543

M

21 6

1 2 3 4

Lo Hi

ML

MH

4231

WB

15B

W16

LR17

GL

19Y

20G

W21

BG

22W

R23

LB24

LG26

YB

r27

BG

28

LW30

LY31

AC & HEATER CONTROLLER

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

INLE

T M

OT

OR

(RE

C)

INLE

T M

OT

OR

(FR

E)

TE

MP

MO

TO

R A

CT

(+)

TE

MP

MO

TO

R A

CT

(-)

TE

MP

M/A

CT

(PB

R)

MO

TO

R A

CT

(RE

F)

MO

DE

M/A

CT

(DE

F)

MO

DE

M/A

CT

(FO

OT

)

MO

DE

M/A

CT

(M+

)

MO

DE

M/A

CT

(M-)

MO

DE

M/A

CT

(PB

R)

BLO

WE

R R

ELA

Y(L

O)

BLO

WE

R R

ELA

Y(M

1)

BLO

WE

R R

ELA

Y(M

2)

BLO

WE

R R

ELA

Y(H

I)

CO

MP

RE

SS

OR

(DP

S)

CO

ND

EN

SE

R F

AN

BG

18 25Y

B

YB

29

7

1 42

5

7

BG

22

GW

21

MODE(D/FOOT)

543

M

21 6 7

3 7

WB

15

BW

16

INLET M/ACT

543

M

21 6 7

3 7

GB

9A

GL

19

BG

18

Y20

LR17

TEMP M/ACT

543

M

21 6 7

1 42

5

7

GB

10

GW

BW

RGRW

RW

BrW

BrW

1817

16

151413

1211

10987654321 1413

1211

10987654321

WO

r

BW

L BO

r

G Y GY

BW

WO

r

LW Y LW YW

BO

r

YW

LW Y2324252627282930313233343536373839 4041424344454647 52

OrW

1 2 3 4 5 6 7 8 9 10 11 12 13 141 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

AC

-1A

C-1

1

AC

-22

AC

-2

30868785

87a

86 858730

87a

30868785

87a

86 858730

87a

30868785

87a

86 858730

87a

51

9 10

1

2

3

4

5

6

7

8

9

10

24

7

0I

30868785

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86 858730

87a

30868785

87a

86 858730

87a

30868785

87a

86 858730

87a

30868785

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86 858730

87a

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86 858730

87a

30868785

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86 858730

87a

6

1 2 3 4 5 6

1

53

0 I

0, I

H

4 2

B

H BR ACC ST C

6

9 10

1

2

3

4

5

6

7

8

9

10

1

8

3

0I

0,

I

1

2

1

2

3

4 C

T

E

S

1

2

3

4 C

T

E

S

30868785

87a

86 858730

87a

30868785

87a

86 858730

87a

1 2 3 431

2 4

1 2 3 431

2 4 M1 2

1 2

572

573

21

CL-

DL

CN

-7

C

C

GROUP 2 ELECTRICAL CIRCUITGROUP 2 ELECTRICAL CIRCUIT

830K7EL10

6-4

GROUP 3 GROUP 3 MONITORING SYSTEMMONITORING SYSTEM

1. CLUSTER1. 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.

830K3CD02K

※

※

Engine oil pressure warning lamp

T/M oil temperature gauge

T/M oil pressure gauge

Right turning pilot lamp

Parking brake warning lamp

Left turning pilot lamp

High beam pilot lamp

Fuel gauge

Battery charging warning lamp

Engine coolant temperature gauge

Brake air pressure gauge

Brake air pressure warning lamp

6-5

This gauge indicates the temperature of coolant.·Red range : Above 100˚̊C (219˚̊F)

If the indicator is in operating range, it is normal.

Keep idling engine at low speed until the indicator is in the operating range.

If the indicator is in the red range, turn OFF the engine, check the radiator and engine.

ENGINE COOLANT TEMPERATURE GAUGEENGINE COOLANT TEMPERATURE GAUGE

TRANSMISSION OIL TEMPERATURE GAUGETRANSMISSION OIL TEMPERATURE GAUGE

(1)

(2)

(3)

(4)

This gauge indicates the temperature of transmission oil.·Red range : Above 120˚̊C (225˚̊F)


Keep idling engine at low speed until the indicator is in the operating range.

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.

(1)

(2)

(3)

(4)

850K3CD05

850K3CD07

TRANSMISSION OIL PRESSURE GAUGETRANSMISSION OIL PRESSURE GAUGE

This gauge indicates the pressure of transmission oil.


If the indicator is in the red range, stop the engine and check the transmission system.

(1)

(2)

(3)

850K3CD08

This gauge indicates the amount of fuel in the fuel tank.

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 can be caused by the poor connection of electricity or sensor.

(1)

(2)

※

FUEL GAUGEFUEL GAUGE

850K3CD04

1)1)

2)2)

3)3)

4)4)

Operating range

Operating range

Red

Operating

range Red

Red

6-6

BRAKE AIR PRESSURE GAUGEBRAKE AIR PRESSURE GAUGE

HIGH BEAM PILOT LAMPHIGH BEAM PILOT LAMP

DIRECTION PILOT LAMPDIRECTION PILOT LAMP

PARKING BRAKE WARNING LAMPPARKING BRAKE WARNING LAMP

BRAKE AIR PRESSURE WARNING LAMPBRAKE AIR PRESSURE WARNING LAMP

This gauge indicates the air pressure of service brake. ·Red range : Below 0.4 MPa


If the indicator is in the red range, keep idling engine at low speed until the operating range indicates.

This lamp works when the illuminating direction is upward.

This lamp comes ON when the dimmer switch is operated, e.g., when passing another vehicle.

This lamp flashes when the signal indicator lever is moved.

When the lamp lights up, the alarm (50 dB) sounds.

When the parking brake is actuated, the lamp lights ON.

Check the lamp is OFF before driving.

The lamp lights ON when the air pressure of service brake drops below the normal range.

When the lamp is ON, stop the engine and check for its cause.

Do not operate until any problems are corrected.

(1)

(2)

(3)

(1)

(2)

(1)

(2)

(1)

※

(1)

(2)

※

850K3CD06

77073CD12

77073CD10

77073CD13

850K3CD16

5)5)

7)7)

6)6)

8)8)

9)9)

Red

Operating range

6-7

BATTERY CHARGING WARNING LAMPBATTERY CHARGING WARNING LAMP

ENGINE OIL PRESSURE WARNING LAMPENGINE OIL PRESSURE WARNING LAMP

This lamp is ON when key ON, it is turned OFF after starting the engine.

Check the battery charging circuit when this lamp comes ON during engine operation.

This lamp is comes ON after starting the engine because of the low oil pressure.

If the lamp comes ON during engine operation, shut OFF engine immediately. Check oil level.

(1)

(2)

(1)

(2)

77073CD22

77073CD18

10)10)

11)11)

6-8

2. SWITCHES2. SWITCHES

STARTING SWITCHSTARTING SWITCH

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.

(1)

830K3CD29E

77073CD41

1)1)

Starting switch

Beacon switch

Horn buttonMulti function switch

Hazard switch Front wiper/washer switch

Work lamp switch

Cab celing (LH)

Front

Engine cover switch

Engine stop switch

6-9

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.

(1)

WORK LAMP SWITCHWORK LAMP SWITCH

77073CD46

3)3)

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.

(1)

FRONT WIPER AND WASHER SWITCHFRONT WIPER AND WASHER SWITCH4)4)

Use for parking, or roading machine.Both turn signal lights will flash simultaneously.

If the switch is left ON for a long time, the battery may be discharged.ON

OFF(1)(2)

※

HAZARD SWITCHHAZARD SWITCH

77073CD42

2)2)

77073CD47

This switch turns ON the rotary light on the cab.(1)

BEACON SWITCH BEACON SWITCH (option)(option)

77073CD50

5)5)

If you press the button on the top of the multifunction switch, the horn will sound.

(1)

HORN BUTTONHORN BUTTON

850K3CD28A

6)6)

Horn button

6-10

This switch is used to turn the head lights direction.Switch positions·Up : To flash for passing·Middle : Head lights low beam ON·Down : Head lights high beam ONIf you release the switch when it's in up position, the switch will return to middle

This switch is used to warn or signal the turning direction of the machine to other vehicles or equipment.Push the lever up for turning left, pull the lever down for turning right.

①②

③

①

②

MULTI FUNCTION SWITCHMULTI FUNCTION SWITCH

850K3CD30

850K3CD31

8)8)

This switch turns ON the cab room lamp. (1)

CAB LAMP SWITCHCAB LAMP SWITCH

73033CD24

7)7)

This switch is used to open or close the engine cover.

Turn the staring switch to the ON position, press the button.·Green button : Open the engine cover·Red button : Close the engine cover

(1)

(2)

ENGINE COVER SWITCHENGINE COVER SWITCH

830K3CD46

9)9)

If the switch is pressed, the engine stops immediately.(1)

ENGINE STOP SWITCHENGINE STOP SWITCH

830K3CD37

10)10)

Dimmer switchDimmer switch

Turning switchTurning switch

(1)(1)

(2)(2)

Left turning

Right turning

Up

M

Down

RedGreen

6-11

Connector number

TypeNo. of

pinDestination Connector part no.

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

GROUP 4 GROUP 4 CONNECTORCONNECTOR

1. MAIN HARNESS1. MAIN HARNESS

6-12

Connector number

TypeNo. of


CN-7 CHINA 8 CAB CHASSIS SIDE DJ7081-6.3-11

CL-7 TYCO 2 BEACON 174198-1

CN-23 CN-24

KET 2 SPEAKER 7123-1520

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

Connector number

TypeNo. of


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

2. CAB HARNESS2. CAB HARNESS

3. DASHBOARD HARNESS3. DASHBOARD HARNESS

6-13

Connector number

TypeNo. of


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

Connector number

TypeNo. of


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


4. REAR FRAME HARNESS4. REAR FRAME HARNESS

5. FRONT HARNESS5. FRONT HARNESS

6-14

Connector number

Type No. of pin Destination Connector part no.

CN-55 CN-53 CN-54 CN-52 CN-51

SWF KSC2620

21×3

BARO METER TC TEMP GAUGE FUEL LEVEL GAUGE ENGINE COOLANT TEMP TM OIL PRESSURE

913328 R 1.25-4

CL-51 A,B CL-52 A,B CL-26 A,B CL-53 A,B

CHINA 2×2

TURN-LH, CHARGEHIGH BEAM, BRAKE LOW PRESSUREPARKINGTURN-RH, ENGINE OIL PRESSURE

DJ702256-6.3-21

CN-56 TYCO 16 GAUGE BOARD 368050-1

Connector number

Type No. of pin Destination Connector part no.

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

CR-23 KET 2×2 START RELAYST710384-2 ST710589-2

CN-45KSC 2620 KET

1 1

STARTERR14-12

ST710246-2

CN-74KSC 2620 KSC 2620

11

ALTERNATORR14-8 Rl.25-4

CN-12 TYCO 12 ENGINE SIDE DJ7121-6.3-11

CN-28KSC 2620 KSC 2620

11

COMPRESSORNMWP01F-B

Rl.25-10

6. GAUGE HARNESS6. GAUGE HARNESS

7. ENGINE HARNESS7. ENGINE HARNESS

6-15

8. CONNECTION TABLE FOR CONNECTORS8. CONNECTION TABLE FOR CONNECTORS

58-L TYPE CONNECTOR58-L TYPE CONNECTOR1) 1)

No. of pin Receptacle connector (female) Plug connector (male)

1

2

1

S813-030100

1

S813-130100

1 2

S813-030200

1 2

S813-130200

6-16

5

2 5

1 3

S811-005002

1 3

2 5

S811-105002

3 7

1 4

S811-007002

1 4

3 7

S811-107002

4 9

1 5

S811-009002

1 5

4 9

S811-109002

5 11

1 6

S811-011002

1 6

5 11

S811-111002

7

9

11

PA TYPE CONNECTORPA TYPE CONNECTOR2) 2)


6-17

13

6 13

1 7

S811-013002

17

21

1 7

6 13

S811-113002

8 17

1 9S811-017002

1 9

8 17

S811-117002

1 21

1 11

1 11

1 21

S811-121002S811-021002


10

10

6-18

No. ofpin Receptacle connector (female) Plug connector (male)

2

3

4

8

1

2 2

1

2

3 1

3 1

2

3 1

4 2

4 2

3 1

6 3 1

8 5 2

8 5 2

6 3 1

S816-002001 S816-102001

S816-003001 S816-103001

S816-004001 S816-104001

S816-008001 S816-108001

J TYPE CONNECTORJ TYPE CONNECTOR3) 3)

2

1

6-19

No. ofpin Receptacle connector (Female) Plug connector (male)

1

1

S814-001000

2

3

4

1

S814-101000

2

1

1

2

S814-002000 S814-102000

3

2 1

1

2 3

S814-003000 S814-103000

2 4

1 3

1 3

2 4

S814-004000 S814-104000

SWP TYPE CONNECTORSWP TYPE CONNECTOR4) 4)

6-20

6

8

12

14

3 6

1 4

1 4

3 6

S814-006000 S814-106000

4 8

1 5

1 5

4 8

S814-008000 S814-108000

4 12

1 9

1 9

4 12

S814-012000 S814-112000

3 14

1 11

1 11

3 14

S814-014000 S814-114000


6-21

1

1

S810-001202

2

3

4

1

S810-101202

2

1

S810-002202

2

1

S810-102202

3

1 2

S810-003202

2

1 3

S810-103202

2 4

1 3

S810-004202

1 3

2 4

S810-104202

CN TYPE CONNECTORCN TYPE CONNECTOR5) 5)


4

6-22


6

3 6

1 4

S810-006202

8

1 4

3 6S810-106202

1 5

4 8

S810-108202

4 8

1 5

S810-008202

6-23


10

1

2

9

10

SWF593757

ITT SWF CONNECTORITT SWF CONNECTOR


1

1

NMWP01F-B

MWP NMWP CONNECTORMWP NMWP CONNECTOR

6) 6)

7) 7)

6-24


21 2

DT06-2S

3

12

DT04-2P

2 1

3

DT06-3S

21

3

DT04-3P

DEUTSCH DT CONNECTORSDEUTSCH DT CONNECTORS

DT 06 - 3S - ★★★★

Modifications (see below)

Number of contacts (P : Pin, S : Socket)

04 : Receptacle, 06 : Plug

Deutsch connetors

ModificationE003 : Standard end cap - grayE004 : Color of connector to be blackE005 : Combination - E004 & E003EP04 : End capEP06 : Combination P012 & EP04P012 : Front seal enhancement - connectors color to black for 2, 3, 4 & 6pin

※

4

4

23

1

DT06-4S

41

32

DT04-4P

8) 8)

6-25


6

6 1

4 3

DT06-6S

61

43

DT04-6P

5 4

8 1

8

54

81

DT06-8S

12

DT04-8P

6 7

1 12

DT06-12S

7 6

12 1

DT04-12P

6-26

2 1


1

2

3

4

S816-101002

S816-102002

S816-103002

S816-104002

ECONOSEAL J TYPE CONNECTORSECONOSEAL J TYPE CONNECTORS

21

S816-001002

S816-002002

S816-003002

S816-004002

9) 9)

6-27


6

8

10

12

S816-106002

S816-108002

S816-110002

S816-112002

S816-006002

S816-008002

S816-010002

S816-012002

6-28


21

2

MG610070

KET 090 CONNECTORKET 090 CONNECTOR10) 10)


15

2-85262-1368301-1

6-29

KET 090 WP CONNECTORSKET 090 WP CONNECTORS11) 11)


21

2

MG640605

2 1

2

MG640795

CHINA CONNECTORSCHINA CONNECTORS12) 12)


4

12

4 3DJ7041-6.3-11

8 4

1

8

5

DJ7081-6.3-21

1

43

2

DJ7041-6.3-21

6-30

TYCO CONNECTORTYCO CONNECTOR13) 13)


2

2

1

2

174198-1

12

282080-1

11

5 11

1 6

172497-1

Date post:	27-Oct-2014
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